QCS - 2014.pdf

QCS 2014

Contents

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CONTENTS

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SECTION 2 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15

GENERAL Introduction Use and Maintenance of the Site Site Access and Entry onto the Site Protection Interference Project Meetings Submittals Building Demolition Materials Occupational Health and Safety Engineer’s Site Facilities Contractor’s Site Facilities Setting Out of the Works Temporary Works and Equipment Temporary Controls Traffic Diversions Project Co-ordination Other Contractors Regulatory Requirements Clearance of the Site Final Inspection and Handover Procedures New Technologies and Innovations Design and Supervision Consultant Quality Requirement Construction Dewatering

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SECTION 1 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22 Part 23 Part 24

QUALITY ASSURANCE AND QUALITY CONTROL General Submittals Contractor’s Quality Personnel Document and Data Control Quality Records Quality Audits Inspection And Test Materials Nonconformance Monitoring Laboratories Site Meetings And Reports Failure By The Contractor To Meet Acceptable Quality Performance Suspension of Work APPENDIX A – Sampling and Testing Frequencies APPENDIX B – Templates (Contractors Project Quality Plan Template, Contractors Inspection And Test Plan Template, and Quality Non-conformance Template)

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GROUND INVESTIGATION General Boreholes Pits and Trenches Soil Sampling in-Situ Testing, Instrumentation and Monitoring Laboratory Testing

SECTION 4 Part 1 Part 2 Part 3 Part 4 Part 5

Foundations and Retaining Structures General Requirements for Piling Work Concrete Works for Piling Shadow Foundations Deep Foundations Retaining Structures

SECTION 5 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20

CONCRETE General Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing Of Concrete Formwork Curing Reinforcement Joints Inspection and Testing Of Hardened Concrete Protective Treatments for Concrete Hot Weather Concreting Miscellaneous Structural Precast Concrete Prestressed Concrete Testing of Water Retaining Structures Personnel Qualifications and Certification

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SECTION 3 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6

SECTION 6 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9

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QCS 2014

ROADWORKS General Site Clearance Earthworks Unbound Pavement Materials Asphalt Works Concrete Road Pavements Asphalt Plants Recycled and Stabilised Road Materials Recycled Aggregate for Roadworks

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Vehicle Crash Barriers Kerbs, Footways and Paved Areas Fencing Traffic Signs, Markings and Studs Works in Relation To Services Road Lighting Traffic Signals Road Drainage Geosynthetics Miscellaneous


GREEN CONSTRUCTIONS Introduction Global Sustainability Assessment System - GSAS Energy Water [W] Indoor Environment Cultural and Economic Value

SECTION 8 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12

DRAINAGE WORKS General Earthworks Pipes and Fittings Materials Pipeline Installation Valves, Penstocks and Appurtenances Miscellaneous Metal Works Miscellaneous GRP Works Protective Coatings and Painting Trenchless Pipeline Construction Pipelines Cleaning and Inspection Survey Sewer Rehabilitation Vacuum Sewerage System

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Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19

SECTION 9 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14

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QCS 2014

MECHANICAL AND ELECTRICAL EQUIPMENT General Submersible Pumps Centrifugal Pumps (Dry Well) Centrifugal Pumps (Split Casing) Archimedian Screw Pumps Surge Control System Lifting Equipment Electric and Pneumatic Actuators Odour Control Equipment-Carbon Type Odour Control Equipment-Scrubber Type Screening Equipment Grit Removal Equipment Aeration Equipment Air Blowers and Compressors

QCS 2014

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Settlement Tank Equipment Tertiary Treatment Granular Filters Sludge Thickening and Dewatering Equipment Mixers and Stirrers Chlorination Plant Equipment Washwater Systems Miscellaneous Equipment Ventilation Systems


INSTRUMENTATION, CONTROL AND AUTOMATION General Telemetry/SCADA Primary Elements Panel Mounted and Miscellaneous Instruments Control Panels and Control Room Hardware

SECTION 11 Part 1 Part 2

HEALTH & SAFETY Regulatory Document Safety and Accident Prevention Management / Administration System (SAMAS)


EARTHWORKS RELATED TO BUILDINGS General Excavations Filling Utility Trenches Installation of Protective Membranes


MASONRY General Mortar and Grout Accessories Unit Masonry Masonry Laying

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Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22


ROOFING General Membrane Roofing Metal and Plastic Roofing Roof and Deck Insulation Roofing Tiles

SECTION 15 Part 1 Part 2 Part 3

SECTION 15 INSULATION OF BUILDINGS General Building Insulation Cold Stores

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STRUCTURAL STEELWORKS General Materials Drawings Fabrication Welding Bolting Accuracy of Fabrication Erection Accuracy of Erected Steelwork Protective Treatment


METALWORK General Materials Classification Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding Support Workmanship

SECTION 18 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7

CARPENTRY, JOINERY AND IRONMONGERY General Wood Treatment Structural Timber (Rough Carpentry) Architectural Timber (Finished Carpentry, Millwork) Joinery Fasteners and Adhesives Ironmongery (Hardware)


PLUMBING WORK General Water Distribution Plumbing Pipework in Trenches Cold Water Storage Hot Water Storage Commissioning of Systems Plumbing for Gases

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SECTION 16 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10


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DRAINAGE WORKS FOR BUILDINGS General Internal Drainage Works External Drainage Works Drainage Pipes in Trenches Structures Related To Drainage Work Surface Water Drainage Commissioning Of Systems

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ELECTRICAL WORKS General Provisions for Electrical Installation MV Factory Built Assemblies (FBA’s) Protective Devices Motor Starters Low Voltage Variable Speed Controllers Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Wiring Accessories and General Power Light Fittings Emergency Lighting Telephone Installations Structured Cabling Systems Electric Motors Power Factor Correction Capacitors Standby Diesel Generator Set Uninterruptible Power Supply Systems Sound and Call Systems Elevators/Escalators Lightning Protection Earthing and Bonding Inspection and Testing Documentation Format Electrical Identification Electromagnetic Compatibility Battery and Battery Charger Small Enclosures Underfloor Ducts Duct Bank and Manholes Power Distribution Transformers 11 kv Switchgear Actuators HV Variable Frequency Drive

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SECTION 21 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22 Part 23 Part 24 Part 25 Part 26 Part 27 Part 28 Part 29 Part 30 Part 31 Part 32 Part 33 Part 34

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QCS 2014


AIR CONDITIONING, REFRIGERATION AND VENTILATION General Central Refrigeration and Air Conditioning Equipment Unitary Equipment Air Handling Equipment Chilled Water Pipework Ductwork and Air-Side Equipment Thermal Insulation Exhaust Fans Accessories

SECTION 23 Part 1 Part 2

FIRE FIGHTING AND FIRE ALARM SYSTEMS General Fire Alarm and Detection Systems

QCS 2014

Contents

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Analogue Addressable Fire Alarm Systems Fire Fighting System Testing and Commissioning

SECTION 24 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14

FINISHES TO BUILDINGS General Lath and Plaster Dry Lining (Wall Board) Special Wall Surfaces Tiles Terrazzo Stone Flooring Unit Masonry Flooring Floor Screeds and Treatments Joints, Caulking and Sealants Recessed Duct Covers Carpeting Other Floor Coverings Ceilings

SECTION 25 Part 1 Part 2 Part 3 Part 4

GLASS AND GLAZING General Glass Workmanship Glazed Curtain Walling System

SECTION 26 Part 1 Part 2 Part 3 Part 4

PAINTING AND DECORATING General Surface Preparation for Painting Primers, Paints and Coatings Wall Coverings of Decorative Papers/Fabrics

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Part 3 Part 4 Part 5

SECTION 28 Part 1 Part 2 Part 3

EXTERNAL WORKS General Block Paved Areas Fences and Gates Fountains and Aquatic Features Site Furniture Flag Poles Protective or Shade Cover Systems Play Field and Park Equipment Miscellaneous Other External Works LANDSCAPING Landscape Planting Landscape Irrigation System Play Equipment General Specification

QCS 2014

Contents RAILWAYS Design Related Issues Aspects Site Clearance Geotechnical Specifications Tunnel Cut and cover Structure Earthworks and Roadworks Concrete Structures Steel Structures Drainage Railway Track Monitoring and Instrumentation Survey and Setting Out

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SECTION 29 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12

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QCS 2014

Introduction

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INTRODUCTION The purpose of the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS2014)] is to provide technical guidance in connection with the execution of constructions in the State of Qatar. Such guidance includes the establishment of the minimum acceptable material quality and workmanship for those kinds of work which commonly occur in engineered projects in the State of Qatar. Qatar Construction Specifications 2014 (QCS 2014) supersedes Qatar National Construction Standards 2010 (QCS 2010) in all respects.

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While working earnestly to benefit from new engineering developments, Laboratories and Standardisation Affairs in the Ministry of Environment requests that all those undertaking works projects in the State of Qatar to implement the specifications contained herein.

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We welcome any observations, suggestions or additions for future issues.

QCS 2014

Document History

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DOCUMENT HISTORY The purpose of the Document History is to record changes to Qatar Construction Specifications. In the event of a revision to the technical regulation, Laboratories and Standardisation Affairs in the Ministry of Environment will issue the amended pages and re-issue the Document History. The Document History pages should contain a description of the change, the issue reference and the date of issue as noted below. The updated Document History should replace the superseded history and the revised pages of the technical regulation should be placed in the appropriate position in the technical regulation. The technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)] replaces Qatar Construction Specification 2002 (QCS 2002) and it supersedes in all respects.



The technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)] replaces the technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)] and it supersedes in all respects.



Further, the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS 2014)] replaces the technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)] and it supersedes in all respects.

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Description

Date

Original Issue

April 2000

Qatar Construction Specification 2002

Revision I

November 2002

Qatar National Construction Standards 2007

Revision II

July 2007

Qatar Construction Specifications 2010

Revision III

March 2011

Qatar Construction Specifications 2014

Revision IV

October 2014

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Qatar Construction Specification

Issue

QCS 2014

Acknowledgements

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ACKNOWLEDGEMENTS

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The Qatar Construction Specifications (QCS 2014) has been drawn upon the technical knowledge and experience of a number of Governmental Ministries, Departments and Authorities in the State of Qatar. The QCS technical committee and associated subcommittees whose members are acknowledged below spearheaded the current revision of QCS 2014.

Eng. Khalid Al-Emadi Chairman of QCS Manager of Q&S Dept. Ashghal

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Dr. Mohammed Saif Al-Kuwari Assistant Undersecretary Ministry of Environment

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Abdul Hameed M. Al-Yahri Sec. of the committee Ministry of Environment

Yousef Mahmoud Ahmed Nooh Asst. Sec. of the committee H/ of the Documents Editing Quality Supervisor -Ashghal

Meshal Saoud Al Mesallam Ministry Of Energy & Trade

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Nasser Al- Naimi Deputy Chairman of QCS Ministry of Environment

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Technical Committee for Preparing and Development of QCS

Dr. Noureddin Daas

Moaaz Hashim

Dr. Khaled Hassan

Osman Elhussien

Chairperson of Concrete Committee Ministry of Environment

Chairperson of Road Committee Member of: Rail committee Quality Expert - Ashghal

Member of Concrete Committee TRL

Chairperson of Rail Committee Member of Road committee Quality Researcher - Ashghal

Sharif Mohamed Chairperson of Drainage Committee Member of Rail Sub-committee Design Engineer- Ashghal

Gareth Thomas Chairperson of: Quality Committee Quality Assurance & Quality Control Expert - Ashghal

Ehab G Saleh Chairperson of: Safety Committee Safety Specialist - Ashghal

QCS 2014

Acknowledgements

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Sub Committees Members

Adel M. Quraan Reviewers CH2M HILL

Adrian Black Safety Committee MWH

Ahmed Mohd. Sayd Concrete Committee Ministry of Environment

Allan McEwan Quality Committee KBR

Ahmed Sami Roads Committee Ashghal

Amr Elmotasem Concrete Committee AEB

Arthur Hannah Roads Committee (TRL) London

David Matyus Concrete Committee QPMC

David Lewis Roads Committee AMEY

Dick Steer Drainage Committee Ashghal

Dr.Hany Mohamed Reviewers Ashghal

Effrosyni Plexousaki Quality Committee ANAS

Elie Khairallah Concrete Committee ACTS

Essam El Sarag Green Building GORD

Fatih Türk Concrete&RailCommittee Mace / EC Harris

Fraser McCaskill Quality Committee Mace / EC Harris

Gary Cook Roads Committee ANAS

Ghaleb Al Zubi Reviewers ACES

Gireesh Babu Concrete Committee QDC

Hazem Abdel Rahman Roads Committee Ashghal

Huw Woodyatt Roads Committee Exova

Issam A. Sarhan Website Developer MOE

Jaafar. Al-Aloosi Concrete Committee Ashghal

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Abdulrahim Sukik Concrete Committee ACES

Jaafer Mohammed Roads Committee MOE

Jose Vellattukudy Drainage Committee Ashghal

Karunarathna T A Drainage Committee Ashghal

Karen O’Sullivan Roads Committee FUGRO

Kim Catrambone Roads Committee Parsons Brinckerhoff

Konstantinos k Roads Committee Ashghal

Martin Cahalan Quality Committee AMEY

Mathhar Mustafa Concrete Committee Hilti Qatar

Markus Kretschmer Concrete&RailCommittee Qatar Rail

Melina Davies Roads Committee Parsons Brinckerhoff

Mohammed Adil Document Controller Ashghal

Mohammed Al-Yahri Drainage Committee Ashghal

QCS 2014

Acknowledgements

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Mohanasundaram Concrete Committee QDC

Michael De Roos Safety Committee Ashghal

Michelle Magbojos Roads Committee Ashghal

Neil Courtman Quality Committee Mace

Neil Kirkpatrick Green Building Parsons Brinckerhoff

Nicholas Ray Quality Committee CH2MHill

Packiaraj Drainage Committee Ashgha

Petru Ghicu Drainage Committee Ashghal

Peter E. Sebaaly Roads Committee ANAS

Peter Latham Concrete Committee ReadyMix

Peter Sutton Safety Committee AMEY

Rabih Boukaidbey Concrete Committee ACTS

Rania Hashim Abadi Roads Committee Ashghal

Rawshan Haniffa Document Controller Ashghal

Rabih Fakih Concrete Committee GREY MATTERS

Rolando Matias Quality Committee Parsons Brinckerhoff

Roy Cupples Roads Committee Ashghal

Salah Mousa Safety Committee Ministry of Labor

Richard James Ellis Roads Committee Gulf Laboratories

Robert Overett Roads Committee Parsons Brinckerhoff

Saleem Purayil Purayil Document Controller Ashghal

Shyam Sundar Concrete Committee QDC

Sheik Pahary Safety Committee QPM

Subrato Mukherjee Concrete Committee QDC

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Srinivasan Samiappan Concrete Committee QDC l

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Mohamed El sherbiny Green Building Ashghal

Tom Baines Safety Committee EC Harris

Yasser Berzan Safety Committee Ashghal

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Acknowledgements

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QCS 2014

Ministry of Environment Dr Mohamed Saif Al-Kuwari Undersecretary Assistant of MoE

Preparing and Development of Qatar Building Code Committee Technical Committee for Preparing and Development of QCS

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ORGANIZATIONAL CHART

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Eng. Khalid Al-Emadi Chairman of QCS

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Nasser Al-Naimi Deputy Chairman of QCS

Abdul Hameed M. Al-Yahri, Yousef Mahmoud Ahmed Nooh, Gareth H. Thomas, Noureddin Daas, Moaaz Hashim, Osman Elhussien, Sharif Mohamed, Ehab Saleh

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Sub Committees

QUALITY

Gareth H. Thomas Effrosyni Plexousaki Neil Courtman Allan McEwan Martin Cahalan Nicholas Ray Rolando Matias Fraser McCaskill

CONCRETE Noureddin Daas Khaled Hassan Jaafar Isam S. Al-Aloosi Rabih Fakih David Matyus Peter Latham Gireesh Babu.K.M Srinivasan Samiappan Shyam Sundar Rajaram Mohanasundaram Rangasamy Ahmed Mohamed El Sayd Amr Elmotasem Elkady Abdulrahim Mohammed Mathhar Ghazi Mustafa Sabet Hajem Ibrahi Elie Khairallah Subrato Mukherjee Rabih Bahij Boukaidbey Fatih Türk

ROADS

GREEN BUILDING

DRAINAGE

SAFETY

RAIL

Moaaz Hashim Osman Elhussien Jaafer Mohammed Al Saidi Gary Cook Huw Woodyatt Richard James Ellis Arthur Hannah Khaled Hassan Michelle Magbojos

Khalid Al- Emadi Noureddin Daas Mohamed El sherbiny Essam El Sarag Neil Kirkpatrick

Sharif Mohamed Dick Steer Mohammed Homoud Al-Yahri Petru Ghicu Jose Vellattukudy Packiaraj Thangaswamy Karunarathna T A. Kithsiri

Ehab Saleh Yasser Berzan Peter Sutton Tom Baines Salah Mousa Michael De Roos Adrian Black Sheik Pahary

Osman Elhussien Moaaz Hashim Sharif Mohamed Markus Kretschmer Fatih Turk

Contributors to Road Section Peter E. Sebaaly Karen O’Sullivan Konstantinos Kanellaidis Recycling Robert Overett Moaaz Hashim Osman Elhussien Gary Cook Ahmed Sami Sayed Abbas

Road Lighting Work Group

Website Developer

Kim Catrambone Melina Davies Hazem Abdel Rahman David Lewis Roy Cupples Rania Hashim Al-Abadi

Issam A. Sarhan

Reviewers

Document Controllers

Dr.Hany Mohamed Ghaleb Al Zubi Adel M. Quraan

Yousef Mahmoud Nooh Saleem Puthiya Purayil Mohammed Adil Rawshan Haniffa

QCS 2014

Feedback

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FEEDBACK It is intended that the technical regulation, Qatar Construction Specifications (QCS), will be amended periodically. Any suggestions for amendments to Qatar Construction Specifications should be sent to Laboratories and Standardisation Affairs in the Ministry of Environment. By post:

The Coordinator Qatar Construction Specifications 2014 Laboratories & Standardisation Affairs Ministry of Environment PO Box 23277 Doha, Qatar

By e-mail:

[email protected]

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Section number and title Part number and title Clause and paragraph number Page Your name and contact details

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Please ensure that the following information are included in all correspondences:

Please use the following feedback form where possible and applicable.

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QCS 2014 Feedback

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Section name and title

Clause and paragraph number

Comments / Suggestions / Technical Justifications

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Name and contact details

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QCS 2014

Section 01: General Part 01: Introduction

Page1

1

INTRODUCTION ........................................................................................... 2

1.1

GENERAL ...................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4

Scope of this Section Scope of the Qatar Construction Specification References Precedence of Specification and Documents

1.2

COMPLIANCE ............................................................................................... 3

1.2.1 1.2.2

Compliance with the Qatar Construction Specification Compliance with the General Conditions of Contract

1.3

STANDARDS ................................................................................................. 3

1.3.1 1.3.2 1.3.3

References to Standards 3 Government Published Specifications, Regulations, Notices and Circulars 3 Survey Marks 5

1.4

TERMS AND DEFINITIONS .......................................................................... 5

1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16 1.4.17 1.4.18 1.4.19 1.4.20 1.4.21 1.4.22

General Approved Contract Contract Documents Contractor Drawings Engineer Engineer’s Representative Government Government Departments and Utility Services Guarantee Independent Agency Owner Permanent Works Plant Project Documentation Singular and Plural Site Specifications Specified Temporary Works Works

1.5

ABBREVIATIONS AND SYMBOLS ............................................................... 7

1.5.1 1.5.2

General Site Conditions

1.6

LANGUAGE ................................................................................................. 10

1.6.1

Contract Language

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QCS 2014


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INTRODUCTION

1.1

GENERAL

1.1.1

Scope of this Section

1

This Section specifies the general clauses applicable to Works being carried out in accordance with this Specification.

1.1.2

Scope of the Qatar Construction Specification

1

The clauses in this Specification are applicable to each and every part of the Works. Their function is to bring together all those statements which are normally common to most types of work.

2

The Qatar Construction Specification applies to the entire Works, whether on the Site or in yards, workshops and factories employed elsewhere in connection with the Works.

1.1.3

References

1

The following standards are referred to in this Part:

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BS 6100......................Building and civil engineering: Vocabulary

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BS ISO 80000 ............Quantities and Units

BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions

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BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for buildings

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ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures Guide to the Design of Concrete Structures in the Arabian Peninsula, 2008

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Seismic hazard and seismic design requirements for the Arabian Peninsula region. The 14th World Conference on Earthquake Engineering October 2008

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Civil Aviation Authority wind records. Ministry of Communication & Transport, Department of Civil Aviation & Meterology. 1.1.4

Precedence of Specification and Documents

1

The precedence of documents shall be: (a)

Particular Conditions of Contract.

(b)

General Conditions of Contract.

(c)

Project Specific Specification.

(d)

Project Specific and General Drawings.

(e)

Qatar Construction Specification.

QCS 2014


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COMPLIANCE

1.2.1

Compliance with the Qatar Construction Specification

1

Unless otherwise stated in the Project Documentation, the Contractor shall comply with every requirement of the Qatar Construction Specification that is relevant to the type of work forming any part of the Contract and shall adopt whichever permissible option or alternative that is best suited to the needs of the construction work being undertaken.

2

Any information in the Contract documents as to the whereabouts of existing services and mains is approximate and for the guidance of the Contractor who shall not be relieved of his obligations under of the General Conditions of Contract .

1.2.2

Compliance with the General Conditions of Contract

1

The Qatar Construction Specification is intended for use with the General Conditions of Contract.

2

The Contractor shall comply with the provisions of the General Conditions of Contract in the course of construction of the Works.

1.3

STANDARDS

1.3.1

References to Standards

1

Any standard referred to in this Specification shall be deemed to be the version and/or standard(s), that was current forty-two days prior to the date of return of Tenders.

2

Any standard referred to in this Specification shall be taken as a reference to an equivalent Specification.

3

The Contractor shall have copies of all referenced standards applicable to the work being undertaken. Translations of standards not written in English shall be provided where necessary.

1.3.2

Government Published Specifications, Regulations, Notices and Circulars

1

The works shall be executed in accordance with the following Government specifications, regulations, notices and circulars:

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1.2

(a)

The General Conditions of Contract.

(b)

The Qatar Construction Specification (QCS) issued by the Qatar Standards, Laboratories and Standardisation Affairs, Ministry of Environment, 2014 and all revisions and addenda issued by the same ministry prior to the date of the announcement inviting tenderer.

(c)

The Code of Practice and Specification for Road Openings in the Highway prepared by the Ministry of Industry & Public Works, January 1992.

(d)

The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Public Works.

(e)

The Qatar Survey Manual prepared by the Survey Section of the former Ministry of Industry & Public Works.

QCS 2014


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The Qatar Traffic Manual prepared by the former Ministry of Public Works and the Qatar Highway Design Manual prepared by MMAA, 1997.

(g)

The Traffic Control at Road Works Manual issued by the former Ministry of Industry & Public Works.

(h)

Rules, Regulations and Code of Practice for Design and Installation of Air Conditioning, Heating, Ventilation & Refrigeration (ACHVR) Systems for Government Buildings, 2nd Edition, 1989, prepared by Qatar General Electricity and Water Corporation (QGEWC).

(i)

Regulations for the Installation of Electrical Wiring by the former Qatar National Telephone Services.

(j)

The Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment, Feb 2006 Edition prepared by the Qatar General Electricity and Water Corporation (QGEWC).

(k)

Rules and Regulations for Plumbing Works prepared by the Qatar General Electricity and Water Corporation (QGEWC).

(l)

Any current and relevant regulations, notices or circulars issued by the Public Works Authority, Ministry of Municipal Affairs & Agriculture (including the previous Ministry of Public Works and the previous Ministry of Industry and Public Works), Qatar General Electricity and Water Corporation (QGEWC) (including the previous Ministry of Electricity and Water), Qatar Telecom (Q-TEL), the Qatar Standards, the Supreme Council for the Environment and Natural Reserves or the appropriate local Municipality prior to the date of the announcement inviting tenderer.

(m)

State of Qatar Law No. 30 of 2002 and all subsequent amendments concerning “The Environment and Natural Resources Protection” – Articles 6, 17, 19 & 35.

(n)

State of Qatar Law No. (6) of 1987 and all subsequent amendments concerning Materials and Equipment from Qatar or other CCASG countries.

(o)

The Method of Measurement for Road and Bridgeworks published by the Ministry of Industry and Public Works, Civil Engineering Department , 1987.

(p)

Standard Method of Measurement of Building Works published by the Ministry of Public Works, Engineering Services Department, 1973.

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Safety Rules issued by the Electricity Networks Department of the former Ministry of Electricity and Water.

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(f)

2

(r)

The Jointing Manual prepared by the Electricity Networks Department of the former Ministry of Electricity and Water.

(s)

The Labour Law, No. (14) of The Year 2004 Published by Labour Department of Ministry of Civil Service Affairs & Housing, 2005.

(t)

Developer’s Drainage Guide prepared by the Public Works Authority, 2007.

(u)

Qatar Traffic Law No. 19 of the Year 2007.

(v)

CDD (Civil Defence Department) – Fire Safety Handbook.

(w)

Civil Defence Law No. 9 of the Year 2012.

(x)

Worker Rights Booklet 2009 (National Human Rights Committee).

The Contractor shall be deemed to have his own copy of the Government specifications, regulations, notices and circulars given at (a) to (t) above.

QCS 2014


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Where any standard publication, specification, regulation, notice, etc or any correspondence refers to a Government Ministry, department, division, section, etc it will be deemed to be the same as any successor Ministry, department, division, section, etc which has or may subsequently be officially promulgated by the Government of the State of Qatar.

1.3.3

Survey Marks

1

The Contractor shall consult the Engineer prior to any earth or other works to determine if the work is likely to disturb survey marks. If the Engineer requires a survey mark to be moved the Contractor will be responsible for recreating the survey mark to an approved design and specification, and for resurveying the point using survey companies approved by the Engineer authority.

2

The Contractor shall be responsible for the protection of the survey marks within the boundaries of the site for the duration of the contract period, and shall be liable for all costs of any remedial work required by the Engineer.

3

On the practical completion of the Works the Engineer will issue a certificate stating that all survey marks, whether disturbed or otherwise by the Contractor, have been reinstated or protected to the satisfaction of the Engineer.

4

In the event of failure to comply with the requirements of this Clause the Engineer, without prejudice to any other method of recovery, may deduct the costs of any remedial work after the practical completion date carried out by the Engineer, from any monies in its hands or which may become due to the Contractor.

1.4

TERMS AND DEFINITIONS

1.4.1

General

1

The following terms and conditions shall apply when used within, or in association with, the Qatar Construction Specification. Terms, which are restricted in their application to certain types of material or workmanship, are dealt with in the appropriate Section.

2

The definitions given in the General Conditions of Contract shall apply to this specification.

1.4.2

Approved

1

means terms such as “approved’, “approved by”, “to the approval”, “as directed” and the like refer always to approval or directions given by the Engineer in writing.

1.4.3

Contract

1

means the binding agreement entered into between the parties and the Contractor for the construction of the Works.

1.4.4

Contract Documents

1

means documents which together form the Contract

1.4.5

Contractor

1

means the party responsible for the construction of the Works.

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Drawings

1

The drawings included in the Project Documentation.

1.4.7

Engineer

1

means the party appointed by the Owner to administer the Contract

1.4.8

Engineer’s Representative

1

means the party appointed from time to time by the Engineer to perform duties on behalf of the Engineer whose authority and delegated powers shall be notified in writing to the Contractor by the Engineer.

1.4.9

Government

1

means the Government of the State of Qatar, including its ministries and offices

1.4.10

Government Departments and Utility Services

1

means any governmental, semi-governmental, administrative, fiscal or judicial ministry, department, commission, authority, tribunal, agency, municipality or body, and shall include the provider of electricity, gas, water, wastewater and other public services, and any party with a regulatory function under the laws of the State of Qatar.

1.4.11

Guarantee

1

A Guarantee is a written assurance that a material, product, component, item of equipment, finishing or any other part of the Works meets certain defined standards or quality criteria and/or lasts for a certain length of time.

2

A warranty is the same as a Guarantee as defined in Clause 1.4.17.1.

1.4.12

Independent Agency

1

means a party where specified in the Contract Documents or as instructed by the Engineer as an Approved agency who is responsible for specific tasks assigned to that party by the Contract Documents

1.4.13

Owner

1

means the party for whom the Project is being undertaken and to whom the handover of the final product will be made.

1.4.14

Permanent Works

1

means the permanent works, forming part of the Works, to be designed and / or executed and completed by the Contractor under the Contract.

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1.4.6

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Plant

1

means, irrespective of ownership, all plant, facilities, temporary structures and accommodation, equipment, tools, appliances, apparatus, machinery, vehicles and other things required for the design, execution and completion of the Works and the remedying of defects, whether imported or locally supplied, but excluding Temporary Works and any other things intended to form or forming part of the Permanent Works

1.4.16

Project Documentation

1

All documents associated with and applicable to the Project Contract.

1.4.17

Singular and Plural

1

Words importing the singular only also include the plural vice versa where the context requires.

1.4.18

Site

1

Means the places provided by the Owner where the permanent works are to be executed and to which Plant and Materials are to be delivered, any other places that may be specified in the Contract Documents or by an instruction of the Engineer as forming part of the Site

1.4.19

Specifications

1

All specifications contained in the Contract including any modifications or additions thereto as may from time to time be issued or approved in writing by the Engineer.

1.4.20

Specified

1

Specified in the Project Documentation.

1.4.21

Temporary Works

1

means temporary works of every kind (other than Plant) required on the Site for the execution and completion of the Permanent Works and the remedying of Defects.

1.4.22

Works

1

means all works, supplies and services of any kind, including Permanent Works and Temporary Works, required for the project and to satisfy the requirements of the Contract Documents.

1.5

ABBREVIATIONS AND SYMBOLS

1.5.1

General

1

Units shall generally be in accordance with the Systèm International d’Unités and the relevant provisions of BS ISO 80000

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1.4.15

QCS 2014

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microns ampere Celsius centi day diameter gram (me) hour hectare joule kilo litre mega metre milli Newton number number Pascal radius second tonne volt Watt

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µ A C c d dia g h ha J k l M m m N No. nr Pa r sec t V W

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American Association of State Highway and Transportation Officials American Concrete Institute American National Standards Institute American Society of Mechanical Engineers American Society for Testing & Materials American Welding Society American Water Works Association British Standard British Standard Institution Cement and Concrete Association Commission of approval of Electrical Equipment Chartered Institution of Building Services Engineers Concrete Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institute fur Normung (German Institute for Standardization) Electronic Industries Association European Standards (Euro-Norm) Federal Highway Authority Factory Mutual Engineering Division Gulf Standards Institution of Civil Engineers International Electrotechnical Commission Institution of Electrical Engineers

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AASHTO ACI ANSI ASME ASTM AWS AWWA BS BSI C & CA CEE CIBSE CIRIA CRSI CS DIN EIA EN FHWA FM GS ICE IEC IEE

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Reference to a technical society, institution, association or governmental authority is made in the Specifications in accordance with the following abbreviations:

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The following abbreviations are used in this Specification:

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IEEE ISO LPC LPCB MMAA NEMA NFPA PCI PWA QCS QGEWC QS

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Institute of Electrical and Electronic Engineering International Organization for Standardization Loss Prevention Council Loss Prevention Certification Board Ministry of Municipal Affairs and Agriculture National Electrical Manufacturer’s Association National Fire Protection Agency Prestressed Concrete Institute Public Works Authority (Ashghal) Qatar Construction Specification Qatar General Electricity & Water Corporation Qatar Standards (Laboratories and Standardisation Affairs, Ministry of Environment) Qatar Telecom Provider Swedish Standards Institute United Kingdom Department of Transport Urban Planning and Development Authority Verband Deutscher Elektrotechniker (Association for Electrical, Electronic and Information Technologies)

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Ooredoo SIS UK DOT UPDA VDE

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QCS 2014

Site Conditions

1

The Site conditions shall be assumed to be as follows for tendering purposes:

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1.5.2

Maximum ambient temperature .......................... 50C

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Minimum ambient temperature ........................... 5C

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Design ambient temperature ............................... 50C Maximum metal temperature under the sun ....... 85C

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Maximum ambient humidity ................................ 100% Minimum ambient humidity ................................. 20%

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Design ambient humidity ..................................... 100% 50-year return period Wind Speed:

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(a) Nominal wind speed for 3 sec gust ……… 38 m/s (A per ASCE 7-05 / IBC 2012) (b) Mean hourly wind speed…………….…… 25 m/s (as per BS 6399-2)

(c) Mean 10 minutes wind speed…………… 27 m/s (as per BS EN 1991-1-4)

Yearly rainfall ....................................................... 80 - 150 mm 2

The wind is very directional and that the W-NNW sector predominates for velocities greater than 8m/s (30km/h). However, the wind in coastal areas tends to exhibit a diurnal pattern, with onshore winds during daylight hours changing to offshore at night.

3

The temperature is relatively mild from October to May and hot from June to September.

4

The relative ambient humidity is generally low from October to May and generally high from June to September.

5

Under certain climatic conditions, considerable condensation may take place.

6

A considerable amount of salt is contained in the atmosphere which together with the relatively high ambient humidity, can produce sever corrosion problems.

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7

Distribution and occurrence of rainfall events are very erratic. Rainfall events are generally of a high intensity with a short duration and usually occur between December and March.

8

The prevailing wind directions are from the north and west.

9

The seismic design for all building structure shall be based upon local seismic accelerations recommended as per ASCE 7-10, IBC 2012 or BS EN 1998-1:2004. Local seismic spectral accelerations based upon uniform hazard response spectra for 475 year and 2475 year return period as below. Peak Ground Acceleration (PGA) 2475 year

475 year

2475 year

475 year

0.045

0.10

0.090

0.147

0.045

2475 year

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475 year

0.065

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Wind tunnel test is recommended for buildings under below criteria Total building height exceeding 120m from ground.

(b)

Structure with irregular geometry or shape.

(c)

Unusual terrain or surrounding structure in the area.

(d)

Any other factor as per design requirements or designer recommendation.

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(a)

The ratio of the wind speed for any return period to the 50 year return period wind speed as per Peterka & Shahid Equation is

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1 second Spectral Acceleration (g) – S1

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0.2 second Spectral Acceleration (g) - Ss

Building structure design working life shall be minimum as specified below

10

Examples

Temporary structures (a)

10 to 25

Replaceable structural parts, eg. Gantry girders, bearings

3

15 to 30

Storage and similar structures

4

50 to 75

Building structures and other common structures

5

120

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Indicative design working life (years)

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Design working life category

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12

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VT / V50 = [0.36+0.1 ln (12T)]

(a)

Civil engineering structures like bridges, tunnel etc.

Structures or parts of structures that can be dismantled with intention of being reused, aren’t temporary structures.

1.6

LANGUAGE

1.6.1

Contract Language

1

All communications, meetings and documentation shall be in English. END OF PART

QCS 2014

Section 01: General Part 10: Occupational Health and Safety

Page 1

10

OCCUPATIONAL HEALTH AND SAFETY .................................................... 3

10.1

GENERAL ...................................................................................................... 3 3 3 4 5 6 6 7 7 7 8 8 10 10 11

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10.1.1 Scope 10.1.2 Responsibility 10.1.3 Organisation for Occupational Health and Safety 10.1.4 Reporting Accidents 10.1.5 General Sanitation 10.1.6 Safety Notice Board 10.1.7 Compensation for Damage 10.1.8 Occupational Health and Safety Performance 10.1.9 Occupational Health and Safety Leadership and Accountability 10.1.10 Safe-working Arrangements 10.1.11 Labour Rights, Benefits & Obligations 10.1.12 Language barriers and communications issues 10.1.13 Communications, Consultations and Participation 10.1.14 Management Review

CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN ............. 11

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6

General Occupational Health and Safety Policy Risk Assessment and Job Hazard Analysis Intervention Requirement for Training Method Statements

10.3

EMERGENCY RESPONSE PLAN (ERP) .................................................... 19

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10.3.1 General

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10.2

11 16 16 16 17 19 19

EARTHQUAKE EMERGENCY MANAGEMENT PLAN ............................... 20

10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.4.6 10.4.7

Background Requirements Phase One: Gap Analysis (‘as is’) Phase Two: Implementation (‘to be’) Phase Three: Future Requirements What Should We Do During An Earth Quake? What Should We Do After An Earth Quake?

10.5

SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS ..................... 24

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10.5.1 Permits 10.5.2 Guarantee 10.5.3 Mechanical Plant, Machinery and Equipment 10.5.4 Existing Utilities 10.5.5 Excavations 10.5.6 Warning Signs 10.5.7 Confined Spaces 10.5.8 Lifting Operation 10.5.9 Lifting Gear 10.5.10 Scaffolding

20 21 21 22 22 23 23 24 24 24 25 26 28 28 30 30 31

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10.5.11 Hot work and Welding 10.5.12 Compressed Gas Cylinders 10.5.13 Working at Height 10.5.14 Electrical 10.6

32 33 34 36

FIRST AID ................................................................................................... 37

10.6.1 First Aid and Clinic 10.7

37

FIRE PRECAUTION AND PREVENTION ................................................... 37

10.7.1 General 10.7.2 Emergency Equipment 10.7.3 Hazardous Substances

SAFETY OF THE PUBLIC ........................................................................... 41

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10.8

37 39 40

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10.8.1 Working in Public Areas

41

WELFARE, SAFETY AND PROTECTION OF WORKMEN ........................ 42

10.9.1 10.9.2 10.9.3 10.9.4 10.9.5 10.9.6 10.9.7

General Personal Protective Equipment (PPE) / Attire Safety Equipment Support Facilities for Contractors Staff and Labour Summer Working Conditions and fatigue Additional Environmental Protection and Pollution Control Plant and Equipment Test Certificates

10.10

LABOUR ACCOMODATION ....................................................................... 46

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10.9

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10.10.1 General 10.10.2 Quality of Labour Accommodation 10.10.3 Provision for Fire Safety 10.10.4 Provision for Health Care 10.10.5 Access to Transport 10.10.6 Access to Religious, Social and Domestic Facilities 10.10.7 Access to Communications 10.10.8 Number, Quality and Location of Sanitation Facilities 10.10.9 Food Preparation Areas 10.10.10 Pest and Vermin Control 10.10.11 Security at Labour Accommodation 10.10.12 Social Issues 10.10.13 Competence of Labour Accommodation Management 10.10.14 Environmental Conditions at Labour Accommodation 10.10.15 Health and Safety for Labour Accommodation Residents

42 42 42 43 45 45 46 46 46 47 47 48 48 49 49 49 50 50 50 51 51 52

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10

OCCUPATIONAL HEALTH AND SAFETY

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the Health, Safety and Welfare requirements for construction and its associated practices.

2

Related Sections and Parts are as follows.

Section 11

Health and Safety

.

Protection Building Demolition Materials Engineer’s Site Facilities Setting-out of the Works

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Part 4 Part 8 Part 9 Part 11 Part 13

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This Section

Responsibility

1

It is the Contractors responsibility to implement an Occupational Health and Safety Management System meeting as a minimum the requirements of BS OHSAS 18001. It shall be the duty of the Contractor to provide the following:

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10.1.2

Safe plant and equipment;

(b)

Safe means of handling, transporting and storage of articles and substances;

(c)

Adequate training, instruction, information and supervision;

(d)

A safe place of work with safe access to and egress from the place of work;

(e)

A safe and healthy environment; and

(f)

Adequate welfare facilities.

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(a)

It is the Contractor’s responsibility to conduct his operations in such a manner as to prevent injury to persons or damage to property. The Contractor shall take precautions for protection against risks and shall inspect Occupational Health and Safety conditions where the Works are being executed.

3

The Contractor shall conform to all Acts, Orders and Regulations made by any official authority with respect to Occupational Health and Safety.

4

The Contractor shall note that Occupational Health and Safety (OHS) shall be treated with high importance at all stages of the Contract. Contractor shall understand that the Contract Price includes the Execution Programme for provision and implementation of an Occupational Health and Safety Policy and Plan to ensure the highest standards are enforced throughout Construction, Pre-commissioning and Commissioning.

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The Contractor’s attention is drawn to the requirements of latest revision of: Qatar Construction Specification – QCS,

(b)

Qatar Law No.14 of the Year 2004 – The Labour Law, and the ministerial decisions issued in implementation of the provisions of the Labour Law issued by Law No. 14 of 2004,

(c)

Qatar Traffic Law No. 19 of the Year 2007,

(d)

Environmental Protection Law No. 30 of the Year 2002 and Decision No. (4) for the year 2005 by issuing the executive regulations of Environmental Protection Law,

(e)

Civil Defence Law No. 9 of the Year 2012,

(f)

CDD (Department of Civil Defence) – Fire Safety Handbook; and

(g)

Worker Rights Booklet 2009 (National Human Rights Committee).

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The Contractor is required to fully comply with the stated requirements relating to Occupational Health and Safety. In the event that legislation is updated the latest version shall be followed. The Contractor shall ensure that Contractor Personnel and Subcontractor’s employees comply with all requirements of latest revision of QATAR legislation mention above (but not limited to). Compliance with the standards shall be considered as a minimum requirement and Contractor shall establish additional arrangements as circumstances may require. Any failure by Contractor to obtain copies of that mentioned laws applicable to the Contract shall in no way relieve the Contractor from any responsibilities or obligation under the Contract.

7

The Contractor’s Representative shall be responsible for all Occupational Health and Safety matters during the performance of the Work up to and including the Completion Date. The Contractor’s Representative shall ensure that an effective Occupational Health and Safety management organization is maintained at all times to undertake the duties to comply with this requirement.

10.1.3

Organisation for Occupational Health and Safety

1

The Contractor shall submit an Occupational Health and Safety Organisation Plan detailing planning and management considerations for construction at an organisational level for the Engineer’s approval within Thirty (30) days of the award of the Contract.

2

The Occupational Health and Safety Organisation Plan shall provide the names, qualifications, experience and skills of all the Safety Team and key support staff.

3

The Contractor shall submit the names of the following to the Engineer for approval:-

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(a)

The details of its proposed competent and experienced Occupational Health and Safety Manager. The minimum education for the proposed Occupational Health and Safety Manager are but not limited to Bachelor degree in Engineering / Science or equivalent with 10 years experiences in the same field as Safety Manager and the ability to communicate with all nationalities, plus Professional OHS Qualification by Examination (NEBOSH, IOSH Managing Safely, OSHA 30 hours, ... etc), Management Qualification prefer certified as BS OHSAS 18001 lead auditor, implementation and continues improvement Relevant Training Attendance. The Engineer shall review the details and if necessary interview the proposed individual to assess his/her suitability for the position prior to giving approval for appointment. The Contractor is not

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permitted to execute any form of Work on the Worksite until such time as an approved Occupational Health and Safety Manager has been deployed on a full time basis to the Worksite. The Contractor shall not remove the appointed Occupational Health and Safety Manager without prior approval from the Engineer. (b)

Deputy Occupational Health and Safety Manager who is capable of performing all of the duties of the Occupational Health and Safety Manager in the event of his absence. The requirements and procedure outlined in Clause (a) above applies equally to the appointment of the Deputy Occupational Health and Safety Manager.

The Contractor shall appoint Occupational Health and Safety Officers and support staff in sufficient numbers to ensure the effective function of the Occupational Health and Safety discipline within the Contractor’s organisation. The minimum education for the Occupational Health and Safety Officer are HND / HNC with 4 years experiences in the same field as Safety officer, certified from NEBOSH, IOSH or OSHA 30 hours, Professional in control and monitoring the site activity. The Contractor shall appoint and deploy full time on the Worksite one Occupational Health and Safety Officer for each and every 50 persons employed at the Worksite. For a less than 50 persons employed at the Worksite, a minimum of one (1) Safety Officer shall be present on site during all working hours each day throughout the Contract period. This is in addition to the Occupational Health and Safety Manager and his Deputy.

5

The Safety Officers shall have no other duties, either on-site or off-site, other than Occupational Health and Safety duties, and shall be exclusive to one site.

6

The Contractor shall ensure that each and every Subcontractor employed on the Worksite appoints suitably competent and experienced qualified Occupational Health and Safety staff to ensure the effective function of the Occupational Health and Safety discipline within the Subcontractor’s organisation. The requirements and procedure outlined above for contractor Occupational Health and Safety staff to be applies equally to the appointment of the Subcontractor Occupational Health and Safety Staff. The Subcontractor shall appoint and deploy full time on the Worksite one Occupational Health and Safety Officer for each and every 50 persons that they employ at the Worksite. Any Subcontractor that employs more than 100 persons will appoint an Occupational Health and Safety Manager. This is in addition to the Occupation Occupational Health and Safety Officers.

10.1.4

Reporting Accidents

1

The Contractor shall promptly report to the Engineer any accident whatsoever arising out of, or in connection with, the Works whether on or adjacent to the Site which caused death, personal injury or property damage, giving full details and enclosing statements of witnesses.

2

Promptly shall mean immediately by telephone where it impacts on the operation of the project and electronically in all cases never more than 24 hours.

3

The Contractor shall implement arrangements for effectively managing any emergency incident that may occur as a result of Work and/or on the Worksite.

4

The Contractor shall make all necessary arrangements for emergency preparedness including, but not limited to, medical equipment and facilities, trained personnel, communication systems, transportation, search and rescue equipment.

5

The Contractor shall produce and submit to the Engineer monthly performance reports and incident reports. Reports shall be in the format approved by the Engineer.

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6

The Contractor shall refer to, and in particular, QCS 2013 (Section 11, Part 2) for all incident classifications and definitions.

7

Incident Investigation final reports to be submitted for all lost time major / reportable Incidents within 10 days of the incident. All incidents that result in lost time from work, near miss, dangerous occurrence or damage to property (asset) shall be reported. The normal steps to be taken after an incident shall be; Submit incident notifications immediately;

(b)

Conduct the investigation;

(c)

Prepare the report with conclusions and recommendations;

(d)

Prepare appropriate plan of corrective action;

(e)

Include in monthly Health and Safety statistics report;

(f)

Submit to Engineer for review and re-submittal if required.

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(a)

General Sanitation

1

The Contractor shall maintain the Site and all working areas in a sanitary condition and in all matters of health and sanitation shall comply with the requirements of the Supreme Council of Health and the Public Works Authority.

2

The Contractor is responsible for all measures necessary to prevent the breeding of mosquitoes on the Site for the duration of the Contract.

3

The Contractor shall ensure that pests are not permitted to the Site facility by initiating a routine pest control program. Non-toxic pest control methods shall be used.

4

The disposal surplus water and the accompanying growth of trees and the proliferation of insects and rodents. Does the site cause an environmentally danger to the surrounding area?

10.1.6

Safety Notice Board

1

The Contractor shall set up and maintain (cleaned and legible) throughout the course of the Contract safety notice boards in prominent places on the Site. These notice boards shall be located in positions approved by the Engineer such that they are clearly visible to the Contractor’s employees. They shall be fully illustrated and provide details of key safety procedures to be followed.

2

The notice boards shall be in Arabic, English and;

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10.1.5

(a)

In all other languages which are the mother tongue of five or more of the Contractor’s employees, or

(b)

The preferred languages (can be understood) by the workers on the Worksite.

3

The Contractor’s employees shall be made fully aware of the notice boards prior to commencing duties on Site.

4

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Work.

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Compensation for Damage

1

Claims for compensation arising from damage or injury caused by the Contractor’s failure to provide adequate Occupational Health and Safety measures shall be the sole responsibility of the Contractor.

2

The Contractor shall notify the Engineer of any claim made against him which is in any way connected to the Contract.

3

The Contractor is required to copy to the Engineer any formal Occupational Health and Safety related communication between the Contractor and enforcing authorities or government organizations.

10.1.8

Occupational Health and Safety Performance

1

The Contractor shall ensure acceptable Occupational Health and Safety performance of all Subcontractors, visitors, vendors, public and other parties that may enter the Worksite or the amounts identified in the Bills of Quantities.

2

Should acceptable Occupational Health and Safety performance not be maintained by the Contractor then the Engineer may, in addition to any other amounts withheld under the Contract, withhold up to 10% of the amount of any interim invoice issued by the Contractor.

3

The Contractor shall develop and implement programmes which shall act as incentives for their teams at all levels, to make a positive contribution to good health and safety performance.

10.1.9

Occupational Health and Safety Leadership and Accountability

1

The Contractor shall be committed to Health and Safety leadership and this is to be achieved through working in partnership with the main project stakeholders including the Engineer and the Client.

2

The Contractor shall demonstrate commitment to the safety, health and welfare of all stakeholders and workers on projects and shall demonstrate leadership in achieving the following objectives:

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10.1.7

(a)

A safe, healthy workplace

(b)

Be consulted on their working conditions, to be heard, and to influence their working conditions

(c)

Return home from work unharmed at the end of each working day; to which everyone has a right to.

3

The Contractor shall provide opportunities through forums and meetings involving important project stakeholders, including the Client, The Engineer, sub-contractors and other relevant contractors to raise health and safety issues, assist in the development of leadership programmes, share good practice and be recognised for good performance.

4

The Contractor’s senior management shall visibly demonstrate support, commitment, Leadership and Accountability on all health and safety issues by the following actions: (a)

The Engineer’s Zero Harm Initiative;

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Training employees to work safely;

(c)

Recognizing and rewarding employees;

(d)

Identify risks to health and safety and develop mitigation/control plans and communicate these to workers;

(e)

Reinforce safe work practices;

(f)

Place health and safety as the first item on the agenda at meetings.

(g)

Allocate adequate resources for health and safety management and implementation

(h)

Develop health and safety targets and objectives and measure and review performance;

(i)

Foster positive health and safety culture and behaviour through their own actions;

(j)

Treat health and safety as a core value equal in importance with productivity, quality and ethical standards;

(k)

Participate in health and safety meetings and safety walkabouts;

(l)

Develop efficient contingency plans and allocate adequate emergency resources;

(m)

Provide trained and competent workforce;

(n)

Promote personal health and well-being; and

(o)

Seek to exceed current legislation in relation to welfare and labour facilities.

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10.1.10 Safe-working Arrangements

The Contractor shall have arrangements to empower their staff to make sensible decisions about their own safety and the safety of others affected by what they do, and not put themselves or others at risk of harm.

2

Contractor to have safe-working arrangement that ensures:

Employees can stop work immediately where they believe they or others are at risk of harm

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(b)

That health and safety concerns can be raised and associated actions taken

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(c)

No disciplinary action is taken against those who use the worksafe arrangement to raise a genuine health and safety concern

(d)

That the process is cascaded to their subcontractors

3

All such arrangements shall be briefed to all staff, including any agency or sub contract staff before they start work.

4

Where safety concerns are raised or a stop work process has been invoked employers shall document them and the action taken to resolve them; and shall advise others working on the project were the issue is likely to impact on them or be similar to those faced by other organisation

10.1.11 Labour Rights, Benefits & Obligations 1

The Contractor shall document implementation of Labour Law, in particular with respect to the following:

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Recruitment – The Contractor shall maintain an up-to-date list of all agents/agencies used and should provide copies of licences for same to the Engineer. The Contractor shall, through their best endeavours, satisfy themselves, and the Engineer, that recruitment agents/agencies used do not charge recruits any fees inconsistent with those allowed for under the Labour Law (Qatar Law no.14 of the year 2004).

(b)

Contracts – The Contractor shall retain, for inspection by the Engineer, copies of written employment contracts for all employees working on the project. Such employment contracts shall be in accordance with the requirements of the Labour Law and no contract clause may contravene the Labour Law.

(c)

Wages – A Wage Register shall be retained in accordance with the requirements of the Labour Law. The Contractor shall update the Wage Register to ensure that employee wages, including relevant overtime payments, are paid in a timely fashion and in a manner consistent with the requirements of the Labour Law. These records shall be available for inspection by the Engineer and shall clearly identify overtime payments and rates.

(d)

Severance Pay – The Contractor shall retain records to demonstrate that payment of severance payments have been made, where appropriate, in accordance with Article 132 of the Labour Law.

(e)

Records & Files – These shall be retained in accordance with the Labour Law, and shall be made available to the Engineer for inspection.

(f)

Work Rules & Disciplinary Rules – These shall be in accordance with the Labour Law, shall be conspicuously displayed, and shall be provided to the Engineer.

(g)

Working Hours & Leave - The Contractor shall retain records to demonstrate that all employees’ working hours and leave allowances are consistent with the requirements of the Labour Law.

(h)

Collective Labour Disputes - Any/all collective labour disputes shall be dealt with in accordance with the requirements of the Labour Law. Complete records of all such disputes shall be retained by the Contractor for review by the Engineer. As a minimum, the Contractor shall inform the Engineer immediately, on receipt of complaint/claim from the employees. Subcontracts As such, obligations, relating to Recruitment, Contracts, Wages, Records & Files, Work Rules & Disciplinary Rules, Working Hours & Leave and Collective Labour Disputes shall be passed on to the subcontractor in the event that works are subcontracted by the Contractor. Similarly, subcontractor records shall be made available to the Engineer.

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(a)

2

The Contractor shall provide copies of Contracts, Work Rules, Disciplinary Rules, Pay Slips, etc. to employees in a range of appropriate languages, as widely understood by the workforce.

3

The Contractor shall submit a monthly declaration to the Engineer outlining compliance with Labour Law in relation to payment of wages and working hours for the preceding period.

4

The Contractor shall facilitate contact between project employees and relevant independent bodies such consulates, NGOs, or other relevant organisations offering social support. A list of such local contacts shall be provided to new employees during their induction process. An up-to-date list of contact details for these organisations shall also be displayed in public areas such as the canteen, recreational areas, etc.

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10.1.12 Language barriers and communications issues 1

The Contractors shall ensure that their workforce fully understand site health and safety requirements, including emergency arrangements and site rules in place. The language needs of personnel shall be addressed during induction and through training. Emphasis should be placed on ensuring proper supervision of all staff, but in particular those who may have difficulties in understanding verbal or written communications. Where practicable, signage shall make maximum use of pictograms.

2

Those who have responsibility for managing Contractor personnel on construction site shall be able to communicate in both written and oral English to a standard appropriate to the tasks being performed. Note that there may be personnel who are not competent in the English language, and this is permitted provided that the Contractor can demonstrate that:

(b)

Such team members shall receive the required health and safety training / briefing (including any emergency procedures) before commencing work in a form that they understand

(c)

Appropriate arrangements are made to ensure that instructions are effectively communicated to and understood by all team members

(d)

Particular attention has been given to the communication requirements of safety critical workers. ensuring a translator is available who is capable of instructing the nonEnglish speaking personnel in safety and other operational matters, and

(e)

Maintaining a reasonable ratio of non-English speaking personnel to each translator at all times.

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Such team members are able to give oral instructions and warnings to others

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Special provisions for safety critical instructions conveyed by the translator shall be recorded as being received and clearly understood by each non-English speaking person. Such records shall include those for safety induction, emergency procedures, safety method statements and safety awareness talks.

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10.1.13 Communications, Consultations and Participation The Contractor shall be required to disseminate and transfer information regarding Health and Safety issues. Typical information to be communicated should include but not be limited to; any new policies or procedures and general awareness.

2

The Contractor shall ensure communications arrangements are in place to inform of key health and safety issues. These will include lessons learnt from incidents, sharing of good practice, health and safety campaigns and initiatives. Contractors shall have processes in place to ensure an appropriate cascade to all site personnel.

3

The following methods of communication but not limited to shall be observed;

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(a)

Meetings; Health and safety meetings shall be conducted on a weekly basis separate from other meeting that have safety on the agenda

(b)

Safety Alerts; Safety alerts shall be produced by the Contractor after a Major Accident/Incident or when appropriate.

(c)

Notice Boards; Information that shall be included as a minimum on an office notice board is any relevant emergency procedures, policy statement, safety alerts or updates

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(d)

Campaigns; Health and safety campaigns must be initiated by the Contractor to implement throughout the year. At least 4 campaigns must be run annually on a prorata basis. One of the campaigns must detail heat stress before the summer months.

(e)

Posters/Signs; Must be focused on themes relevant to site specific work activities/hazards

(f)

Safety Awards; The Contractor shall initiate a scheme whereby he recognises and rewards for positive health and safety related performance by individuals. This shall be on a monthly basis and communicated throughout the project workforce.

10.1.14 Management Review The Contractor has to supply evidence that their senior management have carried out a management review, at least annually, of their OHSE systems to ensure continuous improvement.

2

The review shall include, but not limited to, where appropriate, an evaluation of and / or changes to:

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Health and safety policy;

(b)

Objectives and targets;

(c)

Action plans;

(d)

Follow-up action from previous meetings;

(e)

Health and safety system suitability;

(f)

Audit results;

(g)

Preventive and corrective actions;

(h)

Regulatory changes;

(i)

Continual improvement measures;

(j)

Performance measures;

(k)

Major procedure and risk review changes; and

(l)

Health and safety plans.

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CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN

10.2.1

General

1

The Contractor shall prepare a Contract specific Occupational Health and Safety Plan (the “Safety Plan”) and submit a Safety Plan to the Engineer for review and approval within thirty (30) days of the award of the Contract. The Contractor is not permitted to Work on the Worksite until such time as the Plan has been approved by Engineer. It will be a condition precedent to starting the works that the Contractor will have an approved Health and Safety Plan, Traffic Management Plan, and an Emergency Response Plan.

2

The Safety Plan shall include the Contractor’s proposals for the maintenance of safety on the Site. These proposals shall address the safety measures applicable with respect to all tasks to be undertaken in the construction of the Works.

3

The Safety Plan shall include the Contractor’s proposals for accident prevention. Accident prevention shall include but not be limited to training, monitoring and review of safety related procedures, enforcement of safety related matters and promoting safety awareness.

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The Safety Plan shall include a safety organisation chart showing the names and responsibility of all safety personnel deployed both on and off the Worksite to maintain acceptable Occupational Health and Safety performance of the Contract and the Work at all times, even outside the normal working hours, in particular night-time and holiday working. (refer to 10.1.3)

5

The Contractor is required to work in areas where dangerous concentrations of gases may be present in manholes, trench excavations and the like. It is the Contractor’s responsibility to provide all necessary detection equipment and to ensure that, if toxic or explosive gases are found, adequate measures are taken to protect his staff, workmen and members of the public.

6

The Safety Plan shall be specific to one Contract.

7

The Contractor shall regularly review the suitability of the Safety Plan. The Contractor shall undertake a full formal review of the Safety Plan annually on the date of award of the Contract or when necessary but no less than 6 monthly intervals and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendment be required.

8

The Safety Plan shall contain the Contractor’s Occupational Health and Safety Policy. (refer to 10.2.2)

9

The Plan for construction works shall support and supported by the Contractor’s systems for risk management in particular risk assessment and method statement (refer to the Regulatory Document Section 11 Part 1 in particular section 1.1.7: Risk Assessments and Method Statement and Guidance document Section 11 Part 2 Section 2.4: Guidance on Risk Assessment and Method Statement). The plan shall include a schedule of risk assessments for all work activities in relation to the project. The plan shall include a list or schedule of identified work activities for which method statement will be developed before their execution..

10

The Safety Plan shall include the contract risk assessment and detail the arrangements for ensuring that it is updated to reflect any changes throughout the duration of the Work.

11

The Safety Plan shall detail the arrangements for undertaking job hazard analysis and ensuring that such analysis is included in each and every method statement.

12

The Safety Plan shall detail the management arrangements and standards to be used for each of the following:

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(a)

Scaffolding

(b)

Suspended Working Platforms

(c)

Fall Prevention and Fall Arrest

(d)

Prevention of Falling Objects

(e)

Excavations

(f)

Electricity

(g)

Structural Steel Erection

(h)

Demolition and Dismantling

Section 01: General Part 10: Occupational Health and Safety False work and Formwork

(j)

Reinforcement and Concreting

(k)

Cladding and Roof work

(l)

Confined Spaces

(m)

Lifting Appliances and Lifting Gear

(n)

Mobile Plant and Vehicles

(o)

Mobile Elevating Working Platforms

(p)

Construction Lifts

(q)

Machinery and Equipment

(r)

Power Tools

(s)

Hazardous Substances

(t)

Hot Work and Welding

(u)

Fire Prevention and Protection

(v)

Access and Egress

(w)

Housekeeping

(x)

Warning Signs and Barricades

(y)

Material Handling, Transportation and Storage

(z)

Lock Out and Tag Out

(aa)

Temporary Works

(bb)

Temporary Facilities

(cc)

Underground and Overhead Utilities

(dd)

Working Over or Adjacent to Water

(ee)

Working Environment

(ff)

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Personal Protective Equipment Site Traffic Control (including setting and taking down of all temporary traffic devices)

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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure acceptable Occupational Health and Safety performance of all Subcontractors that may enter the Worksite. It shall detail the arrangements for evaluating Subcontractors prior to them being contracted to undertake Work. It shall detail the methods that the Contractor shall use to monitor their work and the penalties that shall be imposed should acceptable standards not be maintained.

14

The Safety Plan shall detail the manner in which the Contractor shall review, approve and incorporate all Subcontractor Occupational Health and Safety plans, risk assessments and method statements and incorporate them into their Occupational Health and Safety management system.

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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure acceptable Occupational Health and Safety performance of all persons on the Worksite. In particular it shall detail the arrangements for penalties and disciplinary action that shall be taken should Contractor Personnel, Subcontractor employees or any other person on the Worksite not comply with Occupational Health and Safety requirements.

16

The Safety Plan shall detail the arrangements that the Contractor shall use to control and ensure acceptable Occupational Health and Safety performance of visitors and delivery personnel that may enter the Worksite.

17

The Safety Plan shall detail the Contractor’s arrangements for effectively managing any emergency incident that may occur as a result of Work or on the Worksite. The detail shall include the facilities required for emergency preparedness.

18

The Safety Plan shall detail the arrangements for notification and investigation of any incident that may occur as a result of Work or on the Worksite.

19

The Safety Plan shall detail the arrangements for the Contractor’s monthly performance reporting and incident reporting.

20

The Contractor shall ensure that their project monthly health and safety statistics report is completed and submitted by the agreed date to the Engineer and Quality & Safety Department. The Engineer will provide the necessary format for this report. The information collected will be submitted to the Engineer and Quality & Safety Department.

21

The Safety Plan shall detail the arrangements for assessing the general Health of employees and any job specific Health checks that may be required.

22

The Safety Plan shall detail the arrangements for self-inspection and auditing that shall be used to monitor the Work.

23

The Safety Plan shall detail the arrangements for tracking and effectively closing any Occupational Health and Safety related nonconformity or deficiency that may be identified as a result of monitoring. Written records of inspection, auditing and tracking shall be maintained and made available to any representative of Client on request.

24

The Safety Plan shall detail the arrangements for ensuring that all Contractor Personnel and Subcontractor employees are trained and competent to undertake their work in accordance with the required standards. In particular the Safety plan shall detail the training and competence requirements for the following employees;

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(a)

Supervisors

(b)

Electricians

(c)

Mobile plant and vehicle operators

(d)

Crane and lifting appliance operators

(e)

Riggers

(f)

Excavation Supervisors

(g)

Machinery operators

(h)

Scaffolders

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Scaffolding Supervisors

(j)

Confined space workers

(k)

Confined space supervisors

(l)

All persons working at height

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The Safety Plan shall detail the training arrangements specify the type and nature of training to be given including but not limited to induction, pre-work briefings, tool box talks, general awareness training, skills training and formal training conducted by training professionals or agencies. Written records of the attendees, training given and assessment of competency shall be maintained by the Contractor and made available for inspection by any representative of Client upon request.

26

The Safety Plan shall detail the Contractor’s arrangements for promoting the awareness of Occupational Health and Safety issues through notices, posters, newsletters, booklets, Occupational Health and Safety alerts and any other means. All such information shall be provided in the languages preferred by the training recipients of the training.

27

The Safety Plan shall detail the arrangements that the Contractor shall make to reinforce good performance. Such arrangements shall include incentive schemes to reward Contractor Personnel, Subcontractor employees or areas of Work that demonstrate exemplary Occupational Health and Safety performance.

28

The Safety Plan shall include details of all meetings that are held to specifically deal with Occupational Health and Safety issues. In particular the Contractor shall hold a monthly meeting chaired by the Contractor’s Representative, which Client shall be invited to attend, with the following items on the agenda;

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Suitability of the Contractor’s Occupational Health and Safety organization for the ongoing and planned Work;

(b)

Effectiveness of the Contractor’s system;

(c)

Significant areas of planned activity and associated risk;

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Method statement review and job hazard analysis planning; Tracking and closure of any identified deficiencies or nonconformities;

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(f)

Incident review;

(g)

Occupational Health and Safety promotion planning;

(h)

Training needs assessment;

(i)

Auditing and inspection planning;

The Occupational Health and Safety Plan shall describe the Contractor’s Safety Management System that will be used throughout and shall conform with all requirements defined within the Contract and related documentation The contents shall include but not be limited to the following: (a)

Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Occupational Health and Safety Objectives

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Occupational Health and Safety Policy and BS OHSAS 18001 Certificate (if applicable)

(e)

Control of Occupational Health and Safety Plan

(f)

Reference Documentation

(g)

Safety Organisation and Responsibilities

(h)

Subcontractor Occupational Health and Safety

(i)

Risk Assessments and Method Statement

(j)

Non-conformance, Corrective and Preventative Action

(k)

Incident Reporting

(l)

Audits

(m)

Training

(n)

Key Performance Indicators and Continual Improvement

(o)

Management Review

(p)

Safety Meetings

(q)

Monthly Safety Report

(r)

Appendices

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(d)

Occupational Health and Safety Policy

1

The Contractor shall comply with the Client vision, mission and strategic objectives.

2

The Contractor shall develop and implement its own written Occupational Health and Safety Policy which shall be Project specific and demonstrate the Contractor’s understanding of and commitment to maintaining standards of Occupational Health and Safety (OHS) that are consistent with and an integral part of the Contractor’s business strategy.

3

The Contractor must set objectives and targets that shall be applicable to SMART - Specific, Measurable, Achievable, and Realistic and to a Time scale.

10.2.3

Risk Assessment and Job Hazard Analysis

1

Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

10.2.4

Intervention

1

A system of positive intervention shall be used throughout the Project and the Contractor shall adopt the system by authorizing and requiring all Contractor Personnel and Subcontractor employees to intervene in any unsafe act or condition and take immediate corrective action to prevent any incident occurring.

2

Work may be monitored by any representative of Client who may intervene in any unsafe act or condition and require the Contractor to take immediate corrective action to prevent any incident occurring.

3

The Contractor is required to acknowledge that the system of positive intervention in use on the Project is one that shall enhance the following;

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(a)

levels of understanding and awareness of Occupational Health and Safety issues throughout the Project;

(b)

levels of personal responsibility and accountability for Occupational Health and Safety issues;

(c)

levels of proactively towards Occupational Health and Safety issues;

(d)

levels of compliance with contractual requirements and Project Occupational Health and Safety standards;

(e)

incident and injury prevention

The Contractor may be the focus of Occupational Health and Safety audits conducted by any representative of Client. The Contractor is required to cooperate with such audits and to acknowledge all audit findings. The Contractor shall take all corrective and preventive actions that may be required to address any nonconformity identified during such auditing.

5

The Contractor may be the focus of Occupational Health and Safety inspections conducted by any representative of Client. The Contractor is required to cooperate with and acknowledge such inspections and take all corrective and preventive actions that may arise as the result of such inspections.

6

The Contractor shall undertake routine Occupational Health and Safety inspections and audits for the on-going Work. Written records of inspections and audits shall be maintained and made available to any representative of Client upon request.

7

The Contractor may be issued with stop work instructions from the Engineer for any observed cases of serious or imminent danger associated with the Work. On receipt of a stop work instruction the Contractor shall refrain from work until such time as remedial action has been taken to alleviate the serious or imminent danger and to prevent it reoccurring.

8

The Contractor shall stop work if any unknown or unplanned conditions occur that give rise to serious or imminent danger. In such circumstances the Contractor shall assess the risks associated with any remedial work required and revise the method statements and job hazard analysis. The revised method statement shall be reviewed and approved by the Contractor’s Occupational Health and Safety Manager. Revised method statements shall be approved by the Engineer before recommencing Work.

10.2.5

Requirement for Training

1

The Contractor shall conduct training including contract specific induction, pre-work briefings, tool box talks, general awareness training, skills training and formal training conducted by training professionals or agencies. The contract specific induction will be at least 2 hours duration, approved by the Engineer and provided for all persons that enter the Worksite. Such induction training will be reviewed, revised and repeated for all persons that enter the Worksite at periods not exceeding 6 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training.

2

The Contractor is required to provide employees of Client with Occupational Health and Safety training relating to Work undertaken by the Contractor. Training is an integral part of job performance.

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The Contractor shall provide all Contractor Personnel and Subcontractor’s employees with individually unique Contract specific photo identity cards. Such cards shall be made available to any representative of Client on request. The Contractor shall not permit any Contractor Personnel or Subcontractor’s employees to access the Worksite unless they have been issued with their individually unique photo identity card. Such cards will not be issued prior to the Contractor Personnel or Subcontractor’s employee attending the Contractor’s induction training course.

4

The Contractor shall appoint a competent supervisor for each and every area of the following Work activities Temporary & permanent electrical installation

(b)

Crane and lifting appliance operations

(c)

Scaffolding erection, alteration and dismantling

(d)

Confined space entry

(e)

Excavation

(f)

Working at height

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The Contractor shall produce a health and Safety Training Matrix based on training needs analysis of all personnel working on the project. The matrix must detail positions against the training courses required from the analysis. All training courses provided to employees shall be free of charge, i.e. the cost will be borne by the Contractor.

6

The training topics will be based on a number of factors, such as but not limited to;

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Trends in monthly statistics;

(b)

Objectives that have been set;

(c)

Recurring issues on site; and

(d)

Accident/incidents on site.

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Courses designed to meet the needs of specific operatives involved in specialized trades including their roles and responsibilities must be provided through training. The following training could be consider as specialist, but not limited to: Safe entry into confined spaces;

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(b)

Crane operation;

(c)

Slingers/banks men;

(d)

Scaffolding/ false work/temporary works;

(e)

Abrasive wheels;

(f)

Woodworking machinery;

(g)

Excavation support equipment;

(h)

First aid;

(i)

Fire Marshall;

(j)

Accident Investigation;

Note – any external training must be delivered by a competent organisation (i.e. 3th Party).

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The Contractor shall provide training and instruction to their employees in relation to the performance of their work. This training shall be provided during working hours and immediately after an employee commences employment. It shall include: (a)

Occupational hygiene.

(b)

Essential elements of local laws and regulations.

(c)

Policies and procedures concerning aspects of human rights those are relevant to operations.

The Contractor shall actively encourage the following for their workforce: Creating employment opportunities.

(b)

Facilitating training opportunities for employees with a view to improving skill levels.

(c)

Ensuring non-discrimination in hiring and promotion practices.

(d)

Promoting life-long learning and on-the-job training.

(e)

All training shall be provided in appropriate languages, based on the demographics of the labour accommodation facility.

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The Contractor shall retain records of all training provided to labour accommodation residents. Such records shall include, as a minimum, the name, age and nationality of those attending the training course/session and the type of training provided. These records shall be available for inspection by the Engineer.

11

The Contractors shall conduct Emergency Drills to thoroughly test its emergency preparedness and response within 6 months of the date of award of the Contract and thereafter at periods not exceeding 6 months throughout the duration of the Work.

12

The Contractor shall hold a Contract Specific Occupational Health and Safety Meeting chaired by the Contractor’s representative on a monthly basis throughout the duration of the WORK. Additionally the Contractor shall include Occupational Health and Safety as an item on the agenda for each and every meeting held and ensure that the subject is actively discussed.

13

The Contractor shall provide contract specific Safe Practice Booklets for each and every person employed on the Worksite and provide training on the content of the booklet.

10.2.6

Method Statements

1

Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

10.3

EMERGENCY RESPONSE PLAN (ERP)

10.3.1

General

1

The Contractor shall prepare an emergency response plans for the project and the following but not limited to shall be addressed;

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(a)

Responsibilities;

(b)

Risk assessment and hazard identification and controls for potential emergencies;

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Hazard identifications and controls;

(d)

Coordination with outside emergency response organizations;

(e)

Arrival of outside emergency response groups;

(f)

Emergency response equipment;

(g)

Emergency drills;

(h)

Tests of emergency preparedness and response program;

(i)

Crisis management plan - major events emergency response plan;

(j)

Evacuation procedure;

(k)

Medical facilities;

(l)

Site fire prevention and response reporting;

(m)

Environmental spills and releases;

(n)

Security including (bomb threat);

(o)

Malicious threats; and

(p)

Severe weather conditions.

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It shall be mandatory that all personnel are aware and understand what actions to take and when to take them in the event of an emergency situation. The Contractor shall provide such information, instruction and training as may be required to assist the personnel to respond appropriately, in the event of an emergency.

3

The Contractor shall develop ERPs for review by the Engineer in order to verify the suitability and capability of arrangements. The Contractor shall ensure a schedule is produced to conduct drills and exercises on a regular basis at the sites under its control.

4

Records of drills and exercises conducted shall to be kept together with details of follow up actions and performance assessments for audit purpose.

5

The first emergency drill shall be conducted within first the 30 calendar days following commencement of operations; afterwards emergency drills shall be conducted on a 6 monthly basis as a minimum.

6

All ERPs’ shall be reviewed and whenever necessary revised and updated every 6 months, periodic auditing must be carried out to ensure compliance.

10.4

EARTHQUAKE EMERGENCY MANAGEMENT PLAN

10.4.1

Background

1

During the month of April 2013 earthquakes occurred in Iran with varying degrees of tremors felt in the State of Qatar and the wider Middle East Region.

2

April 16th 2013 was by far the larger earthquake measuring 7.8 on the Richter scale with the tremors physically being felt in numerous locations and buildings across the region. Whilst events of this type are rare, the impacts could be serious both from a human and business scale.

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Following these events it is clear that should have an earthquake evacuation procedure. This emergency management plan has been developed; however it requires integration into the existing emergency and evacuation plans.

4

It is to be advised that the earthquake procedure whilst very important is one element of a much larger requirement for Emergency Management Planning to ensure that all scenario’s and eventualities are addressed inclusive of crisis management and business continuity.

10.4.2

Requirements

1

Outlined below is a suggested approach that could be taken to take into account those other elements of emergency planning starting with a review of the current arrangements for buildings, towers and associated structures inclusive of car parks.

2

The suggested overall approach would be a three phase priority approach. The first phase identifying the ‘as is’ situation to the desired outcome of ‘to be’ and the ‘future’ requirements, but this is not limited and may require additional elements as recommended by other experts.

10.4.3

Phase One: Gap Analysis (‘as is’)

1

Engage the relevant technical experts for the various aspects of the review, inclusive of but not limited to Fire Design Engineer, Health and Safety Consultant, training providers etc.

2

Review all existing emergency process, procedures, plans and protocols within the organisation and engage with other stakeholders such as Civil Defence to understand any wider requirements, etc.

3

Review of all buildings physical emergency evacuation systems to ensure they meet relevant codes and legislative requirements.

4

Review all evacuation assembly points and engage other building owners nearby the organisation building.

5

Develop work assignments for the organisation personnel and Safety Wardens during earthquakes.

6

Review the organisation buildings maintenance department records.

7

Identify relevant codes, legislative requirements and specific procedures needed for forward planning.

8

Identify salient issues for consideration namely high rise building, crowded indoor public places, indoor safety, outdoor safety, automobiles etc.

9

Identify non-structural hazards such as file cabinets, rack storage units, book shelves, HVAC ...etc.

10

Involve other stakeholders such as the organisation Health and Safety Section, Civil Defence, Ministry of Environment, other building owners in the immediate district etc to ensure their views, requirements, interests and responsibilities are established.

11

Review existing business resiliency and continuity plans, process and procedure.

12

Review existing crisis management plans, process and procedure.

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Indicate future planning and requirements inclusive of the proposed new and existing car park.

14

Include training and awareness plan for the wider organisation based upon the identified training needs.

15

Undertake training and awareness for any developed process and procedures.

16

Produce gap analysis report detailing all required changes, upgrades to process, procedures, plans, training requirements, emergency systems etc.

17

Present outcomes of gap analysis.

18

Develop an initial implementation plan, methodology and programme for Phase 2 and 3 based upon the outcomes of the Gap Analysis.

19

Review plans to backup computer records and equipment of vital records.

10.4.4

Phase Two: Implementation (‘to be’)

1

Implement agreed gap analysis outputs/approach inclusive of all manuals, procedures, technical information required.

2

Develop administrative processes and procedures to support the plan.

3

Communicate the plan to all those affected at different level of the business.

4

Include for planning of any associated drills and lessons learnt.

5

Implement lessons learnt into plan, processes and procedures.

6

Establish periodic review of emergency systems.

10.4.5

Phase Three: Future Requirements

1

Advise if engagement of further consultants/engineers to undertake seismic survey of existing buildings.

2

Development of business continuity plans.

3

Development of post-earthquake assessment procedures.

4

Development of crisis management plans.

5

Undertake training and awareness for any developed process and procedures.

6

Include for planning of any associated drills and lessons learnt.

7

Development of all related support materials.

8

Development of coordination procedures with Civil Defence and other authorities during earthquakes.

9

Periodic review of emergency planning systems.

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What Should We Do During An Earth Quake?

1

Stay calm!

2

If you're indoors, stay inside and if you're outside, stay outside.

3

If you're indoors, stand against a wall near the centre of the building, stand in a doorway, or crawl under heavy furniture (a desk or table i.e. cover your head and neck).

4

Drop down onto your hands and knees.

5

Stay away from windows and outside doors.

6

If you're outdoors, stay in the open away from power lines or anything that might fall. Stay away from buildings.

7

Don't use matches, candles, or any flame.

8

Broken gas lines and fire don't mix.

9

If you're in a car, stop the car and stay inside the car until the earthquake stops.

10

Don't use elevators or put yourself at risk.

11

For impaired mobility, if you cannot drop to the ground, try to sit or remain seated so you are not knocked down. If you are in a wheelchair lock your wheels. Protect your head and neck with a large book, a pillow, or your arms.

10.4.7

What Should We Do After An Earth Quake?

1

Check yourself and others for injuries. Provide first aid for anyone who needs it.

2

Check the building, water, and electric lines for damage. If any are damaged, isolate if possible and report to relevant authorities.

3

Turn on the radio. Don't use mobile phones unless it's an emergency.

4

Stay out of damaged buildings.

5

Stay inside buildings unless directed to do otherwise.

6

Evaluate and critique once a crisis situation is stabilised.

7

Expect further aftershocks.

8

Stay away from beaches. Tsunamis sometimes hit after the ground has stopped shaking.

9

If you're at work follow the emergency arrangements and instructions for the particular building after the earthquake.

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10.4.6

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SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS

10.5.1

Permits

1

A permit-to-work system (Hot work, Excavation, Scaffolding & Electric work) shall be observed (correctly issued, Signed & Client requirement enforced) when undertaking any work on an existing utility, service, item of equipment or structure.

2

A permit-to-enter system shall be observed (correctly issued, Signed & Client requirement enforced) when undertaking any work in a confined space.

10.5.2

Guarantee

1

Where the Contract requires work to be carried out within or adjacent to any pipeline or at a sewage treatment plant, the Contractor shall comply with any requirement of the Public Works Authority.

10.5.3

Mechanical Plant, Machinery and Equipment

1

Sufficient suitable standby plant shall be immediately available in cases where the safety of the Works or of personnel depends upon mechanical plant.

2

Test and thorough examination by a competent person of all equipment that is capable of storing energy, such as air receivers and pressure vessels, is required at periods not exceeding 12 months. Reports of such test and examination will be held on the Worksite and made available to the employer on request.

3

The Contractor will make arrangements for all mobile plant and vehicles that enter the Worksite to be checked by 3rd party certification to ensure the following are provided and in good working order: Braking systems

(b)

Steering systems

(c)

Gauges and warning lights Operating controls

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(e)

Windscreens and wipers

(f)

Reversing alarms

(g)

Rear view mirrors

(h)

Roll over protection devices

(i)

Wheels, tyres, track

(j)

Pneumatic and hydraulic hoses

(k)

Seat belts and anchors

(l)

Fuel lines and tanks

(m)

Electrical control systems

(n)

Suspension and stabilization systems

(o)

Bodywork, covers and panels

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Mobile plant and vehicles that are defective will be removed from use in work areas and taken to a repair facility on the Worksite or removed from the Worksite.

5

Repair work will only be carried out by trained and authorised mobile plant and vehicle repair technicians.

6

Whenever maintenance work is ongoing the machinery or equipment will be isolated and deenergized.

7

All mobile plant and vehicle operators will hold relevant Qatari driving licenses for the category of plant or vehicle that they operate. In addition operators of mobile plant will be in possession of a 3rd party training certificate to verify that they have the skills necessary for safe use of the plant.

8

Operators will use mobile plant and vehicles only in accordance with their operating manuals.

9

The Contractor will conduct a job hazard analysis for each item of machinery and equipment that will be used.

10

The following site rules will be observed by all mobile plant and vehicle operators:

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Mobile plant and delivery vehicles will not be reversed without a banks man in attendance.

(b)

No passengers will be carried on mobile plant or vehicles other that in seats that are specifically designed for carrying passengers.

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The Contractor shall prevent oil / fuel leak causing environmentally pollution.

12

The Contractor will eliminate or reduce the associated hazards for construction lift such as, construction lift failure, falling persons and falling objects by meeting or bettering these specifications. And: All construction lifts will have flat base plates without holes or openings, enclosed sides and roof that are designed to prevent from falling objects. All construction lifts will have overload protection devices that prevent movement of the platform if it is overloaded.

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10.5.4

Existing Utilities

1

Prior to excavating in any area, the location of existing utilities shall be confirmed from asbuilt drawings, contact with utility authorities and trial holes.

2

Excavation in the vicinity of any utility shall be carried out to the requirements of the utility owner.

3

Protection for utilities is the least effective means of controlling any associated risk. Where Contractors use this method the following will be provided: (a)

Marker posts or blocks that clearly indicate the nature, depth and path of all underground utilities.

(b)

Where traffic routes pass over underground utilities temporary protection will be provided. Warning signs stating the maximum vehicle weight that may safely cross the utility will be positioned on the access route at each side of the utility.

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(c)

Temporary barriers or fences that run parallel to the route of any overhead utilities. Warning signs detailing the nature of any overhead utilities on the barriers or fences.

(d)

Where traffic routes pass below overhead utilities warning signs stating the maximum vehicle height and height restrictors will be positioned on the access route at each side of the overhead utility.

Where any construction activity adjacent to a utility is undertaken the minimum clearance distances will be clearly established and communicated to each and every person involved with the construction activity.

5

Traffic routes and material stockpile areas will be clearly identified and established prior to excavation work commencing. All excavation areas, traffic routes and stockpile areas are to be surveyed for overhead services. Any services identified are to be removed or clearly marked with height restrictors and warning information.

10.5.5

Excavations

1

During the planning stage all materials and equipment required for the safe excavation work must be clearly identified. Such equipment and materials may include the following:

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Shoring

(b)

Solid Barriers

(c)

Vehicle stop blocks

(d)

Access ladders or scaffolding

(e)

Ventilation

(f)

Lighting

(g)

Signage

(h)

Pumps

(i)

Generators

(j)

Air Monitoring Devices

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Movement Monitoring Equipment

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Rescue Equipment

2

For all excavation work a competent excavation supervisor will be appointed. The level of training and experience required to determine competence will vary depending on the complexity of the excavation. He will have previous experience of the type of excavation work to be undertaken and formal Occupational Health and Safety training relating to the safety of excavation work.

3

Temporary safety barriers should be used to protect workers and the travelling public from excavations that are more than 300mm deep in accordance with the Qatar Work Zone Traffic Management Guide.

4

Once the design requirements are known a job hazard analysis of the excavation work will be completed by the excavation supervisor with the assistance of Occupational Health and Safety staff and engineers as required. The Job Hazard Analysis will clearly identify the job specific risks and control measures for the excavation work.

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5

Prior to commencement of any excavation work all persons involved will be given a pre-work briefing based on the Job Hazard Analysis relating to the risks and required control measures for the excavation work. The appointed excavation supervisor will be responsible for presenting and recording the briefing.

6

Prior to commencement of work all materials, plant and equipment will be checked to ensure that they are in good condition. In particular the condition of all mechanical excavators will be checked to ensure that: All windows in the drivers cab are clean, unbroken and unobstructed.

(b)

Rear view mirrors are securely attached, unbroken and clean.

(c)

All track plates and connectors are in good condition and secured with proprietary locking pins.

(d)

All dipper arm joints and attachments are secured with proprietary pins and locking pins.

(e)

All task and indicator lighting is in working order.

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Trucks will only be operated by persons with valid Qatari driving licenses. Plant such as excavators, loading shovels etc shall only be operated by trained and competent operators that hold valid 3rd Party certification for the type of plant being operated. This certification is required in addition to Qatari driving license requirements.

8

When the reversing of trucks is necessary for the collection or delivery of materials a banks man will be in attendance. All banks men will be provided with high visibility clothing and be trained in the safety aspects of reversing vehicles. Where vehicles are reversing up to an excavation or travelling alongside an excavation vehicle stop blocks or vehicle barriers will be provided to prevent them falling into the excavation.

9

Continuous adequate solid barriers will be placed around all excavations over 1.2m deep at a distance at least of 1.2m. Where night time pedestrian or vehicle access is adjacent to excavation then all solid barriers will be fitted with warning lights.

10

Pedestrian access to and from all excavations will be by means of ladder or adequately constructed staircases. The possibility of a person falling from a height of more than 2m from the access will be prevented. The horizontal distance between access points will not exceed 15m.

11

All ladders used on the Project will be manufactured in accordance with an internationally recognised standard. Any ladder that is found to be defective will be removed from use immediately.

12

All straight ladders will be positioned at an angle to minimize the risk of slipping or falling backwards. The distance between the base of the vertical plane and the base of the ladder will be 1 unit out for each 4 units in height of the vertical plane.

13

Ladders that are used to gain access from one level to another will extend at least 1m above the upper level surface. Where a general access ladder run extends a distance of more than 6m a landing point with a firm level platform and fall prevention measures will be provided at each and every 6m.

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Excavations shall be kept clean and tidy at all times. Accumulated waste and unused materials will be removed from excavations on a daily basis. All excavations will be thoroughly cleaned prior to any backfilling operations commencing.

15

To prevent the risk associated with falling objects excavated materials, other materials and equipment shall not be stored at the edge of any excavation. A clear distance of 2m shall be maintained around all excavations.

10.5.6

Warning Signs

1

The Contractor shall set up and maintain (cleaned and legible) throughout the course of the Contract enough traffic diversion signs in accordance with the Qatar Work Zone Traffic Management Guide and additional warning signs & guides.

2

Additional areas that require warnings signs and barriers are: Excavations over 1.2m deep

(b)

Any edge, opening or platform from where a person may fall more than 2m

(c)

Electrical transformers and substations

(d)

Confined space entry points

(e)

Areas below and around working at height and heavy lifting operations

(f)

Areas of open water more than 1m deep

(g)

Areas where flammable goods are stored

(h)

Areas where radiation sources are used or stored

(i)

Areas within Worksites that are classed as non-construction areas

(j)

Areas within non construction areas where construction activity is on-going

(k)

Areas below overhead utilities

(l)

Areas above underground services

(m)

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Areas where test and commissioning activities are on-going

Warning signs will clearly state the nature of the hazard and instruct people of the correct actions to take. Warning signs will be manufactures in accordance with internationally recognised standards. All signs will be in English, Arabic and the languages preferred (can be understand) by the workers on the Worksite.

4

All safety barriers and barricades are to comply with the Qatar Work Zone Traffic Management Guide..

10.5.7

Confined Spaces

1

Entry into a confined space will only be permitted where a competent person is appointed to directly supervise the work. The competent person will hold a certificate of training or license that is issued by a 3rd party. The competent person will be appointed in writing by the Contractor and the appointment will be copied to the employer.

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Any person that enters into a confined space will have received formal training in the safe methods of entry and working in a confined space. Such training will include the arrangements for emergency communication and response. In addition every person that enters into a confined space will be given a briefing by the appointed competent person relating to the specific hazards of the work and the control measures that have been detailed in the job hazard analysis.

3

Any person that acts as an attendant for confined space work will have received formal training in the safe methods of rescue from a confined space and the arrangements for emergency communications with external emergency services.

4

The contractor will only permit trained workers, under the direct supervision of an authorised competent person, with confined space attendants present, to enter a confined space.

5

Internal combustion engines will not be taken into a confined space or operated in a position where their exhaust gasses may be drawn into the confined space.

6

Persons entering into a confined space will wear a full body rescue harness that is attached to a rescue line anchored outside the confined space

7

The contractor will implement a safe working procedure for confined space entry that includes the following: Preparation of a confined space entry permit

(b)

Provision of all equipment necessary for entering into and working in the confined space including access, lighting, mechanical ventilation, gas detectors, communication, personal protective equipment and emergency rescue equipment. All such equipment will be manufactured in accordance with internationally recognised standards

(c)

Provision of warning signs and barriers around the confined space entry point

(d)

Setting up emergency communication and rescue equipment

(e)

Issue of a permit to enter the confined space

(f)

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Checking of the atmosphere inside the confined space and installation of ventilation equipment

(g)

Installation of lighting

(h)

Entry into and work in the confined space.

(i)

Monitoring of conditions in the confined space.

(j)

Continuous checking and recording of all persons entering into and exiting from the confined space by the confined space attendant

(k)

Completion of work and removal of all equipment from the confined space

(l)

Accounting for all persons and equipment that entered the confined space

(m)

Securing the entry point to the confined space

(n)

Closing the confined space entry permit

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Lifting Operation

1

The Contractor will appoint a competent lifting operations supervisor for the Worksite. The lifting operation supervisor will ensure that the requirements of this specification are met at all times.

2

Rigging of loads and signalling of cranes will be undertaken only by trained and competent persons. All riggers will be required to wear a blue construction safety helmet and a red high visibility vest for the purpose of easy identification on the Worksite.

3

Cranes will only be operated by trained and competent operators who are in possession of an operator’s license issued by a 3rd party. In addition appropriate Qatari driving licenses are required for all mobile equipment’s.

4

A thorough examination of each lifting appliance will be made by a 3rd party inspector at periods not exceeding 12 months and after substantial re-erection, alteration or repair. Load capacity to be displayed.

5

All lifting appliances on the Worksite will have a copy of the manufacturers operating manual and load rating charts available for use and kept with the operator cabinet or machine.

6

Before a mobile crane is positioned for a lift, attention will be paid to the condition of the ground upon which the crane will stand, as this will be subjected to high point-loadings from outriggers or tyres. Dependent upon the nature of the ground and/or the size of the crane to be used, a special hard standing may have to be prepared.

7

The maximum safe working wind speeds for all construction activity and in particular lifting operations and Working at height activity is 25 Knots. The construction will monitor the weather conditions and suspend work when wind speeds in excess of the maximum safe working speeds are anticipated.

8

Outriggers will be properly set and locked if a locking device is provided. When controlled remotely from the cab, the operator will make a physical check to ensure that each pad has an adequate bearing before a load is lifted. Sound timber packing or metal plates will be used under each outrigger pad to distribute the load. It is essential that outriggers are supported at the jacking points and not under the outrigger beams. Also, lifting location to be barrier off.

9

A method statement and job hazard analysis will be provided to the Engineer for all structural steel erection activity. No structural steelwork erection will commence prior to approval of the method statement and job hazard analysis by the Engineer. All structural steel erectors will be fully conversant with the construction method, sequence and hazard control measures prior to any work activity commencing.

10.5.9

Lifting Gear

1

Lifting gear means any chain sling, rope sling, or similar gear, and any ring, link, hook, plate clamp, shackle, swivel or eye bolt, used on the Worksite.

2

All lifting gear will be subjected to a thorough examination by a competent person from 3rd party at intervals not exceeding 6 months. Identity number and SWL to be check.

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3

A wire rope used in raising, lowering or suspension of a load, will not be used if it is kinked, significantly rusted, the core is visible or the rope has visible broken wires, exceeding 5% of the total or in any length equal to 10 times the diameter of the rope.

4

Riggers will check the condition of lifting gear prior to each and every lift.

5

Any lifting gear that is found to be defective will be removed from service and sprayed with red paint to indicate that it is not to be used. All defective equipment will be removed from the Worksite.

6

A system will be established on the Worksite for storage of all lifting equipment not regularly in use. Such equipment will not be left in the work areas.

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10.5.10 Scaffolding For all scaffolding construction activity and dismantling activity a competent scaffolding supervisor will be appointed. The level of training and experience required to determine competence will vary depending on the complexity of the scaffolding structure to be erected or dismantling. Industry standards and codes detail competency requirements.

2

All employees involved in scaffolding construction activities and dismantling activity will be trained in the safe methods of working and in particular the manner in which fall prevention or arrest is to be achieved. Contractors will maintain detailed information of the training provided and the methods that they have used for assessment of competency and suitability for all employees undertaking scaffolding construction activities.

3

All scaffolding erection areas and dismantling areas will be provided with barriers and warning signs to exclude all personnel that are not specifically involved with the scaffolding construction and dismantling activity. Where such areas are adjacent to roadways barriers with a capability to prevent vehicles entering the area will be erected or dismantling. Where such areas are adjacent to members of the public or 3rd parties then screening and falling object protection will be provided. The appointed scaffolding supervisor is to be made responsible for ensuring that exclusion zones are in place and maintained at all times whilst scaffolding construction and dismantling activity is on-going.

4

All materials being used for scaffolding construction will be checked prior to them being used to ensure they are in good condition. Any materials found to be defective will be clearly marked as defective and discarded or removed from the construction area to ensure that they are not used.

5

Scaffolding that has been constructed in accordance with the design will be inspected for use by displaying green scaff tag at all access points of the scaffolding detailing the following information:

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(a)

the unique identification and location of the scaffolding inspected

(b)

the name of the person making the inspection

(c)

the date that the inspection was completed

(d)

the intended use and capacity of the scaffolding

(e)

the required re-inspection frequency for the scaffolding

The person making the scaffold inspection will maintain written details of the inspection that they have conducted to enable them to verify their scaff tag system.

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All scaffolding that does not display green scaff tag for use will be fitted with red scaff tag states that the scaffolding is not fit for use and the access points will be removed or made unusable.

8

Users of scaffolding will at all times conduct their work in a manner that eliminates the possibility of falling objects.

9

Users of scaffolding are to be prohibited from altering or dismantling any part of scaffolding.

10

Users of scaffolding are required to maintain unobstructed access and egress at all times. All debris and materials no longer required will be removed from scaffolding on a daily basis. All materials and equipment used on scaffolding will be stored in a manner that does not obstruct the free movement of the people using the scaffolding.

11

The frequency of re-inspection of scaffolding – every 7(seven) days – will be displayed on the green scaff tag. Users of scaffolding are required to check that the period of re-inspection has not been exceeded before using the scaffolding. In any case where the re-inspection date has been exceeded the user will request the appointed scaffolding supervisor to make the re-inspection and to re-sign the green scaff tag for use. The user will not access the scaffolding until such time as the re-inspection has been made.

12

Before any dismantling activity is undertaken on scaffolding it will be removed from use. All green scaff tag will be removed and replaced with red scaff tag which is not fit for use and all scaffolding access points will be removed or made unusable.

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The contractor will only use electric welding equipment in accordance with the following requirements: Welding cables and equipment will be properly maintained and inspected before use. Defective equipment will be removed from use and arrangement for repair will be made.

(b)

Electric welding cables are to be kept as short as possible and routed away from pedestrian walkway areas.

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(d)

All connections between welding equipment and welding cables will be securely bolted.

(e)

Pipelines containing flammable liquids or gases, or electrical cables will not be used as a ground.

(f)

When electrode holders are to be left unattended, the electrodes will be removed and the holder placed where it is protected from unintentional contact.

(g)

A fire resistant container will be provided for spent electrode stubs.

(h)

Welding machines will be turned off when being moved or when the equipment is not in use.

Electric welding operations will only be undertaken with earth return electrodes connected to the work piece.

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10.5.11 Hot work and Welding

2

Tanks, vessels and drums that have contained flammable or toxic liquids will be filled with water or thoroughly cleaned before hot work or welding is undertaken on them.

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3

Where coatings are present on materials to be heated the coating will be removed to prevent the coating being heated.

4

Suitable portable fire extinguishing equipment will be located within 6 meters of any hot work location.

10.5.12 Compressed Gas Cylinders The Contractor will only use compressed fuel gasses in accordance with the following requirements; Cylinders will not be transported with regulators, gauges and hoses attached.

(b)

Cylinders will be transported in an upright position and will not be hauled in equipment beds or truck beds on their side.

(c)

Cylinders lifted from one elevation to another will be lifted only in racks or containers designed for that purpose. Cylinders will not be hoisted by the valve cap or by means of magnets or slings.

(d)

Cylinders will not be used as, or placed where they may become part of, an electrical circuit.

(e)

Cylinders will be protected from extreme heat and from being struck by moving equipment and falling objects.

(f)

Cylinders will not be taken into a confined space.

(g)

Cylinders will not be used as rollers; will be transport on appropriate trolley.

(h)

Damaged or defective cylinders will not be used or be permitted to remain on the Worksite.

(i)

Type of gas clearly marked on cylinders and segregation of incompatible gases is required.

(j)

Oxygen cylinders will be kept free of oil and grease.

(k)

Cylinders will be secured in place during use and storage. Securing shall be around the body of the cylinder, securing around the cylinder neck or cap will be prohibited.

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Cylinder valves will be closed at all times when cylinders are not in use.

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A key wrench is required to be in place on the valve of acetylene cylinders at all times during use.

(n)

Fuel gas and oxygen hoses will be of different colours and will not be interchanged.

(o)

All hose, valve and regulator assemblies will incorporate a flashback arrestor.

(p)

Hoses are to be kept as short as possible and routed away from walkway areas.

(q)

Under no circumstances are damaged hoses or torches to be used.

(r)

Torches will be ignited by friction lighters or other approved devices only.

(s)

Fuel gases will only be used for the purposes of cutting or heating. They will never be used for pressure testing or ventilation.

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10.5.13 Working at Height Contractors are required to reduce the risk of persons falling from height by providing a means of fall prevention or arrest for every person on the Worksite that is exposed to a risk of falling a distance of 2m or more.

2

Supervisors of persons using fall arrest systems will be trained in the correct installation, use and maintenance of fall arrest systems. Training will be provided by a 3rd party. All persons required to use fall arrest systems will receive formal training in safe working at height prior to using such systems.

3

The use of safety belts as part of a fall arrest system is prohibited.

4

Safe access to the point at which a person will attach themselves to a fall arrest system will be provided. In cases where a person using a safety harness has to detach the lanyard from the anchor point and reattach it to a different anchor point, whilst being in a position where the risk of falling exists, double lanyards will be used with one of the lanyards remaining attached to the anchor point at all times.

5

Where any form of fall arrest system is used the contractor will put in place arrangements to rescue any person that is caught by the fall arrest system. The rescue system and equipment will be capable of rescuing any person that may be unconscious whilst suspended and or suffering from suspension trauma. The system will be capable of rescuing the suspended person within 3 minutes of the fall being arrested.

6

All edges of working platforms and work areas that objects may fall from will be provided with securely fixed continuous toe boards that are at least 200mm high.

7

All holes and openings in floor areas will be fitted with temporary covers to prevent objects falling to lower levels of the structure.

8

Where work is on-going on the exterior faces of structures the working platforms that are used to gain access will be fitted with lightweight mesh or netting to prevent objects falling from them.

9

Materials and equipment will not be stored or located within 2m of edges of working areas or platforms.

10

All materials and waste that may be blown by the wind from raised structures will be secured and stored in a manner that prevents them from being blown from the structure.

11

Where designated pedestrian walkways, entrances or exits are located beneath edges or openings where work is on-going steel framed and sheeted canopies will be erected to protect pedestrians from falling objects.

12

The contractor will produce a method statement and job hazard analysis for all roof and canopy work activity. For work on new structures safety information will be obtained from the designers and incorporated into the method statement and job hazard analysis. For work on existing structures where design information is not available then a survey of the existing structure will be made to identify hazards such as:

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Fragile coverings

(b)

Holes and openings

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Exposed edges

(d)

Lack of safe access

(e)

Damage or disrepair of the existing structure

(f)

Adjacent structures, facilities or services

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A method statement and job hazard analysis will be provided to the Engineer for all roof and canopy work activity. No work will commence prior to approval of the method statement and job hazard analysis by the Engineer. All roof and canopy installation workers will be fully conversant with the construction method, sequence and hazard control measures prior to any work activity commencing.

14

The contractor will meet the following roof and canopy work specific Occupational Health and Safety requirements:

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The storage of materials on roof surfaces will be minimized at all times

(b)

Storage of materials on roof surfaces is not permitted within 2m of any edge or eave

(c)

All openings and non-walkable areas will be protected by barriers and signage to prevent pedestrian access

(d)

All waste will be removed from the work areas on a daily basis and prior to any areas being left unattended

(e)

All areas of roof or canopy covering will be fully fixed at the time of positioning. The practice of laying large areas of unfixed coverings is prohibited

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The structure that the suspended working platform is attached to or mounted on will be surveyed and assessed to ensure that it is capable of supporting the loads that the equipment will impose on it.

16

The installation, maintenance, use and dismantling of suspended working platforms will be under the control of a competent person that is appointed by the Contractor. The competent person will be fully familiar with each and every type of suspended working platform in use on the Worksite. Persons who work from suspended working platforms will have received formal training to ensure the safety of themselves and of other persons that may be affected by the operation with particular emphasis on the correct use of the equipment, working at height and falling object prevention.

17

The following requirements will be met for all use of suspended working platforms;

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(a)

Users will not alter or interfere with any part of the suspended working platform, control or safety devices.

(b)

The work area below the suspended working platform will be clearly marked a pedestrian exclusion zone will be created.

(c)

The user will check all controls and safety devices on a daily basis to ensure that they are functioning correctly.

(d)

Use will cease whenever wind speed in excess of the maximum permissible is anticipated.

(e)

The suspended working platform will be maintained in a horizontal position whilst it is in use.

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(f)

The practice of transferring people or materials from the suspended working platform is prohibited other than at the designated access points.

(g)

Every person working from a suspended working platform shall wear a full body safety harness that is attached to an independent lifeline.

(h)

The platform will be kept free of loose materials or articles liable to endanger or interfere with the worker’s hand hold or foot hold

(i)

The power supply will be disabled whenever the suspended working platform is left unattended.

10.5.14 Electrical This specification applies to all temporary electrical systems on the Worksite and all electrical equipment used for construction, commissioning and testing purposes. The requirements given are minimum requirements and Contractors are required to equal or better them.

2

A competent electrician or electrical engineer will be appointed or employed on every contract. The competency requirements will be determined by the nature of the temporary electrical system that will be installed on the Worksite

3

The Contractor will reduce risk by using cordless tools or electrical equipment that is operated at reduced voltages. Only intrinsically safe electrical equipment will be permitted for use at any location where flammable atmospheres may exist or confined space.

4

All electrical equipment used on the Worksite will be manufactured in accordance with an internationally recognised standard.

5

Portable Power Tools will be of a double insulated type.

6

Jointing of all electrical cables and wires shall be by means of proprietary terminations or connectors. The practice of twisting and taping electrical components together to create a connection is prohibited.

7

Temporary power supplies for the Worksite may be provided from generators or via a Worksite specific transformer connected to the national power network. All generators and transformers on the Worksite shall be located in areas that are fenced and secured to prevent any unauthorized entry. Each such location will be provided with portable fire extinguishers. All electrical systems shall be bonded to the earth.

8

All electrical circuits that are created will be protected by earth leakage circuit breakers (ELCB). All metal components of an electrical system shall be earthed. Distribution of electrical power shall be provided through distribution panels and switches that are enclosed or housed in securely closed and locked boxes or cabinets.

9

Warning signs that clearly indicate electrical hazards shall be fixed to all electrical switch boxes and distribution panels. Similar signs shall be displayed at all transformers, generators and overhead power line locations.

10

All signs and notices shall be in English and Arabic and the language preferred (can be understand) by the workers employed on the Worksite.

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All electricity supply cables shall be buried or properly supported and protected and shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used. All electrical installations shall be in charge of a competent person who shall accept full responsibility for its use and any alterations or additions thereto. The name, designation and telephone number of such person shall be prominently displayed close to the main switch or circuit breaker of the installation, and also in the Contractor’s site office.

10.6

FIRST AID

10.6.1

First Aid and Clinic

1

The Contractor shall provide and maintain first aid Boxes / Clinic (according to number of workers as per Qatar Law No.14 of the Year 2004 – The Labour Law) complete with all first aid kits and equipment (as a minimum but not limited to Clean room with potable water supply, Stretcher, Ambulance, Standby Vehicle, ... etc) necessary for the initial care of any of the Contractor’s or Engineer’s personnel who may be injured.

2

The box shall be kept in a conspicuous place in the establishment and shall be available to the workers.

3

The use of the box shall be entrusted to a worker trained in providing first-aid medical services.

4

As a minimum, there should be a first aid box with Medical record book in all areas where work is in progress.

5

The Contractor shall ensure that the first aid Kits and equipment at each first aid box / clinic is complete and within expiration date in all respects at all times.

6

At each first aid box / clinic the names and contact Telephone numbers of the Contractor’s staff who are trained to render first aid shall be displayed.

7

The Contractor shall provide and maintain Periodic medical examinations for workers and follow up (maximum every year from employment date).

10.7

FIRE PRECAUTION AND PREVENTION

10.7.1

General

1

The Contractor shall take all necessary precautions against fire as required by the insurance company insuring the Works, the Department of Civil Defence and the Engineer.

2

Quantities of flammable materials on site shall be kept to an absolute minimum and shall be properly handled and stored. Any handling and storage recommendations made by Material Safety Data Sheet (MSDS) and the manufacturers of flammable materials shall be strictly adhered to.

3

All flammable materials storage areas will be located at least 20m away from other structures, areas where combustible materials are stored and areas where sources of ignition are found. Storage areas will be freely ventilated to eliminate any possible build up of flammable vapour or gas. Flammable material storage facilities will not be constructed of combustible materials.

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Except as otherwise provided herein, the Contractor shall not permit fires to be built or open type heating devices to be used in any part of the Site.

5

The Contractor shall provide, regularly checked and maintain approved by Department of Civil Defence fire fighting equipment in the site offices, the stores and about the Works where applicable. The type, amount and location of fire fighting equipment shall be to the requirements of the Department of Civil Defence. The Contractor shall confirm to the Engineer in writing that the requirements of the Department of Civil Defence have been met.

6

The Contractor shall make arrangements with the Department of Civil Defence to inspect the Works and promptly carry out their recommendations at his own expense if requested to do so by the Engineer.

7

Combustible fuel oils shall be stored in designated storage areas. Fuel oil shall only be contained in tanks or containers that are in good condition. Tanks and containers will be located in bounded areas capable of containing any spillage or leak. Bounded areas will be kept free of water and debris. All pump equipment and fuel oil lines or hoses will be maintained regularly to ensure that there no leaking parts. Fuel oil lines and hoses will be terminated with filler nozzles or valves that stop the flow of fuel oil when the device is not held. Any electrical equipment such as lighting and pumps that is located in fuel oil storage areas shall have an operating voltage of 110V or less.

8

Hot work and welding operations at height require particular controls to prevent people or materials below being exposed to the risks of the work activity, the following controls will be put in place;

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All work activity will be coordinated with other activities in areas below

(b)

Areas below will be cleared of all combustible and flammable materials.

(c)

Fire blanket / Fire retardant material will be used to cover any combustible materials that cannot be cleared.

(d)

Fire blanket / Fire retardant material must be removed after hot work and welding activities are completed.

(e)

A fire watchman will remain at the site of hot work activity for 30 minutes after work is finished.

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The Contractor will provide training in the correct selection and use of portable fire extinguishers for every person employed at the Worksite.

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Portable fire extinguishers will be provided at the following locations:

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(a)

Every electrical generator, transformer and main distribution panel

(b)

Every piece of mobile plant and equipment

(c)

Every area of flammable materials storage and use

(d)

Every area of hot work activity

(e)

Every temporary structure

(f)

Every work area where combustible materials are present.

Smoking will be prohibited in any areas where flammable or combustible materials are stored. It will also be prohibited in any temporary structure other than in clearly designated and defined smoking areas. Smoking areas will be cleaned on a daily basis, a means of extinguishing cigarettes will be provided.

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Fire escape routes, exits and assembly areas will be provided for all enclosed temporary structures and permanent structures under construction. All such areas will be kept free from obstructions at all times. Wherever possible in permanent structures under construction the fire escape routes, exits and assembly areas used will be those designed for use in the occupied structure.

13

Information and warning signs will be provided at the following locations or areas: Flammable materials stores

(b)

Combustible materials stores

(c)

Temporary fire systems

(d)

Portable fire extinguishers

(e)

Fire escape routes, exits and assembly areas.

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The Contractor shall make all arrangements to keep access for Fire Brigade cleared and Emergency Alarms audible in all areas.

10.7.2

Emergency Equipment

1

Temporary fire protection equipment for the Worksite will be provided by the Contractor for the duration of the contract. Such equipment may include but is not be limited to: Portable fire extinguishers

(b)

Fire sand buckets

(c)

Fire water storage and distribution systems

(d)

Fire suppression systems

(e)

Fire / Smoke / Gas detection systems

(f)

Fire warning / Alarm / Emergency Evacuation systems

(g)

Procedures

(h)

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Emergency contact telephone numbers / Communications Breathing apparatus and / or respirators (if applicable)

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(j)

Torches

(k)

Loud Hailer

(l)

Emergency lighting

(m)

Adequate and safe Emergency Exit / Doors are provided

(n)

Assembly / Muster point

2

Escape routes, access ways to alarm points, extinguishers, hydrants and other fire fighting equipment and first aid kits kept clear of obstruction at all times

3

All structures that are normally occupied by five to twenty five people will be provided with the following: (a)

Portable fire extinguisher equipment.

(b)

First aid kit.

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(c)

Trained first aider.

(d)

Emergency contact information notices.

(e)

Telephone or radio communication equipment.

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All temporary facility structures that are normally occupied by twenty five to one hundred people will be provided with the above plus the following: (a)

Smoke detectors

(b)

One first aid kit for each 25 people.

(c)

Designated emergency evacuation routes.

(d)

An emergency preparedness and evacuation plan.

(e)

An emergency alarm system.

(f)

An emergency evacuation drill at periods not exceeding 6 months.

(g)

An area set aside for the heating and consumption of food.

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All temporary facilities structures that are normally occupied by more than 100 people will be provided with the above plus the following: A fire water system

(b)

An appointed nurse

(c)

Emergency lighting system

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All temporary fire protection equipment will be manufactured, inspected, tested and maintained in accordance with the Department of Civil Defence or internationally recognised standards.

10.7.3

Hazardous Substances

1

The Contractor will control the use, handling, transportation and storage of hazardous substances to reduce the associated health risks. These requirements below are the minimum that the Contractor will meet to comply with their contractual Occupational Health and Safety obligations.

2

Radioactive materials are hazardous substances and any use of such materials on Site will require a method statement and job hazard analysis to be submitted to the Engineer for approval prior to any radioactive material being delivered to the Worksite.

3

Where any spillage of liquid occurs the contractor will take action to immediately clean the spillage and remove any contaminated materials from the Worksite.

4

To effectively control the hazards associated with the use, storage, handling and transportation of hazardous substances the Contractor will:

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Maintain a register of all hazardous substances on the Worksite

(b)

Obtain Material Safety Data Sheets for all hazardous substances

(c)

Make an assessment of the health risks associated with the intended use of each hazardous substance

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(d)

Provide the control measures required to reduce the risks identifies to acceptable levels. Acceptability will be based on internationally recognised best practices and standards

(e)

Train people that use, handle or transport hazardous substances in the associated risks and control measures

(f)

Provide routine health checks for employees that are exposed to hazardous substances

(g)

Provide appropriate spill containment and disposal Spill kit

(h)

Toxic/ hazardous substance correctly tagged/ labelled/ signage and secured

(i)

Adequate storage provided and Class B fire extinguisher near by

SAFETY OF THE PUBLIC

10.8.1

Working in Public Areas

1

The Contractor must ensure that control measures are in place to protect the public, workforce and assets by providing appropriate lighting, fencing, barricades, and lockable units. Adequate levels of security including the use of trained security guards will be required. The Contractor must also ensure appropriate warning signage is displayed and where appropriate safe pedestrian walkways are identified and maintained.

2

Safety and security procedures shall be implemented in accordance with the Qatar Work Zone Traffic Management Guide and as required by the Department of Civil Defence and the police. These shall be included, as a minimum, warning signs and lights, adequate barricades, railings, road hump for reduced & control speed and other safeguards as required by the nature and location of the work being undertaken.

3

Access to all properties shall be maintained by adequately sign posted diversions, temporary bridges or other facilities.

4

A night watchman shall be assigned to ensure that all barricades, lights and other protective apparatus are maintained during the hours of darkness.

5

Designated pedestrian routes will be clearly signed and with firm even surfaces that are free from distractions. Where such routes traverse level changes they will be slopped at gradients not exceeding 10% or cut with steps of even height and a tread width of at least 400mm. Slopes and steps will have anti-slip surfaces. Where the edges of pedestrian routes are raised more than 1.2m above the surrounding level solid barriers will be provided at each raised edge to prevent people from falling.

6

All such equipment shall be routed away from pedestrian access areas. Where such equipment crosses pedestrian areas it will be located under the pedestrian area or over it at a height of at least 2.5m above the surface. Where such equipment is routed over a pedestrian area it will be clearly marked with warning signs.

7

No electrical cables, hoses or pipes shall be routed along any staircase, ladder access or across any doorway. This applies to both temporary and permanent works.

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Contractor shall provide Client with photocopies of passports, police clearances and any similar personal security documentation necessary to obtain Client temporary identification cards and passes for Contractor Personnel to enter Client STP / PTP / premises. Contractor shall ensure that Contractor Personnel display such identification at all times when they are on Client STP / PTP / premises.

9

The Contractor will provide a method statement and job hazard analysis for all demolition and dismantling activities. Everyone involved in the work needs to know what measures are to be taken to control the risks and a pre work briefing based on the method statement and job hazard analysis will be given and recorded by the supervisor. Workers will be closely supervised to ensure that the control measures required are put into practice. An exclusion zone will be created around the demolition or dismantling area to prevent persons not directly involved with the work activity around the work area gaining access. The Contractor will not allow materials to fall into any area where people are working or passing through. Protection screens, fences or canopies may be needed to control falling objects.

10.9

WELFARE, SAFETY AND PROTECTION OF WORKMEN

10.9.1

General

1

The Contractor must make arrangements for suitable welfare facilities to be present from the start of the work. There are specific requirements for provision of welfare facilities in the (Section 11, Part 1 Regulatory Document, 1.1.8, Appendix 1)

10.9.2

Personal Protective Equipment (PPE) / Attire

1

All the Contractor’s personnel shall be provided with safety helmets, eye protection and foot protection. Safety helmets, eye protection and foot protection shall be worn at all times by all Contractor’s personnel on the Site except.

2

All the Contractor’s personnel shall be provided with gloves, hearing protection, safety reflecting vests, dust mask and other protective clothing suitable for the nature of work they are performing and their working environment (Shorts and sleeveless shirts are prohibited).

3

All the Contractor’s personnel shall wear high visibility clothing as the outer layer of clothing at all times when working on a road or within a road works zone in accordance with the Qatar Work Zone Traffic Management Guide.

4

The need for other types of PPE will be identified by the contractor as part of their job hazard analysis or risk assessment process.

5

The Contractor will display signage detailing the requirements for mandatory PPE throughout to Worksite. Signage shall be in a format that is easily recognisable to all persons on site regardless of their preferred language.

10.9.3

Safety Equipment

1

Construction equipment must only be used in the manner and limitations for which it is designed, inspected regularly with colour code sticker and Qatar license for driver / operators must be available.

2

Adequate hard barricading, temporary bridges, temporary footpaths, lighting, warning tape and sign posting shall be provided at all excavations.

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3

Adequate bracing and shoring shall be provided at all excavations. 2m spoils clearance from the excavated pit and sloping shall be maintained (if applicable).

4

Correctly made ladders must be provided for access into excavations and onto scaffolding and buildings. Contractor’s self-made ladders shall not be used.

5

Scaffolding shall be erected in accordance with the international recognize standard, best practises and manufacturer’s recommendations and shall be fitted with toe boards, guardrails (top & mid rail), proper access, fully boarded platforms, tagging system and hand railing (refer to 10.3.10).

6

The following basic safety equipment is required for any works in confined spaces and shall be supplied by the Contractor: gas detectors/monitors complete with carrying case, rechargeable batteries and battery charger, calibration kit, all to the approval of the Engineer; consumable items and sensors to be replaced in accordance with the manufacturer’s recommendations during the course of the Contract (2 No.)

(b)

full body rescue safety harness with lifelines and shackles (6 No.)

(c)

lifting frame complete with fall arrest device (1 No.)

(d)

constant flow escape breathing apparatus complete with storage cases (2 No.)

(e)

automatic positive pressure self-contained breathing apparatus complete with storage case (1 No.)

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The Contractor shall maintain all safety equipment in good working order with up to date calibration and test certificates where appropriate.

8

The Contractor shall ensure that any personnel working above 2 m using fall protection devices with valid 3rd party certificate and to provide them proper training in the selection and use of fall protection devices.

9

The Contractor shall provide and maintain in good working order one compressed air escape respirator set (Dräger “Saver Auto PP” or similar) in the Contractor’s site office.

10

One oxygen resuscitation unit shall be provided in the Contractor’s site office.

11

Truck or Trailer Mounted Attenuators (TMAs), or lorry mounted crash cushions must be used in accordance with the Qatar Work Zone Traffic Management Guide.

10.9.4

Support Facilities for Contractors Staff and Labour

1

The Contractor shall provide, regularly clean and maintain for the duration of the Contract potable water, washing facilities and sufficient Toilets (with steel exhaust fan) & sanitary facilities for use by workmen in accommodation areas, at messing facilities and in areas where work is in progress.

2

The Contractor shall provide and maintain for the duration of the Contract messing facilities and a separate designated area for the consumption of food for his staff and labourers.

3

Cooking and dining facilities that are provided will be operated and maintained in a clean and hygienic condition. Food preparation and storage areas will be separated from eating areas.

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(a)

No person with any communicable disease will be permitted to work in any kitchen or dining room

(b)

Kitchen workers who have cuts or skin conditions on their hands will not be permitted to work in any kitchen or dining area

(c)

Kitchen workers that handle or serve food will wear latex gloves, hairnets and clean clothing.

When allowed for in the Project Documentation, the Contractor may provide accommodation facilities for his staff and labourers at the Site. Such facilities shall be maintained in a proper manner and to the satisfaction of the appropriate government departments and the Engineer.

5

The Contractor shall provide transportation between staff accommodation and areas of work for his staff and labourers.

6

The Contractor shall provide sufficient bins for waste and scrap regularly collected, segregated and removed from site.

7

Arrangements for the temporary storage of waste on site shall be made in clearly designated and defined areas that have fences and signs to clearly indicate the nature of the waste where combustible wastes are stored portable fire extinguishers will be provided.

8

Waste collection points will be provided throughout the work areas and will be clearly marked with signage to indicate the nature of the waste that is to be collected. Waste will be separated and collected in the following categories: Metals

(b)

Oils

(c)

Concrete & Stone

(d)

Tyre & rubber

(e)

Glass

(f)

General

(g)

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Where temporary facilities are created for the storage of materials and equipment such areas shall be clearly defined and fenced. Notices will be displayed to indicate the nature of the storage area. (a)

Any hazardous substances that are stored shall only be kept in accordance with the supplier’s recommendations and the requirements of the Hazardous Substances Specifications.

(b)

Flammable materials and fuel oil storage areas must be separated from other temporary structures or works under construction by a distance of 30m.

(c)

Where materials are stored in stacks they will not be stacked to a height of more than 1.5 m where the materials are to be manually handled. Materials for mechanical handling that are on pallets or contained in bins will not be stacked more that 3 units high with the base bin or pallet being on firm level ground.

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Circular materials such as pipes and tubes will be stored in a manner that prevents item from rolling. They will be placed in a container or frame, or have timber wedges of an adequate size inserted between the materials and the ground to prevent rolling.

The Contractors will make arrangements to maintain an adequate working environment and take into account the requirements of this specification to fulfil their contractual obligations relating to Occupational Health and Safety. Adequate arrangements will be based on internationally recognised standards. Ergonomics and proper layout of work area.

(b)

Darkness or poor visibility increases the risk of persons on the Worksite slipping, tripping or falling. It also increased the risk of operator error for plant, vehicle, machinery and equipment operations. To reduce such risks the Contractor will provide the following:

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(a)

Temporary lighting for all Worksite access areas and roads that will be used during the hours of darkness.

(ii)

Task lighting for all work activity at night or in areas with poor visibility.

(iii)

Emergency lighting for pedestrian access routes in areas of poor visibility and those used during night time working.

(iv)

Ensure the absence of glare.

(v)

Proper lighting in corridors.

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Summer Working Conditions and fatigue

1

During the period from June 15th until August 31st, work under direct sun rays is prohibited from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control and ease effect of the direct sun on the workers. This arrangement should be approved by the Engineer’s Representative and should be agreed upon before implementation.

2

High outdoor temperatures expose persons on the Worksite to the risk of dehydration. The Contractor will provide shaded rest areas, rest periods and drinking water supplies for all persons on the Worksite.

3

Sunlight exposes persons on the Worksite to the risk of skin disorders. Employers will provide work wear that covers the skin for employees working in direct sunlight. Sunlight may also cause glare for operators of mobile plant, vehicles, machinery and equipment which increases the risk of operator errors. The Contractor will provide shaded operating positions to reduce such risks.

4

Contractor shall develop suitable management arrangements to control working hours and/ or shift patterns in order to address and manage the risk of fatigue.

10.9.6

Additional Environmental Protection and Pollution Control

1

The Contractor shall comply with all conditions of Environmental Clearance issued for the Contract by the Ministry of Environment (MoE), and also where relevant, the predecessor to the MoE, the Supreme Council for the Environment and Natural Reserves.

2

The Contractor shall comply with all rules and regulations regarding environmental protection and pollution control issued by the MoE, and also where relevant, the predecessor to the MoE, the Supreme Council for the Environment and Natural Reserves.

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Plant and Equipment Test Certificates

1

Cranes, whether used to construct the Works or provided as part of the permanent Works, must have a current test certificate.

2

Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works of provided as part of the permanent Works, must have either a current manufacturer’s test certificate or a current test certificate.

3

Test certificates must be issued by a competent testing authority approved by the Engineer.

4

The Contractor must have a copy of each test certificate on site available for inspection by the Engineer.

5

The following British Standards and Code of Practice shall be complied with:

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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010

(b)

Overhead Cranes: BS 466 and BS 5744

(c)

Slings: BS 1290

(d)

Chain Blocks: BS 3243

(e)

Shackles: Alloy : BS 3551, High Tensile Steel : BS 3032

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10.10.1 General

These specifications for workers' accommodation can be accepted for implementation as long as in the interest of the worker provided they do not disturb the labour accommodation requirements of the decision of the Minister of Labour No. (17) for the year 2005 or any other matters developed in this context.

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10.9.7

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10.10.2 Quality of Labour Accommodation The Contractor shall provide space per person that meets or exceeds what is required by local legislation or 4.5 m2 per person within each room/accommodation unit.

2

The residential density shall not exceed (the lower of): that specified by appropriate local regulation or 4 persons per room/accommodation unit.

3

The Contractor shall provide personal storage space for residents’ belongings including secure storage for valuables.

4

The Contractor shall provide allowances for open spaces and pedestrian movement (e.g. hard surface walkways with minimum 0.75 m width) and shaded communal areas.

5

Where permissible under local planning guidelines, the Contractor shall provide air conditioned communal areas such as television/games rooms.

6

The Contractor shall designate pick up and drop off points (for buses) in such a way as to minimize walking distances for residents and to minimize noise and air quality impacts on residential buildings.

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The Contractor shall configure buildings/units in such a way as to create a sense of place and community.

8

The Contractor shall provide tea and coffee making facilities in kitchen and mess areas.

9

The Contractor shall provide physical barriers (e.g. fencing or landscaping) to visually screen the camp from adjacent worksites, etc.

10

The Contractor shall provide written evidence that all local planning guidelines have been adhered to when designing large scale, project related, labour accommodation facilities. Local planning guidelines indicate the numbers and type of community facilities which should be provided for a given population. Consideration shall be given at planning stage to the availability and capacity of communal facilities and spaces in the surrounding area. Where such facilities are not readily accessible, provision of public transport to access such facilities shall be considered.

11

The Contractor shall be aware of any changes in law relating to the provision of temporary labour accommodation.

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10.10.3 Provision for Fire Safety

The Contractor shall provide for adequate fire-fighting equipment in the labour accommodation (notwithstanding other local laws and regulations requiring same).

2

All relevant signage, notices, documentation and training relating to fire safety at labour accommodation shall be provided in appropriate languages, based on the demographics of the facility.

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10.10.4 Provision for Health Care

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The Contractor shall retain detailed records of all medical treatment carried out on-site. Records shall be retained for all instances of residents being transported for off-site medical attention. Such records shall include, as a minimum, the name, age and nationality of the treated party, and the nature of the complaint. These records shall be used to identify medical trends and implement proactive treatment to reduce absenteeism.

2

The Contractor shall provide all labour accommodation residents with access to a level of healthcare beyond basic first aid. Such facilities shall be readily accessible by residents, staffed by professional medical staff and have appropriate provisions and equipment. The exact specification of the facility shall be determined on a case-by-case basis, depending on the location and population of the labour accommodation.

3

The Contractor shall provide a facility to transport those requiring medical attention from the labour accommodation to and from appropriate off-site medical facilities, free-of-charge and in a timely manner.

4

The Contractor shall provide medical insurance for all workers in accordance with Qatar Labour Law.

5

The Contractor shall include a Public Health Training module as part of induction training for all new labour accommodation residents. As a minimum, this shall address:

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(a)

Personal hygiene and the appropriate use of the sanitary facilities provided (flush toilets, showers, hand washing, waste disposal facilities etc.).

(b)

Awareness of communicable diseases (including Sexually Transmitted Diseases), their transmission and prevention.

(c)

Practical information regarding residents’ rights and means of access to on-site and off-site medical facilities.

(d)

Food safety.

(e)

Littering, safe disposal of waste and related community hygiene standards.

The Contractor shall promote public health awareness throughout all facets of the accommodation. This shall include: (a)

Signage in kitchens, bathrooms etc. promoting hygienic practices.

(b)

Educational videos and presentations.

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The Contractor shall provide access to transport, free-of-charge to/from: Worksites, including backup services from worksite to labour accommodation for those who failed to access scheduled services.

(b)

Availability nearby for community facilities, shops and recreation areas during leisure time.

(c)

Religious facilities at suitable times.

(d)

Off-site medical facilities, including emergency access at all times.

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10.10.5 Access to Transport

Transport services shall be scheduled in such a way as to minimise waiting times and maximise accessibility.

3

The Contractor shall use safe modes of transport only. The practice of transporting workers in open-back trucks is forbidden.

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10.10.6 Access to Religious, Social and Domestic Facilities 1

The size and number of religious, social and domestic facilities shall be relative to and appropriate to the population of the labour accommodation.

2

The Contractor shall facilitate access to religious facilities for those required to work on Fridays.

3

The Contractor shall provide an on-site hall to facilitate religious practices. Alternatively, transport may be provided to facilitate off-site worship.

4

The Contractor shall provide adequate shaded areas to facilitate social interaction. Similarly, an appropriately sized, air-conditioned communal area(s) shall be provided (e.g. television and games room). The size and number of these facilities shall be relative to and appropriate to the population of the labour accommodation.

5

The Contractor shall provide preferably on-site, open spaces (for sports and recreation). Where space constraints are such that this is impossible, readily accessible off-site spaces shall be provided.

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The Contractor shall provide access nearby to basic domestic amenities. include, as a minimum:

These shall

(a)

Access to banking/money transfer services, including transportation to banking/money transfer facilities.

(b)

Laundry facilities.

(c)

Retail outlet(s) selling, as a minimum, essential items (e.g. food items, clothing, toiletries, phone cards, stamps etc.).

(d)

Communications.

These services shall preferably be available on or within walking distance of the labour accommodation.

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10.10.7 Access to Communications The Contractor shall provide a telephone, available at all times, for calling the emergency services. This facility shall be centrally located, conspicuous and all residents shall be aware of this facility.

2

The Contractor shall provide access nearby to the following:

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Retail outlet selling mobile phone credit.

(b)

Postal service, both inward and outbound.

(c)

Facility for residents to receive emergency messages (e.g. in case of family emergency abroad).

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10.10.8 Number, Quality and Location of Sanitation Facilities The Contractor shall adhere to an appropriate standard for the provision of toilets and showers etc. These facilities shall be maintained in good working order and shall be cleaned regularly.

2

The Contractor shall develop and implement a Waste Management Plan for the labour accommodation. This plan shall address the collection, segregation, storage, transport (offsite) and disposal (recycling) of wastes.

3

The Contractor shall provide adequate sanitary means for the disposal of waste water (including sewerage) from labour accommodation. The Contractor shall provide adequate management of surface water runoff to prevent the accumulation of standing/stagnant water (and the associated health risks).

4

The Contractor shall provide laundry areas, separate from washrooms and food preparation areas. Such laundry areas shall be adequately drained.

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10.10.9 Food Preparation Areas 1

The Contractor shall adhere to relevant local regulations relating to food preparation facilities. In the absence of such local regulations, an appropriate regional standard shall be applied The Contractor shall provide adequate food preparation facilities to allow cultural sensitivities to be respected such as separate preparation areas for meat and vegetables, and appropriate labelling and handling of food products.

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Where meals are provided to residents, the food offered shall be culturally appropriate based on the demographics of residents.

10.10.10 Pest and Vermin Control 1

The Contractor shall engage a pest control company to service the labour accommodation site.

2

Self closing doors fitted with fine mesh shall be installed at the entrances to food premises, washrooms, living areas and any other enclosed spaces.

10.10.11 Security at Labour Accommodation The Contractor shall provide adequate security personnel, based on the size, layout and population of labour accommodation.

2

The Contractor shall provide Protocols (Codes of Conduct) for the security personnel operating at labour accommodation. These Protocols shall clearly define the nature and permitted magnitude of response to security incidents. They shall also set out the circumstances under which security incidents should be handed over to Police control. Protocols will be developed in consultation with the Engineer

3

The Contractor shall ensure that all security personnel are adequately trained in the Protocols for security personnel.

4

The Contractor shall retain records of all security incidents arising at labour accommodation. Such records shall include, as a minimum, the name, age and nationality of all those involved (including security personnel), and the nature of the incident. These records shall be made available to the Engineer.

5

The Contractor shall provide labour accommodation residents with secure facilities for the storage of personal items and valuables.

6

The Contractor shall manage the movement of goods and personnel onto the accommodation facility.

7

The Contractor shall maintain adequate lighting on and around the labour accommodation at all times, therefore making it safer for residents to move around at all times.

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10.10.12 Social Issues 1

Any social issues arising at labour accommodation shall be addressed at regular project Quality, Health, Safety and Environment (QHSE) meetings.

2

The Contractor shall include an Intercultural Understanding module as part of induction training for all new labour accommodation residents. This shall include: (a)

Basic introduction to cultural norms and practices of other accommodation residents.

(b)

An explanation of native or local customs, festivals or religious rites.

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The Contractor shall enforce a ban on the sale, possession and consumption of solvents, alcohol and inhalants, for the purposes of intoxication, on labour accommodation sites. The Contractor shall use its best endeavours to prevent these substances from entering labour accommodation facilities.

4

The Contractor shall provide residents with contact details for relevant bodies such as consulates, NGOs, or other relevant organisations offering social support. A list of such local contacts shall be provided to new employees during their induction process. An up-to-date list of contact details for these organisations shall also be displayed in public areas such as the canteen, recreational areas, etc.

5

Any incidents of suicide or attempted suicide shall be investigated as a social issue to try to determine the root causes with a view to reducing the likelihood of a recurrence. This may include the engagement of qualified medical personnel to assist in this process (such as psychiatrists or psychologists).

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10.10.13 Competence of Labour Accommodation Management

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The Contractor shall provide Protocols (Codes of Conduct) for the labour accommodation management personnel. These Protocols shall clearly define the nature of issues and incidents which are considered within the remit of labour accommodation management. They shall also include guidelines outlining appropriate parties to whom incidents should be referred and at what stage. Protocols will be developed in consultation with the Engineer

2

The Contractor shall retain records of all issues and incidents, at labour accommodation, which are reported to or dealt with by labour accommodation management. Such records shall include, as a minimum, the name, age and nationality of all those involved (including members of the accommodation management team), and the nature of the issue or incident. These records shall be made available to the labour accommodation management company.

3

The Contractor shall ensure that no member of labour accommodation management accepts any form of payment by way of bribery or extortion or for any reason. Similarly the Contractor shall commit to permanently removing any member of labour accommodation management, from the accommodation, if they are found to have accepted or demanded such payments. In this event, the Contractor shall report any such offences to the appropriate local authorities to determine if a criminal offence has been committed.

4

The Contractor shall maintain labour accommodation facilities to a high standard and not allow them to fall into disrepair.

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10.10.14 Environmental Conditions at Labour Accommodation 1

The Contractor shall provide the Engineer with copies of the relevant environmental permits relating to the construction and operations of their labour accommodation facilities. The nature of the permitting requirements will be dependent on the jurisdiction of the facility.

2

Where labour accommodation is to be sited on or close to work sites/industrial sites, the accommodation facilities shall be located up-wind (based on prevailing wind) of the site and the distance between the camp and air discharge points around the site shall be maximised. Noise levels shall not exceed the requirements for night time hours – residential areas, as outlined in local laws and regulations.

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The accommodation area shall be separate from the work site and shall not be used for any operation activities (e.g. storage, workshops, etc.).

4

Where on site facilities such as a Sewage Treatment Plant (STP) are located on or close to the accommodation, planning requirements in relation to buffer zones, etc. shall be respected and integrated into site layout. Similarly, adequate buffer zones shall be included to ensure that sleeping accommodation is not immediately adjacent to main roads.

5

Appropriate waste management, storage and disposal facilities shall be provided on site. There shall be no burning of wastes on site. Similarly, there shall be no fires onsite.

6

Use of labour accommodation facilities shall be restricted to those normally resident in the accommodation. Where necessary, separate facilities, e.g. toilets, etc., shall be provided for adjacent work sites, etc.

7

Roads and parking areas shall be paved, or where this is impractical, dust suppression techniques shall be used to keep dust levels down within labour accommodation.

8

The Contractor shall appoint/engage a team of personnel dedicated to cleaning communal areas around the camp on a regular (daily) basis.

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10.10.15 Health and Safety for Labour Accommodation Residents The Contractor shall extend Workmen’s Compensation and Employer’s Liability Insurance to cover their staff while resident in labour accommodation.

2

The Contractor shall extend the accident reporting requirements, to include accidents occurring at off-site labour accommodation directly associated with the Project.

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END OF PART

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

ENGINEER’S SITE FACILITIES .............................................................................. 2

11.1 11.1.1

GENERAL ............................................................................................................... 2 Scope 2

11.2 11.2.1 11.2.2 11.2.3 11.2.4

ENGINEER’S SITE OFFICES ................................................................................. 2 General 2 Type 1 Offices 2 Type 2 Offices 3 Car Parking Facilities 6

11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5

UTILITY CONNECTIONS ........................................................................................ 6 General 6 Electricity 6 Water 6 Telephone 7 Internet 7

11.4 11.4.1 11.4.2 11.4.3 11.4.4 11.4.5 11.4.6 11.4.7

PROVISION OF EQUIPMENT AND SUPPLIES ...................................................... 7 General 7 Computers and Scanners/Printers 7 Photocopier 8 Measuring and Recording Equipment 9 Stationary Supplies 9 Safety Equipment and Clothing 10 Telephones and Facsimile Machines 10

11.5 11.5.1 11.5.2

ATTENDANCE ...................................................................................................... 11 Assistance to the Engineer 11 Contract Administration 11

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11

ENGINEER’S SITE FACILITIES

11.1

GENERAL

11.1.1

Scope

1

This Part specifies the requirements for the Engineer’s temporary site facilities and includes site offices, utility connections, provision of equipment and supplies and attendance.

2

Related Sections and Parts are as follows Part 10 Part 13

Occupational Health and Safety Setting Out of the Works

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ENGINEER’S SITE OFFICES

11.2.1

General

1

The Contractor shall provide site offices the type and number as stated in the Project Documentation. The position of the site offices shall be to the approval of the Engineer.

2

Upon removal of the site offices, the area occupied or otherwise affected by them shall be reinstated to its original condition.

11.2.2

Type 1 Offices

1

Unless described elsewhere in the Project Documentation the Contractor shall provide, maintain and remove on completion of the Works the Engineer’s site offices described in this Clause.

2

The Contractor shall proceed with the provision of a site office for the exclusive use of the Engineer immediately following the award of the Contract and shall provide temporary alternative accommodation to the Engineer’s approval until such time as the office is made available.

3

The office shall have a minimum area of 20 m and shall comply with the following:

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(a)

The structure shall be weatherproof.

(b)

The windows and doors shall be dust-proof and the windows shall be fitted with fly screens.

(c)

The office shall be air-conditioned to maintain a maximum steady dry bulb temperature of 25ºC at a relative humidity of 50% under the expected climatic conditions expected at the Site.

(d)

Adequate effective lighting and power outlets shall be installed in accordance with the latest requirements of the Qatar General Electricity & Water Corporation.

(e)

The walls and ceilings shall be painted with emulsion paint.

The office shall be provided with the following furniture to the approval of the Engineer: (a)

1 No. kneehole pattern desk with a total of six lockable drawers, approximately 1500 x 800 x 760 mm in size.

QCS 2014


(b)

1 No. swivel chair with armrests.

(c)

2 No. stacking or folding chairs.

(d)

1 No. hanging file or plan chest suitable for AO size prints.

(e)

1 No. wastepaper basket.

(f)

1 No. two drawer filing cabinet.

(g)

1 No. wall mounted pin board, 1000 x 2000 mm in size.

Sanitary and washing facilities shall be provided for the exclusive use of the Engineer and shall include a WC and a wash-hand basin an adequate supply of hot and cold water shall be provided at all times.

6

The Contractor shall insure the site offices against fire, burglary and other risks.

7

The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled drinking water for the consumption of the Engineer.

8

The Contractor shall maintain the offices in a clean and sanitary condition.

11.2.3

Type 2 Offices

1

The Engineer’s site offices described in this Clause shall be provided in lieu of Type 1 Offices only where it is a stated requirement of the Project Documentation.

2

The offices shall be portable units, mounted on skids or similar and where directed in the Project Documentation shall become the property of the Government on completion of the Contract. On completion of the Contract, the offices which are to become the property of the Government shall be repaired and redecorated to the satisfaction of the Engineer; they shall then delivered to a location designated by the Engineer within 50 km of the Site.

3

The buildings shall conform to the general configuration shown below. The number of each type of unit shall be as stated in the Project Documentation.

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The Contractor shall proceed with the provision of the portable offices, which shall be for the exclusive use of the Engineer immediately following the award of the Contract and shall provide temporary alternative accommodation to the Engineer’s approval until such time as the offices are made available.

5

The Contractor shall submit to the Engineer for approval a comprehensive specification and drawings showing the accommodation proposed complete with furnishings, equipment and fittings before placing any orders.

6

The units shall be mounted on adequate concrete foundations and shall be provided with concrete access steps where necessary.

7

The units may be constructed of composite timber framed panels with wood or metal cladding, any combination of these, or alternative forms or construction which comply with the following levels of performance:

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Walls

Thermal conductance Fire resistance -

0.60 w/m ºC ½ hour

Roof

Thermal conductance Roof resistance -

0.60 m ºC ½ hour

2

8

Roof coverings shall be selected for durability, freedom from excessive maintenance, and the ability to withstand extreme exposure to sun, heat and humidity.

9

The units shall be finished internally and externally with low maintenance materials.

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10

The offices shall be air-conditioned with wall mounted units to maintain each room at a maximum steady dry bulb temperature of 25ºC at a relative humidity of 50% under the expected climatic conditions expected at the Site. Extract fans capable of 10 air changes per hour shall be provided in the kitchen and toilets.

11

The installation and testing of wiring and electrical equipment in the units shall be in accordance with the latest requirements of the Qatar General Electricity & Water Corporation.

12

Each office shall be provided with the following furniture to the approval of the Engineer:

1 No. swivel chair with armrests.

(c)

No. stacking or folding chairs.

(d)

1 No. hanging file or plan chest suitable for AO size prints.

(e)

1 No. wastepaper basket.

(f)

1 No. two drawer filing cabinet.

(g)


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Each toilet shall be provided with the following sanitary fittings to the approval of the Engineer and an adequate supply of hot and cold water at all times: 1 No. low level WC suite.

(b)

1 No. Wash-hand basin.

(c)

1 No. shower tray, mixer fittings, rose and shower curtain.

(d)

1 No. toilet roll holder, towel rail, soap dish and mirror.

(e)

a suitable number of cups, saucers and drinking glasses.

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The samples and meeting room shall be provided with the following furniture to the approval of the Engineer: (a) (b)

No. folding or stacking chairs.

(c)

1 No. wall mounted blackboard, 1000 x 2000 mm in size.

(d)


(e)

1 No. shelf unit for approved samples with 5 tiers of shelves 400 mm wide x 2400 mm long overall.

2 No. tables, each approximately 1200 x 2000 mm in size.

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1 No. kneehole pattern desk with a total of six lockable drawers and approximately 1500 x 800 x 760 mm in size.

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(a)

15

All furniture and equipment shall remain the property of the Contractor and shall be removed following completion of the Works unless otherwise noted in the Project Documentation.

16

The Kitchen shall be provided with the following equipment to the approval of the Engineer (a)

1 No. stainless steel single bowl single drainer sink with hot and cold water and cupboards underneath

(b)

1 No. floor mounted two door cupboards to match sink.

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(c)

Cabinets and shelves to match sink, as required.

(d)

2 ring cooker and microwave.

(e)

1 No. Refrigerator/Freezer with a capacity no less than 500 litres.

(f)

1 No. three pint kettle and sufficient crockery and cutlery.

(g)

A suitable number of mugs, cups, saucers and drinking glasses.

(h)

Table coasters for use on desk tops.

(i)

Hand towels and drying up cloths, laundered regularly.

(j)

Dishwashing facilities, clothes, sponges and washing up liquid, all replaceable.

(k)

Cleaning brushes, mop, bucket and floor clothes.

The Contractor shall insure the site offices against fire, burglary and other risks.

18

The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled drinking water for the consumption of the Engineer.

19

The Contractor shall maintain the Offices in a clean and sanitary condition.

20

Each type of unit shall be provided with fire extinguishers and water cooler.

11.2.4

Car Parking Facilities

1

Parking areas shall be paved or have a finished surface as approved by the Engineer and shall be covered with a suitable canopy to provide shading.

2

The number of shaded car parking spaces required shall be 2 No. for Type 1 Offices and 6 No. for Type 2 Offices unless otherwise stated in the Project Documentation.

11.3

UTILITY CONNECTIONS

11.3.1

General

1

The Contractor shall make all arrangements and pay all charges in connection with the installation, maintenance, operation and removal of the service utilities described in this Clause.

11.3.2

Electricity

1

The Contractor shall arrange for the provision of an uninterrupted electrical power supply to the Engineer’s offices during all working hours and any at other time as requested by the Engineer for the duration of the Contract.

11.3.3

Water

1

The Contractor shall arranged for the provision of an uninterrupted water supply to the Engineer’s offices during all working hours and at any other time as requested by the Engineer for the duration of the Contract.

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The Contractor shall provide inline filters on all water supplies into Employer and Engineer’s site Facilities. The Contractor shall maintain these at regular intervals as per manufacturer instruction throughout the duration of the Work order.

11.3.4

Telephone

1

The Contractor shall arrange for the provision of two (2) land lines for the sole use of the Engineer for Type 1 Offices and three (3) land lines for the sole use of the Engineer for Type 2 Offices.

2

The Contractor may recover the net cost of international calls made by the Engineer.

11.3.5

Internet

1

.The Contractor shall arrange for the provision of a dedicated and uninterrupted internet access to the Engineer’s offices during all working hours and at any other time as requested by the Engineer for the duration of the Contract. The internet connection should be provided with a bandwidth running at a minimum of 1 mbps upload capacity.

11.4

PROVISION OF EQUIPMENT AND SUPPLIES

11.4.1

General

1

The following items of equipment, supplies and associated level of service shall all be provided unless detailed elsewhere in the Contract Documentation.

11.4.2

Computers and Scanners/Printers

1

The Contractor shall provide new network/internet capable computers and scanners/printers for the sole use of the Engineer. The number of computers and scanners/printers required and their performance specification shall be as detailed in the Project Documentation. The Contractor shall also supply and install any computer software as detailed in the Project Documentation.

2

The Contractor shall maintain the computers and scanners/printer for the duration of the Contract and provide all consumables necessary for its operation.

3

The Contractor shall be responsible for installing legal copies of operating system and software, trouble shooting, supplying of required consumables and maintenance of the system.

4

Operating system and software requirements shall be as specified by the Engineer, with the following as a minimum:

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(a)

Latest version of Microsoft Windows Operating System

(b)

Latest version of Microsoft Office

5

All software must be of latest version and Arabic enabled, to the approval of the Engineer.

6

The Contractor shall ensure that all computers and scanners/printers provided for the Engineers use are networked within the Engineers facilities to the satisfaction of the Engineer.

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7

The Contactor shall provide new desktop computers and laptops as shown in the Schedule of Rates minimum 20-inch Flat Panel VGA/analogue colour monitors for use by the Engineer.

8

The Desktop and laptop computers shall comply with the following: Intel Core 2 Duo Processor (1.86GHz,1066MHz,2MB cache)

(b)

1000GB(7200rpm)Serial ATA Hard Drive

(c)

56k Modem

(d)

32X DVD+/-RW Drive

(e)

Wireless network adaptor (Wi-Fi)

(f)

Wireless Keyboard & Mouse

(g)

Card Reader

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(a)

The Desktop and laptop computers shall comply with the following: New licensed copies of MS Windows, MS Office Professional, MS Project and AUTOCAD, Primavera P6 and Primavera Contract Manager (PCM) SOFTWARE SHALL BE PROVIDED.

10

Colour printer shall be of the laser type suitable for A3 size paper and having scanning and copying facilities built in. It shall be quiet in operation (Hewlett Packard Desk Jet (latest model) or similar).

11

The Computer equipment shall be returned to the Contractor at the end of Maintenance Period. The Contractor shall be responsible for supply of all necessary cartridges and paper and for maintenance of the equipment by the manufacture’s agent throughout the period of the Work order.

12

The Contractor shall provide all necessary voltage stabilization equipment to ensure troublefree operation of the computer equipment.

13

All computers and printers shall be networked.

11.4.3

Photocopier

1

The Contractor shall provide a new photocopier for the sole use of the Engineer. The performance specification for the photocopier shall be as detailed in the Project Documentation.

2

The Contractor shall maintain the photocopier for the duration of the Contract and provide all consumables necessary for its operation.

3

Contractors shall provide a new floor standing, stationary platen, and plain paper colour photocopier for use and approved by the Engineer.

4

The photocopier shall be provided with an automatic document feeder capable of copying both sides.

5

The Range of copy sizes of the photocopier shall be from A3 size (297×420mm) to A4 size (210×297mm), portrait and landscape. Three paper storage trays shall be provided.

6

The photocopier shall be capable of reducing/enlarging originals by 50% to 200% in 1% increments.

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The photocopier shall have an A4 size rotating paper cassette and automatic paper size/zoom ratio selection.

8

Throughput shall be not lesson than 40 A4 copies per minute.

9

The photocopier shall be able to scan and email documents.

10

The photocopier shall be returned to the contractor at the end of period of Maintenance. The contractor shall be responsible for supplying the necessary paper and maintenance of the equipment by the manufacture’s agent throughout the work order.

11.4.4

Measuring and Recording Equipment

1

The Contractor shall provide measuring and recording equipment for the sole use of the Engineer. The following items, which shall be to the approval of the Engineer, shall be provided for the duration of the Contract:

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1 No. Electronic Distance Measurement (EDM) station.

(b)

1 No. 1” Total Station theodolite (or equivalent) including all necessary tripods, prisms etc.

(c)

1 No. Automatic engineer’s level including tripod.

(d)

1 No. Metric levelling staff.

(e)

1 No. Calibrated steel survey band 50m long.

(f)

2 No. 30m nylon tapes.

(g)

2 No. 25 m metal tapes.

(h)

4 No. 5m pocket tapes.

(i)

6 No. Ranging rods.

(j)

1 No. Mason’s Spirit level.

(k)

1 No. Bitmac thermometer.

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1 No. digital camera. Level and field books as required.

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(a)

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Other equipment such as pegs, tools, etc, which are necessary for the checking of the Works shall be provided as requested by the Engineer.

3

The Contractor shall maintain and replace as necessary the equipment for the duration of the Contract. Surveying instruments shall be new or in as good as new condition, of an approved make with a current certificate of adjustment.

11.4.5

Stationary Supplies

1

The Contractor shall supply stationary for the Engineer for the duration of the Contract. Stationary items shall include, but not necessarily be limited to, the following: (a)

Files and file dividers (A4 and A3 size).

(b)

Paper (A4 and A3 size).

(c)

Writing pens, marker pens, highlighter pens (various colours).

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(d)

Pencils (various colours).

(e)

Pencil sharpeners.

(f)

Erasers.

(g)

Staplers and staples.

(h)

Hole punches.

(i)

Paper chips and bull dog clips.

11.4.6

Safety Equipment and Clothing

1

The Contractor shall supply safety equipment and clothing for the Engineer and his staff. Safety equipment and clothing shall include, but not necessarily be limited to, the following: Safety helmets, boots, gloves, High visibility vests, safety glasses (Clear and tinted)

(b)

Safety belts and harnesses.

(c)

Boiler suits.

(d)

Any other PPE identified by the Contractors job hazard analysis or risk assessment process

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(a)

The Contractor shall also supply gas detection equipment and breathing apparatus in accordance with the relevant provisions of Part 10 of this Section, Occupational Health and Safety.

11.4.7

Telephones and Facsimile Machines

1

For Type 1 Offices, the Contractor shall supply and install a telephone and facsimile machine. The telephone and facsimile machine should conform to the relevant provisions of any Telecom Provider standard or requirement.

2

For Type 2 Offices, the Contractor shall supply and install a telephone in each office and the meeting room. Each telephone shall be connected to a private address box exchange (PABX) system. The Contractor shall also supply and install a facsimile machine. The telephones, PABX system and facsimile shall conform to the relevant provisions of any Telecom Provider standard or requirement.

3

The Contractor shall provide a new A4 size plain paper desktop facsimile machine complying with the following:

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(a)

2 Line × 24 character LCD Display

(b)

ITU compatible

(c)

Resolution horizontal scanning 8 pixel/mm

(d)

Vertical scanning Standard 3.85 lines/mm

(e)

Fine 7.7 lines/mm

(f)

150 sheet paper tray (80g/m2

The facsimile machine shall be returned to the contractor at the end of maintenance period. The Contractor shall be responsible for supply of all necessary toner or ink cartridges and plain white paper and for maintenance of the equipment by the manufactures’ s agent throughout the Work order.

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The Contractor shall provide six digital cameras and one digital video camera for the exclusive use of the Engineer or his designated representative and supply software, batteries, cables and USB flash drives or external hard drives as required. The Digital camera shall have a minimum specification of 35-105 zoom, with a minimum of 16.0 megapixels for prints up to 20”×30”, 8GB internal memory and video/audio facility. The cameras shall be returned to the contractor at the end of the contract period

11.5

ATTENDANCE

11.5.1

Assistance to the Engineer

1

The Contractor shall provide every assistance to the Engineer in carrying out his duties.

2

The Contractor shall provide for the use of the Engineer’s Representative and his staff, any chainman/assistants to carry out any duties whatsoever, as required by the Engineer’s Representative.

11.5.2

Contract Administration

1

The Contractor shall provide secretaries, cleaners and tea persons for the exclusive use of the Engineer for the duration of the Contract.

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Section 01: General Part 12: Contractor’s Site Facilities

Page 1

12

CONTRACTOR’S SITE FACILITIES GENERAL ........................................... 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 Scope 12.1.2 References

2 2

12.2

CONTRACTOR’S SITE FACILITIES ............................................................. 2

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

Buildings Site Fabrication Areas Materials Storage Area Power, Water, Lighting and Heating Miscellaneous

12.3

PROJECT SIGN BOARD............................................................................... 3

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12.3.1 Project Sign Board

ADVERTISING .............................................................................................. 4 4 4

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12.4.1 Photographs 12.4.2 Name Boards and Other Advertising

PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE STATION ....................................................................................................... 4

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12

CONTRACTOR’S SITE FACILITIES GENERAL

12.1

GENERAL

12.1.1

Scope

1

This Part specifies the requirements for the Contractor’s temporary site facilities.

12.1.2

References

1

Related Sections and Parts are as follows: Part 9 Materials.

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CONTRACTOR’S SITE FACILITIES

12.2.1

Buildings

1

The Contractor shall provide all offices, sheds, stores and other buildings necessary for him to undertake all duties, obligations and activities associated with the construction of the Works.

2

All buildings shall be supplied and maintained in good condition and shall be of neat appearance.

3

The position of all the Contractor’s temporary site buildings shall be to the approval of the Engineer.

4

The Contractor shall maintain an office at the Site for the duration of the Contract. This office shall be open at all times during Site working hours.

5

Upon completion of the Contract, all temporary site buildings shall be removed and the area occupied or otherwise affected by them reinstated to its original condition.

6

The Government of Qatar will grant a right of access only within the road reservation. Should the Contractor need to use adjacent areas of land for camps, plant site etc, he shall arrange for the right to use the said land himself.

7

This clause in no way invalidates the obligations of the General Conditions of Contract.

12.2.2

Site Fabrication Areas

1

The Contractor shall provide an area suitable for assembly and fabrication purposes.

2

Fabrication areas shall simulate factory conditions if required in the Project Documentation.

12.2.3

Materials Storage Area

1

The Contractor shall provide sufficient and appropriate materials storage areas. The storage areas shall be suitable for the materials to be stored in them and shall offer necessary protection where required.

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The Contractor shall ensure that the storage areas comply with the relevant provisions of Part 9 of this Section, Materials.

12.2.4

Power, Water, Lighting and Heating

1

The Contractor shall provide, maintain and subsequently remove temporary services for power supply, water supply, lighting and heating.

2

All electrical installations shall be in the charge of a competent person who shall accept full responsibility for its use and any alterations or additions thereto. The name, designation and telephone number of such person shall be prominently displayed close to the main switch or circuit breaker of the installation, and also in the Contractor’s site office.

3

Site work power tool supplies (except for operation of pumps) shall be of 110 volts (55 volts to earth). All electricity supply cables shall be buried or properly supported and protected and shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used.

4

All site electrical installations shall comply with the requirements of the current regulations of QGEWC.

12.2.5

Miscellaneous

1

The Contractor shall provide, maintain and subsequently remove temporary roads, paths, parking areas and refuse disposal areas. The area occupied by temporary roads, paths, parking areas and refuse disposal areas or otherwise affected by them shall be restored to their original condition on completion of the Contract.

12.3

PROJECT SIGN BOARD

12.3.1

Project Sign Board

1

Standard Signboard: The Contractor shall provide and erect a temporary signboard at the location of his approved site compound. In addition he shall provide signboards at the start and end of each ongoing work location for all works whether major or minor.

2

Project Identification Signboard: Information signboards shall be clearly displayed on approaches to works in the highway at each ongoing work location for all works whether major or minor. These shall be provided by the Contractor and shall be positioned so as not to cause hindrance to the movement of vehicular or pedestrian traffic. The signs shall be mounted on sturdy metal frames, be mobile and reusable, and shall be illuminated at night.

3

The Project sign boards shall comply with the standard details, as updated by the project drawings and specifications, and shall be to the approval of the Engineer. In addition, the Contractor shall obtain all necessary approvals from the relevant authorities prior to erection. The Contractor shall be responsible for the structural stability of the signboards but shall submit details of his proposals for support to the Engineer for approval.

4

The Contractor shall maintain, move and adapt the signboards as required during the progress of the Works and shall remove them upon completion.

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ADVERTISING

12.4.1

Photographs

1

The Contractor shall not use photographs or any details of his work in connection with the Contract in any form of publicity or advertisement in any part of the world without having first obtained the Engineer’s approval to its content and context.

12.4.2

Name Boards and Other Advertising

1

Details of any further sign boards other than as designed in Clause 12.3.1 or advertisements that the Contractor may wish to erect on site shall be to the approval of the Engineer.

12.5

PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE STATION

12.5.1

General

1

Ambulance Spoke Station is a temporary structure. This can be relocated quickly to any location in a rapidly changing infrastructure, which is a vital component of the design. It is designed to provide covered parking for up to two ambulances and accommodation for a small crew room for up to four paramedics. The crew need shelter from the summer heat in a safe environment in a prime response location to be ready for emergency calls. The stations are versatile and designed to be completely self-contained. It doesn't require to be connected to Electricity, Water or Sewerage or require any physical links to service providers. All of its power is provided by solar panels. The cabin can be dismantled and moved to another site within 48 hours, enabling Hamad Medical Corporation to relocate these small stations. The station does not require any form of building foundations, just level ground. Depending on the location, some stations may require minor works for access to and from the road.

2

The contractor will in no way be relieved of his responsibility under Qatari law to provide medical care, facilities, insurance, etc. to workers on site, and that Hamad Medical Corporations facility is mainly for the purpose of the general public (so that Hamad Medical Corporation can respond more quickly to emergency incidents in a rapidly changing infrastructure)

12.5.2

Requirements

1

If instructed by the Engineer, the Contractor shall make provision within or adjacent his site facilities for an Ambulance Spoke Station.

2

The Contractor is only required to provide an area for the for the facilities. The Ambulance Spoke Station and vehicles will be provided and installed by Hamad Medical Corporation or an entity on their behalf.

3

The area shall be a minimum of 10 metres by 17 metres.

4

The area must be levelled as the surrounding area of the Contractor facilities.

5

The areas shall be provided with clear access to the road network.

6

Access to the Ambulance Spoke Station is required 24hours/day 7 days/week.

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7

Ambulance vehicle access is required to at least one long side.

8

Access for maintenance (water resupply, cleaning, removal of waste etc.) is required to one short side.

9

The allocated area shall be approved in writing by the Engineer after consultation with Hamad Medical Corporation.

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13

Section 01: General Part 13: Setting Out of the Works

Page 1

SETTING OUT OF THE WORKS .................................................................. 2

13.1 GENERAL ...................................................................................................... 2 13.1.1 Scope 2 13.2 SITE INFORMATION AND INSPECTION ..................................................... 2 13.2.1 Site Information 2 13.2.2 Site Inspection 2 13.3 LEVELS AND REFERENCE GRID ................................................................ 2 13.3.1 Temporary Bench Marks 2 13.3.2 Site Grid 3

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13.4 SURVEYING .................................................................................................. 3 13.4.1 Site Survey 3

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13

SETTING OUT OF THE WORKS

13.1

GENERAL

13.1.1

Scope

1

This Part specifies the requirements for setting out of the Works and includes locating existing services, surveying the Site and establishment of temporary bench marks.

2

The Engineer reserves the right to order levels to be taken at any time considered necessary for the full and proper supervision and measurement of the Works.

3

Related Sections and Parts are as follows:

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Engineer’s Site facilities.

Part 11

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This Section

SITE INFORMATION AND INSPECTION

13.2.1

Site Information

1

Before commencing the setting out of the Works the Contractor shall ascertain the location of all existing underground services within the Site boundary. The Contractor shall prepare a plan detailing the location of the services.

2

Any conflict between existing services and any part of the proposed Works shall be brought to the attention to the Engineer without delay.

3

Any re-work resulting from the Contractor’s failure to locate and identify services shall be undertaken at the Contractor’s cost.

13.2.2

Site Inspection

1

Before commencing the setting out of the Works, the Contractor and the Engineer shall make an inspection of the Site.

2

Where appropriate, the Engineer shall require the Contractor to arrange for surveys to be undertaken, in conjunction with the owners or occupiers, of the condition of roads, properties, lands and crops which may be affected by the Works. Before any work affecting such roads, properties, lands or crops is commenced, the Contractor shall confirm in writing to the Engineer that the relevant survey is a true and accurate record of their condition.

13.3

LEVELS AND REFERENCE GRID

13.3.1

Temporary Bench Marks

1

. The Contractor shall establish accurate temporary bench marks on permanent blocks from which the levels to which the Works are to be constructed may be transferred. The location of temporary bench marks shall be agreed with the Engineer. The level of temporary bench marks shall be related to the Qatar National Height Datum.

2

The Contractor shall prepare a plan detailing the location of the bench marks and temporary bench marks and keep it up to date for the duration of the Contract.

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The Contractor shall protect and maintain the temporary bench marks until the Works are complete. Upon completion of the Works the Contractor shall clear away the temporary bench marks to the satisfaction of the Engineer.

4

The Contractor is responsible for checking the accuracy of temporary bench mark. Any rework resulting from incorrect or inaccurate temporary bench marks shall be undertaken at the Contractor’s cost.

13.3.2

Site Grid

1

When it is a requirement of the Project Documentation, or unless otherwise notified by the Engineer, the Contractor shall establish a Site Grid. The orientation of the Site Grid shall be determined by the layout of the proposed works and as agreed with by the Engineer. Grid spacing shall be 20m in each direction unless otherwise notified by the Engineer. Grid notation shall be numerical in one direction (y-axis) and alphabetic in the other (x-axis).

2

The grid shall be tied to the Qatar National Grid. An existing control station related to the Qatar National grid will be indicated by the Engineer for this purpose.

13.4

SURVEYING

13.4.1

Site Survey

1

The Contractor shall provide the Site survey and the correctness of that survey shall be entirely the Contractor’s responsibility.

2

The Site survey shall comply with the requirements of the Qatar Survey Manual as a minimum.

3

The Contractor shall, within 3 weeks of the date of commencement of the Works, carry out a check of the co-ordinates and levels of all permanent monuments, bench marks and survey markers used in the determination of the site survey model and proposed to be used for the setting out of the Works.

13.5

SETTING OUT

13.5.1

Setting Out of the Works

1

The Contractor shall carry out at his own cost the setting out of the Works.

2

The Contractor shall be responsible for:

3

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3

(a)

True and proper settings out of the Works in relation to reference data given in the Project Documentation.

(b)

Accurately setting out the positions, levels and dimensions of all parts of the Works.

Any delay or loss resulting from errors in the setting out of the Works shall be the responsibility of the Contractor. Setting out shall be reviewed by the Engineer before commencing the Works, but such approval shall in no way relieve the Contractor of his responsibility for the correct execution of the Work.

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The Contractor shall provide measuring and recording equipment for the Engineer in accordance with the relevant provisions of Part 11 of this Section, Engineer’s Site Facilities. The Contractor shall maintain all measuring and recording equipment in good working order at all times.

5

The Contractor shall provide all assistance which the Engineer may require for checking the setting out and taking measurements of the Works, including labour, equipment and transportation.

13.5.2

Setting Out of Works Sited on Private Land

1

The Contractor shall notify the Engineer in writing fourteen (14) days in advance of his intention to set out any of part of the Works that lies in private land.

2

The Contractor shall ensure that all requirements and instructions of private land owners are strictly adhered to.

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Section 01: General Part 14: Temporary Works and Equipment

Page 1

TEMPORARY WORKS AND EQUIPMENT ............................................................. 2

14.1 14.1.1

GENERAL ............................................................................................................... 2 Scope 2

14.2 14.2.1

TEMPORARY WORKS ........................................................................................... 2 General 2

14.3 14.3.1

TEMPORARY EQUIPMENT .................................................................................... 2 General 2

14.4 14.4.1

TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE ............................... 3 General 3

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14

TEMPORARY WORKS AND EQUIPMENT

14.1

GENERAL

14.1.1

Scope

1

This Part specifies the requirements for Temporary Works required in connection with construction of the Works and temporary plant and equipment required in connection with aiding the construction of the Works. It does not include overpumping activities in respect of sewers and drains.

2

Related Parts and Sections are as follows: Quality Assurance and Quality Control

Section 11

Health and Safety

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Section 2

Occupational Health and Safety concerning temporary works and equipment is covered in Section 11 Health and Safety

4

Quality Controlling temporary works and equipment’s is covered in Assurance and Quality Control

14.2

TEMPORARY WORKS

14.2.1

General

1

Everything used for and in connection with the Temporary Works shall be fit for the purpose, in serviceable condition and in compliance with any relevant standard.

2

The Contractor shall design his Temporary Works to be of adequate strength, stability and suitability.

3

The Contractor shall submit details of any Temporary Works proposed to the Engineer for review before commencing the work. Such details shall include, but not be limited to design calculations and drawings. The submission to the Engineer of any such details shall not relieve the Contractor of his responsibility for sufficiency of the Temporary Works or of his other duties and responsibilities under the Contract.

4

The Contractor is responsible for ensuring that Temporary Works are not in any way detrimental to existing structures in any way. Particular care shall be taken with scaffolding to avoid staining or mechanical damage to finishing.

5

The Contractor shall make safe and reinstate all areas affected by Temporary Works.

14.3

TEMPORARY EQUIPMENT

14.3.1

General

1

The Contractor shall provide and maintain in good condition on the Site all plant, tools and vehicles necessary for the proper and safe execution of the Works.

2

Temporary equipment shall be fit for the purpose for which it is to be used.

Section 2 Quality

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Temporary equipment shall only be operated by personnel who are trained and qualified.

14.4

TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE

14.4.1

General

1

Cranes, whether used to construct the Works or provided as part of the permanent Works, must have a current test certificate.

2

Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works or provided as part of the permanent Works, must have either a current test certificate.

3

Test certificates must be issued by a competent testing authority approved by the Engineer.

4

The Contractor must have a copy of each test certificate on site available for inspection by the Engineer.

5

The following Standards and Code of Practice shall be complied with and where such documents are replaced or superseded the Contractor shall comply with the latest version:

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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010.

(b)

Overhead Cranes: BS 466 and BS 5744.

(c)

Slings: BS 1290, BS EN 1492, ISO 4309 / 3481 Pt 2, ASME B30.9.

(d)

Chain Blocks: BS 3243.

(e)

Shackles: Alloy: BS 3551/ BS 6994.

(f)

Chain: BS 4942 part 1 & 6.

(g)

Hooks: BS 2903, ASME B30.10.

(h)

Ring and link: BS 2902.

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A monthly inspection of lifting appliances shall be carried out by a competent person employed by the Contractor. Full records of all such inspections and tests shall be kept by the Contractor in an approved form and shall be made available to the Engineer immediately upon demand. Copies of monthly inspection reports shall be submitted to the Engineer.

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Section 01: General Part 15: Temporary Controls

Page 1

TEMPORARY CONTROLS ..................................................................................... 2

15.1 15.1.1

GENERAL ............................................................................................................... 2 Scope 2

15.2 15.2.1 15.2.2 15.2.3 15.2.4 15.2.5 15.2.6 15.2.7

TEMPORARY CONTROLS ..................................................................................... 2 Construction Cleaning 2 Dust Control 2 Noise 2 Nuisance and Trespass 2 Pollution Control 3 Surface Water and Groundwater Control 3 Environmental protection 4

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15

TEMPORARY CONTROLS

15.1

GENERAL

15.1.1

Scope

1

This Part specifies the Contractor’s responsibilities with respect to temporary controls needed to protect the Works and the environment.

2

Related Sections and Parts are as follows: This Section

Part 5

Interference

TEMPORARY CONTROLS

15.2.1

Construction Cleaning

1

The Contractor shall be responsible for the proper upkeep and maintenance of the Site and Works and shall remove from the Site all rubbish and other waste as it accumulates. Materials and equipment shall be positioned, stored and stacked in an orderly manner.

2

Properly constructed rubbish chutes shall be used for clearing the debris from upper floors. Debris shall be accumulated in suitable pre-determined areas and removed from the Site as often as is practical.

3

On completion of the Works, any protective tape and other temporary coverings shall be removed and the internal and external surface of the structure shall be thoroughly cleaned to completely remove all dust, dirt, stains, handmarks, paint spots, plaster, mortar droppings and other blemishes.

15.2.2

Dust Control

1

The Contractor shall conduct his operations and activities in such a manner that no operation shall be included which will emit into the atmosphere any flying dust or dirt which might constitute a nuisance.

15.2.3

Noise

1

The Contractor shall restrict the use of plant, machinery, equipment and work practises likely to produce unacceptable noise levels to normal working hours.

15.2.4

Nuisance and Trespass

1

All reasonable means shall be used to avoid inconveniencing owners and occupiers of adjacent properties. All plant, machinery or equipment shall be placed and used on the Site so as to avoid any nuisance or trespass on adjoining property.

2

Should it be necessary for any plant, machinery or equipment to project or operate over adjoining property, the Contractor shall obtain the permission of the adjoining owner or occupier. Details of approvals shall be submitted to the Engineer in writing.

3

No workmen employed on the Works shall be allowed to trespass upon adjoining properties.

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If in the execution of the Works it is necessary for the Contractor to enter adjacent properties, he shall firstly obtain the permission of the owners of the property. The Contractor shall ensure that any instructions made by the owners of the properties are strictly adhered to.

5

The Contractor shall be held responsible for and shall indemnify the Employer against all claims, which may arise out of his failure to comply with provisions of items 1. 2. 3 and 4 of Clause 1.15.2.4

15.2.5

Pollution Control

1

The Contractor shall ensure that none of his operations or work practises result in the polluting of the air, underground strata or any existing watercourse, canal, lake, reservoir borehole and aquifer.

2

The Contractor shall rectify any problem resulting from pollution caused by the Contractor to the satisfaction of the Engineer.

3

The Contractor will be held responsible for and shall indemnify owner against all claims in connection with noise, vibration, dust, smoke, diesel spillage and any other nuisance arising from the execution of the Works.

15.2.6

Surface Water and Groundwater Control

1

The Contractor shall keep the Work well drained until the Engineer certifies that the whole of the Works is substantially complete and shall ensure that so far as is practicable all work is carried out in the dry. Excavated areas shall be kept well drained and free from standing water.

2

The Contractor shall construct, operate and maintain all temporary dams, water courses and other works of all kinds including pumping and well-point dewatering that may be necessary to exclude water from the Works while construction is in progress. Such temporary works shall not be removed without the approval of the Engineer.

3

Notwithstanding any approval by the Engineer of the Contractor’s arrangements for the exclusion of water, the Contractor shall be responsible for the sufficiency thereof and for keeping the Works safe at all times, particularly during periods of rainfall that may result in flooding. Any damage to the Works arising through the Contractor’s failure to provide sufficient protection against water, including flooding, shall be made good at his own expense.

4

It is the Contractor’s responsibility to dispose of all extracted groundwater and collected surface water. The Contractor shall submit details of his proposed disposal methods to the Engineer for approval. Discharge of groundwater and/or surface water to existing drainage facilities shall only be permitted if written approval is given by Public Works Authority and/or concerned other authorities; copies of such approvals shall be submitted to the Engineer.

5

The Contractor is to take all necessary precautions to avoid floatation of any structure.

6

The Contractor shall ensure that his groundwater control activities do not adversely affect any existing structure or service.

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15.2.7

Environmental protection

1

The Contractor shall comply with all conditions of the environmental clearance issued for the project by the Supreme Council for the Environment and Natural Reserves.

2

The Contractor shall comply with all rules and regulations regarding environmental protection and pollution control issued by the Supreme Council for the Environment and Natural Reserves.

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END OF PART

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Section 01: General Part 16: Traffic Diversions

Page 1

16

TRAFFIC DIVERSIONS................................................................................. 2

16.1

GENERAL ...................................................................................................... 2

16.1.1 16.1.2 16.1.3 16.1.4 16.1.5

Scope Conformance Safety System Description Traffic Police Requirements

16.2

TEMPORARY TRAFFIC DIVERSIONS ......................................................... 3

2 2 2 2 2 3 3

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16.2.1 General Requirements 16.2.2 Maintenance of Traffic flow

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TRAFFIC DIVERSIONS

16.1

GENERAL

16.1.1

Scope

1

This Part specifies requirements associated with traffic diversions. Traffic diversions include for work in, or affecting the use of, roads, footpaths and right of ways and may comprise the construction and maintenance of paved and unpaved detour carriageways including all earthworks and the provision of adequate drainage, lighting, sign posting, street furniture and traffic control devices.

2

Related Sections and Parts are as follows: Part 4

Protection

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16

Conformance

1

Signs, control and control devices associated with traffic diversions shall conform to the relevant provisions of “Traffic Control at Roadworks” produced by the Ministry of Public Works (latest edition/version) and shall be to the approval of the Traffic Police and the Public Works Authority.

16.1.3

Safety

1

The Contractor is responsible for all safety issues associated with the installation, operation, maintenance and removal of traffic diversions.

2

The Contractor shall provide lighting in accordance with the relevant provisions of Part 4 of this Section, Protection.

16.1.4

System Description

1

Where the diversion of any existing road, footpath or public right or way is temporarily necessitated by the Works, the Contractor shall provide and maintain an alternative which shall be operational before interference with the existing facility.

2

Temporary traffic control devices as well as any other traffic management requirement shall be erected and maintained by the Contractor for the duration of any activity in, or affecting the use of, roads, footpaths and right of ways.

16.1.5

Traffic Police Requirements

1

Before any work in, or affecting the use of, any road, footpath, and right of way is commenced, the Contractor’s proposed method of working shall be agreed with, and confirmed in writing to, the Engineer and the Traffic Police.

2

Throughout the execution of the Works and the maintenance period, the Contractor shall cooperate with the Traffic Police concerning works in, or access to, roads, footpaths and right of ways. The Contractor shall inform the Engineer of any requirements of, or arrangements made with, the Traffic Police.

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TEMPORARY TRAFFIC DIVERSIONS

16.2.1

General Requirements

1

The Contractor shall prepare detailed plans showing any proposed traffic diversions. The plans shall fully detail the diversion in all respects and shall include construction details if necessary. The plans shall show the position of ramps, traffic signs, cones, barriers, demarcation posts and tape, flashing lights and any other traffic control devices. The plans shall be submitted to the Engineer for review and shall be approved by the Traffic Police. Traffic diversion apparatus shall not be erected until the Traffic Police have reviewed and approved the traffic diversion plans.

2

Persons acting as flagmen shall be physically and mentally qualified, trained in their duties and courteous. Each flagman on duty shall be identified with appropriate and distinctive apparel approved by the Engineer and equipped with bilingual STOP/GO signs. Reflective apparel is required for flagging duties during darkness.

3

Where paved carriageways, unpaved carriageways or ramps are required, they shall be provided and maintained to a standard suitable in all respects for the class or classes of traffic or pedestrians requiring the use of them.

4

On completion, all traffic diversion works and apparatus shall be removed and land affected by them reinstated to its original condition.

16.2.2

Maintenance of Traffic flow

1

The Contractor shall allow for the construction of temporary diversions to permit all existing traffic movements for the duration of the Contract period.

2

All diversions shall be constructed in accordance with the latest edition/version of Qatar Traffic Manual “Traffic Control at Roadworks” booklet and the Qatar Highway Design Manual, and shall be approved prior to the implementation by both the Engineer and Traffic Police. It is the Contractor’s responsibility to ensure that any traffic diversion required is properly signed, demarcated, illuminated, controlled and maintained at all times.

3

Upon the Engineer’s request, the Contractor shall install and commission temporary traffic signals capable of handling the diverted traffic.

4

Sequential arrow boards operating on a 24-hour basis (engine or solar powered) must be used at all diversion points.

5

Within the limits of the project where pedestrian traffic is present, all excavated areas, regardless of depth, must be cordoned off by means of wired mesh panels of height no less than 1.8m connected together to form a continuous barrier wall.

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END OF PART

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17

Section 01: General Part 17: Project Co-ordination

Page 1

PROJECT CO-ORDINATION ........................................................................ 2

17.1 GENERAL ...................................................................................................... 2 17.1.1 Scope 2 17.1.2 Responsibility 2

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CO-ORDINATION .......................................................................................... 2 Contractor’s Activities 2 Sub-Contractors 3 Other Contractors 3 Other Ministries 3 Liaison with the Public Utility Authorities and other Contractors 3

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17

PROJECT CO-ORDINATION

17.1

GENERAL

17.1.1

Scope

1

This Part specifies the co-ordination activities for which the Contractor is responsible.

2

Related Parts and Sections are as follows: Part 18

Other Contractors

Part 19

Regulatory Requirements

.

This Section

Responsibility

1

The Contractor shall be responsible for the proper co-ordination of all his activities associated with the construction of the Works including that required between the Engineer, utility owners, government departments, sub-contractors and other contractors.

2

No major operations shall be commenced or work outside the usual working hours be carried out without the consent in writing of the Engineer or without full and complete notice also in writing being given to him sufficiently in advance of the time of operation so as to enable him to make such arrangements as he may deem necessary for its inspection.

17.2

CO-ORDINATION

17.2.1

Contractor’s Activities

1

The Contractor shall undertake the following co-ordination activities:

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Co-ordinate construction activities under the various Sections of these Specifications to assure efficient and orderly installation of each part of the Works. Co-ordinate construction operations included under the various Sections of this Specification that is dependent upon each other for proper installation, connection, and operation.

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17.1.2

(c)

Where installation of one part of the Work is dependent on installation of other components, either before or after its own installation, the Contractor shall prepare schedules and construction activities in the sequence required to obtain the best results.

(d)

Where availability of space is limited, co-ordinate installation of different components to assure maximum accessibility for required maintenance, service and repair.

(e)

Make adequate provisions to accommodate items scheduled for later installation.

(f)

Where necessary, prepare memoranda for distribution of each party involved outlining special procedures required for co-ordination; include such items as required notices, reports and attendance at meetings.

(g)

Prepare similar memoranda for the Engineer, separate contractors and subcontractors where co-ordination of their work is required.

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(h)

Take special care and precautions for specific co-ordination requirements for the installation of plant and items of equipment.

(i)

Co-ordinate the scheduling and timing of required administrative procedures with other construction activities to avoid conflicts and ensure orderly progress of the work.

Sub-Contractors

1

The Contractor is responsible for co-ordinating the work of his sub-contractors in all respects.

17.2.3

Other Contractors

1

The Contractor shall co-ordinate his work as necessary with other contractors in accordance with the relevant provisions of Part 18, Other Contractors, of this Section.

17.2.4

Other Ministries

1

The Contractor shall co-ordinate his work as necessary with other Ministries in accordance with the relevant provisions of Part 19, Regulatory Requirements, of this Section.

17.2.5

Liaison with the Public Utility Authorities and other Contractors

1

The Contractor shall liaise with all public utility authorities for water, electricity, telephones, etc and shall:

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17.2.2

Provide public utility authorities with storage areas where applicable.

(b)

Assist in unloading of stores and equipment.

(c)

Ensure that all services or diversions of services are installed under the carriageway and footways before they are surfaced.

(d)

Work out an overall programme for any works to be carried out by public utility authorities and ensure that this programme is maintained.

(e)

Keep public utility authorities informed of the Contractor’s own progress.

(f)

Arrange for supply of services for all the affected permanent and temporary accommodation, buildings, shops, trading areas etc even if it is not clearly mentioned in the Project Documentation for the duration for the Contract:

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Give the appropriate public utility authority adequate notice in writing that he intends to install dry ducts so that a representative of the utility concerned may attend the installation and record the location of the ducts together with the Contractor.

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(a)

2

The Contractor shall make due allowance for carrying out the works, whilst public utility authorities are working on the Site, during the Contract period. This due allowance shall include programming of the works to suit the programmes of the public utility authorities.

3

The Contractor shall at all times be responsible for the compliance with these requirements of his sub-contractors.

4

Before final surfacing of any carriageways or footways takes place, the Contractor is responsible for ascertaining from all public utility authorities that their underground works have been completed. In the event that the Contractor failing to carry out this obligation to the satisfaction of the Engineer and completed surfacing is subsequently disturbed, the Engineer may instruct the Contractor to carry out work at his own expense. END OF PART

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Section 01: General Part 18: Other Contractors

Page 1

18

OTHER CONTRACTORS.............................................................................. 2

18.1

GENERAL ...................................................................................................... 2

18.1.1 Scope 18.2

2

ACCESS FOR OTHER CONTRACTORS ..................................................... 2

18.2.1 Unhindered Access 18.3

2

CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS 2

18.3.1 Co-operation at Site Level 18.4

2

FACILITIES FOR OTHER CONTRACTORS ................................................. 2 2

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18.4.1 Site Facilities for Other Contractors

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Section 01: General Part 18: Other Contractors

Page 2

OTHER CONTRACTORS

18.1

GENERAL

18.1.1

Scope

1

This Part specifies the requirements for access to the Site for other contractors, for co-operation and co-ordination with other contractors and for the provision of facilities with other contractors.

18.2

ACCESS FOR OTHER CONTRACTORS

18.2.1

Unhindered Access

1

The Contractor shall allow other contractors unhindered access to any part of the Works when in the opinion of the Engineer those parts are sufficiently completed.

18.3

CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS

18.3.1

Co-operation at Site Level

1

The Contractor shall carry out his work in a manner that causes the minimum amount of interference to other contractors working on the Site.

2

The Contractor shall co-ordinate his operations with the activities of other contractors where necessary in order to avoid conflicts and ensure orderly progress of the Works.

3

Those works associated with existing or future service installation shall only be carried out by a contractor or sub-contractor approved by the public utility authority concerned. The Engineer shall require proof of such approval in writing prior to the commencement of works.

18.4

FACILITIES FOR OTHER CONTRACTORS

18.4.1

Site Facilities for Other Contractors

1

If specified in the Contract, the Contractor shall provide site facilities for other contractors.

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END OF PART

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 1

REGULATORY REQUIREMENTS -------------------------------------------------------------------------- 2 GENERAL---------------------------------------------------------------------------------------------------------- 2

19.1.1

SCOPE --------------------------------------------------------------------------------------------------------------- 2

19.1.2

REFERENCES ------------------------------------------------------------------------------------------------------- 2

19.2

NOTICES ------------------------------------------------------------------------------------------------------------- 3

19.2.1

GENERAL ------------------------------------------------------------------------------------------------------------ 3

19.2.2

NOTICE OF INTENT ------------------------------------------------------------------------------------------------- 3

19.3

MISCELLANEOUS --------------------------------------------------------------------------------------------------- 3

19.3.1

W ORK REQUIRED TO BE CARRIED OUT BY THE DEPARTMENT ----------------------------------------------- 3

19.3.2

REGULATIONS OF ROAD OPENINGS----------------------------------------------------------------------------- 3

19.4

PROVISION FOR PERSONS WITH DISABILITIES ----------------------------------------------------- 4

19.4.1

SCOPE --------------------------------------------------------------------------------------------------------------- 4

19.5

THERMAL COMFORT ----------------------------------------------------------------------------------------------- 5

19.6

THERMAL INSULATION --------------------------------------------------------------------------------------------- 5

19.7

ACOUSTICAL CONTROL ------------------------------------------------------------------------------------------- 5

19.8

W ASTE MANAGEMENT -------------------------------------------------------------------------------------------- 5

19.8.1

CONSTRUCTION AND DEMOLITION W ASTE --------------------------------------------------------------------- 5

19.8.2

BULK W ASTE COLLECTION --------------------------------------------------------------------------------------- 6

19.8.3

W ASTE STORAGE -------------------------------------------------------------------------------------------------- 6

19.8.4

W ASTE COLLECTION ---------------------------------------------------------------------------------------------- 6

19.8.5

RECYCLABLE W ASTE MANAGEMENT FACILITIES: ------------------------------------------------------------- 6

19.9

BUILDING FACADE/ EXTERNAL CLADDING MATERIAL -------------------------------------------------------- 7

19.9.1

CERTIFICATION AND APPROVAL ---------------------------------------------------------------------------------- 7

19.9.2

MATERIAL PROPERTIES ------------------------------------------------------------------------------------------- 7

19.10

EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS -------------------------- 8

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19.10.1 GENERAL ------------------------------------------------------------------------------------------------------------ 8 19.10.2 MAINTENANCE MANUAL ------------------------------------------------------------------------------------------- 8

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19.10.3 ACCESS OF CLEANING AND MAINTENANCE -------------------------------------------------------------------- 8 19.10.4 CLEANING ----------------------------------------------------------------------------------------------------------- 9 19.10.5 INSPECTION --------------------------------------------------------------------------------------------------------- 9 19.11

PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS ------------------------------------------------- 9

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REGULATORY REQUIREMENTS

19.1

GENERAL

19.1.1

Scope

1

This part specifies the requirements for co-ordination, co-operation and liaison with the following utility and infrastructure owners:

This part also specifies the requirements for co-ordination, co-operation and liaison with the following authorities and departments:

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ASHGHAL- Infrastructure Affairs ASHGHAL- Building Affairs ASHGHAL- Assets Affairs Qatar General Electricity & Water Corporation- KAHRAMAA Qatar Telecom - Provider Qatar Petroleum, QP Q Rail

.

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Civil Aviation Authority Ministry of Awqaf and Islamic Affairs Ministry of Environment

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Authorities having Municipal jurisdiction (Ministry of Energy & Industry, New Industrial area, RLIC, MIC etc.)

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Ministry of Interior (Civil Defense Department, Traffic Police, Department of Immigration, Security Systems Department, etc)

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Ministry of Municipal Affairs and Urban Planning (MMUP) Private Engineering Office The above shall collectively be known as “Department” in this Part.

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Traffic Diversions Project Co-ordination

Section 7 Section 11 Section 15 Section 25

Green Construction Health and Safety Insulation of Buildings Glass and Glazing

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This Section Part 16 Part 17

5

Where any requirement(s) conflict with any other requirement(s) of Authorities or Departments in the State of Qatar, the most stringent requirement(s) shall prevail.

19.1.2

References Al Wakra City Zoning Plan and Regulations Report, 2008, Ministry of Municipality & Urban Planning, State of Qatar Civil Defense Regulations, Fire Prevention Department, General Administration of Civil Defense, Ministry of Interior, State of Qatar

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Code on Barrier-Free Accessibility in Buildings, 2002 (ver 1.0), Building and Construction Authority, Singapore Conditions and Descriptions of the Expedient Workers Residences, Resolution of the Minister of Civil Service and Housing Affairs No. (17) of 2005, State of Qatar NFPA 101 Life Safety Code, 2012 Edition, National Fire Protection Association, U.S.A. Planning and Building Regulations for Flats & Flat Complexes, 1994, Planning Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Planning and Building Regulations for Villas & Villa Complexes, 1995, Planning Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Qatar Highway Design Manual, 1997 (Rev 0), Civil Engineering Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Qatar Survey Manual, UPDA, The Centre for GIS – State of Qatar.

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Qatar Traffic Manual – Vol. 1 Qatar Traffic Manual – Vol. 2

Universal Design Guidelines, 2006, Building and Construction Authority, Singapore

NOTICES

19.2.1

General

1

All notices required to be given by the Contractor to the Department shall be in writing and delivered by hand. The Contractor shall furnish the Engineer with a copy of all notices issued by the Contractor.

19.2.2

Notice of Intent

1

The Contractor shall give at least seven days notice to the Department of the date upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the Department: such operations or work shall only be carried out in the presence a representative of the Department unless written confirmation shall have been obtained that this unnecessary.

19.3

MISCELLANEOUS

19.3.1

Work required to be carried out by the Department

1

If the Department requires work to be carried out on its installations during the execution of the Works, the Contractor shall provide all facilities to the Department’s contractor or workmen. The Contractor shall co-ordinate the work of the Department and his own activities, and when necessary shall amend his programme to suit the requirements of the Department and shall keep the Engineer informed of all arrangements made.

19.3.2

Regulations of Road Openings

1

For Works including road openings, the Contractor shall comply with all relevant provisions of the following Parts of this Section or direction of the Engineer.

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19.2

Part 16 Part 21

Traffic Diversions. Final Inspection and Handover

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19.4

PROVISION FOR PERSONS WITH DISABILITIES

19.4.1

Scope

1

The aim of this provision is to set out the fundamental design and construction requirements and guidelines for making those buildings specified in Table 1 accessible to persons with disabilities. Table 1: Accessibility for Persons with Disabilities No

Accessible areas

Residential buildings: (a) 3-storeys and below

All communal areas and facilities at ground floor.

(b) 4-storeys and above

All communal areas and facilities.

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Types of buildings

Office buildings

All areas intended for access by employees or public.

3

Shophouses

The ground floor for non-residential use shall be accessible to employees or public.

4

Shopping complexes and multipurpose complexes


5

Hotels and boarding houses


6

Religious buildings and Mosques

All areas intended for access by worshippers or public.

7

Places of public resort

8

Cinemas, theatres, concert halls, stadia or other places of public resort where permanent seating arrangement is provided


9

Schools, colleges, universities or institutions of learning


10

Hostels, halls of residence or dormitories All areas intended for access by staff, students or public.

11

Sports complexes and public swimming pools

All areas intended for public access.

12

Restaurants and eating establishments


13

Markets and hawker or food centres

All areas intended for public access.

14

Hospitals, clinics, dispensaries, nursing homes, homes for the aged and welfare homes

All areas intended for access by staff, patients, inmates or public.

15

Factories, workshops and industrial buildings 4-storeys and above


16

Transport stations, interchanges, passenger terminals and administration buildings in depots


17

Vehicle parks (surface parking or vehicle parking buildings)

Prescribed areas.

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The Owner is recommended to follow and adopt suitable and relevant international barrier free access guidelines which will allow persons with disabilities to enter, move around and leave an establishment without hindrances.

3

Universal Design is a continuous process of innovation targeted at improving usability for everyone. It is also known that Universal Design is the design of products and environment to be usable by all people, to the greatest extent possible, without the need for adaptation or specialised design. It is highly recommended that the Owner adopt Universal Design until the authority (MMUP) approve reference.

19.5

THERMAL COMFORT

1

The heating, ventilation and air conditioning (HVAC) system must be capable of providing the following range of conditions for 95% of the year Lower Limit DB: 22.5 ˚C

Relative humidity

RH: 30% (min)

Upper Limit

DB: 25.5 ˚C RH: 60% (max)

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Dry bulb temperature

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For occupant comfort, normal occupied spaces should have a terminal air velocity between (0.2-0.3) m/s.

19.6

THERMAL INSULATION

1

As specified in section 15

19.7

ACOUSTICAL CONTROL

1

As specified in section 15

19.8

WASTE MANAGEMENT

19.8.1

Construction and Demolition Waste

1

For all new buildings unless or until specified otherwise, at least fifty percent (50%) by volume or weight of waste material generated during the construction and/ or demolition of buildings must be diverted from disposal in landfills. Diverted materials must be recycled or reused.

2

This should be done through one or more of the following three paths:

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(a)

Concrete and Asphalt waste must be diverted to Construction Waste Treatment Plant.

(b)

Excavated soil, land-clearing debris and hazardous waste must be diverted to places designated by the concerned Department of MMUP.

(c)

Other recyclable materials such as woods plastics and metals can be used at site or diverted to a Recycling Facility.

The following materials are exempt from the calculation of the percentage of waste diverted from disposal at landfill facilities: (a)

Excavated soil and land-clearing debris; and

(b)

Hazardous waste

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Bulk Waste Collection

1

For all new residential apartment buildings, an area must be provided for residents to place items of bulky waste such as furniture, electrical appliances and sanitary ware. The area 2 provided must cover a space of approximately ten square meters (10 m ). The area does not have to be designated solely for the purpose of bulky waste collection (eg: set aside to the car park).

2

The bulky waste storage area must be reachable, must not restrict access to the building and comply with safety and fire requirement.

19.8.3

Waste Storage

1

For all new villas and apartments (single family units), domestic kitchen must be provided with a minimum storage facility of two ten (10) liter waste receptacles clearly labeled for ‘recyclable’ and ‘non-recyclable’. The storage facility should be in a proper place within the kitchen.

19.8.4

Waste Collection

1

All new buildings which require chute for general waste, in accordance with Qatar MMUP Regulations, one of the following must be provided:

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19.8.2

A second chute must be provided to handle recyclable material and discharge into a separate receptacle within the waste management area; or

(b)

The garbage room on each floor must have a minimum floor area of two square 2 meters (2 m ) where recyclable waste can be stored until collected daily by the building operator. Waste must be transported through designated medium (chute, service elevator etc.) into the waste management area.

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All new buildings which does not require chute for general waste, in accordance with Ministry of Municipal Affairs and Urban Planning Regulation, the garbage room on each floor must 2 have a minimum floor area of three square meters (3 m ) where non-recyclable and recyclable waste can be stored until collected daily by the building operator. Waste must be transported in a service left discharge into a designated receptacle within the waste management.

19.8.5

Recyclable Waste Management Facilities:

1

For all new buildings other than villas, a sorting and storage facility for recyclable materials must be provided.

2

This facility must be easily accessible and comply with the requirements of the location, access and specifications of general waste areas in accordance with Qatar Municipality Building Regulations.

3

The sorting and storage facility may be part of the general waste management facility or a separate facility.

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(a)

Recycled waste facility incorporated into the general waste collection: 2

The size of the room must be increased by 10% and not less than 5 m , to allow additional room to sort and store the recyclable waste.

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(b)


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Recycled waste facility separated from the general waste collection: The recycled waste facility must be sized as a percentage from the total Built Up Area (BUA) of the building in accordance with Table 2.

Where the Total Built Up Area (BUA) of the building falls between the figures outlined in the Table, linear interpolation must be used to determine an appropriate percentage area for the recyclable storage space. Table 2: Sizing Requirements for Storage of Recyclables Built Up Area (BUA)

Minimum Space for Storage of Recyclables

Less than 500 m2

7.5m

2

1.5% of BUA

5,000 m

2

0.8% of BUA

.

1,000 m

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0.35% of BUA

2

10,000 m or greater

0.25% of BUA

BUILDING FACADE/ EXTERNAL CLADDING MATERIAL

19.9.1

Certification and approval

1

External Cladding material must be tested by an approved 3 manufacturer shall have certified ISO 9000 compliant QMS.

2

External Cladding materials that are combustible must be submitted to the Qatar Civil Defense for review and approval. Submissions shall include copies of relevant test reports and details on the proposed fixings used to secure the material to the building. On approval, a Qatar Civil Defense certificate for the External Cladding material will be issued to the submitting party.

19.9.2

Material properties

1

External Cladding Material (ECM) fixed to buildings shall be non-combustible and shall be composed of environmentally friendly materials and substances.

2

ECM not complying with 19.8.2.1 above must have the following fire propagation and flame spread properties.

rd

party test laboratory. The

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19.9

(a)

(b)

When tested in accordance with BS 476 Part 6: (i)

Fire Propagation index, no greater than 4.0

(ii)

any sub index must not be greater than 2.0, and

When tested in accordance with BS 476 Part 7: (i)

flame spread after 10 minutes must be less than 25 mm

3

Alternative test methods and Standards such as AS, BSI and ISO may be used to verify compliance in test reports provided the method of testing is demonstrated to be equivalent and verifies an equal or better fire performance result to those nominated in 19.8.2.2 above.

4

Details of the ECM's approval and listings, its method of fixing and the extent of usage shall be included in the proposed Building Plans fire safety submission for compliance verification.

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19.10


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EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS

19.10.1 General 1.

Any building measuring 28 meters or above in height is classified as a high rise building as per Qatar Civil Defense Department. This section is intended to provide a framework for the cleaning and maintenance of the façade for high rise buildings. The façade will require both cleaning and maintenance to achieve its anticipated life and desired purpose. Failure to undertake this work can considerably reduce the life of materials, components and finishes. The provision of correct documentation and instruction at the completion of construction will permit the building owner to gain the best achievable performance from the façade.

ta

A maintenance manual should be produced for the completed works. The number and specific requirements for the manual should be specified at tender stage. The manual should be developed in parallel with the design and should include, but not be limited to, the following information: The name, address and telephone number of each firm and/ or sub-contractor involved in the supply of materials, components, assemblies and finishes.

(b)

A clear and concise description of the construction used to form the various areas of façade on the particular project.

(c)

Copies of material, component and finishes certification and test reports as required by the Specifier.

(d)

A method statement showing the means of access to all parts of the wall and safe loadings.

(e)

A method statement covering the procedures for replacement of damaged or otherwise defective materials or components, and materials and components that have a design life less than the design of the façade and will therefore require replacement during the life of the façade.

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(a)

Recommendations for routine maintenance, cleaning, suitable cleaning agents and any lubrication/adjustments to working parts.

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19.10.2 Maintenance Manual

(g)

A full set of construction drawings updated to include any changes made up to the time of completion.

(h)

The terms and conditions of any guarantees.

19.10.3 Access of Cleaning and Maintenance 1

The Building Owner/ Specifier should provide a means of access which enables all parts of the façade to be safely reached for the purpose of cleaning, inspection and maintenance. The intended method of access should be established at the design stage and the relevant loads catered for. Particular care should be made to define all possible imposed loads including impact loads and uplift forces on projections by snagging.

2

The access system should comply with the appropriate British Standards (BS 6037, BS 5974). Specifiers should also make themselves aware of any statutory obligations related to Occupational Health and Safety at Work.

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3

The access system should not be capable of imparting forces upon the cladding system exceeding those agreed at the design stage. It is important that the various parties agree the design parameters early in the design process.

4

The access equipment should be maintained, examined periodically by a competent person and certified in accordance with statutory regulations.

19.10.4 Cleaning The supplier of the façade should provide instruction for the proper cleaning and routine maintenance of the façade.

2

Cleaning of the façade should be undertaken by trained personnel working to an agreed procedure, based upon the façade contractor’s recommendations, at a frequency not less than the recommended intervals.

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19.10.5 Inspection

The façade should be inspected at regular intervals to an agreed method. The façade contractor, in consultation with the project team, should suggest methods and procedures to be utilized. The purpose of this inspection includes, but is not necessarily limited to, the following:

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To review the effectiveness of cleaning methods employed.

(b)

To monitor the performance of the materials and components of the façade system against their anticipated life.

(c)

Inspecting for damage or failure of any part of the system.

(d)

Checking on the effectiveness of maintenance or remedial work.

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It is recommended that a detailed inspection plan is drawn up at the time of construction in consultation between the design and construction teams. The inspection plan should include procedures and recording methods to enable a systematic monitoring of the condition of the Curtain wall and assist in the prediction of the need for preventative maintenance or replacement of component parts.

3

Inspections should be carried out by suitably experienced persons to the specific procedures detailed in the inspection plan. The results of these inspections should be compared with previous inspections where appropriate. The building owner should ensure these results are available for reference.

19.11

PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS

1

The public buildings, for the purpose of provision of Ablution facilities are considered to be Offices, Shopping Centres, Malls and Hypermarkets.

2

The occupant load (population) for each building type shall be calculated as per guidelines of Qatar Civil Defense Department.

3

Separate Ablution facilities are to be provided for Men and Women close to the Prayer Area.

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The number of Ablution stalls shall be calculated as per Table 3 below. Table 3: Provision of Ablution Facility Facility Type

Occupant Population

No. of Ablution Stalls

Up to 50

02

For 51 and above

01 For each additional 50

Up to 200

02

For 201 and above

01 For each additional 200

Up to 200

02

Office Building

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Shopping Mall

01 For each additional 400 01 For each additional 1000

201- 2000 people

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END OF PART

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Section 01: General Part 02: Use and Maintenance of the Site

Page 1

USE AND MAINTENANCE OF THE SITE ............................................................... 2

2.1 2.1.1

GENERAL ............................................................................................................... 2 Scope 2

2.2 2.2.1

USE OF THE SITE .................................................................................................. 2 General 2

2.3 2.3.1

MAINTENANCE OF THE SITE................................................................................ 2 General 2

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Section 01: General Part 02: Use and Maintenance of the Site

Page 2

2

USE AND MAINTENANCE OF THE SITE

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the uses and maintenance requirements of the Site.

2

Related Sections and parts are as follows: This Section


Occupational Health and Safety Engineer’s Site Facilities Contractor’s Site Facilities

USE OF THE SITE

2.2.1

General

1

The Site shall not be used for any purpose other than that of carrying out the Works.

2

Temporary camps, housing and cooking facilities shall not be permitted on the Site unless otherwise stated in the Project Documentation. When temporary camps, housing and cooking facilities are permitted they shall comply with Section 1 Part 10.

2.3

MAINTENANCE OF THE SITE

2.3.1

General

1

In accordance with the Conditions of Contract the Site, the equipment used upon it and the Works shall be kept clean at all times.

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2.2

END OF PART

QCS 2014

Section 01: General Part 20: Clearance of the Site

Page 1

CLEARANCE OF SITE ............................................................................................ 2

20.1 20.1.1

GENERAL ............................................................................................................... 2 Scope 2

20.2 20.2.1 20.2.2 20.2.3 20.2.4

FINAL CLEARING ................................................................................................... 2 General 2 Internal and External Surfaces 2 The Site 2 Miscellaneous 3

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CLEARANCE OF SITE

20.1

GENERAL

20.1.1

Scope

1

This Part specifies the requirements for the final clearance of the Site.

20.2

FINAL CLEARING

20.2.1

General

1

Final clearing shall be done before the final inspection.

2

All waste materials shall be removed from the Site and disposed of properly.

20.2.2

Internal and External Surfaces

1

The Contractor shall clean all interior and external surfaces exposed to view. The Contractor shall undertake the following to the satisfaction of the Engineer:

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Remove temporary labels, stains and foreign substances.

(b)

Polish transparent and glossy surfaces.

(c)

Clean roofs, gutters, downspouts, and drainage systems.

(d)

Remove debris and surface dust from limited access spaces.

(e)

Broom clean concrete floors and unoccupied spaces.

(f)

Clean light fixtures and lamps so they operate at maximum efficiency.

(g)

Other cleaning tasks as specified by the Engineer.

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(a)

The Site

1

The Contractor shall clean the Site and shall undertake the following to the satisfaction of the Engineer:

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20.2.3

2

(a)

Sweep paved areas and rake all other surfaces.

(b)

Remove litter and foreign substances.

(c)

Remove stains, chemical spills and other foreign deposits.

(d)

Any other cleaning tasks as specified by the Engineer.

The Contractor shall abide by the latest regulations of the Ministry of Municipal Affairs and Agriculture and relevant municipalities in clearance of construction works refuse.

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Clearance and transportation of construction works refuse: (a)

The Contractor shall undertake to carry out the following within a maximum period of 30 days after completion of the agreed building or project and preparing it for use or stoppage of work for an indefinite period. (i)

Removal of the entire Contractor’s equipment, machinery and other belongings from the work site.

(ii)

Clearance of all earth, debris and refuse whatsoever and transporting them to the location designated by the concerned municipality, delivering the building or project absolutely clean and free of any such materials and delivery of the surrounding area levelled to the natural level of the street pavement.

In the case of Contractor’s delay or refusal to carry out such a job, he shall have to pay a penal compensation as defined in the contract for delay for each day or part of day. This compensation shall be final and the judiciary shall not be entitled to mitigate it and it does not require establishing the occurrence of any damage to the owner.

(c)

In addition, the Owner shall be entitled to clear the refuse himself and transport it to the location designated by the concerned municipality. The Owner shall deduct the cost of refuse clearance, transport and any other related costs including the office expenses and overhead cost from the payment or the money due to the Contractor. He may also stop the final payment due to the Contractor until such refuse has been cleared and a certificate confirming this has been obtained from the concerned Municipality.

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(b)

Miscellaneous

1

The Contractor shall clean or replace all mechanical filters for equipment included in the Works and for equipment directly affected by the construction of the Works.

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20.2.4

END OF PART

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 1

21

FINAL INSPECTION AND HANDOVER PROCEDURES .............................. 2

21.1

GENERAL PROCEDURES FOR INSPECTION AND HANDOVER .............. 2

21.1.1 21.1.2 21.1.3 21.1.4

Scope Pre-requisite for Final Inspection Approvals from Public Authorities Hand Over

21.2

ITEMS TO BE PROVIDED BY THE CONTRACTOR .................................... 4

2 2 3 3

21.2.1 Provision of Tools, Spare Parts and Maintenance Materials 21.2.2 Guarantee Warrantees and Bonds

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21.3.1 Operation Data 21.3.2 Operation and Maintenance Manuals 21.3.3 Operational, Field and Performance Testing

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MECHANICAL AND ELECTRICAL WORKS ................................................. 4

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21.3

4 4 4 4 5

PROJECT RECORD DOCUMENTS.............................................................. 5

21.4.1 21.4.2 21.4.3 21.4.4

General Record Drawings Record Specifications Maintenance Period Final Inspection

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5 6 6 6

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21

FINAL INSPECTION AND HANDOVER PROCEDURES

21.1

GENERAL PROCEDURES FOR INSPECTION AND HANDOVER

21.1.1

Scope

1

This Part specifies the requirements and procedures associated with the inspection and handover of the Works.

2

Related sections and Parts are as follows: Part 7 Part 9 Part 20

Submittals Materials Clearance of Site

Section 2 Section 9

Quality Assurance and Quality Control Mechanical and Electrical Equipment

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Pre-requisite for Final Inspection

1

The Contractor shall complete the following to the satisfaction of the Engineer before requesting the pre-handover Inspection:

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21.1.2

Submit final manufacturer certification, guarantees, warranties and similar documents.

(b)

Submit occupancy permits, operating certificates, final inspection and test certificates and similar releases enabling full and unrestricted use of the Works.

(c)

Submit record drawings, operation and maintenance manuals, final project photographs, damage or settlement surveys, property surveys and similar physical items.

(d)

Complete submittal of record documents.

(e)

Make final changeover of locks and deliver the keys to the Engineer.

(f)

Complete start-up, testing of system, and training of the Owner’s operations and maintenance personnel; submit equipment operating data as well as all test reports and test data required by the Contract.

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(g)

Dismantle and remove temporary facilities and services from the Site; this includes utilities, construction tools, buildings and facilities, mock-ups, and similar elements

(h)

Complete final cleaning.

(i)

Repair and restore exposed finishes which have been marred or otherwise damaged.

(j)

Handover all spare parts, tools and maintenance equipment.

(k)

In Network Projects, partial handling over would be acceptable, if it completely met all the above mentioned requirements.

(l)

Closure of all identified Non-conformance and deficiencies to the satisfaction of the Engineer

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Page 3

When the Contractor has completed and cleaned the Works to the satisfaction of the Engineer the Contractor shall request a final inspection. The request shall be forwarded to the Owner by the Engineer’s Representative and a suitable date for the inspection shall be arranged. The Contractor, Engineer’s Representative, maintenance department (if any) and the supervising consultant (if any) shall be present. A list of outstanding items (if any) shall be agreed and issued to the Contractor.

3

Upon completion of the listed outstanding items a further inspection shall be requested by the Contractor, the request shall be forwarded to the Owner by the Engineer’s Representative and a suitable date for the inspection shall be arranged. The Contractor, Engineer’s Representative, maintenance department (if any) and the supervising consultant (if any) shall be present.

4

A list of any items still outstanding shall be issued to the Contractor. If any of these are deemed to be significant the Contractor shall complete these items and then request another inspection as described in clause 21.1.2-2.

5

In respect of pumping station or Works involving mechanical or electrical equipment if items outstanding are deemed not to be significant or if no outstanding items remain then a 7 day commissioning and running test shall be initiated. On completion of all tests and agreement by the Engineer’s Representative that the plant is considered operable then it shall be handed over. A 14 day training period for the maintenance department staff on the operation of the pumping station shall commence.

6

For works that have no mechanical or electrical equipment if the outstanding items are deemed not to be significant or if no outstanding items remain the Works inspected shall be handed over.

21.1.3

Approvals from Public Authorities

1

The Contractor shall obtain all clearance certificates and approvals required as a prerequisite to connecting the Works to the permanent water and/or power supply.

2

The Contractor shall co-ordinate with the Engineer to obtain the necessary documents from the Qatar General Electricity & Water Corporation regarding connection to the permanent water and/or power supply.

21.1.4

Hand Over

1

When the Contractor considers that the Works are complete he shall submit the following:

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(a)

A certificate stating that the Works are complete and that all the requirements of the Project Documentation have been met.

(b)

A certificate stating that the Works have been inspected.

(c)

A certificate from the appropriate Municipality regarding cleanliness of the Site.

(d)

Approval from the PWA regarding satisfactory trench reinstatement in the Highway (if applicable).

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ITEMS TO BE PROVIDED BY THE CONTRACTOR

21.2.1

Provision of Tools, Spare Parts and Maintenance Materials

1

The Contractor shall provide all tools, spare parts and maintenance materials specified in the Project Documentation.

2

The Contractor shall provide an itemised list of all the items to be furnished under this Clause. Each item to be furnished shall be given a unique reference number. The list shall include the reference number, a description of the item and the appropriate Specification Section and Paragraph.

3

All the items furnished under this Clause shall be packaged for long term storage. Any items requiring special storage conditions shall be brought to the attention of the Engineer.

4

All items furnished under this Clause shall be provided with a mark or tag for identification purposes. The mark or tag shall include the reference number detailed in Clause 21.2.1-2.

5

Unless otherwise instructed, all items furnished under this Clause shall be delivered to the Government Stores in accordance with the relevant provision of Part 9 of this Section, Materials.

21.2.2

Guarantee Warrantees and Bonds

1

The Contractor shall provide notarised copies of all guarantees, warranties and bonds as required by the Project Documentation. The guarantees, warranties and bonds should be assembled in a binder with a durable plastic cover, complete with a table of contents.

2

The start of the warranty or guarantee period shall be either:

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21.2

The date when any item is placed into full time operation for the Government’s benefit and with the Engineer’s approval.

(b)

The date of issue of the completion certificate.

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MECHANICAL AND ELECTRICAL WORKS

21.3.1

Operation Data

1

The Contractor shall provide all operating data for all mechanical and electrical equipment supplied under the Contract.

2

The operating data shall be presented on A4 size paper in ring binder with a durable plastic cover.

21.3.2

Operation and Maintenance Manuals

1

The Contractor shall provide approved Operation and Maintenance Manuals in accordance with the relevant provisions of Section 9, Mechanical and Electrical Equipment and Part 7 of this Section, Submittals.

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Operational, Field and Performance Testing

1

After all construction and starting is complete and before taking-over of any part of the Works, the Contractor shall perform operational, field and performance tests as called for in the Project Documentation.

2

The Contractor shall demonstrate operation of the facilities of the Engineer showing proper sequence of operation as well as satisfactory performance of the system and individual components. Any improper operation of the system or any improper, neglected or faulty construction shall be repaired or corrected to the satisfaction of the Engineer. The Contractor shall make such changes, adjustments or replacement of equipment as may be required to make same comply with the Specifications, or replace any defective parts or material.

3

Failure of the system to perform at the specified level at the time of testing will be the responsibility of the Contractor. In the event of failure of equipment to meet the specified performance, the Owner reserves the right to reject such equipment or system, withhold retention money or make claims on the Performance Bond.

4

The Contractor shall submit a consolidated schedule of operation, field and performance tests no later than three (3) months before the schedule start of the first test and weekly a schedule of tests to be carried out the following week. The Contractor shall inform the Engineer not later than 24 hours in advance of changes in the scheduling of a test.

5

For all specified performance tests, the Contractor shall prepare and submit the following:

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21.3.3

A draft test procedure no later than two (2) months in advance of the schedule test date.

(b)

A final test procedure no later two (2) weeks in advance of the scheduled test date.

(c)

A test report within two (2) weeks of the successful completion of the test.

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PROJECT RECORD DOCUMENTS

21.4.1

General

1

Project Record Documents shall be kept separate from construction/working documents.

2

Project Record Documents shall be stored in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

3

Project Record Documents shall include, but not be limited to the following:

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21.4

(a)

Drawings.

(b)

Specifications.

(c)

Addenda.

(d)

Variation orders.

(e)

Correspondence.

(f)

Transmittals

(g)

Inspection and Test Records

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Record Drawings

1

Record drawings shall be clearly and correctly “red-marked” by the Contractor to show all changes made during the construction process. The record drawings shall show the Works as executed in accordance with the relevant provisions of Part 7 of this Section - Submittals.

21.4.3

Record Specifications

1

Record specifications shall be clearly and correctly annotated to show all changes made during the construction process.

21.4.4

Maintenance Period Final Inspection

1

During the last month of the period of maintenance the Engineer will notify the maintenance department that the maintenance period is about to expire. An inspection of the Works by the Engineer’s Representative, maintenance department, and the Contractor shall be undertaken to verify that all outstanding items have been completed.

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END OF PART

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Section 01: General Part 22: New Technologies and Innovations

Page 1

22

NEW TECHNOLOGIES AND INNOVATIONS............................................... 2

22.1

GENERAL PROCEDURES FOR APPROVAL............................................... 2

22.1.1 22.1.2 22.1.3 22.1.4 22.1.5

Scope Pre-requisite for Approval Technologies And Innovations Of Interest Documentation Final Inspection And Approval

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NEW TECHNOLOGIES AND INNOVATIONS

22.1

GENERAL PROCEDURES FOR APPROVAL

22.1.1

Scope

1

Qatar is committed to researching and using new technology and innovations within construction industry. Because of this commitment it is open to proposals from outside agencies in the use of new technologies and innovations.

2

This Part specifies the requirements associated with the proposal and approval of new technologies and innovations for use in construction in Qatar.

22.1.2

Pre-requisite for Approval

1

New technologies / innovations are allowed for use in any project on experimental or research basis after getting an approval from National Committee For Construction and Building materials Specifications (NCCBS) of the Ministry of Environment and any other concerned parties.

2

The period allowed for such an experiment or research shall be limited to a trial period of a maximum of two years after which it will be evaluated prior to approval or otherwise by the concerned parties.

3

The supplier will be required to submit a guarantee certificate for an agreed period of time.

4

The supplier shall submit a written warranty to bear all fiscal and legal responsibilities as a result of using the experiment if not meeting the suppliers’ claims/specifications. He shall remove any material or debris left from the experiment.

22.1.3

Technologies And Innovations Of Interest

1

The following are of particular interest to Qatar : (a)

Polymer Modified Bitumen (PMB) Superpave

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2

(c)

Performance Grade Binders suitable for the climatic conditions of Qatar (i.e. PG 76-10)

(d)

Cold Laid Asphalt

(e)

Rubber Recycling

(f)

Stone Mastic Asphalt (SMA)

(g)

Glass Reinforced Plastic (GRP) pipes

(h)

Polyethylene (PE) Plain and Corrugated pipes

(i)

Fibre Reinforced Concrete

(j)

Recycling of materials from demolished buildings and roads

Notwithstanding the above Qatar wishes suppliers to propose technology and innovations that it believes can benefit Qatar and the environment.

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22.1.4

Documentation

1

The technology provider shall be requested to submit with his proposals the following documents: Drawings

(b)

Specifications

(c)

Technology Reference and Manual

(d)

Specifications and Source

(e)

Reference from previous clients

(f)

Transmittals

(g)

Inspection and Test Records

(h)

Health and Safety requirements

(i)

Environmental requirements

(j)

Material Safety Data Sheet (MSDS) regarding but not limited to transportation, handling & storage, and First Aid requirements

(k)

Financial arrangements

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(a)

Final Inspection And Approval

1

Final approval of the technology will be dependant on NCCBS visits, inspection and tests. Upon satisfaction of the committee, written approval shall be given and the specifications incorporated into the QCS.

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22.1.5

END OF PART

QCS 2014

Section 01: General Page 1 Part 23: Design & Supervision Consultant Quality Requirements

DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS................................ 2

23.1 23.1.1 23.1.2 23.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 2

23.2 23.2.1 23.2.2 23.2.3 23.2.4 23.2.5 23.2.6

DESIGN CONSULTANT QUALITY REQUIREMENTS ............................................ 3 Quality Responsibility and Duties 3 Quality System Documentation 3 Quality Plan 4 Construction Inspection and Test Requirements Specification 5 Design Consultant Verification of Sub Consultants 5 Quality Records 5

23.3 23.3.1 23.3.2 23.3.3 23.3.4 23.3.5 23.3.6 23.3.7 23.3.8 23.3.9 23.3.10 23.3.11 23.3.12 23.3.13 23.3.14 23.3.15

SUPERVISION CONSULTANT QUALITY REQUIREMENTS.................................. 5 Quality Responsibilities and Duties 5 Quality System Documentation 7 Quality Plan 8 Inspection and Test Plan’s (ITP’S) 9 Technical Procedures, Work Instructions and Method Statements 9 Monitoring by Supervision Consultants 10 Review of Contractor Quality Documentation 10 Inspection Responsibilities 11 Inspections and Test Surveillance Points 11 Visits 12 Supervision Consultant Verification 12 Interfacing 12 Punch Lists 12 Protection of the Works 12 Quality Records 12

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23

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DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS

23.1

GENERAL

23.1.1

Scope

1

This Part specifies the Quality Assurance activities to be performed by Design and Supervision Consultants during all phases of the Contract and should be read in conjunction with all other parts of the Contract.

2

The purpose of this part is to define Design and Supervision Consultants responsibility for demonstrating that the work under the contract is executed to the quality standards required by the contract and to outline verification activities.

23.1.2

References

1

The following standards are referred to in this part:

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Quality Management systems. Fundamentals and vocabulary

BS EN ISO 9001:2008

Quality Management systems. Requirements

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BS EN ISO 9000:2005

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BS ISO 10006:2003 ...Quality Management systems, Guidelines for Quality Management in Projects BS EN ISO 19011:2011

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BS ISO 10005:2005 ...Quality Management systems. Guidelines for Quality Plans Guidelines for auditing management systems

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QCS Qatar Construction Specification Definitions

1

Defect or Non-conformance: any part of the Works not executed, provided or completed in accordance with the Contract. For the avoidance of doubt and without limiting the generality of the expression the term shall be taken to include any item of Plant, material, goods or work incorporated or used in the Works which does not or may not conform to the relevant quality standards or pass the tests prescribed in or to be inferred from the Contract

2

Owner: The Ministry, Municipality, Department, Affairs, Agency, Authority, or individual for whom the Project is being undertaken and to whom the handover of the final product will be made.

3

QA & QC: Quality Assurance & Quality Control and this may be written as QA/QC.

4

QA: Quality Assurance. Part of quality management focused on providing confidence that quality requirements will be fulfilled. QA involves a continuous evaluation of the adequacy and effectiveness of the overall Quality Management System in order to evaluate the deviation from established quality objectives.

5

QC: Quality Control. Part of quality management focused on fulfilling quality requirements. The QC involves specific control points during design, fabrication or construction stages to check the fulfilling of design criteria, acceptance criteria (tolerance, etc.), performance criteria or functional criteria.

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23.1.3

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QMS: Quality Management System. A set of interrelated or interacting processes, activities or tasks to direct Project resources to achieve established quality policy and objectives.

7

Quality Management: Coordinated activities to direct and control an organization with regards to quality.

23.2

DESIGN CONSULTANT QUALITY REQUIREMENTS

23.2.1

Quality Responsibility and Duties

1

The Design Consultant shall be responsible for setting up implementing and monitoring his own Contract Specific Quality Management System meeting the requirements of this part.

2

The Design Consultant shall be responsible for quality auditing, monitoring and oversight of any sub-consultants under their control.

3

The Design Consultant shall perform and or witness any examinations and tests necessary to demonstrate conformance of the works to the requirements of the Contract and shall accept only works by the Contractor that so conform:

4

The Design Consultant shall establish and maintain a system of records which shall provide objectives evidence that the supervision Consultant is meeting the requirements of this specification and that the Contractors control and inspections are effective in meeting the minimum standards required under their contract. Records shall be made available to the Engineer in accordance with the requirements stated herein or elsewhere in the contract.

5

The Design Consultant will be subject to monitoring through audit and surveillance by the Engineer. In both cases the Design Consultant shall promptly rectify any negative findings with their Quality System rectify non-conformities and corrective actions found during audit and surveillance activities directed at them.

6

No part of the Quality system shall be used to preclude or otherwise negate the requirement of any part of the contract, or the obligation of the Design Consultant pursuant to the Contract.

7

The Design Consultant shall appoint a suitably qualified, Quality Manager to verify that the requirements of this specification are met. The proposed Quality Manager shall be subject to approval by the Engineer.

23.2.2

Quality System Documentation

1

The Design Consultant Quality system shall Include as a minimum the following

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(a)

Quality Plan as detailed in 23.2.3 below

(b)

Procedures and work instruction: The Design Consultant Quality system must include all relevant technical procedures and other pertinent documentation to ensure that the design works are completed in accordance with the contract, with specific reference to the minimum requirements of standards reference in 23.1.2 above and including the mandatory procedures required by ISO 9001:2008.

QCS 2014


(c)

Quality Records: In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Design Consultant shall identify project quality records in compliance with the minimum requirements standards referenced in 23.1.2 above.

(d)

Reference and other related documents.

Quality system documents shall be submitted to the owner for review, comment and approval within 30 days after contract award. In the event that comments are made on the contract Quality system documentation submitted for review and comment, the design consultant shall make adjustments, correction, amendment or alteration required. Such comment will be made on the premise that the adjustment, correction, amendment or alteration is within the scope of the contract and will not affect the contract conditions, specifications, guarantees, price or the like in anyway.

3

Adjustments, corrections, amendments or alterations made by the Design Consultant to the contract quality system shall, after revision be resubmitted by the Design Consultant to the owner for review and approval.

23.2.3

Quality Plan

1

Design Consultants are required to submit Quality Plan (addressing their design activities) which are specific (not generic) to the Contract, meeting as a minimum the requirements of the standards referenced in 23.1.2 above. This plan shall reference, or include other documentation which is relevant to the Contract. However as a stand-alone document, the Quality Plan shall clearly indicate how the Quality process shall be applied to meet the requirements of the contract. Particular emphasis is to be placed on the following. Relevant extracts from the Corporate Quality Manual reference to specifications, standards etc;

(b)

List of all procedures applicable to the project;

(c)

QA/QC Organisation;

(d)

Document Control;

(e) (f)

(g)

List of all procedures applicable to the Consultants Project Quality System;

(h)

Audits (including internal and external Audits Plans);

(i)

Management Review;

(j)

Quality objectives, Key Performance Indicators (KPIs)

(k)

Allocation of resources;

(l)

Responsibilities and authority for all phases of work;

(m)

Control of Non-conformance, corrective and preventive actions.

(n)

Contract Changes;

(o)

Lessons learned and continual improvement;

(p)

Purchasing Process e.g. Sub Consultants.

(q)

Quality Records

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Inspection and Test;

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Specific work practices;

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2

The Design Consultants Quality plan will make reference to and take into account applicable codes, standards, specifications, quality characteristics and regulatory requirements as necessary. It will identify the criteria by which the design and developments inputs and outputs should be accepted, and how, at what stage(s) and by whom, the outputs should be reviewed, verified and validated.

3

The Design Consultants Quality Plan will also state the following. How request for changes and development will be controlled to meet Contractual requirements;

(b)

Who is authorised to initiate a change request;

(c)

How changes will be reviewed in terms of their impact;

(d)

Who is authorised to approve or rejects changes;

(e)

How the implementation of changes will be verified;

(f)

When design and development reviews take place;

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(a)

Construction Inspection and Test Requirements Specification

1

The Design Consultant shall provide a specification addressing the complete inspection and testing regime related to their design output, taking into account the requirements of the QCS. This shall be guiding document by which Supervision Consultants and Contractors will be held accountable for all on and off site tests and inspections to be performed. The Inspection and Test Requirements Specifications must be sufficiently detailed to leave no questions regarding the number of samples required or types of tests to be made over and above the requirements of the QCS and which standards must be complied with.

23.2.5

Design Consultant Verification of Sub Consultants

1

The Design Consultant is required to perform audits and verification activities at any sub consultants premises to gain assurance that the subcontracted product conforms to specified requirements.

23.2.6

Quality Records

1

In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Design Consultant shall determine project Quality records in compliance with requirements of ISO 9001:2008 and other relevant standards stated in contract documents and 23.1.2 above.

2

The list of quality records generated during the life of the contract, and made available upon request for review by the Owner, shall be indexed by the Design Consultant in his Quality Plan.

3

The Design Consultant shall maintain Registers for all incoming and outgoing documents.

23.3

SUPERVISION CONSULTANT QUALITY REQUIREMENTS

23.3.1

Quality Responsibilities and Duties

1

The Supervision Consultant shall be responsible for setting up implementing and monitoring his own Contract Specific Quality Management System meeting the requirements of this part

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23.2.4

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The Supervision Consultant shall be responsible for quality auditing, monitoring and oversight of themselves any consultants, contractors, sub-contractors (Including laboratories) under their control.

3

The Supervision Consultant shall perform and/or witness any examinations and tests necessary to demonstrate conformance of the works to the requirements of the Contract and shall accept only works by the Contractor that comply with the specified requirements.

4

The Supervision Consultant shall witness sampling and related testing performed on as well as testing performed in external Third Party Laboratories.

5

The Supervision Consultant shall establish and maintain a system of records which shall provide objectives evidence that the supervision Consultant is meeting the requirements of this specification and that the Contractors control and inspections are effective in meeting the minimum standards required under their contract. Records shall be made available to the Engineer in accordance with the requirements stated herein or elsewhere in the contract.

6

The Supervision Consultant will be subject to monitoring through audit and surveillance by the Engineer. In both cases the Supervision Consultant shall promptly rectify any negative findings with their quality system rectify non-conformities and corrective actions found during audit and surveillance activities directed at them.

7

The Supervision Consultants shall follow up on all findings (NCR’s, CAR’s Observations) issued on the project to, or by the contractor or other entities under the contract.

8

No part of the quality system shall be used to preclude or otherwise negate the requirement of any part of the contract, or the obligation of the Supervision Consultant pursuant to the Contract.

9

The Supervision Consultant is responsible for ensuring the contactor’s Work meets all technical and quality requirements of the contract and shall keep continuous records of action taken and shall advise the Engineer in writing of significant alteration to construction or manufacturing techniques to ensure that specified requirements are met.

10

The Supervision Consultant shall conduct audit and surveillance activities to provide evidence of the use and effectiveness of the Contractors quality system throughout the execution of the contract.

11

The Supervision Consultant will ensure that the Contractor has included the quality assurance requirements of the contract into subcontracts entered into by the Contractor.

12

The Supervision Consultant shall provide an effective audit and surveillance process for works performed by a Contractor’s Subcontractors..

13

The Supervision Consultant shall verify that the Contractor’s Project Quality Plan, Inspection and Test Plans and other such quality documentation includes or references the Quality Plans, and Inspection and Test Plans of subcontractors and vice versa. All of these documents must be reviewed and approved by the Supervision Consultant.

14

The Supervision Consultant shall hold contract specific QA/QC meetings chaired by the Consultant on a monthly basis throughout the duration of the Work. Topics to be addressed at the site quality meeting shall include, but shall not be limited too:

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QCS 2014

Section 01: General Page 7 Part 23: Design & Supervision Consultant Quality Requirements Reviewing of the previous months Quality

(b)

Current Performance of the activities

(c)

Providing 4 week look ahead of planned activities

(d)

Non Conformance of activities

(e)

Key performance indicators

(f)

Audit schedule

(g)

Status of inspection of test plans and method statements

(h)

Quality Training

(i)

Contractors Project quality plan and quality control plans review and on-going effectiveness

.

(a)

The Supervision Consultant shall be responsible for providing a Monthly Quality Report template, meeting the Owner requirements, to the Contractor and reviewing the completed reports submitted by the Contractor.

16

The Supervision Consultant shall be responsible for completing any QA/QC Questionnaires or Reports required by the Owner.

17

The Supervision Consultant shall appoint a suitably qualified, full time, Quality Manager to verify that the requirements of this specification are met. The proposed Quality Manager shall be subject to approval by the Owner.

23.3.2

Quality System Documentation

1

The Supervision Consultant Quality System shall include as a minimum the following elements.

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Quality Plan as detailed in 23.2.3 below

(b)

Procedures and work instruction: The Supervision Consultant Quality system must include all relevant technical procedures and other pertinent documentation to ensure that the design works are completed in accordance with the contract, with specific reference to the minimum requirements of standards reference in 23.1.2 above including the mandatory procedure required by ISO 9001:2008

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(a)

2

(c)

Quality Records: In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Supervision Consultant shall identify project quality records in compliance with the minimum requirements standards referenced in 23.1.2 above

(d)

Reference and other related documents

These Quality system documents shall be submitted to the Owner for review, comment and approval within 30 days after contract award. In the event that comments are made on the contract quality system documentation submitted for review and comment, the Supervision Consultant shall make adjustments, correction, amendment or alteration required. Such comment will be made on the premise that the adjustment, correction, amendment or alteration is within the scope of the contract and will not affect the contract conditions, specifications, guarantees, price or the like in anyway.

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Adjustments, corrections, amendments or alterations made by the Supervision Consultant to the contract quality system shall, after revision be resubmitted by the Supervision Consultant to the Owner for review and approval.

23.3.3

Quality Plan

1

Supervision Consultants are required to submit Quality Plans (addressing their supervision activities) which are specific (not generic) to the Contract, meeting as a minimum the requirements of the standards referenced in 23.1.2 above. This plan shall reference, or include other documentation which is relevant to the Contract. However as a stand-alone document, the Quality Plan shall clearly indicate how the Quality process shall be applied to meet the requirements of the contract. Particular emphasis is to be placed on the following requirements of ISO 9001:2008. Relevant extracts from the Corporate Quality Manual reference to specifications, standards etc;

(b)

List of all procedures applicable to the project;

(c)

QA/QC Organisation;

(d)

Document Control;

(e)

Inspection and Test;

(f)

Specific work practices;

(g)

List of all procedures applicable to the Consultants Project Quality System;

(h)

Audits (including internal and external Audits Plans);

(i)

Management Review;

(j)

Quality objectives, Key Performance Indicators (KPIs)

(k)

Allocation of resources;

(l)

Responsibilities and authority for all phases of work;

(m)

Control of Non-conformance, corrective and preventive actions.

(n) (o) (p)

Purchasing Process e.g. Sub Consultants.

(q)

Quality Records;

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Contract Changes;

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Lessons learned and continual improvement;

2

The Supervision Consultants Quality Plan will make reference to applicable codes, standards, specifications, quality characteristics and regulatory requirements as appropriate. It will identify the criteria by which inputs and outputs should be accepted, and how, at what stage(s), and by whom, the outputs should reviewed, verified and validated.

3

The Supervision Consultants Quality Plan will also address the following: (a)

How request for changes and development will be controlled to meet Contractual requirements;

(b)

Who is authorised to initiate a change request;

(c)

How changes will be reviewed in terms of their impact;

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(d)

Who is authorised to approve or reject changes;

(e)

How the implementation of changes will be verified;

(f)

When reviews take place;

(g)

Redline and As-Built process;

Where design is required by the Contractors contract, the Supervision Consultant responsibilities for the Contractors design work shall be as defined under the contract, however not withstanding this the Supervision Consultant shall responsible for auditing this function of the Contractors quality system.

23.3.4

Inspection and Test Plan’s (ITP’S)

1

As per the requirements of QCS, the Supervision Consultants shall require the Contractor to submit Inspection and Test Plans to the Supervision Consultant a minimum 30 days prior to the programmed work start date covered by each Inspection and Test Plan.

2

The Minimum requirements for the Contractors Inspection and Test Plan are defined in QCS, and the supervision Consultant is responsible for ensuring the Contractors Inspection and Test Plan as a minimum meet these requirements or the recommendations of the Design Consultants.

3

The Supervision Consultants shall ensure that the Contactors Inspect and Test Plan adequately cover any Inspections and test points (Hold/Witness/Surveillance/Record Review) required for the Supervision Consultant to ensure that the works are completed in accordance with the contract.

4

Where the Design Consultant for the Contract has detailed specific specifications or inspection and test requirements, the supervision Consultants shall ensure these have been addressed within the Contractors Inspect and Test Plan. Where a discrepancy exits between Inspections and Test requirements of the Design Consultant and the requirements of QCS, the more stringent requirements shall be adopted.

5

The Supervision Consultant is responsible for reviewing and approving all Inspection and Test Plans and other such documentation submitted by the Contractor and returning to the Contractor within two weeks of their receipt unless otherwise agreed.

6

The Supervision Consultant shall ensure that inspection of processes, materials, good, services and subcontracted works are described in the Inspection and Test plan submitted by the Contractor.

23.3.5

Technical Procedures, Work Instructions and Method Statements

1

The Supervision Consultants shall verify through audit and surveillance that the Contractor’s quality system includes all relevant Technical Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure that the Works are completed in accordance with the contract. These shall be submitted by the contractor in accordance with the submission schedule agreed with the Supervision Consultant including those which form part of the Contractors Quality System.

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2

The Supervision Consultants own Quality system likewise shall include relevant Technical Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure that the works are completed in accordance with the contract with specific reference to the development and implementation of Quality Procedures specified in ISO 9001:2008. These shall be submitted to the Owner by the Supervision Consultant in accordance with the submission schedule agreed with the Owner including those which form part of the Supervision Consultants corporate quality system.

23.3.6

Monitoring by Supervision Consultants

1

Surveillance by the Supervision Consultants will include a variety of typical activities: review of contractor documentations

(b)

audits of Contractor

(c)

attendance at Hold/Witness/Surveillance Points

(d)

Record Review

(e)

Visits to Contractors off site works etc

(f)

Factory Acceptance Tests

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(a)

With the exception of visits, these activities will be announced to the Contractors in advance. The Supervision Consultants shall give reasonable notice to the Contractor who is required to make or arrange to be made available all facilities, documentations records and personnel, including those of any subcontractors, which are required for any surveillance activity to be taken.

3

The Supervision Consultants shall advise the Contractor in writing of any deficiency or deviation in the contract quality system which comes to the Supervision Consultant’s attention as a result of surveillance activities. The Contractor shall be required to rectify the system within as short a period as may be reasonably expected considering the deficiency or deviation. The Supervision Consultant may direct the Contractor in writing to stop the operation and immediately carry out any corrective action, and the Contractor must comply with such direction at his cost. All deficiencies uncovered shall be documented with a NonConformance Report or Corrective Action Request as appropriate (Refer to QCS, Section 2 for a NCR template).

23.3.7

Review of Contractor Quality Documentation

1

All audits of the Contractor shall be conducted in accordance with a schedule establish by the Supervision Consultant. These audits are to be performed in accordance with formal procedures by trained and qualified auditors.

2

The types of audit to be conducted are as follow:

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(a)

Systems Audit: One System audit will undertaken at or before the start of work on the contract deliverables (the specified Works). The audit will be conducted against the requirements of ISO9001:2008

(b)

Compliance Audits: A number of compliance audits will be conducted at defined milestones in the contract deliverable period. The scope of a compliance audit shall be set by the supervision Consultant to suit the timing of activities, and the findings of the system audit. For example, the scope of a compliance audit could cover any of the following:

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(c)

Section 01: General Page 11 Part 23: Design & Supervision Consultant Quality Requirements (i)

the complete requirements of the standards and the contract,

(ii)

specific elements of the standard

(iii)

specific clauses of the contract

(iv)

the whole or a part of a single end-to-end process.

Product audit: This is a Quality audit of particular deliverable products to check their compliance with specified requirements. Such audits should include performance testing where appropriate.

The Audit Notification shall also be copies to the Owner for information and they may attend these audits as an observes. The Audit Reports shall be submitted to the Owner within 7 days.

23.3.8

Inspection Responsibilities

1

For all work the Supervision Consultant shall:

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Review and check that the contractors Method statement and Inspection & Test Plans are in accordance with the contract Surveillance Points.

(b)

Inspect all works to verify Contractors compliance with the Method Statements, Inspections and Test Plans, Construction Drawings and Specifications.

(c)

Verify that notices of nonconformity have been properly actioned.

(d)

Oversee the sampling and testing of materials to ensure conformity to the specifications and the contract.

(e)

Review all test results and verify that they are in conformity with the Specifications and the Contract.

(f)

Maintain comprehensive records to verify the above.

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(a)

Inspections and Test Surveillance Points

1

The Supervision Consultant shall nominate his own surveillance points to observe the Contractors and Subcontractors activities and maintain evidence of such surveillance.

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23.3.9

(a)

Hold Points – Specific critical task in procurement, manufacturing, inspection and testing for which the Supervision Consultant is pre-notified, in advance of the task and for which no further work is carried out until the supervision Consultant has verified and confirmed conformity by signing off the relevant Records Forms

(b)

Witness Points- Specific critical task in procurement, manufacturing, inspection and testing for which the Supervision Consultant is pre-notified in advance of the task and for which the Supervision Consultant may elect to attend or waive. When attended, the Supervision Consultant shall confirm conformity by signing off the relevant Record Forms. When then Supervision Consultant waives his right to inspect, it should be recorded as such on the appropriate Record Forms.

(c)

Surveillance points- Any procurement, manufacturing, inspection and testing task, so identified on the Inspection and Test Plan, performed on a random basis, without notification by the supervision Consultant.

(d)

Record Review- When specified this point requires the Supervision Consultant to Collect and review for approval the contractor Inspection & Rest Records.

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23.3.10 Visits 1

The Supervision Consultants is empowered to visit any of the Contractor’s or Subcontractor’s work sites for any purpose at reasonable times. The Contractors will assist with such visits and make available those records and personnel necessary to satisfy the supervision Consultants requirements. Such visits may include surveillance points identified by the Contractor and Subcontractors. These visits may include works situated outside of Qatar.

23.3.11 Supervision Consultant Verification 1

The Supervision Consultant has the right to perform verification activities at the Contractor’s and the Subcontractor’s premises (including the construction site) to gain assurance that the subcontracted product conforms to specified requirements.

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The Supervision Consultant is responsible for ensuring that the interfaces between the contract works and different packages of work and different Contracting entities are managed appropriately and that technical integrity and configuration control is maintained.

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23.3.12 Interfacing

The Supervision Consultants shall be responsible to ensure that the Contractor prepares punch lists at appropriate inspection and acceptance stages to record the outstanding work. Defects identified during the punch list walk downs will also require NCR’s to be raised, other than for minor defects. The Owner or its nominee may at any time add pending items or defects or Nonconformances to Punch Lists.

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23.3.13 Punch Lists

The Supervision Consultant has the responsibility to ensure that the Contractor is taking necessary precautions for the protection of works before the Initial/Final Acceptance/Handover to owner or its nominee.

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23.3.14 Protection of the Works

23.3.15 Quality Records

In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Supervision Consultant shall determine project Quality records in compliance with requirements of ISO 9001:2008 and other relevant standards stated in contract documents and 23.1.2 above.

2

The list of quality records generated during the life of the contract, and made available upon request for review by the Owner, shall be indexed by the Supervision Consultant in his Quality Plan.

3

The Supervision Consultant shall maintain Registers for all incoming and outgoing documents.

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END OF PART

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CONSTRUCTION DEWATERING GENERAL Scope REQUIREMENTS Current Procedure Requirements Relevant Qatari Laws and Regulations EIA Requirements Air Quality Standards Noise Standards Discharge to Surface and Groundwater Network Standards Environmental Impact Assessment (EIA) Geotechnical and Geo-Environmental Study Requirements Existing Groundwater Monitoring Documents Risk Assessment of Construction Dewatering Dewatering Monitoring Plan Training Requirements DEWATERING TECHNIQUES Construction Dewatering Methods Guide Lines Sump Pits Well System Deep Wells Ditches/ French Drains Cut-Off Excavation Barriers Dewatering Effluent Treatment Settlement Tank Settlement Tank Types Tank Size OTHER TREATMENT Silt and Fine Grained Soils Contamination of Groundwater DISPOSAL OPTIONS DISCHARGE TO SEA Discharge to Sea via Surface and Groundwater Network Direct Discharge to Sea Discharge to Lagoons: Discharge by injection to deep groundwater aquifer (Deep well injection) Groundwater Recycle & Reuse Onsite Integrated Management of Construction Dewatering Construction Environmental Management Plan (CEMP) Monitoring Plan Training Plan Odour Control Health & Safety Considerations Site Investigation Design Considerations Housekeeping Considerations

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24 24.1 24.1.1 24.2 24.2.1 24.2.2 24.2.3 24.2.4 24.2.5 24.2.6 24.2.7 24.2.8 24.2.9 24.2.10 24.2.11 24.2.12 24.3 24.3.1 24.3.2 24.3.3 24.3.4 24.3.5 24.3.6 24.3.7 24.3.8 24.3.9 24.3.10 24.4 24.4.1 24.4.2 24.5 24.6 24.6.1 24.6.2 24.6.3 24.6.4 24.6.5 24.6.6 24.6.7 24.6.8 24.6.9 24.6.10 24.6.11 24.6.12 24.6.13 24.6.14

Section 01: General Part 24: Construction Dewatering

Appendices

2 2 2 2 2 2 3 3 3 3 3 3 4 4 5 6 7 7 8 8 8 9 9 9 9 9 10 10 10 12 12 13 13 15 16 17 18 19 19 19 20 20 20 21 21 21 22

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CONSTRUCTION DEWATERING

24.1

GENERAL

24.1.1

Scope

1

This Part specifies the general procedures and requirements for construction dewatering.

2

It should be noted that legislative requirements, standards and requirements detailed in this Part are minimum standards, and methods should be employed with the intent to continually improve on these standards.

3

Related Parts and Sections are as follows: Earthworks Mechanical and Electrical Equipment

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Section 8 Section 9

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24

REQUIREMENTS

24.2.1

Current Procedure Requirements

1

There are four types of construction dewatering disposal options that require licensing in Qatar, as follows:

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Discharge to the Sea via surface and groundwater network; the licensing authority should be ASHGHAL and MOE.

(b)

Direct discharge to the Sea; if the discharge is pumped directly to the sea, then the Ministry of Environment (MOE) should be the licensing authority.

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Discharge to Lagoon totally covered with geotextile from all sides. This method of disposal requires a license from MOE.

(ii)

Discharge to Lagoon not covered. This method of disposal requires a license from MOE.

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Discharge through Deep Well Injection. This method of disposal requires a license from MOE.

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24.2.2

Relevant Qatari Laws and Regulations

1

The list of parameters required by MoE for dewatering permit is included in Appendix A together with Annex 4 of Law 30 of 2002 which specifies the limits for the discharged water into the marine environment (refer to Appendix A). The annex controls the parameters of pollutants in the water disposed to the marine environment whether via the Surface and Groundwater Network, or direct discharge to the sea.

2

If the construction dewatering effluent is discharged to foul network, the discharging party is liable to having committed a criminal offence.

3

In the case of illegal discharge to Surface and Groundwater Network, the discharging party will be subjected to legal actions taken by the licensing authorities.

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EIA Requirements

1

Environmental approvals from the MoE as per Article 7 of the Law No. 30 of 2002.

24.2.4

Air Quality Standards

1

The air quality standards are controlled by the Law No. 30 of 2002 under Annex (3/First).The standards applicable to dewatering activities may include the following:

2

Maximum limits (of air pollutants) allowed for emissions from the movable sources; and Ambient air quality standards.

24.2.5

Noise Standards

1

The noise levels are also controlled by the Qatari Legislation under Law No. 30 of 2002 Annex (2/Fifth).

24.2.6

Discharge to Surface and Groundwater Network Standards

1

Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) Of 2002. Annex No. (4) Criteria and Specifications of the Hazardous Materials when disposed of in the Water Environments (MoE regulations).

24.2.7

Environmental Impact Assessment (EIA)

1

For projects requiring an EIA at the design stage, the EIA should be carefully reviewed by the Design Consultant / Contractor. The EIA should be forwarded to MoE for their approval and for issuing the relevant Environmental Permit.

2

Where available, the EIA will contain details of geotechnical surveys including groundwater, adopted from the previously mentioned report.

3

Although the EIA may not directly contribute to the construction dewatering design, it will document possible contamination in the area and environmental constraints, and should therefore be considered when preparing construction dewatering application papers. Existing contamination, or potential for contamination, should be carefully considered and must be taken into account when dewatered groundwater is tested for compliance.

4

To ensure that dewatering systems are designed to maximise environmental protection and to assist in expediting license approval processes, the above investigations shall be taken into consideration as early in the project as possible and included when applying for the discharge permit.

24.2.8

Geotechnical and Geo-Environmental Study Requirements

1

After the awarding of the Contract to the Contractor and prior to obtaining the discharge permit, if required by the Contract or requested by the Engineer, the Contractor shall carry out a geotechnical and geo-environmental investigations in order to confirm the geotechnical and environmental conditions on site and groundwater levels.

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24.2.3

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The geotechnical and geo-environmental study must as a minimum identify soil types, permeability, groundwater hydrology, and the required drawdown for the construction activities. This study is required if the area is suspected for contamination or if the EIA at the design stage has indicated the existence of contamination.

3

The output of the geotechnical and geo-environmental study should include as a minimum the following items: (a)

Time required for construction dewatering.

(b)

Flow rate of the dewatering discharge.

(c)

Required drawdown.

(d)

Method of construction dewatering based on all of the above findings.

To assist in the approval process all of the above information must be provided in the application for discharge.

5

It is important to note that the requirements of the Geotechnical and Geo-environmental study are completely subject to project settings, type of contamination, and MoE’s specific requirements of each project.

24.2.9

Existing Groundwater Monitoring Documents

1

It is the Contractor’s responsibility to ensure he has been providing the latest existing groundwater level information from Ashghal and the MoE. This information should be used by the Contractor to assist in determining the current site conditions.

2

All groundwater information gathered during studies by the Contractor, are to be submitted to Ashghal for reference and inclusion in the country database. The collection of this information is paramount to the continuous improvement of government information databases.

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24.2.10 Risk Assessment of Construction Dewatering It is important to note that risks are site specific and depend on the intent of the Contractor. The Contractor is responsible for developing, implementing and managing a Risk Management System and conducting a Risk Assessment in terms of dewatering activities and otherwise onsite.

2

This Risk Management System and Risk Assessment shall be the submitted to the Engineer for the approval within the 30 days of the contract award.

3

Risk assessment in this instance can be defined as the identification and characterisation of the nature of existing and potential adverse effects to humans and the environment resulting from dewatering activities employed on site.

4

Risk is a function of the probability of an event occurring and the degree of damage that would result should it happen.

5

Details and information gathered during the concept design and associated site studies (geotechnical, groundwater & environmental) are needed to assess the risks associated with the proposed activities. The assessment allows significant risks to be identified so that they can be targeted for action.

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6

The initial risk assessment needs to also be regularly reviewed and will become an integral part of the Construction Environmental Management Plan. This includes a review of existing risks and the identification of new risks detected through the surveillance or the monitoring program.

7

To conduct the Risk Assessment the Contractor should undertake the following key steps: (a)

Information gathering: A risk assessment requires information about site conditions.

(b)

Risk identification:

Risk analysis:

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(c)

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Hazard identification involves the identification of risks/hazards that could lead to an adverse effect on the receiving environment and/or health & safety.

Risk analysis considers the likelihood of the risk being realised. Consequence analysis:

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Consequence analysis determines the effect on the environment and health & safety should a risk be realised. The overall risk is a function of the likelihood of the activity or event causing environmental harm or impacting on health & safety and the consequence should that risk be realised.

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The risks are then ranked according to their magnitude and mitigation strategies developed.

10

The objective of this process is to identify and rank all potential risks that may arise from the dewatering of the construction site and then reduce risks to acceptable levels by implementing a suitable method of dewatering and/or action plan.

11

Risks generally associated with dewatering activities onsite include but not limited to the following: (a)

Soil and slope stability and soil erosion due to dewatering activities. Soil contamination. Whether contamination exists in the project area prior to commencement of construction or is caused by dewatering activities.

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(c)

Change of groundwater properties due to dewatering practices.

(d)

Excessive abstraction (dewatering) of groundwater which affects nearby groundwater related activities.

(e)

Health and safety related issues.

(f)

Risks associated with impacts of dewatering activities on surrounding environment and sensitive receptors.

(g)

Risks associated with failure of dewatering system and/or disposal methods.

24.2.11 Dewatering Monitoring Plan 1

When dewatering activities are included within the project site, the Contractor shall prepare a Dewatering Monitoring Plan as detailed below.

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2

The Dewatering Monitoring Plan shall be submitted to the Engineer for approval within 30 days of contract award.

3

The monitoring plan will assist the licensing authority, as well as the Contractor, in keeping track of dewatering activities onsite, and identify corrective actions to be carried out.

4

The monitoring plan can also assist in identifying liability issues concerned with reported dewatering problems and accidents.

5

Outline and components of monitoring plan are as follow: Identification of opportunities to reuse the dewatering effluent onsite in order to reduce the amount of disposed effluent.

(b)

Dewatering techniques being employed on site

(c)

Disposal methods employed on-site and relevant monitoring plan to ensure compliance with discharge limits.

(d)

Copy of discharge limits.

(e)

Roles and responsibilities of the Environmental Advisor on site.

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(a)

Roles and responsibilities have to be clearly defined when designing a dewatering system. These roles and responsibilities are to be submitted as an essential element to satisfy the Construction Environmental Management Plan requirements when applying for the dewatering effluent discharge permit.

7

Refer to Appendix B for an example of inspection sheet for the dewatering process.

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24.2.12 Training Requirements

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The Contractor shall prepare a Construction Dewatering Training Plan submitted along with the necessary documentation for a discharge permit.

2

The construction dewatering training plan shall be submitted to the Engineer for approval within 30 days of contract award.

3

The training plan will assist the licensing authority in evaluating the level of knowledge passed on to the Contractor’s staff, and is therefore an indirect indication on how well the dewatering process is being executed. The components of the submitted training plan are detailed below.

4

The integration of construction dewatering training into the Training Plan of the Contractor is essential to introduce all staff to construction dewatering related information.

5

It is recommended that information on dewatering equipment and related emergencies are included in the training provided to staff entering or working on the site.

6

The training for all staff does not have to be comprehensive; however, it should include basic items such as:

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(a)

Brief explanation of the construction dewatering purpose

(b)

Introduction to the dewatering equipment. Inclusion of photos in the training presentation.

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(c)


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Health and safety related concerns, education on related emergencies, and contact information of person in charge of dewatering to be provided in the presentation.

24.3

DEWATERING TECHNIQUES

24.3.1

Construction Dewatering Methods Guide Lines

1

The design of effective construction dewatering methods should be based on a number of information sources: Geotechnical and groundwater site investigations undertaken at the commencement of any project;

(b)

Information provided by any geotechnical study undertaken during the concept design stage[if applicable];

(c)

Groundwater information sourced from relevant authorities; and,

(d)

A site risk assessments.

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(a)

The Contractors choice of dewatering method will depend primarily on the soil type and permeability and the amount of groundwater to be removed. Whilst the Contractor will be trying to find the most cost effective method of dewatering (based on the geotechnical report) he shall implement the most effective dewatering method which minimises environmental damage, protects the health & safety of on-site personnel and meets all legislative discharge limits.

3

It is important to note that if contamination exists in the area all precautions need to be implemented. Contamination will be dealt with in coordination with MoE by safe disposal in designated areas as per the Environmental Law number 30 for 2002.

4

The figure below demonstrates the range of common dewatering techniques, whilst accounting for soil permeability and drawdown.

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Range of Application of Pumped Well Groundwater Control Techniques ** Source: Preene, M. Roberts, T. Powrie, W. Dyer, M R (2000)- Groundwater Control Design & Practice (CIRIA C515), London, CIRIA.

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As seen in the above figure, the choice of dewatering method depends on the required drawdown and permeability. The drawdown is determined during the design stage of structures and the groundwater investigation stage at the start of the project and the permeability is tested during the geotechnical investigation stage.

6

After the drawdown is determined, the Contractor shall choose the method of dewatering based on the permeability of soil. The method can vary during the stages of the project depending on the required drawdown. The shaded areas near the methods’ boundaries indicate that the choices can overlap, and then the Contractor can decide between the two (or more) options.

7

Filtering and filling materials of aggregate is required by most dewatering methods. Therefore when required, aggregates to be used shall be free draining, washed and free of debris (organic or non-organic). Preference is for a single sized aggregate (less than 10% fines).

8

Whilst the range of dewatering practices varies across sites depending on their size, construction depth and site conditions, the most commonly used methods of dewatering in Qatar are indicated below. Each method’s use depends on the requirements and stage of project.

24.3.2

Sump Pits

1

The Sump Pit method is the simplest form of dewatering system on a construction site. Sump pits are generally utilised as a quick, least cost, solution and can be seen to be used at the start of projects as the excavation stage commences. Provided with an aggregate lining, as per O&M requirements, sump pits can be an effective means of filtering groundwater, unless the groundwater has come into contact with silt and/or limestone, which usually results in reported high turbidity.

2

If soil has silty characteristics; it is recommended that proper installation of geotextile and aggregates in sump pits be implemented in order to improve the quality of dewatering effluent and significantly decrease turbidity.

24.3.3

Well System

1

The most common practice of dewatering used in Qatar is the implementation of a Well System. Wells are systematically drilled around the construction area and submersible pumps placed into these wells. This practice appears to work effectively for many projects, especially those building projects that require excavations for deep basements.

24.3.4

Deep Wells

1

Deep wells are rarely used in Qatar. Deep wells are usually equipped with filter packs & submersible pumps, and are operated using a control cabin.

2

Although not found to be present in Qatar at present, deep wells have unlimited drawdown, they require a minimum spacing of 10 meters, and have far greater efficiency.

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Ditches/ French Drains

1

Ditches and French drains (commonly known as trenches in construction projects in Qatar) are also used on Qatar’s construction sites. The ditches are formed in a pre-planned manner, allowing groundwater flow to surface in the deeper level trenches. Perforated pipes are then placed in the trenches, and groundwater extracted through these pipelines to be filtered. These trenches were particularly common in infrastructure network projects.

2

Graded aggregates and geotextile layer to be used when laying out the pipelines.

24.3.6

Cut-Off Excavation Barriers

1

Cut Off barriers are designed to limit and/or control groundwater entering the construction site from a neighbouring property. An assessment of groundwater infiltration is required to determine to what extent barriers are required and how they are constructed.

2

Commonly used excavation barriers in Qatar include structural concrete walls and secant piles. Both techniques are applicable to most types of soil and provide slope stability for deep excavated areas.

24.3.7

Dewatering Effluent Treatment

24.3.8

Settlement Tank

1

The settlement tank is the most common and most effective methods of treatment in Qatar. The settlement tank is primarily used to maximise the distance that the effluent has to travel prior to reaching the discharge point, and therefore increasing the settlement efficiency.

2

All projects in Qatar which apply for a discharge permit are obligated to provide a settlement tank.

3

When choosing the settlement tank, the choice should be based on the following factors: The type of soil to be dewatered.

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24.3.5

(d)

Retention time required for solids to settle. This will also be based on the soil type.

Flow rate quantity and frequency. Possible peak factors flows.

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24.3.9

Settlement Tank Types

1

The common types of weir tanks used are Regular tank and V-notch tanks (30°, 60°, and 90°). The V-notch tanks serve to accelerate the passing of the effluent through the tank.

2

For safety purposes, it is recommended that tanks be suitably covered with a top cover or specific lid, to ensure unauthorised access is not permitted.

3

It is important to note that sometimes these tanks are used onsite as a discharge tanks. Therefore, it is important that tanks are used as settlement tanks and be marked clearly as such.

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24.3.10 Tank Size 1

In order to make a decision on the tank size, the volume of tank are to be estimated as per the below equations.

2

The volumes calculated depend primarily on the retention time of water in the tank, and the flow rate of discharge.

Equation 3

V=Qt

The tank's depth

d = V/A

d: depth (m) 3 V: volume(m ) 2 A: surface area(m )

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Tank volume

V: Volume (m ) 3 Q: Expected flow rate (m /hour) t: retention period (hour)

It is important to note that these equations are to be used as a guide only, but do provide a basis for calculating the minimum tank size required based on the flow rate provided by the Contractor.

4

For fine grained type of soils, it is preferred to have secondary methods of treatment as detailed below.

24.4

OTHER TREATMENT

24.4.1

Silt and Fine Grained Soils

1

For the removal of silt and fine grained suspended particles, the following inexpensive methods can be effectively applied:

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Dewatering Tank:

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a dewatering tank can remove sediment (sand, silt, and visible oil). The dewatering tank is equipped with a fabric filter. The flow passes through the filter before being discharged at the bottom end of the tank. The tank can be used in addition to the weir tank or any other treatment method. It is portable, inexpensive and many types of filter clothes can be used. Yet, the dewatering tanks should be subjected to periodic cleaning based on the visual inspection or reduced flow, through lifting the sand and silt from the tank.

(b)

Gravity Bag Filter: (Also known as dewatering bag) is made of geotextile fabric that can filter out silt and fine grained soil particles. This filter is easy to install, inexpensive, and becomes more effective as sediment builds up inside the bag. The type of bag should be selected based on the flow rates of discharge and permeability of soil. This method is to be used as a secondary treatment for groundwater. It requires continuous monitoring to avoid hose failure, particularly if sediment builds up in a manner that interferes with the acquisition of a reasonable flow rate discharge.

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The Gravity Bag Filter does not require cleaning, as it is a disposable filter. The filter is to be disposed of in accordance with the waste management guidelines of the project. The filter is to be replaced when it starts passing solids, or blocks the passing of water at a rate that is adequate. (c)

Slurry Water “The drilling [slurry] muds containing substantial quantities of organic liquids and water-soluble salts are treated to render them environmentally acceptable for disposal” (C M Wilwerding 1989)

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Slurry water occurrence is common during dewatering processes in Qatar. While there is filtration equipment and water treatment technology available to treat slurry water, these are best used in countries with a different climate to that of Qatar’s. The best option for treating slurry by filtration is using a Centrifugal Filter. However, as previously mentioned, this is not a preferable to be used in Qatar as slurry can be dried easily in a more environmentally friendly manner.

3

It is also important to note that even when treatment equipment is used, the resulting silt will have to be disposed at a licensed landfill, along with having to dispose of the equipment at its end of service life.

4

If the silt contains hazardous material, then a license should be issued from MoE as per the procedures detailed in Annex (7.2) of the Qatari Law of Environment (Copy of the procedures together with the form of application is provided in Appendix (C)). And if the silt has no hazardous materials then the license shall be issued from the concerned Municipality.

5

To eliminate the issues with incompatible equipment and hot climates, it is recommended that treatment methods be designed to manage the slurry either onsite by drying the first instance before transfer to landfill, or by transfer to the landfill directly.

6

The conventional drying process comprises laying out of slurry mud on an air permeable drying bed lined with suitable material.

7

The drying process must commit to the following environmental considerations:

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Amount of slurry generated must not exceed the capacity of the spreading system.

(b)

Drying process must not impose nuisance or emit odor.

(c)

Drying process must not impose health and safety risks.

8

The choice of drying process, whether by using a centrifuge machine or a drying lagoon is subject to project settings and expected amount of slurry to be generated.

9

The slurry handling process is to be submitted with the dewatering permit application if generation of slurry is expected to occur.

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24.4.2

Contamination of Groundwater

1

In the event of discovering the contamination of the receiving environment such as groundwater by dewatering effluent, the contractor is obligated to report the discovery to the licensing authority (ASHGHAL, MoE) and the effluent is to be dealt with as per the construction Environmental Management Plan (CEMP). Samples of groundwater should be taken and tested. Reasonable suspicion can be established by one of the following methods: Possible history of contamination in the area; such as prior land use (eg. petrol station), or the area is known to have septic tank issues.

(b)

EIA: if there is an EIA prepared for the project, it should be reviewed and approved by MoE in order to eliminate the possibility of contamination. If the EIA indicates the presence of contamination, the Contractor is obligated to report the findings to MoE for their feedback, and test for the type of contamination detected in the EIA.

(c)

The Contractor shall use the following Water Quality Assessment to establish the possibility of contamination in the area.

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Water Quality Assessment

The following questions provide n initial assessment of the quality of the water to be discharged from the dewatering operation.

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Common Sense Test

1. Review the project records. Is there any reason to suspect that the water may be polluted by something other than sediment? No Yes 2. Is the water located in an area of known contamination? No Yes Does the water have an abnormal visual feature, such as: (circle) Oily Sheen, Floating Foam, Murky Appearance, Unusual Colour Other

Smell Test

Does the water have an odor? No Yes Possible odors include gasoline, petroleum, ammonia, sewage, etc.

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Sight Test

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If you answered YES to any of the above questions, explain: If you answered YES to any of the questions in the assessment or suspect that the water contains pollutants other than sediments, contact the Engineer for assistance with additional testing and management options.

Water Quality Assessments ** Adapted from Source: The office of Environmental Engineering, California Department of Transportation (Caltrans), Field Guide to Construction Site Dewatering, USA, 2001. In the event of discovering groundwater contamination, the Contractor is obligated to report the discovery to the Engineer and Licensing Authority (MOE / ASHGHAL) and the effluent is to be dealt with as per the Construction Environmental Management Plan (CEMP), or as directed by the Engineer.

24.5

DISPOSAL OPTIONS

1

Qatar construction sites use four (4) common means of disposal, namely: (a)

Discharge to sea via the Surface and Groundwater Network;

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(b)

Direct Discharge to the sea;

(c)

(A) Discharge to lagoon totally covered by geotextile from all sides; (B) Discharge to lagoon not covered, and;

(d)

Discharge by injection to deep groundwater aquifer (Deep well injection).

The following section discusses the options available in Qatar in terms of dewatering effluent disposal, and describes the best option depending on the circumstances of the project.

24.6

DISCHARGE TO SEA

24.6.1

Discharge to Sea via Surface and Groundwater Network

1

Disposal of dewatering effluent to the Surface and Groundwater Network is the most common practice in Qatar. The Surface and Groundwater Network eventually leads to outfalls that discharge to Sea.

2

The disposal to the network directly via pipelines, or via tankers, depends on the availability of Surface and Groundwater Network in the project area.

3

The Surface and Groundwater Network is an acceptable option for disposal given that Contractor is also reusing the effluent on site whenever possible.

4

If a Contractor chooses to discharge to the Surface and Groundwater Network, obtaining a license from ASHGHAL is required to allow the discharge of groundwater to the Surface and Groundwater Network. A license from the Ministry of Environment is also required through the submission of an Environmental Permit Application.

5

Measurements of flow rates must be undertaken in order to monitor the discharge flow and ensure that it is within the limits provided to the licensing authority (refer Appendix A for discharge limits).

6

The Contractor must provide the licensing authority with the maximum expected flow rate (i.e the peak flow) and the expected average flow rate, in order to avoid back flooding when flows exceed the capacity of the manhole assigned to the Contractor. Therefore, the contractor should install a flow meter at the construction site in order to measure the quantities of groundwater flow.

7

The Contractor should also notify the licensing authority if peak flows are expected to be reached frequently during the winter season, particularly when heavy rain is forecast, so as to avoid penalties if the manhole back floods.

8

If a Contractor is operating from an area which is not served by a Surface and Groundwater Network, and determines that the most cost effective solution is to use tankers to transport dewatering effluent to the nearest assigned manhole, the Contractor is then obligated to provide a brief statement demonstrating the traffic impacts caused by their tankers.

9

If the resultant traffic impact proves to be significant, the Contractor is either to consider other options of disposal, or retain dewatering effluent onsite and then transport the effluent when traffic is less congested, therefore minimising traffic impacts.

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In the event that tankers are used to transport dewatering effluent, in order to monitor discharge to Surface and Groundwater Network the Contractor must record all particulars associated with its removal, such as: (a)

Installing a flow meter at the construction site in order to measure the quantities of groundwater flow.

(b)

Record of tankers coming to and leaving the site (eg. registration plate no., capacity, records of water quality)

(c)

Volumes of effluent transported.

The recording of tanker movements is in addition to the installation of a meter on the weir/sediment tank.

12

When applying for the discharge permit the following documents are required:

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Official letter from the company addressed to: The Manager of Drainage Networks O&M Dept- Asset Affairs- ASHGHAL. (Includes start and end date of dewatering works & method of statement for dewatering).

(b)

Application form for pumping groundwater to be filled and stamped.

(c)

Copy of building permit.

(d)

Copy of the site map.

(e)

Copy of ID card of the applicant’s engineer.

(f)

Copy of the registration company.

(g)

Copy of Road Opening (RO) Permit.

(h)

Copy of Traffic Department Approval, as part of the RO Permit

(i)

Testing of samples, and conformation of compliant results prior to obtaining the twomonth permit. The Contractor must note that the sample testing is to be carried out after obtaining the five-day temporary permit, and is to be submitted after the previous requirements are submitted and a temporary permit is granted.

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Once the application is submitted, the project is given a reference number which includes a serial number, type of discharge (e.g groundwater) and the date of application. Drawing and comments are then returned to the applicant for information and/or action and the applicant will be advised the applicable disposal option and a manhole to be assigned for the discharge.

14

The applicant is issued a temporary permit for five days. The purpose of the temporary permit is to allow the applicant to obtain approvals from the concerned authorities, and install the equipment in order to take water samples.

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During the temporary dewatering permit; only discharge is allowed for collecting samples and to proceed with other department requirements. All samples are taken by laboratory representative from the list of laboratories approved by ASHGHAL and MOE; it’s prohibited for samples to be taken by the Contractor. The collected samples should be tested for Total Suspended Solids (TSS, turbidity and the short list of parameters included in Appendix A. Test results should be uploaded online to QSD by the laboratory. Yet, it should be highlighted here that any testing activities are not only limited to the parameters provided on the short list developed by QSD; it should also cover the list of parameters required by MOE for dewatering permit. Approval is then granted if the test results meet the requirements of discharge. The Quality Limits are attached in Appendix A.

16

If the installation requires a road crossing, a RO permit is required. If not, a RO is not required. The applicant must obtain a license from the concerned authorities for installation of all tanks and hoses.

17

Following the issuance of the permit, regular inspections by the O&M staff are carried out. The Contractor is then required to undertake weekly laboratory tests for TSS and turbidity of effluent samples, and bi-monthly tests prior to renewing the permit. Permit renewal request should be submitted in 7 days advance before expiry day of the previous permit. The bimonthly tests are for TSS, turbidity and the short list of parameters included in Appendix A together with the parameters listed under Annex (4) of the law of Environment number 30/2002.

18

A copy of the Permitting Application and pro-forms are attached in Appendix C.

19

Refer to Appendix D for a flowchart of the permitting procedure for the discharge to sea via Surface and Groundwater network.

24.6.2

Direct Discharge to Sea

1

MOE is the licensing authority for discharging dewatering effluent direct to the Sea.

2

If a Contractor found that the applicable option for dewatering is the direct discharge to sea, a secondary method of treatment must be installed to allow the dewatering effluent to settle before reaching the discharge outfall point. The discharge to the outfall point is achieved through the use of pipelines or transportation via tankers. Based on the number of tankers, the transportation may be subjected to a traffic impact assessment study based on the requirements of MOE.

3

The Contractor may therefore be subject to a number of pertinent laws and regulations:

4

When issuing direct sea discharge permits, MOE have the following concerns that need to be addressed as per Annex 4 of the Qatari Law of Environment and the list of parameters required by MOE for dewatering permit (included in Appendix A), which includes the test of the following parameters:

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(a)

Bacterial counts

(b)

Turbidity and TSS levels

(c)

Presence of Petroleum compounds.

(d)

Presence of heavy metals.

(e)

Others, as per MoE requirements.

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5

Refer to Appendix D for a flowchart of the permitting procedure for the direct discharge to sea. A copy of the environmental permit application form is included in Appendix E.

6

For more information, contact MoE on: Telephone +974 4420 7777

24.6.3

Fax

+ 974 4420 7000

Email

[email protected]

Discharge to Lagoons:

A. Discharge to Lagoon totally covered with geotextile from all sides Lagoons are licensed by MOE.

2

It is recommended that a lagoon totally covered with geotextile from all sides, formed in a depressive area, is used in locations where it is logistically impossible or cost and socially prohibitive to deliver effluent to the Surface and Groundwater Network using other means.

3

If Contractor chooses to discharge the dewatering effluent to a lagoon, license is given by MOE. The dewatering to lagoons is mainly based on the requirements by MOE which is given for case by case. The use of this option is depending on the water quality. Yet, the general requirements of MOE can be summarised in the following information:

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Dewatering effluent quantity.

(b)

Detailed Engineering drawings for the lagoon showing the geotextile lining of the lagoon.

(c)

Duration of dewatering discharge

(d)

Dewatering effluent quality. Dewatering effluent quality is tested initially against the list of parameters required by MoE for dewatering permit (included in Appendix A). And then tested weekly. Monthly testing is also required for selected parameters.

(e)

Coordinates of lagoon, inclusive of dewatering discharge points.

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Location map Others, as per MOE requirements.

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Refer to Appendix D for a flowchart of the permitting procedure for the discharge through the use of lagoons. A copy of the environmental permit application form is included in Appendix E.

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For more information, contact MOE on: Telephone +974 4420 7777 Fax

+ 974 4420 7000

Email

[email protected]

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B. Discharge to Lagoon not covered 6

The discharge to a logon which is not covered is depending on the discharged water quality. Similar to the above option, the licensing authority for this option is the Ministry of Environment. The list of parameters required by MOE for dewatering permit is included in Appendix A. The general requirements of MOE are similar to the above option.

7

Refer to Appendix C for a flowchart of the permitting procedure for the discharge through the use of lagoons. A copy of the environmental permit application form is included in Appendix E.

8

For more information, contact MOE on: Telephone +974 4420 7777 + 974 4420 7000

Email

[email protected]

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Discharge by injection to deep groundwater aquifer (Deep well injection)

1

Disposal by injection to groundwater aquifer is a common method in Qatar to dispose of treated effluent of sewage treatment plants. Yet, the use of deep well injection for the discharge of dewatering effluent to groundwater aquifer is also done in few big projects.

2

However and prior to the discharge to the deep well, a careful assessment of geological conditions must be conducted in order to determine the suitable depth and location of porous aquifer reservoirs and identifying the safe rate of injection to the deep aquifer. Generally, the depth of the deep well should not be less than 400 – 600 m deep, which is the expected depth of Umm Er Radhumma (UER) aquifer.

3

In all cases, MOE require the contractor to conduct an Environmental Assessment for the impact from the project as soon as drilling of the deep well and the analysis of the samples is achieved. This shall be done by a qualified consultant with previous experience in similar projects.

4

The general requirements of MOE for the use of the deep well injection can be summarised in the following information:

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(a)

Duration of dewatering discharge.

(b)

Dewatering effluent quality. Dewatering effluent quality is tested initially against the parameters specified in the standards for the water use for irrigation purpose of the Qatari Law of Environment. And then periodically testing each week based on MoE requirements.

(c)

The parameters required for the physical, chemical, biological, microbiological analysis includes but not limited to: EC, Temperature, DO, pH, Turbidity, FRC, TPH, O&G, Sulphide, Metals, BOD, COD, TOC, surfactants, VOC, BETX, TDS, TSS, PAHs, TAlk, Nitrate, Nitrite, Ammonia, TKN, Phosphorus, Chloride, Sodium, Sulphite, Total Phenol, Carbonate, E-Coli, Faecal Coliform, Bacteria and SAR.

(d)

A0 design map for the whole project including the location of the injection well and network of shallow trenches connecting the wells.

(e)

Comparison study between the use of the shallow networking and the perforated pipelines.

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(f)

Drilling of monitoring wells to suitable depth to monitor the impact on the shallow aquifer.

(g)

Providing the injection wells with emergency valves to stop injection in case of contamination.

5

Refer to Appendix D for a flowchart of the permitting procedure for the discharge through the use of deep well injection. A copy of the environmental permit application form is included in Appendix E.

6

As mentioned above, the injection of dewatering effluent to groundwater aquifer is licensed by MOE and is completely subject to their approval, therefore for further information, please contact MOE on:

Fax

+ 974 4420 7000

Email

[email protected]

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Telephone +974 4420 7777

Groundwater Recycle & Reuse Onsite

1

It is recommended, where environmentally safe and cost effective, that dewatering effluent is reused or recycled onsite.

2

The reuse options onsite will depend on a number of factors, including the type of project. The contractor should propose the treatment in case the water is polluted by organic and inorganic chemicals or subjected to biological contamination. The treatment should focus but not limited to low DO, presence of Bacteria, elevated levels of TSS or turbidity and presence of oil.

3

The CEMP should be used to identify all opportunities of reuse onsite. Yet, the options for the reuse of the groundwater should be discussed with MOE and shall be subjected to the approval by MOE.

4

Options could include but not be limited to: Control of dust onsite. (Subject to the level of safety and quality of dewatering effluent).

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(b)

Reuse of dewatering effluent.

(c)

Concrete curing.

(d)

Excavation activities requiring water.

(e)

Washing of machinery and site equipment.

(f)

Watering of onsite landscaping, when the turbidity is very low to avoid compromising the integrity of the soil.

(g)

If the dewatering effluent quality is within limits of soil compaction parameters requirements (refer to QCS), it can be used for soil compaction purposes.

Contractor to conduct a feasibility study to evaluate whether it’s feasible to erect an RO system for dewatering effluent treatment, in order to use the dewatering effluent instead of fresh potable water.

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The feasibility study is to compare both options in terms of financial viability.

24.6.6

Integrated Management of Construction Dewatering

1

Construction dewatering practices are better managed if they are integrated with existing construction management systems, such as a CEMP, monitoring plan and training programmes. The dewatering practice will then form part of the regular construction inspection/monitoring program.

24.6.7

Construction Environmental Management Plan (CEMP)

1

The CEMP is prepared to minimise the impacts of the project and its activities on the receiving environment. The CEMP is prepared prior to mobilising to site.

2

The Contractor should uses the geotechnical investigations and previous EIA (if applicable) as guidelines when preparing the CEMP.

3

When dewatering activities are included within the project site, the preparation of the CEMP should include the following:

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Identification of opportunities to reuse the dewatering effluent onsite in order to reduce the amount of disposed effluent.

(b)

Dewatering techniques being employed on site

(c)

Disposal methods employed on-site and relevant monitoring plan to ensure compliance with discharge limits.

(d)

Copy of discharge limits.

(e)

Roles and responsibilities of the Environmental Advisor on site.

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Roles and responsibilities have to be clearly defined when designing a dewatering system. These roles and responsibilities are to be submitted as an essential element to satisfy the CEMP requirements when applying for the dewatering effluent discharge permit.

5

Refer to Appendix B for an example of inspection sheet for the dewatering process.

24.6.8

Monitoring Plan

1

The environmental monitoring plan is used to monitor the anticipated impacts of the project o the surrounding and receiving environments. It is imperative that, should dewatering activities exist on site, there is integration all testing and monitoring requirements.

2

Integration of monitoring plans may be between systems within individual sites or between several sites, depending on management systems or owners

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Environmental monitoring plan: The environmental monitoring plan is to outline the steps required for monitoring of construction dewatering practices. The integration of dewatering practices into the monitoring plan will pave the way to introduce a dewatering monitoring plan.

(b)

The findings of the dewatering monitoring reports are to be summarised and included in the environmental monitoring reports.

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The dewatering practices monitoring plan: Introduction of a dewatering practices monitoring plan, sampling points, variables, frequencies and reporting. This plan should be cyclic which stands to be audited as part of the master environmental monitoring plan. Corrective actions from audits are to be implemented to ensure improved performance.

Training Plan

1

The integration of construction dewatering training into the training plan of the Contractor is essential to introduce all staff to construction dewatering related information.

2

It is recommended that information on dewatering equipment and related emergencies are included in the training provided to staff entering or working on the site.

3

The training for all staff does not have to be comprehensive; however, it should include basic items such as:

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Brief explanation of the construction dewatering purpose

(b)

Introduction to the dewatering equipment. Inclusion of photos in the training presentation.

(c)

Health and safety related concerns, education on related emergencies, and contact information of person in charge of dewatering to be provided in the presentation.

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Training for dewatering staff, however, should be the responsibility of the Project Consultant and as per each Project needs and requirements. The training should be comprehensive and should include all components dewatering staff need to be familiar with.

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24.6.9

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24.6.10 Odour Control

The odour levels have been given a threshold value as indicated in the Qatar Construction Specifications (QCS). Therefore, it is highly recommended to measure the level of odour parameters, a devise should be installed within the construction site to measure odour parameters (eg: H2S).

2

The QCS has identified two types of odour control equipment; control equipment carbon type and control equipment scrubber type. Refer to Section 9 Part 9 and Part 10 for details.

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24.6.11 Health & Safety Considerations 1

Health and safety issues are the most important part of any construction project. It is recommended that health and safety measures in relation to dewatering practices are enforced strictly, in order to prevent and/or minimise on-site accidents.

2

In addition to the conventional health and safety measures implemented in construction sites, the following considerations are to be incorporated to contribute to the health and safety practices relating to construction dewatering:

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24.6.12 Site Investigation 1

During the initial site investigations, the Contractor has to identify potential health and safety risks in the project area. Examples of risks are: potential contamination posing health and safety concern to labour workers and site staff, slope stability issues due to dewatering practices... etc.

2

Identified risks have to be considered and mitigated against during design and execution of dewatering.

3

This exercise can be undertaken during the Risk Assessment process as described earlier in this Guideline.

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24.6.13 Design Considerations The design of dewatering stage is the most convenient stage to plan properly in order to prevent foreseeable health and safety issues arising during operational dewatering.

2

All designs must take into account the health & safety considerations associated with dewatering, which include but are not limited to:

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Preparation of layout plan for dewatering equipment.

(b)

Ensure access to dewatering equipment, without compromising the safety of staff.

(c)

Ensure that all dewatering equipment –especially equipment placed offsite- is marked clearly with name of project and Contractor, and contact person details.

(d)

Provide protective covers for assigned manholes which do not hinder the discharged flow.

(e)

The mandatory use of PPE. All staff entering a project’s safe zone have to be wearing appropriate safety gear. This also applies to staff managing dewatering equipment offsite.

(f)

The Contractor is to exercise duty of care when designing, installing and operating the dewatering equipment and process.

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24.6.14 Housekeeping Considerations It is recommended that during the regular inspection of projects, the licensing authority is to observe the status of housekeeping of dewatering equipment. Inadequate housekeeping can expose staff and visitors to injury.

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APPENDICES Short List of Parameters as provided by ASHGHALMoE list of Parameters for Dewatering Permit Environmental Laws and Regulations- Annex 4, Law 30 of 2002

23

Appendix B:

Dewatering Process Inspection Sheet

32

Appendix C:

Discharge Permit Forms

36

Appendix D:

Application for Permit- Procedure Flowchart for each Dewatering Option

40

Appendix E:

Environmental Permit Application- MoE

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Appendix A:

23 23 23 23

Appendix B DEWATERING PROCESS INSPECTION SHEET

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Appendix C DISCHARGE PERMIT FORMS

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Appendix A SHORT LIST OF PARAMETERS AS PROVIDED BY ASHGHAL MOE LIST OF PARAMETERS REQUIRED FOR DEWATERING PERMITS ENVIRONMENTAL LAWS AND REGULATIONS‐ ANNEX 4, LAW 30 OF 2002

36 36 40

Appendix E ENVIRONMENTAL PERMIT APPLICATION‐ MOE

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Appendix D APPLICATION FOR PERMIT‐ PROCEDURE FLOWCHART FOR EACH DEWATERING OPTION

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Appendix A

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Short List of Parameters as provided by Ashghal

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MoE list of Parameters required for Dewatering Permits

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Appendix B

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Discharge Permit Forms


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Appendix D

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Application for Permit‐ Procedure Flowchart for each Dewatering Option


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Environmental Permit Application‐ MoE


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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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QUALITY NON-CONFORMANCE TEMPLATE

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Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 1

SUBMITTALS .......................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

GENERAL ............................................................................................................... 2 Project Quality Plan 2 Quality Organisation Plan 3 Inspection and Test Plans 4 Quality Checklists 5 Key Performance Indicators 5 Method Statements 6 Commissioning Plan 6

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SUBMITTALS

2.1

GENERAL

2.1.1

Project Quality Plan

1

The Contractor shall prepare the necessary Contract specific Project Quality Plan as specified in this Section, the Contract Documents and as a minimum meeting the requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and approval within 30 days of the award of Contract. The Contractor is not permitted to Work on the worksite until such time as the plan has been approved by the Engineer.

2

The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor shall undertake a full formal review of the quality plans annually with reference to the date of award of the Contract and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendments be required.

3

The Project Quality Plan shall describe the Contractor’s Quality Management System that will be used throughout the Contract and the contents shall include but not be limited to the following: Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Quality Objectives

(d)

Quality Policy and ISO 9001 Certificate (if applicable)

(e)

Control of Project Quality Plan

(f)


(g)

Project Management, Planning and Resources

(h)

Management, Organisation and Responsibilities

(i)

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Contract Review Project Deliverables

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(k)

Communication with the Engineer

(l)

Management of Documents, Data and Records

(m)

Design (Including Temporary Works)

(n)

Procurement of Services, Equipment and Materials

(o)

Method Statements

(p)

Inspection and Test

(q)

Product Identification and Traceability

(r)

Owner Supplied Product

(s)

Handling, Storage, Packaging and Delivery

(t)


(u)

Control of Inspection, Measuring and Test Equipment

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals Audits

(w)

Training

(x)


(y)

Management Review

(z)

Quality Meetings

(aa)

Monthly Quality Report

(bb)

Commissioning

(cc)

Interface Management

(dd)

Project Completion and Handover

(ee)

Appendices

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And include as a minimum:

a detailed description of procedures, instructions, and reports to be used to ensure compliance with the Project Documentation

(b)

a detailed description of procedures for reviewing shop drawings, samples, certificates and other submittals necessary for compliance with the Project Documentation

(c)

a detailed description of procedures used to identify, report and resolve problems

(d)

a description of the services provided by outside organisations such as testing laboratories, architects, and consulting engineers

(e)

a detailed description of inspections and tests required

(f)

copies of forms and reports to be used to document quality assurance operations

(g)

the names of personnel responsible for each part of the Works

(h)

a submittal status log listing required submittals and action required by the Contractor and Engineer

(i)

a detailed description of document and submittal control procedures

(j)

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an inspection and test schedule keyed to the construction programme procedures to identify and control the use of items and materials

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No construction shall begin and no requests for payment from the Contractor shall be processed until the Contractor’s Project Quality Plan is approved.

6

A Contractors Project Quality Plan Template with guidance notes is included in Part 15 Appendix B of this Section. The format of the Contractors Project Quality Plan must follow this template including all clauses contained within.

2.1.2

Quality Organisation Plan

1

The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Quality Organisation Plan shall provide the names, qualifications, experience and skills of all the QA/QC Team including Corporate QA/QC Manager, Quality Management Representative and key support staff.

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The Quality Organisation Plan shall show the organisation of Contractor’s quality team and shall include, but not be limited to, the following: (a)

an organisation chart identifying all personnel responsible for quality

(b)

Identify the quality team showing that the team is independent of the job supervisory staff with clear lines of authority to top tier management.

(c)

Indicate and describe the area of responsibility and authority of each individual in the quality assurance team.

The Quality Organisation Plan should also define quality responsibilities of any of the Contractors team with responsibilities under the Contractors Project Quality Plan.

5

The Contractor’s Quality staff shall have relevant educational and professional qualifications, and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of the works at the worksite until such time as approved quality personnel have been deployed on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed quality personnel without prior approval from the Engineer.

6

The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a standalone document and cross-referenced within the Project Quality Plan.

2.1.3

Inspection and Test Plans

1

As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be prepared for the Works and the target dates for their submission to the Engineer for his approval.

3

The Inspection and Test Plans shall consider the requirements of each Section of the Specification and shall identify, as a minimum, the following:

(b)

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(c)

the required inspection and testing frequency

(d)

the acceptance/rejection criteria

(e)

whom from the Contractors team is responsible and qualified to perform the inspection or test

(f)

Quality Records to be generated

(g)

Hold, Witness, surveillance and Record Review points of the Contractors team, the Engineer and any other agencies having jurisdictional authority over the work relating to each inspection and test to be performed.

Details each activity, inspection and test to be performed Reference to specifications, standards etc.

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Each inspection and test shall have a unique reference number.

5

Inspection and Test Plans are required to address the Contractors on and off site Work and preparation, submission and approval of related documentation.

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Inspection and Test Plans are required for all operations including major temporary works and commissioning.

7

No work covered by the Inspection and Test Plan shall begin until the plan has been approved by the Engineer.

8

A Contractors Inspection and Test Plan Template with guidance notes is included in Appendix B of this Section and must be used by the Contractor

2.1.4

Quality Checklists

1

The Contractor shall develop specific quality checklists for all activities to be checked as per the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection Test Plans submission prior to the start of the activity.

2

The Contractor shall inspect the work and sign off the relevant checklist and Inspection Request prior to the final inspection with the Engineer.

3

The checklist shall be attached with the Inspection Request and other relevant attachments and submitted to the Engineer.

2.1.5

Key Performance Indicators

1

The Contractor shall develop and report Key Performance Indicators (KPI’s). KPI’s are a set of quantifiable measures that are used to gauge performance of the Contractors Performance.

2

The KPI’s shall be defined in the Contractors Project Quality Plan and be subject to Engineers approval.

3

The Contractor is responsible for developing his own KPI’s for all elements of his contract (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPI’s.

Time between opening and closure of Nonconformance Reports (NCR) and Corrective Action Requests (CAR).

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NCR and CAR statistics per areas, sections, discipline, subcontractor etc.

(d)

Percentage of reoccurring NCR’s and CAR’s – Trends on NCR’s and CAR’s.

(e)

Approval status of critical documentation for the progress of the works (Method Statements, ITPs etc.).

(f)

Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed, pass first time, etc.).

(g)

Completion packages (As-Built folders) progress.

Reporting of the KPI’s shall include a graphical bar chart representation on a month by month basis from the start of the Contract.

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Method Statements

1

Contractor shall ensure that Method Statements address quality issues. Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

2.1.7

Commissioning Plan

1

The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than sixty (60) days unless agreed otherwise with the engineer before the start of the commissioning of the Works or any part thereof.

2

The Commissioning Plan shall consider the requirements of each Section of the Specification in turn and shall identify the following:

.

2.1.6

all required commissioning work required by that Section of the Specification

(b)

any prerequisites to commissioning

(c)

a list of the commissioning procedure

(d)

a detailed description of the duties and responsibilities on the personnel involved in the commissioning process

(e)

a detailed list of the tests/checks/activities that will be performed, linked to the relevant construction activities and referenced to any links/documents to the ITPs performed during the construction

(f)

specific reference to the witness/hold and review points of the engineer

(g)

a detailed list of the standards /specifications/regulatory requirements that need to be performed

(h)

a detailed description of the interactions/communication organization/public service or other legal/regulatory institutions

(i)

a detailed description of the test/activities of the maintenance needed during the life time of the project, with reference to any special requirements/qualifications of the personnel involved in the maintenance activities

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a detailed description of any spare parts/equipment/fixtures and other type of the of consumables that might be needed, with an estimation of quantities, for the life time of the project

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a detailed description of the as built project file that will be created after the commission phase

(l)

a procedure for up-date and revision of the commissioning plan

No work covered by the Commissioning Plan shall begin until the plan has been approved. END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 1

CONTRACTOR’S QUALITY PERSONNEL ............................................................. 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

INTRODUCTION ..................................................................................................... 2 General 2 Quality Assurance Manager 2 Quality Control Manager 2 Quality Engineer 2 Quality Inspector 3 Personnel Qualifications 3 Quality Staff Requirement 3 Quality Training for Contractor’s Employees and Labour 5

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CONTRACTOR’S QUALITY PERSONNEL

3.1

INTRODUCTION

3.1.1

General

1

Contractor shall, throughout the execution and completion of the Works and the remedying defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only with matters regarding the quality and protection against damage before, during and after execution of Works as specified in this section. This team shall be qualified and experienced in their work and shall have the authority to issue instructions and shall take protective measures to prevent execution of Works that do not comply with the Specifications.

2

The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any of the quality team designated in the Quality Organisation Plan.

3

The Contractor shall have adequate quality personnel on the site during all production operations, including adequate coverage during night shift operations and off site work.

4

The Contractor's quality team shall have the authority to stop any portion of the work which does not comply with the requirements of the Project Documentation.

5

Minimum qualifications and experience of the Contractors Quality Personnel shall be as defined in the Contract.

3.1.2

Quality Assurance Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Assurance Manager who shall be responsible for overseeing the implementation and operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report directly to Top Tier Management and be independent of the Contractors organisation responsible for construction.

3.1.3

Quality Control Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Control Manager who reports directly to the Quality Assurance Manager and shall be responsible for supervision of the construction quality control management activities and ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.4

Quality Engineer

1

Where required by this section, the Contractor shall designate and assign a Quality Engineer who reports directly to the Quality Assurance Manager or Quality Control Manager and shall be responsible for assisting them with their day to day responsibilities and may be assigned to cover several locations or areas of work relating to the Contract. Where a Quality Assurance Manager or Quality Control Manager are not required by this section the Quality Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.

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Quality Inspector

1

The Contractor shall designate and assign a Quality Inspector for each shift for each location where work is being performed. Each Quality Inspector shall be qualified by training and experience in all the construction or fabrication activities being conducted at the location of work and is directly responsible for ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.6

Personnel Qualifications

1

The Contractor shall identify activities requiring qualified production, inspection, and test personnel and establish their minimum competence level.

2

The Contractor shall maintain records of personnel qualifications as quality records.

3.1.7

Quality Staff Requirement

1

Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified quality personnel for the Work as per below tables.

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No of workers on Worksite

Requirement

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1 Quality Inspector (Part time, 15 hours of duty per week)

Less than 10

2.

More than 11 but less than 50

3.


4.


1 Quality Assurance Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

More than 1501

1 Quality Assurance Manager and 1 Quality Control Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

1 Quality Inspector

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Quality Management and Control staff Qualifications & Experience Matrix Minimum Qualifications Required

Position

Minimum Years of Experience

Minimum Key Competencies

Degree in relevant 12 years, 5 of which at Engineering discipline and Management Level and 3 related training in Quality years Regional experience Management Techniques. Internationally recognised Lead Auditor Certificate

Qualified Professional who can manage a Quality Management System and coordinate specialised activities. Excellent written & verbal communication skills in English


Degree in relevant 12 years, 5 of which at Excellent written & verbal Engineering discipline and Management Level and 3 communication skills in related training in Quality years Regional experience English Management Techniques. Internationally recognised Lead Auditor Certificate

Quality Engineer

Degree in relevant Engineering discipline. Internationally recognised Lead Auditor Certificate

Quality Inspector

Certificate or Diploma in the appropriate engineering discipline

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Good written & verbal communication skills in English

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5 years’ experience in Good written & verbal related Quality Control and communication skills in Materials Testing activities English along with 2 years Regional Experience

The Contractor shall appoint deputy quality personnel who are capable of performing all the duties of the quality personnel in the event of their absence.

3

The Contractor shall appoint support staff in sufficient numbers to ensure the effective function of the quality related work within the Contractor’s organisation.

4

The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints suitably qualified quality staff to ensure the effective function of the quality related issues within the Sub-contractor’s organisation. The Sub-contractor shall appoint and deploy fulltime on the Worksite one Quality Inspector for every 100 workers that they employ at the Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality Engineer. This shall be in addition to the Contractor’s Quality Team.

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Quality Training for Contractor’s Employees and Labour

1

The Contractor shall conduct quality training including Contract specific induction, pre-work briefings, skills training, tool box talks and formal training conducted by training professionals or agencies for all the Contractor’s employees. The Contract specific induction will be at least 1 hour duration, approved by the Engineer and provided for all persons involved in the Works. Such induction training will be reviewed, revised and repeated at intervals not exceeding 12 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training. Training shall focus on improving competency and skill for those performing activities that impact quality.

2

The Contractor must conduct regular tool box talks to his Labour workforce Such training should include as a minimum Health and Safety issues and Construction Method best practice.

3

The Owner may organise quality related training, meetings, seminars, workshops or similar events at any time throughout the Contract Period. The Contractor is required to participate in such events when requested at his own expense.

4

The Contractor shall maintain records of all training conducted including details of the training given and a list of attendees, including attendee’s signature and ID numbers.

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Section 02: Quality Assurance and Quality Control Part 04: Document & Data Control

Page 1

DOCUMENT & DATA CONTROL ............................................................................ 2

4.1 4.1.1 4.1.2 4.1.3

INTRODUCTION ..................................................................................................... 2 General 2 Document and Data Approval and Issue 2 Document and Data Changes 2

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DOCUMENT & DATA CONTROL

4.1

INTRODUCTION

4.1.1

General

1

The Contractor shall establish and maintain documented procedures to control all documents and data that relate to the requirements of the Specification. Documents and data can be in the form of any type of media, such as hard copy or electronic media.

2

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Contract.

4.1.2

Document and Data Approval and Issue

1

The documents and data shall be reviewed and approved for adequacy by authorised personnel prior to issue. A master list or equivalent document control procedure identifying the current revision status of documents shall be established and be readily available to preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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The pertinent issues of appropriate documents are available at all locations where operations essential to the effective functioning of the quality system are performed

(b)

Invalid and/or obsolete documents are promptly removed from all points of issue or use, or otherwise assured against unintended use

(c)

Any obsolete documents retained for legal and/or knowledge preservation purposes are suitably identified

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(a)

Document and Data Changes

1

Where practicable, the nature of the change shall be identified in the document or appropriate attachments.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 05: Quality Records

Page 1

QUALITY RECORDS..................................................................................... 2

5.1 5.1.1

INTRODUCTION ........................................................................................... 2 General 2

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QUALITY RECORDS

5.1

INTRODUCTION

5.1.1

General

1

The Contractor shall establish and maintain documented procedures for identification, collection, indexing, access, filing, storage, maintenance and disposition of quality records.

2

The Contractor shall supplement these quality records as necessary to monitor quality throughout the Contract period.

3

Quality records shall be maintained to demonstrate conformance of materials and equipment to specified technical requirements and the effective operation of the quality system.

4

All quality records shall be legible and shall be stored and retained in such a way that they are readily retrievable in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

5

As a minimum, the quality record for any particular item shall include: name of item

(b)

item number

(c)

item description

(d)

suppliers name

(e)

serial number or other identification (where applicable)

(f)

Specification reference (where applicable)

(g)

verification of receipt of all required supporting documentation

(h)

quantity of items

(i)

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non-conformance number (if applicable)

(l)

Observations / comments.

(m)

Signatures of responsible person

END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 06: Quality Audits

Page 1

QUALITY AUDITS ................................................................................................... 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Contractor’s Quality Audit 2 Engineer’s Quality Audit 2

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QUALITY AUDITS

6.1

GENERAL

6.1.1

Contractor’s Quality Audit

1

The Contractor shall establish and maintain documented procedures in line with ISO 190011 for planning and implementing internal quality audits to verify whether quality activities and related results comply with planned arrangements and to determine the effectiveness of the quality system.

2

Internal quality audits shall be scheduled on the basis of the status and importance of the activity to be audited and shall be carried out by personnel independent of those having direct responsibility for the activity being audited. Unless otherwise agreed with the Engineer in writing, the Contractor shall carry out a full system quality audit every three months.

3

The results of the audits shall be recorded and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on deficiencies found during the audit.

4

Follow-up audit activities shall verify and record the implementation and effectiveness the corrective action taken.

5

The results of the Contractor’s quality audits shall be made available for review by the Engineer. The Contractor shall implement any recommendations made by the Engineer based on the results of the internal audit.

6

The Contractor shall allow the Engineer to observe the Contractor’s internal audit upon request.

7

Quality audits must be undertaken by suitably qualified personnel with an internationally recognized audit qualification to recognized standards.

6.1.2

Engineer’s Quality Audit

1

The Engineer may undertake a quality audit of any of the Contractor’s activities at any time during the course of the Contract. The Contractor shall make all personnel and facilities available to the Engineer as necessary to undertake quality audits.

2

The Engineer shall make the results of his quality audit available to the Contractor for review. The Contractor shall implement any recommendations made by the Engineer based on the results of the Engineer’s quality audit.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 1

INSPECTION AND TEST ........................................................................................ 2

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

INTRODUCTION ..................................................................................................... 2 General 2 Inspections and Tests 2 Inspection and Test Status 3 Inspections by the Engineer during construction 3 Inspections by the Engineer during Defects Liability Period 4 Workmanship 4 Measuring and Test Equipment 4

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INSPECTION AND TEST INTRODUCTION

7.1.1

General

1

The Contractor shall provide equipment, instruments, qualified personnel, and facilities necessary to inspect the work and perform the tests required by the Project Documentation.

2

The Contractor shall repeat tests and inspections after correcting non-conforming work until all work complies with the requirements. All re-testing and re-inspections shall be performed at no additional cost to the Client.

3

The Engineer may elect to perform additional inspections and tests at the place of the manufacture or the shipping point to verify compliance with applicable Specifications. Inspections and tests performed by the Engineer shall not relieve the Contractor of his responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be considered a guarantee that materials delivered at a later time will be acceptable. All costs associated with the foregoing shall be borne by the Contractor.

4

Inspections and tests conducted by persons or agencies other than the Contractor, shall not in any way relieve the Contractor of his responsibility and obligation to meet all Specifications and referenced standards.

7.1.2

Inspections and Tests

1

All inspections and tests shall be conducted in accordance with written test procedures as detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed and approved by the Engineer.

2

Mandatory Products and Materials Sampling and Testing Frequencies are included in Part 14, Appendix A of this section. The Contractor shall follow the Sampling and Testing Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in Appendix A shall be read and understood in tandem with the footnotes in Appendix A.

3

Inspection and test procedures submitted for approval shall include, but not be limited to, the following:

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7.1

(a)

inspection/test procedure reference

(b)

references to Clauses of this Specification and other standards along with applicable inspection/test levels specified therein

(c)

prerequisites for the given inspection/test

(d)

required tools, equipment

(e)

necessary environmental conditions

(f)

acceptance criteria

(g)

data to be recorded

(h)

reporting forms

(i)

Identification of items inspected and tested.

(j)

Contractors and Engineers Hold, Witness, Surveillance and Record Review Points

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Approved procedures and instructions shall be readily available and used by inspection and test personnel at the time of inspection or test. All revisions to these procedures and instructions shall be approved prior to being used to inspect or test the work. No deviations from the approved procedures and instructions shall be allowed without written authorisation from the Engineer.

5

Inspection and testing work shall be performed by personnel designated by the Contractor. Such personnel shall not be the same as those performing the work.

6

The Contractor shall furnish the Engineer with a signed inspection report for each item of work inspected and tested. The report shall indicate whether the item of work, material and/or equipment complies with all the inspection/test criteria. The Contractor shall submit inspection/test results to the Engineer prior to incorporating the item(s) into the work. Inspection/test failures shall be reported to the Engineer immediately.

7

Inspection and test reports shall, as a minimum, identify the following: inspection/test procedure reference

(b)

name of inspector/tester

(c)

observations/comments

(d)

specified requirements

(e)

acceptability

(f)

deviations/non-conformance

(g)

corrective action

(h)

evaluation of results

(i)

authorised signature

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The Contractor shall clearly document and identify the inspections and test status of all materials and equipment throughout construction. Identification may be by means of stamps, tags, or other control devices attached to, or accompanying, the material or equipment.

7.1.3

Inspection and Test Status

1

The inspection and test status of materials, equipment and construction work shall be identified by suitable means, which indicates the conformance or non-conformance of materials, equipment and construction work with regard to inspection and tests performed. The identification of inspection and test status shall be maintained, as defined in the Quality Assurance Plan and/or documented procedures, throughout the course of construction to ensure that only materials, equipment and construction work that have passed the required inspections and tests are used or installed.

7.1.4

Inspections by the Engineer during construction

1

The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and Record Review points for the Engineer during construction. The contractor shall prepare, document and implement a Request for Inspection system that defines how the Engineer will be given sufficient notice to inspect the works in accordance with the Inspection and Test Plans.

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Inspections by the Engineer during Defects Liability Period

1

The Engineer will give the Contractor due notice of his intention to carry out any inspections during the defects liability period.

2

The Contractor shall arrange for a responsible representative to be present at the times and dates named by the Engineer.

3

The Contractor’s representative shall render all necessary assistance and take note of all matters to which his attention is directed by the Engineer

7.1.6

Workmanship

1

The Contractor shall comply with industry standards except when more restrictive tolerances or specified requirements indicate more rigid standards or more precise workmanship.

2

Only persons qualified to produce workmanship of the required quality shall perform works

3

The Contractor shall comply with manufactures’ published installation instructions / guides in full, including each step in sequence. Should instructions conflict with project documentation, the Contractor shall request clarification from the Engineer before proceeding.

7.1.7

Measuring and Test Equipment

1

The Contractor shall establish and maintain documented procedures which conform to accepted and approved national or international standards to control, calibrate and maintain inspection, measuring and test equipment used by the Contractor to demonstrate the conformance of materials, equipment and/or construction work with the requirements of the Project Documentation.

2

Inspection, measuring and test equipment shall be used in a manner which ensures that the measurement uncertainty is known and is consistent with the required measurement capability

3

The Contractor shall establish a unique identification number for each item of measuring and test equipment. This unique identification number shall be permanently affixed to each item of measuring and test equipment

4

The Contractor shall ensure that each item of inspection, measuring and test equipment is calibrated at intervals recommended by the manufacturer. Valid calibration certificates for measuring and testing equipment shall be present and available for inspection during inspections and tests.

5

The Contractor shall establish a log of all measuring and test equipment and record:

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(a)

equipment description

(b)

identification number

(c)

date of the last calibration

(d)

date that the next calibration is due.

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The Contractor shall assess and record the validity of the previous measuring results when the equipment is subsequently found not to confirm to requirements. The Contractor shall take appropriate action on the equipment and any product affected.

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END OF PART

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Section 02: Quality Assurance and Quality Control Part 08: Materials

Page 1

MATERIALS .................................................................................................. 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ...................................................................................................... 2 Plant, Materials, Goods and Workmanship 2 Handling and Storage of Materials 2 Identification and Control of Items and Materials 2

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MATERIALS

8.1

GENERAL

8.1.1

Plant, Materials, Goods and Workmanship

1

All Plant, materials, goods and workmanship shall be of the respective kinds described in the Contract with necessary approvals from the concerned authorities and in accordance with the Engineer's instructions and shall be subjected from time to time to such tests as the Engineer may direct at the place of manufacture or fabrication or on the Site or at all or any such places. The Contractor shall provide such assistance, instruments, machines, labour and material as are normally required for examining, measuring and testing any work and the quality, weight or quantity of any materials used and shall supply samples of materials before incorporation in the Works for testing as may be selected and required by the Engineer.

8.1.2

Handling and Storage of Materials

1

The Contractor shall establish procedures for handling and storage of materials and equipment.

2

The Contractor’s storage and handling procedures shall be designed to prevent damage, deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or substitution.

3

The handling procedures shall address the use, inspection and maintenance of special devices such as crates, boxes, containers, dividers, slings, material handling and transportation equipment and other facilities.

4

The Contractor shall identify equipment and/or material requiring special handling or storage.

8.1.3

Identification and Control of Items and Materials

1

The Contractor shall establish control procedures to ensure that equipment and materials are properly used and installed.

2

The Contractor shall identify all items and materials so that they are traceable throughout all inspections, test activities, and records. For stored items, the identification method shall be consistent with the expected duration and type of storage.

3

The Contractor shall record equipment and material identifications and ensure that they are traceable to the location where they are incorporated into the Works.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 1

NONCONFORMANCE MONITORING .................................................................... 2

9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6

INTRODUCTION ..................................................................................................... 2 General 2 Review and Disposition of Nonconforming Items 2 Corrective Action 3 Identification of Nonconforming Items 3 Acceptance and Approval of Nonconforming items 4 Nonconformance Records 4

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9

NONCONFORMANCE MONITORING

9.1

INTRODUCTION

9.1.1

General

1

The Contractor shall ensure that product which does not conform to Specification requirements is identified and controlled to prevent its unintended use or delivery. A documented procedure shall be established to define the controls and relate responsibilities and authorities for dealing with nonconforming product: by taking action to estimate the detected nonconformity

(b)

by authorizing its use, release or acceptance under concession by the Engineer

(c)

by taking action to preclude its original intended use or application

(d)

by taking action appropriate to the effects, or potential effects, of the nonconformity when nonconformity product is detected after delivery or use has started .

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(a)

When Conforming product is corrected it shall be subject to re-verification to demonstrate conformity to requirements.

3

Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained by the engineer, shall be maintained.

4

The monitoring system shall apply to material and equipment as well as installation and construction which fail to conform to the Contract.

5

A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this Section and must be used for recording Nonconformance.

9.1.2

Review and Disposition of Nonconforming Items

1

The responsibility for review and authority for the disposition of nonconforming items shall be defined in the Quality Plan.

2

Nonconforming items shall be reviewed in accordance with documented procedures. A nonconforming item may be:

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2

(a)

reworked to meet the specified requirements

(b)

accepted with or without repair if agreed in writing by the Engineer

(c)

re-graded for alternative applications

(d)

rejected or scrapped.

3

The proposed use or repair of an item which does not conform to the requirements of the Project Documentation shall be reported to the Engineer. The description of the nonconformity and of repairs shall be recorded to denote the actual condition.

4

Repaired and/or reworked products shall be inspected in accordance with the Quality Assurance Plan and/or documented procedures

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9.1.3

Corrective Action

1

The Contractor shall take action to eliminate the causes of nonconformities in order to prevent recurrence. Corrective actions shall be appropriate to the effects of the nonconformity encountered. A documented procedure shall be established to define requirements for: Reviewing nonconformities (including Engineer complaints)

(b)

Determining the causes of nonconformities

(c)

Evaluating the need for action to ensure that conformities do not occur

(d)

Determining and implementing actions needed

(e)

Records of the results of action taken and

(f)

Reviewing the effectiveness of the corrective action taken

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Any corrective or preventive action taken to eliminate the causes of actual or potential nonconformities shall be to a degree appropriate to the magnitude of problems and commensurate with the risks encountered.

3

The Contractor shall implement and record any changes to the documented procedures for implementing corrective and preventive action.

4

The Contractor shall take prompt action to identify the causes of each nonconformance and the corrective action necessary prevent recurrence. The results of failure and discrepancy report summaries, Contractor evaluations, and any other pertinent applicable data shall be used for determining corrective action. Information developed during construction, tests, and inspections that support the implementation of required improvements and corrections shall be used to support the adequacy of corrective action taken.

5

The procedures for preventive action shall include:

determination of the steps needed to deal with any problems requiring preventive action

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(b)

the use of appropriate sources of information such as processes and work operations which affect product quality, concessions, audit results, quality records and service reports to detect, analyse and eliminate potential causes of nonconformities

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(c)

initiation of preventive action and application of controls to ensure that it is effective

(d)

ensuring that relevant information on actions taken is submitted for management review

9.1.4

Identification of Nonconforming Items

1

The Contractor shall clearly identify each nonconforming item with a status tag or other distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and removing these status tags and identify personnel authorised to remove status tags.

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9.1.5

Acceptance and Approval of Nonconforming items

1

Acceptance of the Contractors proposed disposition of Nonconforming items should be his obtained in writing from the Engineer prior to the undertaking of any remedial works by the his Contractor.

2

Close out of Nonconforming items must be agreed in writing by the Engineer.

9.1.6

Nonconformance Records

1

The Contractor shall provide the Engineer with the following information for each nonconformance:

(b)

description of nonconformance

(c)

evaluation of nonconformance to establish the cause

(d)

recommended corrective action

(e)

date nonconformance was identified

(f)

date corrective action was completed

(g)

description of final corrective action.

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identification of nonconformance

unique sequential reference number

(b)

date issued

(c)

originator

(d)

description of item deemed to be in nonconformance

(e)


(f) (g)

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The Contractor shall establish and maintain a nonconformance log. The log shall contain the following information as a minimum:

Contractors recommended and final disposition Engineers acceptance of Contractors recommended and final disposition

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(a)

(h)

date closed

(i)

remarks, as applicable

END OF PART

QCS 2014

Section 03: Ground Investigation Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2 Definitions 2

1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7

SUBMITTALS .......................................................................................................... 3 Programme of Works 3 Preliminary Logs 3 Exploratory Hole Logs 4 Preliminary Laboratory Test Results 5 Digital Data 5 Form of Report 5 Approval of Report 6

1.3

QUALITY ASSURANCE .......................................................................................... 6

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16

GENERAL PROJECT/SITE CONDITIONS .............................................................. 7 General 7 Working Areas 7 Turf and Topsoil 7 Paved Areas 7 Paving Slabs and Blocks 7 Claims for Damage 8 Geotechnical and Environmental Personnel 8 Location of Exploratory Holes 8 Ground Elevation of Exploratory Holes 8 Exploratory Work 8 Methods of Investigation 8 Safety and Management 9 Anomalous Conditions 9 Surface Water Control 9 Photographs 9 Facilities for the Engineer 10

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1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

General requirements and information for the execution of ground investigations.

2

Related Sections are as follows:

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Section 1 ......... General Section 2 ......... Quality Assurance and Quality Control Section 4 ......... Foundations and Retaining Structures Section 6 ......... Roadworks Section 8 ......... Drainage Works Section 12 ....... Earthworks Related to Buildings References

1

The following standards and other documents are referred to in this Part:

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BS 5930......................Code of practice for site investigations BS EN 1997................Ground Investigation and testing

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US symposium on rock mechanics. AIME, New York, 1967

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Definitions

1

Topsoil: the surface layer of earth that contains organic material and can also support vegetation.

2

Soil: earthen material not classified herein as topsoil or hard stratum.

3

Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean natural or artificial material, including rock, which cannot be penetrated except by the use of chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

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1.1.3

(a)

Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more than 300 mm

(b)

Condition (2) a standard penetration resistance test shows a resistance in excess of 35 blows/75 mm.

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Page 3

Fill: deposits or embankments which have been formed by persons, as distinct from geological agencies.

5

Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the purpose of ground investigation.

6

Boring: hole in earth, excavated by either percussion or auger equipment.

7

Drilling: any hole in rock, excavated by rotary equipment.

8

Borehole: exploratory hole excavated by boring or drilling techniques.

1.2

SUBMITTALS

1.2.1

Programme of Works

1

The Geotechnical Investigation Contractor shall prepare a programme of works for the investigation which will give a detailed schedule showing proposed time schedule for all aspect of the work, details of all plant and equipment to be used in addition to a list of personnel who will work on the project.

1.2.2

Preliminary Logs

1

The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer in duplicate within seven working days of completion of the explorations to which they refer to, and shall contain the information required for the exploratory hole logs.

2

Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment (MOE) requirements and/or those of other Government Departments, Ministries and Statutory Organizations.

3

The Geotechnical Investigation Contractor shall obtain all necessary work permits and security permits prior to commencement of Geotechnical investigation of the site.

4

The investigation shall provide detailed information on the nature of the sub-strata, superficial deposits and ground water table at the site together with general recommendations for designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

5

The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in Section 2.

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The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table 1.1. Table 1.1: Minimum Depth of Boreholes No of floors

Depth of Boreholes (m)

3 or Less

6

4

8

5

9

6

10

7

12

8

13 0.7

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2m below the inverted level; 1.5width of excavation. 2D (D=Diameter or equivalent diameter of the tunnel/underground structure.

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  

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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:

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Notes:  The depth of boreholes is measured from foundation level.  S is the number of floors.  For structures small in plan area, exploration should be made at a minimum of three points, unless other reliable information is available in the immediate vicinity. Where a structure consists of a number of adjacent units, one exploration point per unit may suffice.  For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the diameter of the pile at the toe) whichever is greater.  For roads, the depth of Boreholes shall be greater than 2m below the proposed formation Level.

Exploratory Hole Logs

1

The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The logs shall include all the information that follows, such information having been updated as necessary in the light of laboratory testing and further examination of samples and cores.

2

Information for exploratory hole logs:

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Drilling

Pit and Trench

Static and Dynamic Probing









National grid co-ordinates









Ground level related to the datum









Elevation of each stratum referred to the datum







()

Rotary Borehole

All the designated information

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Drilling

Pit and Trench








()

Details of groundwater observations







()

Symbolic legend of strata in accordance with BS 5930







()

Rotary Borehole Description of each stratum in accordance with BS 5930 and initials of person who carried out the logging (and responsible Supervisor if under training)

Core recovery as percentage of each core run



Rock Quality Designation, RQD (Deere et al. 1967)



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_____ Note:  means information required; () means information required if applicable. Preliminary Laboratory Test Results

1

Laboratory test results shall be submitted to the Engineer in batches at the completion of each week's testing. Legible photocopies of work sheets are acceptable.

1.2.5

Digital Data

1

Data from the investigation shall be provided in digital form to the approval of the Engineer.

1.2.6

Form of Report

1

The report shall comprise of a factual or interpretative or both types of reports as required by the Employer or Engineer. Reports shall begin with a cover page showing the name of the Contract and the names of the Employer, Engineer and Geotechnical Investigation Contractor. Report pages shall be numbered consecutively.

2

The factual report shall contain, as a minimum, the following information: A statement from the Engineer on the purpose and rationale of the investigation.

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1.2.4

(b)

A description of the work carried out, including reference to specification and standards adopted and any deviations from them.

(c)

Exploratory hole logs.

(d)

In-situ test records.

(e)

Laboratory test results.

(f)

Plan with locations of exploratory holes.

(g)

Site location plan.

(h)

Geological cross-sections (if appropriate).

The plans shall be to a stated scale and shall include a north arrow. Additional information shall be provided as designated.

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The interpretative report shall contain the following information: (a)

A written appraisal of the ground and water conditions.

(b)

Analysis and recommendations as designated.

When so designated, the Geotechnical Investigation Contractor shall supply the calculations and analyses on which recommendations are based. Approval of Report

1

A draft copy of the factual report and the interpretative report shall be submitted to the Engineer for approval before submission of the final report.

1.3

QUALITY ASSURANCE

1

Only Geotechnical Investigation Contractors holding a current approval certificate from the Central Materials Laboratory shall be permitted to carry out ground investigations.

2

The work shall be carried out in accordance with the relevant British Standards or equivalent.

3

Where specifically designated, all work shall be carried out in accordance with a quality management system established in accordance with Section 2 Quality Assurance and Quality Control of the QCS. Records to indicate compliance with quality management shall be made available to the Engineer on request.

4

The Geotechnical Investigation Contractor shall provide full time professional attendance on site. The professional attendant shall be approved by the Engineer, and shall be responsible for the technical direction of all fieldwork.

5

The Geotechnical Investigation Contractor’s geotechnical and environmental personnel employed on the Contract shall be competent to undertake the work required. Categories of personnel who may be required by the Contract are as follows:

(b)

Graduate Engineer/Geologist/Environmental Scientist. Graduate Engineer/Geologist/Environmental Scientist with at least three years of

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Technician.

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1.2.7

relevant experience since graduation.

(d)

Professional Engineer/Geologist/Environmental Scientist with at least five years of relevant experience.

(e)

6

Professional Engineer/Geologist/Environmental Specialist with at least ten years of relevant experience.

All drillers employed on the Contract shall be experienced and competent in percussion or auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent drilling supervisor per site shall be permanently on the Site during borehole operations.

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GENERAL PROJECT/SITE CONDITIONS

1.4.1

General

1

Geotechnical Investigation Contractor shall only use access routes to and between exploration sites that are approved by the Engineer.

2

Where the presence of underground services is likely, exploratory holes shall be started by means of a hand excavated inspection pit.

3

In addition to any designated notice, at least one working day's notice of the intended time of entry shall be given to the land owner and occupier of the exploration site.

4

All work shall be carried out with the least possible damage to the Site and its environs.

5

All barriers breached or otherwise disturbed during the execution of site operations shall be immediately repaired or replaced to the same standard.

6

Working hours shall be restricted to those designated.

7

Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the end of each day’s work.

1.4.2

Working Areas

1

Operations shall be confined to the minimum area of ground required for the Works. Unless otherwise designated, on completion of each exploration all equipment, surplus material and rubbish of every kind shall be cleared away and removed from the Site. Damage to land or property in the vicinity of the exploratory hole and on access routes shall be made good. The whole of the Site and any ancillary works shall be left in a clean and tidy condition.

1.4.3

Turf and Topsoil

1

Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by the operations shall either be removed and stockpiled as above, or otherwise protected from damage. After completion of the exploration all topsoil shall be replaced and the Site restored to its original condition.

1.4.4

Paved Areas

1

Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the minimum extent necessary for each exploration. After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving replaced.

2

Restoration of highway pavement shall be in accordance with the current Code of Practice and Specification for Road Openings in the Highway issued by the Government.

1.4.5

Paving Slabs and Blocks

1

Paving slabs and blocks shall be removed from the Site, as required for each exploration, and stored for reuse.

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1.4

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Contiguous paving slabs and blocks which are liable to be damaged by the operations shall either be removed and stored as above or otherwise protected from damage.

3

After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving slabs and blocks relayed.

1.4.6

Claims for Damage

1

Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall be reported to the Engineer.

1.4.7

Geotechnical and Environmental Personnel

1

In addition to the provision of the designated personnel by the Geotechnical Investigation Contractor, the Engineer may specifically require the services of geotechnical and environmental personnel for advice, assistance or preparation of interpretative reports. The form of interpretative reports shall be agreed with the Engineer. Details of the qualifications and experience of the personnel shall be supplied to the Engineer.

1.4.8

Location of Exploratory Holes

1

The location of each exploratory hole shall be measured from an approved grid co-ordinate system, and shall be accurate to within 1 m, and the position recorded on a plan as

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designated.

Ground Elevation of Exploratory Holes

1

The elevation of the ground at each exploratory hole shall be established, on the basis of the Qatar National Datum unless otherwise designated or approved by the Engineer, to the nearest 0.05 m.

1.4.10

Exploratory Work

1

The location and depth of each exploratory hole shall be as designated. The Engineer may, after consultation with the Geotechnical Investigation Contractor, vary the location and depth of any exploratory hole and the sequence or quantity of in-situ testing depending on the actual ground conditions encountered. When the position of an exploratory hole has been varied, the Geotechnical Investigation Contractor shall take all necessary measurements and shall inform the Engineer of the revised co-ordinates and ground elevation or other measurements required to locate the exploratory hole.

1.4.11

Methods of Investigation

1

The Engineer will have the option to require any of the following methods of investigation. These options will comprise, but not necessarily be limited to, the following:

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1.4.9

(a)

Desk study.

(b)

Geological mapping.

(c)

Topographic survey.

(d)

Aerial photographs.

or any other methods described in this Section.

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Safety and Management

1

The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA) to all site activities including but not limited to potential hazard, who/what might be harmed, control/ recovery measure, responsible person…etc.

2

The presence and nature of known areas of hazardous or contaminated ground are designated, based on available records. If evidence of further hazardous or contaminated ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform the Engineer. If required by the Engineer, the Geotechnical Investigation Contractor’s work plan shall be revised appropriately to take into account the nature and level of contamination encountered. Where contaminated land is present or suspected the Geotechnical Investigation Contractor shall take the appropriate health and safety precautions as directed by the Engineer and where appropriate by the Civil Defence Department of the Government. Care shall be taken to avoid contaminating the egress from the Site.

3

A method statement indicating the safety procedures to be followed during the investigation of hazardous or contaminated ground shall be provided by the Geotechnical Investigation Contractor before beginning the investigation in the hazardous or contaminated ground.

4

Traffic safety and management measures shall be provided, in accordance with the provisions of traffic control of Section 1, General. Where the circumstances of any particular case are not designated, proposals for dealing with such situations shall be submitted to the Engineer for approval.

1.4.13

Anomalous Conditions

1

Where anomalous or unexpected features are revealed, the Geotechnical Investigation Contractor shall immediately inform the Engineer.

1.4.14

Surface Water Control

1

Surface water or other water shall be prevented from entering the exploratory hole, except as permitted by the Engineer.

1.4.15

Photographs

1

Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor as designated. Each photograph shall clearly show all necessary details, and shall have its scale identified.

2

A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be submitted to the Engineer for his approval, within seven working days of the photography. In the event that the photographs are of a quality unacceptable to the Engineer, they shall be retaken.

3

On acceptance of the quality of the photograph, two complete sets of prints of all the photographs shall be presented, annotated and submitted in bound volumes, together with the original photograph digital format with the factual report.

4

Particular requirements for photographs of cores and pits and trenches are given in Parts 3 and 4

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1.4.16

Facilities for the Engineer

1

When required by the particular contract documentation, facilities to the designated standard shall be provided for the use of the Engineer, as described in Section 1.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 1

BOREHOLES .......................................................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1 2.2.2 2.2.3

BOREHOLES GENERALLY .................................................................................... 2 Method and Diameter 2 Addition of Water to the Borehole 3 Backfilling 3

2.3 2.3.1

PERCUSSION BORING .......................................................................................... 3 Hard Stratum or Obstruction in Percussion Boring 3

2.4 2.4.1 2.4.2 2.4.3

AUGER BORING ..................................................................................................... 3 Hand Auger 3 Continuous Flight Auger Boring 3 Hollow Stem Flight Auger 3

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6

ROTARY DRILLING ................................................................................................ 3 General 3 Drilling Fluid 4 Rotary Drilling with Core Recovery 4 Rotary Drilling without Core Recovery 6 Backfilling 6 Photographs 6

2.6

BOREHOLES OVERWATER .................................................................................. 6

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2

BOREHOLES

2.1

GENERAL

2.1.1

Scope

1

Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

2


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Section 4, ........ Foundations and Retaining Structures Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings

.

Part 1 ............... General

References

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BS 5930 ......................Code of practice for site investigations.

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purposes (1970).

BOREHOLES GENERALLY

2.2.1

Method and Diameter

1

The method of advancement and the diameter of a borehole shall be such that the boring can be completed and logged to the designated depth, and samples of the designated diameter can be obtained, in-situ testing carried out and instrumentation installed.

2

The following methods may be employed for advancement of a borehole unless otherwise designated:

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(a)

Percussion boring.

(b)

Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the Employer that the SPT values obtained are not effected by disturbance of the soil by the auger head, or the presence of material within the hollow stem.).

(c)

Rotary drilling.

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Addition of Water to the Borehole

1

Jetting with water shall not be used to assist the advance of the borehole, except where approved by the Engineer. Where the borehole penetrates below the water table and disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

2.2.3

Backfilling

1

The Contractor shall backfill boreholes in such a manner as to minimise subsequent depression at the ground surface due to settlement of the backfill. In some circumstances, grout or special infilling may be required by the Engineer. Where artesian or other water conditions make normal backfilling impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the borehole.

2.3

PERCUSSION BORING

2.3.1

Hard Stratum or Obstruction in Percussion Boring

1

In a borehole where percussion boring is employed and a hard stratum or obstruction is encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.

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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform the Engineer, who may instruct the use of one or more of the following: continuation of chiselling techniques

(b)

rotary or other approved drilling until the stratum is penetrated

(c)

abandonment of the borehole.

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AUGER BORING

2.4.1

Hand Auger

1

Hand auger boring may be appropriate in suitable self-supporting strata.

2.4.2

Continuous Flight Auger Boring

1

Where continuous flight auger boring is used, it shall be carried out under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) who shall produce, as boring proceeds, a record of the material and groundwater encountered.

2.4.3

Hollow Stem Flight Auger

1

Where hollow stem flight auger boring is used, the equipment used shall be such as to bore and recover samples as designated. Sampling shall be carried out through the hollow stem.

2.5

ROTARY DRILLING

2.5.1

General

1

Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in rock, with or without core recovery.

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Drilling Fluid

1

The drilling fluid shall normally be clean water, air or air mist. However, with the approval of the Engineer, drilling muds, additives or foam may be used.

2.5.3

Rotary Drilling with Core Recovery

1

Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube coring system incorporating a removable inner liner or split tube. The triple tube system may be affected by use of a double tube barrel with an approved semi-rigid liner.

2

Rotary core drilling shall produce cores of not less than the designated diameter throughout the core length. Care shall be exercised in the drilling so as to optimise core recovery.

3

The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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normally exceed 3 m in length and the core barrel shall be removed from the drill hole as

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Removal of cores and labelling of liners shall be carried out as follows: All operations entailed in recovering the cores from the ground after completion of drilling shall be carried out in a manner such as to minimise disturbance to the cores.

(b)

Core barrels or inner tube in case of wireline shall be held horizontally while the innermost liner containing the core is removed without vibration and in a manner to prevent disturbance to the core. The core should be rigidly supported at all times while it is being extruded and during subsequent handling, and the liner containing the core must not be allowed to flex

(c)

Immediately after removing the liner the top and bottom shall be marked in indelible ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall

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often as is required to obtain the best possible core recovery or alternatively the core samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing between drill runs.

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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be used, the samples shall be placed in half cut PVC pipes sealed with the second half after core samples description with marking of the core run on the PVC tube and the core box.

5

(d)

Where the length of core recovered from any single core run is such that it cannot be accommodated in one channel of the core box, the liner shall be cut to coincide, if possible, with existing fractures. The liner either side of the cut shall be marked 'cut' and the ends capped as above.

(e)

Each section of liner shall be marked with the contract title, exploratory hole reference number, date and the depths of the top and bottom of the drill run.

(f)

Core obtained without a liner and that from within the core catcher but not inside the liner shall be wrapped in two layers of plastic cling film and labelled to indicate the depth and exploratory hole reference number.

Core boxes, packing, labelling, storing shall be carried out as follows: (a)

Core boxes shall be soundly constructed and fitted with stout carrying handles, fastenings and hinged lids. The total weight of the cores and box shall together not exceed 60 kg.

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Cores shall be rigidly and securely packed at the site of drilling and during all subsequent handling and storage the cores shall remain packed unless required for examination or testing. Cores shall be placed in the box, in their liners where used, with the shallowest core to the top left hand corner, the top being considered adjacent to the hinged section. Cores from the core catcher shall also be placed in the core boxes at the correct relative depth.

(c)

Depth shall be indicated on the core box by durable markers at the beginning and end of each drill run. Rigid core spacers shall be used to indicate missing lengths. The contract title, exploratory hole reference number and the depth of coring contained in each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand end of the box and on the inside of the box lid.

(d)

Core boxes containing core shall be kept horizontal and moved and handled with care at all times. Cores shall be protected from direct sunlight. At the end of each day's work, core boxes shall be stored secure from interference and protected from the weather.

Cores shall be prepared for examination as follows: (a)

Cores shall be prepared for examination by the removal of sealing materials and splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut lengthways such that at least half the core circumference is exposed. If half PVC is used, care should be taken while removing and replacing the split half.

(b)

Before examination of the core, the Contractor shall photograph the cores. The time between beginning preparation and the examination of the prepared and photographed cores shall be minimised to prevent loss of moisture from the core samples.

(c)

Cores shall be examined and described on site by a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purpose (1970).

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(b)

When the examination of the cores has been completed, the Contractor may be required to retain separately designated core sub-samples for possible laboratory testing. The Contractor shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of moisture and sample disturbance. They shall be clearly labelled so that the location, depth and origin of the sub-samples can be readily identified. Cores in their liners remaining after the designated sub-samples have been removed shall be end-capped and resealed and replaced in the original core box location. Rigid spacers shall be placed in the spaces in the cores boxes previously occupied by the core sub-samples to prevent movement of adjacent cores and these shall be labelled identically to the core sub-samples that they replace. The core sub-samples shall be retained in separate core boxes clearly marked to indicate the origin of the cores contained within.

8

The Contractor shall protect all cores and transport them including loading and unloading to

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(a)

The Contractor's premises.

(b)

For a number of selected cores, to the designated address.

After submittal of the approved final report, the Contractor shall retain cores, other than those delivered to the designated address, for a period of time required by the Engineer. The Engineer's written permission shall be obtained before disposal of the cores, but the required retention period will normally not exceed three months.

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2.5.4

Rotary Drilling without Core Recovery

1

Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole diameter shall be as designated.

2

When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other cavities or anomalous conditions, drilling shall be under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a systematic record shall be made of the drilling methods, rate of penetration, loss of flushing medium, the material penetrated and any cavities or broken ground encountered. Backfilling

1

Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean, well graded aggregate. The aggregate size and gradation shall be approved by the Engineer. Under special circumstances grout may be required to backfill the holes. The grout shall consist of equal portions by weight of ordinary Portland cement and bentonite mixed by machine or hand to a uniform colour and consistency before placing, with a moisture content not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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2.5.5

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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds. Where artesian water conditions or voids make normal grouting impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the drill hole.

2.5.6

Photographs

1

In addition to the requirements of Part 1, the Contractor shall photograph cores where required in a fresh condition before logging and ensure that the following criteria are fulfilled:

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A graduated scale in centimetres is provided.

(b)

Labels and markers are clearly legible in the photograph.

(c)

A clearly legible reference board identifying the project title, exploratory hole number, date, and depth of drill runs shall be included in each photograph.

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Core boxes are evenly and consistently lit.

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(e)

The length of the core box in each photograph fills the frame.

(f)

The focal plane of the camera and the plane of the core box are parallel.

(g)

The camera is placed in the same position with respect to the core box in every photograph.

(h)

The resolution of the camera is not less than 8Mpixels.

(i)

The photograph taken should be in focus along all the core samples length.

2.6

BOREHOLES OVERWATER

1

When boreholes are required overwater the method of drilling and sampling shall comply in general with the other requirements given in this Section, with the exception of backfilling.

2

Overwater boreholes shall be undertaken by the use of overwater staging, work over platform (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the Engineer.

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Page 7

Control of the elevation related to the borehole/seabed surface or varying stratums shall be related to the top of the casing installed. Anchored floating vessels will keep a constant record of tidal movement between the vessel and the fixed casing elevation and make any allowances necessary.

4

Boring or drilling operations will cease when the wave height exceeds the designated maximum value relating to standing time due to inclement weather, if this item is applicable to the Contract under the contract specific documentation.

5

An accurate method of measuring wave height from trough to crest will be installed on the drilling vessel or platform and calibrated and approved by the Engineer before beginning drilling operations.

6

All overwater operations will comply with all local government regulations related to such work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at the time.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 03: Pits and Trenches

Page 1

PITS AND TRENCHES ........................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Quality Assurance 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

PITS AND TRENCHES GENERALLY ..................................................................... 2 Pit and Trench Dimensions 2 Contaminated Ground 2 Groundwater 3 Protection to Pits and Trenches Left Open 3 Backfilling and Restoration 3 Photographs 3

3.3 3.3.1 3.3.2 3.3.3

INSPECTION PITS .................................................................................................. 3 Excavation Method 3 Services 3 Sidewall Stability 4

3.4 3.4.1 3.4.2 3.4.3 3.4.4

TRIAL PITS AND TRENCHES ................................................................................ 4 Excavation Method 4 Services 4 Sidewall Stability 4 Trial Pits Examination 4

3.5 3.5.1 3.5.2 3.5.3

OBSERVATION PITS AND TRENCHES ................................................................. 4 Excavation Method 4 Services 5 Sidewall Stability 5

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3

PITS AND TRENCHES

3.1

GENERAL

3.1.1

Scope

1

Inspection pits, trial pits and trenches, observation pits and trenches.

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Section 1, ....... General Section 4, ....... Foundations and Retaining Structures Section 6, ....... Roadworks Section 8, ....... Drainage Works Section 12, ..... Earthworks Related to Buildings.

.

Part 1, .............. General

References

1


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BS 5930 ...................... Code of practice for site investigations

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Quality Assurance

1

Trial pits and trenches and observation pits and trenches shall be examined and described by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) and photographed, if required.

3.2

PITS AND TRENCHES GENERALLY

3.2.1

Pit and Trench Dimensions

1

Unless otherwise designated

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2.

(a)

Trial pits and observation pits shall have a minimum base area of 1.5 m

(b)

Trial trenches and observation trenches shall not be less than 1 m wide.

3.2.2

Contaminated Ground

1

Ground that is suspected of being contaminated shall be described by an environmental or geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c).

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Groundwater

1

The Contractor shall divert surface water runoff from entering pits and trenches.

2

Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous work if required.

3.2.4

Protection to Pits and Trenches Left Open

1

Where pits and trenches are required to be left open and unattended, the Contractor shall provide fencing together with all necessary lighting and signing.

2

Precautions shall be taken to protect the pits and trenches from the adverse effects of weather during this period.

3.2.5

Backfilling and Restoration

1

Pits and trenches shall be backfilled as soon as practicable and reinstated to their original condition.

2

The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as to minimise any subsequent settlement of the ground surface.

3

The use of sand backfill compacted by flooding may be permitted, but this method requires the approval of the Engineer.

4

In paved areas, the pavement shall be restored.

3.2.6

Photographs

1

In addition to the requirements of Part 1, photographs shall clearly show details of the ground conditions in the pit and trench with any support in place and shall contain a graduated scale.

2

Material derived from the excavation shall be photographed, when directed by the Engineer. Artificial lighting shall be used where necessary.

3

Unless directed otherwise by the Engineer, three photographs will normally be required at every pit and trench.

3.3

INSPECTION PITS

3.3.1

Excavation Method

1

Inspection pits for the location of underground services shall be excavated by hand to a depth of 1.2 m unless otherwise designated.

2

Hand-operated power tools may be used to assist excavation where necessary.

3.3.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

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3.2.3

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Sidewall Stability

1

Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

3.4

TRIAL PITS AND TRENCHES

3.4.1

Excavation Method

1

Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by machine to the required depth to enable visual examination and sampling from outside the pit or trench as required.

2

Where dewatering is required, the pumping equipment used shall be adequate to lower the water table to the required level.

3.4.2

Services

1


3.4.3

Sidewall Stability

1

Excavations deeper than 1.2 m shall be braced if necessary.

3.4.4

Trial Pits Examination

1

All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party.

2

Disturbed samples shall be obtained from the trial pits for laboratory testing and geological description purposes. The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

3

Color photographs shall be taken for each excavated trial pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5

OBSERVATION PITS AND TRENCHES

3.5.1

Excavation Method

1

Observation pits and trenches shall be excavated by hand or machine and shall be adequately supported to enable personnel to enter safely and to permit in-situ examination, soil sampling and testing as required. In areas where dewatering is required, the equipment and methods proposed must be approved by the Engineer before beginning the work.

2

All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or ASTM D 2488.

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3.3.3

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Disturbed samples shall be obtained for laboratory testing and geological description purposes (if required). The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

4

Color photographs shall be taken for each excavated pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5.2

Services

1


3.5.3

Sidewall Stability

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 04: Soil Sampling

Page 1

SOIL SAMPLING ..................................................................................................... 2

4.1 4.1.1 4.1.2


4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

SAMPLING GENERALLY ........................................................................................ 2 Sampling and Testing Frequency 2 Recording depths of samples 3 Description of samples 3 Labelling, Protection and Transportation of Samples 3 Retention and Disposal of Samples 3

4.3 4.3.1 4.3.2 4.3.3 4.3.4

SOIL SAMPLES....................................................................................................... 3 Small Disturbed Samples 3 Bulk Disturbed Samples 3 Open Tube and Piston Samples 4 Standard Penetration Test Samples 4

4.4

GROUNDWATER SAMPLES .................................................................................. 4

4.5

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4

4.6

GAS SAMPLING...................................................................................................... 5

4.7

SPECIAL SAMPLING .............................................................................................. 5

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4

SOIL SAMPLING

4.1

GENERAL

4.1.1

Scope

1

Taking of samples of soil, groundwater, gas and contaminants. Sample handling, transportation, storage, retention and disposal.

2


References

1

The following documents are referred to in this Part:

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Part 1, .............. General Part 2, .............. Boreholes Part 3, .............. Pits and Trenches.

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure) BS 5930 ......................Code of practice for site investigations

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BSI –DD 175 ..............Code of practice for the identification of potentially contaminated land and its investigation (draft for development).

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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in construction, Part 4, Guidelines for the safe investigation by drilling of landfills and contaminated land, Thomas Telford, (1993).

SAMPLING GENERALLY

4.2.1

Sampling and Testing Frequency

1

The frequency of sampling and in-situ testing is dependent on the ground conditions. In the absence of designated requirements the intervals observed shall be as follows:

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4.2

(a)

(b)

in boreholes (i)

first open tube sample (generally in clay soils) or standard penetration test (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth, thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

(ii)

small disturbed samples shall be taken from the topsoil, at each change in soil

(iii)

type or consistency and midway between successive open tube samples or SPT’s.

(iv)

Bulk disturbed samples shall be taken of each soil type.

in pits and trenches

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(i)

Small disturbed samples shall be taken of the topsoil, at each change in soil type or consistency and between successive bulk disturbed samples.

(ii)

Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one large bulk disturbed sample of each soil type.

Recording depths of samples

1

The depths below ground level at which samples are taken shall be recorded. For open tube and piston samples the depth to the top and bottom of the sample, and the length of sample obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

4.2.3

Description of samples

1

All samples shall be examined and described by a geotechnical person meeting the requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930. Samples of suspected contaminated ground and leachate shall be described by an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell with reference to specific inclusions.

4.2.4

Labelling, Protection and Transportation of Samples

1

Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater, leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a red label.

2

Samples shall be protected from direct heat and sunlight.

3

Samples shall be transported to the Contractor's premises. Where required by the Engineer, selected samples shall be delivered to the designated address.

4.2.5

Retention and Disposal of Samples

1

Samples shall be kept for the designated period after submission of the approved final report. This period shall not exceed three months, unless specifically designated otherwise. The Contractor shall ultimately dispose of all samples other than those delivered to the designated address.

4.3

SOIL SAMPLES

4.3.1

Small Disturbed Samples

1

Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately in airtight containers, which they should sensibly fill.

4.3.2

Bulk Disturbed Samples

1

Bulk disturbed samples shall be representative of the zone from which they have been taken.

2

Normal bulk disturbed samples shall weigh not less than 10 kg.

3

Large bulk disturbed samples shall weigh not less than 30 kg.

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Open Tube and Piston Samples

1

Open tube and piston samples shall be taken using the sampling equipment and procedures as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

2

Before an open tube or piston sample is taken, the bottom of the hole shall be carefully cleared of disturb materials and where a casing is being used the sample shall be taken below the bottom of the casing. Following a break in the work exceeding one hour, the borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

3

Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be cleaned out for the full depth to which the sampling tube has penetrated and the recovered soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful the Contractor shall agree with the Engineer as to alternative means of sampling.

4

The samples shall be sealed immediately to preserve their natural moisture content and in such a manner as to prevent the sealant from entering any voids in the sample.

5

Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed sample.

4.3.4

Standard Penetration Test Samples

1

When a standard penetration test (SPT) is made, the sample from the split barrel sampler shall be retained as a small disturbed sample.

4.4

GROUNDWATER SAMPLES

1

Groundwater samples shall be taken from each exploratory hole where groundwater is encountered. Where more than one groundwater level is found, each one shall be sampled separately. Where water has been previously added, the hole shall be bailed out before

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sampling so that only groundwater is present. The sample volume shall be not less than 0.25 l.

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

1

Samples of suspected contaminated ground, groundwater and leachate shall be taken in accordance with DD 175 and the SISG publication under the supervision of an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

2

The size and type of sample and container, method of sampling and time limitations for carrying out specific analyses shall be commensurate with the range of analyses to be carried out or as designated.

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GAS SAMPLING

1

Samples of gas for chromatographic analysis shall be obtained from exploratory holes or standpipes in accordance with DD 175 and the SISG publication. The sampling method shall relate to the volume of gas available and the type of laboratory analysis. The sampler receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas bombs.

4.7

SPECIAL SAMPLING

1

The Engineer may require special sampling. This work will normally require supervision on site by a geotechnical person and shall be carried out in accordance with BS 5930 or as designated.

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END OF PART

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Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

Page 1

IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2

5.1 5.1.1 5.1.2


5.2 5.2.1 5.2.2

TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2 Testing 2 Instrumentation and Monitoring 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

TESTS ..................................................................................................................... 3 Tests in accordance with BS 1377 or BS EN 1997 3 Tests in accordance with BS 5930 4 Geophysical Methods of Investigation 4 Special In-Situ Testing 4 Hand Penetrometer and Hand Vane for Shear Strength 5 Self-boring Pressuremeter 5

5.4 5.4.1 5.4.2 5.4.3

INSTRUMENTATION AND MONITORING .............................................................. 6 Groundwater 6 Installation of Standpipes and Piezometers 6 Installation of Gas Monitoring Standpipes 6

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5

IN-SITU TESTING, INSTRUMENTATION AND MONITORING

5.1

GENERAL

5.1.1

Scope

1

Testing of soils in place, and provision of instrumentation and monitoring of groundwater and subsurface gases.

2


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Part 1 ............... General Part 2 ............... Boreholes Part 3 ............... Pits and Trenches. References

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BS 1377......................Methods of tests for soils for civil engineering purposes BS 5930......................Code of practice for site investigations

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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes

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BS EN 1997................Ground Investigation and testing

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The Geological Society Engineering Group Working Party Report on Engineering Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.

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Clarke B.G. and Smith A., A model specification for radial displacement measuring pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.

TESTING, INSTRUMENTATION AND MONITORING GENERALLY

5.2.1

Testing

1

The following information shall be submitted for each test record to be included in the daily report, preliminary log and factual report:

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5.2

(a)

Date of test.

(b)

Project name, exploratory hole number and location.

(c)

Depth and location of test or depths covered by test.

(d)

Information on water levels in exploratory hole during testing.

(e)

Original ground level at test site.

(f)

Soil type and description as identified from the sample.

All results shall be reported in SI units.

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Where load, displacement or other measuring equipment is used which necessitates regular calibration, then this shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer's instructions, by a calibration service approved by the Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall be supplied to the Engineer prior to commencing work and when otherwise requested.

5.2.2

Instrumentation and Monitoring

1

The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected by a cover. The type of protective cover shall be approved by the Engineer.

2

When instructed by the Engineer, the Contractor shall install a protective fence around the top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the climate of Qatar or a fence as a agreed upon with the Engineer.

3

Daily readings of depths to water in groundwater monitoring standpipes and piezometers shall be made by the Contractor, with an instrument approved by the Engineer.

4

Where the presence of gas is suspected or when directed by the Engineer, gas measurements, using an approved in-situ meter, shall be made by the Contractor during construction of exploratory holes and in gas monitoring standpipes. The depth to water and barometric pressure shall be measured immediately after each gas measurement.

5

Unless otherwise designated, piezometers, and standpipes protection shall not be removed from the site.

6

Other instrumentation and monitoring shall be carried out as designated.

5.3

TESTS

5.3.1

Tests in accordance with BS 1377 or BS EN 1997

1

The following in-situ tests shall be carried out and reported in accordance with BS 1377 or BS EN 1997: in-situ density by

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(i)

Small pouring cylinder method.

(ii)

Large pouring cylinder method.

(iii)

Water replacement method.

(iv)

Core cutter method.

(v)

Nuclear method.

(b)

Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise designated

(c)

Dynamic probing (DPH or DPSH).

(d)

Standard penetration test (SPT).

(e)

Plate loading test.

(f)

Shallow pad maintained load test.

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(g)

California bearing ratio (CBR).

(h)

Vane shear strength.

(i)

Apparent resistivity of soil.

(j)

Redox potential.

(k)

Pressurementer or Self-boring Pressuremeter (PMT)

(l)

Pocket Penetrometer.

Page 4

5.3.2

Tests in accordance with BS 5930

1

The following in-situ tests shall be carried out where applicable and reported in accordance with BS 5930:

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Constant head permeability test. Variable head permeability test. Packer permeability test.

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(a) (b) (c)

Geophysical Methods of Investigation

1

Geophysical testing shall be carried out as designated. The Contractor shall submit to the Engineer a full description of equipment and procedure for each geophysical method required.

2

The equipment and procedure, and information to be submitted for the following geophysical methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological Society Engineering Group Working Party Report on Engineering Geophysics:

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electrical resistivity method

(b)

seismic refraction and reflection method

(c)

magnetic method

(d)

gravity method

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electromagnetic method

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(i)

Ground conductivity.

(ii)

Transient electromagnetic.

(iii)

Ground probing radar (optional).

(f)

Borehole geophysical logging.

(g)

Cross-hole seismic method.

(h)

Multi Channel Analysis of Surface Waves (MASW)

(i)

Refraction Microtremor (ReMi)

5.3.4

Special In-Situ Testing

1

Special in-situ testing shall be carried out as designated.

2

The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for the execution of inspection tests.

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Inspection tests shall be decided as directed by the Engineer. These tests shall include but not limited to those in Table 3.2. Table 3.2: Quality Assurance Tests for Completed Work Recommended Test per Layer Deep Fill (boreholes)

In-situ CBR

Field density

Plate load Test

Layer Thickness

Field density

DCP Test

Layer Thickness

SPT

DCP Test

Pressure meter

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Shallow Fill (trench or test pit)

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Large Scale Loading Hand Penetrometer and Hand Vane for Shear Strength

1

Hand penetrometer and hand vane tests shall be carried out where required to give a preliminary estimate of undrained shear strength of the soil tested.

2

Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with 2 stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.

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5.3.5

Hand vane equipment shall be of an approved proprietary make with stainless steel vanes having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be

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The scale shall be suitably graduated. The procedure for the test shall be in accordance with the manufacturer's instructions. Both unconfined compressive strength and estimated shear strength shall be reported for the soil tested.

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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the manufacturer's instructions. Peak shear strength and residual shear strength shall be

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recorded. 4

The reported shear strengths for the hand penetrometer and handvane shall be the average of 3 tests in close proximity. Tests giving inconsistent results shall be reported and comments on the relevance of the tests noted.

5.3.6

Self-boring Pressuremeter

1

The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP) unless otherwise designated. The instruments, calibration, operator, installation, testing procedure, on-site data processing and analysis, information to be submitted, report data processing and analysis and information to be submitted in the report shall be as described by Clarke and Smith (1992) and as designated..

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5.4

INSTRUMENTATION AND MONITORING

5.4.1

Groundwater

1

When groundwater is encountered in exploratory holes, the depth from ground level of the point of entry shall be recorded together with depth of any casing. Exploratory hole operations shall be stopped and the depth from ground level to water level recorded with an approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the

.

period of 20 minutes the water level is still rising, this shall be recorded together with the depth to water below ground level, unless otherwise instructed by the Engineer, and the exploratory hole shall then be continued. If casing is used and this forms a seal against the entry of groundwater, the Contractor shall record the depth of casing at which no further entry or only insignificant infiltration of water occurred. Water levels shall be recorded as required by the Contract and at the beginning and end of each shift. On each occasion when groundwater levels are recorded, the depth of the exploratory hole, the depth of any casing and the time shall also be recorded.

3

Where artesian conditions are encountered, the Contractor shall immediately inform the Engineer and agree a method for dealing with the conditions.

5.4.2

Installation of Standpipes and Piezometers

1

Standpipes for monitoring groundwater levels and changes in groundwater levels shall be installed in exploratory holes, as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions and depths shall be recorded at the time of installation.

2

Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be installed as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions. The installation details of the standpipe piezometers shall be recorded.

3

The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type described in BS 5930 or as designated by the Engineer.

5.4.3

Installation of Gas Monitoring Standpipes

1

Standpipes for monitoring gas concentration in exploratory holes shall be installed as instructed by the Engineer. Warning signs or other safety measures required by the Civil Defence Department of the Government shall be complied with. Standpipes shall be of the designated form and detail. All dimensions and depths shall he recorded at the time of installation.

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END OF PART

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Section 03: Ground Investigation Part 06: Laboratory Testing

Page 1

LABORATORY TESTING ........................................................................................ 2

6.1 6.1.1 6.1.2


6.2

SCHEDULE OF TESTS ........................................................................................... 2

6.3 6.3.1 6.3.2 6.3.3 6.3.4

TESTING PROCEDURES ....................................................................................... 3 General 3 Geotechnical Testing on Contaminated Samples 3 Soil Testing 3 Rock Testing 3

6.4 6.4.2 6.4.3

CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4 Laboratory Testing On Site 6 Special Laboratory Testing 6

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6

LABORATORY TESTING

6.1

GENERAL

6.1.1

Scope

1

Geotechnical tests and testing procedures carried out in the laboratory or, when designated, on site.

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ASTM SP 402.............Special Technical Publications No. 402

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BS 1377 ......................Methods of tests for soils for civil engineering purposes BS 1881 ......................Analysis of hardened concrete

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BS 812 ........................Testing aggregates

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BS EN 1997--------- .....Ground Investigation and testing

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Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for Rock Mechanics Suggested Methods. 1981. Pergamon Press. C2 through C25 and C27 through C31, Methods for examination of waters and associated materials, HMSO IRSM Commission on Testing Methods. Suggested method for determining Point Load Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22, 51-60 (1985).

6.2

SCHEDULE OF TESTS

1

The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be necessary to designate additional testing after the results of the original tests are available. Unless otherwise agreed, testing schedules are to be provided within six working days of the receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the Engineer within six working days from the receipt of the approved testing schedule if a sample referred to in the schedule is not available for testing.

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TESTING PROCEDURES

6.3.1

General

1

Where applicable, all preparation, testing and reporting shall be in accordance with the relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are not covered by these Standards, they shall be performed in accordance with the procedures in the references or as designated.

2

Calibration of load-displacement or other measuring equipment shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer’s instructions by a calibration service approved by the Central Materials Laboratory. Evidence of current calibrations shall be supplied to the Engineer.

6.3.2

Geotechnical Testing on Contaminated Samples

1

Where geotechnical testing is required on samples of suspected contaminated material, indicative chemical testing shall be carried out and a safe method of working approved by the Engineer before any such work is started. It should be noted that this may include but is not limited to the safe storage, transportation and handling of all suspect material.

6.3.3

Soil Testing

1

Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards unless otherwise designated.

6.3.4

Rock Testing

1

Rock testing shall be carried out and reported in accordance with the following references and as designated: Classification.

Natural water content - Brown (1981).

(ii)

Porosity/density - Brown (1981).

(iii)

Void index - Brown (1981).

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6.3

(b)

(c)

(d)

(iv)

Carbonate content - BS 1881.

(v)

Petrographic description -Brown (1981).

Durability. (i)

Slake durability index - Brown (1981).

(ii)

Soundness by solution of magnesium sulphate - BS 812.

Hardness. (i)

Shore sclerometer -Brown (1981).

(ii)

Schmidt rebound hardness - Brown (1981).

Aggregates. (i)

Aggregate crushing value - BS 812.

(ii)

Ten percent fines - BS 812.

(iii)

Aggregate impact value - BS 812.

(iv)

Aggregate abrasion value - BS 812.

(v)

Polished stone value - BS 812.

(vi)

Aggregate frost heave - BS 812.

Strength. (i)

Uniaxial compressive strength - Brown (1981).

(ii)

Deformability in uniaxial compression -Brown (1981).

(iii)

Tensile strength-Brown (1981).  

Direct tensile strength. Indirect tensile strength by the Brazilian method.

Undrained triaxial compression without measurement of porewater pressureBrown (1981).

(v)

Direct shear strength - Brown (1981).

(vi)

Swelling pressure - Brown (1981).

(vii)

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Swelling pressure index under conditions of zero volume change. Swelling strain index for a radially confined specimen with axial surcharge. Swelling strain developed in an unconfined rock specimen.

Point load test - IRSM Commission on Testing Methods (1985).

Geophysical. Seismic velocity-Brown (1981).

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(iv)

   (f)

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CHEMICAL TESTING FOR CONTAMINATED GROUND

1

Chemical testing for contaminated ground shall be carried out and reported in accordance with the following references and as designated:

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Primary contaminants in soil. Arsenic total - C4.

(ii)

Cadmium total - C2.

(iii)

Chromium total - C2.

(iv)

hexavalent chromium (undertaken if total chromium content >25 mg/kg dry

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Mass) -C2.

(v)

Lead total - C2.

(vi)

Mercury total - C3.

(vii)

Selenium total - C4.

(viii)

Boron, water-soluble - C5.

(ix)

Copper total - C2.

(x)

Nickel total - C2.

(xi)

Zinc total - C2.

(xii)

Cyanide total (alkali extraction methods) - C6.

(xiii)

Cyanide complex - C6.

(xiv) Cyanide free - C6. (xv)

Thiocyanate - C6.

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(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods shall follow alkali extraction.) (xvii) Phenols total - C7. (xviii) Sulphide - C8. (xix) Sulphate - total, acid, soluble - C9. (xx)

Sulphate - water soluble, 2 : 1 extract - C9.

(xxi) Sulphur free - C10. (xxii) PH value - C9. (xxiii) Toluene extractable matter - Cl1.

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(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter> 2000 g/kg dry mass of soil) - C12.

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Antimony total - C13.

(ii)

Barium total - C13.

(iii)

Beryllium total - C15.

(iv)

Vanadium total - C13.

(v)

Cyclohexane extractable matter - C14.

(vi)

Freon extractable matter - C15.

(vii)

Mineral oils - C31.

(viii)

Chloride - C9.

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(i)

Contaminants in water.

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Secondary contaminants in soil.

(i)

Arsenic - C4.

(ii)

Cadmium - C2 and C23. Chromium - C2 and C24.

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(xxv) Asbestos. Asbestos content determination shall be carried out by visual examination and polarised light microscopy.

Hexavalent chromium - C2.

(v)

Lead - C2 and C25.

(vi)

Mercury - C3.

(vii)

Selenium - C4.

(viii)

Boron - C5 and C6.

(ix)

Copper - C2 and C27.

(x)

Nickel - C2 and C28.

(xi)

Zinc - C2 and C29.

(xii)

Cyanide total - C6.

(xiii)


(xiv)

Cyanide free - C6.

(xv)

Thiocyanate - C6.

(xvi)

Phenols total - C7.

(xvii)

Sulphide - C8.

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Sulphate - C9.

(xix)

Sulphur free - C10.

(xx)

PH value - C9.

(xxi)

Polyaromatic hydrocarbons - C 12.

(xxii)

Antimony-C13.

(xxiii)

Barium-C13.

(xxiv)

Beryllium-C15.

(xxv)

Vanadium - C 13.

(xxvi)

Chloride - C9.

(xxvii)

Ammoniacal nitrogen - C16.

(xxviii)

Nitrate nitrogen - Cl7.

(xxix)

Chemical oxygen demand - C18.

(xxx)

Biochemical oxygen demand - C19.

(xxxi)

Total organic carbon - C20.

(xxxii)

Volatile fatty acids - C21.

(xxxiii)

Iron - C22.

(xxxiv)

Manganese - C22.

(xxxv)

Calcium - C31.

(xxxvi)

Sodium - C31.

(xxxvii)

Magnesium - C31.

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Constituents of gas samples. Carbon dioxide - C30.

(ii)

Hydrogen - C30.

(iii)

Hydrogen sulphide - C30.

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(xxxviii) Potassium - C21.

Methane - C30.

(v)

Nitrogen - C30.

(vi)

Oxygen - C30.

(vii)

Ethane- C30.

(viii)

Propane- C30.

(ix)

Carbon monoxide - C30.

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6.4.2

Laboratory Testing On Site

1

When designated, tests listed under laboratory testing shall be carried out on site.

6.4.3

Special Laboratory Testing

1

When designated, special laboratory testing shall be carried out. END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 1

GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 General Contract Requirements 2 Submittals 3 Records 3

1.2 1.2.1 1.2.2

GROUND CONDITIONS ......................................................................................... 3 Ground Investigation Reports 3 Unexpected Ground Conditions 4

1.3 1.3.1 1.3.2 1.3.3

MATERIALS AND WORKMANSHIP........................................................................ 4 General 4 Sources of Supply 4 Rejected materials 5

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6

INSTALLATION TOLERANCES .............................................................................. 5 Setting Out 5 Position 6 Verticality 6 Rake 6 Tolerance Variations 6 Forcible Corrections to Pile 6

1.5 1.5.1 1.5.2 1.5.3 1.5.4

NUISANCE AND DAMAGE ..................................................................................... 6 Noise and Disturbance 6 Damage to Adjacent Structures 7 Damage to Piles 7 Temporary Support 7

1.6 1.6.1 1.6.2 1.6.3

SAFETY .................................................................................................................. 7 General 7 Life-Saving Appliances 7 Driving 7

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GENERAL REQUIREMENTS FOR PILING WORK

1.1

GENERAL

1.1.1

Scope

1

This Part is concerned with all works associated with installation of piles by any of the recognised techniques.

1.1.2

References

1

The following standards and codes of practice are referred to in this Part:

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BS 5228......................Noise control on construction and open sites

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Part I, Code of practice for basic information and procedures for noise control Part IV, Code of practice for noise and vibration control applicable to piling operations

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BS 8008......................Safety precautions and procedures for the construction and descent of machine-bored shafts for piling and other purposes

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BS EN 1997................Eurocode 7, Geotechnical Design.

General Contract Requirements

1

The following matters, where appropriate, are described in the contract specific documentation for the Works: general items related to Works Nature of the Works.

(ii)

Classes of loads on piles.

(iii)

Contract drawings.

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(i)

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1.1.3

(b)

(iv)

Other works proceeding at the same time.

(v)

Working area.

(vi)

Order of the Works.

(vii)

Datum.

(viii)

Offices for the Engineer's Representative.

(ix)

Particular facilities and attendance items where not included in this section.

(x)

Details of soil investigation reports.

specific items related to particular type of pile (i)

Soil sampling, laboratory testing and in-situ soil testing.

(ii)

Designed concrete or grout mixes, grades of concrete or grout, type of cement and aggregate, grout or concrete admixtures, concreting of piles.


Page 3

Grades and types of reinforcement and prestressing tendons.

(iv)

Pile dimensions, length and marking of piles.

(v)

Type and quality of pile shoe/splice.

(vi)

Type and quality of permanent casing.

(vii)

Specified working loads.

(viii)

Sections of proprietary types of pile, grades of steel, minimum length to be supplied, thickness of circumferential weld reinforcement.

(ix)

Surface preparation, types and thickness of coatings.

(x)

Test piles, driving resistance or dynamic evaluation and penetration.

(xi)

Detailed requirements for driving records.

(xii)

Acceptance criteria for piles under test.

(xiii)

Disposal of cut-off lengths.

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(iii)

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QCS 2014

(xiv) Preboring. Submittals

1

The Contractor shall supply for approval all relevant details of the method of piling and the plant he proposes to use. Any alternative method to that specified shall be subject to approval.

2

The Contractor shall submit to the Engineer on the first day of each week, or at such longer periods as the Engineer may from time to time direct, a progress report showing the current rate of progress and progress during the previous period on all important items of each section of the Works.

3

The Contractor shall inform the Engineer each day of the intended programme of piling for the following day and shall give adequate notice of his intention to work outside normal hours and at weekends.

1.1.5

Records

1

The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation of each pile and shall submit two signed copies of these records to the Engineer not later than noon of the next working day after the pile is installed. The signed records will form a record of the work. Any unexpected driving or boring conditions shall be noted briefly in the records.

1.2

GROUND CONDITIONS

1.2.1

Ground Investigation Reports

1

Factual information and reports on site investigations for the Works and on the previous known uses of the Site will be provided by the Engineer where they exist as part of the specific contract documentation. However, even if a full report is given, including interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any opinions or conclusions which may be given in the reports.

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Page 4

Before the start of work the Contractor shall be given a copy of any subsequent information which may have been obtained relating to the ground conditions and previous uses of the Site.

1.2.2

Unexpected Ground Conditions

1

The Contractor shall report immediately to the Engineer any circumstance which indicates that in the Contractor's opinion the ground conditions differ from those reported in or which could have been inferred from the site investigation reports or test pile results.

1.3

MATERIALS AND WORKMANSHIP

1.3.1

General

1

All materials and workmanship shall be in accordance with the appropriate British Standards, codes of practice and other approved standards current at the date of tender except where the requirements of these standards or codes of practice are in conflict with this Section in which case the requirements of this Section shall take precedence.

1.3.2

Sources of Supply

1

The sources of supply of materials shall not be changed without prior approval.

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Table 1.1

Driven segmental concrete piles

Driven cast-in-place concrete piles

Bored cast-in-place concrete piles

Continuous flight auger concrete or grout piles

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Nominal cross-sectional dimensions or diameter

*

*

*

*

*

Nominal diameter of underream/base

-

-

-

*

-

Length of preformed pile

*

*

-

-

-

Standing groundwater level from direct observation or given site investigation data.

-

-

*

*

*

Date and time of driving, redriving or boring

*

*

*

*

*

Date of concreting

-

-

*

*

*

Ground level/sea bed level at pile position at commencement of installation of pile (commencing surface)

*

*

*

*

*

Working elevation of pile driver

*

*

*

*

*

Depth from ground level at pile position to pile tip

*

*

*

*

*

Tip elevation

*

*

*

*

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Driven steel, precast concrete and steel sheet piles

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Records to be Kept (Indicated by an Asterisk)

Contract

Pile type

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Pile reference number (location)



Pile head elevation, as constructed

*

*

*

*

*

Pile cut-off elevation

*

*

*

*

*

Length of temporary casing

-

-

*

*

-

Length of permanent casing

-

-

*

*

-

Type, weight, drop and mechanical condition of hammer and equivalent information for other equipment

*

*

*

-

-

Number and type of packings used and type and condition of dolly used during driving of the pile

*

*

-

-

*

*

-

-

*

ta

Set of pile or pile tube in millimetres per 10 blows or number of blows per 25 mm of penetration

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Data

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Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work Driven steel, precast concrete and steel sheet piles

QCS 2014

*

*

*

-

-

If required, temporary compression of ground and pile from time of a marked increase in driving resistance until pile reached its final level

*

*

*

-

-

*

*

*

-

-

Soil samples taken and in-situ tests carried out during pile installation

*

*

*

*

*

Length and details of reinforcements

-

-

*

*

*

Concrete mix

-

-

*

*

*

-

-

*

*

*

*

*

*

*

*

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If required, the sets taken at intervals during the last 3 m of driving

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If required, driving resistance taken at regular intervals over the last 3 m of driving

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Volume of concrete supplied to pile obstructions

delays

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All information regarding interruptions to the work

and

other

1.3.3

Rejected materials

1

Rejected materials are to be removed promptly from the Site.

1.4

INSTALLATION TOLERANCES

1.4.1

Setting Out

1

Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at pile positions, as required by the Contract, shall be located by the Contractor from the main grid lines of the proposed structure. Before installation of the pile, the pile position relative to the main grid lines shall be verified.

QCS 2014


Page 6

Position

1

For a pile cut off at or above ground level the maximum permitted deviation of the pile centre from the centre-point shown on the drawings shall be 75 mm in any direction. An additional tolerance for a pile head cut off below ground level will be permitted in accordance with Clauses 1.4.3 and 1.4.4.

1.4.3

Verticality

1

At the commencement of installation, the pile, or pile-forming equipment in the case of a driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the finished pile from the vertical is 1 in 75.

1.4.4

Rake

1

As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The piling rig shall be set and maintained to attain the required rake. The maximum permitted deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.

1.4.5

Tolerance Variations

1

In exceptional circumstances where these tolerances are difficult to achieve, the tolerances of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of the implications of such action.

1.4.6

Forcible Corrections to Pile

1

Forcible corrections to concrete piles to overcome errors of position or alignment shall not be made. Forcible corrections may be made to other piles only if approved and where the pile shaft is not fully embedded in the soil.

1.5

NUISANCE AND DAMAGE

1.5.1

Noise and Disturbance

1

The Contractor shall carry out the work in such a manner and at such times as to minimise noise, vibration and other disturbance in order to comply with current environmental legislation.

2

The Contractor shall endeavour to ascertain the nature and levels of noise produced by the mechanical equipment and plant that will be used. He shall than take steps to reduce either the level or the annoying characteristics, or both, of the noise. Reference should be made to BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to piling operations.

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1.4.2

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Damage to Adjacent Structures

1

If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services or adjacent structures, he shall submit to the Engineer his proposals for making preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding such damage.

1.5.3

Damage to Piles

1

The Contractor shall ensure that during the course of the work, displacement or damage which would impair either performance or durability does not occur to completed piles.

2

The Contractor shall submit to the Engineer his proposed sequence and timing for driving or boring piles, having the intent of avoiding damage to adjacent piles.

1.5.4

Temporary Support

1

The Contractor shall ensure that where required, any permanently free-standing piles are temporarily braced or stayed immediately after driving to prevent loosening of the piles in the ground and to ensure that the pile will not be damaged by oscillation, vibration or ground movement.

1.6

SAFETY

1.6.1

General

1

A competent person, properly qualified and experienced, should be appointed to supervise the piling operations. This person should be capable of recognising and assessing any potential dangers as they arise; e.g., unexpected ground conditions that may require a change in construction technique, or unusual smells which may indicate the presence of noxious or dangerous gases.

2

Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN 1997. Refer Section 1 for general safety standards to be adopted at a construction site.

1.6.2

Life-Saving Appliances

1

The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and available for use at all times.

2

Site operatives shall be instructed in the use of safety equipment and periodic drills shall be held to ensure that all necessary procedures can be correctly observed.

1.6.3

Driving

1

Before any pile driving is started, the Contractor shall supply the Engineer with two copies of the code of signals to be employed, and shall have a copy of the code prominently displayed adjacent to the driving control station on the craft, structure or site from which the piles will be driven.

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1.5.2

END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 02: Concrete Works for Piling

Page 1

CONCRETE WORKS FOR PILING ......................................................................... 2

2.1 2.1.1 2.1.2


2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

MATERIALS ............................................................................................................ 2 Cementitious 2 Aggregate 2 Water 2 Admixtures 2 Steel Reinforcement and Prestressing Steel 2

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

CONCRETE MIXES FOR PILING WORK ............................................................... 3 General 3 Grade Designation 3 Designed Mix 3 Durability 3 Exposure Classes 3

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7

PLACING CONCRETE ............................................................................................ 3 General 3 Inspection 4 Cleanliness of Pile Bases 4 Workability of Concrete 4 Compaction 4 Placing Concrete in Dry Borings 5 Placing Concrete under Water or Drilling Fluid 5

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CONCRETE WORKS FOR PILING

2.1

GENERAL

2.1.1

Scope

1

This part applies to cast in-situ as well as precast concrete work.

2


Section 5

Concrete.

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This Section Part 1, Part 3 Part 4 Part 5

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Page 2

References

1

The following Standards are referred to in this Part:

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All Standards mentioned in Section 5

MATERIALS

2.2.1

Cementitious

1

All cementitious materials shall comply with the requirements of Section 5, Part 3.

2

All cementitious materials shall be stored in separate containers according to type in waterproof stores or silos.

2.2.2

Aggregate

1

Aggregates shall comply with the requirements of Section 5, Part 2.

2.2.3

Water

1

If water for the Works is not available from a public supply, approval shall be obtained regarding the source of water. For quality of water refer to Section 5, Part 4.

2.2.4

Admixtures

1

Admixtures shall comply with the requirements of Section 5, Part 5

2.2.5

Steel Reinforcement and Prestressing Steel

1

Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free from loose rust and loose mill scale when installed in the Works. For requirements of steel reinforcement refer to Section 5, Part 11.

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Page 3

The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in reinforcement shall be such that the full strength of each bar is effective across the joint and shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

3

For requirements of prestressing steel refer to Section 5, Part 18.

2.3

CONCRETE MIXES FOR PILING WORK

2.3.1

General

1

For general requirements of concrete mixes, trial mixes, batching, mixing and transportation of fresh concrete and testing of hardened concrete refer to Section 5.

2.3.2

Grade Designation

1

Grades of concrete shall be as given in Section 5, Part 6.

2.3.3

Designed Mix

1

The Contractor shall be responsible for selecting the mix proportions to achieve the required strength and workability..

2

Complete information on the mix and sources of aggregate for each grade of concrete and the water/cementitious ratio and the proposed degree of workability shall be approved before work commences.

3

Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.

4

The Contractor shall submit the slump value for approval before work commences.

2.3.4

Durability

1

For piles exposed to aggressive ground or groundwater, approved measures shall be taken to ensure durability. Reference shall be made to Section 5, Part 6.

2.3.5

Exposure Classes

1

The minimum cementitious content and type and the concrete grades shall be specified based on the exposure classes as given in Table 6.8, Section 5, Part 6.

2.4

PLACING CONCRETE

2.4.1

General

1

The workability and method of placing and vibrating the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed.

2

The concrete shall be placed without such interruption as would produce a cold joint in the pile. The method of placing shall be approved.

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Page 4

3

The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter which would adversely affect the performance of the pile shall be permitted to contaminate the concrete.

2.4.2

Inspection

1

Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly before to concrete is placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided by the

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Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 8008. Cleanliness of Pile Bases

1

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the concrete shall be placed by tremie method. Large debris or accumulated sediment, or both of them, shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

2.4.4

Workability of Concrete

1

Slump measured at the time of discharge into the pile bore shall be in accordance with the standards shown in Table 2.1.

2.4.5

Compaction

1

Internal vibrators may be used to compact concrete, with the approval of the Engineer obtained in advance for each specific use.

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2.4.3

Piling mix workability

Table 2.1 Standards for Concrete Slump Slump Minimum

Range

mm

mm

Typical conditions of use

A

75

75-150

Placed into water-free unlined or permanently lined bore of 600 mm diameter or over, or where concrete is placed below temporary casing, and where reinforcement is widely spaced leaving ample room for free movement of concrete between bars.

B

100

100-200

Where reinforcement is not spaced widely, where concrete is placed within temporary casings, where pile bore is water-free, and the diameter less than 600 mm

C

150

150 or more

Where concrete is to be placed by tremie under water or drilling mud, or by pumping

QCS 2014


Page 5

Placing Concrete in Dry Borings

1

Approved measures shall be taken to ensure that the structural strength of the concrete placed in all piles is not impaired through grout loss, segregation or bleeding.

2

Concrete shall be placed by “elephant trunk”, and the free fall shall not exceed 1.2 m.

2.4.7

Placing Concrete under Water or Drilling Fluid

1

Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure that there is no accumulation of silt or other material at the base of the boring, and the Contractor shall ensure that heavily contaminated bentonite suspension, which could impair the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

2

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be discharged freely into the water or drilling fluid. Pumping of concrete may be approved where appropriate.

3

A sample of the bentonite suspension shall be taken from the base of the boring using an approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing of concrete shall not proceed. In this event the Contractor shall modify or replace the bentonite as approved to meet the specification.

4

The concrete shall be a rich, coherent mix and highly workable, and cement content shall be in accordance with Clause 2.3.5.

5

The concrete shall be placed in such a manner that segregation does not occur.

6

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of concrete in the tremie and the water or drilling fluid. The pipe shall at all times penetrate the concrete which has previously been placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of 2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of

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2.4.6

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concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than 150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that external projections are minimised, allowing the tremie to pass within reinforcing cages without causing damage. The internal face of the pipe of the tremie shall be free from projections. END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

Page 1

SHALLOW FOUNDATIONS .................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4

GENERAL ............................................................................................................... 2 Scope 2 Definition 2 References 2 Limit States Considerations 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

DESIGN CONSIDERATIONS .................................................................................. 3 General 3 Allowable Bearing Pressure 3 Selection of Types of Shallow Foundation 3 Pad foundations 4 Strip foundations 4 Raft foundations 5

3.3 3.3.1 3.3.2 3.3.3

BASIS OF GEOTECHNICAL DESIGN .................................................................... 5 Design Requirements 5 Design Situations 7 Durability 8

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9 General 9 Actions 10 Ground Properties 12 Geometrical Data 13 Characteristic and Representative Values of Actions 13 Characteristic Values of Geotechnical Parameters 13 Characteristic Values of Geometrical Data 14 Geotechnical Design Report 14 Actions and Design Situations 15 Design and Construction Considerations 15 Foundations on Rock; Additional Design Considerations 16

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Page 2

SHALLOW FOUNDATIONS

3.1

GENERAL

3.1.1

Scope

1

The provisions of this Section apply to shallow foundations including isolated, pads, strips and rafts.

3.1.2

Definition

1

Shallow foundations are taken to be those where the depth below finished ground level is less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed as deep foundations.

3.1.3

References

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BS 8004,.....................Code of practice for foundations.

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BS EN 1990................Eurocode 0: Basis of Structural Design BS EN 1991................Eurocode 1: Actions on structures BS EN 1992................Eurocode 2: Design of concrete structures -

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BS EN 1993................Eurocode 3: Design of steel structures

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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures BS EN 1995................Eurocode 5: Design of timber structures

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BS EN 1996................Eurocode 6: Design of masonry structures

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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and testing

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BS EN 1998................Eurocode 8: Design of structures for earthquake resistance

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BS 5930......................Code of Practice for Site Investigation Limit States Considerations

1

The following limit states shall be considered and an appropriate list shall be compiled:

m

3.1.4

(a)

Loss of overall stability;

(b)

Bearing resistance failure, punching failure, squeezing;

(c)

Failure by sliding;

(d)

Combined failure in the ground and in the structure;

(e)

Structural failure due to foundation movement;

(f)

Excessive settlements;

(g)

Excessive heave due to swelling, frost and other causes;

(h)

Unacceptable vibrations.

QCS 2014


Page 3

3.2

DESIGN CONSIDERATIONS

3.2.1

General

1

The depth to which foundations should be carried depends on two principal factors: (a)

Reaching an adequate bearing stratum;

(b)

Penetration below the zone in which trouble may be expected from seasonal weather changes.

Other factors such as ground movements, changes in groundwater conditions, long-term stability and heat transmitted from structures to the supporting ground may be important.

3

Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be sought where such conditions are indicated by ground investigation.

3.2.2

Allowable Bearing Pressure

1

The center of area of a foundation or group of foundations should be arranged vertically under the centre of gravity of the imposed loading. If this is not possible, the effects on the structure of rotation and settlement of the foundation need to be considered.

2

Where foundation support is provided by a number of separate bases these should, as far as practicable, be proportioned so that differential settlement is minimal.

3.2.3

Selection of Types of Shallow Foundation

1

The selection of the appropriate type of shallow foundation will normally depend on the magnitude and disposition of the structural loads, the bearing capacity and settlement characteristics of the ground and the need to found in stable soil.

2

A pad foundation is used for the purpose of distributing concentrated loads. Unless special conditions control the design, relatively heavy column loads make it advantageous to use pad foundations.

3

Strip foundations may be more appropriate where column loads are comparatively small and closely spaced or where walls are heavy or heavily loaded.

4

Adjacent pad foundations can be combined or joined together with ground beams to support eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns may be carried on ground beams spanning between the pad foundations.

5

Where the allowable bearing pressure would result in large isolated foundations occupying the majority of the available area, it may be logical to join them to form a raft and spread the loads over the entire area. The combination of isolated foundations to form a raft sometimes results in a complex design and a large increase in the reinforcement requirement.

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Page 4

In connection with the provision of foundations to an extension of an existing building, allowance should be made for differential movement of the foundations between the new and existing structure; such movement affects the structure above foundations. Where a degree of cracking and subsequent remedial work is not acceptable, provision for a joint between the extension and existing building should be considered. Where the foundations of an extension about the foundations of the existing building, the stability of the existing foundations should be ensured.

3.2.4

Pad foundations

1

For buildings such as low rise dwellings and lightly framed structures, pad foundations may be of unreinforced concrete provided that the angle of spread of load from the pier or base plate to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal) and that the stresses in the concrete due to bending and shear do not exceed tolerable limits. For buildings other than low rise and lightly framed structures, it is customary to use reinforced concrete foundations.

2

The thickness of the foundation should under no circumstances be less than 150 mm and will generally be greater than this to maintain cover to reinforcement where provided.

3

Where concrete foundations are used they should be designed in accordance with the design method appropriate to the loading assumptions.

3.2.5

Strip foundations

1

Similar considerations to those for pad foundations apply to strip foundations. On sloping sites strip foundations should be on a horizontal bearing, stepped where necessary to maintain adequate depth.

2

In continuous wall foundations it is recommended that reinforcement be provided wherever an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall foundations will normally be constructed in mass concrete provided that the angle of spread of load from the edge of the wall base to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where regarding is likely to take place, may require to be designed as retaining walls to accommodate steps between adjacent ground floor slabs or finished ground levels. At all changes of level unreinforced foundations should be lapped at the steps for a distance at least equal to the thickness of the foundation or a minimum of 300mm. Where the height of the step exceeds the thickness of the foundation, special precautions should be taken. The thickness of reinforced strip foundations should be not less than 150mm, and care should be taken with the excavation levels to ensure that this minimum thickness is maintained. For the longitudinal spread of loads, sufficient reinforcement should be provided to withstand the tensions induced. It will sometimes be desirable to make strip foundations of inverted tee beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners and junctions the longitudinal reinforcement of each wall foundation should be lapped.

3

Where the use of ordinary strip foundations would overstress the bearing strata, wide strip foundations designed to transmit the foundation loads across the full width of the strip may be used. The depth below the finished ground level should be the same as for ordinary strip foundations.

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Where the nature of the ground is such that narrow trenches can be neatly cut down to the bearing stratum, an economical foundation may be achieved by filling the trenches with concrete. When deciding the trench width, account should be taken of normal building tolerances in relation to setting out dimensions. Where the thickness of such a foundation is 500mm or more, any step should be not greater than the concrete thickness and the lap at such a step should be at least 1 m or twice the step height, whichever is the greater?

5

Where fill or other loose materials occur above the bearing stratum adequate support is required to any excavation. Consideration may be given to the use of lean mix mass concrete replacement under ordinary strip footings placed at shallow depth. This mass concrete can be poured against either permanent or recoverable shuttering. This form of foundation provides a method of dealing with local areas where deeper foundations are required.

3.2.6

Raft foundations

1

General. Suitably designed raft foundations may be used in the following circumstances.

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For lightly loaded structures on soft natural ground where it is necessary to spread the load, or where there is variable support due to natural variations, made ground or weaker zones. In this case the function of the raft is to act as a bridge across the weaker zones. Rafts may form part of compensated foundations.

(b)

Where differential settlements are likely to be significant. The raft will require special design, involving an assessment of the disposition and distribution of loads, contact pressures and stiffness of the soil and raft.

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BASIS OF GEOTECHNICAL DESIGN

3.3.1

Design Requirements

1

For each geotechnical design situation it shall be verified that no relevant limit state is exceeded.

2

When defining the design situations and the limit states, the following factors should be considered: Site conditions with respect to overall stability and ground movements;

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(b)

Nature and size of the structure and its elements, including any special requirements such as the design life;

(c)

Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities, vegetation, hazardous chemicals);

(d)

Ground conditions;

(e)

Ground-water conditions;

(f)

Regional seismicity;

(g)

Influence of the environment (hydrology, surface water, subsidence, seasonal changes of temperature and moisture).

Limit states can occur either in the ground or in the structure or by combined failure in the structure and the ground.

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Limit states should be verified by any appropriate method such as calculation method as described in 3.4;

5

In practice, experience will often show which type of limit state will govern the design and the avoidance of other limit states may be verified by a control check.

6

Buildings should normally be protected against the penetration of ground-water or the transmission of vapor or gases to their interiors.

7

If practicable, the design results should be checked against comparable experience.

8

In order to establish minimum requirements for the extent and content of geotechnical investigations, calculations and construction control checks, the complexity of each geotechnical design shall be identified together with the associated risks. In particular, a distinction shall be made between:

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L ight and simple structures and small earthworks for which it is possible to ensure that the minimum requirements will be satisfied by experience and qualitative geotechnical investigations, with negligible risk;

(b)

Other geotechnical structures.

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For structures and earthworks of low geotechnical complexity and risk, such as defined above, simplified design procedures may be applied.

10

To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3, may be introduced.

11

A preliminary classification of a structure according to Geotechnical Category should normally be performed prior to the geotechnical investigations. The category should be checked and changed, if necessary, at each stage of the design and construction process.

12

The procedures of higher categories may be used to justify more economic designs, or if the designer considers them to be appropriate.

13

The various design aspects of a project can require treatment in different Geotechnical Categories. It is not required to treat the whole of the project according to the highest of these categories.

14

Geotechnical Category 1 should only include small and relatively simple structures:

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(a)

For which it is possible to ensure that the fundamental requirements will be satisfied on the basis of experience and qualitative geotechnical investigations;

(b)

With negligible risk.

15

Geotechnical Category 1 procedures should be used only where there is negligible risk in terms of overall stability or ground movements and in ground conditions, which are known from comparable local experience to be sufficiently straightforward. In these cases the procedures may consist of routine methods for foundation design and construction.

16

Geotechnical Category 1 procedures should be used only if there is no excavation below the water table or if comparable local experience indicates that a proposed excavation below the water table will be straightforward.

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17

Geotechnical Category 2 should include conventional types of structure and foundation with no exceptional risk or difficult soil or loading conditions

18

Designs for structures in Geotechnical Category 2 should normally include quantitative geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

19

Routine procedures for field and laboratory testing and for design and execution may be used for Geotechnical Category 2 designs. the following are examples of conventional structures or parts of structures complying with Geotechnical Category 2: Shallow foundations;

(ii)

Pile foundations;

(iii)

Walls and other structures retaining or supporting soil or water;

(iv)

Excavations;

(v)

Bridge piers and abutments;

(vi)

Embankments and earthworks;

(vii)

Ground anchors and other tie-back systems;

(viii)

Tunnels in hard, non-fractured rock and not subjected to special water tightness or other requirements.

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Geotechnical Category 3 should include structures or parts of structures, which fall outside the limits of Geotechnical Categories 1 and 2.

21

Geotechnical Category 3 should normally include alternative provisions and rules to those in this standard. Geotechnical Category 3 includes the following examples: Very large or unusual structures;

(ii)

Structures involving abnormal risks, or unusual or exceptionally difficult ground or loading conditions;

(iii)

Structures in highly seismic areas;

(iv)

Structures in areas of probable site instability or persistent ground movements that require separate investigation or special measures.

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3.3.2

Design Situations

1

Both short-term and long-term design situations shall be considered.

2

In geotechnical design, the detailed specifications of design situations should include, as appropriate: (a)

The actions, their combinations and load cases;

(b)

The general suitability of the ground on which the structure is located with respect to overall stability and ground movements;

(c)

The disposition and classification of the various zones of soil, rock and elements of construction, which are involved in any calculation model;

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(d)

Dipping bedding planes;

(e)

Mine workings, caves or other underground structures;

(f)

In the case of structures resting on or near rock: (i)

inter bedded hard and soft strata;

(ii)

faults, joints and fissures;

(iii)

possible instability of rock blocks;

(iv)

solution cavities, such as swallow holes or fissures filled with soft material, and continuing solution processes;

The environment within which the design is set, including the following: (i)

effects of scour, erosion and excavation, leading to changes in the geometry of the ground surface;

(ii)

effects of chemical corrosion;

(iii)

effects of weathering;

(iv)

effects of long duration droughts;

(v)

variations in ground-water levels, including, e.g. the effects of dewatering, possible flooding, failure of drainage systems, water exploitation;

(vi)

the presence of gases emerging from the ground;

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Earthquakes;

(i)

Ground movements caused by subsidence due to mining or other activities;

(j)

The sensitivity of the structure to deformations;

(k)

The effect of the new structure on existing structures, services and the local environment.

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Durability

1

At the geotechnical design stage, the significance of environmental conditions shall be assessed in relation to durability and to enable provisions to be made for the protection or adequate resistance of the materials.

2

In designing for durability of materials used in the ground, the following should be considered:

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(a)

For concrete: (i)

(b)

Aggressive agents in the ground-water or in the ground or fill material, such as acids or sulfate salts;

For steel: (i)

Chemical attack where foundation elements are buried in ground that is sufficiently permeable to allow the percolation of ground-water and oxygen;

(ii)

Corrosion on the faces of sheet pile walls exposed to free water, particularly in the mean water level zone;

(iii)

The pitting type of corrosive attack on steel embedded in fissured or porous concrete, particularly for rolled steel where the mill scale, acting as a cathode, promotes electrolytic action with the scale-free surface acting as an anode;

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(c)

Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations For timber: (i)

(d)

Page 9

Fungi and aerobic bacteria in the presence of oxygen;

For synthetic fabrics: (i)

The ageing effects of UV exposure or ozone degradation or the combined effects of temperature and stress, and secondary effects due to chemical degradation.

Reference should be made to durability provisions in construction materials standards.

3.4

GEOTECHNICAL DESIGN BY CALCULATION

3.4.1

General

1

Design by calculation shall be in accordance with the fundamental requirements of EN 1990 and with the particular rules of this specification. Design by calculation involves:

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Actions, which may be either imposed loads or imposed displacements, e.g. from ground movements;

(b)

Properties of soils, rocks and other materials;

(c)

Geometrical data;

(d)

Limiting values of deformations, crack widths, vibrations etc;

(e)

Calculation models.

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It should be considered that knowledge of the ground conditions depends on the extent and quality of the geotechnical investigations. Such knowledge and the control of workmanship are usually more significant to fulfilling the fundamental requirements than is precision in the calculation models and partial factors.

3

The calculation model shall describe the assumed behavior of the ground for the limit state under consideration.

4

If no reliable calculation model is available for a specific limit state, analysis of another limit state shall be carried out using factors to ensure that exceeding the specific limit state considered is sufficiently improbable. Alternatively, design by prescriptive measures, experimental models and load tests, or the observational method, shall be performed.

5

The calculation model may consist of any of the following:

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(a)

An analytical model;

(b)

A semi-empirical model;

(c)

A numerical model.

6

Any calculation model shall be either accurate or err on the side of safety.

7

A calculation model may include simplifications.

8

If needed, a modification of the results from the model may be used to ensure that the design calculation is either accurate or errs on the side of safety.

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If the modification of the results makes use of a model factor, it should take account of the following: (a)

The range of uncertainty in the results of the method of analysis;

(b)

Any systematic errors known to be associated with the method of analysis.

10

If an empirical relationship is used in the analysis, it shall be clearly established that it is relevant for the prevailing ground conditions.

11

Limit states involving the formation of a mechanism in the ground should be readily checked using a calculation model. For limit states defined by deformation considerations, the deformations should be evaluated by calculation or otherwise assessed.

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NOTE: many calculation models are based on the assumption of a sufficiently ductile performance of the ground/structure system. A lack of ductility, however, will lead to an ultimate limit state characterized by sudden collapse. Numerical methods can be appropriate if compatibility of strains or the interaction between the structure and the soil at a limit state are considered.

13

Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for the relative stiffness of structure and ground, may be needed in cases where a combined failure of structural members and the ground could occur. Examples include raft foundations, laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain compatibility for materials that are brittle or that have strain-softening properties.

14

In some problems, such as excavations supported by anchored or strutted flexible walls, the magnitude and distribution of earth pressures, internal structural forces and bending moments depend to a great extent on the stiffness of the structure, the stiffness and strength of the ground and the state of stress in the ground.

15

In these problems of ground-structure interaction, analyses should use stress-strain relationships for ground and structural materials and stress states in the ground that are sufficiently representative, for the limit state considered, to give a safe result.

3.4.2

Actions

1

The definition of actions shall be taken as:

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(a)

Set of forces (loads) applied to the structure (direct action);

(b)

Set of imposed deformations or accelerations caused for example, by temperature changes, moisture variation, uneven settlement or earthquakes (indirect action).

The values of actions shall be taken from EN 1991 or equivalent international standard, where relevant. 2

The values of geotechnical actions to be used shall be selected, since they are known before a calculation is performed; they may change during that calculation. NOTE: Values of geotechnical actions may change during the course of calculation. In such cases they will be introduced as a first estimate to start the calculation with a preliminary, known value.

3

Any interaction between the structure and the ground shall be taken into account when determining the actions to be adopted in the design.

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In geotechnical design, the following should be considered for inclusion as actions: the weight of soil, rock and water;

(b)

stresses in the ground;

(c)

earth pressures and ground-water pressure;

(d)

free water pressures, including wave pressures;

(e)

ground-water pressures;

(f)

seepage forces;

(g)

dead and imposed loads from structures;

(h)

surcharges;

(i)

mooring forces;

(j)

removal of load or excavation of ground;

(k)

traffic loads;

(l)

movements caused by mining or other caving or tunneling activities;

(m)

swelling and shrinkage caused by vegetation, climate or moisture changes;

(n)

movements due to creeping or sliding or settling ground masses;

(o)

movements due to degradation, dispersion, decomposition, self-compaction and solution;

(p)

movements and accelerations caused by earthquakes, explosions, vibrations and dynamic loads;

(q)

temperature effects, including frost action;

(r)

imposed pre-stress in ground anchors or struts;

(s)

down drag.

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Consideration shall be given to the possibility of variable actions occurring both jointly and separately.

6

The duration of actions shall be considered with reference to time effects in the material properties of the soil, especially the drainage properties and compressibility of fine-grained soils.

7

Actions, which are applied repeatedly, and actions with variable intensity shall be identified for special consideration with regard to, e.g. continuing movements, liquefaction of soils, change of ground stiffness and strength.

8

Actions that produce a dynamic response in the structure and the ground shall be identified for special consideration.

9

Actions in which ground- and free-water forces predominate shall be identified for special consideration with regard to deformations, fissuring, variable permeability and erosion.

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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in some situations be considered as coming from a single source. If they are considered so, a single partial factor may be applied to the sum of these actions or to the sum of their effects.

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Ground Properties

1

Properties of soil and rock masses, as quantified for design calculations by geotechnical parameters, shall be obtained from test results, either directly or through correlation, theory or empiricism, and from other relevant data.

2

Values obtained from test results and other data shall be interpreted appropriately for the limit state considered.

3

Account shall be taken of the possible differences between the ground properties and geotechnical parameters obtained from test results and those governing the behavior of the geotechnical structure.

4

The above differences can be due to the following factors: many geotechnical parameters are not true constants but depend on stress level and mode of deformation;

(b)

soil and rock structure (e.g. fissures, laminations, or large particles) that may play a different role in the test and in the geotechnical structure;

(c)

time effects;

(d)

the softening effect of percolating water on soil or rock strength;

(e)

the softening effect of dynamic actions;

(f)

the brittleness or ductility of the soil and rock tested;

(g)

the method of installation of the geotechnical structure;

(h)

the influence of workmanship on artificially placed or improved ground;

(i)

the effect of construction activities on the properties of the ground.

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When establishing values of geotechnical parameters, the following should be considered:

the value of each geotechnical parameter compared with relevant published data and local and general experience;

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published and well recognized information relevant to the use of each type of test in the appropriate ground conditions;

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(c)

the variation of the geotechnical parameters that are relevant to the design;

(d)

the results of any large scale field trials and measurements from neighboring constructions;

(e)

any correlations between the results from more than one type of test;

(f)

any significant deterioration in ground material properties that may occur during the lifetime of the structure.

Calibration factors shall be applied where necessary to convert laboratory or field test results according to EN 1997-2 into values that represent the behavior of the soil and rock in the ground, for the actual limit state, or to take account of correlations used to obtain derived values from the test results.

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Geometrical Data

1

The level and slope of the ground surface, water levels, levels of interfaces between strata, excavation levels and the dimensions of the geotechnical structure shall be treated as geometrical data.

3.4.5

Characteristic and Representative Values of Actions

1

Characteristic and representative values of actions shall be derived in accordance with EN 1990:2002 and the various parts of EN 1991.

3.4.6

Characteristic Values of Geotechnical Parameters

1

The selection of characteristic values for geotechnical parameters shall be based on results and derived values from laboratory and field tests, complemented by well-established experience.

2

The characteristic value of a geotechnical parameter shall be selected as a cautious estimate of the value affecting the occurrence of the limit state.

3

The selection of characteristic values for geotechnical parameters shall take account of the following:

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geological and other background information, such as data from previous projects;

(b)

the variability of the measured property values and other relevant information, e.g. from existing knowledge;

(c)

the extent of the field and laboratory investigation;

(d)

the type and number of samples;

(e)

the extent of the zone of ground governing the behavior of the geotechnical structure at the limit state being considered;

(f)

the ability of the geotechnical structure to transfer loads from weak to strong zones in the ground.

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Characteristic values can be lower values, which are less than the most probable values, or upper values, which are greater.

5

For each calculation, the most unfavorable combination of lower and upper values of independent parameters shall be used.

6

The zone of ground governing the behavior of a geotechnical structure at a limit state is usually much larger than a test sample or the zone of ground affected in an in situ test. Consequently the value of the governing parameter is often the mean of a range of values covering a large surface or volume of the ground. The characteristic value should be a cautious estimate of this mean value.

7

If the behavior of the geotechnical structure at the limit state considered is governed by the lowest or highest value of the ground property, the characteristic value should be a cautious estimate of the lowest or highest value occurring in the zone governing the behavior.

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When selecting the zone of ground governing the behavior of a geotechnical structure at a limit state, it should be considered that this limit state may depend on the behavior of the supported structure. For instance, when considering a bearing resistance ultimate limit state for a building resting on several footings, the governing parameter should be the mean strength over each individual zone of ground under a footing, if the building is unable to resist a local failure. If, however, the building is stiff and strong enough, the governing parameter should be the mean of these mean values over the entire zone or part of the zone of ground under the building.

9

If statistical methods are employed in the selection of characteristic values for ground properties, such methods should differentiate between local and regional sampling and should allow the use of a prior knowledge of comparable ground properties.

10

If statistical methods are used, the characteristic value should be derived such that the calculated probability of a worse value governing the occurrence of the limit state under consideration is not greater than 5%.

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3.4.7

Characteristic Values of Geometrical Data

1

Characteristic values of the levels of ground and ground-water or free water shall be measured, nominal or estimated upper or lower levels.

2

Characteristic values of levels of ground and dimensions of geotechnical structures or elements should usually be nominal values.

3.4.8

Geotechnical Design Report

1

The assumptions, data, methods of calculation and results of the verification of safety and serviceability shall be recorded in the Geotechnical Design Report.

2

The level of detail of the Geotechnical Design Reports will vary greatly, depending on the type of design. For simple designs, a single sheet may be sufficient.

3

The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :

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(a)

a description of the site and surroundings;

(b)

a description of the ground conditions;

(c)

a description of the proposed construction, including actions;

(d)

design values of soil and rock properties, including justification, as appropriate;

(e)

statements on the codes and standards applied;

(f)

statements on the suitability of the site with respect to the proposed construction and the level of acceptable risks;

(g)

geotechnical design calculations and drawings;

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(h)

foundation design recommendations;

(i)

a note of items to be checked during construction or requiring maintenance or monitoring.

4

The Geotechnical Design Report shall include a plan of supervision and monitoring, as appropriate. Items, which require checking during construction or, which require maintenance after construction shall be clearly identified. When the required checks have been carried out during construction, they shall be recorded in an addendum to the Report.

5

In relation to supervision and monitoring the Geotechnical Design Report should state: the purpose of each set of observations or measurements;

(b)

the parts of the structure, which are to be monitored and the locations at which observations are to be made;

(c)

the frequency with which readings is to be taken;

(d)

the ways in which the results are to be evaluated;

(e)

the range of values within which the results are to be expected;

(f)

the period of time for which monitoring is to continue after construction is complete;

(g)

the parties responsible for making measurements and observations, for interpreting the results obtained and for maintaining the instruments.

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An extract from the Geotechnical Design Report, containing the supervision, monitoring and maintenance requirements for the completed structure, shall be provided to the owner/client.

3.4.9

Actions and Design Situations

1

Design situations shall be selected in accordance with 3.3.2.

2

The actions listed in 3.4.2(4) should be considered when selecting the limit states for calculation.

3

If structural stiffness is significant, an analysis of the interaction between the structure and the ground should be performed in order to determine the distribution of actions.

3.4.10

Design and Construction Considerations

1

When choosing the depth of a shallow foundation the following shall be considered:

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(a)

reaching an adequate bearing stratum;

(b)

the depth above which shrinkage and swelling of clay soils, due to seasonal weather changes, or to trees and shrubs, may cause appreciable movements;

(c)

the level of the water table in the ground and the problems, which may occur if excavation for the foundation is required below this level;

(d)

possible ground movements and reductions in the strength of the bearing stratum by seepage or climatic effects or by construction procedures;

(e)

the effects of excavations on nearby foundations and structures;

(f)

anticipated excavations for services close to the foundation;

(g)

high or low temperatures transmitted from the building;

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(h)

the possibility of scour;

(i)

the effects of variation of water content due to long periods of drought, and subsequent periods of rain, on the properties of volume-unstable soils in arid climatic areas;

(j)

the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

2

In addition to fulfilling the performance requirements, the design foundation width shall take account of practical considerations such as economic excavation, setting out tolerances, working space requirements and the dimensions of the wall or column supported by the foundation.

3

One of the following design methods shall be used for shallow foundations: a direct method, in which separate analyses are carried out for each limit state. When checking against an ultimate limit state, the calculation shall model as closely as possible the failure mechanism, which is envisaged. When checking against a serviceability limit state, a settlement calculation shall be used;

(b)

an indirect method using comparable experience and the results of field or laboratory measurements or observations, and chosen in relation to serviceability limit state loads so as to satisfy the requirements of all relevant limit states;

(c)

a prescriptive method in which a presumed bearing resistance is used.

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Foundations on Rock; Additional Design Considerations

1

The design of shallow foundations on rock shall take account of the following features: the deformability and strength of the rock mass and the permissible settlement of the supported structure;

(b)

the presence of any weak layers, for example solution features or fault zones, beneath the foundation;

(c)

the presence of bedding joints and other discontinuities and their characteristics (for example filling, continuity, width, spacing);

(d)

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disturbance of the natural state of the rock caused by construction activities, such as, for example, underground works or slope excavation, being near to the foundation.

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the state of weathering, decomposition and fracturing of the rock;

2

Shallow foundations on rock may normally be designed using the method of presumed bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and sandstones, the presumed bearing pressure are limited by the compressive strength of the concrete foundation.

3

The settlement of a foundation may be assessed on the basis of comparable experience related to rock mass classification. END OF PART

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 1

DEEP FOUNDATIONS ............................................................................................ 4

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4 General 4 Limit States Considerations 4 Precast Reinforced and Prestressed Concrete Piles 4 Materials and components 5 Prestressing 7 Driving Piles 8 Risen Piles 10 Repair and lengthening of piles 10 Cutting off pile heads 10

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10 Scope 10 References 11 Submittals 11 Quality Assurance 11 Tolerances in Pile Dimensions 11 Handling, Transportation, Storage and Acceptance of Piles 12 Materials and components 12 Driving piles 13 Risen Piles 14 Repair and lengthening of piles 15 Cutting off pile heads 15

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6

BORED CAST IN PLACE PILES ........................................................................... 15 Scope 15 References 16 Quality Assurance 16 Materials 16 Boring 17 Extraction of casing 19

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21 Scope 21 Materials 21 Boring 22 Placing of concrete or grout 23 Cutting off pile heads 23

4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6

DRIVEN CAST IN PLACES PILES ........................................................................ 23 Scope 23 Submittals 24 Quality Assurance 24 Materials 24 Driving piles 25 Risen Piles 26

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Extraction of casing

26

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11

STEEL PILES ........................................................................................................ 28 Scope 28 References 28 Submittals 28 Quality Assurance 28 Delivery, Storage and Handling 29 Materials 29 Acceptance Standards For Welds 30 Acceptability and inspection of coatings 31 Driving of piles 31 Risen Piles 33 Preparation of pile heads 33

4.7

MICROPILES (TO BE ADDED LATER) ................................................................. 33

4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5

REDUCTION OF FRICTION ON PILES ................................................................ 33 Scope 33 Submittals 33 Friction Reducing Methods 33 Inspection 34 Driving resistance 35

4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.9.7 4.9.8

PILE LOAD TESTING ........................................................................................... 35 Static Load Testing of Piles 35 Presentation of results 45 Low strain Integrity test 47 Grosshole Sonic Logging Test 48 Calliper Logging Test 48 Axial Tensile Load Test 48 Lateral Load Test 48 Alternative Methods for Testing Piles 48

4.10 4.10.1 4.10.2 4.10.3

DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51 Design method 51 Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations 51 Design Considerations 51

4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 4.11.10

AXIALLY LOADED PILES ..................................................................................... 52 Limit state design 52 Compressive Ground Resistance 53 Ultimate compressive resistance from static load tests 54 Ultimate compressive resistance from ground test results 55 Ultimate compressive resistance from dynamic impact tests 56 Ultimate compressive resistance by applying pile driving formulae 56 Ultimate compressive resistance from wave equation analysis 56 Ground tensile resistance 57 Ultimate tensile resistance from pile load tests 57 Ultimate tensile resistance from ground test results 57

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4.5.7

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4.11.11 Vertical displacements of pile foundations 4.11.12 Pile foundations in compression 4.11.13 Pile foundations in tension

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TRANSVERSELY LOADED PILES ....................................................................... 58 Design method 58 Transverse load resistance from pile load tests 59 Transverse load resistance from ground test results and pile strength parameters 59 Transverse displacement 60

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4.12 4.12.1 4.12.2 4.12.3 4.12.4

58 58 58

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DEEP FOUNDATIONS

4.1

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

4.1.1

General

1

The provisions of this Part apply to end-bearing piles, friction piles, tension piles and transversely loaded piles installed by driving, by jacking, and by screwing or boring with or without grouting.

4.1.2

Limit States Considerations

1


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(b)

bearing resistance failure of the pile foundation;

(c)

Uplift or insufficient tensile resistance of the pile foundation;

(d)

Failure in the ground due to transverse loading of the pile foundation;

(e)

Structural failure of the pile in compression, tension, bending, buckling or shear;

(f)

combined failure in the ground and in the pile foundation;

(g)

combined failure in the ground and in the structure;

(h)

Excessive settlement;

(i)

Excessive heave;

(j)

Excessive lateral movement;

(k)


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(a)

Precast Reinforced and Prestressed Concrete Piles

1

Scope

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This Part applies to precast concrete driven piles usually supplied for use in a single length without facility for joining lengths together.

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4.1.3

(b) 2


References (a)


BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes BS 2789,.....................Spheroidal graphite or nodular graphite cast iron BS 8110,.....................Structural use of concrete. 3

Submittals (a)

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified, the approval of the piles for the main work will not necessarily be given until the results of the driving and loading tests on preliminary piles have been received and evaluated.

QCS 2014

4

Page 5

Quality Assurance (a)

5


After a pile has been cast, the date of casting, reference number, length and, where appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall be marked at the proper locations on each pile.

Tolerances in Pile Dimensions (a)

The cross-sectional dimensions of the pile shall be not less than those specified and shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any cross section along its length deviate by more

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than 1/500 of the pile length from a line joining the centres of area at the ends of the pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

Handling, Transportation and Storage of Piles

The method and sequence of lifting, handling, and storage of piles transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only the designated lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

(b)

All piles within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

(c)

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the lesser. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the agreement of the Engineer.

(d)

Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The

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be reduced below 6 mm on a pro rata basis in accordance with actual length.

measurement shall be made with the pile in its working attitude.

Materials and components

1

Fabricated Steel Components

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4.1.4

(a)

2

Pile Toes (a)

3

In the manufacture of precast concrete piles, fabricated steel components shall comply with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where positional fixity is required on an inclined rock surface or in other circumstances, an approved shoe may be required.

Pile Head Reinforcement (a)

The head of each pile shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

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Page 6

Main Reinforcement (a)

The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one continuous length unless otherwise specified. In piles more than 12 m long, lap splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no more than 25 % of the bars lapped at one location, and laps staggered by a minimum of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is effective across the joint. Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.

(c)

Sufficient reinforcement shall be provided for lifting and handling purposes.

Unless otherwise agreed by the Engineer, concrete shall be compacted with the assistance of vibrators. Internal vibrators shall be capable of producing not less than 150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not

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(a)

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Concrete

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closer than 75 mm to shuttering.

Vibrators shall be operated in such a manner that neither segregation of the concrete mix constituents nor displacement of reinforcement occurs.

(c)

Immediately after compaction, concrete shall he adequately protected from the harmful effects of the weather, including wind, rain, rapid temperature changes and frost. It shall be protected from drying out by an approved method of curing.

(d)

Piles shall not be removed from formwork until a sufficient pile concrete strength has been achieved to allow the pile to be handled without damage.

(e)

The period of curing at an ambient temperature of 10 °C shall not be less than that

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(b)

shown in Table 4.1. If the temperature is greater or less than 10 °C, the periods given

When steam or accelerated curing is used the curing procedure shall be approved. Four hours must elapse from the completion of placing concrete before the temperature is raised. The rise in temperature within any period of 30 min shall not exceed 10 °C and the maximum temperature attained shall not exceed 70 °C. The rate

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shall be adjusted accordingly and shall be approved.

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5

(b)

of subsequent cooling shall not exceed the rate of heating. Table 4.1 Period of Curing at 10 °C Type of cement

Wet curing time after completion of placing concrete, d

Ordinary Portland

4

Sulphate-resisting Portland

4

Portland blast-furnace

4

Super-sulphated

4

Rapid-hardening Portland

3

QCS 2014

6


Page 7

Formwork (a)

shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(b)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections, free from defects. The piles are to be removed from the formwork carefully so as to prevent damage.

4.1.5

Prestressing

1

General Tensioning shall be carried out only when the Engineer is present, unless otherwise approved. In cases where piles are manufactured off site, the Contractor shall ensure that the Engineer is given adequate notice and every facility for inspecting the manufacturing process.

(b)

Prestressing operations shall be carried out only under the direction of an experienced and competent supervisor. All personnel operating the stressing equipment shall have been trained in its use.

(c)

The calculated extensions and total forces, including allowance for losses, shall be agreed with the Engineer before stressing is commenced.

(d)

Stressing of tendons and transfer of prestress shall be carried out at a gradual and steady rate. The force in the tendons shall be obtained from readings on a recently calibrated load cell or pressure gauge incorporated in the equipment. The extension of the tendons under the agreed total forces shall be within 5 % of the agreed calculated extension.

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Concrete Strength

The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to be able to demonstrate by testing two cubes at a time, with approved intervals between pairs of cubes, that the specified transfer strength of the concrete has been reached.

(b)

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Post-Tensioned Piles (a)

4

Unless otherwise permitted, concrete shall not be stressed until two test cubes attain the specified transfer strength.

Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

Grouting Procedure (a)

Grout shall be mixed for a minimum of 2 min and until a uniform consistency is obtained.

(b)

Ducts shall not be grouted when the air temperature in the shade is lower than 3 °C.

(c)

Before grouting is started all ducts shall be thoroughly cleaned by means of compressed air.

(d)

Grout shall be injected near the lowest point in the duct in one continuous operation and allowed to flow from the outlet until the consistency is equivalent to that of the grout being injected.

(e)

Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.

QCS 2014

5

Page 8

Grout (a)

Unless otherwise directed or agreed by the Engineer (i)

the grout shall consist only of ordinary Portland cement, water and approved admixtures; admixtures containing chlorides or nitrates shall not be used

(ii)

the grout shall have a water/cement ratio as low as possible consistent with the necessary workability, and the water/cement ratio shall not exceed 0.45 unless an approved mix containing an expanding agent is used

(iii)

the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess of 4% maximum, when measured at 18 C in a covered glass cylinder approximately 100 mm in diameter with a height of grout of approximately 100 mm, and the water shall be reabsorbed after 24 h.

Records

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The Contractor shall keep detailed records of times of tensioning, measured extensions, pressure gauge readings or load cell readings and the amount of pull-in at each anchorage. Copies of these records shall be supplied to the Engineer within such reasonable time from completion of each tensioning operation as may be required, and in any case not later than noon on the following working day.

(b)

The Contractor shall keep records of grouting, including the date, the proportions of the grout and any admixtures used, the pressure, details of interruption and topping up required. Copies of these records shall be supplied to the Engineer within such reasonable time after completion of each grouting operation as may be required, and in any case not later than noon on the following working day.

Driving Piles

1

Strength of Piles (a)

Piles shall not be driven until the concrete has achieved the specified strength.

At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur.

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Leaders and Trestles

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(a)

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4

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where designated, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

Length of Piles (a)

The length of pile to be driven in any location shall be approved prior to the commencement of driving.

QCS 2014

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Page 9

Driving Procedure and Redrive Checks (a)

The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required.

(c)

At the start of the work in a new area or section, a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles

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specified by the Engineer.

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(e)

Redrive checks, if required, shall be carried out to an approved procedure.

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Final Set (a)

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met:

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(d)

The exposed part of the pile shall be in good condition without damage or distortion.

(ii)

The helmet, dolly and any packing shall be in sound condition.

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(iv)

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required.

Preboring (a)

8

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis, and the head of the pile protected against damage from hammer impact.

If preboring is specified, the diameter and depth of prebore shall be as designated.

Jetting (a)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

QCS 2014

Page 10

Risen Piles Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

(b)

When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process.

(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave effects in subsequent work.

4.1.8

Repair and lengthening of piles

1

Repair of Damaged Pile Heads

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If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the pile-driving to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

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Lengthening of Reinforced and Prestressed Concrete Piles Any provision for lengthening piles incorporated at the time of manufacture shall be as designed or approved.

(b)

If no provision for lengthening piles was incorporated at the time of manufacture, any method for lengthening shall be such that splices are capable of safely resisting the stresses during driving and under service load and shall be subject to approval.

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(a)

Driving Repaired or Lengthened Piles Repaired or lengthened piles shall not be driven until the added concrete has reached the specified strength of the concrete of the pile.

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4.1.7


Cutting off pile heads

1

Unless otherwise directed by the Engineer, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level.

4.2

PRECAST REINFORCED CONCRETE SEGMENTAL PILES

4.2.1

Scope

1

This Part applies to piles made of elements cast at a precasting works away from the site, where work cannot normally be closely supervised by the Engineer. The elements are joined together as necessary on site during driving using special proven steel joints incorporated into the pile elements when cast.

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Page 11

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5,

Concrete.

4.2.2

References

1

The following Standards are referred to in this Part: Eurocode 7, EN1997-1, Section 7 Pile foundation BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes

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BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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BS 8110,.....................Structural use of concrete. Submittals

1

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

4.2.4

Quality Assurance

1

A certificate of quality from the pile manufacturer shall be provided to the Engineer when required stating that the designated requirements have been fulfilled during manufacture.

2

Each pile element shall be marked in such a manner that it can be identified with the records of manufacture, which shall state the date of casting, the cement type, concrete grade, element length and any other relevant data. On delivery, the pile elements shall be accompanied by records of manufacture.

4.2.5

Tolerances in Pile Dimensions

1

The cross-sectional dimensions of the pile shall be not less than those designated.

2

The head of a pile element or the end of the pile upon which the hammer acts shall be square to the pile axis within a tolerance of 1 in 50.

3

Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

4

Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the centres of area at the ends of the element. Where a pile element is less than 3 m long the permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in accordance with actual length.

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Page 12

Handling, Transportation, Storage and Acceptance of Piles

1

The method and sequence of lifting, handling, transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

2

All pile elements within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

3

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the less. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the approval of the Engineer.

4

A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm. The measurement shall be made with the pile in its working attitude.

4.2.7


1


ta qa

In the manufacture of jointed precast concrete segmental piles, fabricated steel components shall comply with BS 7613 grades 43A or 50A, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

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Pile Splices (a)

The splice joints shall be close-fitting face to face and the locking method shall be such as to hold the faces in intimate contact. The design and manufacture of the splicing system shall be approved by the Engineer prior to the commencement of the Contract.

(b)

A spliced pile shall be capable of withstanding the same driving stresses or service axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.

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(c)

3

Pile Toes (a)

4

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where fixity is required or socketing into rock, or in other circumstances, an approved shoe may be required.


5

The welding of a joint to main reinforcement in lieu of a lapped connection with projecting bars affixed to the joint will not be permitted.

Where the pile head is not furnished with a joint, it shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.


The main longitudinal reinforcing bars shall be in one continuous length. Splicing of bars will not be permitted except at element ends.

QCS 2014

Page 13

(b)

Concrete cover to steel reinforcement shall be in accordance with the requirements of BS 8110.

(c)

In very aggressive ground or exposure conditions, cover greater than 25 mm may be required, but alternative protection methods may be approved.

Formwork (a)

If a pile is constructed with a shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile.

(b)

Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(c)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections. The piles are to be removed from the formwork carefully so as to prevent damage.

Driving piles

1

Strength of Piles



Performance of Driving Equipment

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the particular specification, dynamic evaluation and analysis shall be provided. Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile at the moment of driving unless otherwise approved by the Engineer. For other types of hammer, the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

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Piles shall not be driven until the concrete has achieved the specified characteristic strength.

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4

Length of Piles (a)

The length of pile supplied to be driven in any location and any additional lengths to be added during driving shall he approved prior to the commencement of pile-driving. During the execution of the Works, any changes to the supplied lengths shall be approved.

QCS 2014

Page 14


Except when making field splices, the driving of each pile shall he continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall only be used when approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)


(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)


(e)


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Final Set

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)


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(a)

The exposed part of the pile shall be in good condition, without damage or distortion.

(ii)


(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

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7

(v)

The temporary compression of the pile shall be recorded if required.


Jetting (a)

4.2.9


Preboring (a)

8

(iv)


Risen Piles (a)

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

QCS 2014


Page 15

(b)


(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting piles detrimentally affected and for avoidance or control of heave effects in subsequent work.

4.2.10


1

Repair of Damaged Pile Heads If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the driving of the pile to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

Where piles are required to be driven to depths exceeding those expected, leaving insufficient projection for bonding into the following works, the piles shall be extended or replaced as required by the Engineer using approved materials and methods.

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Lengthening of Piles

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(a)


1

Unless otherwise specified, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2


4.3

BORED CAST IN PLACE PILES

4.3.1

Scope

1

This Part applies to bored piles in which the pile bore is excavated by rotary or percussive means, or both, using short augers, buckets, grabs or other boring tools to advance the open bore. Where the open bore is unstable, temporary or permanent casing or bentonite suspension may be used to support the wall of the bore prior to concreting.

2


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4.2.11

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation Section 5, Concrete

QCS 2014


4.3.2

References

1

The following codes of practice are referred to in this Part:

Page 16

BS 5573,.....................Code of practice for safety precautions in the construction of large diameter boreholes for piling and other purposes BS 5930,.....................Code of practice for site investigation. 4.3.3

Quality Assurance

1

Inspection Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly prior to concrete being placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided, by the Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 5573.

Cleanliness of pile bases

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed. Large debris and accumulated sediment shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

Samples and Testing

The taking of samples and all subsequent handling, transporting and testing shall be carried out in accordance with Section 3, Ground Investigation.

m

(b)

If required in the Contract, soil, rock or groundwater samples shall be taken or soil tests carried out in-situ while the pile is being bored. The samples shall be taken to an approved laboratory for testing as specified.

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(a)

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(a)

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(a)

4.3.4

Materials

1

Permanent Casings (a)

2

Permanent casings shall be as specified.

Drilling Fluid Supply (a)

A certificate shall be obtained by the Contractor from the manufacturer of the bentonite powder showing the properties of each consignment delivered to the Site. This certificate shall be made available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range (in Pascal seconds) and the gel strength range (in Pascal) for solids in water.

QCS 2014

3

Page 17

Drilling Fluid Mixing (a)

Bentonite shall be mixed thoroughly with clean fresh water to make a suspension which will maintain the stability of the pile bore for the period necessary to place concrete and complete construction. The temperature of the water used in mixing the bentonite suspension, and of the suspension when supplied to the borehole, shall be not lower than 5 C.

(b)

Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh water so as to render it suitable in all respects for the construction of piles.

Drilling Fluid Tests (a)

The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by the Contractor for approval prior to the commencement of the work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval.

(b)

Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pile bore. For average soil conditions the results shall generally be within the ranges in Table 4.2.

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4


Table 4.2.Tests on Bentonite

ov

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Viscosity

Less than 1.10 g/ml

Mud density balance

30 - 90 s or less than 0.020 Pa • s

Marsh cone method

1.4-10 Pa Or 4-40 Pa

Shear meter

et it

9.5 - 12

Fann viscometer*

Fann viscometer pH indicator paper strips or electrical pH meter

Where the Fann viscometer is specified, the fluid sample should be screened by a number 52 sieve (300 m) prior to testing.

m

*

o

Shear strength (10 minute gel strength) pH

Test method

se

Density

Range of results at 20 C

as

Property to be measured

(c)

The tests shall be carried out until a consistent working pattern has been established account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

4.3.5

Boring

1

Boring Near Recently Cast Piles (a)

Piles shall not be bored so close to other recently completed piles as to damage them.

QCS 2014

Page 18

Temporary Casings (a)

Temporary casing of approved quality or an approved alternative method shall be used to maintain the stability of a pile bore which might otherwise collapse.

(b)

Temporary casings shall be free from significant distortion. They shall be of uniform cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might adversely affect the proper formation of piles.

(c)

The use of a vibrator to insert and withdraw temporary casing may be permitted by the Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent Structures of this section and to the method not causing disturbance of the ground which would adversely affect the construction or the capacity of piles.

(d)

Where piles are bored under water or bentonite suspension in an unlined state, the insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing concrete will not be permitted.

(e)

Where permanent casing is specified to ensure the integrity of a pile, the Contractor shall submit for approval his proposals regarding the method of installation.

ta qa

Stability of Pile

Where boring takes place through unstable water-bearing strata, the process of excavation and the depth of temporary casing employed shall be such that soil from outside the area of the pile is not drawn into the pile section and cavities are not created outside the temporary casing as it is advanced.

(b)

Where the use of drilling fluid is specified or approved for maintaining the stability of a bore, an adequate temporary casing shall be used in conjunction with the method so as to ensure stability of the strata near ground level until concrete has been placed. During construction the level of drilling fluid in the pile excavation shall be maintained within the cased or stable bore so that it is not less than 1.0 m above the level of external standing groundwater at all times.

(c)

In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be backfilled without delay and the instructions of the Engineer shall be obtained before boring at that location is resumed.

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(a)

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2


Spillage and Disposal of Drilling Fluid (a)

5

Pumping from Pile Bores (a)

6

All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from the Site without undue delay. Any disposal of bentonite shall comply with the regulations of the local controlling authority.

Pumping from pile bores shall not be permitted unless the bore has been sealed against further water entry by casing or unless the soil is stable and will allow pumping to take place without ground disturbance below or around the pile.

Continuity of Construction (a)

For a pile constructed in a stable cohesive soil without the use of temporary casing or other form of support, the pile shall be bored and the concrete shall be placed without such delay as would lead to significant impairment of the soil strength.

QCS 2014

7


Enlarged Pile Bases (a)

A mechanically formed enlarged base shall be no smaller than the dimensions specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the shaft diameter. The sloping surface of the frustum forming the enlargement shall make an angle to the axis of the pile of not more than 35 .

4.3.6


1

Workability of Concrete (a)

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted. During extraction the motion of the casing shall be maintained in an axial direction relative to the pile.

.l. l

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Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

The concrete level within a temporary casing shall be topped up where necessary during the course of casing extraction in such a way that the base of the casing is always below the concrete surface until the casting of the pile has been completed.

(c)

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could occur as the casing is withdrawn because of the displacement of water or fluid by the concrete as it flows into its final position against the walls of the pile bore. Where two or more discontinuous lengths of casing (double casing) are used in the construction the proposed method of working shall be approved.

qa

ta

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(a)

For piles cast in dry bores using temporary casing and without the use of a permanent lining, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be above the original ground level. No pile shall be cast with its head below standing water level unless approved measures are taken to prevent inflow of water causing segregation of the concrete as temporary casing is extracted, and, where approved by the Engineer, the groundwater level for each pile shall be treated as the cut-off level for the purpose of calculating tolerance.

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(a)

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Pile Head Casting Level Tolerances

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2

Page 19

(b)

For piles cast in dry bores within permanent lining tubes or permanent casings, or where their cut-off levels are in stable ground below the base of any casing used, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the original ground level.

QCS 2014


Page 20

(c)

For piles cast under water or drilling fluid, the pile heads shall be cast to a level above the specified cut-off so that, after trimming to remove all debris and contaminated concrete, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the commencing surface level. Cut-off levels may be specified below the standing groundwater level, and where this condition applies the borehole fluid level shall not be reduced below the standing groundwater level until the concrete has set.

(d)

Where the cut-off level of piles lies at depths greater than 10 m below the original ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after discussion with the Contractor and before the commencement of the piling to take account of the special conditions which apply. Table 4.3

Casting tolerance above cut-off level, m

rw

Cut-off distance below commencing surface, H, m

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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing and Without the Use of a Permanent Lining

ta

0.3 + H/12 + C/8 where C = length of temporary casing below the commencing surface*

qa

0.15-10.00 *

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If H is greater than C, then this tolerance is no longer applicable and the tolerances in Table 4.4 will apply.

Table 4.4

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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the Base of Any Casing Used

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0.3 + H/10

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0.15-10.00


m

Table 4.5 Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid** Cut-off distance below commencing surface, H, m

0.15-10.00

** 4


1.0 + H /12 + C/8 where C = length of temporary casing below the commencing surface

In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate tolerance is given by deletion of the casing term C/8 in the table.

Water levels (a)

During extraction of temporary casings, where circumstances are such that newly placed unset concrete is brought into contact with external groundwater, precautions shall be taken to ensure that the internal concrete pressure at all levels within the pile exceeds the external groundwater pressure.

QCS 2014

5

After each pile has been cast, any empty bore remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Disposal of excavated material (a)

7

Page 21

Temporary backfilling above pile casting level (a)

6


Disposal of excavated material shall be carried out by the Contractor as necessary to facilitate the Works and to the satisfaction of the Engineer.

Cutting off pile heads (a)

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS

4.4.1

Scope

1

This Part applies to bored piles which employ a continuous flight auger for both advancing the bore and maintaining its stability. The spoil-laden auger is not removed from the ground until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed auger to replace the excavated soil.

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4.4

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This Section

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Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete Materials

1

Concrete Mix Design and Workability

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4.4.2

(a)

2

Where not otherwise stated in this Part, the concrete shall comply with Section 5. The design and workability of concrete to be used in the formation of a pile shall produce a mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless 3 otherwise approved and a minimum cement content of 340 kg/m . The mix shall be designed so that segregation does not occur during the placing process, and bleeding of the mix shall be minimised.

Grout Mix Design and Workability (a)

Mix design of grout shall be subject to approval. Cement, water and aggregates for grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm nominal size and shall be rounded and evenly graded.

QCS 2014

(b)


The workability of grout mixes, where used, shall be measured by a suitable and approved means. The procedure for monitoring the suitability of grout throughout the Works shall be stated in writing to the Engineer before beginning of the Works and shall be subject to approval.

(c)

Additives to the grout shall require prior approval of the Engineer.

Reinforcement All reinforcement shall be placed with the minimum delay after the completion of the concreting or grouting operation. It shall be designed and fabricated in cages to permit it to be placed in the correct position and to the depth specified through the concrete or grout of the pile. Suitable approved spacers shall be provided to maintain the specified concrete or grout cover to steel.

(b)

The transverse reinforcement of any reinforcing cage shall be approved and may consist of either spirals, hoops or links.

(c)

Longitudinal main steel reinforcement shall be continuous over the specified length. Where splices are necessary, the number of laps shall be kept to a minimum and bars shall be welded or joined together in an approved manner.

(d)

Reinforcement shall be supported and centred so that it will provide the required projection above the cut-off level, and the proper concrete cover.

Boring

1

General

During uncased boring with continuous flight auger, the feed forward and speed (revolutions per minute) are to be adjusted according to the soil conditions in a way that the excavation of soil will be limited to a quantity that the lateral support of the uncased borehole wall will be ensured.

Boring Near Recently Cast Piles

Removal of Augers from the Ground

m

3

Piles shall not be bored so close to other piles which have recently been cast as to damage them.

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(a)

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(a)

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4.4.3

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(a)

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Page 22

(a)

4

Depth of Piles (a)

5

Augers shall not be extracted from the ground during the boring or construction of a pile in such a way that an open unsupported bore or inflow of water into the pile section would result. While withdrawing the continuous flight auger, the auger shall be rotated in the same direction as during drilling into the soil or shall be withdrawn without rotation.

Any failure of a pile to reach the designated depth shall be reported to the Engineer without delay and a full statement of the reasons given.

Suitability of Boring Equipment (a)

The piles shall be bored using approved and suitable equipment capable of penetrating the ground without drawing surrounding soils laterally into the pile bore.

QCS 2014


4.4.4

Placing of concrete or grout

1

Equipment for Supply of Concrete or Grout to Piles (a)

Grout or concrete shall be supplied to the pile through suitable tubing and the hollow auger stem. All pipe fitments and connections shall be so constructed that grout does not leak during the injection process.

Commencement of Concrete or Grout Supply to Each Pile (a)

The base of the auger stem shall be fitted with a suitable means of sealing it against ingress of water and soil until concrete or grout placing begins.

(b)

At the beginning of concrete or grout placement this sealing device shall be removed by the application of concrete or grout pressure. Care shall be taken to ensure that the auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water inflow and soil movement at the base of the auger are minimised. The technique and equipment used to initiate and maintain the concrete or grout flow shall be such that a pile of the full specified cross-section is obtained from the maximum depth of boring to the final pile cut-off level.

The concrete or grout shall be supplied to the pile at a sufficient rate during auger withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.

(b)

The rate of withdrawal of the auger, the injection pressures and the rate of supply of concrete or grout shall be measured and recorded throughout the phase of auger withdrawal for each pile.

(c)

The Contractor shall submit proposals for his method of monitoring construction for approval before beginning the Works.

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Completion of Piles

If the concrete or grout placing in any pile cannot be completed in the normal manner, then the pile shall be rebored before concrete has hardened and shall be completely replaced.

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(a)

5

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(a)

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4

Rate of Supply of Concrete or Grout

Casting Level of Pile Head Concrete or grout shall be cast to the original ground level in all cases, and the reinforcing cage set, as appropriate.

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Page 23

4.4.5


1

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or contaminated, cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section up to the cut-off level.

4.5

DRIVEN CAST IN PLACES PILES

4.5.1

Scope

1

This Part applies to piles for which a permanent casing of steel or concrete is driven, reinforcement placed within it if required, and the casing filled with concrete. It also applies to piles in which a temporary casing is driven, reinforcement placed within it and the pile formed in the ground by filling the temporary casing with concrete before and during its extraction.

QCS 2014

2


Page 24

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5, Concrete Section 3, Ground Investigation. Submittals

1

Where the Contractor wishes to form a pile with an enlarged base, details of the proposed method of forming the base and the materials to be used shall be submitted at the time of tendering.

4.5.3

Quality Assurance

1

Before placing concrete in a pile casing, the Contractor shall check in an approved manner that the casing is undamaged, and free from water or other foreign matter. In the event of water or foreign matter having entered the pile casing, either the casing shall be withdrawn, repaired if necessary and re-driven, or other action shall be taken as may be approved to continue the construction of the pile.

4.5.4

Materials

1

Permanent Casings

as

se

Permanent casings shall be as specified. Where a permanent casing is to be made from a series of short sections it shall be designed and placed so as to produce a continuous water-free shaft. The dimensions and quality of the casing shall be adequate to withstand the stresses caused by handling and driving without damage or distortion.

Temporary casings shall be free from significant distortion. They shall be of uniform external cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might prevent the proper formation of piles.

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(a)

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Temporary Casings

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(a)

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4.5.2

3

Pile Shoes (a)

4

Pile shoes shall be manufactured from durable material capable of withstanding the stresses caused by driving without damage, and shall be designed to give a watertight joint during construction.

Reinforcement (a)

This type of pile shall normally be reinforced over its full length unless permanently cased. The use of shorter reinforcement in piles which are not permanently cased shall be subject to the approval of the Engineer.

(b)

The number of splices in longitudinal steel bars shall be kept to a minimum. The full strength of each bar shall be effective across each splice, which shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

QCS 2014


4.5.5

Driving piles

1

Piling Near Recently Cast Piles (a)

2

Casings shall not be driven or piles formed so close to other piles which have recently been cast as to damage them.


The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment

(b)

Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

Length of Piles

Driving Procedure (a)

Each pile casing shall be driven continuously until the specified or approved depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided on resumption the casing can be driven to the specified depth or resistance (set), or both, without damage.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is encountered. A detailed record of the driving resistance over the full length of the nearest available subsequent pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile to be installed and over the last 3 m of the driving of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all facilities to enable the Engineer to check driving resistance. A set shall be taken only in the presence of the Engineer unless otherwise approved.

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Final Set

m

5

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ta

4

The length of pile to be driven in any location shall be approved.

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(a)

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Page 25

(a)

Where piles are driven to a set, the final set of each pile, pile shell or casing shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met: (i)

The exposed part of the pile casing shall be in good condition, without damage or distortion.

(ii)

The dolly, helmet and packing, if any, shall be in sound condition.

(iii)


(iv)


(v)

Temporary compression of the pile casing shall be recorded if required.

QCS 2014

6

If preboring is specified the pile casing shall be pitched after preboring to the designated depth and diameter.

Jetting (a)

8

Page 26

Preboring (a)

7


Jetting shall be carried out only when the Contractor's detailed proposals have been approved by the Engineer

Internal Drop Hammer Where a casing for a pile without an enlarged base is to be driven by an internal drop hammer, a plug consisting of concrete grade 20 with a water/cement ratio not exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to ensure that this height of driving plug is maintained in the casing throughout the period of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of normal driving or after 45 min of hard driving, or, should the driving of a pile be interrupted for 30 min or longer, fresh concrete shall be added prior to driving being resumed.

ta

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(a)

Risen Piles

1

Piles shall be driven in an approved sequence to minimise any detrimental effects of heave and lateral displacement of the ground.

2

When required, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process.

3

When a pile has risen with detrimental effects as a result of adjacent piles being driven the Contractor shall, if required, submit to the Engineer his proposals for correcting or compensating for this and for avoidance or control of heave effects in subsequent work.

4.5.7


1


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4.5.6

(a)

2

3

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted.

Concrete Level (a)

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

Concrete shall be topped up as necessary while the casing is extracted until the required head of concrete to complete the pile in a sound and proper manner has been provided. No concrete is to be placed once the bottom of the casing has been lifted above the top of the concrete.

Vibrating Extractors (a)

The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and Disturbance) and (Damage to Adjacent Structures).

QCS 2014

4


Page 27

Concrete Casting Tolerances (a)

For piles constructed without the use of a rigid permanent lining, pile concrete shall be cast to the original ground level.

(b)

Where piles are constructed inside rigid permanent lining tubes or permanent casings, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. In this case, the tolerance of casting above the cut-off level shall be determined according to Table 4.6. Table 4.6

Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining Tubes or Permanent Casings Cut-off distance below original ground, H, (m)

rw

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Casting tolerance above cut-off level (m)

2.2 + H/10

qa

Repair of damaged pile heads and making-up of piles to the correct level When repairing or extending the head of a pile, the head shall be cut off square in sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water.

(b)

If the driving of a pile has been accepted but sound concrete of the pile is below the cut-off level, the pile shall be made good to the cut-off level with concrete of a grade not inferior to that of the concrete of the pile.

as

(a)

Lengthening of cast-in- place piles after driving When it is required to extend a cast-in-place driven pile above ground, the materials to be used and procedures to be adopted shall be subject to the approval of the Engineer.

7

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(a)

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6

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5

ta

0.15 to any depth

Lengthening of permanent pile casings during construction The lengthening of permanent steel pile casings by adding an additional length of the same steel casing during construction shall be carried out in accordance with the relevant clauses of this Section or by other approved methods. The use of casing extension materials and methods other than those specified shall be subject to approval.

m

(a)

8


9

After each pile has been cast, any hole remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.


When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section to the cut-off level.

QCS 2014


Page 28

4.6

STEEL PILES

4.6.1

Scope

1

This Part applies to driven steel piles designed to act as bearing piles.

2

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete References

1


rw

4.6.2

ta

BS 4, ..........................Structural steel sections

BS 3100, ....................Steel casting for general engineering purposes.

qa

BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel

as

BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates

se

API 5L,........................Interpretation of non-destructive testing. Submittals

1

Where coatings are specified, the Contractor shall submit for approval full details of the coating procedure and surface preparation according to relevant British or Swedish Standards.

4.6.4

Quality Assurance

1

The Contractor shall provide the Engineer with Works test certificates, analyses, and mill sheets, together with a tube manufacturer's certificate showing details of the pile number, cast number of the steel and a record of all tests and inspections carried out. The Engineer has the right to inspect any stage of the manufacturing processes and shall be given adequate notice by the Contractor of such processes and production tests, provided that, once he has been notified, any delay in his attendance does not cause delay to, or disrupt, the manufacturing process. The Contractor shall provide the Engineer with samples for independent testing when requested.

2

The Contractor shall submit for approval full details of the welding procedures and electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the relevant British Standard or as may be required by the Engineer. Only welders who are qualified in the approved welding procedure in accordance with the tests laid down in the relevant British Standard, or who have a proven record over the previous six months, or who have attained a similar standard, shall be employed on the Works. Proof of welders' proficiency shall be made available to the Engineer on request.

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4.6.3

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4.6.5

Delivery, Storage and Handling

1

The Contractor shall (a)

Order the piles to suit the construction programme.

(b)

Obtain the Engineer's approval before placing the order.

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When preliminary piles are specified, the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

3

Each pile shall be clearly numbered and its length shown near the pile head using white paint. In addition, before being driven, each pile shall be graduated at appropriate intervals along its length and at intervals of 250 mm along the top 3 m.

4

All piles within a stack shall be in groups of the same length and on approved supports. All operations such as handling, transporting and storing of piles shall be carried out in a manner such that damage to piles and their coatings is minimised.

4.6.6

Materials

1

Pile Shoes

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Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related standards.

Strengthening of Piles

The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head of a pile shall be made using material of the same grade as the pile unless otherwise approved.

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Manufacturing Tolerance All piles shall be of the type and cross-sectional dimensions specified. For standard rolled sections the dimensional tolerances and weight shall comply with the relevant standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified. For proprietary sections the dimensional tolerances shall comply with the manufacturer's standards. The rolling or manufacturing tolerances for proprietary sections shall be such that the actual weight of section does not differ from the theoretical weight by more than +4 % or -2½ % unless otherwise agreed. The rolling or manufacturing tolerances for steel tubular piles shall be such that the actual weight of section does not differ from the theoretical weight by more than ±5 %.

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Straightness of Piles (a)

For standard rolled sections the deviation from straightness shall be within the compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall length of the pile.

(b)

For proprietary sections made up from rolled sections, and for tubular piles, the deviation from straightness on any longitudinal face shall not exceed 1/600 of the length of the pile nor 5 mm in any 3 m length.

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Fabrication of Piles (a)

For tubular piles where the load will be carried by the wall of the pile, and if the pile will be subject to loads that induce reversal of stress during or after construction, the external diameter at any section as measured by using a steel tape on the circumference shall not differ from the theoretical diameter by more than ±1.

(b)

The ends of all tubular piles as manufactured shall be within a tolerance on ovality of ±1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile length.

(c)

The root edges or root faces of lengths of piles that are to be shop butt-welded shall not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of unequal wall thickness are to be butt-welded, the thickness of the thinner material shall be the criterion.

Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being joined shall, whenever possible, be evenly staggered at the butt. However, if in order to obtain a satisfactory match of the ends of piles or to meet specified straightness, the seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.

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Welding of H-piles and piles that will be subjected to stress reversal, during or after construction, shall be in accordance with BS 5135.

(b)

For a tubular pile where the load will be compressive and non-reversible and will be carried by the wall of the pile or by composite action with a concrete core, the welding shall be to BS 5135 or BS 6265.

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Coating Piles for Protection against Corrosion Where coatings are specified they shall be provided in accordance with the Particular Specification. In general, coatings will not be called for where piles are fully in contact with undisturbed natural soils or below the standing water table. Cathodic protection may be called for when there is a possibility of stray electrical current from the supported structure flowing to earth through the piles.

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4.6.7

Acceptance Standards For Welds

1

Acceptance Standards for Shop Welds (a)

Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the acceptance standard for interpretation of non-destructive testing specified in latest edition of API 5L. The maximum projecting height of weld reinforcement shall not exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall thicknesses greater than 13 mm.

(b)

Longitudinal welds joining the constituent parts of the box or proprietary section shall be in accordance with the manufacturer's specification.

(c)

The maximum projecting height of weld reinforcement for circumferential welds in tubular piles shall be the same as specified above for longitudinal welds in tubular piles.

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Acceptance Standards for Site Butt Welds (a)

Welds shall comply with the requirements of the Weld Quality Acceptance Standards for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation, General Steels Group.

Acceptability and inspection of coatings

1

The finished coating shall be generally of smooth and uniform texture and free from sharp protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

2

Any coat damaged by subsequent processes, or which has deteriorated to an extent such that proper adhesion of the coating is in doubt, shall be removed and the surface shall be cleaned to the original standard and recoated with the specified number and thicknesses of coats.

3

The completed coating shall be checked for thickness by an approved magnetic thickness gauge. Areas where the thickness is less than that specified shall receive approved additional coating.

4

Average measured thickness should be equal to or greater than the specified thickness and no single reading should be less than 85 % of the specified thickness. The completed coating shall also be checked for adhesion by the cross-hatching method with lines spaced at ten times the thickness of the coating. Adhesion tests should not be carried out prior to seven days after coating.

5

The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved shall be sand blasted and recoated. The coating shall be approved before pitching and driving of the piles.

4.6.9

Driving of piles

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At all stages during driving and until incorporation in the superstructure, the free length of the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. In marine works, lengths which remain unsupported after driving shall be adequately restrained until incorporated into the permanent Works. These constraint arrangements shall be such that damage to piles and their coatings is minimised.

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4.6.8

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The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the Contract, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

QCS 2014

Length of Piles (a)

The length of pile to be driven and any additional lengths of pile to be added during driving shall be approved by the Engineer.

Driving Procedure and Redrive Checks The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can be driven to the specified depth or resistance (set), or both, without damage.

(b)

A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(c)

The Contractor shall inform the Engineer as soon as an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest subsequent pile shall be taken, if required by the Engineer.

(d)

At the start of the work in a new area or section a detailed record shall be made over the full driving length of the first pile, and during the last 3 m of the driving of subsequent piles, to establish the driving behaviour. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being specified by the Engineer.

(e)


(f)

Redrive checks, if required, shall be carried out in accordance with an approved procedure.

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When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm. When a final set or resistance is being measured, the following requirements shall be met:

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Final Set or Resistance

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(ii)

The dolly and packing, if any, shall be in sound condition.

(iii)


(iv)

The hammer shall be in good condition, delivering adequate energy per blow and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required by the Engineer.

Preboring (a)

If preboring is specified the pile shall be pitched after preboring to the designated depth and diameter.

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Jetting (a)


Risen Piles

1


2

When required by the Engineer, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving of adjacent piles.

3

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile under load is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave in subsequent work.

4.6.11

Preparation of pile heads

1

If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within 5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete they shall be cut to that same tolerance and protective coatings shall be removed from the surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.

4.7

MICROPILES (TO BE ADDED LATER)

4.8

REDUCTION OF FRICTION ON PILES

4.8.1

Scope

1

This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.

2

Related Parts are as follows:

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4.6.10

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation. 4.8.2

Submittals

1

Where the particular method of reducing friction is not specified, the Contractor shall submit full details of the method which he proposes.

4.8.3

Friction Reducing Methods

1

General (a)

Where a means of reducing friction on any specified length of pile is required by the Contract, the Contractor shall provide a suitable interface between pile and soil by one of the following, or other approved, methods

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(i)

Preapplied bituminous or other proprietary friction-reducing coating.

(ii)

Preapplied low-friction sleeving.

(iii)

Formed-in-place low-friction surrounds.

(iv)

Preinstalled low-friction sleeving.

Preapplied Bituminous or other Friction-Reducing Coating Materials (a)

Where a proprietary product is specified, the process of cleaning pile surfaces, and the conditions and methods of application shall conform to the manufacturer's current instructions. All materials shall conform to the manufacturer's specification, which shall be given to the Engineer before any coating is applied.

(b)

Where a friction-reducing material has been applied to a preformed pile prior to installation, it shall be protected from damage during handling and transportation. In the event of inadvertent damage to the coating, it shall be repaired on site, prior to the pile being driven, to the same specification as the original coating. Where bituminous materials are involved, precautions shall be taken as necessary in hot weather to prevent excessive flow or displacement of the coating. The coated piles shall be adequately protected against direct sunlight and, if stacked, they shall be separated to prevent their coatings sticking together.

(c)

In the case of applied coatings, the piles shall not be driven when the air temperature is such that the coating will crack, flake or otherwise be damaged prior to entry into the ground. Where bituminous materials are involved, driving shall be carried out while the temperature is at or above 5 °C unless otherwise approved or called for in the manufacturer's instructions.

Formed-In-Place Low-Friction Surround Where a hole is bored in the ground and filled with low-friction material through which a pile is subsequently driven or placed, the method and the properties of the low-friction material both above and below standing groundwater level, together with the dimensions of the prebored hole in relation to the pile, shall be approved by the Engineer.

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Piles may be driven with a preapplied low-friction sleeving subject to the approval of the detailed design and method by the Engineer.

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Preinstalled Low-Friction Sleeving (a)

Where a system is employed involving placing a low-friction sleeve in the ground prior to pile installation, the detailed materials and method of installation of the sleeving shall be approved by the Engineer.

4.8.4

Inspection

1

The Engineer may call for piles to be partially exposed or extracted at the commencement of a contract in order to demonstrate that the method of installation does not impair the effectiveness of the system in the circumstances of use on the particular site. Where damage is found to have occurred, or is likely to occur in the opinion of the Engineer, additional measures or variation of the method may be called for. At the discretion of the Engineer, further inspections shall be carried out to ascertain the effectiveness of the additional measures.

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4.8.5

Driving resistance

1

Allowance shall be made in driving piles to a required resistance or set for any differences between the short-term driving resistance and the long-term static resistance of the coating or surrounding low-friction material which is in use.

4.9

PILE LOAD TESTING

4.9.1

Static Load Testing of Piles

1

Scope This Part deals with the testing of a pile by the controlled application of an axial load. It covers vertical and raking piles tested in compression (i.e. subjected to loads or forces in a direction such as would cause the piles to penetrate further into the ground) and vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as would cause the piles to be extracted from the ground).

References The following standard is referred to in this Part:

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Allowable pile capacity: a load which is not less than the specified working load and which takes into account the pile's ultimate bearing capacity, the materials from which the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the overall bearing capacity of the ground beneath the piles and any other relevant factors. The allowable pile capacity indicates the ability of a pile to meet the specified loading requirements.

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Definitions

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When required, the design and full details of the proposed load application system shall be submitted to the Engineer prior to the commencement of testing. The load application system shall be satisfactory for the required test.

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BS 1881, ....................Methods of testing concrete.

(b)

Compression pile: a pile which is designed to resist compressive (downward) axial load.

(c)

Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate the soil at a constant controlled speed, while the loads applied at the top of the pile in order to maintain the constant rate of penetration are continuously measured. The purpose of the test is to derive the ultimate bearing capacity of a pile and not its load settlement characteristics.

(d)

Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is subject to tension rather than compression. The purpose of the test is to determine the 'pull-out' capacity of a pile.

(e)

Design verification load (DVL): a test load, in lieu of a specified working load, applied to a single pile at the time of testing to determine that site conditions conform to design assumptions. This load will be peculiar to each preliminary (test) pile and should equal the maximum specified working load for a pile of the same dimensions and material, plus allowances for soil-induced forces and any other particular conditions of the test.

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Kentledge: ballast used in a loading test.

(g)

Maintained load test: a loading test in which each increment of load is held constant either for a defined period of time or until the rate of settlement falls to a specified value.

(h)

Preliminary pile: a test pile installed before the commencement of the main piling works or a specific part of the Works for the purpose of establishing the suitability of the chosen type of pile and for confirming its design, dimensions and bearing capacity.

(i)

Proof load: a load applied to a selected working pile to confirm that it is suitable for the load at the settlement specified. A proof load should not normally exceed the design verification load plus 50 % of the specified working load.

(j)

Raking pile: a batter pile, installed at an inclination to the vertical.

(k)

Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a resistance against which the pile is tested.

(l)

Specified working load (SWL): the designated load on the head of a pile.

(m)

Tension pile: a pile which is designed to resist a tensile (upward) axial force.

(n)

Test pile: any pile, preliminary or part of the works, to which a test is applied.

(o)

Ultimate bearing capacity: the load at which the resistance of the soil becomes fully mobilised through friction, end bearing or a combination thereof.

(p)

Working pile: one of the piles forming the foundation of a structure.

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Notice of Construction

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The Contractor shall give the Engineer at least 48 hours' notice of the commencement of construction of any preliminary pile which is to be testloaded.

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Method of Construction Each preliminary test pile shall be constructed in a manner similar to that to be used for the construction of the working piles, and by the use of similar equipment and materials. Any variation will be permitted only with prior approval.

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(c)

Boring or Driving Record (i)

(d)

For each preliminary pile to be tested, a detailed record of the conditions experienced during boring and of the progress during driving, shall be made and submitted to the Engineer daily, not later than noon on the next working day. Where the Engineer requires soil samples to be taken or in-situ tests to be made, the Contractor shall include that in the daily report, as well as the test results.

Concrete Test Cubes (i)

In the case of concrete piles, four test cubes shall be made from the concrete 3 used in the manufacturer of each preliminary test pile and from each 50 m of the concrete used in the manufacture of working piles. If a concrete pile is extended or capped for the purpose of testing, an additional four cubes shall be made from the corresponding batch of concrete. The cubes shall be made and tested in accordance with BS 1881.

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations (ii)

(e)

If a test is required on a working pile the Contractor shall cut off or otherwise prepare the pile for testing as required by the Engineer.

Cut-off Level (i)

The cut-off level for a preliminary test pile shall be approved by the Engineer.

.

Supervision The setting-up of pile testing equipment shall be carried out under competent supervision and the equipment shall be checked to ensure that the set-up is satisfactory before the commencement of load application.

(b)

All tests shall be carried out only under the direction of an experienced and competent supervisor experienced with the test equipment and test procedure. All personnel operating the test equipment shall have been trained in its use.

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Safety precautions General

Design, erection and dismantling of the pile test reaction system and the application of load shall be carried out according to the requirements of the various applicable statutory regulations concerned with lifting and handling heavy equipment and shall safeguard operators and others who may from time to time be in the vicinity of a test from all avoidable hazards.

Kentledge

Where kentledge is used, the Contractor shall construct the foundations for the kentledge and any cribwork, beams or other supporting structure in such a manner that there will not be differential settlement, bending or deflexion of an amount that constitutes a hazard to safety or impairs the efficiency of the operation. The kentledge shall be adequately bonded, tied or otherwise held together to prevent it becoming unstable because of deflexion of the supports or for any other reason.

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The pile test shall not be started until the strength of the cubes taken from the pile exceeds twice the average direct stress in any pile section under the maximum required test load, and the strength of the cubes taken from the cap exceeds twice the average stress at any point in the cap under the same load. Variation of procedure will be permitted only if approved by the Engineer.

Preparation of a Working Pile to be Tested (i)

(f)

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(ii)

When kentledge constitutes the principal component of a reaction system, its weight for each test shall be at least 25% greater than the maximum test load for that test. The weight may be determined by scale or the density and volume of the constituent materials. In adding kentledge, care shall be taken to properly position the centre of gravity of the stack.

QCS 2014

(c)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Tension Piles, Reaction Piles and Ground Anchorages (i)

Where tension piles, reaction piles or ground anchorages constitute the principal components of a reaction system, they shall be so designed that they will resist the forces applied to them safely and without excessive deformation which could cause a safety hazard during the work. Such piles (which, unless approved, will not be working piles) or anchorages shall be driven in the specified locations, and all bars, tendons or links shall be aligned to provide a stable reaction in the direction required. Any welding employed to extend or to fix anchorages to a reaction frame shall be carried out so that the full strength of the system is adequate and unimpaired.

Testing Equipment (i)

In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable up to the maximum load to be applied.

(ii)

If in the course of carrying out a test any unforeseen occurrence should take place, further loading shall not be applied until a proper engineering assessment of the condition has been made and steps have been taken to rectify any fault. Reading of gauges should, however, be continued where possible and if it is safe to do so.

(iii)

Where an inadequacy in any part of the system might constitute a hazard, means shall be provided to enable the test to he controlled from a position remote from of the kentledge stack or test frame.

(iv)

The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a pressure of 1.5 times the maximum pressure used in the test without leaking. The maximum test load expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit.

Pile Head for Compression Test For a pile that is tested in compression, the pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile, sufficiently large to accommodate the loading and settlement measuring equipment and adequately reinforced or protected to prevent damage from the concentrated load applied by the loading equipment.

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(f)

(ii)

Any test pile cap shall be concentric with the test pile; the joint between the cap and the pile shall have a strength equivalent to that of the pile.

(iii)

Sufficient clear space shall be made under any part of the cap projecting beyond the section of the pile so that, at the maximum expected settlement, load is not transmitted to the ground by the cap.

Pile Connection for Tension Test (i)

For a pile that is tested in tension, means shall be provided for transmitting the test load axially without inducing moment in the pile. The connection between the pile and the loading equipment shall be constructed in such a manner as to provide strength equal to 1.5 times the maximum load which is to be applied to the pile during the test.

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Reaction systems

(i)

The reaction for compression tests shall be provided by kentledge, tension piles or specially constructed anchorages. Kentledge shall not be used for tests on raking piles except where the test set-up has been specifically designed to conform to Item 7(g). and has been approved by the Engineer.

(ii)

Where kentledge is to be used, it shall be supported on cribwork and positioned so that the centre of gravity of the load is as close as possible to the axis of the pile. The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge stack.

Tension Tests (i)

The reaction for tension tests shall be provided by compression piles, rafts or grillages constructed on the ground. In all cases the resultant force of the reaction system shall be coaxial with the test pile.

(ii)

Where inclined piles or reactions are proposed, full details shall be submitted for approval prior to the commencement of testing.

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Working piles shall not be used as reaction piles without approval from the Engineer.

(ii)

Where working piles are used as reaction piles their movement shall be measured and recorded to with an accuracy of 0.5 mm, and recorded.

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Spacing

Where kentledge is used for loading vertical piles in compression, the distance from the edge of the test pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be not less than 1.3 m.

(ii)

The centre-to-centre spacing of vertical reaction piles from a test pile shall conform to Paragraph 1 above, but shall be not less than three times the diameter of the test pile or the reaction piles or 2 m, whichever is the greatest, except in the case of piles of 300 mm diameter (or equivalent) or less, where the distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no surface of a reaction pile shall be closer to the pile cap of the test pile than one half of the pile cap plan dimension.

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Working Piles

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(e)

Where ground anchorages are used to provide a test reaction for loading in compression, no section of fixed anchor length transferring load to the ground shall be closer to the test pile than three times the diameter of the test pile. Where the pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no section of the fixed anchor transferring load to the ground shall be closer to the pile cap than a distance equal to one half the pile cap plan dimension.

Adequate Reaction (i)

The reaction frame support system shall be adequate to transmit the maximum test load in a safe manner without excessive movement or influence on the test pile. Calculations shall be provided to the Engineer when required to justify the design of the reaction system.

QCS 2014

(f)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Care of Piles (i)

9

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The method employed in the installation of the reaction system shall be such as to prevent damage to any test pile or working pile.

Equipment for applying load The equipment used for applying load shall consist of a hydraulic ram or jack. The jack shall be arranged in conjunction with the reaction system to deliver an axial load to the test pile. Proposals to use more than one ram or jack will be subject to approval by the Engineer of the detailed arrangement. The complete system shall be capable of safely transferring the maximum load required for the test. The length of stroke of a ram shall be sufficient to account for deflexion of the reaction system under load plus a deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise specified or agreed prior to commencement of test loading.

Measurement of load

A load measuring device shall be used and in addition a calibrated pressure gauge included in the hydraulic system. Readings of both the load measuring device and the pressure gauge shall be recorded. In interpreting the test data the values given by the load measuring device shall normally be used; the pressure gauge readings are required as a check for gross error.

(b)

The load measuring device may consist of a load measuring column, pressure cell or other appropriate system. A spherical seating of appropriate size shall he used to avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load application and measuring system. Load measuring and application devices shall be short in axial length in order to secure stability. The Contractor shall ensure that axial loading is maintained.

(c)

The load measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The pressure gauge and hydraulic jack shall be calibrated together. Certificates of calibration shall be supplied to the Engineer.

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Control of loading

The loading equipment shall enable the load to be increased or decreased smoothly or to be held constant at any required value.

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12

Measuring pile head movement (a)

Maintained Load Test (i)

(b)

In a maintained load test, movement of the pile head shall he measured by one of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.

CRP and CRU Tests (i)

In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial gauge shall be graduated in divisions of 0.02 mm or less.


(c)

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Reference Beams and Dial Gauges (i)

An independent reference beam or beams shall be set up to enable measurement of the movement of the pile to be made to the required accuracy. The supports for a beam shall be founded in such a manner and at such a distance from the test pile and reaction system that movements of the ground do not cause movement of the reference beam or beams which will affect the accuracy of the test. The supports of the beam or beams shall be at least three test pile diameters or 2 m from the centre of the test pile, whichever distance is the greater.

(ii)

Check observations of any movements of the reference beam or beams shall be made and a check shall be made of the movement of the pile head relative to a remote reference datum at suitable intervals during the progress of the test.

(iii)

The measurement of pile movement shall be made by four dial gauges rigidly mounted on the reference beam or beams, bearing on prepared flat surfaces fixed to the pile cap or head and normal to the pile axis. Alternatively, the gauges may be fixed to the pile and bear on prepared surfaces on the reference beam or beams. The dial gauges shall be placed equidistant from the pile axis and from each other. The dial gauges shall enable readings to be made to an accuracy of at least 0.1 mm and have a stem travel of at least 25 mm. Machined spacer blocks may be used to extend the range of reading. Equivalent electrical displacement-measuring devices may be substituted.

Optical Levelling Method

An optical levelling method by reference to a remote datum may be used.

(ii)

Where a level and staff are used, the level and scale of the staff shall be chosen to enable readings to be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile cap may be used instead of a levelling staff. At least two reliable independent datum points shall be established. Each datum point shall be so situated as to permit a single setting-up position of the level for all readings.

(iii)

No datum point shall be located where it can be affected by the test loading or other operations on the Site.

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Reference Wires and Scales

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(e)

(f)

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(i)

Two parallel reference wires, one on either side of the pile, shall be held under constant tension at right angles to the test pile axis between supports formed as in the method in Item 11 (d). The wires shall be positioned against scales fixed to the test pile head in an axial direction and the movements of the scales relative to the wires shall be determined.

(ii)

Check observations of any movements of the supports of the wires shall be made and a check shall be made on the movement of the pile head at approved time intervals. Readings shall be taken to within an accuracy of 0.5 mm.

Other Methods (i)

The Contractor may submit for approval any other method of measuring the movement of the test pile head.

QCS 2014

Protection of testing equipment (a)

Protection from Weather (i)

(b)

Throughout the test period all equipment for measuring load and shall be protected from exposure to adverse effect of weather.

movement

Prevention of Disturbance (i)

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Construction activity and persons who are not involved in the testing process shall be kept at a sufficient distance from the test to avoid disturbance to the measuring apparatus. Full records shall be kept of any intermittent unavoidable activity that might affect the test set-up.

Notice of test The Contractor shall give the Engineer at least 24 hours' notice of the commencement of the test. No load shall be applied to the test pile before the commencement of the specified test procedure.

Test procedure

ta

Proof Load Test Procedure (working compression piles)

The maximum load which shall be applied in a proof test shall normally be the sum of the design verification load (DVL) plus 50 % of the specified working load (SWL). The loading and unloading shall be carried out in stages as shown in Table 4.7. Any particular requirements given in the particular contract documentation shall be complied with.

(ii)

Following each application of an increment of load, the load shall be maintained at the specified value for not less than the period shown in Table 4.7 and until the rate of settlement is less than 0.25 mm/h and decreasing. The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points.

(iii)

Each decrement of unloading shall proceed after the expiry of the period shown in Table 4.7.

(iv)

For any period when the load is constant, time and settlement shall be recorded immediately on reaching the load, at not more than 5 min intervals up to 15 min; at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and 4 h; and 1 h intervals between 4 h and 12 h after the application of the increment of load.

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(v)

Where the methods of measuring pile head movement given in Item 11 is used, the periods of time for which loads must be held constant to achieve the specified rates of settlement shall be extended as necessary to take into account the lower levels of accuracy available from these methods and to allow correct assessment of the settlement rate.

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Table 4.7 Minimum time of holding load

25% DVL 50% DVL 75% DVL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 25% SWL 100% DVL + 50% SWL 100% DVL + 25% SWL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 50% SWL 100% DVL + 75% SWL 100% DVL + 100% SWL 100% DVL + 75% SWL 100% DVL + 50% SW 100% DVL + 25% SW 100% DVL 75% DVL 50% DVL 25% DVL 0

1h 1h 1h 1h 10 min 10 min 10 min 1h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 1h 6h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 10 min 10 min 1h

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Load *

(b)

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SWL denotes specified working load; DVL denotes design verification load. Test Procedure for Preliminary Compression Piles

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*

Applicable to tests on Preliminary Pile only

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(i)

The procedure to be adopted for carrying out load tests on preliminary compression piles shall be either the extended proof load test procedure or the constant rate of penetration testing procedure given below. A normal proof load test will constitute the first stage of such a test unless otherwise specified.

(ii)

Extended proof load test procedure. Where test pile is to be loaded up to the sum of design verification load (DVL) plus 100 % of the specified working load, the loading procedure may be carried out as a continuation of the proof load testing procedure given in Item 14 (a).

(iii)

Following the completion of the proof load test, the load shall be restored in two stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages of 25 % of the specified working load. Following each application of an increment of load, the load shall be maintained at the specified value for the period shown in Table 4.7 and until the rate of settlement is decreasing and is less than 0.25 mm/h.


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(iv)

Where verification of required minimum factor of safety is called for or the pile is to be tested to failure, the loading procedure shall be continued after reaching DVL +100 % SWL stage by increasing the load in increments of 25 % of the specified working load or other specified amount until the maximum specified load of the test is reached. Following each application of increment of load, the load shall be maintained at the specified value for not less than 1 h and until the rate of settlement is decreasing and is less than 0.25 mm/h, or other approved rate appropriate to the stage of loading and its proximity to a failure condition. Permissible settlement at the load corresponding to the required minimum factor of safety called for in the design will not normally be specified.

(v)

The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points. Reduction of load at the end of the test shall be gradual as required by Item 14 (a).and the final rebound of the pile head shall be recorded.

(vi)

Constant rate of penetration (CRP) testing procedure. Where it is required to determine the ultimate load of a preliminary compression pile, and particularly where piles are largely embedded in and bearing on clay soils, the CRP testing procedure will normally be specified.

(vii)

The rate of movement of the pile head shall be maintained constant in so far as is practicable and shall be approximately 0.01 mm/s.

(viii)

Readings of loads, penetration and time shall be made simultaneously at regular intervals; the interval chosen shall be such that a curve of load versus penetration can be plotted without ambiguity.

(ix)

Loading shall be continued until one of the following results is obtained

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The maximum required test load.

2.

A constant or reducing load has been recorded for an interval of penetration of 10 mm.

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A total movement of the pile base equal to 10 % of the base diameter, or any other greater value of movement specified, has been reached.

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3.

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1.

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(x)

(c)

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The load shall then be reduced in five approximately equal stages to zero load, penetration and load being recorded at each stage.

Testing of Piles Designed to Carry Load in Tension (i)

The testing of piles designed to carry load in tension shall follow the same procedure as specified in 4.9.1

(ii)

In testing by the constant rate of uplift method, overall movements of the pile head will normally be less than those expected in a constant rate of penetration test. The rate of movement of the pile head shall be maintained at approximately 0.005 mm/s in so far as is practicable.

Completion of a test (a)

Removal of Test Equipment

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(b)


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(i)

On completion of a test and subject to the approval of the Engineer, all measuring equipment and load application devices shall be dismantled and checked. All other test equipment, including kentledge, beams and supporting structures shall be removed from the test pile location. Measuring and other demountable equipment shall be stored in a safe manner so that it is available for further tests, or removed from the Site as approved by the Engineer.

(ii)

Temporary tension piles and ground anchorages shall be cut off below ground level, and off-cut materials removed from the Site. The ground shall be restored to the original contours.

Preliminary Test Pile Cap Unless otherwise specified, the head of each preliminary test pile shall be cut off below ground level, off-cut material shall be removed from the Site and the ground restored to the original contours.

Proof Test Pile Cap

rw

On completion of a test on a proof pile, the test pile cap shall be prepared as specified and left in a state ready for incorporation into the Permanent Works. Any resulting off-cut materials shall be removed from the Site.

Presentation of results

1

Results to be submitted

as

4.9.2

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(i)

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(c)

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(i)

During the progress of a test, all records taken shall be available for inspection by the Engineer.

(b)

Results shall be submitted as

Preliminary report of the test results to the Engineer, unless otherwise directed, within 24 hours of the completion of the test, which shall show. For a test by maintained load: for each stage of loading, the period for which the load was held, the load and the maximum pile movement at the end of the stage.

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1.

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(a)

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2.

(ii)

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For a CRP or CRU test: the maximum load reached and a graph of load against penetration or load against uplift.

The final report of recorded data as prescribed in Item 15 (b).within ten days of the completion of the test.

Schedule of Recorded Data (a)

The Contractor shall provide information about the test pile in accordance with the following schedule where applicable. (i)

General. 1.

site location contract identification

2.

proposed structure

3.

main contractor

4.

piling contractor

5.

engineer client/employer

6.

date and time of test

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Pile details. 1.

all types of pile

2.

identification (number and location)

3.

specified working load (SWL)

4.

design verification load (DVL)

5.

original ground level at pile location

6.

head level at which test load was applied

7.

type of pile

8.

vertical or raking, compression or tension

9.

shape and size of cross-section of pile, and position of any change in cross-section

10.

shoe or base details

11.

head details

12.

length in ground

13.

tip Elevation

14.

dimensions of any permanent casing

15.

concrete piles

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(ii)

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concrete mix/grade



aggregate type and source



cement type and cement replacement and type where used

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admixtures

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

(iii)

16.



slump



cube test results for pile and cap



date of casting of precast pile



reinforcement

steel piles 

steel quality



coating



filling or core materials type and quality, if applicable

Installation details. 1.

2.

all piles 

dates and times of boring, driving and concreting of test pile



difficulties and delays encountered



date and time of casting concrete pile cap

bored piles 

type of equipment used and method of boring



temporary casing - diameter, type and length


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full log of pile borehole



method of placing concrete



Volume of concrete placed



driven preformed and driven cast-in-place piles



Method of support of hammer and pile driven length of pile or temporary casing at final set



Hammer type, and size or weight



Dolly and packing, type and condition



Driving log (depth, hammer drop, blows per 250 mm, interruptions or breaks in driving)



Final set in number of blows to produce penetration of 25 mm



Redrive check, time interval and set in number of blows to produce penetration of 25 mm or other agreed amount at final set and at redrive set, for a drop hammer or for a single acting hammer the length of the drop or stroke, for a diesel hammer the length of the stroke and the blows per minute, for a double acting hammer the operating pressure and the number of blows per minute



condition of pile head or temporary casing after driving



use of a follower



use of preboring



use of jetting



lengthening

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(iv)

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Test procedure.

mass of kentledge

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1.

tension pile, ground anchorage or compression pile details

3.

plan of test arrangement showing position and distances of kentledge supports, rafts, tension or compression piles or ground anchorages, and supports to pile movement reference system

4.

jack capacity

5.

method of load measurement

6.

method(s) of penetration or uplift measurement

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(v)

Test results. 1.

in tabular form

2.

in graphical form: load plotted against pile head movement

3.

ambient temperature records during test.

4.9.3

Low strain Integrity test

1

This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in Section 2

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Grosshole Sonic Logging Test

1

This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as mentioned in Section 2

4.9.5

Calliper Logging Test

1


4.9.6

Axial Tensile Load Test

1


4.9.7

Lateral Load Test

1


4.9.8

Alternative Methods for Testing Piles

1

Scope

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4.9.4

This Part outlines the alternative methods for testing piles. A significant advance in identifying the existence of defects in construction of piles has been the development and adoption of modern integrity testing systems which may be employed to check the quality of construction when required by the Engineer.

(b)

Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance distribution, and immediate settlement characteristics, hammer transfer energy (efficiency), and pile stresses during driving. The results obtained relate directly to dynamic loading conditions.

(c)


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(a)

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This Section Section 2

2

3


The testing shall be carried out by an approved firm.

(b)

The interpretation of tests shall be carried out by persons competent in the test procedure, and the full test results and findings shall normally be given to the Engineer within 10 d of the completion of each phase of testing. Full details of the ground conditions, pile dimensions and construction method shall be made available to the specialist firm when required in order to facilitate interpretation of the tests.

Integrity-testing of piles (a)

General


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(i)

Integrity-testing of piles is designed to give information about the physical dimensions, continuity and consistency of materials used in piles, and not to give direct information about the performance of piles under the conditions of loading. The methods available are normally applied to preformed concrete piles made in a single length, to steel piles and to cast-in-place concrete piles.

(ii)

This type of testing will not be regarded as a replacement for static load testing, but as a source of supplementary information.

(iii)

There is normally a limit to the length: diameter ratio of pile which can be successfully and fully investigated in this way, depending on the ground conditions.

(iv)

In the event that any anomaly is found in the results of such testing, the Engineer may call for further testing to be carried out in order to investigate the cause, nature and extent of the anomaly and whether the pile is satisfactory for its intended use.

Method of Testing

Where integrity-testing is called for but the method is not specified, the method to be adopted shall be approved by the Engineer and shall be one of the following

3.

The sonic logging method.

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The vibration method.

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Other methods may be adopted subject to the approval of the Engineer and subject to satisfactory evidence of performance.

In the case of cast-in-place concrete piles, integrity tests shall not be carried out until 7 d or more have elapsed after pile-casting, unless otherwise approved by the Engineer.

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Preparation of Pile Heads

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2.

Age of Piles at Time of Testing (i)

(d)

The sonic method.

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Where the method of testing requires the positioning of sensing equipment on the pile head, the head shall be clean, free from water, laitance and loose concrete and readily accessible for the purpose of testing.

Dynamic pile-testing (a)

General (i)

Dynamic pile-testing involves monitoring the response of a pile to a heavy impact applied at the pile head. The impact is often provided by the pile-driving hammer and response is normally measured in terms of force and acceleration or displacement close to the pile head.

(ii)

The results directly obtained refer to dynamic loading conditions. Interpretation in terms of static loading requires soil- and pile-dependent adjustments, and corroboration from experience may be required to correlate dynamic testing with normal static load tests as specified in clause 4.9.1 of this Section.

(iii)

Details of the equipment to be used and of the method of analysis of test results shall be provided to the Engineer before the commencement of testing.

QCS 2014

(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Measuring Instruments (i)

(c)

All instruments affixed to the pile for the purpose of measuring stress and movement, and all equipment for receiving and processing data shall be suitable for the purpose. The equipment required to be attached to the pile shall be appropriately positioned and fixed to the approval of the Engineer.

Hammer (i)

(d)

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The hammer and all other equipment used shall be capable of delivering an impact force sufficient to mobilise the equivalent specified test load without damaging the pile.

Preparation of the Pile Head The preparation of the pile head for the application of the dynamic test load shall involve, where appropriate, trimming the head, cleaning and building up the pile using materials which will at the time of testing safely withstand the impact stresses. The impact surface shall be flat and normal to the axis of the pile.

(e)

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(i)

Time of Testing

Dynamic load tests shall be carried out at appropriate and approved times after pile installation. The time between the completion of installation and testing for a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified 28 day strength so that the pile is not damaged under the impact stresses.

Set Measurements

(g)

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Where required and appropriate, the permanent penetration per blow and temporary compression of the pile and soil system shall be measured independently of the instruments being used to record the dynamic test data.

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(i)

Results

Initial the results shall be provided to the Engineer within 24 hours of the completion of a test. These shall include

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(i)

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(f)

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(i)

The maximum force applied to the pile head.

2.

The maximum pile head velocity.

3.

The maximum energy imparted to the pile.

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1.

(ii)

Normally within 10 d of the completion of testing final report shall be given to the Engineer which includes: 1.

Date of pile installation.

2.

Date of test.

3.

Pile identification number and location.

4.

Length of pile below ground surface.

5.

Total pile length, including projection above commencing surface at time of test.

6.

Length of pile from instrumentation position to tip.

7.

Hammer type, drop and other relevant details.

8.

Blow selected for analysis.

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9.

Test load achieved (i.e. total mobilised deduced static load).

10.

Pile head movement at equivalent design verification load.

11.

Pile head movement at equivalent design verification load plus 50 % of specified working load.

12.

Pile head movement at maximum applied test load.

13.

Permanent residual movement of pile head after each blow.

14.

Temporary compression.

DESIGN METHODS AND DESIGN CONSIDERATIONS

4.10.1

Design method

1

The design shall be based on one of the following approaches:

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4.10

The results of static load tests, which have been demonstrated, by means of calculations or otherwise, to be consistent with other relevant experience;

(b)

Empirical or analytical calculation methods whose validity has been demonstrated by static load tests in comparable situations;

(c)

The results of dynamic load tests whose validity has been demonstrated by static load tests in comparable situations;

(d)

The observed performance of a comparable piles foundation, provided that this approach is supported by the results of site investigation and ground testing.

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(a)

Design values for parameters used in the calculations should be in general accordance with design parameters from geotechnical investigations report, but the results of load tests may also be taken into account in selecting parameter values.

3

Static load tests may be carried out on trial piles, installed for test purposes only, before the design is finalized, or on working piles, which form part of the foundation.

4.10.2

Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations

1

When considering a limit state of rupture or excessive deformation of a structural element or section of the ground (Structural and Geotechnical), it shall be verified in accordance with (Eurocode1997-1) or equivalent.

4.10.3

Design Considerations

1

The behavior of individual piles and pile groups and the stiffness and strength of the structure connecting the piles shall be considered.

2

In selecting calculation methods and parameter values and in using load test results, the duration and variation in time of the loading shall be considered.

3

Planned future placement or removal of overburden or potential changes in the ground-water regime shall be considered, both in calculations and in the interpretation of load test results.

4

The choice of type of pile, including the quality of the pile material and the method of installation, shall take into account:

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the ground and ground-water conditions on the site, including the presence or possibility of obstructions in the ground;

(b)

the stresses generated in the pile during installation;

(c)

the possibility of preserving and checking the integrity of the pile being installed;

(d)

the effect of the method and sequence of pile installation on piles, which have already been installed and on adjacent structures or services;

(e)

the tolerances within, which the pile can be installed reliably;

(f)

the deleterious effects of chemicals in the ground;

(g)

the possibility of connecting different ground-water regimes;

(h)

the handling and transportation of piles;

(i)

the effects of pile construction on neighboring buildings.

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(a)

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In considering the aspects listed above, the following items should receive attention: the spacing of the piles in pile groups;

(b)

displacement or vibration of adjacent structures due to pile installation;

(c)

the type of hammer or vibrator used;

(d)

the dynamic stresses in the pile during driving;

(e)

for those types of bored pile where a fluid is used inside the borehole, the need to keep the pressure of the fluid at a level to ensure that the borehole will not collapse and that hydraulic failure of the base will not occur;

(f)

cleaning of the base and sometimes the shaft of the borehole, especially under bentonite, to remove remolded materials;

(g)

local instability of a shaft during concreting, which may cause a soil inclusion within the pile;

(h)

ingress of soil or water into the section of a cast-in-situ pile and possible disturbance of wet concrete by the flow of water through it;

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the effect of unsaturated sand layers around a pile extracting water from the concrete;

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(i)

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(j)

the retarding influence of chemicals in the soil;

(k)

soil compaction due to the driving of displacement piles;

(l)

soil disturbance due to the boring of a pile shaft.

4.11

AXIALLY LOADED PILES

4.11.1

Limit state design

1

The design shall demonstrate that exceeding the following limit states is sufficiently improbable: (a)

ultimate limit states of compressive or tensile resistance failure of a single pile;

(b)

ultimate limit states of compressive or tensile resistance failure of the pile foundation as a whole;

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(c)

ultimate limit states of collapse or severe damage to a supported structure caused by excessive displacement or differential displacements of the pile foundation;

(d)

serviceability limit states in the supported structure caused by displacement of the piles.

Normally the design should consider the margin of safety with respect to compressive or tensile resistance failure, which is the state in which the pile foundation displaces significantly downwards or upwards with negligible increase or decrease of resistance.

3

For piles in compression it is often difficult to define an ultimate limit state from a load settlement plot showing a continuous curvature. In these cases, settlement of the pile top equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

4

For piles that undergo significant settlements, ultimate limit states may occur in supported structures before the resistance of the piles is fully mobilized. In these cases a cautious estimate of the possible range of the settlements shall be adopted in design.

4.11.2

Compressive Ground Resistance

1

To demonstrate that the pile foundation will support the design load with adequate safety against compressive failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations:

qa

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2

as

Fc ≤ Rc

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Where

er

Fc: design axial compression load on a pile or a group of piles

In principle Fc should include the weight of the pile itself and Rc should include the overburden pressure of the soil at the foundation base. However these two items may be disregarded if they cancel approximately. They need not cancel if: (a)

downdrag is significant; the soil is very light,

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(b)

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2

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Rc: design value

(c) 3

the pile extends above the surface of the ground.

For piles in groups, two failure mechanisms shall be taken into account: (a)

compressive resistance failure of the piles individually;

(b)

compressive resistance failure of the piles and the soil contained between them acting as a block.

NOTE: The design resistance shall be taken as the lower value caused by these two

mechanisms. 4

The compressive resistance of the pile group acting as a block may be calculated by treating the block as a single pile of large diameter.

5

The stiffness and strength of the structure connecting the piles in the group shall be considered when deriving the design resistance of the foundation.

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If the piles support a stiff structure, advantage may be taken of the ability of the structure to redistribute load between the piles. A limit state will occur only if a significant numbe r of piles fail together; therefore a failure mode involving only one pile need not be considered.

7

If the piles support a flexible structure, it should be assumed that the compressive resistance of the weakest pile governs the occurrence of a limit state.

8

Special attention should be given to possible failure of edge piles caused by inclined or eccentric loads from the supported structure.

9

If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer on the compressive resistance of the foundation shall be considered.

10

The strength of a zone of ground above and below the pile base shall be taken into account when calculating the pile base resistance.

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NOTE: This zone may extend several diameters above and below the pile base. Any weak ground in this zone has a relatively large influence on the base resistance.

Punching failure should be considered if weak ground is present at a depth of less than 4 times the base diameter below the base of the pile.

12

Where the pile base diameter exceeds the shaft diameter, the possible adverse effect shall be considered.

13

For open-ended driven tube or box-section piles with openings of more than 500 mm in any direction, and without special devices inside the pile to induce plugging, the base resistance should be limited to the smaller of:

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11

the shearing resistance between the soil plug and the inside face of the pile;

(b)

the base resistance derived using the cross-sectional area of the base.

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(a)

Ultimate compressive resistance from static load tests

1

The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be specified in the Geotechnical Design Report.

2

Trial piles to be tested in advance shall be installed in the same manner as the piles that will form the foundation and shall be founded in the same stratum.

3

If the diameter of the trial pile differs from that of the working piles, the possible difference in performance of piles of different diameters should be considered in assessing the compressive resistance to be adopted.

4

In the case of a very large diameter pile, it is often impractical to carry out a load test on a full size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

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4.11.3

(a)

the ratio of the trial pile diameter/working pile diameter is not less than 0,5;

(b)

the smaller diameter trial pile is fabricated and installed in the same way as the piles used for the foundation;

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the trial pile is instrumented in such a manner that the base and shaft resistance can be derived separately from the measurements.

NOTE: This approach should be used with caution for open-ended driven piles because of the influence of the diameter on the mobilisation of the compressive resistance of a soil plug in the pile. In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a displacement that equals the criterion for the verification of the ultimate limit state determined from the load test results, shall be corrected. The correction shall be achieved by subtracting the measured, or the most unfavorable, positive shaft resistance in the compressible stratum and in the strata above, where negative skin friction develops, from the loads measured at the pile head.

6

During the load test of a pile subject to downdrag, positive shaft friction will develop along the total length of the pile. The maximum test load applied to the working pile should be in excess of the sum of the design external load plus twice the downdrag force.

7

When deriving the ultimate characteristic compressive resistance from values measured in one or several pile load tests, an allowance shall be made for the variability of the ground and the variability of the effect of pile installation.

8

The systematic and random components of the variations in the ground shall be recognized in the interpretation of pile load tests.

9

The records of the installation of the test pile(s) shall be checked and any deviation from the normal execution conditions shall be accounted for.

10

The characteristic compressive resistance of the ground may be derived from the characteristic values of the base resistance and of the shaft resistance in accordance with Eurocode1997-1.

4.11.4

Ultimate compressive resistance from ground test results

1

Methods for assessing the compressive resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as described as following to ensure that the predicted compressive resistance is sufficiently safe :

3

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(a)

the range of uncertainty in the results of the method of analysis;

(b)

any systematic errors known to be associated with the method of analysis

In assessing the validity of a model based on ground test results, the following items should be considered: (a)

soil type, including grading, mineralogy, angularity, density, pre-consolidation, compressibility and permeability;

(b)

method of installation of the pile, including method of boring or driving;

(c)

length, diameter, material and shape of the shaft and of the base of the pile (e.g. enlarged base);

(d)

method of ground testing.

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4.11.5

Ultimate compressive resistance from dynamic impact tests

1

Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration versus time during the impact event is used to assess the resistance of individual compression piles, the validity of the result shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type of similar length and cross-section and in similar ground conditions.

2

When using a dynamic impact load test, the driving resistance of the pile should be measured directly on the site in question.

.

NOTE A load test of this type can also include a process of signal matching to measured stress wave figures. Signal matching enables an approximate evaluation of shaft and base resistance of the pile as well as a simulation of its load-settlement behaviour. The impact energy shall be high enough to allow for an appropriate interpretation of the pile capacity at a correspondingly high enough strain level.

4

The design value of the compressive resistance of the pile could be calculated and verified according to Eurocode1997-1.

4.11.6

Ultimate compressive resistance by applying pile driving formulae

1

Pile driving formulae shall only be used if the stratification of the ground has been determined.

2

If pile driving formulae are used to assess the ultimate compressive resistance of individual piles in a foundation, the validity of the formulae shall have been demonstrated by previous experimental evidence of acceptable performance in static load tests on the same type of pile, of similar length and cross-section, and in similar ground conditions.

3

For end-bearing piles driven into non-cohesive soil, the design value of the compressive resistance shall be assessed by the same procedure as in 4.11.5.

4

When a pile driving formula is applied to verify the compression resistance of a pile, the pile driving test should have been carried out on at least 5 piles distributed at sufficient spacing in the piling area in order to check a suitable blow count for the final series of blows.

5

The penetration of the pile point for the final series of blows should be recorded for each pile.

4.11.7

Ultimate compressive resistance from wave equation analysis

1

Wave equation analysis shall only be used where stratification of the ground has been determined by borings and field tests.

2

Where wave equation analysis is used to assess the resistance of individual compression piles, the validity of the analysis shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type, of similar length and cross- section, and in similar ground conditions.

3

The design value of the compressive resistance derived from the results of wave equation analysis of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.

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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving equipment without stress wave measurements on site. The method is usually applied to study hammer performance, dynamic soil parameters and stresses in the pile during driving. It is also, on the basis of the models, possible to determine the required driving resistance (blow count) that is usually related to the expected compressive resistance of the pile. Ground tensile resistance

1

The design of piles in tension shall be consistent with the design rules given in 4.11.2, where applicable. Design rules that are specific for foundations involving piles in tension are presented below.

2

To verify that the foundation will support the design load with adequate safety against a failure in tension, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations in accordance with Eurocode1997-1.

3

For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

4

When considering the uplift of the block of ground containing the piles the shear resistance along the sides of the block may be added to the resisting forces.

5

Normally the block effect will govern the design tensile resistance if the distance between the piles is equal to or less than the square root of the product of the pile diameter and the pile penetration into the main resisting stratum.

6

The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft resistances of individual piles in the group, shall be considered when assessing the tensile resistance of a group of piles.

7

The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be considered.

8

Comparable experience based on pile load tests should be applied to appraise this effect.

4.11.9

Ultimate tensile resistance from pile load tests

1

Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in accordance with 4.9.1 and with regard to 4.11.3.

2

The design tensile resistance could be calculated and verified according to Eurocode1997-1.

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4.11.8

4.11.10 Ultimate tensile resistance from ground test results 1

Methods for assessing the tensile resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as following to ensure that the predicted tensile resistance is sufficiently safe. (a)


(b)

any systematic errors known to be associated with the method of analys is

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The design value of tensile resistance of a pile could be calculated and verified according to Eurocode1997-1.

4.11.11 Vertical displacements of pile foundations 1

Vertical displacements under serviceability limit state conditions shall be assessed and checked.

2

When calculating the vertical displacements of a pile foundation, the uncertainties involved in the calculation model and in determining the relevant ground properties should be taken into account. Hence it should not be overlooked that in most cases calculations will provide only an approximate estimate of the displacements of the pile foundation.

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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety requirements for the ultimate limit state design are normally sufficient to prevent a serviceability limit state in the supported structure.

The occurrence of a serviceability limit state in the supported structure due to pile settlements shall be checked, taking into account downdrag, where probable.

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4.11.12 Pile foundations in compression

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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to satisfy serviceability limit state conditions. Assessment of settlements shall include both the settlement of individual piles and the settlement due to group action.

3

The settlement analysis should include an estimate of the differential settlements that may occur.

4

When no load test results are available for an analysis of the interaction of the piled foundation with the superstructure, the load-settlement performance of individual piles should be assessed on empirically established safe assumptions.

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4.11.13 Pile foundations in tension The assessment of upward displacements shall be done and Particular attention should be paid to the elongation of the pile material.

2

When very severe criteria are set for the serviceability limit state, a separate check of the upward displacements shall be carried out.

4.12

TRANSVERSELY LOADED PILES

4.12.1

Design method

1

The design of piles subjected to transverse loading shall be consistent with the design rules given in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to transverse loading are presented below.

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To demonstrate that a pile will support the design transverse load with adequate safety against failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations: Ftr ≤ Rtr Where; Ftr: design value of the transverse load on a pile or a pile foundation Rtr : design resistance of transversally loaded pile One of the following failure mechanisms should be considered: for short piles, rotation or translation as a rigid body;

(b)

for long slender piles, bending failure of the pile, accompanied by local yielding and displacement of the soil near the top of the pile.

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The group effect shall be considered when assessing the resistance of transversely loaded piles.

5

It should be considered that a transverse load applied to a group of piles may result in a combination of compression, tension and transverse forces in the individual piles.

4.12.2

Transverse load resistance from pile load tests

1

Transverse pile load tests shall be carried out in accordance with 4.9.6.

2

Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not normally be continued to a state of failure. The magnitude and line of action of the test load should simulate the design loading of the pile.

3

An allowance shall be made for the variability of the ground, particularly over the top few meters of the pile, when choosing the number of piles for testing and when deriving the design transverse resistance from load test results.

4

Records of the installation of the test pile(s) should be checked, and any deviation from the normal construction conditions should be accounted for in the interpretation of the pile load test results. For pile groups, the effects of interaction and head fixity should be accounted for when deriving the transverse resistance from the results of load tests on individual test piles.

4.12.3

Transverse load resistance from ground test results and pile strength parameters

1

The transverse resistance of a pile or pile group shall be calculated using a compatible set of structural effects of actions, ground reactions and displacements.

2

The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile in the ground.

3

The calculation of the transverse resistance of a long slender pile may be carried out using the theory of a beam loaded at the top and supported by a deformable medium characterized by a horizontal modulus of subgrade reaction.

4

The degree of freedom of rotation of the piles at the connection with the structure shall be taken into account when assessing the foundation’s transverse resistance.

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4.12.4

Transverse displacement

1

The assessment of the transverse displacement of a pile foundation shall take into account: the stiffness of the ground and its variation with strain level;

(b)

the flexural stiffness of the individual piles;

(c)

the moment fixity of the piles at the connection with the structure;

(d)

the group effect;

(e)

the effect of load reversals or of cyclic loading

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A general analysis of the displacement of a pile foundation should be based on expected degrees of kinematic freedom of movement.

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END OF PART

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Section 04: Foundations & Retaining Structures Part 05: Retaining Structures

Page 2

RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

5.1

GENERAL---------------------------------------------------------------------------------------------------------- 2

5.2

LIMIT STATES ---------------------------------------------------------------------------------------------------- 2

5.2.2 5.2.3

Ultimate Limit State ---------------------------------------------------------------------------------------------- 2 Serviceability Limit State ---------------------------------------------------------------------------------------- 3

5.3

ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3

5.3.1 5.3.2 5.3.3

Actions -------------------------------------------------------------------------------------------------------------- 3 Geometrical data ------------------------------------------------------------------------------------------------- 4 Design Situations ------------------------------------------------------------------------------------------------- 4

5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

5.5

DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General ------------------------------------------------------------------------------------------------------------- 6 At rest values of earth pressure------------------------------------------------------------------------------- 7 Limiting values of earth pressure ----------------------------------------------------------------------------- 7 Intermediate values of earth pressure ----------------------------------------------------------------------- 7 Compaction effects ---------------------------------------------------------------------------------------------- 7

5.6

WATER PRESSURES ------------------------------------------------------------------------------------------ 8

5.7

ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8

5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7

General ------------------------------------------------------------------------------------------------------------- 8 Overall stability ---------------------------------------------------------------------------------------------------- 8 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8 Rotational failure of embedded walls ------------------------------------------------------------------------ 8 Vertical failure of embedded walls --------------------------------------------------------------------------- 9 Structural design of retaining structures -------------------------------------------------------------------- 9 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9

5.8

SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9

5.8.1 5.8.2

General ------------------------------------------------------------------------------------------------------------- 9 Displacements ---------------------------------------------------------------------------------------------------- 9

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5

RETAINING STRUCTURES

5.1

GENERAL

1

The provisions of this Part 5 apply to retaining structures in general. These are structures used to retain ground comprising soil, rock or backfill and water and this at an angle steeper than the angle they would normally adopt without the presence of those structures. Common retaining structures used within the state of Qatar taking into account the prevailing geologic conditions are: Sheet Piles

(b)

Bored and Cast in Place Concrete Piles

Secant Piles

(c)

Diaphragm Walls

(d)

Composite Shoring Systems

(e)

Concrete Retaining Walls

(ii)

Counter Fort Retaining Wall

(iii)

Gravity Retaining Wall

(iv)

Buttressed Retaining Wall

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Cantilever Retaining Wall

Reinforced Soil Retaining Structures Geogrid and Geotextile Reinforced Earth Systems

(ii)

Galvanized Strips Reinforced Earth System

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(i)

Soil and Rock Nailing Systems

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Contiguous Piles

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(a)

This revision of Section 4 – Part 5 is considered preliminary and shall be reviewed and amended as needed in the next revision to elaborate on various subjects not covered herein.

3

This revision of Section 4 – Part 5 is based generally on “EN1997-1:2004+A1:2013” Eurocode 7.

4

Section 4 – Part 5 will cover at this stage the general design aspects knowing that the construction procedures shall be added in future revisions of this Section. Hence, at this stage, the construction related subjects of the retaining structures will follow relevant Parts of the QCS.

5.2

LIMIT STATES

1

During the design of retaining structures the following typical limit states should be considered:

5.2.2

Ultimate Limit State

1

Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.

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Foundation failure of retaining structures with footings: it should be demonstrated that the foundation pressures (lateral and vertical) do not exceed neither the ground allowable bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to water seepage should also be included in the analysis.

3

Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a rigid body.

4

Failure of embedded walls by rotation or horizontal translation or by lack of vertical equilibrium.

5

Failure of a structural element such as a wall, anchorage, wale or strut, including failure of the connection between those elements.

6

Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable leakage of water, or transport of soil particles through or under the wall caused by excessive hydraulic gradients.

5.2.3

Serviceability Limit State

1

Unacceptable movement of the retaining structure, which may affect the appearance or functionality of the structure itself, or other neighbouring structures or utilities influenced by the movement.

2

Unacceptable change in the groundwater regime.

5.3

ACTIONS AND GEOMETRICAL DATA

5.3.1

Actions

1

Generally, the forces exerted on retaining structure with values assumed known at the beginning of the calculation are considered as 'actions', while forces with initially unknown values, to be determined by the interaction of the retaining structure with support elements (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following actions are to be taken into account: Weight of backfill material

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(b)

Surcharges

(c)

Weight of water

(d)

Wave forces for marine projects

(e)

Seepage forces

(f)

Collision forces

(g)

Temperature effects

(h)

Forces from propping elements (i.e. post-tensioned anchors)

(i)

Siesmic related effects

The above actions should result in the determination of various earth pressures acting on the retaining structure.

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5.3.2

Geometrical data

1

This paragraph covers the uncertainties in the geometrical data namely excavation and water levels. In general, small variations in geometrical data are considered to be covered by the safety factors included in the calculations. However, since the design of retaining structures is sensitive to ground and water levels, special requirements are included in this paragraph, mainly for unforeseen over-dig in front of the wall and groundwater levels change on both sides of the wall.

2

Unforeseen over-dig in front of the wall

Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for cantilever walls;

(b)

Equal to 10% of the distance between the lowest support and the excavation level (up to a maximum of 0.5 m), for supported walls.

Groundwater levels in front of and behind the wall

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In Ultimate Limit State design calculations, where the wall stability depends on the earth resistance in front of the wall, the level of the resisting soil should be lowered below the nominally expected level by an amount which depends on the degree of control on the excavation level. With a normal degree of control the expected difference in resisting soil level should be:

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The selection of the levels of the phreatic surfaces in front of and behind the wall must consider long-term variations of the groundwater regime and/or the ground permeability, the presence of perched or artesian aquifers and the possibility that drainage behind the wall may cease to function with time. Design Situations

1

The following conditions shall be considered during the design of retaining structures: Anticipated variations in soil properties

(b)

Variations in actions and the ways they are combined

(c)

Excavation, scour or erosion in front of the retaining structure The effect of compaction of the backfill behind the retaining structure

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(e)

The effect of anticipated future structures and surcharge loads/unloads

(f)

Anticipated ground movements

(g)

Inclination of the wall to the vertical

(h)

Variations in groundwater table and the seepage forces in the ground

(i)

Horizontal as well as vertical equilibrium for the entire retaining structure

(j)

The shear strength and weight density of the ground

(k)

The rigidity of the wall and the supporting system

(l)

The wall roughness

(m)

Seismic effect on the various forces

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5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS

1

The design of retaining structures requires consideration of all relevant Ultimate Service States and Service Limit States.

2

For retaining structures without strict serviceability requirements, the geometry is usually determined by Ultimate Limit State design calculations and checked by Service Limit State calculations (if relevant). For the retaining structures with strict serviceability requirements, the Service Limit State requirements often govern the design.

3

The design and construction considerations should cover the following: Demonstrate that vertical equilibrium can be achieved for the assumed pressure distributions and actions on the wall.

(b)

Verification of vertical equilibrium may be achieved by reducing the wall friction parameters.

(c)

Retaining walls should be designed in such a way that there are visible signs of the approach of an ultimate limit state. The design should prevent brittle failure of the structure, e.g. sudden collapse without conspicuous preliminary deformations.

(d)

A critical limit state should be considered to occur if the wall has displaced enough to cause damage to nearby structures or services. Although collapse of the wall may not be imminent, the degree of damage may considerably exceed a serviceability limit state in the supported structure.

(e)

The design methods and partial factor values recommended by “EN19971:2004+A1:2013” are usually sufficient to prevent the occurrence of ultimate limit states in nearby structures, provided that the soils involved are of at least medium density or firm consistency and adequate construction methods and sequences are adopted. Special care should be taken, however, with some highly over-consolidated clay deposits in which large at rest horizontal stresses may induce substantial movements in a wide area around excavations.

(f)

The complexity of the interaction between the ground and the retaining structure sometimes makes it difficult to design a retaining structure in detail before the actual execution starts. In this case, use of the observational method for the design should be considered. The observational method consists of setting criteria enabling monitoring during construction, allowing necessary corrective actions to be taken to rectify the design. Hence, the following requirements shall be set before construction:

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(a)

(g)

(i)

Acceptable limits of behaviour

(ii)

The range of potential behaviour shall be analysed showing acceptable probability that the actual behaviour will be within the acceptable limits

(iii)

A plan of monitoring shall be established (including necessary instruments and procedures) enabling the comparison of the actual behaviour to the acceptable limits. The monitoring shall allow early detection of nonconformities, allowing enough time for corrective actions to be taken successfully.

(iv)

A list of contingency actions shall be established which could be used if the actual observed behaviour is outside of the acceptable limits.

The effects of constructing the wall, including: (i)

The provision of temporary support to the sides of excavations;

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(ii)

The changes of in situ stresses and resulting ground movements caused both by the wall excavation and its construction;

(iii)

Disturbance of the ground due to driving or boring operations;

(iv)

Provision of access for construction;

The required degree of water tightness of the finished wall;

(i)

The practicability of constructing the wall to reach a stratum of low permeability, so forming a water cut-off. The resulting equilibrium ground-water flow problem shall be assessed;

(j)

The practicability of forming ground anchorages in adjacent ground;

(k)

The practicability of excavating between any propping of retaining walls;

(l)

The ability of the wall to carry vertical load;

(m)

The ductility of structural components;

(n)

Access for maintenance of the wall and any associated drainage measures;

(o)

The appearance and durability of the wall and any anchorages;

(p)

For sheet piling, the need for a section stiff enough to be driven to the design penetration without loss of interlock;

(q)

The stability of borings or slurry trench panels while they are open;

(r)

For fill, the nature of materials available and the means used to compact them adjacent to the wall.

(s)

Drainage systems

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If the safety and serviceability of the designed structure depend on the successful performance of a drainage system, the consequences of its failure shall be considered, taking into account both safety and cost of repair. One of the following conditions (or a combination of them) shall apply: A maintenance program for the drainage system shall be specified and the design shall allow access for this purpose;

(ii)

It shall be demonstrated both by comparable experience and by assessment of any water discharge that the drainage system will operate adequately without maintenance.

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(i)

The quantities, pressures and eventual chemical content of any water discharge should be taken into account.

5.5

DETERMINATION OF EARTH PRESSURES

5.5.1

General

1

The Determination of the earth pressures shall take into account the acceptable mode and amount of any movement and strain, which may occur at the limit state under consideration.

2

In the following context the words "earth pressure" should also be used for the total earth pressure from soft and weathered rocks and should include the pressure of ground-water.

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3

Calculations of the magnitudes of earth pressures and directions of forces resulting from them shall take account of the issues highlighted under paragraph “5.3.3”.

4

The amount of mobilized wall friction and adhesion should be considered as a function of: The strength parameters of the ground

(b)

The friction properties of the wall-ground interface

(c)

The direction and amount of movement of the wall relative to the ground

(d)

The ability of the wall to support any vertical forces resulting from wall friction and adhesion

A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a design wall ground interface parameter  d  k. cv ;d . k should not exceed 2/3 for precast

.

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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be assumed. For a steel sheet pile in clay under undrained conditions immediately after driving, no adhesive or frictional resistance should be assumed. Increases in these values may take place over a period of time. In the case of structures retaining rock masses, calculations of the ground pressures shall take into account the effects of discontinuities, with particular attention to their orientation, spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

7

Account shall be taken of any swelling potential of the ground when calculating the pressures on the retaining structure.

5.5.2

At rest values of earth pressure

1

When no movement of the wall relative to the ground takes place, the earth pressure shall be calculated from the at rest state of stress. The determination of the at-rest state shall take into account the stress history of the ground.

5.5.3

Limiting values of earth pressure

1

Limiting values of earth pressures shall be determined taking into account the relative movement of the soil and the wall at failure and the corresponding shape of the failure surface.

5.5.4

Intermediate values of earth pressure

1

Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize the limiting values. The determination of the intermediate values of earth pressure shall take into account the amount of wall movement and its direction relative to the ground.

2

The intermediate values of earth pressures may be calculated using, for example, various empirical rules, spring constant methods or finite element methods.

5.5.5

Compaction effects

1

The determination of earth pressures acting behind the wall shall take into account the additional pressures generated by any placing of backfill and the procedures adopted for its compaction.

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WATER PRESSURES

1

Determination of characteristic and design water pressures shall take account of water levels both above and in the ground.

2

When checking the ultimate and serviceability limit water pressures shall be accounted for in the combinations of actions considering the possible risks of flooding or change in groundwater levels from either sides of the retaining structure.

3

For structures retaining earth of medium or low permeability (silts and clays), water pressures should normally be assumed to act behind the wall. Unless a reliable drainage system is installed, or infiltration is prevented, the values of water pressures should normally correspond to a water table at the surface of the retained material.

4

Where sudden changes in a free water level may occur, both the non-steady condition occurring immediately after the change and the steady condition shall be examined.

5

Where no special drainage or flow prevention measures are taken, the possible effects of water-filled tension or shrinkage cracks shall be considered.

5.7

ULTIMATE LIMIT STATE DESIGN

5.7.1

General

1

The design of retaining structures shall be checked at the ultimate limit state for the design situations appropriate to that state, as specified in 5.3.3, using the design actions or action effects and design resistances.

2

All relevant limit modes shall be considered. These will include, as a minimum, limit modes of the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.

3

Calculations for ultimate limit states shall establish that equilibrium can be achieved using the design actions or effects of actions and the design strengths or resistances. Compatibility of deformations shall be considered in assessing design strengths or resistances.

5.7.2

Overall stability

1

Principles and calculations should be used as appropriate to demonstrate that an overall stability failure will not occur and that the corresponding deformations are sufficiently small taking into account progressive failure and liquefaction into account as relevant.

5.7.3

Foundation failure of gravity walls

1

The principles of foundation design shall be used as appropriate to demonstrate that a foundation failure is sufficiently remote and that deformations will be acceptable. Both bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should be verified as a minimum.

5.7.4

Rotational failure of embedded walls

1

It shall be demonstrated by equilibrium calculations that embedded walls have sufficient penetration into the ground to prevent rotational failure. As a minimum, limit modes of the types illustrated in Figure 5.3 should be considered.

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The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the relative vertical displacement, which would occur in the design situation.

5.7.5

Vertical failure of embedded walls

1

It shall be demonstrated that vertical equilibrium can be achieved using the design soil strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode of the type illustrated in Figure 5.4 should be considered.

2

Where downward movement of the wall is considered, upper design values shall be used in the calculation of pre-stressing forces, such as those from ground anchorages, which have a vertical downward component. The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the check for vertical and rotational equilibrium. If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using the principles of Pile Foundations Design.

5.7.6

Structural design of retaining structures

1

Retaining structures, including their supporting structural elements such as anchorages and props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013 “2.4 Geotechnical Design by Calculation” and EN1992, EN1993, EN1995 and EN1996. As a minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

5.7.7

Failure by pull-out of anchorages

1

It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground anchorages. Anchors shall be designed in accordance with Anchorage Design procedures with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also be considered.

5.8

SERVICEABILITY LIMIT STATE DESIGN

5.8.1

General

1

The design of retaining structures shall be checked at the serviceability limit state using the appropriate design situations as specified in 5.3.3. The assessment of design values of earth pressures should take account of the initial stress, stiffness and strength of the ground and the stiffness of the structural elements.

2

The design values of earth pressures should be derived taking account of the allowable deformation of the structure at its serviceability limit state. These pressures need not necessarily be limiting values.

5.8.2

Displacements

1

Limiting values for the allowable displacements of walls and the ground adjacent to them shall be established for a particular deformation is the value at which a serviceability limit state, such as unacceptable cracking or displacement of adjacent structures or utilities, is deemed to occur. This limiting value shall be agreed during the design, taking into account the tolerance to displacements of supported structures and services.

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2

If the initial cautious estimate of displacement exceeds the limiting values, the design shall be justified by a more detailed investigation including displacement calculations.

3

It shall be considered to what extent variable actions, such as vibrations caused by traffic loads behind the retaining wall, contribute to the wall displacement.

4

Displacement calculations should also be considered in the following cases: (a)

where the wall retains more than 6m of cohesive soil of low plasticity,

(b)

where the wall retains more than 3m of soils of high plasticity;

(c)

where the wall is supported by soft clay within its height or beneath its base.

Displacement calculations shall take into account the stiffness of the ground and structural elements and the sequence of construction.

6

The effect of vibrations on displacements shall be considered with regard to the following:

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5

Foundations for structures subjected to vibrations or to vibrating loads shall be designed to ensure that vibrations will not cause excessive settlements.

(b)

Precautions should be taken to ensure that resonance will not occur between the frequency of the dynamic load and a critical frequency in the foundation-ground system, and to ensure that liquefaction will not occur in the ground.

(c)

Vibrations caused by earthquakes shall be considered using the guidelines of the designated section of the QCS.

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(a)

Figure 5.1 – Examples of Limit Modes for Overall Stability of Retaining Structures (EN 1997-1:2004+A1:2013)


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Figure 5.2 – Examples of Limit Modes for Foundation Failures of Gravity Walls (EN 1997-1:2004+A1:2013)

Figure 5.3 – Examples of Limit Modes for Rotational Failures of Embedded Walls (EN 1997-1:2004+A1:2013)


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Figure 5.4 – Example of a Limit Mode for Vertical Failure of Embedded Walls (EN 1997-1:2004+A1:2013)

Figure 5.5 – Examples of Limit Modes for Structural Failure of Retaining Structures (EN 1997-1:2004+A1:2013)


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Figure 5.6 – Examples of Limit Modes for Failure by Pull-out of Anchoes (EN 1997-1:2004+A1:2013)

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END OF PART

QCS 2014

Section 05: Concrete Part 01: General

Page 1

GENERAL------------------------------------------------------------------------------------------------------------ 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4

INTRODUCTION --------------------------------------------------------------------------------------------------- 2 Scope ----------------------------------------------------------------------------------------------------------------- 2 References----------------------------------------------------------------------------------------------------------- 2 Definitions ------------------------------------------------------------------------------------------------------------ 3 Approved Products ------------------------------------------------------------------------------------------------ 4

1.2 1.2.1 1.2.2 1.2.3 1.2.4

IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4 Approved Installers ------------------------------------------------------------------------------------------------ 4 Field Quality Control ----------------------------------------------------------------------------------------------- 4 Rejected materials ------------------------------------------------------------------------------------------------- 5 Records --------------------------------------------------------------------------------------------------------------- 5

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GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section includes the requirements for concrete work for pipelines, roadworks, runways, structures, water retaining structures, foundations and bases for structures and equipment.

2

This Part includes relevant standards, definitions, abbreviations, and requirements for testing facilities, rejected materials, and record keeping.

3


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Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing of Concrete Formwork Curing Reinforcement Construction Joints Inspection and Testing of Hardened Concrete Protective Coatings to Concrete Hot Weather Concrete Miscellaneous Precast Concrete Prestressed Concrete Water Retaining Structures

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This Section: Part 2, Part 3, Part 4, Part 5, Part 6, Part 7, Part 8, Part 9, Part 10, Part 11, Part 12, Part 13, Part 14, Part 15, Part 16, Part 17, Part 18, Part 19,

.

1

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Section 1, Section 2, Section 4, Section 6, Section 8, Section 9,

General Quality Assurance and Quality Control Foundations and Retaining Structures Roadworks Drainage Works Mechanical and Electrical Equipment

1.1.2

References

1

The following standards are referred to in this Part: ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in the Field ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete

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BS 6100, ....................Glossary of Building and civil engineering terms BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing laboratory samples BS EN 12350-1 ..........Method of sampling fresh concrete in site BS EN 12350-2 ..........Testing fresh concrete. Slump-test BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2 .......... Making and curing specimens for strength tests GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – Part 2: Properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – Part 3: Making and curing test specimens Definitions

1

Definitions used in this Section.

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1.1.3

The following are terms and abbreviations used:

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degree Celsius calorie centimetre day Characteristic compressive strength of concrete determined by testing cylinders Compressive strength of concrete determined by testing cylinders Characteristic compressive strength of concrete determined by testing cubes Compressive strength of concrete determined by testing cubes Mean compressive strength of concrete Mean compressive strength of concrete at the age of (j) days ground granulated blast furnace slag guaranteed ultimate tensile strength hour kilogram kilojoule kilonewton litre metre square metre cubic metre milligram minute millimetre square millimetre months mega Pascal kilo Pascal moderate sulphate resisting Portland cement ordinary Portland cement pulverised fuel ash polyvinylchloride second silica fume sulphate resisting Portland cement

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C cal cm d fck,cyl fc,cyl fck,cube fc,cube fcm fcm,j GGBS GUTS h kg kJ kN l m 2 m 3 m mg min mm 2 mm months MPa kPa MSRPC OPC PFA PVC s SF SRPC

QCS 2014

ton ppm

1000 kg part per million

micron

10

µm

10 meter

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-6 -6

Reference to a technical society, institution, association or governmental authority is made in accordance with the following abbreviations.

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American Association of State Highway and Transportation Officials American Concrete Institute American Society for Testing and Materials American Welding Society British Standard British Standard Code of Practice British Standards Institution Cement and Concrete Association Construction Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institut fur Normung e.V. Euro Norm Federal Highway Authority GCC Standardization Organization Institution of Civil Engineers International Organization for Standardization Prestressed Concrete Institute Qatar Construction Specifications Qatar Standards United Kingdom Department for Transport

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AASHTO ACI ASTM AWS BS BSCP BSI C & CA CIRIA CRSI CS DIN EN FHWA GSO ICE ISO PCI QCS QS UK DfT Products

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Approved Products

1

The contract specific documentation may identify approved products and approved or prequalified manufacturers and suppliers of products used in concrete work.

1.2

IMPLEMENTATION

1.2.1

Approved Installers

1

The contract specific documentation may identify approved or prequalified providers of concrete construction services.

1.2.2

Field Quality Control

1

The Contractor shall carry out the test procedures required by this Section and any other tests and test procedures as directed by the Engineer from time to time. The test procedures shall be carried out using the facilities of an approved independent testing laboratory.

2

Supply, storage, sampling and testing of all materials shall be the responsibility of the Contractor, unless the Contract specifies otherwise.

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The Engineer may also require the Contractor to take samples of materials and deliver them to the Central Materials Laboratory for additional tests to be carried out by the Employer. Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards, and sample sizes shall conform to the requirements shown in Table 1.1.

4

The minimum equipment required for testing on Site is given in Table 1.2. This equipment shall be maintained on Site at all times during concreting operations together with the necessary scoops, buckets, sample containers, and other items required for sampling. The cube curing tank shall be located in an air-conditioned area as stated in part 06.

1.2.3

Rejected materials

1

Any material rejected by the Engineer, in particular cement which has deteriorated or aggregates which have segregated or become contaminated, shall be immediately removed from the Site.

1.2.4

Records

1

The Contractor shall maintain on the Site full records of all work carried out accurately related to the location of the work on site, which shall include:

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formwork props were fully removed all cubes and other tests

(c)

daily maximum and minimum temperatures.

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One copy of all test results shall be sent to the Engineer immediately upon completion of the tests

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Table 1.1 Sampling Procedure and Minimum Sample Sizes for Central Materials Laboratory

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Cement

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Material

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the time and date when all concrete was poured, formwork removed and when

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Aggregate

Reinforcement Water

Test

Min. Sample

Full range of tests

Composite sample of 7 kg taken from at least 12 bags

Full range of tests

200 kg

Sieve analysis Chemical analysis Soundness test Water absorption Particle density Flakiness index Fines content LA Abrasion value

50 kg

Tensile test

500 mm

Bend test

300 mm

Full range of tests

5 litres

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Table 1.2 Minimum Testing Equipment for Each Site* Test

Equipment to be Provided

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ASTM C1064

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Cube curing BS EN 12390-2 or GSO ISO 1920-3 or ASTM C39

Hessian or sacking, impervious sheet Maximum/minimum thermometer Waterproof marking crayon/paint or equivalent Curing tank (in air conditioned room) Supply of packing materials for sending cubes to commercial laboratory Concrete thermometer

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Cube making BS EN 12390-1 and BS EN 12350-1:2000 or GSO ISO 1920-1 and GSO ISO 1920-3 or ASTM C31 and C39

Slump cone with base plate Compacting rod, circular cross-section and round ends Remixing container, 300 mm ruler, moist cloth Scoop and shovel Timer 100 or 150 mm cubical or cylindrical 1 moulds Compacting rod or bar Set of tools for assembling and stripping moulds Remixing container Trowel, Scoop, Shovel and Mallet Mould release agent in closed container with brush

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Slump test BS EN 12350-2 or GSO ISO 1920-2 or ASTM C143

Minimum Number Required 1 1 1 1 1

6 1 1 1 lot 1 1 1 Lot 1

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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate size is not greater than 20mm

END OF PART

QCS 2014

Section 05: Concrete Part 10: Curing

Page 1

CURING .................................................................................................................. 2

10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2 Storage 2

10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12

CURING .................................................................................................................. 2 General 2 Water for Curing 3 General Requirements 3 Curing of Formed Surfaces 4 Curing of Unformed Surfaces 4 Moisture Curing 4 Moisture Retaining Cover Curing 4 Liquid Membrane Curing 5 Steam Curing 5 Pavements and other slab on ground 5 Buildings, bridges, and other structures 5 Mass concrete 6

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10

CURING

10.1

GENERAL

10.1.1

Scope

1

This part covers the requirements for the curing of concrete.

2


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References AASHTO M 148.74, ...Liquid Membrane Curing

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ACI 308 ..................... Guide to Concrete Curing

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.

This Section Part 1, ............ General Part 4, ............ Water Part 6, ............ Property Requirements Part 15, ........... Hot Weather Concreting Part 16, ........... Miscellaneous.

ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing Concrete

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BS 7542,..................... Method of test for curing compounds for concrete. Quality management systems -- Requirements

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ISO 9001: 2008 Submittals

1

The Contractor shall submit to the Engineer the proposed method of curing for approval.

10.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for approval the details of proposed curing media, if any. Details shall include chemical tests for the product in accordance with BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.

10.1.5

Storage

1

Chemical curing compounds shall be stored in accordance with manufacturer's recommendations.

10.2

CURING

10.2.1

General

1

The Contractor shall ensure that curing is provided for 24 hours per day including holidays and that all related necessary plant and labour resources are also available.

2

Special attention shall be given to the curing of vertical and overhanging surfaces to ensure satisfactory curing.

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The Contractor shall adopt curing measures that preclude the possibility of thermal shock to the concrete during curing. This may be achieved by ensuring that the temperature of the water used for curing does not differ from that of the concrete by more than 15 C.

4

Curing shall continue for at least 7 days and until it attains an in-place compressive strength of the concrete of at least 70% of the specified compressive or flexural strength, whichever period is longer. Curing shall not stop unless otherwise approved by the Engineer.

5

When low W/cm is used, the concrete shall be preferably cured by water.

10.2.2

Water for Curing

1

Water used for any curing purposes shall conform to the requirements of Part 4 of this Section.

10.2.3


1

Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive drying out.

2

All concrete shall be cured for a period of time required to obtain the full specified strength, but not less than seven consecutive days. The method of curing shall be by water for the first seven days and by water or membrane until the concrete has reached the full specified strength.

3

For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative environments, or both, the curing shall start at early anytime between placement and final finishing of the concrete. The curing shall be by reducing the moisture loss from surface using fogging systems and the use of evaporation reducers such as monomolecular water curing compound.

4

Exposed surfaces shall be protected from air blown contamination until 28 d after the concrete is placed.

5

The method of curing shall ensure that sufficient moisture is present to complete the hydration of the cement, and shall be to the approval of the Engineer. The method of curing shall not:

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(a)

disfigure permanently exposed surfaces

(b)

affect bonding of subsequent coatings

(c)

increase the temperature of the concrete.

6

During the curing period, exposed concrete surface shall be protected from the direct rays of the sun.

7

When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water is present on the surface of the concrete.

8

The applied film of the liquid membrane shall be continuous and protected from rain and any damages for at least 14 days.

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Curing of Formed Surfaces

1

Formed surfaces, including the underside of beams, girders, supported slabs and the like, by moist curing with the forms in place for the full curing period, or until the forms are removed.

2

When the forms are stripped, curing shall continue by any approved method.

3

When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In such cases the concrete surface shall be prepared prior to the application of the membrane as recommended by the manufacturer.

4

Water curing is not required when liquid membrane is used.

10.2.5

Curing of Unformed Surfaces

1

Unformed surfaces shall be protected as soon as possible after the concrete has been placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material shall be placed on the concrete surface and shall be kept wet for the required period. The hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of water. Alternatively a curing method approved by the Engineer may be used.

2

Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams shall be water cured and covered with wet hessian for the required curing period.

10.2.6

Moisture Curing

1

Moisture curing shall be performed by :

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10.2.4

covering the surface of the concrete with water and keeping it continuously wet

(b)

continuous use of fine fog water sprays

(c)

covering the surface with a saturated absorptive cover and keeping it continuously wet.

(d)

Burlap, cotton mats, and other absorbent materials can be used to hold water on horizontal or vertical surfaces.

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(a)

2

Where method (a) is employed, the bunds used shall not be made from fill from excavations or any other areas where there is the possibility of chloride contamination.

10.2.7

Moisture Retaining Cover Curing

1

The concrete surface shall be covered with a suitable absorptive covering, such as wet hessian.

2

The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

3

The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

4

Any penetrations or tear in the covering shall be shall be repaired with the same material and waterproof tape.

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Liquid Membrane Curing

1

Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM C 309 or C1315 when tested at the rate of coverage use on the job.

2

ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for determining the efficiency of liquid membrane-forming compounds.

3

Membrane forming curing compounds shall be applied in accordance with the manufacturer's recommendations immediately after any water sheen which may develop after finishing has disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

4

Membrane forming curing compounds shall not be used on surfaces against which additional concrete or other material is to be bonded unless:

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it is proven that the curing compound will not prevent bond, or

(b)

positive measures are taken to remove it completely from those areas which are to receive bonded applications

(c)

on fair faced concrete surfaces.

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(a)

Steam Curing

1

An enclosure shall be formed around the concrete using tarpaulin or other suitable means.

2

Application of steam shall not be commenced until at least 2 h after final placement of concrete.

3

Steam shall be applied at a temperature between 65 C and 80 C.

4

Excessive rates of heating and cooling shall be prevented during steam curing and temperatures in the enclosure shall not be allowed to increase or decrease by more than 22 C per hour.

5

The maximum steam temperature shall be maintained in the enclosure until concrete has reached its specified strength.

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10.2.9

10.2.10 Pavements and other slab on ground 1

Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be initiated immediately to reduce evaporation.

2

Mats used for curing can either be left in place and kept saturated for completion of the curing, or can be subsequently replaced by a liquid membrane-forming curing compound, plastic sheeting, reinforced paper, straw, or water

10.2.11 Buildings, bridges, and other structures 1

Additional curing shall be provided after the removal of forms

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2

After the concrete has hardened and while the forms are still in place on vertical and other formed surfaces, form ties may be loosened when damage to the concrete will not occur and water applied to run down on the inside of the form to keep the concrete wet.

3

Care shall be taken to prevent thermal shock and cracks when using water that is significantly cooler than the concrete surface. Curing water should not be more than about o 11 C cooler than the concrete.

4

Immediately following form removal, the surfaces shall be kept continuously wet by a water spray or water-saturated fabric or until the membrane-forming curing compound is applied. Curing

10.2.12 Mass concrete Mass concrete is often cured with water for the additional cooling benefit in warm weather; however, this can be counterproductive when the temperature gradient between the warmer interior and the cooler surface generates stress in the concrete.

2

Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously wet by water spraying, wet sand, or water saturated fabrics.

3

For vertical and other formed surfaces, after the concrete has hardened and the forms are still in place, the form ties may be loosened and water supplied to run down the inside of the form to keep the concrete wet

4


5

Curing shall start as soon as the concrete has hardened sufficiently to prevent surface damage.

6

For unreinforced massive sections not containing ground granulated blast-furnace slag or pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall be not less than 3 weeks.

7

For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until 70% of the specified compressive strength is obtained, if strength is the key concrete performance criterion. For construction joints, curing shall be continued until resumption of concrete placement or until the required curing period is completed.

8

Curing shall not stop until favourable differential temperature is attained and at the approval of the Engineer.

9

For mass concrete, thermocouples shall be used to monitor the temperature differential of the concrete.

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END OF PART

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 1

REINFORCEMENT ................................................................................................. 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Quality Assurance 3 Delivery Storage and Handling 3

11.2 11.2.1 11.2.2 11.2.3

REINFORCING MATERIALS .................................................................................. 4 Reinforcing Bars 4 Welded Steel Wire Fabric 4 Tie Wire 5

11.3 11.3.2 11.3.3

INSPECTION, SAMPLING AND TESTING.............................................................. 5 Sampling 5 Testing 6

11.4

CUTTING AND BENDING OF REINFORCEMENT ................................................. 6

11.5 11.5.1 11.5.2 11.5.3 11.5.4 11.5.5 11.5.6 11.5.7 11.5.8 11.5.9 11.5.10 11.5.11

FIXING OF REINFORCEMENT ............................................................................... 6 General 6 Welding 7 Mechanical Splices 8 Bundling and Splicing of Bundled Bars 8 Examination 8 Electrolytic Action 8 Cover 8 Reinforcement 8 Forms and Linings 9 Tanking 9 Adjustment and Cleaning 9

11.6 11.6.2 11.6.3 11.6.4

PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9 Epoxy Coated Reinforcing Bars 9 Handling of Epoxy Coated Reinforcement 11 Testing of Epoxy Coated Reinforcement 11

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11

REINFORCEMENT

11.1

GENERAL

11.1.1

Scope

1

This Part includes tension, compression, and temperature reinforcing steel, including welded wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric, ties, and supports.

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References

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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete Reinforcement

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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties Filled

Epoxy-Coated

Seven-Wire

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ASTM A882/A882M- ..Standard Specification for Prestressing Steel Strand

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ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

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ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel Wire and Welded Wire for Concrete Reinforcement

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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for Concrete Reinforcement:

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Part 16 ............. Miscellaneous Part 17 ............. Structural Precast Concrete

BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of concrete BS 4483: 2005............Steel fabric for the reinforcement of concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete EN 1011, ....................Welding. Recommendation for welding of metallic materials EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the reinforcement of concrete

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ISO 3766 ...................Construction drawings -- Simplified representation of concrete reinforcement ISO 9000, ..................Quality management systems. Fundamentals and vocabulary QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric Submittals

1

Product data including the manufacturer’s specification and installation instructions for proprietary materials and reinforcement accessories shall be provided.

2

The Contractor shall submit the manufacturer’s records of chemical and physical properties of each batch of billet steel bars and a certificate that the respective material furnished meets the requirements for the steel reinforcement specified. The manufacturer’s records shall include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

3

Three copies of the steel test report shall be furnished with each consignment of steel reinforcement. The steel shall be tagged and cross-referenced with mill certificates.

11.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for source approval details of the proposed source of supply of the reinforcement. Details shall include chemical and physical tests for the past six months production and any independent test results for this period. Details of quality assurance procedures, including ISO 9000 certificate if held, shall also be given.

2

The Contractor shall furnish the Engineer with a certificate of compliance for each shipment of epoxy coated bars. The certificate of compliance shall state that representative samples of the epoxy coated bars have been tested and that the test results comply with the requirements herein specified. Test results shall be retained by the Contractor for seven years. A complete set of test results shall also be handed to the client at the completion of reinforcement works, and shall be made available to the Engineer upon request.

11.1.5

Delivery Storage and Handling

1

On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show the manufacturer’s test number and lot number and other applicable data that will identify the material with the certificate issued for that lot of steel. The fabricator shall furnish three copies of a certification which shows the batch number or numbers from which each size of bar in the shipment was fabricated.

2

Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the ground surface to prevent damage and accumulation of dirt, rust and other deleterious matter. Storage facilities shall be such as to permit easy access for inspection and identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark reference.

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11.1.3

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3

The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may impair the bond between the concrete and the reinforcement. The reinforcement shall be covered to ensure protection from wind blown dust, condensation and other deleterious materials.

11.2

REINFORCING MATERIALS

11.2.1

Reinforcing Bars

1

Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply with the requirements of: QS ISO 6935 with minimum grade of B500 MPa or

(ii)

BS 4449 with minimum grades of B500 MPa ; or..

(iii)

ASTM A615 / A615M with minimum grade of 75 [520MPa]; or

(iv)

Deformed and Plain, Low-carbon-Chromium-Steel Reinforcement: ASTM A1035/ A1035M

(v)


(vi)


(vii)

Other types of reinforcement, as approved by Qatar Standards

Bars

for

Concrete

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(i)

As per project design, other steel grades of less than B500MPa may be used only for stirrups and secondary reinforcement of diameter of 10mm or less.

3

If the steel has excessive surface rust, dust or other deleterious material then the steel shall be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of the reinforcement or concrete. Dune sand shall not be used for the sandblasting of reinforcement.

4

For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.

11.2.2

Welded Steel Wire Fabric

1

Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483 and shall be delivered to Site in flat mats.

2

Welded intersections shall not be spaced more than:

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(a)

300 mm for plain round bars

(b)

400 mm apart for deformed high yield bars in direction of calculated stress except when used as stirrups.

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Tie Wire

1

Tie wire shall conform to the requirements of BS 4482.

2

1.6 mm black annealed mild steel shall be used for tie wire.

3

No wires smaller than size D-4 shall be used.

11.3

INSPECTION, SAMPLING AND TESTING

1

Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

2

The Contractor shall give 24 hour notice to the Engineer before closing forms or placing concrete.

3

The Engineer may instruct the Contractor to break out and remove completely all sections of the work already constructed under any of the following circumstances:

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11.2.3

reinforcing steel sample under test fails to meet the specification requirements at any time

(b)

the Engineer considers that samples which were presented to him for test were not truly representative

(c)

a previously rejected reinforcing steel has been used in the Works.

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(a)

Sampling

1

Representative samples of all reinforcing steel proposed for use in the Works must be submitted by the Contractor, before work is commenced, to the Engineer for his written approval.

2

Manufacturer's certificates stating clearly for each sample: (a)

place of manufacture expected date and size of deliveries to site

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11.3.2

(c)

all relevant details of composition, manufacture, strengths and other quality of the steel.

3

The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at the work site.

4

Frequency of sampling and the method of quality control shall be in accordance with steel bars manufactured standard QS ISO 6935 or BS 4449 .

5

Where epoxy coated steel is used, a sample of the coating material shall be supplied with each batch in an airtight container and identified by the batch number.

6

Allow 14 days for Engineer’s review of samples.

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Testing

1

Tests shall be carried out when directed by the Engineer.

2

Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

3

The following information shall be provided with each delivery of reinforcement: elastic limit

(b)

ultimate strength

(c)

stress/strain curve

(d)

cross-sectional area

(e)

deformation/bond characteristics of deformed bars.

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11.3.3

The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or rebend tests at own cost, for each size of bar to be used in the concrete construction.

5

Test results for each bar size shall be submitted to the Engineer three weeks before concrete work commences on Site.

6

Full testing shall be required if the source of supply of reinforcement changes, in which case the cost of such extra testing will be borne by the Contractor.

7

When any test results do not conform to the relevant standard the reinforcement steel shall be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.

11.4

CUTTING AND BENDING OF REINFORCEMENT

1

Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and shall be done without the application of heat. Bends shall have a substantially constant curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply

2

Steel bars manufactured according to the approved ASTM standards shall be bent according to the same standard.

3

Reinforcement shall not be straightened or rebent without the approval of the Engineer. If permission is given to bend projecting reinforcement care shall be taken not to damage the concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or BS 8666.

11.5

FIXING OF REINFORCEMENT

11.5.1

General

1

All reinforcement shall be securely and accurately fixed in positions shown on the Drawings to ensure that the reinforcement steel framework as a whole shall retain its shape. The framework shall be supported to retain its correct position in the forms during the process of placing and consolidating the concrete.

2

The ends of all tying wires shall be turned into the main body of the concrete and not allowed to project towards the surface.

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3

No part of the reinforcement shall be used to support access ways, working platform or for the conducting of an electric current.

4

The Contractor’s specific attention is drawn to the following general requirements: (a)

lapped joints shall be as indicated on the Drawings and/or in accordance with the requirements of EN 1992-1-1 or BS 8666

(b)

hooks shall be semicircular with a straight length of at least: (i)

four bar diameters for mild steel

(ii)

six bar diameters for high yield steel.

Welding

1

Welding shall not be used unless authorised by the Engineer and recommended by the reinforcement manufacturer.

2

Where welding is approved it shall be executed under controlled conditions in a factory or workshop.

3

Welding shall not take place on site without the approval of the Engineer and unless suitable safeguards and techniques are employed and the types of steel employed have the required welding properties.

4

Welding if approved, may be used for:

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11.5.2

fixing crossing or lapping reinforcement in position

(b)

fixing bars to other steel members

(c)

structural welds involving transfer of loads between reinforcement or between bars and other steel members.

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The length of run deposited in a single pass shall not exceed five times the bar diameter. If a longer welded length is required, the weld shall be divided into sections with the space between runs made not less than five times the bar diameter.

6

Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be approved, subject to their satisfactory performance in trial joints.

7

Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for lapped joints.

8

Flash butt welding shall be executed with the correct combination of flashing, heating, upsetting and annealing, using only machines which automatically control this cycle of operations.

9

Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement manufacturer.

10

Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of principle reinforcement shall be staggered, unless otherwise approved. The distance between staggered joints shall be not less than the end anchorage length joints.

11

Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.

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Mechanical Splices

1

Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and where indicated on the Drawings.

2

Details of mechanical splices shall be submitted to the Engineer for approval.

11.5.4

Bundling and Splicing of Bundled Bars

1

Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

2

Splicing, except where indicated on the Drawings or approved shop drawings, will not be permitted without the approval of the Engineer.

11.5.5

Examination

1

The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of reinforcement in order to facilitate the inspection of formwork.

2

The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

11.5.6

Electrolytic Action

1

Reinforcement shall not be fixed or placed in contact with non-ferrous metals.

11.5.7

Cover

1

Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer pieces.

2

The cover shall not be less than given in Section 5 Part 6.

3

Spacers, chairs and other supports shall be provided as necessary to maintain the reinforcement in its correct position.

4

In a member where the nominal cover is dimensioned to the links, spacers between the links and formwork shall be the same dimension as the nominal cover.

5

Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars are detailed.

6

Spacers, chairs and other supports shall be made of concrete, plastic or other material to the approval of the Engineer. Where supports are made of concrete they shall have at least the same cube strength as the concrete in the host member.

11.5.8

Reinforcement

1

Placing of all reinforcement steel bars will be checked by the Engineer and in no case is concrete to be placed around any reinforcement steel that has not been approved by the Engineer. Insertion of bars into or the removal of bars from concrete already placed will not be permitted.

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11.5.3

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2

Reinforcement steel temporarily left projecting from the concrete at the joints shall not be bent without the prior approval of the Engineer.

11.5.9

Forms and Linings

1

Damage to forms and linings shall be avoided.

11.5.10 Tanking 1

Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

11.5.11 Adjustment and Cleaning

.

Check position of reinforcement before and during placing concrete: pay particular attention to the position of top reinforcement in cantilever sections

(b)

ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill scale, oil and other substances which may adversely affect reinforcement, concrete, or the bond between the two.

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1

Protect projecting reinforcement from the weather where rust staining of exposed concrete surfaces may occur.

3

At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and freed from all mud, oil or any other coatings that might destroy or reduce the bond:

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clean all set or partially set concrete which may have been deposited thereon during the placing of a previous lift of concrete

(b)

all uncoated rust bars shall be again sand blasted and pressure washed.

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Immediately before concrete placing the reinforcing steel shall be washed thoroughly with high pressure potable water jets to remove any deposited salts.

11.6

PROTECTIVE COATINGS TO REINFORCEMENT

1

All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.

11.6.2

Epoxy Coated Reinforcing Bars

1

Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting, rust, grease, oil and other surface defects detrimental to proper coating.

2

The surface shall be prepared in accordance with ISO 14654.

3

Coating shall be applied to the cleaned surface as soon as possible after cleaning and before any visible oxidation to the surface occurs.

4

Reinforcing steel shall not have surface defects that would be detrimental to coating.

5

Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for coating of reinforcing bars and as follows:

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(a)

epoxy resin powders which do not meet the above requirements must be tested by an approved independent testing laboratory and accepted by the Engineer before use

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Page 10

(b)

only fusion bonded epoxy-coated reinforcing steel will be accepted

(c)

no other means of epoxy coating will be approved.

Patching material shall be: (a)

furnished by the epoxy coating manufacturer

(b)

compatible with the coating

(c)

inert in concrete

(d)

suitable for repairs to the coated reinforcing bars to be made by the coating applicator and the Contractor at the project site.

Fabrication shall be performed before coating except as hereinafter specified for bent bars and straight bars less than 7.6 m long.

8

Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that satisfactory results can be obtained by coating before bending.

9

Any visible cracks in the coating on the outside of the bend or damage to coating resulting in debonding of the coating after bending shall be rejected.

10

Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:

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end damage to coating does not extend more than 12 mm back

(b)

cut end is patched before any visible oxidation appears.

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Flame cutting will not be permitted.

12

Epoxy coating shall be checked visually after cure for continuity of coating and shall be free from holes, contamination, cracks and damaged areas.

13

There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm of the epoxy coated bar.

14

A holiday detector shall be used in accordance with the manufacturer's instruction to check the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or its approved equivalent shall be used.

15

Patching of holidays is not required if there are less than three holidays per 300 mm length. Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced as directed by the Engineer.

16

Epoxy coating film shall be cured and/or post cured to a fully cured condition. A representative proportion of each production lot shall be checked by the epoxy coating applicator, using the method most effective for measuring cure to ensure that the entire production lot of epoxy coating is supplied in the fully cured condition.

17

Contractor shall repair all coating damaged by fixtures used to handle or support the bars in the coating process as follows:

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(a)

patching shall be done as soon as possible and before visible oxidation occurs

(b)

excessive patching from other causes will not be permitted

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satisfactory correction shall consist of proper adjustment of process, and rerunning the bars through the plant.

The Engineer reserves the right for access to the epoxy coating applicator’s plant to witness epoxy coating processes for project work and to obtain specimens from test bars for any testing desired.

19

All chairs, tie wires and other devices used in connecting, supporting, securing or fastening epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

20

Before the reinforcement is lowered into place and before placement of the concrete, the coated bars shall be inspected by the Engineer for damage to the epoxy coating.

21

Sheared ends of bars and other areas requiring limited repair due to scars and minor defects shall be repaired, using the specified patching or repair materials.

11.6.3

Handling of Epoxy Coated Reinforcement

1

Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars or, where used, the epoxy coating.

2

Bars, or where used epoxy coating, damaged in handling or other operations shall be satisfactorily repaired at no additional cost to the Employer.

3

Where epoxy coated bars are used all handling systems shall have plastic mandrel and padded contact areas wherever possible.

4

Where epoxy coated bars are used all bundling bands shall be padded.

5

All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle.

6

Bars or bundles shall not be dropped or dragged.

7

During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not damaged by the pokers.

11.6.4

Testing of Epoxy Coated Reinforcement

1

Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each production lot.

2

At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be furnished as test bars.

3

Test bars may be in one length or multiple lengths as required to have one test bar of each size with each production lot.

4

The production epoxy coated test bars shall be evaluated by bending 120  (after rebound) around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.

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Table 11.1 Mandrel Diameter for Bar Diameter for Evaluation Test of Epoxy Coated Test Bars Diameter of Mandrel (mm)

10 12 13 14 16 18 20 22 24 25 26 28 30 32 34 36

79 95 103 111 127 143 159 175 191 198 206 222 238 254 270 286

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Bar Diameter (mm)

Bend shall be made at a uniform rate and may take up to one minute to complete.

6

Bend test shall be conducted at a room temperature of between 20 °C and 30 °C after the specimen has been exposed to room temperature for a sufficient time to ensure that it has reached thermal equilibrium.

7

No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the bent bar.

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END OF PART

QCS 2014

Section 05: Concrete Part 12: Joints

Page 1

JOINTS.................................................................................................................... 2

12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Definitions 3

12.2 12.2.1 12.2.2

CONSTRUCTION JOINTS ...................................................................................... 4 General 4 Construction Joints in Water Retaining Structures 4

12.3 12.3.1 12.3.2 12.3.3

MOVEMENT JOINTS .............................................................................................. 5 General 5 Joint Filler 6 Joint Sealants 6

12.4 12.4.1

SLIP BEARINGS ..................................................................................................... 7 General 7

12.5 12.5.1 12.5.2 12.5.3 12.5.4

WATERSTOPS ....................................................................................................... 7 General 7 Waterstops 7 Butyl Rubber Waterstops 8 Water Swelling Gaskets 8

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12

JOINTS

12.1

GENERAL

12.1.1

Scope

1

This part deals with movement and construction joints, slip bearings, waterstops and associated sealants and filler materials.

2


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12.1.2

.

This Section Part 1 ............... General Part 10, ............ Curing Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous References

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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness

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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From Olefin Polymers

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BS 903........................Physical testing of rubber BS 2571......................General purpose flexible PVC compounds for moulding and extrusion

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BS 2782,.....................Methods of testing plastics BS 6093,.....................Design of joints and joining in building construction

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BS 7164,.....................Chemical tests for raw and vulcanized rubber

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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop ISO 9001 ....................Quality management systems. Requirements

12.1.3

Submittals

1

The Contractor shall submit for approval by the Engineer as soon as practicable after acceptance of his Tender and not less than three weeks before commencement of concreting, drawings showing his proposals for the position of construction joints having due regard to any that may be shown on the Contract Drawings.

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For slide bearings the Contractor shall provide at least three samples of the proposed material, together with the manufacturer's technical specifications and recommendations in respect of application and performance.

3

For slip joints the Contractor shall provide at least three samples of materials proposed, together with manufacturer's technical specifications and recommendations in respect of application and performance.

4

For waterstops the Contractor shall provide at least three samples of proposed types, including prefabricated joints and junctions, if applicable. If joints are to be made up on site, provide worked samples, including samples for each make of waterstop, where samples from different manufacturers are provided.

5

The Contractor must supply a certificate of compliance for the joint sealant, stating that it meets the requirements of the specification. The Contractor shall also supply the Manufacturer’s technical and installation data for the proposed material. The Contractor shall provide details of previous installations of the product, with the client name, structure name, type of joint and value of contract.

6

The Contractor shall prepare shop drawings that show the layout of the waterstops, specials and joints.

12.1.4

Quality Assurance

1

The joint sealant, including primers and debonding materials shall be compatible with each other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality Assurance Scheme.

12.1.5

Definitions

1

Construction Joint: The surface where two successive placements of concrete meet, across which it is desirable to develop and maintain bond between the two concrete placements, and through which any reinforcement which may be present is not interrupted.

2

Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a weakened plane and regulate the location of cracking resulting from the dimensional change of different parts of the structure. (See also Isolation Joint.)

3

Expansion Joint: A separation between adjoining parts of a concrete structure which is provided to allow small relative movements such as those caused by thermal changes to occur independently.

4

Isolation Joint: A separation between adjoining parts of a concrete structure provided to isolate and element and thus allow independent movement.

5

Joints Fillers: Materials that are used to fill space within movement joints during construction. They may provide support to a sealant applied subsequently.

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CONSTRUCTION JOINTS

12.2.1

General

1

Where construction joints are required in slabs or beams (designed by Direct Design Method DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres. Where slabs are supported by beams then the beams and slabs shall be constructed in one operation.

2

In all cases vertical stop boards of a form to be approved by the Engineer shall be provided by at the end of each section of work which is to be concreted in one operation and the concrete shall be thoroughly compacted against these stop boards.

3

Where slabs, beams and walls incorporate construction joints, panels shall generally be constructed consecutively. Where this is not possible a gap not exceeding one metre shall be formed between adjacent panels. This gap shall not be concreted until a minimum interval of 7 d has expired since the casting of the most recent panel.

4

The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with nominal reinforcement.

5

Horizontal construction joints in walls will only be permitted when the wall is continuous with the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls meeting the soffits of suspended members.

6

Construction joints in monolithic structures shall be aligned with each other whenever practicable.

7

Before placing new concrete against concrete which has already set the latter shall be treated to expose the aggregate over the full section and leave a sound irregular surface. This shall be done while the concrete is still fresh by means of water spray and light brushing or other means approved by the Engineer.

8

Immediately before the new concrete is placed all foreign matter shall be cleaned away and the surface moistened.

9

If during the course of the Contract it should become apparent that the Contractor’s methods of forming construction joints are not proving effective the Engineer may order the Contractor to execute at the Contractor’s expense such preventative measures as the Engineer may consider necessary to ensure the watertightness of the construction joints in further work.

12.2.2

Construction Joints in Water Retaining Structures

1

The floor may be designed as fully restrained against shrinkage and thermal contraction and should be cast directly onto the blinding concrete.

2

In large structures, the floor shall be designed as a series of continuous strips with transverse induced contraction joints provided to ensure that cracking occurs in predetermined positions. Longitudinal joints between the strips should form contraction joints.

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Waterstops shall be incorporated into construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures. The Contractor shall ensure that all such joints are watertight and any joints which may leak or weep shall be rectified by the Contractor to the Engineer’s satisfaction.

4

The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings.

5

Where the positions or type of joints are not indicated on the drawings, the spacing of construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

6

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, construction joints, crack induced joints, contraction joints and expansion joints shall be incorporated into the works as appropriate. for slabs on grade, construction joints or crack induced joints should be provided at areas where differences in subgrade and slab support may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the width of the building. Within each strip for both directions, crack induced joints shall be provided at areas where cracks are expected and not more than 5.0 metre spacing, and construction or contraction joints shall be provided at not more than 15.0m spacing.

7

Construction or contraction joints shall be provided between adjacent strips.

8

Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

9

Engineer’s acceptance shall be obtained by the Contractor, prior to start of work, on the casting sequence and the layout of joints.

12.3

MOVEMENT JOINTS

12.3.1

General

1

Movement joints for expansion and contraction shall be constructed in accordance with the details and to the dimension shown on the Drawings or where otherwise ordered by the Engineer and shall be formed of the elements specified.

2

Movement Joints in Water Retaining Structures shall be in accordance with the details and to the dimension shown on the Drawings and EN 1992-3.

3

The Contractor shall pay particular attention to the effects of climatic extremes on any material which he may desire to use on any movement joint and shall submit for approval by the Engineer his proposals for the proper storage, handling and use of the said materials having due regard for any recommendations made by the manufacturer in this connection.

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Joint Filler

1

Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or equivalent if they are polymer foam type.

2

The joint filler shall be fixed to the required dimensions of the joint cross-section and shall provide a firm base for the joint sealer.

3

When required between two concrete surfaces as a resilient movement joint, the filler shall be an approved granulated cork bound with insoluble synthetic resin.

4

When required between blockwork and concrete as a low density movement joint filler or for building details it shall be an approved bitumen impregnated fibreboard or preformed closed cell polyethylene.

12.3.3

Joint Sealants

1

All joints to be sealed shall be formed and the groove grit blasted to remove all traces of deleterious materials such as form oil or curing compounds and also to remove any surface laitance from the sides of the joint. The joint shall be dry prior the application of priming. Where the use of grit blasting is not possible the Contractor may propose alternative methods subject to the approval of the Engineer.

2

The back of the joint shall receive a debonding tape or polyethylene foam backer cord in order to provide the correct depth to width ratio and prevent three sided adhesion.

3

The areas adjacent to the joint shall be protected using masking tape.

4

The sides of the joint shall be primed with the relevant primer as recommended by the sealant manufacturer and the sealant material applied in accordance with the manufacturers instructions.

5

The sealant material shall be a non-biodegradable multicomponent pitch polyurethane elastomeric joint sealant, carefully selected as appropriate for the specific climatic and environmental exposure conditions expected. Alternative types of sealant will be considered, including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the specification and the approval of the Engineer.

6

Where the joint sealant is to be in contact with a protective coating the Contractor shall satisfy the Engineer that the sealant and protective coating are compatible

7

Sealants shall exhibit the following properties:

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12.3.2

(a)

Movement accommodation factor

25 %

(b)

Shore ‘A’ hardness

(c)

Solids content

(d)

Service temperature range

(e)

Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis

(f)

Width to depth ratio

20 - 25

100 %

2:1

o

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0 C to 90 C

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Where shown on the Drawings sealants shall also be suitable for use with potable water.

9

All surface preparation, priming, mixing and application shall be carried out in strict accordance with the manufacturer’s instructions.

10

The sealant shall have a proven track record of no less than ten years under similar local conditions.

12.4

SLIP BEARINGS

12.4.1

General

1

Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

2

They shall be extruded from specially formulated polyethylene to form a durable lamina resistant to sewage, mineral acids and alkalis, solvents and weathering.

3

Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall be clean and free from deleterious materials such as form oil or curing compounds and surface laitance. The surface shall be level and even along the full length of the joint

4

The applied loads for slip bearings shall not exceed 0.7 MPa.

5

Operating temperatures shall be up to 80 C

6

The coefficient of friction shall not exceed 0.15

12.5

WATERSTOPS

12.5.1

General

1

Waterstops and associated materials shall be by a manufacturer with a minimum of ten years experience in the field of engineering waterproof products.

2

PVC waterstops shall be suitable for storage, handling, installation and service within a range of 15 C to 65 C.

12.5.2

Waterstops

1

The waterstop shall be a high performance system forming a continuous network as shown on the Drawings.

2

Site jointing is to be limited to butt joints and shall be performed strictly in accordance with the manufacturer’s instructions.

3

Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web sections.

4

Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The water bar used at the location of expansion joints shall have a bulb in the centre to accommodate the movements.

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5

Waterstops shall have a minimum thickness of 3 mm.

6

The minimum test performance data for PVC waterstops shall be as follows: Tensile strength Elongation at break Hardness

>12 MPa 300 % Shore ‘A’ 80 to 90

The materials shall be tested in accordance with BS 2571 or BS 2782 or CRD–C572 or ASTM D2240.

12.5.3

Butyl Rubber Waterstops

1

Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in accordance with BS 903.

Property

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BS 903

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Table 12.1 Properties Requirements of Butyl Rubber Waterstops

.

7

Requirements 3

Density

Part A26

Handness

Part A2

Tensile Strength

Part A2

Elongation at break point

Not less than 450 %

Part A/6

Water Absosption (48 hours immersion)

Not exceeding 5 %

1100 kg/m (± 5 %) 60-70 IRHD Not less than 17.5 N/mm

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Part A1

Butyl rubber waterstops shall be suitable for storage, handling, installation and service within a temperature of 0 °C to 40 °C

12.5.4

Water Swelling Gaskets

1

Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer modified chloroprene rubber strips. The rubber strips shall conform to the following properties as applicable: Water pressure resistance

:

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(b)

Expansion in contact with water :

(c)

:

Reversible

:

- 30 to + 70 °C

(d)

2

5 Bar (50 m)

Application Temperatures

2 x original SRE

The selected rubber strips shall be available for three exposures: (a)

Fresh Water

(b)

Seawater

(c)

Chemicals (if the condition demands or upon the Engineer’s request)

The supplier shall furnish references upon request of the Engineer. END OF PART

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 1

INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2

13.1 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5 13.1.6

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Non-Compliance of Work 3 General Fieldwork Requirements 4

13.2 13.2.1 13.2.2 13.2.3 13.2.4

CONCRETE CORES ............................................................................................... 4 General 4 Drilling Cores 5 Testing for Strength 6 Assessment of Strength 7

13.3

REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

13.4 13.4.1 13.4.2 13.4.3 13.4.4

ULTRASONIC PULSE MEASUREMENTS .............................................................. 8 General 8 Selection of Test Locations 8 Execution of Tests 8 Estimated In-Situ Cube Strength 9

13.5

RADIOGRAPHY OF CONCRETE ........................................................................... 9

13.6 13.6.1 13.6.2 13.6.3 13.6.4

SURFACE HARDNESS ........................................................................................... 9 General 9 Method of Test 9 Equipment 10 Reporting 10

13.7 13.7.1 13.7.2

CHEMICAL CONTENT .......................................................................................... 10 Sampling 10 Laboratory Testing 11

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13

INSPECTION AND TESTING OF HARDENED CONCRETE

13.1

GENERAL

13.1.1

Scope

1

This Part of the specification covers the inspection, sampling and testing of hardened concrete.

2

Related Section and Parts are as follows:

.

This Section Part 6 ............... Property Requirements References

1

The following standards are referred to in this part of the specification:

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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength Results

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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and Commentary

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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened Concrete in Constructions

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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete

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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic covermeters BS EN 12350..............Testing fresh concrete

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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and testing in compression BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number

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BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force BS EN 12504-4 ..........Determination of ultrasonic pulse velocity BS EN 13791..............Assessment of in-situ compressive strength in structures and precast concrete components GSO ISO 1920-6 ........ Testing of concrete – part 6: sampling, preparing and testing of concrete core . 13.1.3

Submittals

1

The Contractor shall submit to the Engineer his quality assurance procedures for the particular parts of the testing work that will be carried out.

2

The Contractor shall submit for the Engineer’s approval the curriculum vitae (CV) of the supervisor proposed for the work.

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The Contractor shall through testing agency prepare a factual report that identifies the test methods used and the test results. The report shall also identify any unusual results or pertinent information relating to the testing. The report shall be presented in hard and electronic copies.

4

For each of the test results the Contractor shall identify the precision or repeatability of the particular sampling and testing method. This shall be as given from experience of the particular test by the laboratory or as expected from information in the particular test standard.

5

In-place tests will be valid only if the tests have been conducted using properly calibrated equipment in accordance with recognized standard procedures and acceptable correlation between test results and concrete compressive strength has been established and is submitted.

6

Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete, but they may be used to “evaluate” concrete when the standard-cured strengths fail to meet the specified strength criteria

13.1.4

Quality Assurance

1

All field and laboratory testing of concrete shall be carried out by an independent laboratory approved by the Engineer.

2

The evaluation of concrete in structure is needed when an existing structure is to be modified or redesigned; to assess structural adequacy when doubt arises about the compressive strength in the structure due to defective workmanship, deterioration of concrete due to fire or other causes;when an assessment of the in-situ concrete strength is needed during construction; to assess structural adequacy in the case of non-conformity of the compressive strength obtained from standard test specimens; assessment of conformity of the in-situ concrete compressive strength when specified in a specification or product standard.

13.1.5

Non-Compliance of Work

1

If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

2

The parts or elements of the structure made from the defective batch or batches of concrete as represented by the works test cubes shall be identified by the Engineer and based on this information the Engineer shall instruct the Contractor on the required number and position of concrete cores.

3

The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or ACI 318 whichever is applicable to the structural design.

4

Based on this assessment the Engineer shall decide the acceptability of the concrete in the structural element and may either:

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(a)

accept the concrete

(b)

instruct that certain remedial works are carried out

(c)

instruct that the element is replaced.

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General Fieldwork Requirements

1

The Contractor shall make all arrangements to provide safe stable access to testing locations.

2

When gaining access to testing locations and whilst testing the Contractor shall take care not to damage the structure or leave it in an untidy or unclean state.

3

The Contractor shall take precautions to ensure that cooling water from concrete coring/other operations is discharged such as not to cause a mess or damage the interior or exterior parts of the structure.

4

The Contractor shall be responsible for arranging the water supply required for testing.

5

The Contractor shall arrange for a suitable power supplies. Where testing is being carried out on an occupied structure a power supply from the building services may not available and the Contractor shall make arrangements for power supply and extension leads of adequate length.

6

The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field work. The supervisor shall have not less than five years experience of such work.

7

Before starting the work, the Engineer with the Contractor’s supervisor will mark the positions where field testing is to be carried out. A unique referencing system to identify each sample or testing location will be adopted, and this will either be referenced on sketch plans or drawings or by a detailed description used throughout the report to identify test locations.

8

If testing is being carried out on an occupied structure the Contractor shall co-ordinate with the owner or operator of the structure to arrange the detailed programme for the works and gain access to the various parts of the structure.

9

As soon as laboratory test results are available these shall be submitted by hand or faxed to the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing agency, assigned by the contractor shall provide a technical report providing visual information and analysing the tests conducted.

10

All core holes, dust sample holes and exploratory investigation areas shall be reinstated with a proprietary non shrink cementitious repair mortar. The preparation of the hole or area before reinstatement shall be carried out as per the recommendation of the repair mortar supplier.

11

Before filling any core holes, dust sample holes or exploratory investigation areas, the Contractor shall allow the Engineer time to inspect these areas and obtain written confirmation from the Engineer before filling.

13.2

CONCRETE CORES

13.2.1

General

1

The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the structural design.

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All of the supplementary information listed by the relevant standards shall be included in the test report with photographs of the cores.

3

An assessment of in-situ compressive strength for a particular test region shall be based on at least 3 cores. Consideration shall be given to any structural implications resulting from taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

4

The preferred minimum core diameter is three times the nominal maximum size of the coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse aggregate

5

The Engineer will advise the required number and locations of cores. If the results of the initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain locations.

6

Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not cut through any reinforcing steel. The required diameter and depth of concrete cores shall be as stated in table 13.1

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Table 13.1

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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823) Thickness of Section, m

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Types of Construction

0.3 or less 0.3 or greater

entire depth 0.3

0.15 or less

entire depth

0.15 – 0.6

one half the thickness or 0.15 whichever is greater

0.6 or greater

0.6

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Slabs, pavements, walls, linings, foundations, structural elements accessible from one side only 2 Suspended slabs , walls, conduits, foundations, structural elements exposed to the atmosphere at two or more sides; concrete products Massive sections

Minimum Depth to Be Sampled, m

1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples that are required for all tests, in that case, the necessary additional quantity of concrete in pieces of appropriate minimum size should be taken at each sampling location. 2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as not to lose the core by its falling from the barrel and to make it easier to patch the core hole. 13.2.2

Drilling Cores

1

Before beginning coring operations the Contractor shall use a proprietary cover meter to identify the position of steel reinforcing bars at the testing location.

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The Engineer may instruct that the core is taken through the concrete without hitting any reinforcement or the Engineer may instruct that the core is taken in a position where it is expected reinforcement will be cut in order to provide a sample of the reinforcement to check its condition. The locations of all drilling points shall be chosen so that the core contains no steel parallel to its length.

3

Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared for test the core shall have a length at least equal to the diameter and not more than 1.2 times its diameter.

4

Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm cores should be taken to reduce the variability due to drilling and increase the reliability of the testing, unless reinforcement is congested and the use of 100 mm cores will reduce the possibility that the core will contain steel or it is necessary to restrict the sampling to a length of less than 150 mm.

5

Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores may be used with the permission of the Engineer.

6

During drilling operations, a log of observations that may affect the interpretation of core samples shall be prepared.

7

If instructed by the Engineer, immediately after the core has been cut and removed and the structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein poured over the cut surface. A photograph shall be taken of the cut core with the phenolphthalein solution applied to provide a record of the test.

8

If during the drilling of the core, the core collapses due to weak honeycombed or defective concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent location as advised by the Engineer. If when testing at the second location, the core again breaks due to honeycombed or defective concrete the freshly cut core shall be retained for reference and a note made of the condition.

13.2.3

Testing for Strength

1

The compressive strength of field concrete cores shall be assessed in accordance with BS EN 13791.

2

The details of the concrete core in accordance with BS EN 13791 shall be recorded and two photographs on either side of the core taken.

3

Where there is reinforcement in the core, the size and the type of bar shall be noted along with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a detailed description of any corrosion of the reinforcement.

4

Before carrying out the compressive strength testing of the cores, the Contractor shall inform the Engineer to allow him to witness the testing if required.

5

Crushed core samples shall be retained by the laboratory and only disposed of after written approval by the Engineer.

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Assessment of Strength

1

The estimated in-situ strength of the concrete shall be calculated from the core result using BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

13.3

REINFORCEMENT COVER MEASUREMENTS

1

The measurement of cover to reinforcing steel and other metallic items in concrete shall be carried out in accordance with BS 1881 Part 204 using an electromagnetic device that estimates the position depth and size of the reinforcement.

2

The locations for checking cover and the spacing between measurements shall be advised by the Engineer based on the objective of the investigation. The Contractor shall carry out calibrations of the electric magnetic device for a particular bar size to allow the bar diameter to be measured.

3

While testing, the orientation of steel bars shall be checked.

4

The electromagnetic device shall incorporate scale or digital display range and shall be calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever is the greater over the working range given by the manufacturer.

5

The cover meter shall be used in accordance with the manufacturers instructions and checks on the zero carried out as specified.

6

The search head shall be traversed systematically across the concrete, and, where reinforcement is located, rotated until the maximum disturbance with electromagnetic field is indicated by the meter.

7

The cover to the reinforcement shall be noted along with the axis of the reinforcement. The cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent marking pen.

8

Care should be taken to avoid interference from other metallic sources or magnetic material.

9

The cover meter checks shall be carried out by an operator with five years experience.

10

The test report on cover shall include the following information:

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13.2.4

(a)

date

(b)

time and place of test

(c)

description of the structure or component under investigation

(d)

location of test areas

(e)

make and type of cover meter used

(f)

date of last laboratory calibration of cover meter

(g)

details of site calibration of cover meter, indicated values of cover

(h)

estimated accuracy of quantitative measurements

(i)

configuration of steel reinforcement

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ULTRASONIC PULSE MEASUREMENTS

13.4.1

General

1

The ultrasonic velocity test equipment shall be capable of measuring the transit time of a pulse vibration through concrete. The length of the pulse part between the transducer equipment shall be measured, and the pulse velocity calculated.

2

Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS EN 12504-4.

3

Velocities shall be measured at a number of locations around a structure and a velocity contour of the structure established. A minimum of 40 velocities shall be measured for each structural element.

13.4.2

Selection of Test Locations

1

Wherever possible direct transmission arrangements shall be used. The transducers shall be mounted on a specially formed moulded surface.

2

The minimum path length shall be 100 mm for concrete in which the nominal maximum size of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than required to detect small regions of bad concrete.

3

Where concrete contains steel the pulse velocity shall be adjusted in accordance with the requirement of BS EN 12504-4.

4

Locations that contain reinforcement directly along or close to the pulse paths shall be avoided.

5

Where repositioning is not possible the semi-direct transmission measurement, where transducers are placed on adjacent faces of the concrete, may be used.

13.4.3

Execution of Tests

1

Positions chosen for the test locations shall be clearly and accurately marked on the surface of the concrete.

2

The surface of the concrete shall be shall be cleaned and free from grit and dust. Path lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease) applied to each of the test points.

3

Pulse transit times shall be measured by a skilled operator, with a minimum of five years experience in the use of the equipment.

4

Pulse velocity measurement equipment shall be in accordance with the requirements of BS EN 12504-4.

5

Test results shall be examined and any unusual readings repeated carefully for verification or amendment.

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Estimated In-Situ Cube Strength

1

A correlation shall be established between the cube crushing strength of the particular mix used in the structure and the pulse velocity.

2

Where it is not possible to obtain cubes with the same mix design as the original structure a combination of coring and ultrasonic pulse velocity testing may be carried out at the direction of the Engineer, where the cores are used to provide the correlation information required for the interpretation of the ultrasonic pulse velocity tests.

13.5

RADIOGRAPHY OF CONCRETE

1

Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects: The testing shall be carried out in accordance with the requirements of BS 1881-205 or equivalent.

13.6

SURFACE HARDNESS

13.6.1

General

1

Testing of concrete surfaces for hardness using rebound hammers shall be carried out in accordance with BS EN 12504-2.

2

The rebound hammer shall only be used for estimation of concrete strength where a specific correlation is carried out of the concrete from the structure being tested; this shall be from works test cubes or cores taken from the structure.

3

The correlation between concrete strength and the rebound number shall be carried out in accordance with BS EN 12504-2. The precision of the correlation curve between the mean rebound number and strength shall be stated and this shall be used when reporting any strength interpretations from surface hardness readings. The use of general manufacturers’ correlation or calibration curve for strength shall not be used.

4

It should be noted that the rebound hammer number only provides information on a surface layer of approximately 30 mm in depth of the concrete and that this should be quoted in the test report.

5

The rebound hammer maybe used to establish the uniformity of the finish products or similar elements in a structure at a constant age, temperature, maturity and moisture condition.

13.6.2

Method of Test

1

A minimum of 12 readings shall be taken to establish a single surface hardness at a particular location.

2

The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not exceeding 300 mm by 300 mm.

3

The mean of each set of readings shall be calculated including abnormally high and abnormally low results unless there is good reason to doubt the validity of a particular reading.

4

The coefficient of variation and the standard deviation of the readings shall be reported.

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13.4.4

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Equipment

1

The rebound hammer shall be a proprietary type that has been used successfully and serviced for a minimum of five years.

2

The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact with the surface.

3

The manufacturers’ literature shall identify the impact energy and contact area of the plunger for the hammer.

13.6.4

Reporting

1

The test report shall affirm that the hardness was determined in accordance with BS EN 12504-2 and shall provide the following information:

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13.6.3

date time and place of test

(b)

description of structure and location of test

(c)

details of concrete

(d)

type of cement

(e)

cement content

(f)

type of aggregate

(g)

type of curing

(h)

age of concrete

(i)

type of compaction of concrete

(j)

forming of surface

(k)

moisture condition of the surface

(l)

carbonation state of surface

(m)

any suspected movement of the concrete under test

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direction of test

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(n)

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(a)

(o)

any other factors that are considered significant in influencing the hardness readings.

2

The details of the rebound hammer correlation with strength including the mean, range, standard deviation and coefficient and variation of each reading shall also be included.

13.7

CHEMICAL CONTENT

13.7.1

Sampling

1

The Engineer shall instruct the depth increments over which the dust samples are to be taken, the types of chemical testing to be carried out and the quantity of sample required.

2

The depth of sample shall not be less than the concrete cover to the reinforcement and at least 50 mm from the surface of concrete. In presence of reinforcement, the chemical content shall be tested at least at two levels before and after the depth of reinforcement from the surface of concrete.

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To provide uniform samples of cement matrix and aggregate, three separate holes shall be drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

4

Care shall be taken to discard the material from any render or finish unless this is specifically required under the investigation.

5

Care shall be taken to ensure that dust increments are accurately measured by marking the drill bit.

6

The dust samples increments shall be carefully transferred to plastic bags and sealed to avoid contamination. Each sealed bag shall be uniquely identified by the sample identification and depth increment.

13.7.2

Laboratory Testing

1

Residual split samples of dust from the field investigation shall be retained until the Engineer has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried out on certain samples.

2

Chloride testing of concrete dust samples shall be by an acid soluble method in accordance with BS 1881 Part 124. The results shall be reported to two decimal places.

3

Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124, using an acid soluble method.

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END OF PART

QCS 2014

Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 1

PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2

14.1 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Preinstallation and Co-ordination 4 Delivery, Storage and Handling 4 Protection 4 General Requirements for all Treatments 5 Final Inspection 5

14.2 14.2.1 14.2.2 14.2.3 14.2.4

EPOXY COATING ................................................................................................... 5 General 5 Surface Preparation 5 Materials 6 Application 6

14.3 14.3.1 14.3.2 14.3.3 14.3.4

WATERPROOF MEMBRANE ................................................................................. 6 General 6 Materials 7 Waterproof Membrane 7 Application 7

14.4 14.4.1 14.4.2 14.4.3 14.4.4

PENETRATIVE PRIMER ......................................................................................... 8 General 8 Material 8 Surface Preparation 8 Application 8

14.5 14.5.1 14.5.2 14.5.3 14.5.4

PROTECTIVE COATING ........................................................................................ 9 General 9 Surface Preparation 9 Material 10 Application 10

14.6 14.6.1 14.6.2 14.6.3 14.6.4 14.6.5 14.6.6 14.6.7 14.6.8 14.6.9 14.6.10 14.6.11

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11 General 11 Shop Drawings and Submittals 11 Liner Material Requirements 11 Plastic Sheet Liner Strip Properties 12 Basic Sheet Dimensions 12 Liner Details 12 Installation 13 Testing Requirements 13 Special Requirements 14 Joints in Lining for In-Situ Concrete Structures 15 Testing and repairing damaged surfaces 15

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14

PROTECTIVE TREATMENTS FOR CONCRETE

14.1

GENERAL

14.1.1

Scope

1

This Part covers the materials and application requirements for coatings for concrete surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective coatings, and coatings and treatments for specialist applications where there is a harsh environment.

2


References

1


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14.1.2

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This Section Part 1, ............. General

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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers Tension ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents

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ASTM D570 ................Test Method for Water Absorption of Plastics ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)

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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting

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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for Electrical and Electronic Applications

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ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting

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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion Testers ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials

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ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover BS 1881......................Testing Concrete BS EN 12350..............Testing fresh concrete CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments. ISO 9000 ....................Quality management and quality assurance standards ISO 9001 ....................Quality systems - Model for quality assurance in design, development, production, installation and servicing 14.1.3

Submittals

1

The Contractor shall submit manufacturers' specifications, installation instructions and other data to show compliance with the requirements of this part of the specification and the Contract Documents.

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The Contractor shall submit samples of all materials to be used in the works before delivery of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples of liquid components shall be a minimum of one litre.

3

The Contractor shall submit comprehensive test results for the protective coating system as per the tests in the specification which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

4

The Contractor shall clearly state the chemical composition of the material and the process by which protection is given to the concrete.

5

In addition to the test methods identified in this clause of this specification, the Engineer may require the Contractor to carry out further tests to different standards.

6

If the Contractor wishes to propose a material which has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test, criteria for assessment etc.

7

The Contractor shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include: project name, type/grade of material used, quantity of material used, name of client, name of consultant, name of Contractor. If requested by the Engineer, the Contractor shall supply the contact details of the client, consultant or Contractor where the material was previously installed.

8

The Contractor shall submit a guaranty for the protective coating system and the workmanship. The guaranty shall be worded to reflect the required performance of the material and shall be approved by the Engineer. The guaranty shall be worded to include the phrase ‘the Contractor shall, at the convenience of the Employer, effect all repairs and replacements necessary to remedy defects all to the complete satisfaction of the Engineer’. Unless stated otherwise in the contract specific documentation, the performance guaranty shall be for a period of ten years except for the penetrative primer which shall be for a period of five years.

9

The use of alternatives may be considered by the Engineer. If the Contractor wishes to propose such systems, a technical submission shall be made which shall include a comprehensive justification giving an explanation of why the proposed system is equivalent or superior to the one designated.

14.1.4

Quality Assurance

1

The protective coating system shall be supplied by a manufacturer who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 series certificate that clearly states the scope of the certification.

2

The protective coating system shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on Site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

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The protective coating system shall be applied by a contractor or subcontractor who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification. the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the applicator works to a quality system that is approved by the Engineer.

4

The works shall be executed by an approved specialist subcontractor having a minimum of 5 years successful experience in the installation of the specified material. Only tradesmen experienced with the installation of the materials specified shall be used.

14.1.5

Preinstallation and Co-ordination

1

After approval of all materials and before installation, a prework conference with the Engineer shall be held at the Site. The meeting shall be attended by representatives of the Engineer, Contractor, subcontractor, and manufacturer.

2

The parties shall:

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review drawings, specifications and approved materials

(b)

correct conflicts, if any, between approvals and specification requirements

(c)

examine Site conditions, including inspection of substrate, material labels and methods of storing materials

(d)

review installation procedures and scheduling

(e)

review protection methods for finished work from other trades.

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(a)

Before applying the coating system to the permanent works the Contractor shall carry out a small trial of the coating system for the review and approval of the Engineer.

14.1.6


1

Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly labelled with the manufacturer's name, brand name, and number and batch number of the material where appropriate. Materials and equipment shall be stored as directed in a neat and safe manner.

2

Storage areas shall comply with the manufacturers requirements with regard to shade, ventilation and temperature limits and shall be located away from all sources of excess heat, sparks or open flame. Containers of liquid material shall not be left open at any time in the storage area.

3

Materials not conforming to these requirements will be rejected by the Engineer and shall be removed from the Site and replaced with approved materials.

4

The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and at such times as to permit proper co-ordination of the various parts.

14.1.7

Protection

1

The Contractor shall protect the protection system installation from damage during the construction period so that it will be without any indication of abuse, defects or damage at the time of completion.

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The Contractor shall protect the building/structure from damage resulting from spillage, dripping and dropping of materials.

3

The Contractor shall prevent any materials from running into and clogging drains.

4

Materials and plant shall not be stored on any newly constructed floor without the permission of the Engineer.

5

Impervious membranes shall be laid as protection to all concrete surfaces in contact with the soil and shall consist of tanking or similar accepted material, based on soil investigation report.

6

All foundations shall be provided with protection such as epoxy coatings or similar other accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

14.1.8

General Requirements for all Treatments

1

Protective treatments shall be applied where designated in the contract specific documentation.

2

All protective coating systems to be used shall be applied strictly in accordance with the manufacturers recommendations.

3

The Contractor shall take all necessary precautions against fire and other hazards during delivery, storage and installation of flammable materials specified herein and comply any regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect of the storage and use of hazardous materials required under this section.

4

The Engineer shall specify the required final colour of the coating and the Contractor shall submit samples showing the colour before ordering the materials.

14.1.9

Final Inspection

1

Upon completion of the installation, an inspection shall be made by a representative of the material manufacturer in order to ascertain that the system has been properly installed.

14.2

EPOXY COATING

14.2.1

General

1

The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in two coats to a dry film thickness of 200 m minimum.

14.2.2

Surface Preparation

1

The surface of the concrete shall be free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds. All surface contamination and surface laitance shall be removed by high pressure water jetting or sweep blasting.

2

Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with the product manufacturer’s recommendations.

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Where surface cracking is apparent these cracks shall be chased, by an approved mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased section and providing a flush finish with the concrete surface. A minimum period of 24 h shall be allowed before applying any subsequent protective coating systems.

14.2.3

Materials

1

External above ground coating materials shall provide protection against chlorides and carbonation, and be UV and abrasion resistant.

2

The above ground coating shall be applied over the below ground coating and shall continue for a minimum of 150 mm above the ground level.

3

The epoxy coating shall be UV stable.

4

The finished coating shall be pinhole free and have a total minimum dry film thickness of 200 m.

5

The materials used in the coating system shall comply with the following requirements:

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> 85 % -20 C to 70 C 4 MPa 6 MPa greater than 3.5 MPa 90 MPa (neat resin) 6-8 % (neat resin) Nil 50 mg 97 MPa @ 7 days -6 46.8 x 10 mm/mm/degree C

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Solids content Service temperature Tensile strength (DIN 53504) Resistance against crack (DIN 53515) Adhesion to concrete (ASTM D-4541) Compressive strength (ASTM D-695) Tensile elongation (ASTM D-638) Water absorption (MIL D-24613) Abrasion resistance (ASTM C-501) Compressive strength (ASTM C-579) Thermal coefficient of expansion (ASTM C-531) Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be treated with the material.

3

The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the Engineer.

4

In all operations of storage, mixing and application, the Contractor is to comply with the health and safety recommendations of the manufacturer and governing authorities.

14.3

WATERPROOF MEMBRANE

14.3.1

General

1

This Subpart covers the use of waterproof membrane for general protection to buried concrete.

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Where indicated on the Drawings or directed by the Engineer, concrete in contact with the ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

3

The laying, lapping and sealing of the membrane shall be in accordance with the manufacturer’s instructions.

14.3.2

Materials

1

The material shall be an externally applied waterproof membrane shall be an impervious, cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with silicone coated release paper.

2

Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

3

Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured from selected aggregates, bound in modified bitumen encased between two layers of strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm wide.

14.3.3

Waterproof Membrane

1

The material shall be suitable for use in the Gulf region the compound shall be specially formulated for hot climates and shall have proven experience in the Middle East.

2

The waterproofing material shall conform to the standards detailed in Table 14.1

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Table 14.1 Waterproof Membrane Property Requirements

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Property

Standard ASTM D638

Tear resistance

ASTM D1004

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Elongation Film

Value Longituduial 210 % Transverse 160 % Longitudinal 340 MPa Transverse 310 MPa

Adhesion to primed concrete

ASTM D1000

1.8 MPa

Elongation compound

ASTM D1000

1.8 MPa

Puncture resistance

ASTM E154

220 N over 65 mm

Water resistance

ASTM D570

After 24 h. 0.14 % After 35 d 0.95 %

Environmental resistance Moisture vapour transmission rate

ASTM D543 ASTM E96

Minimum thickness

2

0.3g/M 24 h 1.0 mm.

14.3.4

Application

1

Waterproofing membranes placed on vertical concrete faces shall be protected by preformed asphalt board.

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Boards shall be bonded onto position with high quality solvent borne contact adhesive based on polychloroprene rubber.

3

The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains, equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

4

Areas where waterproofing is applied shall be protected from all traffic and where necessary backfilling. All damage to finished portions of the waterproofing membrane shall be either repaired or replaced, or both, in a manner acceptable to the Engineer.

14.4

PENETRATIVE PRIMER

14.4.1

General

1

The system shall be a penetrating hydrophobic treatment that protects concrete from both water and chloride intrusion, while permitting water vapour transmission.

2

The treatment shall significantly reduce the absorption of water and water borne salts but allow the transmission of water vapour from the substrate.

3

The treatment shall not produce any discoloration of the substrate and shall have excellent resistance to weathering.

14.4.2

Material

1

The material shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

2

The material shall be resistant to petrol, oil, and atmospheric contaminants such as car exhaust fumes and industrial exhausts.

14.4.3

Surface Preparation

1

The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae growth and curing compounds.

2

If the concrete surface is newly cast and has a very smooth finish, the surface shall be roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer shall decide if this means of preparation is required.

3

Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in accordance with the manufacturer’s recommendations.

4

Concrete finishing required shall be completed before the application of the treatment.

5

Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturer’s recommendations.

14.4.4

Application

1

Unless directed otherwise by the Engineer the treatment shall be applied a minimum period of 24 h after the wet curing period, and shall be surface dry.

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The Contractor shall carry out tests to verify the depth of penetration of the material. These tests shall be carried out on specimens of the actual mix design and shall use coloured dyes to trace the penetration of the material.

3

Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats' of the treatment shall be applied before the main treatment.

4

The application of the material on surfaces shall be by a low pressure spray direct from the can. Under no circumstances should thinning of the material be carried out.

5

The rate of application shall ensure that the surface is completely saturated. The impregnated coating shall be applied to two or more flood coats each flood coat shall be a 2 minimum of 0.4 l/m .

6

The material shall be applied strictly in accordance with the manufacturers instructions and as follows:

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the material shall be applied by a fine nozzle spray

(b)

application will not be permitted when the ambient air temperature is above 35 C or in windy conditions

(c)

the surface shall be cleaned by a stiff brush or compressed air to remove all loose deposits

(d)

concrete to be treated shall be surface dry for a minimum period of 24 h before impregnation

(e)

membranes, joint sealers and cast in concrete ancillaries shall be masked off before treatment

(f)

application shall be made by saturation flooding

(g)

the interval between application shall be at least 6 h

(h)

treated areas shall be protected from sea water and rain for 6 h after treatment.

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(a)

PROTECTIVE COATING

14.5.1

General

1

The coating system shall be used for the protection of new or existing reinforced concrete structures against carbonation or chloride induced corrosion.

2

The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat system to minimise ingress of acidic gases, chlorides and water.

14.5.2

Surface Preparation

1

Before application, all surfaces must be dry and free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds.

2

All such contamination and laitence must be removed by the use of grit blasting, high pressure water jetting or equivalent mechanical means.

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14.5

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Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may be affected by the application of the coating shall be fully masked and, in particular, flora and fauna shall be protected.

4

Blow holes and areas of pitting shall be made good with a one part modified cementitious material and allowed to cure in accordance with the manufacturer's recommendations. In particular, the application shall be in accordance with the manufacturer's recommendations, with respect to the maximum application thickness.

14.5.3

Material

1

The materials are required to provide in-depth protection against carbonation and chloride penetration whilst permitting water vapour transmission from the concrete.

2

The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

3

The material employed for the coating shall comply with the following requirements:

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400 µm 200 µm R Value at 325 microns > 161 metres.

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Wet film thickness Dry film thickness Carbon Dioxide diffusion resistance (Taywood Engineering Laboratories) Water vapour transmission (Taywood Engineering Laboratories) Reduction in chloride ion penetration (BS 1881 : Part 124) Tear Resistance (ASTM D624) Crack bridging (BRE Method) Chloride Ion Diffusion (Taywood Engineering Labororatories)

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Shall be more than 13 g/m .d 94 % minimum at 28 d 7.3 kN/mm 5.1 mm

2

-10

3.63 x 10

2

cm /sec.

Where test methods are not specified, the procedure for establishing compliance with the above criteria shall be agreed with the Engineer.

5

The Contractor is required to adhere strictly to the manufacturer's recommendations regarding the use, storage, application and safety rules in respect of the approved materials.

14.5.4

Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials. These trial areas shall be noted on the Drawings and shall be carried out using the type of materials, mixing procedures and applications that will be used on the contract and shall be approved by the Engineer before the Contractor commences with the general work.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be conditioned by the application of a penetrating hydrophobic treatment. The primer shall be allowed to dry in accordance with the manufacturer's requirements.

3

The Contractor shall then apply two coats of pigmented topcoat in accordance with the manufacturer's instructions. The finished coating shall be pinhole free and have a total minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the Engineer.

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5

In all operations of storage, mixing and application the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

14.6

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1

General

1

This Subpart covers the supply and installation of sheet liners in reinforced concrete structures.

2

The liner must be continuous and free of pinholes both across the joints and in the liner itself.

3

All work for and in connection with the installation of the lining in concrete pipe and structure, and the field sealing and welding of joints, will be done in strict conformity with all applicable specifications, instructions, and recommendations of the lining manufacturer.

14.6.2

Shop Drawings and Submittals

1

The Contractor shall submit to the Engineer for approval the following:

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liner schedule

(b)

material certifications

(c)

test results

(d)

material samples

(e)

the manufacturer of the lining will submit an affidavit attesting to the successful use of its material as a lining for sewer pipes and structures for a minimum period of five years in service conditions recognised as corrosive or otherwise detrimental to concrete.

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(a)

Liner Material Requirements

1

The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and other components necessary to make a material of permanent flexibility suitable for a liner in concrete pipes and structures in sewerage service. The weld strips and the joint strips shall be made from like material. For PVC and PE sheet liners, the actual resin used in manufacture must constitute not less than 99 % of the resin used in the formulation.

2

Copolymer resins will not be permitted.

3

All plastic sheets including locking extensions, all joints and welding strips shall be free of cracks, asperities and other defects that may affect the protective properties of the material.

4

The properties of PVC and PE sheet are shown in Table 14.2

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Table 14.2 Properties of PVC and PE Sheet Liners Property

Test Method

PVC Elongation at break Tensile Strength Low Temp. Brittleness PE Elongation at break Tensile Strength Low Temp. Brittleness

Requirement

ASTM D638/882 ASTM D638/412 ASTM D746

300 % 15 MPa 0°C


Exceeds 600 % 10-20 MPa -75 °C

Plastic Sheet Liner Strip Properties

1

Except at shop welds, all plastic sheet liners and strips shall have the properties shown in Table 14.3 when tested at 25 °C.

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14.6.4

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Table 14.3 Properties of Plastic Sheet Liner Strips

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Property

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Shore Durometer

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Weight change

15 MPa 200 % 1 s 50 - 60 5 (with respect to 10 s 35 - 50 5) 1.5 %

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Tensile strength Elongation at break

Requirement

Basic Sheet Dimensions

1

The minimum thickness of the material shall be as shown in Table 14.4

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14.6.5

Table 14.4 Plastic Sheet Liner Minimum Dimensions

Material Thickness

Sheet with locking extensions Sheet, plain Joint strip Weld strip

Structures 4.0 mm 2.3 mm 1.9 mm 2.4 mm

14.6.6

Liner Details

1

Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be integrally extruded with the sheet.

2

Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

3

Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall be repaired and retested.

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14.6.7

Installation

1

Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall be performed in accordance with the recommendations of the manufacturer.

2

The lining to be held snugly in place against inner forms by means of steel banding straps or other means recommended by the manufacturer.

3

Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a careful manner to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

4

In removing forms care shall be taken to protect the lining from damage. In particular:

(b)

when forms are removed, any nails that remain in the lining to be pulled, without tearing the lining, and the resulting holes clearly marked.

(c)

form tie holes to be marked before ties are broken off and all areas of serious abrasion or damage shall be marked.

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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched as follows: patches made entirely with welding strip to be fused to the liner over the entire patch area

(b)

larger patches may consist of smooth liner sheet applied over the damaged area with adhesive

(c)

all edges must be covered with welding strip fused to the patch and the sound lining adjoining the damaged area.

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(a)

Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

7

The Contractor shall take all necessary measures to prevent damage to the installed lining from equipment and materials used in or taken through the work.

14.6.8

Testing Requirements

1

Samples taken from sheets, joints or weld strips shall be tested to determine material properties. Determination of tensile strength and elongation shall be in accordance with ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with ASTM D 2240 using a Type D Durometer, except that a single thickness of material and indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of specimens shall be the thickness of the sheet or strip.

2

The measurement of initial physical properties for tensile strength, weight, elongation and indentation hardness shall be determined before chemical resistance tests.

3

Chemical resistance tests shall be carried out to determine the physical properties of the specimens after exposure to chemical solutions. Test specimens shall be conditioned to constant weight at 43 °C before and after submersion in the solutions detailed in Table 14.5 for a period of 112 d at 25  3 °C.

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Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals, specimens shall be removed from each chemical solution and tested. If any specimen fails to meet the 112 day exposure, the material will be subject to rejection.

5

Pull test for locking extensions: Liner locking extensions embedded in concrete shall withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a period of 1 min, without rupture of the locking extensions or withdrawal from embedment. This test shall be made at a temperature between 21 °C to 27 °C inclusive.

6

Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together, shall be a least equal to the minimum requirements of the liner for thickness, corrosion resistance and impermeability. Welds shall show no cracks or separations and shall be tested for tensile strength. Tensile strength measured across the welded joint in accordance with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25  3 C and the measured minimum width and thickness of the reduced section shall be used.

7

Spark test: All liner shall be shop tested for holes with a spark tester set to provide from 15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before shipment from the manufacturer’s plant.

8

The Contractor shall provide the Engineer with certified copies of test reports before the shipment of the product to the Site.

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Table 14.5 Chemical Resistance Tests

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Chemical Solutions Sodium Hydroxide Nitric Acid

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Soap

5% 1% 1%

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Ferric Chloride

5%

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Ammonium Hydroxide

20 %

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Sulphuric Acid

Concentration

0.1 %

Detergent (Linear alkyl benzyl sulphonate or LAS)

0.1 % BOD not less than 700 mg/l

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Bacteriological

Phosphoric Acid 14.6.9

Special Requirements

1

Liner sheets to be closely fitted and properly secured to the inner forms.

2

50 %

(a)

sheets that are to be cut to fit curved and warped surfaces shall use a minimum number of separate pieces

(b)

a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt joints to prevent wet concrete from flowing around the edges.

Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the surfaces of contact between the concrete structure and items not of concrete and (a)

the same procedure will be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete

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(b)

at each return, the returned liner will be sealed to the item in contact with the plastic lined concrete with an adhesive system

(c)

if the liner cannot be sealed with this adhesive because of the joint at the return being too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 50 mm and finish with a minimum of 25 mm of an approved corrosion resistant material.

14.6.10 Joints in Lining for In-Situ Concrete Structures Field joints and Lining at joints shall be free of all mortar and other foreign material and shall be clean and dry before joints are made.

2

All welding is to be in strict conformance with the specifications of the lining manufacturer.

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all welds shall be physically tested by a non-destructive probing method

(b)

all patches over holes, or repairs to the liner wherever damage has occurred.

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Each transverse welding strip which extends to a lower edge of the liner will be tested by an approved testing agency at the cost of the Contractor. the welding strips will extend 50 mm below the liner to provide a tab.

(b)

a 5 kg pull will be applied to each tab. The force will be applied normal to the face of the structure by means of a spring balance

(c)

liner adjoining the welding strip will be held against the concrete during application of the force

(d)

the 5 kg pull will be maintained if a weld failure develops until no further separation occurs.

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2

All surfaces covered with lining, including welds, will be tested with an approved electrical holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

defective welds will be retested after repairs have been made tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed inspection.

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14.6.11 Testing and repairing damaged surfaces

(g)

inspection will be made within two days after joints has been completed in order to prevent tearing the projecting weld strip and consequent damage to the liner from equipment and materials used in or taken through the work.

END OF PART

QCS 2014

Section 05: Concrete Part 15: Hot Weather Concreting

Page 1

HOT WEATHER CONCRETING ............................................................................. 2

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definition of Hot Weather 2 System Description 3 Submittals 3

15.2

PLACING TEMPERATURE ..................................................................................... 3

15.3

PLANNING CONCRETING ..................................................................................... 4

15.4

MIX DESIGN ........................................................................................................... 4

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6

TEMPERATURE CONTROL ................................................................................... 4 General 4 Aggregates 4 Water 5 Cement 5 Addition of Ice 5 Liquid Nitrogen 6

15.6

BATCHING AND MIXING ........................................................................................ 6

15.7

TRANSPORTATION ............................................................................................... 6

15.8

PLACING AND FINISHING ..................................................................................... 6

15.9

CURING AND PROTECTION.................................................................................. 7

15.10

INSPECTION AND TESTING .................................................................................. 7

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HOT WEATHER CONCRETING

15.1

GENERAL

15.1.1

Scope

1

This Part covers the precautions to be taken for hot weather concreting for all structural concrete except blinding concrete, where a minimum compressive strength is specified.

2


15.1.2

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This Section Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8 .............. Transportation and Placing of Concrete Part 10 ............. Curing

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References

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ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

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ASTM C1064 ..............Measuring the Temperature of Concrete

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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for buildings

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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods

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BS EN 934..................Admixtures for concrete, mortar and grout Definition of Hot Weather

1

The requirements of the following clauses of the specification are applicable during the hot weather period in Qatar.

2

The hot weather period shall be defined as starting when the maximum ambient air shade temperature on the Site exceeds 35 C for three consecutive days. The end of the hot weather period shall be defined as the period when the maximum air shade temperature is below 35 C on three consecutive days.

3

The Contractor shall establish a thermometer on Site that records the ambient air shade temperature. The thermometer shall be established at a position to provide representative air temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange for the calibration of the Site thermometer.

4

Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as:

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15.1.3

(a)

High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer),

(b)

High concrete temperature,

(c)

Low relative humidity,

(d)

High wind speed

QCS 2014


(e)

the rate of evaporation exceeds 0.75 kg/m /h

Page 3

2

15.1.4

System Description

1

The Contractor shall undertake hot weather concreting procedures that are effective in controlling the following potential problems associated with concreting in hot weather: increased water demand of the mix

(b)

increased rate of slump loss

(c)

increased rate of setting

(d)

increased tendency for plastic shrinkage cracking

(e)

decreased long-term strength

(f)

increase tendency for drying shrinkage and cracking

(g)

increased tendency for differential thermal effects with consequent cracking

(h)

decreased durability from cracking where there is increased permeability.

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Submittals

1

The Contractor shall prepare weekly in advance his proposed concreting programme showing the quantities to be placed and the anticipated placing hours.

2

At least one month before the start of the hot weather period the Contractor shall submit his specific proposals for the control of the concrete temperature for the constituent materials; cement, water aggregates.

3

Where required the Contractor shall submit to the Engineer his proposals for the use of liquid nitrogen for cooling which shall include details of previous project application and the intended methods to be used and quantities of liquid nitrogen.

15.2

PLACING TEMPERATURE

1

This Subpart of the specification applies at all times of the year and at all times of the day.

2

Maximum fresh concrete temperature (at placement) shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

3

Concrete shall not be placed if the shade temperature exceeds 40ºC.

4

The temperature of each truck of concrete shall be measured using either a glass, dial type or electronic thermometer, just before the placing of the concrete and the temperature recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire load of concrete in the truck or conveyer.

5

The Contractor shall allow for the increase in concrete temperature in the period from dispatch from the plant while in transportation or whilst awaiting placement on Site and take adequate measures to ensure the maximum temperature is not exceeded.

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15.1.5

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PLANNING CONCRETING

1

During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall plan concreting operations such that no concreting takes place between the hours of 10:00 hours and 17:00 hours.

2

The Contractor shall arrange concrete pours such that the programme of works can be achieved without concreting during the period from 10:00 hours to 17:00 hours.

3

The Contractor shall nominate one member of his staff to be the co-ordinator for the supply of concrete. The co-ordinator’s responsibilities shall include ensuring the batched rate matches that of delivery and placement and the preparations needed before commencing a concrete pour.

15.4

MIX DESIGN

1

In the hot weather period, the Contractor shall review all concrete mix designs to ensure that the design slump or workability specified is achieved without increase in the mix water content. The Contractor shall make modifications to the mix design to allow for increased slump loss during transportation in hot weather.

2

This shall be achieved by adjusting the proportion of admixture, plasticiser or super plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix design with nominal values for cold weather and hot weather use.

3

Under no circumstances will the addition of extra water that increases the water cement ratio be permitted during hotter weather.

4

All concrete materials and proportions used in periods of hot weather shall be those that have a satisfactory record of use in such conditions.

15.5

TEMPERATURE CONTROL

15.5.1

General

1

The Contractor’s specific proposals for the control of the concrete temperature shall include extent and type of shading of aggregates, method of chilling mix water and procedures for batching and mixing, transportation, placing and finishing, curing and protection.

2

These shall include calculations in accordance with ACI 305R, clause 3.1 “estimating concrete temperature”. The Contractor shall calculate the temperature of freshly produced concrete based on the input temperatures of the constituent materials and the weights from particular mix designs. The calculations shall make allowance for the rise in temperature between mixing and placing due to the transportation and waiting period. The calculations shall successfully demonstrate that the temperature can be maintained below 32 C at the point of placing.

15.5.2

Aggregates

1

All practical means shall be employed to keep the aggregates as cool as possible.

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Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is not incident on the aggregates. Shades shall be constructed to allow access for mechanical shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool the aggregate.

3

Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall not be permitted.

15.5.3

Water

1

Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

2

The water shall be chilled by the use of proprietary chillers or the addition of ice to the water tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited directly into the mixer.

3

Water shall not be chilled below a temperature of 5 C.

4

Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and painted white.

5

The mechanical refrigeration equipment and insulated water storage shall be adequate for the anticipated hourly and daily production rates of concrete during the hot weather period.

6

Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank, such procedures shall be to the approval of the Engineer.

7

Ice shall be completely melted in mixing water prior to adding water to the mixer.

15.5.4

Cement

1

The use of freshly ground cement at very high temperatures is not permitted.

2

The cement shall be kept below the temperature which there is a tendency of false set.

3

Under no conditions shall the temperature of the cement exceed 75 C when it enters the mixture.

4

The Contractor shall make arrangements for storage on Site to allow cooling of freshly ground and delivered cement.

15.5.5

Addition of Ice

1

Crushed shaved or chipped ice can be used as part of the mixing water for reducing the concrete temperature.

2

The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted before the completion of mixing of the concrete in the pan.

3

To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of the batch water requirement.

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Page 6

Crushed ice shall be stored at a temperature that will prevent lumps from forming by refreezing of particles.

5

The batching plant shall incorporate a mechanical system for correctly proportioning and weighing the ice to be added to the mixture.

6

The quantity of ice shall be deducted from the total batch water.

7

The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated storage on the Site at the plant to meet the anticipated daily and hourly production rates of concrete during the hot weather period.

15.5.6

Liquid Nitrogen

1

Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

2

Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not frozen.

3

The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and injection facility for the batching plant or one or more injection stations for truck mixers.

4

The system may be set up at the Site for injection just before placing.

5

Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.

15.6

BATCHING AND MIXING

1

The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.

2

Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with water and the drum flushed out with cold water before batching. Care shall be taken to ensure all water is removed from the drum before batching.

3

The temperature of the concrete shall be checked after discharge from the mixer and written on the delivery ticket. Temperature check shall be carried out at the plant on the concrete 3 floor for every 50 m produced or every hour which ever is the minimum.

4

A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN 480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature conditions.

15.7

TRANSPORTATION

1

The transportation, placing, compaction and finishing of concrete shall be at the fastest possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of placement and compaction.

15.8

PLACING AND FINISHING

1

If the temperature of the first truck of concrete of a particular pour is above the specification maximum temperature limit then placing shall not commence.

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Page 7

If a pour is in progress and the temperature of a particular truck exceeds the maximum permitted temperature the placing may be allowed to continue at the discretion of the Engineer in order to avoid the possible development of a cold joint.

3

However, no further concreting pours shall take place until the Contractor has submitted revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the maximum temperature will not be exceeded in the future. Before beginning new pours the temperature of the concrete constituent materials shall be monitored to verify that they meet the assumptions of the calculations.

15.9

CURING AND PROTECTION

1

Curing and protection shall conform to the requirements of Part 10 of this Section.

2

Evaporation shall be minimised, particularly during the first few hours subsequent to placing concrete, by suitable means such as applying moisture by fog spraying or any other means acceptable to the Engineer.

15.10

INSPECTION AND TESTING

1

All thermometers used for the measurement of concrete temperature shall be calibrated weekly against a glass mercury thermometer. Calibration shall be carried out over the temperature range of 10 C to 100 C using a water bath with ice or heating.

2

The method used to determine acceptance of temperature controlled concrete should be in accordance with ASTM C1064.

3

All concrete test specimens for strength or other purposes shall be carefully protected and cured.

4

Specimens shall be protected from accidental damage by plant personnel or equipment on Site.

5

Specimens shall be kept moist by the addition of water or covering by suitable curing materials.

6

The exact time of preparation of the specimen on Site shall be noted and the time when it is transferred to the laboratory. These times shall be written on the test report.

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END OF PART

QCS 2014

Section 05: Concrete Part 16: Miscellaneous

Page 1

MISCELLANEOUS .................................................................................................. 2

16.1 16.1.1 16.1.2


16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.2.5 16.2.6 16.2.7 16.2.8

PAVEMENT QUALITY CONCRETE ........................................................................ 3 Scope 3 Mix Designs 3 Cement 4 Water 4 Aggregates 5 Admixtures 5 Air content 5 Density 5

16.3 16.3.1 16.3.2 16.3.3

CEMENTITIOUS GROUT ........................................................................................ 6 General 6 Material 6 Workmanship 6

16.4 16.4.1 16.4.2

SCREEDS ............................................................................................................... 7 Scope 7 General 7

16.5

CELLULAR CONCRETE ......................................................................................... 9

16.6 16.6.1 16.6.2 16.6.3

REPAIR OF CONCRETE ........................................................................................ 9 General 9 Honeycombing or Spalling 9 Crack injection 11

16.7

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13 General 13 Resin 13 Minimum strength 14

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16

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16

MISCELLANEOUS

16.1

GENERAL

16.1.1

Scope

1

This Part deals with miscellaneous items related to concrete works including pavement quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair of concrete and guniting.

2


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Part 2, .............. Aggregate Part 3, .............. Cementitious Material Part 4, .............. Water Part 5, .............. Admixture Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Placing of Concrete Part 9, .............. Formwork Part 10, ............ Curing Part 15, ............ Hot Weather Concreting.

.

This Section

References

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16.1.2

ACI 506, .....................Guide to Shotcrete

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ASTM C989 –10, ........Standard Specification for Slag Cement for Use in Concrete and Mortars

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BS 146,.......................Portland-blast furnace cement

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BS 812,.......................Testing aggregates BS 1881,.....................Testing concrete

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BS 2782,.....................Methods of testing plastics BS 3892,.....................Pulverised fuel ash BS 4551,.....................Methods of testing mortars, screeds and plasters BS 5075,.....................Concrete admixtures BS 6319,.....................Testing of resin and polymer / cement compositions for use in construction BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement. BS 8203,.....................Code of practice for installation of resilient floor coverings. BS 8500,.....................Concrete BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for common cements BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2, 4, 5, 6, 8, 10, 11, and 12) BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6) BS EN 998,.................Specification for mortar for masonry

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BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis BS EN 12350,.............Testing fresh concrete BS EN 12390-5, .........Flexural strength of test specimens BS EN 12620,............. Aggregates for concrete EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 12350, ..................Testing fresh concrete EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis

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GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

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SHW 1000 ..................Specification for Highway Works – UK ROAD PAVEMENTS – CONCRETE MATERIALS

PAVEMENT QUALITY CONCRETE

16.2.1

Scope

1

This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement bound granular material used as a roadbase or sub-base or as a backfill material for excavations.

16.2.2

Mix Designs

1

Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1 below, in accordance, with the pavement design shown on the Drawings or as directed by the Engineer.

2

All concrete for use in pavements shall be designed mixes or equivalent standard mixes in accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where otherwise specified.

3

Prescribed mixes may be used for rapid construction with the approval of the Engineer.

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16.2

Table 16.1 Pavement Grades Pavement Layer

BS 8500 and GSO EN 2061Designed Mix

Surface Slabs Unreinforced Concrete

C40

Jointed Reinforced Concrete ( JRC )

C40

Continuously Reinforced Concrete Pavement ( CRCP )

C40

Continuously Reinforced Concrete Roadbase ( CRCR )

C40

Ground Anchorage Beam

C40

BS 8500 and GSO EN 206-1 Standard Mix

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Page 4



Wet Lean Mix Concrete 4

C20

ST4


C15

ST3


C10

ST2


C7.5

ST1

Pavement Layer

Cement

1

The general term 'cement' in this Part means the materials shown below.

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Complying with

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Cement

EN 197-1

Specification for pozzolanic pulverised-fuel ash cement (grades C20 or below)

BS 6610

BS 146 or EN 197-4

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Cement. Composition, specifications and conformity criteria for common cements Portland blast furnace cement

The use of a combination of Portland cement and ground granulated blast furnace slag is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix.

3

The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix. PFA shall be in accordance with BS 3892.

4

The use of microsilica in the mix designs will be permitted if approved by the Engineer.

5

The Engineer will stipulate the minimum combined cementitious material content required for the mix where PFA or GGBFS are used.

6

The maximum proportion of ground granulated blastfurnace slag with Portland cement shall be as per Table 6.6 of Part 5.6.

7

In combination with Portland cement, the proportion of PFA by mass to the total cement shall be as per Table 6.6 of Part 5.6.

8

The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

9

The minimum cement content for concrete pavements shall be preapproved by Qatar Standards.

16.2.4

Water

1

Water for use in the making and curing of concrete shall conform to the requirements of Part 4 of this Section.

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The water content shall be the minimum required to provide the agreed workability for full compaction of the concrete to the required density, as determined by trial mixes or other means approved by the Engineer..

16.2.5

Aggregates

1

The requirements of Part 2 of this specification will govern, except as modified below.

2

Aggregates for all pavement concrete shall be complying with BS EN 12620

3

Alternatively coarse aggregate of recycled and secondary aggregate materials may be used to replace up to 50% by mass of coarse aggregate

4

The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not exceed 20 mm.

5

If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate combination to check for the possibility of alkali silica reaction. Such tests shall be carried out in accordance with the procedure laid down in Part 2 of this Section.

16.2.6

Admixtures

1

Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN 934. Admixtures containing calcium chloride shall not be used.

2

Other chloride-free admixtures may be used with the approval of the Engineer.

16.2.7

Air content

1

The total quantity of air in air-entrained concrete as a percentage of the volume of the mix shall be 5  1.5 % for mixes of nominal aggregate size 20 and be 4  1.5 % for mixes of nominal aggregate size 40.

2

The air content shall be determined at the point of delivery by a pressure type air meter in accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at least six times per day whichever is the greater, in conjunction with tests for workability and strength. For areas less than 300 m2, the rate shall be at least one determination to each 20 m length of slab or less constructed at one time or at least three times per day. If the air content is outside the specified limits, a further determination shall be made immediately on the next available load of concrete before discharging. If the air content is still outside the limit, the Contractor shall immediately adjust the air content of the concrete to improve its uniformity, before further concrete is used in the Works.

3

The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure uniform distribution of the agent throughout the batch during mixing.

16.2.8

Density

1

The density of concrete Grades greater than C30 shall be such that without air-entrainment the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.

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The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the theoretical maximum dry density.

16.3

CEMENTITIOUS GROUT

16.3.1

General

1

This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be used to where it is necessary to eliminate shrinkage when filling the void between a base plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including masts, anchor bolts and fence posts.

2

The grout shall be supplied by a reputable construction chemical company as a single pack prepackaged cement based product which is chloride free.

3

For a particular application, the Contractor shall submit a method statement detailing how the formwork will be placed and the points where the grout will be poured.

4

Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of the materials and methods with the suppliers representative being present to train the Contractor’s personnel in the correct use of the material.

16.3.2

Material

1

The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing and non shrink.

2

Positive volumetric expansion shall take place while the grout is plastic by means of gaseous expansion to avoid shrinkage and cracking.

3

The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.

4

The grout shall exhibit a high early strength gain yet not be subject to cracking or other detrimental effects.

5

At ambient temperatures above 35 C, cool water shall be used for mixing the grout before placing.

16.3.3

Workmanship

1

The storage handling and pouring of the grout shall be in strict accordance with the manufacturer’s instructions.

2

The substrate surface shall be free from oil grease or loose or partially bonded material.

3

If the concrete surface is defective or has laitance it shall be cut back to a sound base.

4

Bolt holes and fixing pockets shall be blown clean of dirt or debris.

5

The substrate shall be soaked with fresh potable water before grouting, although immediately before grouting, free water shall be removed and blown out of bolt holes or pockets.

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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide. For larger base plates or flow areas the manufacturers instructions shall be followed.

7

Base plates and metallic items shall be clean and free from oil, grease, or scale.

8

Vent holes shall be provided to allow the release of air from isolated spots.

9

Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between the constructive formwork and joints. Formwork shall extend above the required pour height and if necessary shall be extended to allow a hydrostatic head to aid placement.

10

The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

11

The quantity of water to be added to the preweighed bags shall be enough to give the desirable consistency as trowelable or flowable.

12

Mixing shall take place for a minimum of 5 min.

13

The grout shall be placed within the time limit specified by the manufacturer depending on the actual application temperature.

14

Grout shall be poured from one side and it shall be verified that the grout has flowed under all of the base plate with no voids. Pouring from several sides shall not be permitted.

15

Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.

16.4

SCREEDS

16.4.1

Scope

1

This Subpart covers screeds that provide by means of a layer of mortar a level surface in flooring applications and to provide falls on flat concrete roofs.

16.4.2

General

1

Screeds shall be suitable for application onto a concrete substrate.

2

The screeds shall be suitable for receiving surface finishes which may arrange from thin flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

3

Screed mortars shall generally comprise sand and cement modified by additives or substituted by other materials such as polymers in order to provide specific performance requirements.

4

For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of 10 mm aggregate.

5

Aggregates used for screeds shall not contain deleterious materials such as coal or iron particles which may affect the finish the surface of the screed.

6

Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening and shall comply with the appropriate part of BS EN 480 and BS EN 934.

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7

Polymer based additives may be used to improve adhesion and strength of thin or featured screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or acrylic polymers.

8

Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

9

Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used strictly in accordance with the manufacturers’ instructions.

10

The interface of the screed in the concrete substrate shall be specified as one of the following options by the Engineer: Monolithic with the concrete base: The screed shall be applied within 3 hours of placing the concrete base.

(b)

Bonded to the concrete base: Screed shall be laid onto a concrete base which is hardened and is subsequently been prepared to receive the screed, the minimum thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

(c)

As an unbonded screed: The screed shall be laid on a separating layer.

(d)

As a floating screed: The screed shall be laid on an insulating material.

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The cement and sand screed mix shall have the minimum amount of water added to give sufficient workability and allow the material to be thoroughly compacted.

12

Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water and admixtures shall ensure a thorough homogeneous mixture with no balling up of the cement.

13

Screeds shall be laid either between carefully levelled and trued batons or between strips of screed laid and compacted to a finished level.

14

For bonded screed where a high degree of bond is required the surface laitance of the concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer of neat cement grout shall be applied to the prewetted or dampened concrete and the screed applied and compacted while the grout is wet.

15

Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints around the perimeter shall be particularly well compacted to avoid breaking out and curling.

16

Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be kept protected by waterproof sheeting for at least 7 days after laying.

17

Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and necessary strength achieved.

18

If requested by the Engineer the Contractor shall carry out a soundness and impact test in accordance with BS 8203.

19

Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction or movement joints shall be provided as appropriate, where shown on the drawings or as directed by the Engineer. Bays shall be laid alternatively.

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Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick screed.

16.5

CELLULAR CONCRETE

1

Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing, hardening and most important "ageing ". CC infinitely increases its strength by hydration as long as exposed to humidity in the atmosphere.

2

CC offer more thermal insulation and a substantially higher fire-rating than conventional concrete.

3

Minimum compressive strengths shall be 4.0 MPa.

4

The required density and strength of the CC shall be specified on the drawings and approved by the Engineer.

5

The method of production of Cellular Concrete shall be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the CC along with a list of previous projects where the particular system has been used.

6

After source approval of the material and system the Contractor shall submit a mix design for the CLC for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

7

The Engineer may also instruct that tests are carried out for abrasion resistance and thermal insulation properties.

8

Cellular Concrete shall not be used for structural reinforced members.

16.6

REPAIR OF CONCRETE

16.6.1

General

1

The extent and nature of the defects in concrete shall be established in accordance with Part 15 of this Section. Based on these results the Engineer shall confirm the acceptability of the work and whether remedial works are required.

2

If remedial works are required the Contractor shall submit a detailed method statement identifying the specific materials to be used and the sequence of activities for the repair.

3

Only proprietary proven materials that form part of a standard repair system shall be used.

16.6.2

Honeycombing or Spalling

1

Where there is honeycombed concrete or concrete damaged by physical forces such as impact that has caused spalling, the concrete shall be replaced using a high strength free flowing cementitious micro-concrete.

2

The areas of repair shall be marked out and agreed with the Engineer.

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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until sound concrete is reached. Due account shall be taken of propping or other instructions given by the Engineer regarding sequences of removal and repair.

4

The equipment and methods used to break out the concrete shall be such that no reinforcing steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened or damaged unless so directed by the Engineer.

5

Where the removal of concrete by mechanical means is difficult due to reinforcement congestion, then the use of high pressure water jetting shall be considered and necessary provisions for protecting the rest of the structure shall be made.

6

The prepared void shall be profiled so that entrapment of air is avoided during the repair process using fluid micro-concrete.

7

The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be accepted.

8

The prepared concrete surface shall be sound and clean and free of loose particles, dust and debris.

9

Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose millscale.

10

Reinforcement damaged during the removal of concrete or the preparation process shall, if required by the Engineer, be repaired or replaced.

11

Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair material without distortion or movement during placement.

12

The formwork shall be watertight at all joints between panels and between the formwork and the existing concrete surface so as to prevent grout leakage.

13

The formwork shall be constructed from appropriate materials as agreed with the Engineer to achieve the required finish.

14

Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated with a suitable mould release agent. This shall be used in accordance with the manufacturer's recommendations.

15

The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled completely and no air remains entrapped.

16

Where necessary, provision shall be made for controllable bleed points to prevent air entrapment and enable the extent of flow of the repair material to be assessed.

17

The formwork shall be inspected by the Engineer and, if approved, filled with clean water which demonstrates that the formwork is grout-tight and saturates the prepared concrete surfaces. The formwork shall be then be completely drained and resealed

18

In situations where the completed repair will be subjected to constant immersion an epoxy bonding agent shall be applied in accordance with the manufacturers’ instructions.

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19

Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18 and tested at 20 oC

20

The thermal conductivity and the elastic modulus of the repair material shall be compatible with the host concrete.

21

If requested by the Engineer, recent test results of the material for the following properties shall be submitted: (a)

thermal conductivity

(b)

elastic modulus, BS 1881

(c)

expansion characteristics, ASTM C 827, CRD 621-82A

(d)

flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

The micro-concrete shall be mixed and placed in accordance with the manufacturer's recommendations, particularly with regard to water content, mixing equipment and placing time.

23

As far as possible the placing of the micro-concrete shall be continuous. The mixing operation shall be timed so that there is minimal interruption in the material flow. If, however, placing is interrupted, the operation shall recommence as soon as possible while the repair material retains its flow characteristics.

24

The formwork shall not be removed until the repair micro-concrete has achieved a compressive strength of at least 10 MPa or as directed by the Engineer.

25

Immediately after removal of the formwork the repair area shall be cured in accordance with Part 10 of this Section.

26

The repair material shall:

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be shrinkage compensated in both liquid and cured states

(b)

contain no metallic expansion system

(c)

be prepacked and factory quality controlled

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Table 16.3 Property requirements of micro concrete Property

Test Method

Minimum Value

Compressive strength

BS EN 12390-3 @ 28 d

50 MPa

Flexural strength

BS 4551 @ 28 d

10 MPa

Anchorage bond

BS 8110

Passes

16.6.3

Crack injection

1

This clause of the specification covers non-active cracks within concrete elements caused by shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.

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Before to starting the injection operation it shall be established by testing and investigation work that cracks manifest within concrete elements due to either or both shrinkage or structural movement are non-active.

3

The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be filled shall be marked out in detail on the concrete elements by the Contractor and agreed with the Engineer before proceeding.

4

The extent of the work may be adjusted by the Engineer as the project proceeds, according to the conditions found.

5

Grease, oil or other contaminants shall be removed. Algae and other biological growth shall also be removed by scrubbing with bactericide or detergent and clean water. If necessary, wire brushes shall be used.

6

Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within the marked out scope of the work shall be removed.

7

All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

8

The injection nipples shall be fixed at intervals along the length of each crack. The distance between each nipple will depend on the width and depth of the crack.

9

Spacing shall be close enough to ensure that the resin will penetrate along the crack to the next point of injection. This will normally be between 200 mm and 100 mm.

10

Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant shall be supplied in two pans (liquid base and hardener system). The two components shall be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.

11

The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall be pressed firmly into place and held for several seconds until secure. The mixed sealant shall be applied around each embedded nipple, ensuring a complete seal is made. In this way, all the nipples shall be fixed along the length of the crack.

12

In the case of a wall or slab which is cracked all the way through, nipples shall be located on both sides with those at the back placed at midway points between those it the front.

13

The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to 40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or slab shall be sealed in this way.

14

The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures (5 °C to 12 °C) the curing time will be extended and the Contractor shall ensure that the surface sealant has adequately cured before continuing.

15

One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to either end of horizontal cracks.

16

Each crack shall be treated in a single, continuous operation. Sufficient material shall therefore be made ready before the commencement of the work.

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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of the mixed material.

18

The preparation, mixing and application of the materials shall be undertaken in strict accordance with the manufacturer's recommendations. The Contractor is to ensure that all necessary tools and equipment are on Site.

19

Both the compressive strength and flexural strength shall be tested at 7 d.

20

The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the failure shall be in the concrete and not at the interface.

21

The injection resin shall be of a prepackaged or preweighed type and only the use of full units will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

22

In all operations of storage, mixing and application, the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

23

The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this time.

24

The nipples and bands of surface sealant shall then be removed and damaged areas made good to the satisfaction of the Engineer.

25

The injection material shall be compatible with the host concrete and shall have the properties shown in Table 16.4 when tested in accordance with the relevant standards.

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Property

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Table 16.4 Property Requirement for Epoxy Crack Injection Material Method

BS 4551, BS 2782 BS 6319

Flexural strength

BS EN 12390-5

70 MPa

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Minimum Value

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE

16.7.1

General

1

Polyester resin concrete is a mixture formed from aggregates and fillers which are bound together using a polyester resin (also called Polymer concrete pipes), as defined in ISO 18672-1 or ASTM D 6783 with the amendments given below.

2

Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems (pipes, manhalls, soakways).

16.7.2

Resin

1

The resin used in the pipe system and manufactured as per ISO 18672-1shall have a temperature of deflection of at least 85 °C, when tested in accordance with Method A of ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the applicable requirements of EN 13121-1.

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2

The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method D648. The resin content shall not be less than 7 % of the weight of the sample as determined by Test Method D2584.

16.7.3

Minimum strength

1

The minimum strength classes for different pipe shapes are given below. Table 16.4

.

Minimum strength classes for pipes designated PRC-OC or PRC-TC Strength class Sc Nominal size N/mm DN PRC-TC

150 ≤ DN ≤ 500

180

180

600 ≤ DN ≤ 1000

145

1200 ≤ DN≤ 3000

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Table 16.5 Minimum strength classes for pipes designated PRC-OE or PRC-TE Strength class Sc N/mm

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Nominal width/height WN/HN

PRC-TE

300/450 ≤ WN/HN ≤ 600/900

180

180

700/1050 ≤ WN/HN ≤ 1000/1500

145

160

120

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1200/1800 ≤ WN/HN ≤ 1400/2100

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Table 16.6 — Minimum strength classes for pipes designated PRC-OK or PRC-TK Strength class Sc N/mm

Nominal size DN

PRC-OK

PRC-TK

800 ≤ DN ≤ 1000

145

160

1200 ≤ DN ≤ 1800

120

145

END OF PART


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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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QUALITY NON-CONFORMANCE TEMPLATE

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SUBMITTALS .......................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

GENERAL ............................................................................................................... 2 Project Quality Plan 2 Quality Organisation Plan 3 Inspection and Test Plans 4 Quality Checklists 5 Key Performance Indicators 5 Method Statements 6 Commissioning Plan 6

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SUBMITTALS

2.1

GENERAL

2.1.1

Project Quality Plan

1

The Contractor shall prepare the necessary Contract specific Project Quality Plan as specified in this Section, the Contract Documents and as a minimum meeting the requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and approval within 30 days of the award of Contract. The Contractor is not permitted to Work on the worksite until such time as the plan has been approved by the Engineer.

2

The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor shall undertake a full formal review of the quality plans annually with reference to the date of award of the Contract and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendments be required.

3

The Project Quality Plan shall describe the Contractor’s Quality Management System that will be used throughout the Contract and the contents shall include but not be limited to the following: Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Quality Objectives

(d)

Quality Policy and ISO 9001 Certificate (if applicable)

(e)

Control of Project Quality Plan

(f)


(g)

Project Management, Planning and Resources

(h)

Management, Organisation and Responsibilities

(i)

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Contract Review Project Deliverables

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(a)

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(k)

Communication with the Engineer

(l)

Management of Documents, Data and Records

(m)

Design (Including Temporary Works)

(n)

Procurement of Services, Equipment and Materials

(o)

Method Statements

(p)

Inspection and Test

(q)

Product Identification and Traceability

(r)

Owner Supplied Product

(s)

Handling, Storage, Packaging and Delivery

(t)


(u)

Control of Inspection, Measuring and Test Equipment

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals Audits

(w)

Training

(x)


(y)

Management Review

(z)

Quality Meetings

(aa)

Monthly Quality Report

(bb)

Commissioning

(cc)

Interface Management

(dd)

Project Completion and Handover

(ee)

Appendices

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And include as a minimum:

a detailed description of procedures, instructions, and reports to be used to ensure compliance with the Project Documentation

(b)

a detailed description of procedures for reviewing shop drawings, samples, certificates and other submittals necessary for compliance with the Project Documentation

(c)

a detailed description of procedures used to identify, report and resolve problems

(d)

a description of the services provided by outside organisations such as testing laboratories, architects, and consulting engineers

(e)

a detailed description of inspections and tests required

(f)

copies of forms and reports to be used to document quality assurance operations

(g)

the names of personnel responsible for each part of the Works

(h)

a submittal status log listing required submittals and action required by the Contractor and Engineer

(i)

a detailed description of document and submittal control procedures

(j)

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an inspection and test schedule keyed to the construction programme procedures to identify and control the use of items and materials

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5

No construction shall begin and no requests for payment from the Contractor shall be processed until the Contractor’s Project Quality Plan is approved.

6

A Contractors Project Quality Plan Template with guidance notes is included in Part 15 Appendix B of this Section. The format of the Contractors Project Quality Plan must follow this template including all clauses contained within.

2.1.2

Quality Organisation Plan

1

The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Quality Organisation Plan shall provide the names, qualifications, experience and skills of all the QA/QC Team including Corporate QA/QC Manager, Quality Management Representative and key support staff.

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Page 4

The Quality Organisation Plan shall show the organisation of Contractor’s quality team and shall include, but not be limited to, the following: (a)

an organisation chart identifying all personnel responsible for quality

(b)

Identify the quality team showing that the team is independent of the job supervisory staff with clear lines of authority to top tier management.

(c)

Indicate and describe the area of responsibility and authority of each individual in the quality assurance team.

The Quality Organisation Plan should also define quality responsibilities of any of the Contractors team with responsibilities under the Contractors Project Quality Plan.

5

The Contractor’s Quality staff shall have relevant educational and professional qualifications, and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of the works at the worksite until such time as approved quality personnel have been deployed on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed quality personnel without prior approval from the Engineer.

6

The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a standalone document and cross-referenced within the Project Quality Plan.

2.1.3

Inspection and Test Plans

1

As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be prepared for the Works and the target dates for their submission to the Engineer for his approval.

3

The Inspection and Test Plans shall consider the requirements of each Section of the Specification and shall identify, as a minimum, the following:

(b)

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(c)

the required inspection and testing frequency

(d)

the acceptance/rejection criteria

(e)

whom from the Contractors team is responsible and qualified to perform the inspection or test

(f)

Quality Records to be generated

(g)

Hold, Witness, surveillance and Record Review points of the Contractors team, the Engineer and any other agencies having jurisdictional authority over the work relating to each inspection and test to be performed.

Details each activity, inspection and test to be performed Reference to specifications, standards etc.

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(a)

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Each inspection and test shall have a unique reference number.

5

Inspection and Test Plans are required to address the Contractors on and off site Work and preparation, submission and approval of related documentation.

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Inspection and Test Plans are required for all operations including major temporary works and commissioning.

7

No work covered by the Inspection and Test Plan shall begin until the plan has been approved by the Engineer.

8

A Contractors Inspection and Test Plan Template with guidance notes is included in Appendix B of this Section and must be used by the Contractor

2.1.4

Quality Checklists

1

The Contractor shall develop specific quality checklists for all activities to be checked as per the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection Test Plans submission prior to the start of the activity.

2

The Contractor shall inspect the work and sign off the relevant checklist and Inspection Request prior to the final inspection with the Engineer.

3

The checklist shall be attached with the Inspection Request and other relevant attachments and submitted to the Engineer.

2.1.5

Key Performance Indicators

1

The Contractor shall develop and report Key Performance Indicators (KPI’s). KPI’s are a set of quantifiable measures that are used to gauge performance of the Contractors Performance.

2

The KPI’s shall be defined in the Contractors Project Quality Plan and be subject to Engineers approval.

3

The Contractor is responsible for developing his own KPI’s for all elements of his contract (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPI’s.

Time between opening and closure of Nonconformance Reports (NCR) and Corrective Action Requests (CAR).

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(b)

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(c)

NCR and CAR statistics per areas, sections, discipline, subcontractor etc.

(d)

Percentage of reoccurring NCR’s and CAR’s – Trends on NCR’s and CAR’s.

(e)

Approval status of critical documentation for the progress of the works (Method Statements, ITPs etc.).

(f)

Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed, pass first time, etc.).

(g)

Completion packages (As-Built folders) progress.

Reporting of the KPI’s shall include a graphical bar chart representation on a month by month basis from the start of the Contract.

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Method Statements

1

Contractor shall ensure that Method Statements address quality issues. Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

2.1.7

Commissioning Plan

1

The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than sixty (60) days unless agreed otherwise with the engineer before the start of the commissioning of the Works or any part thereof.

2

The Commissioning Plan shall consider the requirements of each Section of the Specification in turn and shall identify the following:

.

2.1.6

all required commissioning work required by that Section of the Specification

(b)

any prerequisites to commissioning

(c)

a list of the commissioning procedure

(d)

a detailed description of the duties and responsibilities on the personnel involved in the commissioning process

(e)

a detailed list of the tests/checks/activities that will be performed, linked to the relevant construction activities and referenced to any links/documents to the ITPs performed during the construction

(f)

specific reference to the witness/hold and review points of the engineer

(g)

a detailed list of the standards /specifications/regulatory requirements that need to be performed

(h)

a detailed description of the interactions/communication organization/public service or other legal/regulatory institutions

(i)

a detailed description of the test/activities of the maintenance needed during the life time of the project, with reference to any special requirements/qualifications of the personnel involved in the maintenance activities

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a detailed description of any spare parts/equipment/fixtures and other type of the of consumables that might be needed, with an estimation of quantities, for the life time of the project

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(k)

a detailed description of the as built project file that will be created after the commission phase

(l)

a procedure for up-date and revision of the commissioning plan

No work covered by the Commissioning Plan shall begin until the plan has been approved. END OF PART

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Page 1

CONTRACTOR’S QUALITY PERSONNEL ............................................................. 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

INTRODUCTION ..................................................................................................... 2 General 2 Quality Assurance Manager 2 Quality Control Manager 2 Quality Engineer 2 Quality Inspector 3 Personnel Qualifications 3 Quality Staff Requirement 3 Quality Training for Contractor’s Employees and Labour 5

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Page 2

CONTRACTOR’S QUALITY PERSONNEL

3.1

INTRODUCTION

3.1.1

General

1

Contractor shall, throughout the execution and completion of the Works and the remedying defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only with matters regarding the quality and protection against damage before, during and after execution of Works as specified in this section. This team shall be qualified and experienced in their work and shall have the authority to issue instructions and shall take protective measures to prevent execution of Works that do not comply with the Specifications.

2

The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any of the quality team designated in the Quality Organisation Plan.

3

The Contractor shall have adequate quality personnel on the site during all production operations, including adequate coverage during night shift operations and off site work.

4

The Contractor's quality team shall have the authority to stop any portion of the work which does not comply with the requirements of the Project Documentation.

5

Minimum qualifications and experience of the Contractors Quality Personnel shall be as defined in the Contract.

3.1.2


1

Where required by this section, the Contractor shall designate and assign a full time Quality Assurance Manager who shall be responsible for overseeing the implementation and operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report directly to Top Tier Management and be independent of the Contractors organisation responsible for construction.

3.1.3


1

Where required by this section, the Contractor shall designate and assign a full time Quality Control Manager who reports directly to the Quality Assurance Manager and shall be responsible for supervision of the construction quality control management activities and ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.4

Quality Engineer

1

Where required by this section, the Contractor shall designate and assign a Quality Engineer who reports directly to the Quality Assurance Manager or Quality Control Manager and shall be responsible for assisting them with their day to day responsibilities and may be assigned to cover several locations or areas of work relating to the Contract. Where a Quality Assurance Manager or Quality Control Manager are not required by this section the Quality Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.

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Quality Inspector

1

The Contractor shall designate and assign a Quality Inspector for each shift for each location where work is being performed. Each Quality Inspector shall be qualified by training and experience in all the construction or fabrication activities being conducted at the location of work and is directly responsible for ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.6

Personnel Qualifications

1

The Contractor shall identify activities requiring qualified production, inspection, and test personnel and establish their minimum competence level.

2

The Contractor shall maintain records of personnel qualifications as quality records.

3.1.7


1

Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified quality personnel for the Work as per below tables.

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3.1.5

No of workers on Worksite

Requirement

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No

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1 Quality Inspector (Part time, 15 hours of duty per week)

Less than 10

2.


3.


4.


1 Quality Assurance Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

More than 1501

1 Quality Assurance Manager and 1 Quality Control Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

1 Quality Inspector

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1.

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1 Quality Engineer and 1 Quality Inspector per 100 workers

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Quality Management and Control staff Qualifications & Experience Matrix Minimum Qualifications Required

Position

Minimum Years of Experience

Minimum Key Competencies

Degree in relevant 12 years, 5 of which at Engineering discipline and Management Level and 3 related training in Quality years Regional experience Management Techniques. Internationally recognised Lead Auditor Certificate

Qualified Professional who can manage a Quality Management System and coordinate specialised activities. Excellent written & verbal communication skills in English


Degree in relevant 12 years, 5 of which at Excellent written & verbal Engineering discipline and Management Level and 3 communication skills in related training in Quality years Regional experience English Management Techniques. Internationally recognised Lead Auditor Certificate

Quality Engineer

Degree in relevant Engineering discipline. Internationally recognised Lead Auditor Certificate

Quality Inspector

Certificate or Diploma in the appropriate engineering discipline

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Good written & verbal communication skills in English

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10 years’ experience in related Quality Control Activities and 3 years Regional experience

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5 years’ experience in Good written & verbal related Quality Control and communication skills in Materials Testing activities English along with 2 years Regional Experience

The Contractor shall appoint deputy quality personnel who are capable of performing all the duties of the quality personnel in the event of their absence.

3

The Contractor shall appoint support staff in sufficient numbers to ensure the effective function of the quality related work within the Contractor’s organisation.

4

The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints suitably qualified quality staff to ensure the effective function of the quality related issues within the Sub-contractor’s organisation. The Sub-contractor shall appoint and deploy fulltime on the Worksite one Quality Inspector for every 100 workers that they employ at the Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality Engineer. This shall be in addition to the Contractor’s Quality Team.

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Quality Training for Contractor’s Employees and Labour

1

The Contractor shall conduct quality training including Contract specific induction, pre-work briefings, skills training, tool box talks and formal training conducted by training professionals or agencies for all the Contractor’s employees. The Contract specific induction will be at least 1 hour duration, approved by the Engineer and provided for all persons involved in the Works. Such induction training will be reviewed, revised and repeated at intervals not exceeding 12 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training. Training shall focus on improving competency and skill for those performing activities that impact quality.

2

The Contractor must conduct regular tool box talks to his Labour workforce Such training should include as a minimum Health and Safety issues and Construction Method best practice.

3

The Owner may organise quality related training, meetings, seminars, workshops or similar events at any time throughout the Contract Period. The Contractor is required to participate in such events when requested at his own expense.

4

The Contractor shall maintain records of all training conducted including details of the training given and a list of attendees, including attendee’s signature and ID numbers.

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3.1.8

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END OF PART

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Page 1

DOCUMENT & DATA CONTROL ............................................................................ 2

4.1 4.1.1 4.1.2 4.1.3

INTRODUCTION ..................................................................................................... 2 General 2 Document and Data Approval and Issue 2 Document and Data Changes 2

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DOCUMENT & DATA CONTROL

4.1

INTRODUCTION

4.1.1

General

1

The Contractor shall establish and maintain documented procedures to control all documents and data that relate to the requirements of the Specification. Documents and data can be in the form of any type of media, such as hard copy or electronic media.

2

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Contract.

4.1.2

Document and Data Approval and Issue

1

The documents and data shall be reviewed and approved for adequacy by authorised personnel prior to issue. A master list or equivalent document control procedure identifying the current revision status of documents shall be established and be readily available to preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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4

The pertinent issues of appropriate documents are available at all locations where operations essential to the effective functioning of the quality system are performed

(b)

Invalid and/or obsolete documents are promptly removed from all points of issue or use, or otherwise assured against unintended use

(c)

Any obsolete documents retained for legal and/or knowledge preservation purposes are suitably identified

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(a)

Document and Data Changes

1

Where practicable, the nature of the change shall be identified in the document or appropriate attachments.

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4.1.3

END OF PART

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Page 1

QUALITY RECORDS..................................................................................... 2

5.1 5.1.1

INTRODUCTION ........................................................................................... 2 General 2

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QUALITY RECORDS

5.1

INTRODUCTION

5.1.1

General

1

The Contractor shall establish and maintain documented procedures for identification, collection, indexing, access, filing, storage, maintenance and disposition of quality records.

2

The Contractor shall supplement these quality records as necessary to monitor quality throughout the Contract period.

3

Quality records shall be maintained to demonstrate conformance of materials and equipment to specified technical requirements and the effective operation of the quality system.

4

All quality records shall be legible and shall be stored and retained in such a way that they are readily retrievable in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

5

As a minimum, the quality record for any particular item shall include: name of item

(b)

item number

(c)

item description

(d)

suppliers name

(e)

serial number or other identification (where applicable)

(f)

Specification reference (where applicable)

(g)

verification of receipt of all required supporting documentation

(h)

quantity of items

(i)

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location and installation of item inspection/test procedure reference

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(k)

non-conformance number (if applicable)

(l)

Observations / comments.

(m)

Signatures of responsible person

END OF PART

QCS 2014


Page 1

QUALITY AUDITS ................................................................................................... 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Contractor’s Quality Audit 2 Engineer’s Quality Audit 2

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Page 2

QUALITY AUDITS

6.1

GENERAL

6.1.1

Contractor’s Quality Audit

1

The Contractor shall establish and maintain documented procedures in line with ISO 190011 for planning and implementing internal quality audits to verify whether quality activities and related results comply with planned arrangements and to determine the effectiveness of the quality system.

2

Internal quality audits shall be scheduled on the basis of the status and importance of the activity to be audited and shall be carried out by personnel independent of those having direct responsibility for the activity being audited. Unless otherwise agreed with the Engineer in writing, the Contractor shall carry out a full system quality audit every three months.

3

The results of the audits shall be recorded and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on deficiencies found during the audit.

4

Follow-up audit activities shall verify and record the implementation and effectiveness the corrective action taken.

5

The results of the Contractor’s quality audits shall be made available for review by the Engineer. The Contractor shall implement any recommendations made by the Engineer based on the results of the internal audit.

6

The Contractor shall allow the Engineer to observe the Contractor’s internal audit upon request.

7

Quality audits must be undertaken by suitably qualified personnel with an internationally recognized audit qualification to recognized standards.

6.1.2

Engineer’s Quality Audit

1

The Engineer may undertake a quality audit of any of the Contractor’s activities at any time during the course of the Contract. The Contractor shall make all personnel and facilities available to the Engineer as necessary to undertake quality audits.

2

The Engineer shall make the results of his quality audit available to the Contractor for review. The Contractor shall implement any recommendations made by the Engineer based on the results of the Engineer’s quality audit.

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END OF PART

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Page 1

INSPECTION AND TEST ........................................................................................ 2

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

INTRODUCTION ..................................................................................................... 2 General 2 Inspections and Tests 2 Inspection and Test Status 3 Inspections by the Engineer during construction 3 Inspections by the Engineer during Defects Liability Period 4 Workmanship 4 Measuring and Test Equipment 4

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Page 2

INSPECTION AND TEST INTRODUCTION

7.1.1

General

1

The Contractor shall provide equipment, instruments, qualified personnel, and facilities necessary to inspect the work and perform the tests required by the Project Documentation.

2

The Contractor shall repeat tests and inspections after correcting non-conforming work until all work complies with the requirements. All re-testing and re-inspections shall be performed at no additional cost to the Client.

3

The Engineer may elect to perform additional inspections and tests at the place of the manufacture or the shipping point to verify compliance with applicable Specifications. Inspections and tests performed by the Engineer shall not relieve the Contractor of his responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be considered a guarantee that materials delivered at a later time will be acceptable. All costs associated with the foregoing shall be borne by the Contractor.

4

Inspections and tests conducted by persons or agencies other than the Contractor, shall not in any way relieve the Contractor of his responsibility and obligation to meet all Specifications and referenced standards.

7.1.2

Inspections and Tests

1

All inspections and tests shall be conducted in accordance with written test procedures as detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed and approved by the Engineer.

2

Mandatory Products and Materials Sampling and Testing Frequencies are included in Part 14, Appendix A of this section. The Contractor shall follow the Sampling and Testing Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in Appendix A shall be read and understood in tandem with the footnotes in Appendix A.

3

Inspection and test procedures submitted for approval shall include, but not be limited to, the following:

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7.1

(a)

inspection/test procedure reference

(b)

references to Clauses of this Specification and other standards along with applicable inspection/test levels specified therein

(c)

prerequisites for the given inspection/test

(d)

required tools, equipment

(e)

necessary environmental conditions

(f)

acceptance criteria

(g)

data to be recorded

(h)

reporting forms

(i)

Identification of items inspected and tested.

(j)

Contractors and Engineers Hold, Witness, Surveillance and Record Review Points

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Page 3

Approved procedures and instructions shall be readily available and used by inspection and test personnel at the time of inspection or test. All revisions to these procedures and instructions shall be approved prior to being used to inspect or test the work. No deviations from the approved procedures and instructions shall be allowed without written authorisation from the Engineer.

5

Inspection and testing work shall be performed by personnel designated by the Contractor. Such personnel shall not be the same as those performing the work.

6

The Contractor shall furnish the Engineer with a signed inspection report for each item of work inspected and tested. The report shall indicate whether the item of work, material and/or equipment complies with all the inspection/test criteria. The Contractor shall submit inspection/test results to the Engineer prior to incorporating the item(s) into the work. Inspection/test failures shall be reported to the Engineer immediately.

7

Inspection and test reports shall, as a minimum, identify the following: inspection/test procedure reference

(b)

name of inspector/tester

(c)

observations/comments

(d)

specified requirements

(e)

acceptability

(f)

deviations/non-conformance

(g)

corrective action

(h)

evaluation of results

(i)

authorised signature

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4

The Contractor shall clearly document and identify the inspections and test status of all materials and equipment throughout construction. Identification may be by means of stamps, tags, or other control devices attached to, or accompanying, the material or equipment.

7.1.3

Inspection and Test Status

1

The inspection and test status of materials, equipment and construction work shall be identified by suitable means, which indicates the conformance or non-conformance of materials, equipment and construction work with regard to inspection and tests performed. The identification of inspection and test status shall be maintained, as defined in the Quality Assurance Plan and/or documented procedures, throughout the course of construction to ensure that only materials, equipment and construction work that have passed the required inspections and tests are used or installed.

7.1.4

Inspections by the Engineer during construction

1

The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and Record Review points for the Engineer during construction. The contractor shall prepare, document and implement a Request for Inspection system that defines how the Engineer will be given sufficient notice to inspect the works in accordance with the Inspection and Test Plans.

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Page 4

Inspections by the Engineer during Defects Liability Period

1

The Engineer will give the Contractor due notice of his intention to carry out any inspections during the defects liability period.

2

The Contractor shall arrange for a responsible representative to be present at the times and dates named by the Engineer.

3

The Contractor’s representative shall render all necessary assistance and take note of all matters to which his attention is directed by the Engineer

7.1.6

Workmanship

1

The Contractor shall comply with industry standards except when more restrictive tolerances or specified requirements indicate more rigid standards or more precise workmanship.

2

Only persons qualified to produce workmanship of the required quality shall perform works

3

The Contractor shall comply with manufactures’ published installation instructions / guides in full, including each step in sequence. Should instructions conflict with project documentation, the Contractor shall request clarification from the Engineer before proceeding.

7.1.7

Measuring and Test Equipment

1

The Contractor shall establish and maintain documented procedures which conform to accepted and approved national or international standards to control, calibrate and maintain inspection, measuring and test equipment used by the Contractor to demonstrate the conformance of materials, equipment and/or construction work with the requirements of the Project Documentation.

2

Inspection, measuring and test equipment shall be used in a manner which ensures that the measurement uncertainty is known and is consistent with the required measurement capability

3

The Contractor shall establish a unique identification number for each item of measuring and test equipment. This unique identification number shall be permanently affixed to each item of measuring and test equipment

4

The Contractor shall ensure that each item of inspection, measuring and test equipment is calibrated at intervals recommended by the manufacturer. Valid calibration certificates for measuring and testing equipment shall be present and available for inspection during inspections and tests.

5

The Contractor shall establish a log of all measuring and test equipment and record:

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7.1.5

(a)

equipment description

(b)

identification number

(c)

date of the last calibration

(d)

date that the next calibration is due.

QCS 2014

Page 5

The Contractor shall assess and record the validity of the previous measuring results when the equipment is subsequently found not to confirm to requirements. The Contractor shall take appropriate action on the equipment and any product affected.

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END OF PART

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MATERIALS .................................................................................................. 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ...................................................................................................... 2 Plant, Materials, Goods and Workmanship 2 Handling and Storage of Materials 2 Identification and Control of Items and Materials 2

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MATERIALS

8.1

GENERAL

8.1.1

Plant, Materials, Goods and Workmanship

1

All Plant, materials, goods and workmanship shall be of the respective kinds described in the Contract with necessary approvals from the concerned authorities and in accordance with the Engineer's instructions and shall be subjected from time to time to such tests as the Engineer may direct at the place of manufacture or fabrication or on the Site or at all or any such places. The Contractor shall provide such assistance, instruments, machines, labour and material as are normally required for examining, measuring and testing any work and the quality, weight or quantity of any materials used and shall supply samples of materials before incorporation in the Works for testing as may be selected and required by the Engineer.

8.1.2

Handling and Storage of Materials

1

The Contractor shall establish procedures for handling and storage of materials and equipment.

2

The Contractor’s storage and handling procedures shall be designed to prevent damage, deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or substitution.

3

The handling procedures shall address the use, inspection and maintenance of special devices such as crates, boxes, containers, dividers, slings, material handling and transportation equipment and other facilities.

4

The Contractor shall identify equipment and/or material requiring special handling or storage.

8.1.3

Identification and Control of Items and Materials

1

The Contractor shall establish control procedures to ensure that equipment and materials are properly used and installed.

2

The Contractor shall identify all items and materials so that they are traceable throughout all inspections, test activities, and records. For stored items, the identification method shall be consistent with the expected duration and type of storage.

3

The Contractor shall record equipment and material identifications and ensure that they are traceable to the location where they are incorporated into the Works.

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END OF PART

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Page 1

NONCONFORMANCE MONITORING .................................................................... 2

9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6

INTRODUCTION ..................................................................................................... 2 General 2 Review and Disposition of Nonconforming Items 2 Corrective Action 3 Identification of Nonconforming Items 3 Acceptance and Approval of Nonconforming items 4 Nonconformance Records 4

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Page 2

9

NONCONFORMANCE MONITORING

9.1

INTRODUCTION

9.1.1

General

1

The Contractor shall ensure that product which does not conform to Specification requirements is identified and controlled to prevent its unintended use or delivery. A documented procedure shall be established to define the controls and relate responsibilities and authorities for dealing with nonconforming product: by taking action to estimate the detected nonconformity

(b)

by authorizing its use, release or acceptance under concession by the Engineer

(c)

by taking action to preclude its original intended use or application

(d)

by taking action appropriate to the effects, or potential effects, of the nonconformity when nonconformity product is detected after delivery or use has started .

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(a)

When Conforming product is corrected it shall be subject to re-verification to demonstrate conformity to requirements.

3

Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained by the engineer, shall be maintained.

4

The monitoring system shall apply to material and equipment as well as installation and construction which fail to conform to the Contract.

5

A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this Section and must be used for recording Nonconformance.

9.1.2

Review and Disposition of Nonconforming Items

1

The responsibility for review and authority for the disposition of nonconforming items shall be defined in the Quality Plan.

2

Nonconforming items shall be reviewed in accordance with documented procedures. A nonconforming item may be:

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(a)

reworked to meet the specified requirements

(b)

accepted with or without repair if agreed in writing by the Engineer

(c)

re-graded for alternative applications

(d)

rejected or scrapped.

3

The proposed use or repair of an item which does not conform to the requirements of the Project Documentation shall be reported to the Engineer. The description of the nonconformity and of repairs shall be recorded to denote the actual condition.

4

Repaired and/or reworked products shall be inspected in accordance with the Quality Assurance Plan and/or documented procedures

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9.1.3

Corrective Action

1

The Contractor shall take action to eliminate the causes of nonconformities in order to prevent recurrence. Corrective actions shall be appropriate to the effects of the nonconformity encountered. A documented procedure shall be established to define requirements for: Reviewing nonconformities (including Engineer complaints)

(b)

Determining the causes of nonconformities

(c)

Evaluating the need for action to ensure that conformities do not occur

(d)

Determining and implementing actions needed

(e)

Records of the results of action taken and

(f)

Reviewing the effectiveness of the corrective action taken

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(a)

Any corrective or preventive action taken to eliminate the causes of actual or potential nonconformities shall be to a degree appropriate to the magnitude of problems and commensurate with the risks encountered.

3

The Contractor shall implement and record any changes to the documented procedures for implementing corrective and preventive action.

4

The Contractor shall take prompt action to identify the causes of each nonconformance and the corrective action necessary prevent recurrence. The results of failure and discrepancy report summaries, Contractor evaluations, and any other pertinent applicable data shall be used for determining corrective action. Information developed during construction, tests, and inspections that support the implementation of required improvements and corrections shall be used to support the adequacy of corrective action taken.

5

The procedures for preventive action shall include:

determination of the steps needed to deal with any problems requiring preventive action

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(b)

the use of appropriate sources of information such as processes and work operations which affect product quality, concessions, audit results, quality records and service reports to detect, analyse and eliminate potential causes of nonconformities

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(c)

initiation of preventive action and application of controls to ensure that it is effective

(d)

ensuring that relevant information on actions taken is submitted for management review

9.1.4

Identification of Nonconforming Items

1

The Contractor shall clearly identify each nonconforming item with a status tag or other distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and removing these status tags and identify personnel authorised to remove status tags.

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Page 4

9.1.5

Acceptance and Approval of Nonconforming items

1

Acceptance of the Contractors proposed disposition of Nonconforming items should be his obtained in writing from the Engineer prior to the undertaking of any remedial works by the his Contractor.

2

Close out of Nonconforming items must be agreed in writing by the Engineer.

9.1.6

Nonconformance Records

1

The Contractor shall provide the Engineer with the following information for each nonconformance:

(b)


(c)

evaluation of nonconformance to establish the cause

(d)

recommended corrective action

(e)

date nonconformance was identified

(f)

date corrective action was completed

(g)

description of final corrective action.

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identification of nonconformance

unique sequential reference number

(b)

date issued

(c)

originator

(d)

description of item deemed to be in nonconformance

(e)


(f) (g)

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The Contractor shall establish and maintain a nonconformance log. The log shall contain the following information as a minimum:

Contractors recommended and final disposition Engineers acceptance of Contractors recommended and final disposition

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(a)

(h)

date closed

(i)

remarks, as applicable

END OF PART

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Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2 Definitions 2

1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7

SUBMITTALS .......................................................................................................... 3 Programme of Works 3 Preliminary Logs 3 Exploratory Hole Logs 4 Preliminary Laboratory Test Results 5 Digital Data 5 Form of Report 5 Approval of Report 6

1.3

QUALITY ASSURANCE .......................................................................................... 6

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16

GENERAL PROJECT/SITE CONDITIONS .............................................................. 7 General 7 Working Areas 7 Turf and Topsoil 7 Paved Areas 7 Paving Slabs and Blocks 7 Claims for Damage 8 Geotechnical and Environmental Personnel 8 Location of Exploratory Holes 8 Ground Elevation of Exploratory Holes 8 Exploratory Work 8 Methods of Investigation 8 Safety and Management 9 Anomalous Conditions 9 Surface Water Control 9 Photographs 9 Facilities for the Engineer 10

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Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

General requirements and information for the execution of ground investigations.

2


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Section 1 ......... General Section 2 ......... Quality Assurance and Quality Control Section 4 ......... Foundations and Retaining Structures Section 6 ......... Roadworks Section 8 ......... Drainage Works Section 12 ....... Earthworks Related to Buildings References

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1.1.2

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BS 5930......................Code of practice for site investigations BS EN 1997................Ground Investigation and testing

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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US symposium on rock mechanics. AIME, New York, 1967

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Definitions

1

Topsoil: the surface layer of earth that contains organic material and can also support vegetation.

2

Soil: earthen material not classified herein as topsoil or hard stratum.

3

Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean natural or artificial material, including rock, which cannot be penetrated except by the use of chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

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1.1.3

(a)

Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more than 300 mm

(b)

Condition (2) a standard penetration resistance test shows a resistance in excess of 35 blows/75 mm.

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Fill: deposits or embankments which have been formed by persons, as distinct from geological agencies.

5

Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the purpose of ground investigation.

6

Boring: hole in earth, excavated by either percussion or auger equipment.

7

Drilling: any hole in rock, excavated by rotary equipment.

8

Borehole: exploratory hole excavated by boring or drilling techniques.

1.2

SUBMITTALS

1.2.1

Programme of Works

1

The Geotechnical Investigation Contractor shall prepare a programme of works for the investigation which will give a detailed schedule showing proposed time schedule for all aspect of the work, details of all plant and equipment to be used in addition to a list of personnel who will work on the project.

1.2.2

Preliminary Logs

1

The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer in duplicate within seven working days of completion of the explorations to which they refer to, and shall contain the information required for the exploratory hole logs.

2

Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment (MOE) requirements and/or those of other Government Departments, Ministries and Statutory Organizations.

3

The Geotechnical Investigation Contractor shall obtain all necessary work permits and security permits prior to commencement of Geotechnical investigation of the site.

4

The investigation shall provide detailed information on the nature of the sub-strata, superficial deposits and ground water table at the site together with general recommendations for designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

5

The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in Section 2.

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The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table 1.1. Table 1.1: Minimum Depth of Boreholes No of floors

Depth of Boreholes (m)

3 or Less

6

4

8

5

9

6

10

7

12

8

13 0.7

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2m below the inverted level; 1.5width of excavation. 2D (D=Diameter or equivalent diameter of the tunnel/underground structure.

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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:

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

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Notes:  The depth of boreholes is measured from foundation level.  S is the number of floors.  For structures small in plan area, exploration should be made at a minimum of three points, unless other reliable information is available in the immediate vicinity. Where a structure consists of a number of adjacent units, one exploration point per unit may suffice.  For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the diameter of the pile at the toe) whichever is greater.  For roads, the depth of Boreholes shall be greater than 2m below the proposed formation Level.

Exploratory Hole Logs

1

The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The logs shall include all the information that follows, such information having been updated as necessary in the light of laboratory testing and further examination of samples and cores.

2

Information for exploratory hole logs:

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1.2.3

Drilling

Pit and Trench










National grid co-ordinates









Ground level related to the datum









Elevation of each stratum referred to the datum







()

Rotary Borehole

All the designated information

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Drilling

Pit and Trench








()

Details of groundwater observations







()

Symbolic legend of strata in accordance with BS 5930







()

Rotary Borehole Description of each stratum in accordance with BS 5930 and initials of person who carried out the logging (and responsible Supervisor if under training)

Core recovery as percentage of each core run



Rock Quality Designation, RQD (Deere et al. 1967)



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_____ Note:  means information required; () means information required if applicable. Preliminary Laboratory Test Results

1

Laboratory test results shall be submitted to the Engineer in batches at the completion of each week's testing. Legible photocopies of work sheets are acceptable.

1.2.5

Digital Data

1

Data from the investigation shall be provided in digital form to the approval of the Engineer.

1.2.6

Form of Report

1

The report shall comprise of a factual or interpretative or both types of reports as required by the Employer or Engineer. Reports shall begin with a cover page showing the name of the Contract and the names of the Employer, Engineer and Geotechnical Investigation Contractor. Report pages shall be numbered consecutively.

2

The factual report shall contain, as a minimum, the following information: A statement from the Engineer on the purpose and rationale of the investigation.

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1.2.4

(b)

A description of the work carried out, including reference to specification and standards adopted and any deviations from them.

(c)

Exploratory hole logs.

(d)

In-situ test records.

(e)

Laboratory test results.

(f)

Plan with locations of exploratory holes.

(g)

Site location plan.

(h)

Geological cross-sections (if appropriate).

The plans shall be to a stated scale and shall include a north arrow. Additional information shall be provided as designated.

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The interpretative report shall contain the following information: (a)

A written appraisal of the ground and water conditions.

(b)

Analysis and recommendations as designated.

When so designated, the Geotechnical Investigation Contractor shall supply the calculations and analyses on which recommendations are based. Approval of Report

1

A draft copy of the factual report and the interpretative report shall be submitted to the Engineer for approval before submission of the final report.

1.3

QUALITY ASSURANCE

1

Only Geotechnical Investigation Contractors holding a current approval certificate from the Central Materials Laboratory shall be permitted to carry out ground investigations.

2

The work shall be carried out in accordance with the relevant British Standards or equivalent.

3

Where specifically designated, all work shall be carried out in accordance with a quality management system established in accordance with Section 2 Quality Assurance and Quality Control of the QCS. Records to indicate compliance with quality management shall be made available to the Engineer on request.

4

The Geotechnical Investigation Contractor shall provide full time professional attendance on site. The professional attendant shall be approved by the Engineer, and shall be responsible for the technical direction of all fieldwork.

5

The Geotechnical Investigation Contractor’s geotechnical and environmental personnel employed on the Contract shall be competent to undertake the work required. Categories of personnel who may be required by the Contract are as follows:

(b)

Graduate Engineer/Geologist/Environmental Scientist. Graduate Engineer/Geologist/Environmental Scientist with at least three years of

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(c)

Technician.

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1.2.7

relevant experience since graduation.

(d)

Professional Engineer/Geologist/Environmental Scientist with at least five years of relevant experience.

(e)

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Professional Engineer/Geologist/Environmental Specialist with at least ten years of relevant experience.

All drillers employed on the Contract shall be experienced and competent in percussion or auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent drilling supervisor per site shall be permanently on the Site during borehole operations.

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GENERAL PROJECT/SITE CONDITIONS

1.4.1

General

1

Geotechnical Investigation Contractor shall only use access routes to and between exploration sites that are approved by the Engineer.

2

Where the presence of underground services is likely, exploratory holes shall be started by means of a hand excavated inspection pit.

3

In addition to any designated notice, at least one working day's notice of the intended time of entry shall be given to the land owner and occupier of the exploration site.

4

All work shall be carried out with the least possible damage to the Site and its environs.

5

All barriers breached or otherwise disturbed during the execution of site operations shall be immediately repaired or replaced to the same standard.

6

Working hours shall be restricted to those designated.

7

Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the end of each day’s work.

1.4.2

Working Areas

1

Operations shall be confined to the minimum area of ground required for the Works. Unless otherwise designated, on completion of each exploration all equipment, surplus material and rubbish of every kind shall be cleared away and removed from the Site. Damage to land or property in the vicinity of the exploratory hole and on access routes shall be made good. The whole of the Site and any ancillary works shall be left in a clean and tidy condition.

1.4.3

Turf and Topsoil

1

Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by the operations shall either be removed and stockpiled as above, or otherwise protected from damage. After completion of the exploration all topsoil shall be replaced and the Site restored to its original condition.

1.4.4

Paved Areas

1

Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the minimum extent necessary for each exploration. After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving replaced.

2

Restoration of highway pavement shall be in accordance with the current Code of Practice and Specification for Road Openings in the Highway issued by the Government.

1.4.5

Paving Slabs and Blocks

1

Paving slabs and blocks shall be removed from the Site, as required for each exploration, and stored for reuse.

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1.4

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Contiguous paving slabs and blocks which are liable to be damaged by the operations shall either be removed and stored as above or otherwise protected from damage.

3

After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving slabs and blocks relayed.

1.4.6

Claims for Damage

1

Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall be reported to the Engineer.

1.4.7

Geotechnical and Environmental Personnel

1

In addition to the provision of the designated personnel by the Geotechnical Investigation Contractor, the Engineer may specifically require the services of geotechnical and environmental personnel for advice, assistance or preparation of interpretative reports. The form of interpretative reports shall be agreed with the Engineer. Details of the qualifications and experience of the personnel shall be supplied to the Engineer.

1.4.8

Location of Exploratory Holes

1

The location of each exploratory hole shall be measured from an approved grid co-ordinate system, and shall be accurate to within 1 m, and the position recorded on a plan as

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designated.

Ground Elevation of Exploratory Holes

1

The elevation of the ground at each exploratory hole shall be established, on the basis of the Qatar National Datum unless otherwise designated or approved by the Engineer, to the nearest 0.05 m.

1.4.10

Exploratory Work

1

The location and depth of each exploratory hole shall be as designated. The Engineer may, after consultation with the Geotechnical Investigation Contractor, vary the location and depth of any exploratory hole and the sequence or quantity of in-situ testing depending on the actual ground conditions encountered. When the position of an exploratory hole has been varied, the Geotechnical Investigation Contractor shall take all necessary measurements and shall inform the Engineer of the revised co-ordinates and ground elevation or other measurements required to locate the exploratory hole.

1.4.11

Methods of Investigation

1

The Engineer will have the option to require any of the following methods of investigation. These options will comprise, but not necessarily be limited to, the following:

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1.4.9

(a)

Desk study.

(b)

Geological mapping.

(c)

Topographic survey.

(d)

Aerial photographs.

or any other methods described in this Section.

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1

The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA) to all site activities including but not limited to potential hazard, who/what might be harmed, control/ recovery measure, responsible person…etc.

2

The presence and nature of known areas of hazardous or contaminated ground are designated, based on available records. If evidence of further hazardous or contaminated ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform the Engineer. If required by the Engineer, the Geotechnical Investigation Contractor’s work plan shall be revised appropriately to take into account the nature and level of contamination encountered. Where contaminated land is present or suspected the Geotechnical Investigation Contractor shall take the appropriate health and safety precautions as directed by the Engineer and where appropriate by the Civil Defence Department of the Government. Care shall be taken to avoid contaminating the egress from the Site.

3

A method statement indicating the safety procedures to be followed during the investigation of hazardous or contaminated ground shall be provided by the Geotechnical Investigation Contractor before beginning the investigation in the hazardous or contaminated ground.

4

Traffic safety and management measures shall be provided, in accordance with the provisions of traffic control of Section 1, General. Where the circumstances of any particular case are not designated, proposals for dealing with such situations shall be submitted to the Engineer for approval.

1.4.13

Anomalous Conditions

1

Where anomalous or unexpected features are revealed, the Geotechnical Investigation Contractor shall immediately inform the Engineer.

1.4.14

Surface Water Control

1

Surface water or other water shall be prevented from entering the exploratory hole, except as permitted by the Engineer.

1.4.15

Photographs

1

Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor as designated. Each photograph shall clearly show all necessary details, and shall have its scale identified.

2

A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be submitted to the Engineer for his approval, within seven working days of the photography. In the event that the photographs are of a quality unacceptable to the Engineer, they shall be retaken.

3

On acceptance of the quality of the photograph, two complete sets of prints of all the photographs shall be presented, annotated and submitted in bound volumes, together with the original photograph digital format with the factual report.

4

Particular requirements for photographs of cores and pits and trenches are given in Parts 3 and 4

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1.4.12

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1.4.16

Facilities for the Engineer

1

When required by the particular contract documentation, facilities to the designated standard shall be provided for the use of the Engineer, as described in Section 1.

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END OF PART

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BOREHOLES .......................................................................................................... 2

2.1 2.1.1 2.1.2


2.2 2.2.1 2.2.2 2.2.3

BOREHOLES GENERALLY .................................................................................... 2 Method and Diameter 2 Addition of Water to the Borehole 3 Backfilling 3

2.3 2.3.1

PERCUSSION BORING .......................................................................................... 3 Hard Stratum or Obstruction in Percussion Boring 3

2.4 2.4.1 2.4.2 2.4.3

AUGER BORING ..................................................................................................... 3 Hand Auger 3 Continuous Flight Auger Boring 3 Hollow Stem Flight Auger 3

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6

ROTARY DRILLING ................................................................................................ 3 General 3 Drilling Fluid 4 Rotary Drilling with Core Recovery 4 Rotary Drilling without Core Recovery 6 Backfilling 6 Photographs 6

2.6

BOREHOLES OVERWATER .................................................................................. 6

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2

BOREHOLES

2.1

GENERAL

2.1.1

Scope

1

Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

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Section 4, ........ Foundations and Retaining Structures Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings

.

Part 1 ............... General

References

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2.1.2

BS 5930 ......................Code of practice for site investigations.

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Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purposes (1970).

BOREHOLES GENERALLY

2.2.1

Method and Diameter

1

The method of advancement and the diameter of a borehole shall be such that the boring can be completed and logged to the designated depth, and samples of the designated diameter can be obtained, in-situ testing carried out and instrumentation installed.

2

The following methods may be employed for advancement of a borehole unless otherwise designated:

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2.2

(a)

Percussion boring.

(b)

Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the Employer that the SPT values obtained are not effected by disturbance of the soil by the auger head, or the presence of material within the hollow stem.).

(c)

Rotary drilling.

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Addition of Water to the Borehole

1

Jetting with water shall not be used to assist the advance of the borehole, except where approved by the Engineer. Where the borehole penetrates below the water table and disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

2.2.3

Backfilling

1

The Contractor shall backfill boreholes in such a manner as to minimise subsequent depression at the ground surface due to settlement of the backfill. In some circumstances, grout or special infilling may be required by the Engineer. Where artesian or other water conditions make normal backfilling impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the borehole.

2.3

PERCUSSION BORING

2.3.1

Hard Stratum or Obstruction in Percussion Boring

1

In a borehole where percussion boring is employed and a hard stratum or obstruction is encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.

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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform the Engineer, who may instruct the use of one or more of the following: continuation of chiselling techniques

(b)

rotary or other approved drilling until the stratum is penetrated

(c)

abandonment of the borehole.

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(a)

AUGER BORING

2.4.1

Hand Auger

1

Hand auger boring may be appropriate in suitable self-supporting strata.

2.4.2

Continuous Flight Auger Boring

1

Where continuous flight auger boring is used, it shall be carried out under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) who shall produce, as boring proceeds, a record of the material and groundwater encountered.

2.4.3

Hollow Stem Flight Auger

1

Where hollow stem flight auger boring is used, the equipment used shall be such as to bore and recover samples as designated. Sampling shall be carried out through the hollow stem.

2.5

ROTARY DRILLING

2.5.1

General

1

Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in rock, with or without core recovery.

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2.4

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Drilling Fluid

1

The drilling fluid shall normally be clean water, air or air mist. However, with the approval of the Engineer, drilling muds, additives or foam may be used.

2.5.3

Rotary Drilling with Core Recovery

1

Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube coring system incorporating a removable inner liner or split tube. The triple tube system may be affected by use of a double tube barrel with an approved semi-rigid liner.

2

Rotary core drilling shall produce cores of not less than the designated diameter throughout the core length. Care shall be exercised in the drilling so as to optimise core recovery.

3

The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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2.5.2

normally exceed 3 m in length and the core barrel shall be removed from the drill hole as

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Removal of cores and labelling of liners shall be carried out as follows: All operations entailed in recovering the cores from the ground after completion of drilling shall be carried out in a manner such as to minimise disturbance to the cores.

(b)

Core barrels or inner tube in case of wireline shall be held horizontally while the innermost liner containing the core is removed without vibration and in a manner to prevent disturbance to the core. The core should be rigidly supported at all times while it is being extruded and during subsequent handling, and the liner containing the core must not be allowed to flex

(c)

Immediately after removing the liner the top and bottom shall be marked in indelible ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall

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(a)

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often as is required to obtain the best possible core recovery or alternatively the core samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing between drill runs.

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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be used, the samples shall be placed in half cut PVC pipes sealed with the second half after core samples description with marking of the core run on the PVC tube and the core box.

5

(d)

Where the length of core recovered from any single core run is such that it cannot be accommodated in one channel of the core box, the liner shall be cut to coincide, if possible, with existing fractures. The liner either side of the cut shall be marked 'cut' and the ends capped as above.

(e)

Each section of liner shall be marked with the contract title, exploratory hole reference number, date and the depths of the top and bottom of the drill run.

(f)

Core obtained without a liner and that from within the core catcher but not inside the liner shall be wrapped in two layers of plastic cling film and labelled to indicate the depth and exploratory hole reference number.

Core boxes, packing, labelling, storing shall be carried out as follows: (a)

Core boxes shall be soundly constructed and fitted with stout carrying handles, fastenings and hinged lids. The total weight of the cores and box shall together not exceed 60 kg.

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Page 5

Cores shall be rigidly and securely packed at the site of drilling and during all subsequent handling and storage the cores shall remain packed unless required for examination or testing. Cores shall be placed in the box, in their liners where used, with the shallowest core to the top left hand corner, the top being considered adjacent to the hinged section. Cores from the core catcher shall also be placed in the core boxes at the correct relative depth.

(c)

Depth shall be indicated on the core box by durable markers at the beginning and end of each drill run. Rigid core spacers shall be used to indicate missing lengths. The contract title, exploratory hole reference number and the depth of coring contained in each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand end of the box and on the inside of the box lid.

(d)

Core boxes containing core shall be kept horizontal and moved and handled with care at all times. Cores shall be protected from direct sunlight. At the end of each day's work, core boxes shall be stored secure from interference and protected from the weather.

Cores shall be prepared for examination as follows: (a)

Cores shall be prepared for examination by the removal of sealing materials and splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut lengthways such that at least half the core circumference is exposed. If half PVC is used, care should be taken while removing and replacing the split half.

(b)

Before examination of the core, the Contractor shall photograph the cores. The time between beginning preparation and the examination of the prepared and photographed cores shall be minimised to prevent loss of moisture from the core samples.

(c)

Cores shall be examined and described on site by a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purpose (1970).

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(b)

When the examination of the cores has been completed, the Contractor may be required to retain separately designated core sub-samples for possible laboratory testing. The Contractor shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of moisture and sample disturbance. They shall be clearly labelled so that the location, depth and origin of the sub-samples can be readily identified. Cores in their liners remaining after the designated sub-samples have been removed shall be end-capped and resealed and replaced in the original core box location. Rigid spacers shall be placed in the spaces in the cores boxes previously occupied by the core sub-samples to prevent movement of adjacent cores and these shall be labelled identically to the core sub-samples that they replace. The core sub-samples shall be retained in separate core boxes clearly marked to indicate the origin of the cores contained within.

8

The Contractor shall protect all cores and transport them including loading and unloading to

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(a)

The Contractor's premises.

(b)

For a number of selected cores, to the designated address.

After submittal of the approved final report, the Contractor shall retain cores, other than those delivered to the designated address, for a period of time required by the Engineer. The Engineer's written permission shall be obtained before disposal of the cores, but the required retention period will normally not exceed three months.

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2.5.4

Rotary Drilling without Core Recovery

1

Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole diameter shall be as designated.

2

When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other cavities or anomalous conditions, drilling shall be under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a systematic record shall be made of the drilling methods, rate of penetration, loss of flushing medium, the material penetrated and any cavities or broken ground encountered. Backfilling

1

Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean, well graded aggregate. The aggregate size and gradation shall be approved by the Engineer. Under special circumstances grout may be required to backfill the holes. The grout shall consist of equal portions by weight of ordinary Portland cement and bentonite mixed by machine or hand to a uniform colour and consistency before placing, with a moisture content not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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2.5.5

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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds. Where artesian water conditions or voids make normal grouting impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the drill hole.

2.5.6

Photographs

1

In addition to the requirements of Part 1, the Contractor shall photograph cores where required in a fresh condition before logging and ensure that the following criteria are fulfilled:

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A graduated scale in centimetres is provided.

(b)

Labels and markers are clearly legible in the photograph.

(c)

A clearly legible reference board identifying the project title, exploratory hole number, date, and depth of drill runs shall be included in each photograph.

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Core boxes are evenly and consistently lit.

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(a)

(e)

The length of the core box in each photograph fills the frame.

(f)

The focal plane of the camera and the plane of the core box are parallel.

(g)

The camera is placed in the same position with respect to the core box in every photograph.

(h)

The resolution of the camera is not less than 8Mpixels.

(i)

The photograph taken should be in focus along all the core samples length.

2.6

BOREHOLES OVERWATER

1

When boreholes are required overwater the method of drilling and sampling shall comply in general with the other requirements given in this Section, with the exception of backfilling.

2

Overwater boreholes shall be undertaken by the use of overwater staging, work over platform (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the Engineer.

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Control of the elevation related to the borehole/seabed surface or varying stratums shall be related to the top of the casing installed. Anchored floating vessels will keep a constant record of tidal movement between the vessel and the fixed casing elevation and make any allowances necessary.

4

Boring or drilling operations will cease when the wave height exceeds the designated maximum value relating to standing time due to inclement weather, if this item is applicable to the Contract under the contract specific documentation.

5

An accurate method of measuring wave height from trough to crest will be installed on the drilling vessel or platform and calibrated and approved by the Engineer before beginning drilling operations.

6

All overwater operations will comply with all local government regulations related to such work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at the time.

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Page 1

PITS AND TRENCHES ........................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Quality Assurance 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

PITS AND TRENCHES GENERALLY ..................................................................... 2 Pit and Trench Dimensions 2 Contaminated Ground 2 Groundwater 3 Protection to Pits and Trenches Left Open 3 Backfilling and Restoration 3 Photographs 3

3.3 3.3.1 3.3.2 3.3.3

INSPECTION PITS .................................................................................................. 3 Excavation Method 3 Services 3 Sidewall Stability 4

3.4 3.4.1 3.4.2 3.4.3 3.4.4

TRIAL PITS AND TRENCHES ................................................................................ 4 Excavation Method 4 Services 4 Sidewall Stability 4 Trial Pits Examination 4

3.5 3.5.1 3.5.2 3.5.3

OBSERVATION PITS AND TRENCHES ................................................................. 4 Excavation Method 4 Services 5 Sidewall Stability 5

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3

PITS AND TRENCHES

3.1

GENERAL

3.1.1

Scope

1

Inspection pits, trial pits and trenches, observation pits and trenches.

2


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Section 1, ....... General Section 4, ....... Foundations and Retaining Structures Section 6, ....... Roadworks Section 8, ....... Drainage Works Section 12, ..... Earthworks Related to Buildings.

.

Part 1, .............. General

References

1


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BS 5930 ...................... Code of practice for site investigations

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Quality Assurance

1

Trial pits and trenches and observation pits and trenches shall be examined and described by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) and photographed, if required.

3.2

PITS AND TRENCHES GENERALLY

3.2.1

Pit and Trench Dimensions

1

Unless otherwise designated

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3.1.3

2.

(a)

Trial pits and observation pits shall have a minimum base area of 1.5 m

(b)

Trial trenches and observation trenches shall not be less than 1 m wide.

3.2.2

Contaminated Ground

1

Ground that is suspected of being contaminated shall be described by an environmental or geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c).

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Groundwater

1

The Contractor shall divert surface water runoff from entering pits and trenches.

2

Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous work if required.

3.2.4

Protection to Pits and Trenches Left Open

1

Where pits and trenches are required to be left open and unattended, the Contractor shall provide fencing together with all necessary lighting and signing.

2

Precautions shall be taken to protect the pits and trenches from the adverse effects of weather during this period.

3.2.5

Backfilling and Restoration

1

Pits and trenches shall be backfilled as soon as practicable and reinstated to their original condition.

2

The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as to minimise any subsequent settlement of the ground surface.

3

The use of sand backfill compacted by flooding may be permitted, but this method requires the approval of the Engineer.

4

In paved areas, the pavement shall be restored.

3.2.6

Photographs

1

In addition to the requirements of Part 1, photographs shall clearly show details of the ground conditions in the pit and trench with any support in place and shall contain a graduated scale.

2

Material derived from the excavation shall be photographed, when directed by the Engineer. Artificial lighting shall be used where necessary.

3

Unless directed otherwise by the Engineer, three photographs will normally be required at every pit and trench.

3.3

INSPECTION PITS

3.3.1

Excavation Method

1

Inspection pits for the location of underground services shall be excavated by hand to a depth of 1.2 m unless otherwise designated.

2

Hand-operated power tools may be used to assist excavation where necessary.

3.3.2

Services

1


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Sidewall Stability

1


3.4

TRIAL PITS AND TRENCHES

3.4.1

Excavation Method

1

Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by machine to the required depth to enable visual examination and sampling from outside the pit or trench as required.

2

Where dewatering is required, the pumping equipment used shall be adequate to lower the water table to the required level.

3.4.2

Services

1


3.4.3

Sidewall Stability

1

Excavations deeper than 1.2 m shall be braced if necessary.

3.4.4

Trial Pits Examination

1

All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party.

2

Disturbed samples shall be obtained from the trial pits for laboratory testing and geological description purposes. The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

3

Color photographs shall be taken for each excavated trial pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5

OBSERVATION PITS AND TRENCHES

3.5.1

Excavation Method

1

Observation pits and trenches shall be excavated by hand or machine and shall be adequately supported to enable personnel to enter safely and to permit in-situ examination, soil sampling and testing as required. In areas where dewatering is required, the equipment and methods proposed must be approved by the Engineer before beginning the work.

2

All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or ASTM D 2488.

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3.3.3

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Disturbed samples shall be obtained for laboratory testing and geological description purposes (if required). The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

4

Color photographs shall be taken for each excavated pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5.2

Services

1


3.5.3

Sidewall Stability

1


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END OF PART

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Page 1

SOIL SAMPLING ..................................................................................................... 2

4.1 4.1.1 4.1.2


4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

SAMPLING GENERALLY ........................................................................................ 2 Sampling and Testing Frequency 2 Recording depths of samples 3 Description of samples 3 Labelling, Protection and Transportation of Samples 3 Retention and Disposal of Samples 3

4.3 4.3.1 4.3.2 4.3.3 4.3.4

SOIL SAMPLES....................................................................................................... 3 Small Disturbed Samples 3 Bulk Disturbed Samples 3 Open Tube and Piston Samples 4 Standard Penetration Test Samples 4

4.4

GROUNDWATER SAMPLES .................................................................................. 4

4.5

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4

4.6

GAS SAMPLING...................................................................................................... 5

4.7

SPECIAL SAMPLING .............................................................................................. 5

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4

SOIL SAMPLING

4.1

GENERAL

4.1.1

Scope

1

Taking of samples of soil, groundwater, gas and contaminants. Sample handling, transportation, storage, retention and disposal.

2


References

1

The following documents are referred to in this Part:

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Part 1, .............. General Part 2, .............. Boreholes Part 3, .............. Pits and Trenches.

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure) BS 5930 ......................Code of practice for site investigations

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BSI –DD 175 ..............Code of practice for the identification of potentially contaminated land and its investigation (draft for development).

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BS EN 1997--- ............ Ground Investigation and testing

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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in construction, Part 4, Guidelines for the safe investigation by drilling of landfills and contaminated land, Thomas Telford, (1993).

SAMPLING GENERALLY

4.2.1

Sampling and Testing Frequency

1

The frequency of sampling and in-situ testing is dependent on the ground conditions. In the absence of designated requirements the intervals observed shall be as follows:

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4.2

(a)

(b)

in boreholes (i)

first open tube sample (generally in clay soils) or standard penetration test (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth, thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

(ii)

small disturbed samples shall be taken from the topsoil, at each change in soil

(iii)

type or consistency and midway between successive open tube samples or SPT’s.

(iv)

Bulk disturbed samples shall be taken of each soil type.

in pits and trenches

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Page 3

(i)

Small disturbed samples shall be taken of the topsoil, at each change in soil type or consistency and between successive bulk disturbed samples.

(ii)

Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one large bulk disturbed sample of each soil type.

Recording depths of samples

1

The depths below ground level at which samples are taken shall be recorded. For open tube and piston samples the depth to the top and bottom of the sample, and the length of sample obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

4.2.3

Description of samples

1

All samples shall be examined and described by a geotechnical person meeting the requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930. Samples of suspected contaminated ground and leachate shall be described by an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell with reference to specific inclusions.

4.2.4

Labelling, Protection and Transportation of Samples

1

Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater, leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a red label.

2

Samples shall be protected from direct heat and sunlight.

3

Samples shall be transported to the Contractor's premises. Where required by the Engineer, selected samples shall be delivered to the designated address.

4.2.5

Retention and Disposal of Samples

1

Samples shall be kept for the designated period after submission of the approved final report. This period shall not exceed three months, unless specifically designated otherwise. The Contractor shall ultimately dispose of all samples other than those delivered to the designated address.

4.3

SOIL SAMPLES

4.3.1

Small Disturbed Samples

1

Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately in airtight containers, which they should sensibly fill.

4.3.2

Bulk Disturbed Samples

1

Bulk disturbed samples shall be representative of the zone from which they have been taken.

2

Normal bulk disturbed samples shall weigh not less than 10 kg.

3

Large bulk disturbed samples shall weigh not less than 30 kg.

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Open Tube and Piston Samples

1

Open tube and piston samples shall be taken using the sampling equipment and procedures as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

2

Before an open tube or piston sample is taken, the bottom of the hole shall be carefully cleared of disturb materials and where a casing is being used the sample shall be taken below the bottom of the casing. Following a break in the work exceeding one hour, the borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

3

Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be cleaned out for the full depth to which the sampling tube has penetrated and the recovered soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful the Contractor shall agree with the Engineer as to alternative means of sampling.

4

The samples shall be sealed immediately to preserve their natural moisture content and in such a manner as to prevent the sealant from entering any voids in the sample.

5

Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed sample.

4.3.4

Standard Penetration Test Samples

1

When a standard penetration test (SPT) is made, the sample from the split barrel sampler shall be retained as a small disturbed sample.

4.4

GROUNDWATER SAMPLES

1

Groundwater samples shall be taken from each exploratory hole where groundwater is encountered. Where more than one groundwater level is found, each one shall be sampled separately. Where water has been previously added, the hole shall be bailed out before

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sampling so that only groundwater is present. The sample volume shall be not less than 0.25 l.

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

1

Samples of suspected contaminated ground, groundwater and leachate shall be taken in accordance with DD 175 and the SISG publication under the supervision of an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

2

The size and type of sample and container, method of sampling and time limitations for carrying out specific analyses shall be commensurate with the range of analyses to be carried out or as designated.

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Page 5

GAS SAMPLING

1

Samples of gas for chromatographic analysis shall be obtained from exploratory holes or standpipes in accordance with DD 175 and the SISG publication. The sampling method shall relate to the volume of gas available and the type of laboratory analysis. The sampler receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas bombs.

4.7

SPECIAL SAMPLING

1

The Engineer may require special sampling. This work will normally require supervision on site by a geotechnical person and shall be carried out in accordance with BS 5930 or as designated.

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END OF PART

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Page 1

IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2

5.1 5.1.1 5.1.2


5.2 5.2.1 5.2.2

TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2 Testing 2 Instrumentation and Monitoring 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

TESTS ..................................................................................................................... 3 Tests in accordance with BS 1377 or BS EN 1997 3 Tests in accordance with BS 5930 4 Geophysical Methods of Investigation 4 Special In-Situ Testing 4 Hand Penetrometer and Hand Vane for Shear Strength 5 Self-boring Pressuremeter 5

5.4 5.4.1 5.4.2 5.4.3

INSTRUMENTATION AND MONITORING .............................................................. 6 Groundwater 6 Installation of Standpipes and Piezometers 6 Installation of Gas Monitoring Standpipes 6

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5

IN-SITU TESTING, INSTRUMENTATION AND MONITORING

5.1

GENERAL

5.1.1

Scope

1

Testing of soils in place, and provision of instrumentation and monitoring of groundwater and subsurface gases.

2


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BS 1377......................Methods of tests for soils for civil engineering purposes BS 5930......................Code of practice for site investigations

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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes

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BS EN 1997................Ground Investigation and testing

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The Geological Society Engineering Group Working Party Report on Engineering Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.

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Clarke B.G. and Smith A., A model specification for radial displacement measuring pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.

TESTING, INSTRUMENTATION AND MONITORING GENERALLY

5.2.1

Testing

1

The following information shall be submitted for each test record to be included in the daily report, preliminary log and factual report:

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(a)

Date of test.

(b)

Project name, exploratory hole number and location.

(c)

Depth and location of test or depths covered by test.

(d)

Information on water levels in exploratory hole during testing.

(e)

Original ground level at test site.

(f)

Soil type and description as identified from the sample.

All results shall be reported in SI units.

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Page 3

Where load, displacement or other measuring equipment is used which necessitates regular calibration, then this shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer's instructions, by a calibration service approved by the Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall be supplied to the Engineer prior to commencing work and when otherwise requested.

5.2.2

Instrumentation and Monitoring

1

The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected by a cover. The type of protective cover shall be approved by the Engineer.

2

When instructed by the Engineer, the Contractor shall install a protective fence around the top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the climate of Qatar or a fence as a agreed upon with the Engineer.

3

Daily readings of depths to water in groundwater monitoring standpipes and piezometers shall be made by the Contractor, with an instrument approved by the Engineer.

4

Where the presence of gas is suspected or when directed by the Engineer, gas measurements, using an approved in-situ meter, shall be made by the Contractor during construction of exploratory holes and in gas monitoring standpipes. The depth to water and barometric pressure shall be measured immediately after each gas measurement.

5

Unless otherwise designated, piezometers, and standpipes protection shall not be removed from the site.

6

Other instrumentation and monitoring shall be carried out as designated.

5.3

TESTS

5.3.1

Tests in accordance with BS 1377 or BS EN 1997

1

The following in-situ tests shall be carried out and reported in accordance with BS 1377 or BS EN 1997: in-situ density by

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(i)

Small pouring cylinder method.

(ii)

Large pouring cylinder method.

(iii)

Water replacement method.

(iv)

Core cutter method.

(v)

Nuclear method.

(b)

Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise designated

(c)

Dynamic probing (DPH or DPSH).

(d)

Standard penetration test (SPT).

(e)

Plate loading test.

(f)

Shallow pad maintained load test.

QCS 2014


(g)

California bearing ratio (CBR).

(h)

Vane shear strength.

(i)

Apparent resistivity of soil.

(j)

Redox potential.

(k)

Pressurementer or Self-boring Pressuremeter (PMT)

(l)

Pocket Penetrometer.

Page 4

5.3.2

Tests in accordance with BS 5930

1

The following in-situ tests shall be carried out where applicable and reported in accordance with BS 5930:

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(a) (b) (c)

Geophysical Methods of Investigation

1

Geophysical testing shall be carried out as designated. The Contractor shall submit to the Engineer a full description of equipment and procedure for each geophysical method required.

2

The equipment and procedure, and information to be submitted for the following geophysical methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological Society Engineering Group Working Party Report on Engineering Geophysics:

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electrical resistivity method

(b)

seismic refraction and reflection method

(c)

magnetic method

(d)

gravity method

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electromagnetic method

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(i)

Ground conductivity.

(ii)

Transient electromagnetic.

(iii)

Ground probing radar (optional).

(f)

Borehole geophysical logging.

(g)

Cross-hole seismic method.

(h)

Multi Channel Analysis of Surface Waves (MASW)

(i)

Refraction Microtremor (ReMi)

5.3.4

Special In-Situ Testing

1

Special in-situ testing shall be carried out as designated.

2

The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for the execution of inspection tests.

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3


Page 5

Inspection tests shall be decided as directed by the Engineer. These tests shall include but not limited to those in Table 3.2. Table 3.2: Quality Assurance Tests for Completed Work Recommended Test per Layer Deep Fill (boreholes)

In-situ CBR

Field density

Plate load Test

Layer Thickness

Field density

DCP Test

Layer Thickness

SPT

DCP Test

Pressure meter

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Large Scale Loading Hand Penetrometer and Hand Vane for Shear Strength

1

Hand penetrometer and hand vane tests shall be carried out where required to give a preliminary estimate of undrained shear strength of the soil tested.

2

Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with 2 stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.

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5.3.5

Hand vane equipment shall be of an approved proprietary make with stainless steel vanes having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be

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The scale shall be suitably graduated. The procedure for the test shall be in accordance with the manufacturer's instructions. Both unconfined compressive strength and estimated shear strength shall be reported for the soil tested.

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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the manufacturer's instructions. Peak shear strength and residual shear strength shall be

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The reported shear strengths for the hand penetrometer and handvane shall be the average of 3 tests in close proximity. Tests giving inconsistent results shall be reported and comments on the relevance of the tests noted.

5.3.6

Self-boring Pressuremeter

1

The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP) unless otherwise designated. The instruments, calibration, operator, installation, testing procedure, on-site data processing and analysis, information to be submitted, report data processing and analysis and information to be submitted in the report shall be as described by Clarke and Smith (1992) and as designated..

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Page 6

5.4

INSTRUMENTATION AND MONITORING

5.4.1

Groundwater

1

When groundwater is encountered in exploratory holes, the depth from ground level of the point of entry shall be recorded together with depth of any casing. Exploratory hole operations shall be stopped and the depth from ground level to water level recorded with an approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the

.

period of 20 minutes the water level is still rising, this shall be recorded together with the depth to water below ground level, unless otherwise instructed by the Engineer, and the exploratory hole shall then be continued. If casing is used and this forms a seal against the entry of groundwater, the Contractor shall record the depth of casing at which no further entry or only insignificant infiltration of water occurred. Water levels shall be recorded as required by the Contract and at the beginning and end of each shift. On each occasion when groundwater levels are recorded, the depth of the exploratory hole, the depth of any casing and the time shall also be recorded.

3

Where artesian conditions are encountered, the Contractor shall immediately inform the Engineer and agree a method for dealing with the conditions.

5.4.2

Installation of Standpipes and Piezometers

1

Standpipes for monitoring groundwater levels and changes in groundwater levels shall be installed in exploratory holes, as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions and depths shall be recorded at the time of installation.

2

Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be installed as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions. The installation details of the standpipe piezometers shall be recorded.

3

The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type described in BS 5930 or as designated by the Engineer.

5.4.3

Installation of Gas Monitoring Standpipes

1

Standpipes for monitoring gas concentration in exploratory holes shall be installed as instructed by the Engineer. Warning signs or other safety measures required by the Civil Defence Department of the Government shall be complied with. Standpipes shall be of the designated form and detail. All dimensions and depths shall he recorded at the time of installation.

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END OF PART

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Page 1

LABORATORY TESTING ........................................................................................ 2

6.1 6.1.1 6.1.2


6.2

SCHEDULE OF TESTS ........................................................................................... 2

6.3 6.3.1 6.3.2 6.3.3 6.3.4

TESTING PROCEDURES ....................................................................................... 3 General 3 Geotechnical Testing on Contaminated Samples 3 Soil Testing 3 Rock Testing 3

6.4 6.4.2 6.4.3

CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4 Laboratory Testing On Site 6 Special Laboratory Testing 6

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6

LABORATORY TESTING

6.1

GENERAL

6.1.1

Scope

1

Geotechnical tests and testing procedures carried out in the laboratory or, when designated, on site.

2


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ASTM SP 402.............Special Technical Publications No. 402

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BS 1377 ......................Methods of tests for soils for civil engineering purposes BS 1881 ......................Analysis of hardened concrete

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BS EN 1997--------- .....Ground Investigation and testing

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Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for Rock Mechanics Suggested Methods. 1981. Pergamon Press. C2 through C25 and C27 through C31, Methods for examination of waters and associated materials, HMSO IRSM Commission on Testing Methods. Suggested method for determining Point Load Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22, 51-60 (1985).

6.2

SCHEDULE OF TESTS

1

The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be necessary to designate additional testing after the results of the original tests are available. Unless otherwise agreed, testing schedules are to be provided within six working days of the receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the Engineer within six working days from the receipt of the approved testing schedule if a sample referred to in the schedule is not available for testing.

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Page 3

TESTING PROCEDURES

6.3.1

General

1

Where applicable, all preparation, testing and reporting shall be in accordance with the relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are not covered by these Standards, they shall be performed in accordance with the procedures in the references or as designated.

2

Calibration of load-displacement or other measuring equipment shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer’s instructions by a calibration service approved by the Central Materials Laboratory. Evidence of current calibrations shall be supplied to the Engineer.

6.3.2

Geotechnical Testing on Contaminated Samples

1

Where geotechnical testing is required on samples of suspected contaminated material, indicative chemical testing shall be carried out and a safe method of working approved by the Engineer before any such work is started. It should be noted that this may include but is not limited to the safe storage, transportation and handling of all suspect material.

6.3.3

Soil Testing

1

Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards unless otherwise designated.

6.3.4

Rock Testing

1

Rock testing shall be carried out and reported in accordance with the following references and as designated: Classification.

Natural water content - Brown (1981).

(ii)

Porosity/density - Brown (1981).

(iii)

Void index - Brown (1981).

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(i)

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6.3

(b)

(c)

(d)

(iv)

Carbonate content - BS 1881.

(v)

Petrographic description -Brown (1981).

Durability. (i)

Slake durability index - Brown (1981).

(ii)

Soundness by solution of magnesium sulphate - BS 812.

Hardness. (i)

Shore sclerometer -Brown (1981).

(ii)

Schmidt rebound hardness - Brown (1981).

Aggregates. (i)

Aggregate crushing value - BS 812.

(ii)

Ten percent fines - BS 812.

(iii)

Aggregate impact value - BS 812.

(iv)

Aggregate abrasion value - BS 812.

(v)

Polished stone value - BS 812.

(vi)

Aggregate frost heave - BS 812.

Strength. (i)

Uniaxial compressive strength - Brown (1981).

(ii)

Deformability in uniaxial compression -Brown (1981).

(iii)

Tensile strength-Brown (1981).  

Direct tensile strength. Indirect tensile strength by the Brazilian method.

Undrained triaxial compression without measurement of porewater pressureBrown (1981).

(v)

Direct shear strength - Brown (1981).

(vi)

Swelling pressure - Brown (1981).

(vii)

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Swelling pressure index under conditions of zero volume change. Swelling strain index for a radially confined specimen with axial surcharge. Swelling strain developed in an unconfined rock specimen.

Point load test - IRSM Commission on Testing Methods (1985).

Geophysical. Seismic velocity-Brown (1981).

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(i)

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(iv)

   (f)

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(e)


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QCS 2014

CHEMICAL TESTING FOR CONTAMINATED GROUND

1

Chemical testing for contaminated ground shall be carried out and reported in accordance with the following references and as designated:

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Primary contaminants in soil. Arsenic total - C4.

(ii)

Cadmium total - C2.

(iii)

Chromium total - C2.

(iv)

hexavalent chromium (undertaken if total chromium content >25 mg/kg dry

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Mass) -C2.

(v)

Lead total - C2.

(vi)

Mercury total - C3.

(vii)

Selenium total - C4.

(viii)

Boron, water-soluble - C5.

(ix)

Copper total - C2.

(x)

Nickel total - C2.

(xi)

Zinc total - C2.

(xii)

Cyanide total (alkali extraction methods) - C6.

(xiii)


(xiv) Cyanide free - C6. (xv)

Thiocyanate - C6.

QCS 2014


Page 5

(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods shall follow alkali extraction.) (xvii) Phenols total - C7. (xviii) Sulphide - C8. (xix) Sulphate - total, acid, soluble - C9. (xx)

Sulphate - water soluble, 2 : 1 extract - C9.

(xxi) Sulphur free - C10. (xxii) PH value - C9. (xxiii) Toluene extractable matter - Cl1.

.

(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter> 2000 g/kg dry mass of soil) - C12.

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Antimony total - C13.

(ii)

Barium total - C13.

(iii)

Beryllium total - C15.

(iv)

Vanadium total - C13.

(v)

Cyclohexane extractable matter - C14.

(vi)

Freon extractable matter - C15.

(vii)

Mineral oils - C31.

(viii)

Chloride - C9.

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(i)

Contaminants in water.

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(c)

Secondary contaminants in soil.

(i)

Arsenic - C4.

(ii)

Cadmium - C2 and C23. Chromium - C2 and C24.

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(iii)

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(b)

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(xxv) Asbestos. Asbestos content determination shall be carried out by visual examination and polarised light microscopy.

Hexavalent chromium - C2.

(v)

Lead - C2 and C25.

(vi)

Mercury - C3.

(vii)

Selenium - C4.

(viii)

Boron - C5 and C6.

(ix)

Copper - C2 and C27.

(x)

Nickel - C2 and C28.

(xi)

Zinc - C2 and C29.

(xii)

Cyanide total - C6.

(xiii)


(xiv)

Cyanide free - C6.

(xv)

Thiocyanate - C6.

(xvi)

Phenols total - C7.

(xvii)

Sulphide - C8.

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Sulphate - C9.

(xix)

Sulphur free - C10.

(xx)

PH value - C9.

(xxi)

Polyaromatic hydrocarbons - C 12.

(xxii)

Antimony-C13.

(xxiii)

Barium-C13.

(xxiv)

Beryllium-C15.

(xxv)

Vanadium - C 13.

(xxvi)

Chloride - C9.

(xxvii)

Ammoniacal nitrogen - C16.

(xxviii)

Nitrate nitrogen - Cl7.

(xxix)

Chemical oxygen demand - C18.

(xxx)

Biochemical oxygen demand - C19.

(xxxi)

Total organic carbon - C20.

(xxxii)

Volatile fatty acids - C21.

(xxxiii)

Iron - C22.

(xxxiv)

Manganese - C22.

(xxxv)

Calcium - C31.

(xxxvi)

Sodium - C31.

(xxxvii)

Magnesium - C31.

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(xviii)

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Constituents of gas samples. Carbon dioxide - C30.

(ii)

Hydrogen - C30.

(iii)

Hydrogen sulphide - C30.

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(xxxviii) Potassium - C21.

Methane - C30.

(v)

Nitrogen - C30.

(vi)

Oxygen - C30.

(vii)

Ethane- C30.

(viii)

Propane- C30.

(ix)

Carbon monoxide - C30.

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(iv)

6.4.2

Laboratory Testing On Site

1

When designated, tests listed under laboratory testing shall be carried out on site.

6.4.3

Special Laboratory Testing

1

When designated, special laboratory testing shall be carried out. END OF PART

QCS 2014


Page 1

GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 General Contract Requirements 2 Submittals 3 Records 3

1.2 1.2.1 1.2.2

GROUND CONDITIONS ......................................................................................... 3 Ground Investigation Reports 3 Unexpected Ground Conditions 4

1.3 1.3.1 1.3.2 1.3.3

MATERIALS AND WORKMANSHIP........................................................................ 4 General 4 Sources of Supply 4 Rejected materials 5

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6

INSTALLATION TOLERANCES .............................................................................. 5 Setting Out 5 Position 6 Verticality 6 Rake 6 Tolerance Variations 6 Forcible Corrections to Pile 6

1.5 1.5.1 1.5.2 1.5.3 1.5.4

NUISANCE AND DAMAGE ..................................................................................... 6 Noise and Disturbance 6 Damage to Adjacent Structures 7 Damage to Piles 7 Temporary Support 7

1.6 1.6.1 1.6.2 1.6.3

SAFETY .................................................................................................................. 7 General 7 Life-Saving Appliances 7 Driving 7

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Page 2

GENERAL REQUIREMENTS FOR PILING WORK

1.1

GENERAL

1.1.1

Scope

1

This Part is concerned with all works associated with installation of piles by any of the recognised techniques.

1.1.2

References

1

The following standards and codes of practice are referred to in this Part:

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BS 5228......................Noise control on construction and open sites

.

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Part I, Code of practice for basic information and procedures for noise control Part IV, Code of practice for noise and vibration control applicable to piling operations

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BS EN 1997................Eurocode 7, Geotechnical Design.

General Contract Requirements

1

The following matters, where appropriate, are described in the contract specific documentation for the Works: general items related to Works Nature of the Works.

(ii)

Classes of loads on piles.

(iii)

Contract drawings.

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(i)

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1.1.3

(b)

(iv)

Other works proceeding at the same time.

(v)

Working area.

(vi)

Order of the Works.

(vii)

Datum.

(viii)

Offices for the Engineer's Representative.

(ix)

Particular facilities and attendance items where not included in this section.

(x)

Details of soil investigation reports.

specific items related to particular type of pile (i)

Soil sampling, laboratory testing and in-situ soil testing.

(ii)

Designed concrete or grout mixes, grades of concrete or grout, type of cement and aggregate, grout or concrete admixtures, concreting of piles.


Page 3

Grades and types of reinforcement and prestressing tendons.

(iv)

Pile dimensions, length and marking of piles.

(v)

Type and quality of pile shoe/splice.

(vi)

Type and quality of permanent casing.

(vii)

Specified working loads.

(viii)

Sections of proprietary types of pile, grades of steel, minimum length to be supplied, thickness of circumferential weld reinforcement.

(ix)

Surface preparation, types and thickness of coatings.

(x)

Test piles, driving resistance or dynamic evaluation and penetration.

(xi)

Detailed requirements for driving records.

(xii)

Acceptance criteria for piles under test.

(xiii)

Disposal of cut-off lengths.

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QCS 2014

(xiv) Preboring. Submittals

1

The Contractor shall supply for approval all relevant details of the method of piling and the plant he proposes to use. Any alternative method to that specified shall be subject to approval.

2

The Contractor shall submit to the Engineer on the first day of each week, or at such longer periods as the Engineer may from time to time direct, a progress report showing the current rate of progress and progress during the previous period on all important items of each section of the Works.

3

The Contractor shall inform the Engineer each day of the intended programme of piling for the following day and shall give adequate notice of his intention to work outside normal hours and at weekends.

1.1.5

Records

1

The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation of each pile and shall submit two signed copies of these records to the Engineer not later than noon of the next working day after the pile is installed. The signed records will form a record of the work. Any unexpected driving or boring conditions shall be noted briefly in the records.

1.2

GROUND CONDITIONS

1.2.1

Ground Investigation Reports

1

Factual information and reports on site investigations for the Works and on the previous known uses of the Site will be provided by the Engineer where they exist as part of the specific contract documentation. However, even if a full report is given, including interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any opinions or conclusions which may be given in the reports.

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1.1.4

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Page 4

Before the start of work the Contractor shall be given a copy of any subsequent information which may have been obtained relating to the ground conditions and previous uses of the Site.

1.2.2

Unexpected Ground Conditions

1

The Contractor shall report immediately to the Engineer any circumstance which indicates that in the Contractor's opinion the ground conditions differ from those reported in or which could have been inferred from the site investigation reports or test pile results.

1.3

MATERIALS AND WORKMANSHIP

1.3.1

General

1

All materials and workmanship shall be in accordance with the appropriate British Standards, codes of practice and other approved standards current at the date of tender except where the requirements of these standards or codes of practice are in conflict with this Section in which case the requirements of this Section shall take precedence.

1.3.2

Sources of Supply

1

The sources of supply of materials shall not be changed without prior approval.

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Table 1.1





*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Nominal cross-sectional dimensions or diameter

*

*

*

*

*

Nominal diameter of underream/base

-

-

-

*

-

Length of preformed pile

*

*

-

-

-

Standing groundwater level from direct observation or given site investigation data.

-

-

*

*

*

Date and time of driving, redriving or boring

*

*

*

*

*

Date of concreting

-

-

*

*

*

Ground level/sea bed level at pile position at commencement of installation of pile (commencing surface)

*

*

*

*

*

Working elevation of pile driver

*

*

*

*

*

Depth from ground level at pile position to pile tip

*

*

*

*

*

Tip elevation

*

*

*

*

*

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Data

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Driven steel, precast concrete and steel sheet piles

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Records to be Kept (Indicated by an Asterisk)

Contract

Pile type

m

Pile reference number (location)



Pile head elevation, as constructed

*

*

*

*

*

Pile cut-off elevation

*

*

*

*

*

Length of temporary casing

-

-

*

*

-

Length of permanent casing

-

-

*

*

-

Type, weight, drop and mechanical condition of hammer and equivalent information for other equipment

*

*

*

-

-

Number and type of packings used and type and condition of dolly used during driving of the pile

*

*

-

-

*

*

-

-

*

ta

Set of pile or pile tube in millimetres per 10 blows or number of blows per 25 mm of penetration

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Data

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Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work Driven steel, precast concrete and steel sheet piles

QCS 2014

*

*

*

-

-

If required, temporary compression of ground and pile from time of a marked increase in driving resistance until pile reached its final level

*

*

*

-

-

*

*

*

-

-

Soil samples taken and in-situ tests carried out during pile installation

*

*

*

*

*

Length and details of reinforcements

-

-

*

*

*

Concrete mix

-

-

*

*

*

-

-

*

*

*

*

*

*

*

*

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If required, the sets taken at intervals during the last 3 m of driving

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If required, driving resistance taken at regular intervals over the last 3 m of driving

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Volume of concrete supplied to pile obstructions

delays

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All information regarding interruptions to the work

and

other

1.3.3

Rejected materials

1

Rejected materials are to be removed promptly from the Site.

1.4

INSTALLATION TOLERANCES

1.4.1

Setting Out

1

Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at pile positions, as required by the Contract, shall be located by the Contractor from the main grid lines of the proposed structure. Before installation of the pile, the pile position relative to the main grid lines shall be verified.

QCS 2014


Page 6

Position

1

For a pile cut off at or above ground level the maximum permitted deviation of the pile centre from the centre-point shown on the drawings shall be 75 mm in any direction. An additional tolerance for a pile head cut off below ground level will be permitted in accordance with Clauses 1.4.3 and 1.4.4.

1.4.3

Verticality

1

At the commencement of installation, the pile, or pile-forming equipment in the case of a driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the finished pile from the vertical is 1 in 75.

1.4.4

Rake

1

As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The piling rig shall be set and maintained to attain the required rake. The maximum permitted deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.

1.4.5

Tolerance Variations

1

In exceptional circumstances where these tolerances are difficult to achieve, the tolerances of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of the implications of such action.

1.4.6

Forcible Corrections to Pile

1

Forcible corrections to concrete piles to overcome errors of position or alignment shall not be made. Forcible corrections may be made to other piles only if approved and where the pile shaft is not fully embedded in the soil.

1.5

NUISANCE AND DAMAGE

1.5.1

Noise and Disturbance

1

The Contractor shall carry out the work in such a manner and at such times as to minimise noise, vibration and other disturbance in order to comply with current environmental legislation.

2

The Contractor shall endeavour to ascertain the nature and levels of noise produced by the mechanical equipment and plant that will be used. He shall than take steps to reduce either the level or the annoying characteristics, or both, of the noise. Reference should be made to BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to piling operations.

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1.4.2

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Page 7

Damage to Adjacent Structures

1

If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services or adjacent structures, he shall submit to the Engineer his proposals for making preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding such damage.

1.5.3

Damage to Piles

1

The Contractor shall ensure that during the course of the work, displacement or damage which would impair either performance or durability does not occur to completed piles.

2

The Contractor shall submit to the Engineer his proposed sequence and timing for driving or boring piles, having the intent of avoiding damage to adjacent piles.

1.5.4

Temporary Support

1

The Contractor shall ensure that where required, any permanently free-standing piles are temporarily braced or stayed immediately after driving to prevent loosening of the piles in the ground and to ensure that the pile will not be damaged by oscillation, vibration or ground movement.

1.6

SAFETY

1.6.1

General

1

A competent person, properly qualified and experienced, should be appointed to supervise the piling operations. This person should be capable of recognising and assessing any potential dangers as they arise; e.g., unexpected ground conditions that may require a change in construction technique, or unusual smells which may indicate the presence of noxious or dangerous gases.

2

Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN 1997. Refer Section 1 for general safety standards to be adopted at a construction site.

1.6.2

Life-Saving Appliances

1

The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and available for use at all times.

2

Site operatives shall be instructed in the use of safety equipment and periodic drills shall be held to ensure that all necessary procedures can be correctly observed.

1.6.3

Driving

1

Before any pile driving is started, the Contractor shall supply the Engineer with two copies of the code of signals to be employed, and shall have a copy of the code prominently displayed adjacent to the driving control station on the craft, structure or site from which the piles will be driven.

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1.5.2

END OF PART

QCS 2014


Page 1

CONCRETE WORKS FOR PILING ......................................................................... 2

2.1 2.1.1 2.1.2


2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

MATERIALS ............................................................................................................ 2 Cementitious 2 Aggregate 2 Water 2 Admixtures 2 Steel Reinforcement and Prestressing Steel 2

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

CONCRETE MIXES FOR PILING WORK ............................................................... 3 General 3 Grade Designation 3 Designed Mix 3 Durability 3 Exposure Classes 3

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7

PLACING CONCRETE ............................................................................................ 3 General 3 Inspection 4 Cleanliness of Pile Bases 4 Workability of Concrete 4 Compaction 4 Placing Concrete in Dry Borings 5 Placing Concrete under Water or Drilling Fluid 5

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QCS 2014


CONCRETE WORKS FOR PILING

2.1

GENERAL

2.1.1

Scope

1

This part applies to cast in-situ as well as precast concrete work.

2


Section 5

Concrete.

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General Requirements for Piling Work Shallow Foundations Deep Foundations Retaining Structures

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This Section Part 1, Part 3 Part 4 Part 5

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2

Page 2

References

1


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All Standards mentioned in Section 5

MATERIALS

2.2.1

Cementitious

1

All cementitious materials shall comply with the requirements of Section 5, Part 3.

2

All cementitious materials shall be stored in separate containers according to type in waterproof stores or silos.

2.2.2

Aggregate

1

Aggregates shall comply with the requirements of Section 5, Part 2.

2.2.3

Water

1

If water for the Works is not available from a public supply, approval shall be obtained regarding the source of water. For quality of water refer to Section 5, Part 4.

2.2.4

Admixtures

1

Admixtures shall comply with the requirements of Section 5, Part 5

2.2.5

Steel Reinforcement and Prestressing Steel

1

Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free from loose rust and loose mill scale when installed in the Works. For requirements of steel reinforcement refer to Section 5, Part 11.

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Page 3

The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in reinforcement shall be such that the full strength of each bar is effective across the joint and shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

3

For requirements of prestressing steel refer to Section 5, Part 18.

2.3

CONCRETE MIXES FOR PILING WORK

2.3.1

General

1

For general requirements of concrete mixes, trial mixes, batching, mixing and transportation of fresh concrete and testing of hardened concrete refer to Section 5.

2.3.2

Grade Designation

1

Grades of concrete shall be as given in Section 5, Part 6.

2.3.3

Designed Mix

1

The Contractor shall be responsible for selecting the mix proportions to achieve the required strength and workability..

2

Complete information on the mix and sources of aggregate for each grade of concrete and the water/cementitious ratio and the proposed degree of workability shall be approved before work commences.

3

Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.

4

The Contractor shall submit the slump value for approval before work commences.

2.3.4

Durability

1

For piles exposed to aggressive ground or groundwater, approved measures shall be taken to ensure durability. Reference shall be made to Section 5, Part 6.

2.3.5

Exposure Classes

1

The minimum cementitious content and type and the concrete grades shall be specified based on the exposure classes as given in Table 6.8, Section 5, Part 6.

2.4

PLACING CONCRETE

2.4.1

General

1

The workability and method of placing and vibrating the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed.

2

The concrete shall be placed without such interruption as would produce a cold joint in the pile. The method of placing shall be approved.

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Page 4

3

The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter which would adversely affect the performance of the pile shall be permitted to contaminate the concrete.

2.4.2

Inspection

1

Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly before to concrete is placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided by the

.l. l

.

Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 8008. Cleanliness of Pile Bases

1

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the concrete shall be placed by tremie method. Large debris or accumulated sediment, or both of them, shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

2.4.4


1

Slump measured at the time of discharge into the pile bore shall be in accordance with the standards shown in Table 2.1.

2.4.5

Compaction

1

Internal vibrators may be used to compact concrete, with the approval of the Engineer obtained in advance for each specific use.

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2.4.3

Piling mix workability

Table 2.1 Standards for Concrete Slump Slump Minimum

Range

mm

mm

Typical conditions of use

A

75

75-150

Placed into water-free unlined or permanently lined bore of 600 mm diameter or over, or where concrete is placed below temporary casing, and where reinforcement is widely spaced leaving ample room for free movement of concrete between bars.

B

100

100-200

Where reinforcement is not spaced widely, where concrete is placed within temporary casings, where pile bore is water-free, and the diameter less than 600 mm

C

150

150 or more

Where concrete is to be placed by tremie under water or drilling mud, or by pumping

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Placing Concrete in Dry Borings

1

Approved measures shall be taken to ensure that the structural strength of the concrete placed in all piles is not impaired through grout loss, segregation or bleeding.

2

Concrete shall be placed by “elephant trunk”, and the free fall shall not exceed 1.2 m.

2.4.7

Placing Concrete under Water or Drilling Fluid

1

Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure that there is no accumulation of silt or other material at the base of the boring, and the Contractor shall ensure that heavily contaminated bentonite suspension, which could impair the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

2

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be discharged freely into the water or drilling fluid. Pumping of concrete may be approved where appropriate.

3

A sample of the bentonite suspension shall be taken from the base of the boring using an approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing of concrete shall not proceed. In this event the Contractor shall modify or replace the bentonite as approved to meet the specification.

4

The concrete shall be a rich, coherent mix and highly workable, and cement content shall be in accordance with Clause 2.3.5.

5

The concrete shall be placed in such a manner that segregation does not occur.

6

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of concrete in the tremie and the water or drilling fluid. The pipe shall at all times penetrate the concrete which has previously been placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of 2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of

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concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than 150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that external projections are minimised, allowing the tremie to pass within reinforcing cages without causing damage. The internal face of the pipe of the tremie shall be free from projections. END OF PART

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Page 1

SHALLOW FOUNDATIONS .................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4

GENERAL ............................................................................................................... 2 Scope 2 Definition 2 References 2 Limit States Considerations 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

DESIGN CONSIDERATIONS .................................................................................. 3 General 3 Allowable Bearing Pressure 3 Selection of Types of Shallow Foundation 3 Pad foundations 4 Strip foundations 4 Raft foundations 5

3.3 3.3.1 3.3.2 3.3.3

BASIS OF GEOTECHNICAL DESIGN .................................................................... 5 Design Requirements 5 Design Situations 7 Durability 8

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9 General 9 Actions 10 Ground Properties 12 Geometrical Data 13 Characteristic and Representative Values of Actions 13 Characteristic Values of Geotechnical Parameters 13 Characteristic Values of Geometrical Data 14 Geotechnical Design Report 14 Actions and Design Situations 15 Design and Construction Considerations 15 Foundations on Rock; Additional Design Considerations 16

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SHALLOW FOUNDATIONS

3.1

GENERAL

3.1.1

Scope

1

The provisions of this Section apply to shallow foundations including isolated, pads, strips and rafts.

3.1.2

Definition

1

Shallow foundations are taken to be those where the depth below finished ground level is less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed as deep foundations.

3.1.3

References

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BS 8004,.....................Code of practice for foundations.

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BS EN 1990................Eurocode 0: Basis of Structural Design BS EN 1991................Eurocode 1: Actions on structures BS EN 1992................Eurocode 2: Design of concrete structures -

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BS EN 1993................Eurocode 3: Design of steel structures

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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures BS EN 1995................Eurocode 5: Design of timber structures

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BS EN 1996................Eurocode 6: Design of masonry structures

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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and testing

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BS EN 1998................Eurocode 8: Design of structures for earthquake resistance

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BS 5930......................Code of Practice for Site Investigation Limit States Considerations

1


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3.1.4

(a)


(b)

Bearing resistance failure, punching failure, squeezing;

(c)

Failure by sliding;

(d)

Combined failure in the ground and in the structure;

(e)

Structural failure due to foundation movement;

(f)

Excessive settlements;

(g)

Excessive heave due to swelling, frost and other causes;

(h)


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Page 3

3.2


3.2.1

General

1

The depth to which foundations should be carried depends on two principal factors: (a)

Reaching an adequate bearing stratum;

(b)

Penetration below the zone in which trouble may be expected from seasonal weather changes.

Other factors such as ground movements, changes in groundwater conditions, long-term stability and heat transmitted from structures to the supporting ground may be important.

3

Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be sought where such conditions are indicated by ground investigation.

3.2.2

Allowable Bearing Pressure

1

The center of area of a foundation or group of foundations should be arranged vertically under the centre of gravity of the imposed loading. If this is not possible, the effects on the structure of rotation and settlement of the foundation need to be considered.

2

Where foundation support is provided by a number of separate bases these should, as far as practicable, be proportioned so that differential settlement is minimal.

3.2.3

Selection of Types of Shallow Foundation

1

The selection of the appropriate type of shallow foundation will normally depend on the magnitude and disposition of the structural loads, the bearing capacity and settlement characteristics of the ground and the need to found in stable soil.

2

A pad foundation is used for the purpose of distributing concentrated loads. Unless special conditions control the design, relatively heavy column loads make it advantageous to use pad foundations.

3

Strip foundations may be more appropriate where column loads are comparatively small and closely spaced or where walls are heavy or heavily loaded.

4

Adjacent pad foundations can be combined or joined together with ground beams to support eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns may be carried on ground beams spanning between the pad foundations.

5

Where the allowable bearing pressure would result in large isolated foundations occupying the majority of the available area, it may be logical to join them to form a raft and spread the loads over the entire area. The combination of isolated foundations to form a raft sometimes results in a complex design and a large increase in the reinforcement requirement.

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In connection with the provision of foundations to an extension of an existing building, allowance should be made for differential movement of the foundations between the new and existing structure; such movement affects the structure above foundations. Where a degree of cracking and subsequent remedial work is not acceptable, provision for a joint between the extension and existing building should be considered. Where the foundations of an extension about the foundations of the existing building, the stability of the existing foundations should be ensured.

3.2.4

Pad foundations

1

For buildings such as low rise dwellings and lightly framed structures, pad foundations may be of unreinforced concrete provided that the angle of spread of load from the pier or base plate to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal) and that the stresses in the concrete due to bending and shear do not exceed tolerable limits. For buildings other than low rise and lightly framed structures, it is customary to use reinforced concrete foundations.

2

The thickness of the foundation should under no circumstances be less than 150 mm and will generally be greater than this to maintain cover to reinforcement where provided.

3

Where concrete foundations are used they should be designed in accordance with the design method appropriate to the loading assumptions.

3.2.5

Strip foundations

1

Similar considerations to those for pad foundations apply to strip foundations. On sloping sites strip foundations should be on a horizontal bearing, stepped where necessary to maintain adequate depth.

2

In continuous wall foundations it is recommended that reinforcement be provided wherever an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall foundations will normally be constructed in mass concrete provided that the angle of spread of load from the edge of the wall base to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where regarding is likely to take place, may require to be designed as retaining walls to accommodate steps between adjacent ground floor slabs or finished ground levels. At all changes of level unreinforced foundations should be lapped at the steps for a distance at least equal to the thickness of the foundation or a minimum of 300mm. Where the height of the step exceeds the thickness of the foundation, special precautions should be taken. The thickness of reinforced strip foundations should be not less than 150mm, and care should be taken with the excavation levels to ensure that this minimum thickness is maintained. For the longitudinal spread of loads, sufficient reinforcement should be provided to withstand the tensions induced. It will sometimes be desirable to make strip foundations of inverted tee beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners and junctions the longitudinal reinforcement of each wall foundation should be lapped.

3

Where the use of ordinary strip foundations would overstress the bearing strata, wide strip foundations designed to transmit the foundation loads across the full width of the strip may be used. The depth below the finished ground level should be the same as for ordinary strip foundations.

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Page 5

Where the nature of the ground is such that narrow trenches can be neatly cut down to the bearing stratum, an economical foundation may be achieved by filling the trenches with concrete. When deciding the trench width, account should be taken of normal building tolerances in relation to setting out dimensions. Where the thickness of such a foundation is 500mm or more, any step should be not greater than the concrete thickness and the lap at such a step should be at least 1 m or twice the step height, whichever is the greater?

5

Where fill or other loose materials occur above the bearing stratum adequate support is required to any excavation. Consideration may be given to the use of lean mix mass concrete replacement under ordinary strip footings placed at shallow depth. This mass concrete can be poured against either permanent or recoverable shuttering. This form of foundation provides a method of dealing with local areas where deeper foundations are required.

3.2.6

Raft foundations

1

General. Suitably designed raft foundations may be used in the following circumstances.

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For lightly loaded structures on soft natural ground where it is necessary to spread the load, or where there is variable support due to natural variations, made ground or weaker zones. In this case the function of the raft is to act as a bridge across the weaker zones. Rafts may form part of compensated foundations.

(b)

Where differential settlements are likely to be significant. The raft will require special design, involving an assessment of the disposition and distribution of loads, contact pressures and stiffness of the soil and raft.

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(a)

BASIS OF GEOTECHNICAL DESIGN

3.3.1

Design Requirements

1

For each geotechnical design situation it shall be verified that no relevant limit state is exceeded.

2

When defining the design situations and the limit states, the following factors should be considered: Site conditions with respect to overall stability and ground movements;

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3

(b)

Nature and size of the structure and its elements, including any special requirements such as the design life;

(c)

Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities, vegetation, hazardous chemicals);

(d)

Ground conditions;

(e)

Ground-water conditions;

(f)

Regional seismicity;

(g)

Influence of the environment (hydrology, surface water, subsidence, seasonal changes of temperature and moisture).

Limit states can occur either in the ground or in the structure or by combined failure in the structure and the ground.

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Page 6

Limit states should be verified by any appropriate method such as calculation method as described in 3.4;

5

In practice, experience will often show which type of limit state will govern the design and the avoidance of other limit states may be verified by a control check.

6

Buildings should normally be protected against the penetration of ground-water or the transmission of vapor or gases to their interiors.

7

If practicable, the design results should be checked against comparable experience.

8

In order to establish minimum requirements for the extent and content of geotechnical investigations, calculations and construction control checks, the complexity of each geotechnical design shall be identified together with the associated risks. In particular, a distinction shall be made between:

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L ight and simple structures and small earthworks for which it is possible to ensure that the minimum requirements will be satisfied by experience and qualitative geotechnical investigations, with negligible risk;

(b)

Other geotechnical structures.

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(a)

For structures and earthworks of low geotechnical complexity and risk, such as defined above, simplified design procedures may be applied.

10

To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3, may be introduced.

11

A preliminary classification of a structure according to Geotechnical Category should normally be performed prior to the geotechnical investigations. The category should be checked and changed, if necessary, at each stage of the design and construction process.

12

The procedures of higher categories may be used to justify more economic designs, or if the designer considers them to be appropriate.

13

The various design aspects of a project can require treatment in different Geotechnical Categories. It is not required to treat the whole of the project according to the highest of these categories.

14

Geotechnical Category 1 should only include small and relatively simple structures:

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(a)

For which it is possible to ensure that the fundamental requirements will be satisfied on the basis of experience and qualitative geotechnical investigations;

(b)

With negligible risk.

15

Geotechnical Category 1 procedures should be used only where there is negligible risk in terms of overall stability or ground movements and in ground conditions, which are known from comparable local experience to be sufficiently straightforward. In these cases the procedures may consist of routine methods for foundation design and construction.

16

Geotechnical Category 1 procedures should be used only if there is no excavation below the water table or if comparable local experience indicates that a proposed excavation below the water table will be straightforward.

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17

Geotechnical Category 2 should include conventional types of structure and foundation with no exceptional risk or difficult soil or loading conditions

18

Designs for structures in Geotechnical Category 2 should normally include quantitative geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

19

Routine procedures for field and laboratory testing and for design and execution may be used for Geotechnical Category 2 designs. the following are examples of conventional structures or parts of structures complying with Geotechnical Category 2: Shallow foundations;

(ii)

Pile foundations;

(iii)

Walls and other structures retaining or supporting soil or water;

(iv)

Excavations;

(v)

Bridge piers and abutments;

(vi)

Embankments and earthworks;

(vii)

Ground anchors and other tie-back systems;

(viii)

Tunnels in hard, non-fractured rock and not subjected to special water tightness or other requirements.

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(a)

Geotechnical Category 3 should include structures or parts of structures, which fall outside the limits of Geotechnical Categories 1 and 2.

21

Geotechnical Category 3 should normally include alternative provisions and rules to those in this standard. Geotechnical Category 3 includes the following examples: Very large or unusual structures;

(ii)

Structures involving abnormal risks, or unusual or exceptionally difficult ground or loading conditions;

(iii)

Structures in highly seismic areas;

(iv)

Structures in areas of probable site instability or persistent ground movements that require separate investigation or special measures.

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3.3.2

Design Situations

1

Both short-term and long-term design situations shall be considered.

2

In geotechnical design, the detailed specifications of design situations should include, as appropriate: (a)

The actions, their combinations and load cases;

(b)

The general suitability of the ground on which the structure is located with respect to overall stability and ground movements;

(c)

The disposition and classification of the various zones of soil, rock and elements of construction, which are involved in any calculation model;

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(d)

Dipping bedding planes;

(e)

Mine workings, caves or other underground structures;

(f)

In the case of structures resting on or near rock: (i)

inter bedded hard and soft strata;

(ii)

faults, joints and fissures;

(iii)

possible instability of rock blocks;

(iv)

solution cavities, such as swallow holes or fissures filled with soft material, and continuing solution processes;

The environment within which the design is set, including the following: (i)

effects of scour, erosion and excavation, leading to changes in the geometry of the ground surface;

(ii)

effects of chemical corrosion;

(iii)

effects of weathering;

(iv)

effects of long duration droughts;

(v)

variations in ground-water levels, including, e.g. the effects of dewatering, possible flooding, failure of drainage systems, water exploitation;

(vi)

the presence of gases emerging from the ground;

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Earthquakes;

(i)

Ground movements caused by subsidence due to mining or other activities;

(j)

The sensitivity of the structure to deformations;

(k)

The effect of the new structure on existing structures, services and the local environment.

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Durability

1

At the geotechnical design stage, the significance of environmental conditions shall be assessed in relation to durability and to enable provisions to be made for the protection or adequate resistance of the materials.

2

In designing for durability of materials used in the ground, the following should be considered:

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(a)

For concrete: (i)

(b)

Aggressive agents in the ground-water or in the ground or fill material, such as acids or sulfate salts;

For steel: (i)

Chemical attack where foundation elements are buried in ground that is sufficiently permeable to allow the percolation of ground-water and oxygen;

(ii)

Corrosion on the faces of sheet pile walls exposed to free water, particularly in the mean water level zone;

(iii)

The pitting type of corrosive attack on steel embedded in fissured or porous concrete, particularly for rolled steel where the mill scale, acting as a cathode, promotes electrolytic action with the scale-free surface acting as an anode;

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(c)

Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations For timber: (i)

(d)

Page 9

Fungi and aerobic bacteria in the presence of oxygen;

For synthetic fabrics: (i)

The ageing effects of UV exposure or ozone degradation or the combined effects of temperature and stress, and secondary effects due to chemical degradation.

Reference should be made to durability provisions in construction materials standards.

3.4

GEOTECHNICAL DESIGN BY CALCULATION

3.4.1

General

1

Design by calculation shall be in accordance with the fundamental requirements of EN 1990 and with the particular rules of this specification. Design by calculation involves:

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Actions, which may be either imposed loads or imposed displacements, e.g. from ground movements;

(b)

Properties of soils, rocks and other materials;

(c)

Geometrical data;

(d)

Limiting values of deformations, crack widths, vibrations etc;

(e)

Calculation models.

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(a)

It should be considered that knowledge of the ground conditions depends on the extent and quality of the geotechnical investigations. Such knowledge and the control of workmanship are usually more significant to fulfilling the fundamental requirements than is precision in the calculation models and partial factors.

3

The calculation model shall describe the assumed behavior of the ground for the limit state under consideration.

4

If no reliable calculation model is available for a specific limit state, analysis of another limit state shall be carried out using factors to ensure that exceeding the specific limit state considered is sufficiently improbable. Alternatively, design by prescriptive measures, experimental models and load tests, or the observational method, shall be performed.

5

The calculation model may consist of any of the following:

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(a)

An analytical model;

(b)

A semi-empirical model;

(c)

A numerical model.

6

Any calculation model shall be either accurate or err on the side of safety.

7

A calculation model may include simplifications.

8

If needed, a modification of the results from the model may be used to ensure that the design calculation is either accurate or errs on the side of safety.

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Page 10

If the modification of the results makes use of a model factor, it should take account of the following: (a)

The range of uncertainty in the results of the method of analysis;

(b)

Any systematic errors known to be associated with the method of analysis.

10

If an empirical relationship is used in the analysis, it shall be clearly established that it is relevant for the prevailing ground conditions.

11

Limit states involving the formation of a mechanism in the ground should be readily checked using a calculation model. For limit states defined by deformation considerations, the deformations should be evaluated by calculation or otherwise assessed.

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NOTE: many calculation models are based on the assumption of a sufficiently ductile performance of the ground/structure system. A lack of ductility, however, will lead to an ultimate limit state characterized by sudden collapse. Numerical methods can be appropriate if compatibility of strains or the interaction between the structure and the soil at a limit state are considered.

13

Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for the relative stiffness of structure and ground, may be needed in cases where a combined failure of structural members and the ground could occur. Examples include raft foundations, laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain compatibility for materials that are brittle or that have strain-softening properties.

14

In some problems, such as excavations supported by anchored or strutted flexible walls, the magnitude and distribution of earth pressures, internal structural forces and bending moments depend to a great extent on the stiffness of the structure, the stiffness and strength of the ground and the state of stress in the ground.

15

In these problems of ground-structure interaction, analyses should use stress-strain relationships for ground and structural materials and stress states in the ground that are sufficiently representative, for the limit state considered, to give a safe result.

3.4.2

Actions

1

The definition of actions shall be taken as:

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(a)

Set of forces (loads) applied to the structure (direct action);

(b)

Set of imposed deformations or accelerations caused for example, by temperature changes, moisture variation, uneven settlement or earthquakes (indirect action).

The values of actions shall be taken from EN 1991 or equivalent international standard, where relevant. 2

The values of geotechnical actions to be used shall be selected, since they are known before a calculation is performed; they may change during that calculation. NOTE: Values of geotechnical actions may change during the course of calculation. In such cases they will be introduced as a first estimate to start the calculation with a preliminary, known value.

3

Any interaction between the structure and the ground shall be taken into account when determining the actions to be adopted in the design.

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In geotechnical design, the following should be considered for inclusion as actions: the weight of soil, rock and water;

(b)

stresses in the ground;

(c)

earth pressures and ground-water pressure;

(d)

free water pressures, including wave pressures;

(e)

ground-water pressures;

(f)

seepage forces;

(g)

dead and imposed loads from structures;

(h)

surcharges;

(i)

mooring forces;

(j)

removal of load or excavation of ground;

(k)

traffic loads;

(l)

movements caused by mining or other caving or tunneling activities;

(m)

swelling and shrinkage caused by vegetation, climate or moisture changes;

(n)

movements due to creeping or sliding or settling ground masses;

(o)

movements due to degradation, dispersion, decomposition, self-compaction and solution;

(p)

movements and accelerations caused by earthquakes, explosions, vibrations and dynamic loads;

(q)

temperature effects, including frost action;

(r)

imposed pre-stress in ground anchors or struts;

(s)

down drag.

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Consideration shall be given to the possibility of variable actions occurring both jointly and separately.

6

The duration of actions shall be considered with reference to time effects in the material properties of the soil, especially the drainage properties and compressibility of fine-grained soils.

7

Actions, which are applied repeatedly, and actions with variable intensity shall be identified for special consideration with regard to, e.g. continuing movements, liquefaction of soils, change of ground stiffness and strength.

8

Actions that produce a dynamic response in the structure and the ground shall be identified for special consideration.

9

Actions in which ground- and free-water forces predominate shall be identified for special consideration with regard to deformations, fissuring, variable permeability and erosion.

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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in some situations be considered as coming from a single source. If they are considered so, a single partial factor may be applied to the sum of these actions or to the sum of their effects.

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Ground Properties

1

Properties of soil and rock masses, as quantified for design calculations by geotechnical parameters, shall be obtained from test results, either directly or through correlation, theory or empiricism, and from other relevant data.

2

Values obtained from test results and other data shall be interpreted appropriately for the limit state considered.

3

Account shall be taken of the possible differences between the ground properties and geotechnical parameters obtained from test results and those governing the behavior of the geotechnical structure.

4

The above differences can be due to the following factors: many geotechnical parameters are not true constants but depend on stress level and mode of deformation;

(b)

soil and rock structure (e.g. fissures, laminations, or large particles) that may play a different role in the test and in the geotechnical structure;

(c)

time effects;

(d)

the softening effect of percolating water on soil or rock strength;

(e)

the softening effect of dynamic actions;

(f)

the brittleness or ductility of the soil and rock tested;

(g)

the method of installation of the geotechnical structure;

(h)

the influence of workmanship on artificially placed or improved ground;

(i)

the effect of construction activities on the properties of the ground.

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When establishing values of geotechnical parameters, the following should be considered:

the value of each geotechnical parameter compared with relevant published data and local and general experience;

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published and well recognized information relevant to the use of each type of test in the appropriate ground conditions;

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3.4.3

6

(c)

the variation of the geotechnical parameters that are relevant to the design;

(d)

the results of any large scale field trials and measurements from neighboring constructions;

(e)

any correlations between the results from more than one type of test;

(f)

any significant deterioration in ground material properties that may occur during the lifetime of the structure.

Calibration factors shall be applied where necessary to convert laboratory or field test results according to EN 1997-2 into values that represent the behavior of the soil and rock in the ground, for the actual limit state, or to take account of correlations used to obtain derived values from the test results.

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Geometrical Data

1

The level and slope of the ground surface, water levels, levels of interfaces between strata, excavation levels and the dimensions of the geotechnical structure shall be treated as geometrical data.

3.4.5

Characteristic and Representative Values of Actions

1

Characteristic and representative values of actions shall be derived in accordance with EN 1990:2002 and the various parts of EN 1991.

3.4.6

Characteristic Values of Geotechnical Parameters

1

The selection of characteristic values for geotechnical parameters shall be based on results and derived values from laboratory and field tests, complemented by well-established experience.

2

The characteristic value of a geotechnical parameter shall be selected as a cautious estimate of the value affecting the occurrence of the limit state.

3

The selection of characteristic values for geotechnical parameters shall take account of the following:

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3.4.4

geological and other background information, such as data from previous projects;

(b)

the variability of the measured property values and other relevant information, e.g. from existing knowledge;

(c)

the extent of the field and laboratory investigation;

(d)

the type and number of samples;

(e)

the extent of the zone of ground governing the behavior of the geotechnical structure at the limit state being considered;

(f)

the ability of the geotechnical structure to transfer loads from weak to strong zones in the ground.

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Characteristic values can be lower values, which are less than the most probable values, or upper values, which are greater.

5

For each calculation, the most unfavorable combination of lower and upper values of independent parameters shall be used.

6

The zone of ground governing the behavior of a geotechnical structure at a limit state is usually much larger than a test sample or the zone of ground affected in an in situ test. Consequently the value of the governing parameter is often the mean of a range of values covering a large surface or volume of the ground. The characteristic value should be a cautious estimate of this mean value.

7

If the behavior of the geotechnical structure at the limit state considered is governed by the lowest or highest value of the ground property, the characteristic value should be a cautious estimate of the lowest or highest value occurring in the zone governing the behavior.

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When selecting the zone of ground governing the behavior of a geotechnical structure at a limit state, it should be considered that this limit state may depend on the behavior of the supported structure. For instance, when considering a bearing resistance ultimate limit state for a building resting on several footings, the governing parameter should be the mean strength over each individual zone of ground under a footing, if the building is unable to resist a local failure. If, however, the building is stiff and strong enough, the governing parameter should be the mean of these mean values over the entire zone or part of the zone of ground under the building.

9

If statistical methods are employed in the selection of characteristic values for ground properties, such methods should differentiate between local and regional sampling and should allow the use of a prior knowledge of comparable ground properties.

10

If statistical methods are used, the characteristic value should be derived such that the calculated probability of a worse value governing the occurrence of the limit state under consideration is not greater than 5%.

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NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean value of the limited set of geotechnical parameter values, with a confidence level of 95%; where local failure is concerned, a cautious estimate of the low value is a 5% fractal. When using standard tables of characteristic values related to soil investigation parameters, the characteristic value shall be selected as a very cautious value.

3.4.7

Characteristic Values of Geometrical Data

1

Characteristic values of the levels of ground and ground-water or free water shall be measured, nominal or estimated upper or lower levels.

2

Characteristic values of levels of ground and dimensions of geotechnical structures or elements should usually be nominal values.

3.4.8

Geotechnical Design Report

1

The assumptions, data, methods of calculation and results of the verification of safety and serviceability shall be recorded in the Geotechnical Design Report.

2

The level of detail of the Geotechnical Design Reports will vary greatly, depending on the type of design. For simple designs, a single sheet may be sufficient.

3

The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :

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11

(a)

a description of the site and surroundings;

(b)

a description of the ground conditions;

(c)

a description of the proposed construction, including actions;

(d)

design values of soil and rock properties, including justification, as appropriate;

(e)

statements on the codes and standards applied;

(f)

statements on the suitability of the site with respect to the proposed construction and the level of acceptable risks;

(g)

geotechnical design calculations and drawings;

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(h)

foundation design recommendations;

(i)

a note of items to be checked during construction or requiring maintenance or monitoring.

4

The Geotechnical Design Report shall include a plan of supervision and monitoring, as appropriate. Items, which require checking during construction or, which require maintenance after construction shall be clearly identified. When the required checks have been carried out during construction, they shall be recorded in an addendum to the Report.

5

In relation to supervision and monitoring the Geotechnical Design Report should state: the purpose of each set of observations or measurements;

(b)

the parts of the structure, which are to be monitored and the locations at which observations are to be made;

(c)

the frequency with which readings is to be taken;

(d)

the ways in which the results are to be evaluated;

(e)

the range of values within which the results are to be expected;

(f)

the period of time for which monitoring is to continue after construction is complete;

(g)

the parties responsible for making measurements and observations, for interpreting the results obtained and for maintaining the instruments.

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(a)

An extract from the Geotechnical Design Report, containing the supervision, monitoring and maintenance requirements for the completed structure, shall be provided to the owner/client.

3.4.9

Actions and Design Situations

1

Design situations shall be selected in accordance with 3.3.2.

2

The actions listed in 3.4.2(4) should be considered when selecting the limit states for calculation.

3

If structural stiffness is significant, an analysis of the interaction between the structure and the ground should be performed in order to determine the distribution of actions.

3.4.10

Design and Construction Considerations

1

When choosing the depth of a shallow foundation the following shall be considered:

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(a)

reaching an adequate bearing stratum;

(b)

the depth above which shrinkage and swelling of clay soils, due to seasonal weather changes, or to trees and shrubs, may cause appreciable movements;

(c)

the level of the water table in the ground and the problems, which may occur if excavation for the foundation is required below this level;

(d)

possible ground movements and reductions in the strength of the bearing stratum by seepage or climatic effects or by construction procedures;

(e)

the effects of excavations on nearby foundations and structures;

(f)

anticipated excavations for services close to the foundation;

(g)

high or low temperatures transmitted from the building;

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(h)

the possibility of scour;

(i)

the effects of variation of water content due to long periods of drought, and subsequent periods of rain, on the properties of volume-unstable soils in arid climatic areas;

(j)

the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

2

In addition to fulfilling the performance requirements, the design foundation width shall take account of practical considerations such as economic excavation, setting out tolerances, working space requirements and the dimensions of the wall or column supported by the foundation.

3

One of the following design methods shall be used for shallow foundations: a direct method, in which separate analyses are carried out for each limit state. When checking against an ultimate limit state, the calculation shall model as closely as possible the failure mechanism, which is envisaged. When checking against a serviceability limit state, a settlement calculation shall be used;

(b)

an indirect method using comparable experience and the results of field or laboratory measurements or observations, and chosen in relation to serviceability limit state loads so as to satisfy the requirements of all relevant limit states;

(c)

a prescriptive method in which a presumed bearing resistance is used.

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(a)

Foundations on Rock; Additional Design Considerations

1

The design of shallow foundations on rock shall take account of the following features: the deformability and strength of the rock mass and the permissible settlement of the supported structure;

(b)

the presence of any weak layers, for example solution features or fault zones, beneath the foundation;

(c)

the presence of bedding joints and other discontinuities and their characteristics (for example filling, continuity, width, spacing);

(d)

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3.4.11

disturbance of the natural state of the rock caused by construction activities, such as, for example, underground works or slope excavation, being near to the foundation.

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(e)

the state of weathering, decomposition and fracturing of the rock;

2

Shallow foundations on rock may normally be designed using the method of presumed bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and sandstones, the presumed bearing pressure are limited by the compressive strength of the concrete foundation.

3

The settlement of a foundation may be assessed on the basis of comparable experience related to rock mass classification. END OF PART

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DEEP FOUNDATIONS ............................................................................................ 4

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4 General 4 Limit States Considerations 4 Precast Reinforced and Prestressed Concrete Piles 4 Materials and components 5 Prestressing 7 Driving Piles 8 Risen Piles 10 Repair and lengthening of piles 10 Cutting off pile heads 10

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10 Scope 10 References 11 Submittals 11 Quality Assurance 11 Tolerances in Pile Dimensions 11 Handling, Transportation, Storage and Acceptance of Piles 12 Materials and components 12 Driving piles 13 Risen Piles 14 Repair and lengthening of piles 15 Cutting off pile heads 15

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6

BORED CAST IN PLACE PILES ........................................................................... 15 Scope 15 References 16 Quality Assurance 16 Materials 16 Boring 17 Extraction of casing 19

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21 Scope 21 Materials 21 Boring 22 Placing of concrete or grout 23 Cutting off pile heads 23

4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6

DRIVEN CAST IN PLACES PILES ........................................................................ 23 Scope 23 Submittals 24 Quality Assurance 24 Materials 24 Driving piles 25 Risen Piles 26

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26

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11

STEEL PILES ........................................................................................................ 28 Scope 28 References 28 Submittals 28 Quality Assurance 28 Delivery, Storage and Handling 29 Materials 29 Acceptance Standards For Welds 30 Acceptability and inspection of coatings 31 Driving of piles 31 Risen Piles 33 Preparation of pile heads 33

4.7

MICROPILES (TO BE ADDED LATER) ................................................................. 33

4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5

REDUCTION OF FRICTION ON PILES ................................................................ 33 Scope 33 Submittals 33 Friction Reducing Methods 33 Inspection 34 Driving resistance 35

4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.9.7 4.9.8

PILE LOAD TESTING ........................................................................................... 35 Static Load Testing of Piles 35 Presentation of results 45 Low strain Integrity test 47 Grosshole Sonic Logging Test 48 Calliper Logging Test 48 Axial Tensile Load Test 48 Lateral Load Test 48 Alternative Methods for Testing Piles 48

4.10 4.10.1 4.10.2 4.10.3

DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51 Design method 51 Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations 51 Design Considerations 51

4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 4.11.10

AXIALLY LOADED PILES ..................................................................................... 52 Limit state design 52 Compressive Ground Resistance 53 Ultimate compressive resistance from static load tests 54 Ultimate compressive resistance from ground test results 55 Ultimate compressive resistance from dynamic impact tests 56 Ultimate compressive resistance by applying pile driving formulae 56 Ultimate compressive resistance from wave equation analysis 56 Ground tensile resistance 57 Ultimate tensile resistance from pile load tests 57 Ultimate tensile resistance from ground test results 57

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4.5.7

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4.11.11 Vertical displacements of pile foundations 4.11.12 Pile foundations in compression 4.11.13 Pile foundations in tension

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TRANSVERSELY LOADED PILES ....................................................................... 58 Design method 58 Transverse load resistance from pile load tests 59 Transverse load resistance from ground test results and pile strength parameters 59 Transverse displacement 60

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4.12 4.12.1 4.12.2 4.12.3 4.12.4

58 58 58

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DEEP FOUNDATIONS

4.1

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

4.1.1

General

1

The provisions of this Part apply to end-bearing piles, friction piles, tension piles and transversely loaded piles installed by driving, by jacking, and by screwing or boring with or without grouting.

4.1.2

Limit States Considerations

1


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(b)

bearing resistance failure of the pile foundation;

(c)

Uplift or insufficient tensile resistance of the pile foundation;

(d)

Failure in the ground due to transverse loading of the pile foundation;

(e)

Structural failure of the pile in compression, tension, bending, buckling or shear;

(f)

combined failure in the ground and in the pile foundation;

(g)

combined failure in the ground and in the structure;

(h)

Excessive settlement;

(i)

Excessive heave;

(j)

Excessive lateral movement;

(k)


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(a)

Precast Reinforced and Prestressed Concrete Piles

1

Scope

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This Part applies to precast concrete driven piles usually supplied for use in a single length without facility for joining lengths together.

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4.1.3

(b) 2


References (a)


BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes BS 2789,.....................Spheroidal graphite or nodular graphite cast iron BS 8110,.....................Structural use of concrete. 3

Submittals (a)

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified, the approval of the piles for the main work will not necessarily be given until the results of the driving and loading tests on preliminary piles have been received and evaluated.

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Page 5


5


After a pile has been cast, the date of casting, reference number, length and, where appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall be marked at the proper locations on each pile.

Tolerances in Pile Dimensions (a)

The cross-sectional dimensions of the pile shall be not less than those specified and shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any cross section along its length deviate by more

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than 1/500 of the pile length from a line joining the centres of area at the ends of the pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

Handling, Transportation and Storage of Piles

The method and sequence of lifting, handling, and storage of piles transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only the designated lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

(b)

All piles within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

(c)

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the lesser. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the agreement of the Engineer.

(d)

Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The

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be reduced below 6 mm on a pro rata basis in accordance with actual length.

measurement shall be made with the pile in its working attitude.


1


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4.1.4

(a)

2

Pile Toes (a)

3

In the manufacture of precast concrete piles, fabricated steel components shall comply with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where positional fixity is required on an inclined rock surface or in other circumstances, an approved shoe may be required.


The head of each pile shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

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Page 6


The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one continuous length unless otherwise specified. In piles more than 12 m long, lap splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no more than 25 % of the bars lapped at one location, and laps staggered by a minimum of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is effective across the joint. Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.

(c)

Sufficient reinforcement shall be provided for lifting and handling purposes.

Unless otherwise agreed by the Engineer, concrete shall be compacted with the assistance of vibrators. Internal vibrators shall be capable of producing not less than 150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not

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Concrete

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closer than 75 mm to shuttering.

Vibrators shall be operated in such a manner that neither segregation of the concrete mix constituents nor displacement of reinforcement occurs.

(c)

Immediately after compaction, concrete shall he adequately protected from the harmful effects of the weather, including wind, rain, rapid temperature changes and frost. It shall be protected from drying out by an approved method of curing.

(d)

Piles shall not be removed from formwork until a sufficient pile concrete strength has been achieved to allow the pile to be handled without damage.

(e)

The period of curing at an ambient temperature of 10 °C shall not be less than that

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(b)

shown in Table 4.1. If the temperature is greater or less than 10 °C, the periods given

When steam or accelerated curing is used the curing procedure shall be approved. Four hours must elapse from the completion of placing concrete before the temperature is raised. The rise in temperature within any period of 30 min shall not exceed 10 °C and the maximum temperature attained shall not exceed 70 °C. The rate

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shall be adjusted accordingly and shall be approved.

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(b)

of subsequent cooling shall not exceed the rate of heating. Table 4.1 Period of Curing at 10 °C Type of cement

Wet curing time after completion of placing concrete, d

Ordinary Portland

4

Sulphate-resisting Portland

4

Portland blast-furnace

4

Super-sulphated

4

Rapid-hardening Portland

3

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Page 7

Formwork (a)

shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(b)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections, free from defects. The piles are to be removed from the formwork carefully so as to prevent damage.

4.1.5

Prestressing

1

General Tensioning shall be carried out only when the Engineer is present, unless otherwise approved. In cases where piles are manufactured off site, the Contractor shall ensure that the Engineer is given adequate notice and every facility for inspecting the manufacturing process.

(b)

Prestressing operations shall be carried out only under the direction of an experienced and competent supervisor. All personnel operating the stressing equipment shall have been trained in its use.

(c)

The calculated extensions and total forces, including allowance for losses, shall be agreed with the Engineer before stressing is commenced.

(d)

Stressing of tendons and transfer of prestress shall be carried out at a gradual and steady rate. The force in the tendons shall be obtained from readings on a recently calibrated load cell or pressure gauge incorporated in the equipment. The extension of the tendons under the agreed total forces shall be within 5 % of the agreed calculated extension.

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Concrete Strength

The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to be able to demonstrate by testing two cubes at a time, with approved intervals between pairs of cubes, that the specified transfer strength of the concrete has been reached.

(b)

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Post-Tensioned Piles (a)

4

Unless otherwise permitted, concrete shall not be stressed until two test cubes attain the specified transfer strength.

Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

Grouting Procedure (a)

Grout shall be mixed for a minimum of 2 min and until a uniform consistency is obtained.

(b)

Ducts shall not be grouted when the air temperature in the shade is lower than 3 °C.

(c)

Before grouting is started all ducts shall be thoroughly cleaned by means of compressed air.

(d)

Grout shall be injected near the lowest point in the duct in one continuous operation and allowed to flow from the outlet until the consistency is equivalent to that of the grout being injected.

(e)

Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.

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Page 8

Grout (a)

Unless otherwise directed or agreed by the Engineer (i)

the grout shall consist only of ordinary Portland cement, water and approved admixtures; admixtures containing chlorides or nitrates shall not be used

(ii)

the grout shall have a water/cement ratio as low as possible consistent with the necessary workability, and the water/cement ratio shall not exceed 0.45 unless an approved mix containing an expanding agent is used

(iii)

the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess of 4% maximum, when measured at 18 C in a covered glass cylinder approximately 100 mm in diameter with a height of grout of approximately 100 mm, and the water shall be reabsorbed after 24 h.

Records

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The Contractor shall keep detailed records of times of tensioning, measured extensions, pressure gauge readings or load cell readings and the amount of pull-in at each anchorage. Copies of these records shall be supplied to the Engineer within such reasonable time from completion of each tensioning operation as may be required, and in any case not later than noon on the following working day.

(b)

The Contractor shall keep records of grouting, including the date, the proportions of the grout and any admixtures used, the pressure, details of interruption and topping up required. Copies of these records shall be supplied to the Engineer within such reasonable time after completion of each grouting operation as may be required, and in any case not later than noon on the following working day.

Driving Piles

1

Strength of Piles (a)

Piles shall not be driven until the concrete has achieved the specified strength.


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The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where designated, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

Length of Piles (a)

The length of pile to be driven in any location shall be approved prior to the commencement of driving.

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Page 9


The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)


(c)

At the start of the work in a new area or section, a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles

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until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being

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(e)


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Final Set (a)

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25 mm.

(b)


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(d)

The exposed part of the pile shall be in good condition without damage or distortion.

(ii)


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(iv)


(v)

The temporary compression of the pile shall be recorded, if required.

Preboring (a)

8

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis, and the head of the pile protected against damage from hammer impact.


Jetting (a)


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Risen Piles Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

(b)


(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave effects in subsequent work.

4.1.8


1

Repair of Damaged Pile Heads

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If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the pile-driving to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

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Lengthening of Reinforced and Prestressed Concrete Piles Any provision for lengthening piles incorporated at the time of manufacture shall be as designed or approved.

(b)

If no provision for lengthening piles was incorporated at the time of manufacture, any method for lengthening shall be such that splices are capable of safely resisting the stresses during driving and under service load and shall be subject to approval.

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(a)

Driving Repaired or Lengthened Piles Repaired or lengthened piles shall not be driven until the added concrete has reached the specified strength of the concrete of the pile.

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4.1.7



1

Unless otherwise directed by the Engineer, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2


4.2

PRECAST REINFORCED CONCRETE SEGMENTAL PILES

4.2.1

Scope

1

This Part applies to piles made of elements cast at a precasting works away from the site, where work cannot normally be closely supervised by the Engineer. The elements are joined together as necessary on site during driving using special proven steel joints incorporated into the pile elements when cast.

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4.1.9

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Page 11

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5,

Concrete.

4.2.2

References

1

The following Standards are referred to in this Part: Eurocode 7, EN1997-1, Section 7 Pile foundation BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes

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BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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BS 8110,.....................Structural use of concrete. Submittals

1

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

4.2.4

Quality Assurance

1

A certificate of quality from the pile manufacturer shall be provided to the Engineer when required stating that the designated requirements have been fulfilled during manufacture.

2

Each pile element shall be marked in such a manner that it can be identified with the records of manufacture, which shall state the date of casting, the cement type, concrete grade, element length and any other relevant data. On delivery, the pile elements shall be accompanied by records of manufacture.

4.2.5

Tolerances in Pile Dimensions

1

The cross-sectional dimensions of the pile shall be not less than those designated.

2

The head of a pile element or the end of the pile upon which the hammer acts shall be square to the pile axis within a tolerance of 1 in 50.

3

Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

4

Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the centres of area at the ends of the element. Where a pile element is less than 3 m long the permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in accordance with actual length.

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4.2.3

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Handling, Transportation, Storage and Acceptance of Piles

1

The method and sequence of lifting, handling, transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

2

All pile elements within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

3

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the less. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the approval of the Engineer.

4

A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm. The measurement shall be made with the pile in its working attitude.

4.2.7


1


ta qa

In the manufacture of jointed precast concrete segmental piles, fabricated steel components shall comply with BS 7613 grades 43A or 50A, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

er

Pile Splices (a)

The splice joints shall be close-fitting face to face and the locking method shall be such as to hold the faces in intimate contact. The design and manufacture of the splicing system shall be approved by the Engineer prior to the commencement of the Contract.

(b)

A spliced pile shall be capable of withstanding the same driving stresses or service axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.

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4.2.6

(c)

3

Pile Toes (a)

4

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where fixity is required or socketing into rock, or in other circumstances, an approved shoe may be required.


5

The welding of a joint to main reinforcement in lieu of a lapped connection with projecting bars affixed to the joint will not be permitted.

Where the pile head is not furnished with a joint, it shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.


The main longitudinal reinforcing bars shall be in one continuous length. Splicing of bars will not be permitted except at element ends.

QCS 2014

Page 13

(b)

Concrete cover to steel reinforcement shall be in accordance with the requirements of BS 8110.

(c)

In very aggressive ground or exposure conditions, cover greater than 25 mm may be required, but alternative protection methods may be approved.

Formwork (a)

If a pile is constructed with a shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile.

(b)

Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(c)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections. The piles are to be removed from the formwork carefully so as to prevent damage.

Driving piles

1

Strength of Piles



Performance of Driving Equipment

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the particular specification, dynamic evaluation and analysis shall be provided. Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile at the moment of driving unless otherwise approved by the Engineer. For other types of hammer, the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

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Piles shall not be driven until the concrete has achieved the specified characteristic strength.

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4

Length of Piles (a)

The length of pile supplied to be driven in any location and any additional lengths to be added during driving shall he approved prior to the commencement of pile-driving. During the execution of the Works, any changes to the supplied lengths shall be approved.

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Page 14


Except when making field splices, the driving of each pile shall he continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall only be used when approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)


(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)


(e)


as

Final Set

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)


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(a)


(ii)


(iii)


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(i)

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7

(v)

The temporary compression of the pile shall be recorded if required.


Jetting (a)

4.2.9


Preboring (a)

8

(iv)


Risen Piles (a)

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

QCS 2014


Page 15

(b)


(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting piles detrimentally affected and for avoidance or control of heave effects in subsequent work.

4.2.10


1

Repair of Damaged Pile Heads If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the driving of the pile to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

Where piles are required to be driven to depths exceeding those expected, leaving insufficient projection for bonding into the following works, the piles shall be extended or replaced as required by the Engineer using approved materials and methods.

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(a)

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Lengthening of Piles

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(a)


1

Unless otherwise specified, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2


4.3

BORED CAST IN PLACE PILES

4.3.1

Scope

1

This Part applies to bored piles in which the pile bore is excavated by rotary or percussive means, or both, using short augers, buckets, grabs or other boring tools to advance the open bore. Where the open bore is unstable, temporary or permanent casing or bentonite suspension may be used to support the wall of the bore prior to concreting.

2


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4.2.11

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation Section 5, Concrete

QCS 2014


4.3.2

References

1

The following codes of practice are referred to in this Part:

Page 16

BS 5573,.....................Code of practice for safety precautions in the construction of large diameter boreholes for piling and other purposes BS 5930,.....................Code of practice for site investigation. 4.3.3

Quality Assurance

1

Inspection Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly prior to concrete being placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided, by the Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 5573.

Cleanliness of pile bases

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed. Large debris and accumulated sediment shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

Samples and Testing

The taking of samples and all subsequent handling, transporting and testing shall be carried out in accordance with Section 3, Ground Investigation.

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(b)

If required in the Contract, soil, rock or groundwater samples shall be taken or soil tests carried out in-situ while the pile is being bored. The samples shall be taken to an approved laboratory for testing as specified.

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(a)

4.3.4

Materials

1

Permanent Casings (a)

2

Permanent casings shall be as specified.

Drilling Fluid Supply (a)

A certificate shall be obtained by the Contractor from the manufacturer of the bentonite powder showing the properties of each consignment delivered to the Site. This certificate shall be made available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range (in Pascal seconds) and the gel strength range (in Pascal) for solids in water.

QCS 2014

3

Page 17

Drilling Fluid Mixing (a)

Bentonite shall be mixed thoroughly with clean fresh water to make a suspension which will maintain the stability of the pile bore for the period necessary to place concrete and complete construction. The temperature of the water used in mixing the bentonite suspension, and of the suspension when supplied to the borehole, shall be not lower than 5 C.

(b)

Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh water so as to render it suitable in all respects for the construction of piles.

Drilling Fluid Tests (a)

The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by the Contractor for approval prior to the commencement of the work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval.

(b)

Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pile bore. For average soil conditions the results shall generally be within the ranges in Table 4.2.

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Table 4.2.Tests on Bentonite

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Viscosity

Less than 1.10 g/ml

Mud density balance

30 - 90 s or less than 0.020 Pa • s

Marsh cone method

1.4-10 Pa Or 4-40 Pa

Shear meter

et it

9.5 - 12

Fann viscometer*

Fann viscometer pH indicator paper strips or electrical pH meter

Where the Fann viscometer is specified, the fluid sample should be screened by a number 52 sieve (300 m) prior to testing.

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*

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Shear strength (10 minute gel strength) pH

Test method

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Density

Range of results at 20 C

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Property to be measured

(c)

The tests shall be carried out until a consistent working pattern has been established account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

4.3.5

Boring

1

Boring Near Recently Cast Piles (a)

Piles shall not be bored so close to other recently completed piles as to damage them.

QCS 2014

Page 18

Temporary Casings (a)

Temporary casing of approved quality or an approved alternative method shall be used to maintain the stability of a pile bore which might otherwise collapse.

(b)

Temporary casings shall be free from significant distortion. They shall be of uniform cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might adversely affect the proper formation of piles.

(c)

The use of a vibrator to insert and withdraw temporary casing may be permitted by the Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent Structures of this section and to the method not causing disturbance of the ground which would adversely affect the construction or the capacity of piles.

(d)

Where piles are bored under water or bentonite suspension in an unlined state, the insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing concrete will not be permitted.

(e)

Where permanent casing is specified to ensure the integrity of a pile, the Contractor shall submit for approval his proposals regarding the method of installation.

ta qa

Stability of Pile

Where boring takes place through unstable water-bearing strata, the process of excavation and the depth of temporary casing employed shall be such that soil from outside the area of the pile is not drawn into the pile section and cavities are not created outside the temporary casing as it is advanced.

(b)

Where the use of drilling fluid is specified or approved for maintaining the stability of a bore, an adequate temporary casing shall be used in conjunction with the method so as to ensure stability of the strata near ground level until concrete has been placed. During construction the level of drilling fluid in the pile excavation shall be maintained within the cased or stable bore so that it is not less than 1.0 m above the level of external standing groundwater at all times.

(c)

In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be backfilled without delay and the instructions of the Engineer shall be obtained before boring at that location is resumed.

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Spillage and Disposal of Drilling Fluid (a)

5

Pumping from Pile Bores (a)

6

All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from the Site without undue delay. Any disposal of bentonite shall comply with the regulations of the local controlling authority.

Pumping from pile bores shall not be permitted unless the bore has been sealed against further water entry by casing or unless the soil is stable and will allow pumping to take place without ground disturbance below or around the pile.

Continuity of Construction (a)

For a pile constructed in a stable cohesive soil without the use of temporary casing or other form of support, the pile shall be bored and the concrete shall be placed without such delay as would lead to significant impairment of the soil strength.

QCS 2014

7


Enlarged Pile Bases (a)

A mechanically formed enlarged base shall be no smaller than the dimensions specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the shaft diameter. The sloping surface of the frustum forming the enlargement shall make an angle to the axis of the pile of not more than 35 .

4.3.6


1

Workability of Concrete (a)

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted. During extraction the motion of the casing shall be maintained in an axial direction relative to the pile.

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Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

The concrete level within a temporary casing shall be topped up where necessary during the course of casing extraction in such a way that the base of the casing is always below the concrete surface until the casting of the pile has been completed.

(c)

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could occur as the casing is withdrawn because of the displacement of water or fluid by the concrete as it flows into its final position against the walls of the pile bore. Where two or more discontinuous lengths of casing (double casing) are used in the construction the proposed method of working shall be approved.

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(a)

For piles cast in dry bores using temporary casing and without the use of a permanent lining, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be above the original ground level. No pile shall be cast with its head below standing water level unless approved measures are taken to prevent inflow of water causing segregation of the concrete as temporary casing is extracted, and, where approved by the Engineer, the groundwater level for each pile shall be treated as the cut-off level for the purpose of calculating tolerance.

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Pile Head Casting Level Tolerances

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(b)

For piles cast in dry bores within permanent lining tubes or permanent casings, or where their cut-off levels are in stable ground below the base of any casing used, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the original ground level.

QCS 2014


Page 20

(c)

For piles cast under water or drilling fluid, the pile heads shall be cast to a level above the specified cut-off so that, after trimming to remove all debris and contaminated concrete, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the commencing surface level. Cut-off levels may be specified below the standing groundwater level, and where this condition applies the borehole fluid level shall not be reduced below the standing groundwater level until the concrete has set.

(d)

Where the cut-off level of piles lies at depths greater than 10 m below the original ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after discussion with the Contractor and before the commencement of the piling to take account of the special conditions which apply. Table 4.3


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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing and Without the Use of a Permanent Lining

ta

0.3 + H/12 + C/8 where C = length of temporary casing below the commencing surface*

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0.15-10.00 *

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If H is greater than C, then this tolerance is no longer applicable and the tolerances in Table 4.4 will apply.

Table 4.4

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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the Base of Any Casing Used

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0.3 + H/10

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0.15-10.00


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Table 4.5 Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid** Cut-off distance below commencing surface, H, m

0.15-10.00

** 4


1.0 + H /12 + C/8 where C = length of temporary casing below the commencing surface

In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate tolerance is given by deletion of the casing term C/8 in the table.

Water levels (a)

During extraction of temporary casings, where circumstances are such that newly placed unset concrete is brought into contact with external groundwater, precautions shall be taken to ensure that the internal concrete pressure at all levels within the pile exceeds the external groundwater pressure.

QCS 2014

5

After each pile has been cast, any empty bore remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Disposal of excavated material (a)

7

Page 21


6


Disposal of excavated material shall be carried out by the Contractor as necessary to facilitate the Works and to the satisfaction of the Engineer.


When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS

4.4.1

Scope

1

This Part applies to bored piles which employ a continuous flight auger for both advancing the bore and maintaining its stability. The spoil-laden auger is not removed from the ground until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed auger to replace the excavated soil.

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4.4

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This Section

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Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete Materials

1

Concrete Mix Design and Workability

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4.4.2

(a)

2

Where not otherwise stated in this Part, the concrete shall comply with Section 5. The design and workability of concrete to be used in the formation of a pile shall produce a mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless 3 otherwise approved and a minimum cement content of 340 kg/m . The mix shall be designed so that segregation does not occur during the placing process, and bleeding of the mix shall be minimised.

Grout Mix Design and Workability (a)

Mix design of grout shall be subject to approval. Cement, water and aggregates for grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm nominal size and shall be rounded and evenly graded.

QCS 2014

(b)


The workability of grout mixes, where used, shall be measured by a suitable and approved means. The procedure for monitoring the suitability of grout throughout the Works shall be stated in writing to the Engineer before beginning of the Works and shall be subject to approval.

(c)

Additives to the grout shall require prior approval of the Engineer.

Reinforcement All reinforcement shall be placed with the minimum delay after the completion of the concreting or grouting operation. It shall be designed and fabricated in cages to permit it to be placed in the correct position and to the depth specified through the concrete or grout of the pile. Suitable approved spacers shall be provided to maintain the specified concrete or grout cover to steel.

(b)

The transverse reinforcement of any reinforcing cage shall be approved and may consist of either spirals, hoops or links.

(c)

Longitudinal main steel reinforcement shall be continuous over the specified length. Where splices are necessary, the number of laps shall be kept to a minimum and bars shall be welded or joined together in an approved manner.

(d)

Reinforcement shall be supported and centred so that it will provide the required projection above the cut-off level, and the proper concrete cover.

Boring

1

General

During uncased boring with continuous flight auger, the feed forward and speed (revolutions per minute) are to be adjusted according to the soil conditions in a way that the excavation of soil will be limited to a quantity that the lateral support of the uncased borehole wall will be ensured.

Boring Near Recently Cast Piles

Removal of Augers from the Ground

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3

Piles shall not be bored so close to other piles which have recently been cast as to damage them.

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(a)

4

Depth of Piles (a)

5

Augers shall not be extracted from the ground during the boring or construction of a pile in such a way that an open unsupported bore or inflow of water into the pile section would result. While withdrawing the continuous flight auger, the auger shall be rotated in the same direction as during drilling into the soil or shall be withdrawn without rotation.

Any failure of a pile to reach the designated depth shall be reported to the Engineer without delay and a full statement of the reasons given.

Suitability of Boring Equipment (a)

The piles shall be bored using approved and suitable equipment capable of penetrating the ground without drawing surrounding soils laterally into the pile bore.

QCS 2014


4.4.4

Placing of concrete or grout

1

Equipment for Supply of Concrete or Grout to Piles (a)

Grout or concrete shall be supplied to the pile through suitable tubing and the hollow auger stem. All pipe fitments and connections shall be so constructed that grout does not leak during the injection process.

Commencement of Concrete or Grout Supply to Each Pile (a)

The base of the auger stem shall be fitted with a suitable means of sealing it against ingress of water and soil until concrete or grout placing begins.

(b)

At the beginning of concrete or grout placement this sealing device shall be removed by the application of concrete or grout pressure. Care shall be taken to ensure that the auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water inflow and soil movement at the base of the auger are minimised. The technique and equipment used to initiate and maintain the concrete or grout flow shall be such that a pile of the full specified cross-section is obtained from the maximum depth of boring to the final pile cut-off level.

The concrete or grout shall be supplied to the pile at a sufficient rate during auger withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.

(b)

The rate of withdrawal of the auger, the injection pressures and the rate of supply of concrete or grout shall be measured and recorded throughout the phase of auger withdrawal for each pile.

(c)

The Contractor shall submit proposals for his method of monitoring construction for approval before beginning the Works.

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Completion of Piles

If the concrete or grout placing in any pile cannot be completed in the normal manner, then the pile shall be rebored before concrete has hardened and shall be completely replaced.

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4

Rate of Supply of Concrete or Grout

Casting Level of Pile Head Concrete or grout shall be cast to the original ground level in all cases, and the reinforcing cage set, as appropriate.

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4.4.5


1

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or contaminated, cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section up to the cut-off level.

4.5

DRIVEN CAST IN PLACES PILES

4.5.1

Scope

1

This Part applies to piles for which a permanent casing of steel or concrete is driven, reinforcement placed within it if required, and the casing filled with concrete. It also applies to piles in which a temporary casing is driven, reinforcement placed within it and the pile formed in the ground by filling the temporary casing with concrete before and during its extraction.

QCS 2014

2


Page 24

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5, Concrete Section 3, Ground Investigation. Submittals

1

Where the Contractor wishes to form a pile with an enlarged base, details of the proposed method of forming the base and the materials to be used shall be submitted at the time of tendering.

4.5.3

Quality Assurance

1

Before placing concrete in a pile casing, the Contractor shall check in an approved manner that the casing is undamaged, and free from water or other foreign matter. In the event of water or foreign matter having entered the pile casing, either the casing shall be withdrawn, repaired if necessary and re-driven, or other action shall be taken as may be approved to continue the construction of the pile.

4.5.4

Materials

1

Permanent Casings

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Permanent casings shall be as specified. Where a permanent casing is to be made from a series of short sections it shall be designed and placed so as to produce a continuous water-free shaft. The dimensions and quality of the casing shall be adequate to withstand the stresses caused by handling and driving without damage or distortion.

Temporary casings shall be free from significant distortion. They shall be of uniform external cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might prevent the proper formation of piles.

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(a)

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Temporary Casings

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(a)

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4.5.2

3

Pile Shoes (a)

4

Pile shoes shall be manufactured from durable material capable of withstanding the stresses caused by driving without damage, and shall be designed to give a watertight joint during construction.

Reinforcement (a)

This type of pile shall normally be reinforced over its full length unless permanently cased. The use of shorter reinforcement in piles which are not permanently cased shall be subject to the approval of the Engineer.

(b)

The number of splices in longitudinal steel bars shall be kept to a minimum. The full strength of each bar shall be effective across each splice, which shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

QCS 2014


4.5.5

Driving piles

1

Piling Near Recently Cast Piles (a)

2

Casings shall not be driven or piles formed so close to other piles which have recently been cast as to damage them.


The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment

(b)

Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

Length of Piles

Driving Procedure (a)

Each pile casing shall be driven continuously until the specified or approved depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided on resumption the casing can be driven to the specified depth or resistance (set), or both, without damage.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is encountered. A detailed record of the driving resistance over the full length of the nearest available subsequent pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile to be installed and over the last 3 m of the driving of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all facilities to enable the Engineer to check driving resistance. A set shall be taken only in the presence of the Engineer unless otherwise approved.

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Final Set

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The length of pile to be driven in any location shall be approved.

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(a)

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(a)

Where piles are driven to a set, the final set of each pile, pile shell or casing shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met: (i)

The exposed part of the pile casing shall be in good condition, without damage or distortion.

(ii)

The dolly, helmet and packing, if any, shall be in sound condition.

(iii)


(iv)


(v)

Temporary compression of the pile casing shall be recorded if required.

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6

If preboring is specified the pile casing shall be pitched after preboring to the designated depth and diameter.

Jetting (a)

8

Page 26

Preboring (a)

7


Jetting shall be carried out only when the Contractor's detailed proposals have been approved by the Engineer

Internal Drop Hammer Where a casing for a pile without an enlarged base is to be driven by an internal drop hammer, a plug consisting of concrete grade 20 with a water/cement ratio not exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to ensure that this height of driving plug is maintained in the casing throughout the period of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of normal driving or after 45 min of hard driving, or, should the driving of a pile be interrupted for 30 min or longer, fresh concrete shall be added prior to driving being resumed.

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(a)

Risen Piles

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2

When required, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process.

3

When a pile has risen with detrimental effects as a result of adjacent piles being driven the Contractor shall, if required, submit to the Engineer his proposals for correcting or compensating for this and for avoidance or control of heave effects in subsequent work.

4.5.7


1


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4.5.6

(a)

2

3

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted.

Concrete Level (a)

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

Concrete shall be topped up as necessary while the casing is extracted until the required head of concrete to complete the pile in a sound and proper manner has been provided. No concrete is to be placed once the bottom of the casing has been lifted above the top of the concrete.

Vibrating Extractors (a)

The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and Disturbance) and (Damage to Adjacent Structures).

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4


Page 27

Concrete Casting Tolerances (a)

For piles constructed without the use of a rigid permanent lining, pile concrete shall be cast to the original ground level.

(b)

Where piles are constructed inside rigid permanent lining tubes or permanent casings, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. In this case, the tolerance of casting above the cut-off level shall be determined according to Table 4.6. Table 4.6

Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining Tubes or Permanent Casings Cut-off distance below original ground, H, (m)

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Casting tolerance above cut-off level (m)

2.2 + H/10

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Repair of damaged pile heads and making-up of piles to the correct level When repairing or extending the head of a pile, the head shall be cut off square in sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water.

(b)

If the driving of a pile has been accepted but sound concrete of the pile is below the cut-off level, the pile shall be made good to the cut-off level with concrete of a grade not inferior to that of the concrete of the pile.

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(a)

Lengthening of cast-in- place piles after driving When it is required to extend a cast-in-place driven pile above ground, the materials to be used and procedures to be adopted shall be subject to the approval of the Engineer.

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0.15 to any depth

Lengthening of permanent pile casings during construction The lengthening of permanent steel pile casings by adding an additional length of the same steel casing during construction shall be carried out in accordance with the relevant clauses of this Section or by other approved methods. The use of casing extension materials and methods other than those specified shall be subject to approval.

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9

After each pile has been cast, any hole remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.


When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section to the cut-off level.

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4.6

STEEL PILES

4.6.1

Scope

1

This Part applies to driven steel piles designed to act as bearing piles.

2

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete References

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4.6.2

ta

BS 4, ..........................Structural steel sections

BS 3100, ....................Steel casting for general engineering purposes.

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BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel

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BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates

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API 5L,........................Interpretation of non-destructive testing. Submittals

1

Where coatings are specified, the Contractor shall submit for approval full details of the coating procedure and surface preparation according to relevant British or Swedish Standards.

4.6.4

Quality Assurance

1

The Contractor shall provide the Engineer with Works test certificates, analyses, and mill sheets, together with a tube manufacturer's certificate showing details of the pile number, cast number of the steel and a record of all tests and inspections carried out. The Engineer has the right to inspect any stage of the manufacturing processes and shall be given adequate notice by the Contractor of such processes and production tests, provided that, once he has been notified, any delay in his attendance does not cause delay to, or disrupt, the manufacturing process. The Contractor shall provide the Engineer with samples for independent testing when requested.

2

The Contractor shall submit for approval full details of the welding procedures and electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the relevant British Standard or as may be required by the Engineer. Only welders who are qualified in the approved welding procedure in accordance with the tests laid down in the relevant British Standard, or who have a proven record over the previous six months, or who have attained a similar standard, shall be employed on the Works. Proof of welders' proficiency shall be made available to the Engineer on request.

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4.6.3

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4.6.5


1

The Contractor shall (a)

Order the piles to suit the construction programme.

(b)

Obtain the Engineer's approval before placing the order.

Page 29

When preliminary piles are specified, the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

3

Each pile shall be clearly numbered and its length shown near the pile head using white paint. In addition, before being driven, each pile shall be graduated at appropriate intervals along its length and at intervals of 250 mm along the top 3 m.

4

All piles within a stack shall be in groups of the same length and on approved supports. All operations such as handling, transporting and storing of piles shall be carried out in a manner such that damage to piles and their coatings is minimised.

4.6.6

Materials

1

Pile Shoes

ta qa

Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related standards.

Strengthening of Piles

The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head of a pile shall be made using material of the same grade as the pile unless otherwise approved.

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Manufacturing Tolerance All piles shall be of the type and cross-sectional dimensions specified. For standard rolled sections the dimensional tolerances and weight shall comply with the relevant standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified. For proprietary sections the dimensional tolerances shall comply with the manufacturer's standards. The rolling or manufacturing tolerances for proprietary sections shall be such that the actual weight of section does not differ from the theoretical weight by more than +4 % or -2½ % unless otherwise agreed. The rolling or manufacturing tolerances for steel tubular piles shall be such that the actual weight of section does not differ from the theoretical weight by more than ±5 %.

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Straightness of Piles (a)

For standard rolled sections the deviation from straightness shall be within the compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall length of the pile.

(b)

For proprietary sections made up from rolled sections, and for tubular piles, the deviation from straightness on any longitudinal face shall not exceed 1/600 of the length of the pile nor 5 mm in any 3 m length.

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Page 30

Fabrication of Piles (a)

For tubular piles where the load will be carried by the wall of the pile, and if the pile will be subject to loads that induce reversal of stress during or after construction, the external diameter at any section as measured by using a steel tape on the circumference shall not differ from the theoretical diameter by more than ±1.

(b)

The ends of all tubular piles as manufactured shall be within a tolerance on ovality of ±1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile length.

(c)

The root edges or root faces of lengths of piles that are to be shop butt-welded shall not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of unequal wall thickness are to be butt-welded, the thickness of the thinner material shall be the criterion.

Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being joined shall, whenever possible, be evenly staggered at the butt. However, if in order to obtain a satisfactory match of the ends of piles or to meet specified straightness, the seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.

as

Welding

Welding of H-piles and piles that will be subjected to stress reversal, during or after construction, shall be in accordance with BS 5135.

(b)

For a tubular pile where the load will be compressive and non-reversible and will be carried by the wall of the pile or by composite action with a concrete core, the welding shall be to BS 5135 or BS 6265.

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(a)

Coating Piles for Protection against Corrosion Where coatings are specified they shall be provided in accordance with the Particular Specification. In general, coatings will not be called for where piles are fully in contact with undisturbed natural soils or below the standing water table. Cathodic protection may be called for when there is a possibility of stray electrical current from the supported structure flowing to earth through the piles.

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4.6.7

Acceptance Standards For Welds

1

Acceptance Standards for Shop Welds (a)

Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the acceptance standard for interpretation of non-destructive testing specified in latest edition of API 5L. The maximum projecting height of weld reinforcement shall not exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall thicknesses greater than 13 mm.

(b)

Longitudinal welds joining the constituent parts of the box or proprietary section shall be in accordance with the manufacturer's specification.

(c)

The maximum projecting height of weld reinforcement for circumferential welds in tubular piles shall be the same as specified above for longitudinal welds in tubular piles.

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2


Page 31

Acceptance Standards for Site Butt Welds (a)

Welds shall comply with the requirements of the Weld Quality Acceptance Standards for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation, General Steels Group.

Acceptability and inspection of coatings

1

The finished coating shall be generally of smooth and uniform texture and free from sharp protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

2

Any coat damaged by subsequent processes, or which has deteriorated to an extent such that proper adhesion of the coating is in doubt, shall be removed and the surface shall be cleaned to the original standard and recoated with the specified number and thicknesses of coats.

3

The completed coating shall be checked for thickness by an approved magnetic thickness gauge. Areas where the thickness is less than that specified shall receive approved additional coating.

4

Average measured thickness should be equal to or greater than the specified thickness and no single reading should be less than 85 % of the specified thickness. The completed coating shall also be checked for adhesion by the cross-hatching method with lines spaced at ten times the thickness of the coating. Adhesion tests should not be carried out prior to seven days after coating.

5

The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved shall be sand blasted and recoated. The coating shall be approved before pitching and driving of the piles.

4.6.9

Driving of piles

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At all stages during driving and until incorporation in the superstructure, the free length of the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. In marine works, lengths which remain unsupported after driving shall be adequately restrained until incorporated into the permanent Works. These constraint arrangements shall be such that damage to piles and their coatings is minimised.

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4.6.8

2


The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the Contract, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

QCS 2014

Length of Piles (a)

The length of pile to be driven and any additional lengths of pile to be added during driving shall be approved by the Engineer.

Driving Procedure and Redrive Checks The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can be driven to the specified depth or resistance (set), or both, without damage.

(b)

A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(c)

The Contractor shall inform the Engineer as soon as an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest subsequent pile shall be taken, if required by the Engineer.

(d)

At the start of the work in a new area or section a detailed record shall be made over the full driving length of the first pile, and during the last 3 m of the driving of subsequent piles, to establish the driving behaviour. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being specified by the Engineer.

(e)


(f)

Redrive checks, if required, shall be carried out in accordance with an approved procedure.

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When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm. When a final set or resistance is being measured, the following requirements shall be met:

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Final Set or Resistance

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(i)


(ii)

The dolly and packing, if any, shall be in sound condition.

(iii)


(iv)

The hammer shall be in good condition, delivering adequate energy per blow and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required by the Engineer.

Preboring (a)

If preboring is specified the pile shall be pitched after preboring to the designated depth and diameter.

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7


Page 33

Jetting (a)


Risen Piles

1


2

When required by the Engineer, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving of adjacent piles.

3

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile under load is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave in subsequent work.

4.6.11

Preparation of pile heads

1

If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within 5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete they shall be cut to that same tolerance and protective coatings shall be removed from the surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.

4.7

MICROPILES (TO BE ADDED LATER)

4.8

REDUCTION OF FRICTION ON PILES

4.8.1

Scope

1

This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.

2


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4.6.10

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation. 4.8.2

Submittals

1

Where the particular method of reducing friction is not specified, the Contractor shall submit full details of the method which he proposes.

4.8.3

Friction Reducing Methods

1

General (a)

Where a means of reducing friction on any specified length of pile is required by the Contract, the Contractor shall provide a suitable interface between pile and soil by one of the following, or other approved, methods

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Page 34

(i)

Preapplied bituminous or other proprietary friction-reducing coating.

(ii)

Preapplied low-friction sleeving.

(iii)

Formed-in-place low-friction surrounds.

(iv)

Preinstalled low-friction sleeving.

Preapplied Bituminous or other Friction-Reducing Coating Materials (a)

Where a proprietary product is specified, the process of cleaning pile surfaces, and the conditions and methods of application shall conform to the manufacturer's current instructions. All materials shall conform to the manufacturer's specification, which shall be given to the Engineer before any coating is applied.

(b)

Where a friction-reducing material has been applied to a preformed pile prior to installation, it shall be protected from damage during handling and transportation. In the event of inadvertent damage to the coating, it shall be repaired on site, prior to the pile being driven, to the same specification as the original coating. Where bituminous materials are involved, precautions shall be taken as necessary in hot weather to prevent excessive flow or displacement of the coating. The coated piles shall be adequately protected against direct sunlight and, if stacked, they shall be separated to prevent their coatings sticking together.

(c)

In the case of applied coatings, the piles shall not be driven when the air temperature is such that the coating will crack, flake or otherwise be damaged prior to entry into the ground. Where bituminous materials are involved, driving shall be carried out while the temperature is at or above 5 °C unless otherwise approved or called for in the manufacturer's instructions.

Formed-In-Place Low-Friction Surround Where a hole is bored in the ground and filled with low-friction material through which a pile is subsequently driven or placed, the method and the properties of the low-friction material both above and below standing groundwater level, together with the dimensions of the prebored hole in relation to the pile, shall be approved by the Engineer.

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Piles may be driven with a preapplied low-friction sleeving subject to the approval of the detailed design and method by the Engineer.

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Preapplied Low-Friction Sleeving

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Preinstalled Low-Friction Sleeving (a)

Where a system is employed involving placing a low-friction sleeve in the ground prior to pile installation, the detailed materials and method of installation of the sleeving shall be approved by the Engineer.

4.8.4

Inspection

1

The Engineer may call for piles to be partially exposed or extracted at the commencement of a contract in order to demonstrate that the method of installation does not impair the effectiveness of the system in the circumstances of use on the particular site. Where damage is found to have occurred, or is likely to occur in the opinion of the Engineer, additional measures or variation of the method may be called for. At the discretion of the Engineer, further inspections shall be carried out to ascertain the effectiveness of the additional measures.

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Page 35

4.8.5

Driving resistance

1

Allowance shall be made in driving piles to a required resistance or set for any differences between the short-term driving resistance and the long-term static resistance of the coating or surrounding low-friction material which is in use.

4.9

PILE LOAD TESTING

4.9.1

Static Load Testing of Piles

1

Scope This Part deals with the testing of a pile by the controlled application of an axial load. It covers vertical and raking piles tested in compression (i.e. subjected to loads or forces in a direction such as would cause the piles to penetrate further into the ground) and vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as would cause the piles to be extracted from the ground).

References The following standard is referred to in this Part:

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(a)

Allowable pile capacity: a load which is not less than the specified working load and which takes into account the pile's ultimate bearing capacity, the materials from which the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the overall bearing capacity of the ground beneath the piles and any other relevant factors. The allowable pile capacity indicates the ability of a pile to meet the specified loading requirements.

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Definitions

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When required, the design and full details of the proposed load application system shall be submitted to the Engineer prior to the commencement of testing. The load application system shall be satisfactory for the required test.

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(a)

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Submittals

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3

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BS 1881, ....................Methods of testing concrete.

(b)

Compression pile: a pile which is designed to resist compressive (downward) axial load.

(c)

Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate the soil at a constant controlled speed, while the loads applied at the top of the pile in order to maintain the constant rate of penetration are continuously measured. The purpose of the test is to derive the ultimate bearing capacity of a pile and not its load settlement characteristics.

(d)

Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is subject to tension rather than compression. The purpose of the test is to determine the 'pull-out' capacity of a pile.

(e)

Design verification load (DVL): a test load, in lieu of a specified working load, applied to a single pile at the time of testing to determine that site conditions conform to design assumptions. This load will be peculiar to each preliminary (test) pile and should equal the maximum specified working load for a pile of the same dimensions and material, plus allowances for soil-induced forces and any other particular conditions of the test.

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Kentledge: ballast used in a loading test.

(g)

Maintained load test: a loading test in which each increment of load is held constant either for a defined period of time or until the rate of settlement falls to a specified value.

(h)

Preliminary pile: a test pile installed before the commencement of the main piling works or a specific part of the Works for the purpose of establishing the suitability of the chosen type of pile and for confirming its design, dimensions and bearing capacity.

(i)

Proof load: a load applied to a selected working pile to confirm that it is suitable for the load at the settlement specified. A proof load should not normally exceed the design verification load plus 50 % of the specified working load.

(j)

Raking pile: a batter pile, installed at an inclination to the vertical.

(k)

Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a resistance against which the pile is tested.

(l)

Specified working load (SWL): the designated load on the head of a pile.

(m)

Tension pile: a pile which is designed to resist a tensile (upward) axial force.

(n)

Test pile: any pile, preliminary or part of the works, to which a test is applied.

(o)

Ultimate bearing capacity: the load at which the resistance of the soil becomes fully mobilised through friction, end bearing or a combination thereof.

(p)

Working pile: one of the piles forming the foundation of a structure.

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(f)

Notice of Construction

(b)

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The Contractor shall give the Engineer at least 48 hours' notice of the commencement of construction of any preliminary pile which is to be testloaded.

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(i)

Method of Construction Each preliminary test pile shall be constructed in a manner similar to that to be used for the construction of the working piles, and by the use of similar equipment and materials. Any variation will be permitted only with prior approval.

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Construction of a preliminary pile to be tested

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(c)

Boring or Driving Record (i)

(d)

For each preliminary pile to be tested, a detailed record of the conditions experienced during boring and of the progress during driving, shall be made and submitted to the Engineer daily, not later than noon on the next working day. Where the Engineer requires soil samples to be taken or in-situ tests to be made, the Contractor shall include that in the daily report, as well as the test results.

Concrete Test Cubes (i)

In the case of concrete piles, four test cubes shall be made from the concrete 3 used in the manufacturer of each preliminary test pile and from each 50 m of the concrete used in the manufacture of working piles. If a concrete pile is extended or capped for the purpose of testing, an additional four cubes shall be made from the corresponding batch of concrete. The cubes shall be made and tested in accordance with BS 1881.

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations (ii)

(e)

If a test is required on a working pile the Contractor shall cut off or otherwise prepare the pile for testing as required by the Engineer.

Cut-off Level (i)

The cut-off level for a preliminary test pile shall be approved by the Engineer.

.

Supervision The setting-up of pile testing equipment shall be carried out under competent supervision and the equipment shall be checked to ensure that the set-up is satisfactory before the commencement of load application.

(b)

All tests shall be carried out only under the direction of an experienced and competent supervisor experienced with the test equipment and test procedure. All personnel operating the test equipment shall have been trained in its use.

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(a)

Safety precautions General

Design, erection and dismantling of the pile test reaction system and the application of load shall be carried out according to the requirements of the various applicable statutory regulations concerned with lifting and handling heavy equipment and shall safeguard operators and others who may from time to time be in the vicinity of a test from all avoidable hazards.

Kentledge

Where kentledge is used, the Contractor shall construct the foundations for the kentledge and any cribwork, beams or other supporting structure in such a manner that there will not be differential settlement, bending or deflexion of an amount that constitutes a hazard to safety or impairs the efficiency of the operation. The kentledge shall be adequately bonded, tied or otherwise held together to prevent it becoming unstable because of deflexion of the supports or for any other reason.

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The pile test shall not be started until the strength of the cubes taken from the pile exceeds twice the average direct stress in any pile section under the maximum required test load, and the strength of the cubes taken from the cap exceeds twice the average stress at any point in the cap under the same load. Variation of procedure will be permitted only if approved by the Engineer.

Preparation of a Working Pile to be Tested (i)

(f)

Page 37

(ii)

When kentledge constitutes the principal component of a reaction system, its weight for each test shall be at least 25% greater than the maximum test load for that test. The weight may be determined by scale or the density and volume of the constituent materials. In adding kentledge, care shall be taken to properly position the centre of gravity of the stack.

QCS 2014

(c)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Tension Piles, Reaction Piles and Ground Anchorages (i)

Where tension piles, reaction piles or ground anchorages constitute the principal components of a reaction system, they shall be so designed that they will resist the forces applied to them safely and without excessive deformation which could cause a safety hazard during the work. Such piles (which, unless approved, will not be working piles) or anchorages shall be driven in the specified locations, and all bars, tendons or links shall be aligned to provide a stable reaction in the direction required. Any welding employed to extend or to fix anchorages to a reaction frame shall be carried out so that the full strength of the system is adequate and unimpaired.

Testing Equipment (i)

In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable up to the maximum load to be applied.

(ii)

If in the course of carrying out a test any unforeseen occurrence should take place, further loading shall not be applied until a proper engineering assessment of the condition has been made and steps have been taken to rectify any fault. Reading of gauges should, however, be continued where possible and if it is safe to do so.

(iii)

Where an inadequacy in any part of the system might constitute a hazard, means shall be provided to enable the test to he controlled from a position remote from of the kentledge stack or test frame.

(iv)

The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a pressure of 1.5 times the maximum pressure used in the test without leaking. The maximum test load expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit.

Pile Head for Compression Test For a pile that is tested in compression, the pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile, sufficiently large to accommodate the loading and settlement measuring equipment and adequately reinforced or protected to prevent damage from the concentrated load applied by the loading equipment.

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(f)

(ii)

Any test pile cap shall be concentric with the test pile; the joint between the cap and the pile shall have a strength equivalent to that of the pile.

(iii)

Sufficient clear space shall be made under any part of the cap projecting beyond the section of the pile so that, at the maximum expected settlement, load is not transmitted to the ground by the cap.

Pile Connection for Tension Test (i)

For a pile that is tested in tension, means shall be provided for transmitting the test load axially without inducing moment in the pile. The connection between the pile and the loading equipment shall be constructed in such a manner as to provide strength equal to 1.5 times the maximum load which is to be applied to the pile during the test.

QCS 2014

Page 39

Reaction systems

(i)

The reaction for compression tests shall be provided by kentledge, tension piles or specially constructed anchorages. Kentledge shall not be used for tests on raking piles except where the test set-up has been specifically designed to conform to Item 7(g). and has been approved by the Engineer.

(ii)

Where kentledge is to be used, it shall be supported on cribwork and positioned so that the centre of gravity of the load is as close as possible to the axis of the pile. The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge stack.

Tension Tests (i)

The reaction for tension tests shall be provided by compression piles, rafts or grillages constructed on the ground. In all cases the resultant force of the reaction system shall be coaxial with the test pile.

(ii)

Where inclined piles or reactions are proposed, full details shall be submitted for approval prior to the commencement of testing.

ta qa

Working piles shall not be used as reaction piles without approval from the Engineer.

(ii)

Where working piles are used as reaction piles their movement shall be measured and recorded to with an accuracy of 0.5 mm, and recorded.

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(i)

Spacing

Where kentledge is used for loading vertical piles in compression, the distance from the edge of the test pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be not less than 1.3 m.

(ii)

The centre-to-centre spacing of vertical reaction piles from a test pile shall conform to Paragraph 1 above, but shall be not less than three times the diameter of the test pile or the reaction piles or 2 m, whichever is the greatest, except in the case of piles of 300 mm diameter (or equivalent) or less, where the distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no surface of a reaction pile shall be closer to the pile cap of the test pile than one half of the pile cap plan dimension.

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(d)

Working Piles

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(c)

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Compression Tests

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(a)

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(iii)

(e)

Where ground anchorages are used to provide a test reaction for loading in compression, no section of fixed anchor length transferring load to the ground shall be closer to the test pile than three times the diameter of the test pile. Where the pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no section of the fixed anchor transferring load to the ground shall be closer to the pile cap than a distance equal to one half the pile cap plan dimension.

Adequate Reaction (i)

The reaction frame support system shall be adequate to transmit the maximum test load in a safe manner without excessive movement or influence on the test pile. Calculations shall be provided to the Engineer when required to justify the design of the reaction system.

QCS 2014

(f)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Care of Piles (i)

9

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The method employed in the installation of the reaction system shall be such as to prevent damage to any test pile or working pile.

Equipment for applying load The equipment used for applying load shall consist of a hydraulic ram or jack. The jack shall be arranged in conjunction with the reaction system to deliver an axial load to the test pile. Proposals to use more than one ram or jack will be subject to approval by the Engineer of the detailed arrangement. The complete system shall be capable of safely transferring the maximum load required for the test. The length of stroke of a ram shall be sufficient to account for deflexion of the reaction system under load plus a deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise specified or agreed prior to commencement of test loading.

Measurement of load

A load measuring device shall be used and in addition a calibrated pressure gauge included in the hydraulic system. Readings of both the load measuring device and the pressure gauge shall be recorded. In interpreting the test data the values given by the load measuring device shall normally be used; the pressure gauge readings are required as a check for gross error.

(b)

The load measuring device may consist of a load measuring column, pressure cell or other appropriate system. A spherical seating of appropriate size shall he used to avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load application and measuring system. Load measuring and application devices shall be short in axial length in order to secure stability. The Contractor shall ensure that axial loading is maintained.

(c)

The load measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The pressure gauge and hydraulic jack shall be calibrated together. Certificates of calibration shall be supplied to the Engineer.

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(a)

Control of loading

The loading equipment shall enable the load to be increased or decreased smoothly or to be held constant at any required value.

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Measuring pile head movement (a)

Maintained Load Test (i)

(b)

In a maintained load test, movement of the pile head shall he measured by one of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.

CRP and CRU Tests (i)

In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial gauge shall be graduated in divisions of 0.02 mm or less.


(c)

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Reference Beams and Dial Gauges (i)

An independent reference beam or beams shall be set up to enable measurement of the movement of the pile to be made to the required accuracy. The supports for a beam shall be founded in such a manner and at such a distance from the test pile and reaction system that movements of the ground do not cause movement of the reference beam or beams which will affect the accuracy of the test. The supports of the beam or beams shall be at least three test pile diameters or 2 m from the centre of the test pile, whichever distance is the greater.

(ii)

Check observations of any movements of the reference beam or beams shall be made and a check shall be made of the movement of the pile head relative to a remote reference datum at suitable intervals during the progress of the test.

(iii)

The measurement of pile movement shall be made by four dial gauges rigidly mounted on the reference beam or beams, bearing on prepared flat surfaces fixed to the pile cap or head and normal to the pile axis. Alternatively, the gauges may be fixed to the pile and bear on prepared surfaces on the reference beam or beams. The dial gauges shall be placed equidistant from the pile axis and from each other. The dial gauges shall enable readings to be made to an accuracy of at least 0.1 mm and have a stem travel of at least 25 mm. Machined spacer blocks may be used to extend the range of reading. Equivalent electrical displacement-measuring devices may be substituted.

Optical Levelling Method

An optical levelling method by reference to a remote datum may be used.

(ii)

Where a level and staff are used, the level and scale of the staff shall be chosen to enable readings to be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile cap may be used instead of a levelling staff. At least two reliable independent datum points shall be established. Each datum point shall be so situated as to permit a single setting-up position of the level for all readings.

(iii)

No datum point shall be located where it can be affected by the test loading or other operations on the Site.

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Reference Wires and Scales

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QCS 2014

(i)

Two parallel reference wires, one on either side of the pile, shall be held under constant tension at right angles to the test pile axis between supports formed as in the method in Item 11 (d). The wires shall be positioned against scales fixed to the test pile head in an axial direction and the movements of the scales relative to the wires shall be determined.

(ii)

Check observations of any movements of the supports of the wires shall be made and a check shall be made on the movement of the pile head at approved time intervals. Readings shall be taken to within an accuracy of 0.5 mm.

Other Methods (i)

The Contractor may submit for approval any other method of measuring the movement of the test pile head.

QCS 2014

Protection of testing equipment (a)

Protection from Weather (i)

(b)

Throughout the test period all equipment for measuring load and shall be protected from exposure to adverse effect of weather.

movement

Prevention of Disturbance (i)

14

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Construction activity and persons who are not involved in the testing process shall be kept at a sufficient distance from the test to avoid disturbance to the measuring apparatus. Full records shall be kept of any intermittent unavoidable activity that might affect the test set-up.

Notice of test The Contractor shall give the Engineer at least 24 hours' notice of the commencement of the test. No load shall be applied to the test pile before the commencement of the specified test procedure.

Test procedure

ta

Proof Load Test Procedure (working compression piles)

The maximum load which shall be applied in a proof test shall normally be the sum of the design verification load (DVL) plus 50 % of the specified working load (SWL). The loading and unloading shall be carried out in stages as shown in Table 4.7. Any particular requirements given in the particular contract documentation shall be complied with.

(ii)

Following each application of an increment of load, the load shall be maintained at the specified value for not less than the period shown in Table 4.7 and until the rate of settlement is less than 0.25 mm/h and decreasing. The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points.

(iii)

Each decrement of unloading shall proceed after the expiry of the period shown in Table 4.7.

(iv)

For any period when the load is constant, time and settlement shall be recorded immediately on reaching the load, at not more than 5 min intervals up to 15 min; at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and 4 h; and 1 h intervals between 4 h and 12 h after the application of the increment of load.

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(v)

Where the methods of measuring pile head movement given in Item 11 is used, the periods of time for which loads must be held constant to achieve the specified rates of settlement shall be extended as necessary to take into account the lower levels of accuracy available from these methods and to allow correct assessment of the settlement rate.

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Page 43

Table 4.7 Minimum time of holding load

25% DVL 50% DVL 75% DVL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 25% SWL 100% DVL + 50% SWL 100% DVL + 25% SWL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 50% SWL 100% DVL + 75% SWL 100% DVL + 100% SWL 100% DVL + 75% SWL 100% DVL + 50% SW 100% DVL + 25% SW 100% DVL 75% DVL 50% DVL 25% DVL 0

1h 1h 1h 1h 10 min 10 min 10 min 1h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 1h 6h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 10 min 10 min 1h

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Load *

(b)

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SWL denotes specified working load; DVL denotes design verification load. Test Procedure for Preliminary Compression Piles

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*

Applicable to tests on Preliminary Pile only

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(i)

The procedure to be adopted for carrying out load tests on preliminary compression piles shall be either the extended proof load test procedure or the constant rate of penetration testing procedure given below. A normal proof load test will constitute the first stage of such a test unless otherwise specified.

(ii)

Extended proof load test procedure. Where test pile is to be loaded up to the sum of design verification load (DVL) plus 100 % of the specified working load, the loading procedure may be carried out as a continuation of the proof load testing procedure given in Item 14 (a).

(iii)

Following the completion of the proof load test, the load shall be restored in two stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages of 25 % of the specified working load. Following each application of an increment of load, the load shall be maintained at the specified value for the period shown in Table 4.7 and until the rate of settlement is decreasing and is less than 0.25 mm/h.


Page 44

(iv)

Where verification of required minimum factor of safety is called for or the pile is to be tested to failure, the loading procedure shall be continued after reaching DVL +100 % SWL stage by increasing the load in increments of 25 % of the specified working load or other specified amount until the maximum specified load of the test is reached. Following each application of increment of load, the load shall be maintained at the specified value for not less than 1 h and until the rate of settlement is decreasing and is less than 0.25 mm/h, or other approved rate appropriate to the stage of loading and its proximity to a failure condition. Permissible settlement at the load corresponding to the required minimum factor of safety called for in the design will not normally be specified.

(v)

The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points. Reduction of load at the end of the test shall be gradual as required by Item 14 (a).and the final rebound of the pile head shall be recorded.

(vi)

Constant rate of penetration (CRP) testing procedure. Where it is required to determine the ultimate load of a preliminary compression pile, and particularly where piles are largely embedded in and bearing on clay soils, the CRP testing procedure will normally be specified.

(vii)

The rate of movement of the pile head shall be maintained constant in so far as is practicable and shall be approximately 0.01 mm/s.

(viii)

Readings of loads, penetration and time shall be made simultaneously at regular intervals; the interval chosen shall be such that a curve of load versus penetration can be plotted without ambiguity.

(ix)

Loading shall be continued until one of the following results is obtained

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QCS 2014

The maximum required test load.

2.

A constant or reducing load has been recorded for an interval of penetration of 10 mm.

ov

A total movement of the pile base equal to 10 % of the base diameter, or any other greater value of movement specified, has been reached.

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(x)

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The load shall then be reduced in five approximately equal stages to zero load, penetration and load being recorded at each stage.

Testing of Piles Designed to Carry Load in Tension (i)

The testing of piles designed to carry load in tension shall follow the same procedure as specified in 4.9.1

(ii)

In testing by the constant rate of uplift method, overall movements of the pile head will normally be less than those expected in a constant rate of penetration test. The rate of movement of the pile head shall be maintained at approximately 0.005 mm/s in so far as is practicable.

Completion of a test (a)

Removal of Test Equipment

QCS 2014

(b)


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(i)

On completion of a test and subject to the approval of the Engineer, all measuring equipment and load application devices shall be dismantled and checked. All other test equipment, including kentledge, beams and supporting structures shall be removed from the test pile location. Measuring and other demountable equipment shall be stored in a safe manner so that it is available for further tests, or removed from the Site as approved by the Engineer.

(ii)

Temporary tension piles and ground anchorages shall be cut off below ground level, and off-cut materials removed from the Site. The ground shall be restored to the original contours.

Preliminary Test Pile Cap Unless otherwise specified, the head of each preliminary test pile shall be cut off below ground level, off-cut material shall be removed from the Site and the ground restored to the original contours.

Proof Test Pile Cap

rw

On completion of a test on a proof pile, the test pile cap shall be prepared as specified and left in a state ready for incorporation into the Permanent Works. Any resulting off-cut materials shall be removed from the Site.

Presentation of results

1

Results to be submitted

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4.9.2

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(i)

During the progress of a test, all records taken shall be available for inspection by the Engineer.

(b)

Results shall be submitted as

Preliminary report of the test results to the Engineer, unless otherwise directed, within 24 hours of the completion of the test, which shall show. For a test by maintained load: for each stage of loading, the period for which the load was held, the load and the maximum pile movement at the end of the stage.

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2.

(ii)

2

For a CRP or CRU test: the maximum load reached and a graph of load against penetration or load against uplift.

The final report of recorded data as prescribed in Item 15 (b).within ten days of the completion of the test.

Schedule of Recorded Data (a)

The Contractor shall provide information about the test pile in accordance with the following schedule where applicable. (i)

General. 1.

site location contract identification

2.

proposed structure

3.

main contractor

4.

piling contractor

5.

engineer client/employer

6.


QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Pile details. 1.

all types of pile

2.

identification (number and location)

3.

specified working load (SWL)

4.

design verification load (DVL)

5.

original ground level at pile location

6.

head level at which test load was applied

7.

type of pile

8.

vertical or raking, compression or tension

9.

shape and size of cross-section of pile, and position of any change in cross-section

10.

shoe or base details

11.

head details

12.

length in ground

13.

tip Elevation

14.

dimensions of any permanent casing

15.

concrete piles

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(ii)

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concrete mix/grade



aggregate type and source



cement type and cement replacement and type where used

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admixtures

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

(iii)

16.



slump



cube test results for pile and cap



date of casting of precast pile



reinforcement

steel piles 

steel quality



coating



filling or core materials type and quality, if applicable

Installation details. 1.

2.

all piles 

dates and times of boring, driving and concreting of test pile



difficulties and delays encountered



date and time of casting concrete pile cap

bored piles 

type of equipment used and method of boring



temporary casing - diameter, type and length


Page 47

full log of pile borehole






Volume of concrete placed



driven preformed and driven cast-in-place piles



Method of support of hammer and pile driven length of pile or temporary casing at final set



Hammer type, and size or weight



Dolly and packing, type and condition



Driving log (depth, hammer drop, blows per 250 mm, interruptions or breaks in driving)



Final set in number of blows to produce penetration of 25 mm



Redrive check, time interval and set in number of blows to produce penetration of 25 mm or other agreed amount at final set and at redrive set, for a drop hammer or for a single acting hammer the length of the drop or stroke, for a diesel hammer the length of the stroke and the blows per minute, for a double acting hammer the operating pressure and the number of blows per minute



condition of pile head or temporary casing after driving



use of a follower



use of preboring



use of jetting



lengthening

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Test procedure.

mass of kentledge

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1.

tension pile, ground anchorage or compression pile details

3.

plan of test arrangement showing position and distances of kentledge supports, rafts, tension or compression piles or ground anchorages, and supports to pile movement reference system

4.

jack capacity

5.

method of load measurement

6.

method(s) of penetration or uplift measurement

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(v)

Test results. 1.

in tabular form

2.

in graphical form: load plotted against pile head movement

3.

ambient temperature records during test.

4.9.3

Low strain Integrity test

1


QCS 2014


Page 48

Grosshole Sonic Logging Test

1

This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as mentioned in Section 2

4.9.5

Calliper Logging Test

1


4.9.6

Axial Tensile Load Test

1


4.9.7

Lateral Load Test

1


4.9.8

Alternative Methods for Testing Piles

1

Scope

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4.9.4

This Part outlines the alternative methods for testing piles. A significant advance in identifying the existence of defects in construction of piles has been the development and adoption of modern integrity testing systems which may be employed to check the quality of construction when required by the Engineer.

(b)

Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance distribution, and immediate settlement characteristics, hammer transfer energy (efficiency), and pile stresses during driving. The results obtained relate directly to dynamic loading conditions.

(c)


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This Section Section 2

2

3


The testing shall be carried out by an approved firm.

(b)

The interpretation of tests shall be carried out by persons competent in the test procedure, and the full test results and findings shall normally be given to the Engineer within 10 d of the completion of each phase of testing. Full details of the ground conditions, pile dimensions and construction method shall be made available to the specialist firm when required in order to facilitate interpretation of the tests.

Integrity-testing of piles (a)

General


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(i)

Integrity-testing of piles is designed to give information about the physical dimensions, continuity and consistency of materials used in piles, and not to give direct information about the performance of piles under the conditions of loading. The methods available are normally applied to preformed concrete piles made in a single length, to steel piles and to cast-in-place concrete piles.

(ii)

This type of testing will not be regarded as a replacement for static load testing, but as a source of supplementary information.

(iii)

There is normally a limit to the length: diameter ratio of pile which can be successfully and fully investigated in this way, depending on the ground conditions.

(iv)

In the event that any anomaly is found in the results of such testing, the Engineer may call for further testing to be carried out in order to investigate the cause, nature and extent of the anomaly and whether the pile is satisfactory for its intended use.

Method of Testing

Where integrity-testing is called for but the method is not specified, the method to be adopted shall be approved by the Engineer and shall be one of the following

3.

The sonic logging method.

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The vibration method.

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Other methods may be adopted subject to the approval of the Engineer and subject to satisfactory evidence of performance.

In the case of cast-in-place concrete piles, integrity tests shall not be carried out until 7 d or more have elapsed after pile-casting, unless otherwise approved by the Engineer.

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Preparation of Pile Heads

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2.

Age of Piles at Time of Testing (i)

(d)

The sonic method.

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QCS 2014

Where the method of testing requires the positioning of sensing equipment on the pile head, the head shall be clean, free from water, laitance and loose concrete and readily accessible for the purpose of testing.

Dynamic pile-testing (a)

General (i)

Dynamic pile-testing involves monitoring the response of a pile to a heavy impact applied at the pile head. The impact is often provided by the pile-driving hammer and response is normally measured in terms of force and acceleration or displacement close to the pile head.

(ii)

The results directly obtained refer to dynamic loading conditions. Interpretation in terms of static loading requires soil- and pile-dependent adjustments, and corroboration from experience may be required to correlate dynamic testing with normal static load tests as specified in clause 4.9.1 of this Section.

(iii)

Details of the equipment to be used and of the method of analysis of test results shall be provided to the Engineer before the commencement of testing.

QCS 2014

(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Measuring Instruments (i)

(c)

All instruments affixed to the pile for the purpose of measuring stress and movement, and all equipment for receiving and processing data shall be suitable for the purpose. The equipment required to be attached to the pile shall be appropriately positioned and fixed to the approval of the Engineer.

Hammer (i)

(d)

Page 50

The hammer and all other equipment used shall be capable of delivering an impact force sufficient to mobilise the equivalent specified test load without damaging the pile.

Preparation of the Pile Head The preparation of the pile head for the application of the dynamic test load shall involve, where appropriate, trimming the head, cleaning and building up the pile using materials which will at the time of testing safely withstand the impact stresses. The impact surface shall be flat and normal to the axis of the pile.

(e)

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(i)

Time of Testing

Dynamic load tests shall be carried out at appropriate and approved times after pile installation. The time between the completion of installation and testing for a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified 28 day strength so that the pile is not damaged under the impact stresses.

Set Measurements

(g)

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Where required and appropriate, the permanent penetration per blow and temporary compression of the pile and soil system shall be measured independently of the instruments being used to record the dynamic test data.

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(i)

Results

Initial the results shall be provided to the Engineer within 24 hours of the completion of a test. These shall include

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(i)

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(f)

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(i)

The maximum force applied to the pile head.

2.

The maximum pile head velocity.

3.

The maximum energy imparted to the pile.

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1.

(ii)

Normally within 10 d of the completion of testing final report shall be given to the Engineer which includes: 1.

Date of pile installation.

2.

Date of test.

3.

Pile identification number and location.

4.

Length of pile below ground surface.

5.

Total pile length, including projection above commencing surface at time of test.

6.

Length of pile from instrumentation position to tip.

7.

Hammer type, drop and other relevant details.

8.

Blow selected for analysis.

QCS 2014


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9.

Test load achieved (i.e. total mobilised deduced static load).

10.

Pile head movement at equivalent design verification load.

11.

Pile head movement at equivalent design verification load plus 50 % of specified working load.

12.

Pile head movement at maximum applied test load.

13.

Permanent residual movement of pile head after each blow.

14.

Temporary compression.

DESIGN METHODS AND DESIGN CONSIDERATIONS

4.10.1

Design method

1

The design shall be based on one of the following approaches:

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4.10

The results of static load tests, which have been demonstrated, by means of calculations or otherwise, to be consistent with other relevant experience;

(b)

Empirical or analytical calculation methods whose validity has been demonstrated by static load tests in comparable situations;

(c)

The results of dynamic load tests whose validity has been demonstrated by static load tests in comparable situations;

(d)

The observed performance of a comparable piles foundation, provided that this approach is supported by the results of site investigation and ground testing.

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(a)

Design values for parameters used in the calculations should be in general accordance with design parameters from geotechnical investigations report, but the results of load tests may also be taken into account in selecting parameter values.

3

Static load tests may be carried out on trial piles, installed for test purposes only, before the design is finalized, or on working piles, which form part of the foundation.

4.10.2

Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations

1

When considering a limit state of rupture or excessive deformation of a structural element or section of the ground (Structural and Geotechnical), it shall be verified in accordance with (Eurocode1997-1) or equivalent.

4.10.3

Design Considerations

1

The behavior of individual piles and pile groups and the stiffness and strength of the structure connecting the piles shall be considered.

2

In selecting calculation methods and parameter values and in using load test results, the duration and variation in time of the loading shall be considered.

3

Planned future placement or removal of overburden or potential changes in the ground-water regime shall be considered, both in calculations and in the interpretation of load test results.

4

The choice of type of pile, including the quality of the pile material and the method of installation, shall take into account:

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the ground and ground-water conditions on the site, including the presence or possibility of obstructions in the ground;

(b)

the stresses generated in the pile during installation;

(c)

the possibility of preserving and checking the integrity of the pile being installed;

(d)

the effect of the method and sequence of pile installation on piles, which have already been installed and on adjacent structures or services;

(e)

the tolerances within, which the pile can be installed reliably;

(f)

the deleterious effects of chemicals in the ground;

(g)

the possibility of connecting different ground-water regimes;

(h)

the handling and transportation of piles;

(i)

the effects of pile construction on neighboring buildings.

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In considering the aspects listed above, the following items should receive attention: the spacing of the piles in pile groups;

(b)

displacement or vibration of adjacent structures due to pile installation;

(c)

the type of hammer or vibrator used;

(d)

the dynamic stresses in the pile during driving;

(e)

for those types of bored pile where a fluid is used inside the borehole, the need to keep the pressure of the fluid at a level to ensure that the borehole will not collapse and that hydraulic failure of the base will not occur;

(f)

cleaning of the base and sometimes the shaft of the borehole, especially under bentonite, to remove remolded materials;

(g)

local instability of a shaft during concreting, which may cause a soil inclusion within the pile;

(h)

ingress of soil or water into the section of a cast-in-situ pile and possible disturbance of wet concrete by the flow of water through it;

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the effect of unsaturated sand layers around a pile extracting water from the concrete;

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(j)

the retarding influence of chemicals in the soil;

(k)

soil compaction due to the driving of displacement piles;

(l)

soil disturbance due to the boring of a pile shaft.

4.11

AXIALLY LOADED PILES

4.11.1

Limit state design

1

The design shall demonstrate that exceeding the following limit states is sufficiently improbable: (a)

ultimate limit states of compressive or tensile resistance failure of a single pile;

(b)

ultimate limit states of compressive or tensile resistance failure of the pile foundation as a whole;

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(c)

ultimate limit states of collapse or severe damage to a supported structure caused by excessive displacement or differential displacements of the pile foundation;

(d)

serviceability limit states in the supported structure caused by displacement of the piles.

Normally the design should consider the margin of safety with respect to compressive or tensile resistance failure, which is the state in which the pile foundation displaces significantly downwards or upwards with negligible increase or decrease of resistance.

3

For piles in compression it is often difficult to define an ultimate limit state from a load settlement plot showing a continuous curvature. In these cases, settlement of the pile top equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

4

For piles that undergo significant settlements, ultimate limit states may occur in supported structures before the resistance of the piles is fully mobilized. In these cases a cautious estimate of the possible range of the settlements shall be adopted in design.

4.11.2

Compressive Ground Resistance

1

To demonstrate that the pile foundation will support the design load with adequate safety against compressive failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations:

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Fc ≤ Rc

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Where

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Fc: design axial compression load on a pile or a group of piles

In principle Fc should include the weight of the pile itself and Rc should include the overburden pressure of the soil at the foundation base. However these two items may be disregarded if they cancel approximately. They need not cancel if: (a)

downdrag is significant; the soil is very light,

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Rc: design value

(c) 3

the pile extends above the surface of the ground.

For piles in groups, two failure mechanisms shall be taken into account: (a)

compressive resistance failure of the piles individually;

(b)

compressive resistance failure of the piles and the soil contained between them acting as a block.

NOTE: The design resistance shall be taken as the lower value caused by these two

mechanisms. 4

The compressive resistance of the pile group acting as a block may be calculated by treating the block as a single pile of large diameter.

5

The stiffness and strength of the structure connecting the piles in the group shall be considered when deriving the design resistance of the foundation.

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If the piles support a stiff structure, advantage may be taken of the ability of the structure to redistribute load between the piles. A limit state will occur only if a significant numbe r of piles fail together; therefore a failure mode involving only one pile need not be considered.

7

If the piles support a flexible structure, it should be assumed that the compressive resistance of the weakest pile governs the occurrence of a limit state.

8

Special attention should be given to possible failure of edge piles caused by inclined or eccentric loads from the supported structure.

9

If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer on the compressive resistance of the foundation shall be considered.

10

The strength of a zone of ground above and below the pile base shall be taken into account when calculating the pile base resistance.

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NOTE: This zone may extend several diameters above and below the pile base. Any weak ground in this zone has a relatively large influence on the base resistance.

Punching failure should be considered if weak ground is present at a depth of less than 4 times the base diameter below the base of the pile.

12

Where the pile base diameter exceeds the shaft diameter, the possible adverse effect shall be considered.

13

For open-ended driven tube or box-section piles with openings of more than 500 mm in any direction, and without special devices inside the pile to induce plugging, the base resistance should be limited to the smaller of:

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11

the shearing resistance between the soil plug and the inside face of the pile;

(b)

the base resistance derived using the cross-sectional area of the base.

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(a)

Ultimate compressive resistance from static load tests

1

The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be specified in the Geotechnical Design Report.

2

Trial piles to be tested in advance shall be installed in the same manner as the piles that will form the foundation and shall be founded in the same stratum.

3

If the diameter of the trial pile differs from that of the working piles, the possible difference in performance of piles of different diameters should be considered in assessing the compressive resistance to be adopted.

4

In the case of a very large diameter pile, it is often impractical to carry out a load test on a full size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

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4.11.3

(a)

the ratio of the trial pile diameter/working pile diameter is not less than 0,5;

(b)

the smaller diameter trial pile is fabricated and installed in the same way as the piles used for the foundation;

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the trial pile is instrumented in such a manner that the base and shaft resistance can be derived separately from the measurements.

NOTE: This approach should be used with caution for open-ended driven piles because of the influence of the diameter on the mobilisation of the compressive resistance of a soil plug in the pile. In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a displacement that equals the criterion for the verification of the ultimate limit state determined from the load test results, shall be corrected. The correction shall be achieved by subtracting the measured, or the most unfavorable, positive shaft resistance in the compressible stratum and in the strata above, where negative skin friction develops, from the loads measured at the pile head.

6

During the load test of a pile subject to downdrag, positive shaft friction will develop along the total length of the pile. The maximum test load applied to the working pile should be in excess of the sum of the design external load plus twice the downdrag force.

7

When deriving the ultimate characteristic compressive resistance from values measured in one or several pile load tests, an allowance shall be made for the variability of the ground and the variability of the effect of pile installation.

8

The systematic and random components of the variations in the ground shall be recognized in the interpretation of pile load tests.

9

The records of the installation of the test pile(s) shall be checked and any deviation from the normal execution conditions shall be accounted for.

10

The characteristic compressive resistance of the ground may be derived from the characteristic values of the base resistance and of the shaft resistance in accordance with Eurocode1997-1.

4.11.4

Ultimate compressive resistance from ground test results

1

Methods for assessing the compressive resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as described as following to ensure that the predicted compressive resistance is sufficiently safe :

3

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(a)


(b)

any systematic errors known to be associated with the method of analysis

In assessing the validity of a model based on ground test results, the following items should be considered: (a)

soil type, including grading, mineralogy, angularity, density, pre-consolidation, compressibility and permeability;

(b)

method of installation of the pile, including method of boring or driving;

(c)

length, diameter, material and shape of the shaft and of the base of the pile (e.g. enlarged base);

(d)

method of ground testing.

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4.11.5

Ultimate compressive resistance from dynamic impact tests

1

Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration versus time during the impact event is used to assess the resistance of individual compression piles, the validity of the result shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type of similar length and cross-section and in similar ground conditions.

2

When using a dynamic impact load test, the driving resistance of the pile should be measured directly on the site in question.

.

NOTE A load test of this type can also include a process of signal matching to measured stress wave figures. Signal matching enables an approximate evaluation of shaft and base resistance of the pile as well as a simulation of its load-settlement behaviour. The impact energy shall be high enough to allow for an appropriate interpretation of the pile capacity at a correspondingly high enough strain level.

4

The design value of the compressive resistance of the pile could be calculated and verified according to Eurocode1997-1.

4.11.6

Ultimate compressive resistance by applying pile driving formulae

1

Pile driving formulae shall only be used if the stratification of the ground has been determined.

2

If pile driving formulae are used to assess the ultimate compressive resistance of individual piles in a foundation, the validity of the formulae shall have been demonstrated by previous experimental evidence of acceptable performance in static load tests on the same type of pile, of similar length and cross-section, and in similar ground conditions.

3

For end-bearing piles driven into non-cohesive soil, the design value of the compressive resistance shall be assessed by the same procedure as in 4.11.5.

4

When a pile driving formula is applied to verify the compression resistance of a pile, the pile driving test should have been carried out on at least 5 piles distributed at sufficient spacing in the piling area in order to check a suitable blow count for the final series of blows.

5

The penetration of the pile point for the final series of blows should be recorded for each pile.

4.11.7

Ultimate compressive resistance from wave equation analysis

1

Wave equation analysis shall only be used where stratification of the ground has been determined by borings and field tests.

2

Where wave equation analysis is used to assess the resistance of individual compression piles, the validity of the analysis shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type, of similar length and cross- section, and in similar ground conditions.

3

The design value of the compressive resistance derived from the results of wave equation analysis of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.

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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving equipment without stress wave measurements on site. The method is usually applied to study hammer performance, dynamic soil parameters and stresses in the pile during driving. It is also, on the basis of the models, possible to determine the required driving resistance (blow count) that is usually related to the expected compressive resistance of the pile. Ground tensile resistance

1

The design of piles in tension shall be consistent with the design rules given in 4.11.2, where applicable. Design rules that are specific for foundations involving piles in tension are presented below.

2

To verify that the foundation will support the design load with adequate safety against a failure in tension, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations in accordance with Eurocode1997-1.

3

For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

4

When considering the uplift of the block of ground containing the piles the shear resistance along the sides of the block may be added to the resisting forces.

5

Normally the block effect will govern the design tensile resistance if the distance between the piles is equal to or less than the square root of the product of the pile diameter and the pile penetration into the main resisting stratum.

6

The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft resistances of individual piles in the group, shall be considered when assessing the tensile resistance of a group of piles.

7

The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be considered.

8

Comparable experience based on pile load tests should be applied to appraise this effect.

4.11.9

Ultimate tensile resistance from pile load tests

1

Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in accordance with 4.9.1 and with regard to 4.11.3.

2

The design tensile resistance could be calculated and verified according to Eurocode1997-1.

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4.11.8

4.11.10 Ultimate tensile resistance from ground test results 1

Methods for assessing the tensile resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as following to ensure that the predicted tensile resistance is sufficiently safe. (a)


(b)

any systematic errors known to be associated with the method of analys is

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The design value of tensile resistance of a pile could be calculated and verified according to Eurocode1997-1.

4.11.11 Vertical displacements of pile foundations 1

Vertical displacements under serviceability limit state conditions shall be assessed and checked.

2

When calculating the vertical displacements of a pile foundation, the uncertainties involved in the calculation model and in determining the relevant ground properties should be taken into account. Hence it should not be overlooked that in most cases calculations will provide only an approximate estimate of the displacements of the pile foundation.

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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety requirements for the ultimate limit state design are normally sufficient to prevent a serviceability limit state in the supported structure.

The occurrence of a serviceability limit state in the supported structure due to pile settlements shall be checked, taking into account downdrag, where probable.

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4.11.12 Pile foundations in compression

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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to satisfy serviceability limit state conditions. Assessment of settlements shall include both the settlement of individual piles and the settlement due to group action.

3

The settlement analysis should include an estimate of the differential settlements that may occur.

4

When no load test results are available for an analysis of the interaction of the piled foundation with the superstructure, the load-settlement performance of individual piles should be assessed on empirically established safe assumptions.

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4.11.13 Pile foundations in tension The assessment of upward displacements shall be done and Particular attention should be paid to the elongation of the pile material.

2

When very severe criteria are set for the serviceability limit state, a separate check of the upward displacements shall be carried out.

4.12

TRANSVERSELY LOADED PILES

4.12.1

Design method

1

The design of piles subjected to transverse loading shall be consistent with the design rules given in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to transverse loading are presented below.

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To demonstrate that a pile will support the design transverse load with adequate safety against failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations: Ftr ≤ Rtr Where; Ftr: design value of the transverse load on a pile or a pile foundation Rtr : design resistance of transversally loaded pile One of the following failure mechanisms should be considered: for short piles, rotation or translation as a rigid body;

(b)

for long slender piles, bending failure of the pile, accompanied by local yielding and displacement of the soil near the top of the pile.

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The group effect shall be considered when assessing the resistance of transversely loaded piles.

5

It should be considered that a transverse load applied to a group of piles may result in a combination of compression, tension and transverse forces in the individual piles.

4.12.2

Transverse load resistance from pile load tests

1

Transverse pile load tests shall be carried out in accordance with 4.9.6.

2

Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not normally be continued to a state of failure. The magnitude and line of action of the test load should simulate the design loading of the pile.

3

An allowance shall be made for the variability of the ground, particularly over the top few meters of the pile, when choosing the number of piles for testing and when deriving the design transverse resistance from load test results.

4

Records of the installation of the test pile(s) should be checked, and any deviation from the normal construction conditions should be accounted for in the interpretation of the pile load test results. For pile groups, the effects of interaction and head fixity should be accounted for when deriving the transverse resistance from the results of load tests on individual test piles.

4.12.3

Transverse load resistance from ground test results and pile strength parameters

1

The transverse resistance of a pile or pile group shall be calculated using a compatible set of structural effects of actions, ground reactions and displacements.

2

The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile in the ground.

3

The calculation of the transverse resistance of a long slender pile may be carried out using the theory of a beam loaded at the top and supported by a deformable medium characterized by a horizontal modulus of subgrade reaction.

4

The degree of freedom of rotation of the piles at the connection with the structure shall be taken into account when assessing the foundation’s transverse resistance.

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4.12.4

Transverse displacement

1

The assessment of the transverse displacement of a pile foundation shall take into account: the stiffness of the ground and its variation with strain level;

(b)

the flexural stiffness of the individual piles;

(c)

the moment fixity of the piles at the connection with the structure;

(d)

the group effect;

(e)

the effect of load reversals or of cyclic loading

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END OF PART

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RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

5.1

GENERAL---------------------------------------------------------------------------------------------------------- 2

5.2

LIMIT STATES ---------------------------------------------------------------------------------------------------- 2

5.2.2 5.2.3

Ultimate Limit State ---------------------------------------------------------------------------------------------- 2 Serviceability Limit State ---------------------------------------------------------------------------------------- 3

5.3

ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3

5.3.1 5.3.2 5.3.3

Actions -------------------------------------------------------------------------------------------------------------- 3 Geometrical data ------------------------------------------------------------------------------------------------- 4 Design Situations ------------------------------------------------------------------------------------------------- 4

5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

5.5

DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General ------------------------------------------------------------------------------------------------------------- 6 At rest values of earth pressure------------------------------------------------------------------------------- 7 Limiting values of earth pressure ----------------------------------------------------------------------------- 7 Intermediate values of earth pressure ----------------------------------------------------------------------- 7 Compaction effects ---------------------------------------------------------------------------------------------- 7

5.6

WATER PRESSURES ------------------------------------------------------------------------------------------ 8

5.7

ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8

5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7

General ------------------------------------------------------------------------------------------------------------- 8 Overall stability ---------------------------------------------------------------------------------------------------- 8 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8 Rotational failure of embedded walls ------------------------------------------------------------------------ 8 Vertical failure of embedded walls --------------------------------------------------------------------------- 9 Structural design of retaining structures -------------------------------------------------------------------- 9 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9

5.8

SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9

5.8.1 5.8.2

General ------------------------------------------------------------------------------------------------------------- 9 Displacements ---------------------------------------------------------------------------------------------------- 9

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5

RETAINING STRUCTURES

5.1

GENERAL

1

The provisions of this Part 5 apply to retaining structures in general. These are structures used to retain ground comprising soil, rock or backfill and water and this at an angle steeper than the angle they would normally adopt without the presence of those structures. Common retaining structures used within the state of Qatar taking into account the prevailing geologic conditions are: Sheet Piles

(b)

Bored and Cast in Place Concrete Piles

Secant Piles

(c)

Diaphragm Walls

(d)

Composite Shoring Systems

(e)

Concrete Retaining Walls

(ii)

Counter Fort Retaining Wall

(iii)

Gravity Retaining Wall

(iv)

Buttressed Retaining Wall

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Cantilever Retaining Wall

Reinforced Soil Retaining Structures Geogrid and Geotextile Reinforced Earth Systems

(ii)

Galvanized Strips Reinforced Earth System

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(i)

Soil and Rock Nailing Systems

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Contiguous Piles

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(a)

This revision of Section 4 – Part 5 is considered preliminary and shall be reviewed and amended as needed in the next revision to elaborate on various subjects not covered herein.

3

This revision of Section 4 – Part 5 is based generally on “EN1997-1:2004+A1:2013” Eurocode 7.

4

Section 4 – Part 5 will cover at this stage the general design aspects knowing that the construction procedures shall be added in future revisions of this Section. Hence, at this stage, the construction related subjects of the retaining structures will follow relevant Parts of the QCS.

5.2

LIMIT STATES

1

During the design of retaining structures the following typical limit states should be considered:

5.2.2

Ultimate Limit State

1

Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.

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Foundation failure of retaining structures with footings: it should be demonstrated that the foundation pressures (lateral and vertical) do not exceed neither the ground allowable bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to water seepage should also be included in the analysis.

3

Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a rigid body.

4

Failure of embedded walls by rotation or horizontal translation or by lack of vertical equilibrium.

5

Failure of a structural element such as a wall, anchorage, wale or strut, including failure of the connection between those elements.

6

Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable leakage of water, or transport of soil particles through or under the wall caused by excessive hydraulic gradients.

5.2.3

Serviceability Limit State

1

Unacceptable movement of the retaining structure, which may affect the appearance or functionality of the structure itself, or other neighbouring structures or utilities influenced by the movement.

2

Unacceptable change in the groundwater regime.

5.3

ACTIONS AND GEOMETRICAL DATA

5.3.1

Actions

1

Generally, the forces exerted on retaining structure with values assumed known at the beginning of the calculation are considered as 'actions', while forces with initially unknown values, to be determined by the interaction of the retaining structure with support elements (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following actions are to be taken into account: Weight of backfill material

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(b)

Surcharges

(c)

Weight of water

(d)

Wave forces for marine projects

(e)

Seepage forces

(f)

Collision forces

(g)

Temperature effects

(h)

Forces from propping elements (i.e. post-tensioned anchors)

(i)

Siesmic related effects

The above actions should result in the determination of various earth pressures acting on the retaining structure.

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5.3.2

Geometrical data

1

This paragraph covers the uncertainties in the geometrical data namely excavation and water levels. In general, small variations in geometrical data are considered to be covered by the safety factors included in the calculations. However, since the design of retaining structures is sensitive to ground and water levels, special requirements are included in this paragraph, mainly for unforeseen over-dig in front of the wall and groundwater levels change on both sides of the wall.

2

Unforeseen over-dig in front of the wall

Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for cantilever walls;

(b)

Equal to 10% of the distance between the lowest support and the excavation level (up to a maximum of 0.5 m), for supported walls.

Groundwater levels in front of and behind the wall

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In Ultimate Limit State design calculations, where the wall stability depends on the earth resistance in front of the wall, the level of the resisting soil should be lowered below the nominally expected level by an amount which depends on the degree of control on the excavation level. With a normal degree of control the expected difference in resisting soil level should be:

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The selection of the levels of the phreatic surfaces in front of and behind the wall must consider long-term variations of the groundwater regime and/or the ground permeability, the presence of perched or artesian aquifers and the possibility that drainage behind the wall may cease to function with time. Design Situations

1

The following conditions shall be considered during the design of retaining structures: Anticipated variations in soil properties

(b)

Variations in actions and the ways they are combined

(c)

Excavation, scour or erosion in front of the retaining structure The effect of compaction of the backfill behind the retaining structure

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5.3.3

(e)

The effect of anticipated future structures and surcharge loads/unloads

(f)

Anticipated ground movements

(g)

Inclination of the wall to the vertical

(h)

Variations in groundwater table and the seepage forces in the ground

(i)

Horizontal as well as vertical equilibrium for the entire retaining structure

(j)

The shear strength and weight density of the ground

(k)

The rigidity of the wall and the supporting system

(l)

The wall roughness

(m)

Seismic effect on the various forces

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5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS

1

The design of retaining structures requires consideration of all relevant Ultimate Service States and Service Limit States.

2

For retaining structures without strict serviceability requirements, the geometry is usually determined by Ultimate Limit State design calculations and checked by Service Limit State calculations (if relevant). For the retaining structures with strict serviceability requirements, the Service Limit State requirements often govern the design.

3

The design and construction considerations should cover the following: Demonstrate that vertical equilibrium can be achieved for the assumed pressure distributions and actions on the wall.

(b)

Verification of vertical equilibrium may be achieved by reducing the wall friction parameters.

(c)

Retaining walls should be designed in such a way that there are visible signs of the approach of an ultimate limit state. The design should prevent brittle failure of the structure, e.g. sudden collapse without conspicuous preliminary deformations.

(d)

A critical limit state should be considered to occur if the wall has displaced enough to cause damage to nearby structures or services. Although collapse of the wall may not be imminent, the degree of damage may considerably exceed a serviceability limit state in the supported structure.

(e)

The design methods and partial factor values recommended by “EN19971:2004+A1:2013” are usually sufficient to prevent the occurrence of ultimate limit states in nearby structures, provided that the soils involved are of at least medium density or firm consistency and adequate construction methods and sequences are adopted. Special care should be taken, however, with some highly over-consolidated clay deposits in which large at rest horizontal stresses may induce substantial movements in a wide area around excavations.

(f)

The complexity of the interaction between the ground and the retaining structure sometimes makes it difficult to design a retaining structure in detail before the actual execution starts. In this case, use of the observational method for the design should be considered. The observational method consists of setting criteria enabling monitoring during construction, allowing necessary corrective actions to be taken to rectify the design. Hence, the following requirements shall be set before construction:

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(a)

(g)

(i)

Acceptable limits of behaviour

(ii)

The range of potential behaviour shall be analysed showing acceptable probability that the actual behaviour will be within the acceptable limits

(iii)

A plan of monitoring shall be established (including necessary instruments and procedures) enabling the comparison of the actual behaviour to the acceptable limits. The monitoring shall allow early detection of nonconformities, allowing enough time for corrective actions to be taken successfully.

(iv)

A list of contingency actions shall be established which could be used if the actual observed behaviour is outside of the acceptable limits.

The effects of constructing the wall, including: (i)

The provision of temporary support to the sides of excavations;

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(ii)

The changes of in situ stresses and resulting ground movements caused both by the wall excavation and its construction;

(iii)

Disturbance of the ground due to driving or boring operations;

(iv)

Provision of access for construction;

The required degree of water tightness of the finished wall;

(i)

The practicability of constructing the wall to reach a stratum of low permeability, so forming a water cut-off. The resulting equilibrium ground-water flow problem shall be assessed;

(j)

The practicability of forming ground anchorages in adjacent ground;

(k)

The practicability of excavating between any propping of retaining walls;

(l)

The ability of the wall to carry vertical load;

(m)

The ductility of structural components;

(n)

Access for maintenance of the wall and any associated drainage measures;

(o)

The appearance and durability of the wall and any anchorages;

(p)

For sheet piling, the need for a section stiff enough to be driven to the design penetration without loss of interlock;

(q)

The stability of borings or slurry trench panels while they are open;

(r)

For fill, the nature of materials available and the means used to compact them adjacent to the wall.

(s)

Drainage systems

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If the safety and serviceability of the designed structure depend on the successful performance of a drainage system, the consequences of its failure shall be considered, taking into account both safety and cost of repair. One of the following conditions (or a combination of them) shall apply: A maintenance program for the drainage system shall be specified and the design shall allow access for this purpose;

(ii)

It shall be demonstrated both by comparable experience and by assessment of any water discharge that the drainage system will operate adequately without maintenance.

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The quantities, pressures and eventual chemical content of any water discharge should be taken into account.

5.5

DETERMINATION OF EARTH PRESSURES

5.5.1

General

1

The Determination of the earth pressures shall take into account the acceptable mode and amount of any movement and strain, which may occur at the limit state under consideration.

2

In the following context the words "earth pressure" should also be used for the total earth pressure from soft and weathered rocks and should include the pressure of ground-water.

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3

Calculations of the magnitudes of earth pressures and directions of forces resulting from them shall take account of the issues highlighted under paragraph “5.3.3”.

4

The amount of mobilized wall friction and adhesion should be considered as a function of: The strength parameters of the ground

(b)

The friction properties of the wall-ground interface

(c)

The direction and amount of movement of the wall relative to the ground

(d)

The ability of the wall to support any vertical forces resulting from wall friction and adhesion

A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a design wall ground interface parameter  d  k. cv ;d . k should not exceed 2/3 for precast

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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be assumed. For a steel sheet pile in clay under undrained conditions immediately after driving, no adhesive or frictional resistance should be assumed. Increases in these values may take place over a period of time. In the case of structures retaining rock masses, calculations of the ground pressures shall take into account the effects of discontinuities, with particular attention to their orientation, spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

7

Account shall be taken of any swelling potential of the ground when calculating the pressures on the retaining structure.

5.5.2

At rest values of earth pressure

1

When no movement of the wall relative to the ground takes place, the earth pressure shall be calculated from the at rest state of stress. The determination of the at-rest state shall take into account the stress history of the ground.

5.5.3

Limiting values of earth pressure

1

Limiting values of earth pressures shall be determined taking into account the relative movement of the soil and the wall at failure and the corresponding shape of the failure surface.

5.5.4

Intermediate values of earth pressure

1

Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize the limiting values. The determination of the intermediate values of earth pressure shall take into account the amount of wall movement and its direction relative to the ground.

2

The intermediate values of earth pressures may be calculated using, for example, various empirical rules, spring constant methods or finite element methods.

5.5.5

Compaction effects

1

The determination of earth pressures acting behind the wall shall take into account the additional pressures generated by any placing of backfill and the procedures adopted for its compaction.

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WATER PRESSURES

1

Determination of characteristic and design water pressures shall take account of water levels both above and in the ground.

2

When checking the ultimate and serviceability limit water pressures shall be accounted for in the combinations of actions considering the possible risks of flooding or change in groundwater levels from either sides of the retaining structure.

3

For structures retaining earth of medium or low permeability (silts and clays), water pressures should normally be assumed to act behind the wall. Unless a reliable drainage system is installed, or infiltration is prevented, the values of water pressures should normally correspond to a water table at the surface of the retained material.

4

Where sudden changes in a free water level may occur, both the non-steady condition occurring immediately after the change and the steady condition shall be examined.

5

Where no special drainage or flow prevention measures are taken, the possible effects of water-filled tension or shrinkage cracks shall be considered.

5.7

ULTIMATE LIMIT STATE DESIGN

5.7.1

General

1

The design of retaining structures shall be checked at the ultimate limit state for the design situations appropriate to that state, as specified in 5.3.3, using the design actions or action effects and design resistances.

2

All relevant limit modes shall be considered. These will include, as a minimum, limit modes of the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.

3

Calculations for ultimate limit states shall establish that equilibrium can be achieved using the design actions or effects of actions and the design strengths or resistances. Compatibility of deformations shall be considered in assessing design strengths or resistances.

5.7.2

Overall stability

1

Principles and calculations should be used as appropriate to demonstrate that an overall stability failure will not occur and that the corresponding deformations are sufficiently small taking into account progressive failure and liquefaction into account as relevant.

5.7.3

Foundation failure of gravity walls

1

The principles of foundation design shall be used as appropriate to demonstrate that a foundation failure is sufficiently remote and that deformations will be acceptable. Both bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should be verified as a minimum.

5.7.4

Rotational failure of embedded walls

1

It shall be demonstrated by equilibrium calculations that embedded walls have sufficient penetration into the ground to prevent rotational failure. As a minimum, limit modes of the types illustrated in Figure 5.3 should be considered.

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The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the relative vertical displacement, which would occur in the design situation.

5.7.5

Vertical failure of embedded walls

1

It shall be demonstrated that vertical equilibrium can be achieved using the design soil strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode of the type illustrated in Figure 5.4 should be considered.

2

Where downward movement of the wall is considered, upper design values shall be used in the calculation of pre-stressing forces, such as those from ground anchorages, which have a vertical downward component. The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the check for vertical and rotational equilibrium. If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using the principles of Pile Foundations Design.

5.7.6

Structural design of retaining structures

1

Retaining structures, including their supporting structural elements such as anchorages and props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013 “2.4 Geotechnical Design by Calculation” and EN1992, EN1993, EN1995 and EN1996. As a minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

5.7.7

Failure by pull-out of anchorages

1

It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground anchorages. Anchors shall be designed in accordance with Anchorage Design procedures with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also be considered.

5.8

SERVICEABILITY LIMIT STATE DESIGN

5.8.1

General

1

The design of retaining structures shall be checked at the serviceability limit state using the appropriate design situations as specified in 5.3.3. The assessment of design values of earth pressures should take account of the initial stress, stiffness and strength of the ground and the stiffness of the structural elements.

2

The design values of earth pressures should be derived taking account of the allowable deformation of the structure at its serviceability limit state. These pressures need not necessarily be limiting values.

5.8.2

Displacements

1

Limiting values for the allowable displacements of walls and the ground adjacent to them shall be established for a particular deformation is the value at which a serviceability limit state, such as unacceptable cracking or displacement of adjacent structures or utilities, is deemed to occur. This limiting value shall be agreed during the design, taking into account the tolerance to displacements of supported structures and services.

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2

If the initial cautious estimate of displacement exceeds the limiting values, the design shall be justified by a more detailed investigation including displacement calculations.

3

It shall be considered to what extent variable actions, such as vibrations caused by traffic loads behind the retaining wall, contribute to the wall displacement.

4

Displacement calculations should also be considered in the following cases: (a)

where the wall retains more than 6m of cohesive soil of low plasticity,

(b)

where the wall retains more than 3m of soils of high plasticity;

(c)

where the wall is supported by soft clay within its height or beneath its base.

Displacement calculations shall take into account the stiffness of the ground and structural elements and the sequence of construction.

6

The effect of vibrations on displacements shall be considered with regard to the following:

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Foundations for structures subjected to vibrations or to vibrating loads shall be designed to ensure that vibrations will not cause excessive settlements.

(b)

Precautions should be taken to ensure that resonance will not occur between the frequency of the dynamic load and a critical frequency in the foundation-ground system, and to ensure that liquefaction will not occur in the ground.

(c)

Vibrations caused by earthquakes shall be considered using the guidelines of the designated section of the QCS.

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(a)

Figure 5.1 – Examples of Limit Modes for Overall Stability of Retaining Structures (EN 1997-1:2004+A1:2013)


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Figure 5.2 – Examples of Limit Modes for Foundation Failures of Gravity Walls (EN 1997-1:2004+A1:2013)

Figure 5.3 – Examples of Limit Modes for Rotational Failures of Embedded Walls (EN 1997-1:2004+A1:2013)


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Figure 5.4 – Example of a Limit Mode for Vertical Failure of Embedded Walls (EN 1997-1:2004+A1:2013)

Figure 5.5 – Examples of Limit Modes for Structural Failure of Retaining Structures (EN 1997-1:2004+A1:2013)


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Figure 5.6 – Examples of Limit Modes for Failure by Pull-out of Anchoes (EN 1997-1:2004+A1:2013)

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END OF PART

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Page 1

GENERAL------------------------------------------------------------------------------------------------------------ 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4

INTRODUCTION --------------------------------------------------------------------------------------------------- 2 Scope ----------------------------------------------------------------------------------------------------------------- 2 References----------------------------------------------------------------------------------------------------------- 2 Definitions ------------------------------------------------------------------------------------------------------------ 3 Approved Products ------------------------------------------------------------------------------------------------ 4

1.2 1.2.1 1.2.2 1.2.3 1.2.4

IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4 Approved Installers ------------------------------------------------------------------------------------------------ 4 Field Quality Control ----------------------------------------------------------------------------------------------- 4 Rejected materials ------------------------------------------------------------------------------------------------- 5 Records --------------------------------------------------------------------------------------------------------------- 5

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GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section includes the requirements for concrete work for pipelines, roadworks, runways, structures, water retaining structures, foundations and bases for structures and equipment.

2

This Part includes relevant standards, definitions, abbreviations, and requirements for testing facilities, rejected materials, and record keeping.

3


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Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing of Concrete Formwork Curing Reinforcement Construction Joints Inspection and Testing of Hardened Concrete Protective Coatings to Concrete Hot Weather Concrete Miscellaneous Precast Concrete Prestressed Concrete Water Retaining Structures

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This Section: Part 2, Part 3, Part 4, Part 5, Part 6, Part 7, Part 8, Part 9, Part 10, Part 11, Part 12, Part 13, Part 14, Part 15, Part 16, Part 17, Part 18, Part 19,

.

1

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Section 1, Section 2, Section 4, Section 6, Section 8, Section 9,

General Quality Assurance and Quality Control Foundations and Retaining Structures Roadworks Drainage Works Mechanical and Electrical Equipment

1.1.2

References

1

The following standards are referred to in this Part: ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in the Field ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete

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Page 3

BS 6100, ....................Glossary of Building and civil engineering terms BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing laboratory samples BS EN 12350-1 ..........Method of sampling fresh concrete in site BS EN 12350-2 ..........Testing fresh concrete. Slump-test BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2 .......... Making and curing specimens for strength tests GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – Part 2: Properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – Part 3: Making and curing test specimens Definitions

1

Definitions used in this Section.

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1.1.3

The following are terms and abbreviations used:

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degree Celsius calorie centimetre day Characteristic compressive strength of concrete determined by testing cylinders Compressive strength of concrete determined by testing cylinders Characteristic compressive strength of concrete determined by testing cubes Compressive strength of concrete determined by testing cubes Mean compressive strength of concrete Mean compressive strength of concrete at the age of (j) days ground granulated blast furnace slag guaranteed ultimate tensile strength hour kilogram kilojoule kilonewton litre metre square metre cubic metre milligram minute millimetre square millimetre months mega Pascal kilo Pascal moderate sulphate resisting Portland cement ordinary Portland cement pulverised fuel ash polyvinylchloride second silica fume sulphate resisting Portland cement

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C cal cm d fck,cyl fc,cyl fck,cube fc,cube fcm fcm,j GGBS GUTS h kg kJ kN l m 2 m 3 m mg min mm 2 mm months MPa kPa MSRPC OPC PFA PVC s SF SRPC

QCS 2014

ton ppm

1000 kg part per million

micron

10

µm

10 meter

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-6 -6

Reference to a technical society, institution, association or governmental authority is made in accordance with the following abbreviations.

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American Association of State Highway and Transportation Officials American Concrete Institute American Society for Testing and Materials American Welding Society British Standard British Standard Code of Practice British Standards Institution Cement and Concrete Association Construction Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institut fur Normung e.V. Euro Norm Federal Highway Authority GCC Standardization Organization Institution of Civil Engineers International Organization for Standardization Prestressed Concrete Institute Qatar Construction Specifications Qatar Standards United Kingdom Department for Transport

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AASHTO ACI ASTM AWS BS BSCP BSI C & CA CIRIA CRSI CS DIN EN FHWA GSO ICE ISO PCI QCS QS UK DfT Products

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Approved Products

1

The contract specific documentation may identify approved products and approved or prequalified manufacturers and suppliers of products used in concrete work.

1.2

IMPLEMENTATION

1.2.1

Approved Installers

1

The contract specific documentation may identify approved or prequalified providers of concrete construction services.

1.2.2


1

The Contractor shall carry out the test procedures required by this Section and any other tests and test procedures as directed by the Engineer from time to time. The test procedures shall be carried out using the facilities of an approved independent testing laboratory.

2

Supply, storage, sampling and testing of all materials shall be the responsibility of the Contractor, unless the Contract specifies otherwise.

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1.1.4

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The Engineer may also require the Contractor to take samples of materials and deliver them to the Central Materials Laboratory for additional tests to be carried out by the Employer. Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards, and sample sizes shall conform to the requirements shown in Table 1.1.

4

The minimum equipment required for testing on Site is given in Table 1.2. This equipment shall be maintained on Site at all times during concreting operations together with the necessary scoops, buckets, sample containers, and other items required for sampling. The cube curing tank shall be located in an air-conditioned area as stated in part 06.

1.2.3

Rejected materials

1

Any material rejected by the Engineer, in particular cement which has deteriorated or aggregates which have segregated or become contaminated, shall be immediately removed from the Site.

1.2.4

Records

1

The Contractor shall maintain on the Site full records of all work carried out accurately related to the location of the work on site, which shall include:

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formwork props were fully removed all cubes and other tests

(c)

daily maximum and minimum temperatures.

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One copy of all test results shall be sent to the Engineer immediately upon completion of the tests

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Table 1.1 Sampling Procedure and Minimum Sample Sizes for Central Materials Laboratory

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Cement

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Material

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the time and date when all concrete was poured, formwork removed and when

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3

Aggregate

Reinforcement Water

Test

Min. Sample

Full range of tests

Composite sample of 7 kg taken from at least 12 bags

Full range of tests

200 kg

Sieve analysis Chemical analysis Soundness test Water absorption Particle density Flakiness index Fines content LA Abrasion value

50 kg

Tensile test

500 mm

Bend test

300 mm

Full range of tests

5 litres

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Page 6

Table 1.2 Minimum Testing Equipment for Each Site* Test

Equipment to be Provided

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ASTM C1064

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Cube curing BS EN 12390-2 or GSO ISO 1920-3 or ASTM C39

Hessian or sacking, impervious sheet Maximum/minimum thermometer Waterproof marking crayon/paint or equivalent Curing tank (in air conditioned room) Supply of packing materials for sending cubes to commercial laboratory Concrete thermometer

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Cube making BS EN 12390-1 and BS EN 12350-1:2000 or GSO ISO 1920-1 and GSO ISO 1920-3 or ASTM C31 and C39

Slump cone with base plate Compacting rod, circular cross-section and round ends Remixing container, 300 mm ruler, moist cloth Scoop and shovel Timer 100 or 150 mm cubical or cylindrical 1 moulds Compacting rod or bar Set of tools for assembling and stripping moulds Remixing container Trowel, Scoop, Shovel and Mallet Mould release agent in closed container with brush

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Slump test BS EN 12350-2 or GSO ISO 1920-2 or ASTM C143

Minimum Number Required 1 1 1 1 1

6 1 1 1 lot 1 1 1 Lot 1

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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate size is not greater than 20mm

END OF PART

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Page 1

CURING .................................................................................................................. 2

10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2 Storage 2

10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12

CURING .................................................................................................................. 2 General 2 Water for Curing 3 General Requirements 3 Curing of Formed Surfaces 4 Curing of Unformed Surfaces 4 Moisture Curing 4 Moisture Retaining Cover Curing 4 Liquid Membrane Curing 5 Steam Curing 5 Pavements and other slab on ground 5 Buildings, bridges, and other structures 5 Mass concrete 6

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10

CURING

10.1

GENERAL

10.1.1

Scope

1

This part covers the requirements for the curing of concrete.

2


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References AASHTO M 148.74, ...Liquid Membrane Curing

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ACI 308 ..................... Guide to Concrete Curing

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10.1.2

.

This Section Part 1, ............ General Part 4, ............ Water Part 6, ............ Property Requirements Part 15, ........... Hot Weather Concreting Part 16, ........... Miscellaneous.

ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing Concrete

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BS 7542,..................... Method of test for curing compounds for concrete. Quality management systems -- Requirements

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ISO 9001: 2008 Submittals

1

The Contractor shall submit to the Engineer the proposed method of curing for approval.

10.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for approval the details of proposed curing media, if any. Details shall include chemical tests for the product in accordance with BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.

10.1.5

Storage

1

Chemical curing compounds shall be stored in accordance with manufacturer's recommendations.

10.2

CURING

10.2.1

General

1

The Contractor shall ensure that curing is provided for 24 hours per day including holidays and that all related necessary plant and labour resources are also available.

2

Special attention shall be given to the curing of vertical and overhanging surfaces to ensure satisfactory curing.

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10.1.3

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Page 3

The Contractor shall adopt curing measures that preclude the possibility of thermal shock to the concrete during curing. This may be achieved by ensuring that the temperature of the water used for curing does not differ from that of the concrete by more than 15 C.

4

Curing shall continue for at least 7 days and until it attains an in-place compressive strength of the concrete of at least 70% of the specified compressive or flexural strength, whichever period is longer. Curing shall not stop unless otherwise approved by the Engineer.

5

When low W/cm is used, the concrete shall be preferably cured by water.

10.2.2

Water for Curing

1

Water used for any curing purposes shall conform to the requirements of Part 4 of this Section.

10.2.3


1

Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive drying out.

2

All concrete shall be cured for a period of time required to obtain the full specified strength, but not less than seven consecutive days. The method of curing shall be by water for the first seven days and by water or membrane until the concrete has reached the full specified strength.

3

For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative environments, or both, the curing shall start at early anytime between placement and final finishing of the concrete. The curing shall be by reducing the moisture loss from surface using fogging systems and the use of evaporation reducers such as monomolecular water curing compound.

4

Exposed surfaces shall be protected from air blown contamination until 28 d after the concrete is placed.

5

The method of curing shall ensure that sufficient moisture is present to complete the hydration of the cement, and shall be to the approval of the Engineer. The method of curing shall not:

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3

(a)

disfigure permanently exposed surfaces

(b)

affect bonding of subsequent coatings

(c)

increase the temperature of the concrete.

6

During the curing period, exposed concrete surface shall be protected from the direct rays of the sun.

7

When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water is present on the surface of the concrete.

8

The applied film of the liquid membrane shall be continuous and protected from rain and any damages for at least 14 days.

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Page 4

Curing of Formed Surfaces

1

Formed surfaces, including the underside of beams, girders, supported slabs and the like, by moist curing with the forms in place for the full curing period, or until the forms are removed.

2

When the forms are stripped, curing shall continue by any approved method.

3

When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In such cases the concrete surface shall be prepared prior to the application of the membrane as recommended by the manufacturer.

4

Water curing is not required when liquid membrane is used.

10.2.5

Curing of Unformed Surfaces

1

Unformed surfaces shall be protected as soon as possible after the concrete has been placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material shall be placed on the concrete surface and shall be kept wet for the required period. The hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of water. Alternatively a curing method approved by the Engineer may be used.

2

Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams shall be water cured and covered with wet hessian for the required curing period.

10.2.6

Moisture Curing

1

Moisture curing shall be performed by :

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10.2.4

covering the surface of the concrete with water and keeping it continuously wet

(b)

continuous use of fine fog water sprays

(c)

covering the surface with a saturated absorptive cover and keeping it continuously wet.

(d)

Burlap, cotton mats, and other absorbent materials can be used to hold water on horizontal or vertical surfaces.

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(a)

2

Where method (a) is employed, the bunds used shall not be made from fill from excavations or any other areas where there is the possibility of chloride contamination.

10.2.7

Moisture Retaining Cover Curing

1

The concrete surface shall be covered with a suitable absorptive covering, such as wet hessian.

2

The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

3

The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

4

Any penetrations or tear in the covering shall be shall be repaired with the same material and waterproof tape.

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Page 5

Liquid Membrane Curing

1

Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM C 309 or C1315 when tested at the rate of coverage use on the job.

2

ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for determining the efficiency of liquid membrane-forming compounds.

3

Membrane forming curing compounds shall be applied in accordance with the manufacturer's recommendations immediately after any water sheen which may develop after finishing has disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

4

Membrane forming curing compounds shall not be used on surfaces against which additional concrete or other material is to be bonded unless:

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it is proven that the curing compound will not prevent bond, or

(b)

positive measures are taken to remove it completely from those areas which are to receive bonded applications

(c)

on fair faced concrete surfaces.

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(a)

Steam Curing

1

An enclosure shall be formed around the concrete using tarpaulin or other suitable means.

2

Application of steam shall not be commenced until at least 2 h after final placement of concrete.

3

Steam shall be applied at a temperature between 65 C and 80 C.

4

Excessive rates of heating and cooling shall be prevented during steam curing and temperatures in the enclosure shall not be allowed to increase or decrease by more than 22 C per hour.

5

The maximum steam temperature shall be maintained in the enclosure until concrete has reached its specified strength.

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10.2.9

10.2.10 Pavements and other slab on ground 1

Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be initiated immediately to reduce evaporation.

2

Mats used for curing can either be left in place and kept saturated for completion of the curing, or can be subsequently replaced by a liquid membrane-forming curing compound, plastic sheeting, reinforced paper, straw, or water

10.2.11 Buildings, bridges, and other structures 1

Additional curing shall be provided after the removal of forms

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2

After the concrete has hardened and while the forms are still in place on vertical and other formed surfaces, form ties may be loosened when damage to the concrete will not occur and water applied to run down on the inside of the form to keep the concrete wet.

3


4

Immediately following form removal, the surfaces shall be kept continuously wet by a water spray or water-saturated fabric or until the membrane-forming curing compound is applied. Curing

10.2.12 Mass concrete Mass concrete is often cured with water for the additional cooling benefit in warm weather; however, this can be counterproductive when the temperature gradient between the warmer interior and the cooler surface generates stress in the concrete.

2

Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously wet by water spraying, wet sand, or water saturated fabrics.

3

For vertical and other formed surfaces, after the concrete has hardened and the forms are still in place, the form ties may be loosened and water supplied to run down the inside of the form to keep the concrete wet

4


5

Curing shall start as soon as the concrete has hardened sufficiently to prevent surface damage.

6

For unreinforced massive sections not containing ground granulated blast-furnace slag or pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall be not less than 3 weeks.

7

For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until 70% of the specified compressive strength is obtained, if strength is the key concrete performance criterion. For construction joints, curing shall be continued until resumption of concrete placement or until the required curing period is completed.

8

Curing shall not stop until favourable differential temperature is attained and at the approval of the Engineer.

9

For mass concrete, thermocouples shall be used to monitor the temperature differential of the concrete.

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END OF PART

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Page 1

REINFORCEMENT ................................................................................................. 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Quality Assurance 3 Delivery Storage and Handling 3

11.2 11.2.1 11.2.2 11.2.3

REINFORCING MATERIALS .................................................................................. 4 Reinforcing Bars 4 Welded Steel Wire Fabric 4 Tie Wire 5

11.3 11.3.2 11.3.3

INSPECTION, SAMPLING AND TESTING.............................................................. 5 Sampling 5 Testing 6

11.4

CUTTING AND BENDING OF REINFORCEMENT ................................................. 6

11.5 11.5.1 11.5.2 11.5.3 11.5.4 11.5.5 11.5.6 11.5.7 11.5.8 11.5.9 11.5.10 11.5.11

FIXING OF REINFORCEMENT ............................................................................... 6 General 6 Welding 7 Mechanical Splices 8 Bundling and Splicing of Bundled Bars 8 Examination 8 Electrolytic Action 8 Cover 8 Reinforcement 8 Forms and Linings 9 Tanking 9 Adjustment and Cleaning 9

11.6 11.6.2 11.6.3 11.6.4

PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9 Epoxy Coated Reinforcing Bars 9 Handling of Epoxy Coated Reinforcement 11 Testing of Epoxy Coated Reinforcement 11

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11

REINFORCEMENT

11.1

GENERAL

11.1.1

Scope

1

This Part includes tension, compression, and temperature reinforcing steel, including welded wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric, ties, and supports.

2


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References

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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete Reinforcement

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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties Filled

Epoxy-Coated

Seven-Wire

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ASTM A882/A882M- ..Standard Specification for Prestressing Steel Strand

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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for Concrete Reinforcement:

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11.1.2

.

Part 16 ............. Miscellaneous Part 17 ............. Structural Precast Concrete

BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of concrete BS 4483: 2005............Steel fabric for the reinforcement of concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete EN 1011, ....................Welding. Recommendation for welding of metallic materials EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the reinforcement of concrete

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Page 3

ISO 3766 ...................Construction drawings -- Simplified representation of concrete reinforcement ISO 9000, ..................Quality management systems. Fundamentals and vocabulary QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric Submittals

1

Product data including the manufacturer’s specification and installation instructions for proprietary materials and reinforcement accessories shall be provided.

2

The Contractor shall submit the manufacturer’s records of chemical and physical properties of each batch of billet steel bars and a certificate that the respective material furnished meets the requirements for the steel reinforcement specified. The manufacturer’s records shall include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

3

Three copies of the steel test report shall be furnished with each consignment of steel reinforcement. The steel shall be tagged and cross-referenced with mill certificates.

11.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for source approval details of the proposed source of supply of the reinforcement. Details shall include chemical and physical tests for the past six months production and any independent test results for this period. Details of quality assurance procedures, including ISO 9000 certificate if held, shall also be given.

2

The Contractor shall furnish the Engineer with a certificate of compliance for each shipment of epoxy coated bars. The certificate of compliance shall state that representative samples of the epoxy coated bars have been tested and that the test results comply with the requirements herein specified. Test results shall be retained by the Contractor for seven years. A complete set of test results shall also be handed to the client at the completion of reinforcement works, and shall be made available to the Engineer upon request.

11.1.5

Delivery Storage and Handling

1

On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show the manufacturer’s test number and lot number and other applicable data that will identify the material with the certificate issued for that lot of steel. The fabricator shall furnish three copies of a certification which shows the batch number or numbers from which each size of bar in the shipment was fabricated.

2

Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the ground surface to prevent damage and accumulation of dirt, rust and other deleterious matter. Storage facilities shall be such as to permit easy access for inspection and identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark reference.

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11.1.3

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3

The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may impair the bond between the concrete and the reinforcement. The reinforcement shall be covered to ensure protection from wind blown dust, condensation and other deleterious materials.

11.2

REINFORCING MATERIALS

11.2.1

Reinforcing Bars

1

Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply with the requirements of: QS ISO 6935 with minimum grade of B500 MPa or

(ii)

BS 4449 with minimum grades of B500 MPa ; or..

(iii)

ASTM A615 / A615M with minimum grade of 75 [520MPa]; or

(iv)

Deformed and Plain, Low-carbon-Chromium-Steel Reinforcement: ASTM A1035/ A1035M

(v)


(vi)


(vii)

Other types of reinforcement, as approved by Qatar Standards

Bars

for

Concrete

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(i)

As per project design, other steel grades of less than B500MPa may be used only for stirrups and secondary reinforcement of diameter of 10mm or less.

3

If the steel has excessive surface rust, dust or other deleterious material then the steel shall be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of the reinforcement or concrete. Dune sand shall not be used for the sandblasting of reinforcement.

4

For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.

11.2.2

Welded Steel Wire Fabric

1

Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483 and shall be delivered to Site in flat mats.

2

Welded intersections shall not be spaced more than:

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(a)

300 mm for plain round bars

(b)

400 mm apart for deformed high yield bars in direction of calculated stress except when used as stirrups.

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Page 5

Tie Wire

1

Tie wire shall conform to the requirements of BS 4482.

2

1.6 mm black annealed mild steel shall be used for tie wire.

3

No wires smaller than size D-4 shall be used.

11.3

INSPECTION, SAMPLING AND TESTING

1

Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

2

The Contractor shall give 24 hour notice to the Engineer before closing forms or placing concrete.

3

The Engineer may instruct the Contractor to break out and remove completely all sections of the work already constructed under any of the following circumstances:

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11.2.3

reinforcing steel sample under test fails to meet the specification requirements at any time

(b)

the Engineer considers that samples which were presented to him for test were not truly representative

(c)

a previously rejected reinforcing steel has been used in the Works.

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(a)

Sampling

1

Representative samples of all reinforcing steel proposed for use in the Works must be submitted by the Contractor, before work is commenced, to the Engineer for his written approval.

2

Manufacturer's certificates stating clearly for each sample: (a)

place of manufacture expected date and size of deliveries to site

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11.3.2

(c)

all relevant details of composition, manufacture, strengths and other quality of the steel.

3

The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at the work site.

4

Frequency of sampling and the method of quality control shall be in accordance with steel bars manufactured standard QS ISO 6935 or BS 4449 .

5

Where epoxy coated steel is used, a sample of the coating material shall be supplied with each batch in an airtight container and identified by the batch number.

6

Allow 14 days for Engineer’s review of samples.

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Page 6

Testing

1

Tests shall be carried out when directed by the Engineer.

2

Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

3

The following information shall be provided with each delivery of reinforcement: elastic limit

(b)

ultimate strength

(c)

stress/strain curve

(d)

cross-sectional area

(e)

deformation/bond characteristics of deformed bars.

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11.3.3

The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or rebend tests at own cost, for each size of bar to be used in the concrete construction.

5

Test results for each bar size shall be submitted to the Engineer three weeks before concrete work commences on Site.

6

Full testing shall be required if the source of supply of reinforcement changes, in which case the cost of such extra testing will be borne by the Contractor.

7

When any test results do not conform to the relevant standard the reinforcement steel shall be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.

11.4

CUTTING AND BENDING OF REINFORCEMENT

1

Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and shall be done without the application of heat. Bends shall have a substantially constant curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply

2

Steel bars manufactured according to the approved ASTM standards shall be bent according to the same standard.

3

Reinforcement shall not be straightened or rebent without the approval of the Engineer. If permission is given to bend projecting reinforcement care shall be taken not to damage the concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or BS 8666.

11.5

FIXING OF REINFORCEMENT

11.5.1

General

1

All reinforcement shall be securely and accurately fixed in positions shown on the Drawings to ensure that the reinforcement steel framework as a whole shall retain its shape. The framework shall be supported to retain its correct position in the forms during the process of placing and consolidating the concrete.

2

The ends of all tying wires shall be turned into the main body of the concrete and not allowed to project towards the surface.

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Page 7

3

No part of the reinforcement shall be used to support access ways, working platform or for the conducting of an electric current.

4

The Contractor’s specific attention is drawn to the following general requirements: (a)

lapped joints shall be as indicated on the Drawings and/or in accordance with the requirements of EN 1992-1-1 or BS 8666

(b)

hooks shall be semicircular with a straight length of at least: (i)

four bar diameters for mild steel

(ii)

six bar diameters for high yield steel.

Welding

1

Welding shall not be used unless authorised by the Engineer and recommended by the reinforcement manufacturer.

2

Where welding is approved it shall be executed under controlled conditions in a factory or workshop.

3

Welding shall not take place on site without the approval of the Engineer and unless suitable safeguards and techniques are employed and the types of steel employed have the required welding properties.

4

Welding if approved, may be used for:

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11.5.2

fixing crossing or lapping reinforcement in position

(b)

fixing bars to other steel members

(c)

structural welds involving transfer of loads between reinforcement or between bars and other steel members.

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The length of run deposited in a single pass shall not exceed five times the bar diameter. If a longer welded length is required, the weld shall be divided into sections with the space between runs made not less than five times the bar diameter.

6

Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be approved, subject to their satisfactory performance in trial joints.

7

Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for lapped joints.

8

Flash butt welding shall be executed with the correct combination of flashing, heating, upsetting and annealing, using only machines which automatically control this cycle of operations.

9

Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement manufacturer.

10

Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of principle reinforcement shall be staggered, unless otherwise approved. The distance between staggered joints shall be not less than the end anchorage length joints.

11

Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.

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Mechanical Splices

1

Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and where indicated on the Drawings.

2

Details of mechanical splices shall be submitted to the Engineer for approval.

11.5.4

Bundling and Splicing of Bundled Bars

1

Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

2

Splicing, except where indicated on the Drawings or approved shop drawings, will not be permitted without the approval of the Engineer.

11.5.5

Examination

1

The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of reinforcement in order to facilitate the inspection of formwork.

2

The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

11.5.6

Electrolytic Action

1

Reinforcement shall not be fixed or placed in contact with non-ferrous metals.

11.5.7

Cover

1

Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer pieces.

2

The cover shall not be less than given in Section 5 Part 6.

3

Spacers, chairs and other supports shall be provided as necessary to maintain the reinforcement in its correct position.

4

In a member where the nominal cover is dimensioned to the links, spacers between the links and formwork shall be the same dimension as the nominal cover.

5

Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars are detailed.

6

Spacers, chairs and other supports shall be made of concrete, plastic or other material to the approval of the Engineer. Where supports are made of concrete they shall have at least the same cube strength as the concrete in the host member.

11.5.8

Reinforcement

1

Placing of all reinforcement steel bars will be checked by the Engineer and in no case is concrete to be placed around any reinforcement steel that has not been approved by the Engineer. Insertion of bars into or the removal of bars from concrete already placed will not be permitted.

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11.5.3

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2

Reinforcement steel temporarily left projecting from the concrete at the joints shall not be bent without the prior approval of the Engineer.

11.5.9

Forms and Linings

1

Damage to forms and linings shall be avoided.

11.5.10 Tanking 1

Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

11.5.11 Adjustment and Cleaning

.

Check position of reinforcement before and during placing concrete: pay particular attention to the position of top reinforcement in cantilever sections

(b)

ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill scale, oil and other substances which may adversely affect reinforcement, concrete, or the bond between the two.

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Protect projecting reinforcement from the weather where rust staining of exposed concrete surfaces may occur.

3

At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and freed from all mud, oil or any other coatings that might destroy or reduce the bond:

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clean all set or partially set concrete which may have been deposited thereon during the placing of a previous lift of concrete

(b)

all uncoated rust bars shall be again sand blasted and pressure washed.

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Immediately before concrete placing the reinforcing steel shall be washed thoroughly with high pressure potable water jets to remove any deposited salts.

11.6

PROTECTIVE COATINGS TO REINFORCEMENT

1

All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.

11.6.2

Epoxy Coated Reinforcing Bars

1

Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting, rust, grease, oil and other surface defects detrimental to proper coating.

2

The surface shall be prepared in accordance with ISO 14654.

3

Coating shall be applied to the cleaned surface as soon as possible after cleaning and before any visible oxidation to the surface occurs.

4

Reinforcing steel shall not have surface defects that would be detrimental to coating.

5

Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for coating of reinforcing bars and as follows:

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(a)

epoxy resin powders which do not meet the above requirements must be tested by an approved independent testing laboratory and accepted by the Engineer before use

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6


Page 10

(b)

only fusion bonded epoxy-coated reinforcing steel will be accepted

(c)

no other means of epoxy coating will be approved.

Patching material shall be: (a)

furnished by the epoxy coating manufacturer

(b)

compatible with the coating

(c)

inert in concrete

(d)

suitable for repairs to the coated reinforcing bars to be made by the coating applicator and the Contractor at the project site.

Fabrication shall be performed before coating except as hereinafter specified for bent bars and straight bars less than 7.6 m long.

8

Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that satisfactory results can be obtained by coating before bending.

9

Any visible cracks in the coating on the outside of the bend or damage to coating resulting in debonding of the coating after bending shall be rejected.

10

Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:

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end damage to coating does not extend more than 12 mm back

(b)

cut end is patched before any visible oxidation appears.

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Flame cutting will not be permitted.

12

Epoxy coating shall be checked visually after cure for continuity of coating and shall be free from holes, contamination, cracks and damaged areas.

13

There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm of the epoxy coated bar.

14

A holiday detector shall be used in accordance with the manufacturer's instruction to check the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or its approved equivalent shall be used.

15

Patching of holidays is not required if there are less than three holidays per 300 mm length. Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced as directed by the Engineer.

16

Epoxy coating film shall be cured and/or post cured to a fully cured condition. A representative proportion of each production lot shall be checked by the epoxy coating applicator, using the method most effective for measuring cure to ensure that the entire production lot of epoxy coating is supplied in the fully cured condition.

17

Contractor shall repair all coating damaged by fixtures used to handle or support the bars in the coating process as follows:

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(a)

patching shall be done as soon as possible and before visible oxidation occurs

(b)

excessive patching from other causes will not be permitted

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(c)


Page 11

satisfactory correction shall consist of proper adjustment of process, and rerunning the bars through the plant.

The Engineer reserves the right for access to the epoxy coating applicator’s plant to witness epoxy coating processes for project work and to obtain specimens from test bars for any testing desired.

19

All chairs, tie wires and other devices used in connecting, supporting, securing or fastening epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

20

Before the reinforcement is lowered into place and before placement of the concrete, the coated bars shall be inspected by the Engineer for damage to the epoxy coating.

21

Sheared ends of bars and other areas requiring limited repair due to scars and minor defects shall be repaired, using the specified patching or repair materials.

11.6.3

Handling of Epoxy Coated Reinforcement

1

Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars or, where used, the epoxy coating.

2

Bars, or where used epoxy coating, damaged in handling or other operations shall be satisfactorily repaired at no additional cost to the Employer.

3

Where epoxy coated bars are used all handling systems shall have plastic mandrel and padded contact areas wherever possible.

4

Where epoxy coated bars are used all bundling bands shall be padded.

5

All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle.

6

Bars or bundles shall not be dropped or dragged.

7

During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not damaged by the pokers.

11.6.4

Testing of Epoxy Coated Reinforcement

1

Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each production lot.

2

At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be furnished as test bars.

3

Test bars may be in one length or multiple lengths as required to have one test bar of each size with each production lot.

4

The production epoxy coated test bars shall be evaluated by bending 120  (after rebound) around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.

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Table 11.1 Mandrel Diameter for Bar Diameter for Evaluation Test of Epoxy Coated Test Bars Diameter of Mandrel (mm)

10 12 13 14 16 18 20 22 24 25 26 28 30 32 34 36

79 95 103 111 127 143 159 175 191 198 206 222 238 254 270 286

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Bar Diameter (mm)

Bend shall be made at a uniform rate and may take up to one minute to complete.

6

Bend test shall be conducted at a room temperature of between 20 °C and 30 °C after the specimen has been exposed to room temperature for a sufficient time to ensure that it has reached thermal equilibrium.

7

No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the bent bar.

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END OF PART

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Page 1

JOINTS.................................................................................................................... 2

12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Definitions 3

12.2 12.2.1 12.2.2

CONSTRUCTION JOINTS ...................................................................................... 4 General 4 Construction Joints in Water Retaining Structures 4

12.3 12.3.1 12.3.2 12.3.3

MOVEMENT JOINTS .............................................................................................. 5 General 5 Joint Filler 6 Joint Sealants 6

12.4 12.4.1

SLIP BEARINGS ..................................................................................................... 7 General 7

12.5 12.5.1 12.5.2 12.5.3 12.5.4

WATERSTOPS ....................................................................................................... 7 General 7 Waterstops 7 Butyl Rubber Waterstops 8 Water Swelling Gaskets 8

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12

JOINTS

12.1

GENERAL

12.1.1

Scope

1

This part deals with movement and construction joints, slip bearings, waterstops and associated sealants and filler materials.

2


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12.1.2

.

This Section Part 1 ............... General Part 10, ............ Curing Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous References

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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness

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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From Olefin Polymers

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BS 903........................Physical testing of rubber BS 2571......................General purpose flexible PVC compounds for moulding and extrusion

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BS 2782,.....................Methods of testing plastics BS 6093,.....................Design of joints and joining in building construction

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BS 7164,.....................Chemical tests for raw and vulcanized rubber

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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop ISO 9001 ....................Quality management systems. Requirements

12.1.3

Submittals

1

The Contractor shall submit for approval by the Engineer as soon as practicable after acceptance of his Tender and not less than three weeks before commencement of concreting, drawings showing his proposals for the position of construction joints having due regard to any that may be shown on the Contract Drawings.

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Page 3

For slide bearings the Contractor shall provide at least three samples of the proposed material, together with the manufacturer's technical specifications and recommendations in respect of application and performance.

3

For slip joints the Contractor shall provide at least three samples of materials proposed, together with manufacturer's technical specifications and recommendations in respect of application and performance.

4

For waterstops the Contractor shall provide at least three samples of proposed types, including prefabricated joints and junctions, if applicable. If joints are to be made up on site, provide worked samples, including samples for each make of waterstop, where samples from different manufacturers are provided.

5

The Contractor must supply a certificate of compliance for the joint sealant, stating that it meets the requirements of the specification. The Contractor shall also supply the Manufacturer’s technical and installation data for the proposed material. The Contractor shall provide details of previous installations of the product, with the client name, structure name, type of joint and value of contract.

6

The Contractor shall prepare shop drawings that show the layout of the waterstops, specials and joints.

12.1.4

Quality Assurance

1

The joint sealant, including primers and debonding materials shall be compatible with each other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality Assurance Scheme.

12.1.5

Definitions

1

Construction Joint: The surface where two successive placements of concrete meet, across which it is desirable to develop and maintain bond between the two concrete placements, and through which any reinforcement which may be present is not interrupted.

2

Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a weakened plane and regulate the location of cracking resulting from the dimensional change of different parts of the structure. (See also Isolation Joint.)

3

Expansion Joint: A separation between adjoining parts of a concrete structure which is provided to allow small relative movements such as those caused by thermal changes to occur independently.

4

Isolation Joint: A separation between adjoining parts of a concrete structure provided to isolate and element and thus allow independent movement.

5

Joints Fillers: Materials that are used to fill space within movement joints during construction. They may provide support to a sealant applied subsequently.

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CONSTRUCTION JOINTS

12.2.1

General

1

Where construction joints are required in slabs or beams (designed by Direct Design Method DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres. Where slabs are supported by beams then the beams and slabs shall be constructed in one operation.

2

In all cases vertical stop boards of a form to be approved by the Engineer shall be provided by at the end of each section of work which is to be concreted in one operation and the concrete shall be thoroughly compacted against these stop boards.

3

Where slabs, beams and walls incorporate construction joints, panels shall generally be constructed consecutively. Where this is not possible a gap not exceeding one metre shall be formed between adjacent panels. This gap shall not be concreted until a minimum interval of 7 d has expired since the casting of the most recent panel.

4

The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with nominal reinforcement.

5

Horizontal construction joints in walls will only be permitted when the wall is continuous with the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls meeting the soffits of suspended members.

6

Construction joints in monolithic structures shall be aligned with each other whenever practicable.

7

Before placing new concrete against concrete which has already set the latter shall be treated to expose the aggregate over the full section and leave a sound irregular surface. This shall be done while the concrete is still fresh by means of water spray and light brushing or other means approved by the Engineer.

8

Immediately before the new concrete is placed all foreign matter shall be cleaned away and the surface moistened.

9

If during the course of the Contract it should become apparent that the Contractor’s methods of forming construction joints are not proving effective the Engineer may order the Contractor to execute at the Contractor’s expense such preventative measures as the Engineer may consider necessary to ensure the watertightness of the construction joints in further work.

12.2.2

Construction Joints in Water Retaining Structures

1

The floor may be designed as fully restrained against shrinkage and thermal contraction and should be cast directly onto the blinding concrete.

2

In large structures, the floor shall be designed as a series of continuous strips with transverse induced contraction joints provided to ensure that cracking occurs in predetermined positions. Longitudinal joints between the strips should form contraction joints.

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12.2

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Waterstops shall be incorporated into construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures. The Contractor shall ensure that all such joints are watertight and any joints which may leak or weep shall be rectified by the Contractor to the Engineer’s satisfaction.

4

The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings.

5

Where the positions or type of joints are not indicated on the drawings, the spacing of construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

6

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, construction joints, crack induced joints, contraction joints and expansion joints shall be incorporated into the works as appropriate. for slabs on grade, construction joints or crack induced joints should be provided at areas where differences in subgrade and slab support may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the width of the building. Within each strip for both directions, crack induced joints shall be provided at areas where cracks are expected and not more than 5.0 metre spacing, and construction or contraction joints shall be provided at not more than 15.0m spacing.

7

Construction or contraction joints shall be provided between adjacent strips.

8

Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

9


12.3

MOVEMENT JOINTS

12.3.1

General

1

Movement joints for expansion and contraction shall be constructed in accordance with the details and to the dimension shown on the Drawings or where otherwise ordered by the Engineer and shall be formed of the elements specified.

2

Movement Joints in Water Retaining Structures shall be in accordance with the details and to the dimension shown on the Drawings and EN 1992-3.

3

The Contractor shall pay particular attention to the effects of climatic extremes on any material which he may desire to use on any movement joint and shall submit for approval by the Engineer his proposals for the proper storage, handling and use of the said materials having due regard for any recommendations made by the manufacturer in this connection.

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Joint Filler

1

Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or equivalent if they are polymer foam type.

2

The joint filler shall be fixed to the required dimensions of the joint cross-section and shall provide a firm base for the joint sealer.

3

When required between two concrete surfaces as a resilient movement joint, the filler shall be an approved granulated cork bound with insoluble synthetic resin.

4

When required between blockwork and concrete as a low density movement joint filler or for building details it shall be an approved bitumen impregnated fibreboard or preformed closed cell polyethylene.

12.3.3

Joint Sealants

1

All joints to be sealed shall be formed and the groove grit blasted to remove all traces of deleterious materials such as form oil or curing compounds and also to remove any surface laitance from the sides of the joint. The joint shall be dry prior the application of priming. Where the use of grit blasting is not possible the Contractor may propose alternative methods subject to the approval of the Engineer.

2

The back of the joint shall receive a debonding tape or polyethylene foam backer cord in order to provide the correct depth to width ratio and prevent three sided adhesion.

3

The areas adjacent to the joint shall be protected using masking tape.

4

The sides of the joint shall be primed with the relevant primer as recommended by the sealant manufacturer and the sealant material applied in accordance with the manufacturers instructions.

5

The sealant material shall be a non-biodegradable multicomponent pitch polyurethane elastomeric joint sealant, carefully selected as appropriate for the specific climatic and environmental exposure conditions expected. Alternative types of sealant will be considered, including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the specification and the approval of the Engineer.

6

Where the joint sealant is to be in contact with a protective coating the Contractor shall satisfy the Engineer that the sealant and protective coating are compatible

7

Sealants shall exhibit the following properties:

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12.3.2

(a)

Movement accommodation factor

25 %

(b)

Shore ‘A’ hardness

(c)

Solids content

(d)

Service temperature range

(e)

Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis

(f)

Width to depth ratio

20 - 25

100 %

2:1

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0 C to 90 C

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Where shown on the Drawings sealants shall also be suitable for use with potable water.

9

All surface preparation, priming, mixing and application shall be carried out in strict accordance with the manufacturer’s instructions.

10

The sealant shall have a proven track record of no less than ten years under similar local conditions.

12.4

SLIP BEARINGS

12.4.1

General

1

Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

2

They shall be extruded from specially formulated polyethylene to form a durable lamina resistant to sewage, mineral acids and alkalis, solvents and weathering.

3

Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall be clean and free from deleterious materials such as form oil or curing compounds and surface laitance. The surface shall be level and even along the full length of the joint

4

The applied loads for slip bearings shall not exceed 0.7 MPa.

5

Operating temperatures shall be up to 80 C

6

The coefficient of friction shall not exceed 0.15

12.5

WATERSTOPS

12.5.1

General

1

Waterstops and associated materials shall be by a manufacturer with a minimum of ten years experience in the field of engineering waterproof products.

2

PVC waterstops shall be suitable for storage, handling, installation and service within a range of 15 C to 65 C.

12.5.2

Waterstops

1

The waterstop shall be a high performance system forming a continuous network as shown on the Drawings.

2

Site jointing is to be limited to butt joints and shall be performed strictly in accordance with the manufacturer’s instructions.

3

Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web sections.

4

Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The water bar used at the location of expansion joints shall have a bulb in the centre to accommodate the movements.

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5

Waterstops shall have a minimum thickness of 3 mm.

6

The minimum test performance data for PVC waterstops shall be as follows: Tensile strength Elongation at break Hardness

>12 MPa 300 % Shore ‘A’ 80 to 90

The materials shall be tested in accordance with BS 2571 or BS 2782 or CRD–C572 or ASTM D2240.

12.5.3

Butyl Rubber Waterstops

1

Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in accordance with BS 903.

Property

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BS 903

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Table 12.1 Properties Requirements of Butyl Rubber Waterstops

.

7

Requirements 3

Density

Part A26

Handness

Part A2

Tensile Strength

Part A2

Elongation at break point

Not less than 450 %

Part A/6

Water Absosption (48 hours immersion)

Not exceeding 5 %

1100 kg/m (± 5 %) 60-70 IRHD Not less than 17.5 N/mm

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Part A1

Butyl rubber waterstops shall be suitable for storage, handling, installation and service within a temperature of 0 °C to 40 °C

12.5.4

Water Swelling Gaskets

1

Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer modified chloroprene rubber strips. The rubber strips shall conform to the following properties as applicable: Water pressure resistance

:

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(b)

Expansion in contact with water :

(c)

:

Reversible

:

- 30 to + 70 °C

(d)

2

5 Bar (50 m)

Application Temperatures

2 x original SRE

The selected rubber strips shall be available for three exposures: (a)

Fresh Water

(b)

Seawater

(c)

Chemicals (if the condition demands or upon the Engineer’s request)

The supplier shall furnish references upon request of the Engineer. END OF PART

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INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2

13.1 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5 13.1.6

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Non-Compliance of Work 3 General Fieldwork Requirements 4

13.2 13.2.1 13.2.2 13.2.3 13.2.4

CONCRETE CORES ............................................................................................... 4 General 4 Drilling Cores 5 Testing for Strength 6 Assessment of Strength 7

13.3

REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

13.4 13.4.1 13.4.2 13.4.3 13.4.4

ULTRASONIC PULSE MEASUREMENTS .............................................................. 8 General 8 Selection of Test Locations 8 Execution of Tests 8 Estimated In-Situ Cube Strength 9

13.5

RADIOGRAPHY OF CONCRETE ........................................................................... 9

13.6 13.6.1 13.6.2 13.6.3 13.6.4

SURFACE HARDNESS ........................................................................................... 9 General 9 Method of Test 9 Equipment 10 Reporting 10

13.7 13.7.1 13.7.2

CHEMICAL CONTENT .......................................................................................... 10 Sampling 10 Laboratory Testing 11

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13

INSPECTION AND TESTING OF HARDENED CONCRETE

13.1

GENERAL

13.1.1

Scope

1

This Part of the specification covers the inspection, sampling and testing of hardened concrete.

2


.

This Section Part 6 ............... Property Requirements References

1

The following standards are referred to in this part of the specification:

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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength Results

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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and Commentary

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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened Concrete in Constructions

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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete

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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic covermeters BS EN 12350..............Testing fresh concrete

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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and testing in compression BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number

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BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force BS EN 12504-4 ..........Determination of ultrasonic pulse velocity BS EN 13791..............Assessment of in-situ compressive strength in structures and precast concrete components GSO ISO 1920-6 ........ Testing of concrete – part 6: sampling, preparing and testing of concrete core . 13.1.3

Submittals

1

The Contractor shall submit to the Engineer his quality assurance procedures for the particular parts of the testing work that will be carried out.

2

The Contractor shall submit for the Engineer’s approval the curriculum vitae (CV) of the supervisor proposed for the work.

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The Contractor shall through testing agency prepare a factual report that identifies the test methods used and the test results. The report shall also identify any unusual results or pertinent information relating to the testing. The report shall be presented in hard and electronic copies.

4

For each of the test results the Contractor shall identify the precision or repeatability of the particular sampling and testing method. This shall be as given from experience of the particular test by the laboratory or as expected from information in the particular test standard.

5

In-place tests will be valid only if the tests have been conducted using properly calibrated equipment in accordance with recognized standard procedures and acceptable correlation between test results and concrete compressive strength has been established and is submitted.

6

Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete, but they may be used to “evaluate” concrete when the standard-cured strengths fail to meet the specified strength criteria

13.1.4

Quality Assurance

1

All field and laboratory testing of concrete shall be carried out by an independent laboratory approved by the Engineer.

2

The evaluation of concrete in structure is needed when an existing structure is to be modified or redesigned; to assess structural adequacy when doubt arises about the compressive strength in the structure due to defective workmanship, deterioration of concrete due to fire or other causes;when an assessment of the in-situ concrete strength is needed during construction; to assess structural adequacy in the case of non-conformity of the compressive strength obtained from standard test specimens; assessment of conformity of the in-situ concrete compressive strength when specified in a specification or product standard.

13.1.5

Non-Compliance of Work

1

If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

2

The parts or elements of the structure made from the defective batch or batches of concrete as represented by the works test cubes shall be identified by the Engineer and based on this information the Engineer shall instruct the Contractor on the required number and position of concrete cores.

3

The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or ACI 318 whichever is applicable to the structural design.

4

Based on this assessment the Engineer shall decide the acceptability of the concrete in the structural element and may either:

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(a)

accept the concrete

(b)

instruct that certain remedial works are carried out

(c)

instruct that the element is replaced.

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General Fieldwork Requirements

1

The Contractor shall make all arrangements to provide safe stable access to testing locations.

2

When gaining access to testing locations and whilst testing the Contractor shall take care not to damage the structure or leave it in an untidy or unclean state.

3

The Contractor shall take precautions to ensure that cooling water from concrete coring/other operations is discharged such as not to cause a mess or damage the interior or exterior parts of the structure.

4

The Contractor shall be responsible for arranging the water supply required for testing.

5

The Contractor shall arrange for a suitable power supplies. Where testing is being carried out on an occupied structure a power supply from the building services may not available and the Contractor shall make arrangements for power supply and extension leads of adequate length.

6

The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field work. The supervisor shall have not less than five years experience of such work.

7

Before starting the work, the Engineer with the Contractor’s supervisor will mark the positions where field testing is to be carried out. A unique referencing system to identify each sample or testing location will be adopted, and this will either be referenced on sketch plans or drawings or by a detailed description used throughout the report to identify test locations.

8

If testing is being carried out on an occupied structure the Contractor shall co-ordinate with the owner or operator of the structure to arrange the detailed programme for the works and gain access to the various parts of the structure.

9

As soon as laboratory test results are available these shall be submitted by hand or faxed to the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing agency, assigned by the contractor shall provide a technical report providing visual information and analysing the tests conducted.

10

All core holes, dust sample holes and exploratory investigation areas shall be reinstated with a proprietary non shrink cementitious repair mortar. The preparation of the hole or area before reinstatement shall be carried out as per the recommendation of the repair mortar supplier.

11

Before filling any core holes, dust sample holes or exploratory investigation areas, the Contractor shall allow the Engineer time to inspect these areas and obtain written confirmation from the Engineer before filling.

13.2

CONCRETE CORES

13.2.1

General

1

The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the structural design.

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13.1.6

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All of the supplementary information listed by the relevant standards shall be included in the test report with photographs of the cores.

3

An assessment of in-situ compressive strength for a particular test region shall be based on at least 3 cores. Consideration shall be given to any structural implications resulting from taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

4

The preferred minimum core diameter is three times the nominal maximum size of the coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse aggregate

5

The Engineer will advise the required number and locations of cores. If the results of the initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain locations.

6

Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not cut through any reinforcing steel. The required diameter and depth of concrete cores shall be as stated in table 13.1

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Table 13.1

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2

1

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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823) Thickness of Section, m

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Types of Construction

0.3 or less 0.3 or greater

entire depth 0.3

0.15 or less

entire depth

0.15 – 0.6

one half the thickness or 0.15 whichever is greater

0.6 or greater

0.6

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Slabs, pavements, walls, linings, foundations, structural elements accessible from one side only 2 Suspended slabs , walls, conduits, foundations, structural elements exposed to the atmosphere at two or more sides; concrete products Massive sections

Minimum Depth to Be Sampled, m

1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples that are required for all tests, in that case, the necessary additional quantity of concrete in pieces of appropriate minimum size should be taken at each sampling location. 2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as not to lose the core by its falling from the barrel and to make it easier to patch the core hole. 13.2.2

Drilling Cores

1

Before beginning coring operations the Contractor shall use a proprietary cover meter to identify the position of steel reinforcing bars at the testing location.

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The Engineer may instruct that the core is taken through the concrete without hitting any reinforcement or the Engineer may instruct that the core is taken in a position where it is expected reinforcement will be cut in order to provide a sample of the reinforcement to check its condition. The locations of all drilling points shall be chosen so that the core contains no steel parallel to its length.

3

Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared for test the core shall have a length at least equal to the diameter and not more than 1.2 times its diameter.

4

Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm cores should be taken to reduce the variability due to drilling and increase the reliability of the testing, unless reinforcement is congested and the use of 100 mm cores will reduce the possibility that the core will contain steel or it is necessary to restrict the sampling to a length of less than 150 mm.

5

Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores may be used with the permission of the Engineer.

6

During drilling operations, a log of observations that may affect the interpretation of core samples shall be prepared.

7

If instructed by the Engineer, immediately after the core has been cut and removed and the structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein poured over the cut surface. A photograph shall be taken of the cut core with the phenolphthalein solution applied to provide a record of the test.

8

If during the drilling of the core, the core collapses due to weak honeycombed or defective concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent location as advised by the Engineer. If when testing at the second location, the core again breaks due to honeycombed or defective concrete the freshly cut core shall be retained for reference and a note made of the condition.

13.2.3

Testing for Strength

1

The compressive strength of field concrete cores shall be assessed in accordance with BS EN 13791.

2

The details of the concrete core in accordance with BS EN 13791 shall be recorded and two photographs on either side of the core taken.

3

Where there is reinforcement in the core, the size and the type of bar shall be noted along with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a detailed description of any corrosion of the reinforcement.

4

Before carrying out the compressive strength testing of the cores, the Contractor shall inform the Engineer to allow him to witness the testing if required.

5

Crushed core samples shall be retained by the laboratory and only disposed of after written approval by the Engineer.

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Assessment of Strength

1

The estimated in-situ strength of the concrete shall be calculated from the core result using BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

13.3

REINFORCEMENT COVER MEASUREMENTS

1

The measurement of cover to reinforcing steel and other metallic items in concrete shall be carried out in accordance with BS 1881 Part 204 using an electromagnetic device that estimates the position depth and size of the reinforcement.

2

The locations for checking cover and the spacing between measurements shall be advised by the Engineer based on the objective of the investigation. The Contractor shall carry out calibrations of the electric magnetic device for a particular bar size to allow the bar diameter to be measured.

3

While testing, the orientation of steel bars shall be checked.

4

The electromagnetic device shall incorporate scale or digital display range and shall be calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever is the greater over the working range given by the manufacturer.

5

The cover meter shall be used in accordance with the manufacturers instructions and checks on the zero carried out as specified.

6

The search head shall be traversed systematically across the concrete, and, where reinforcement is located, rotated until the maximum disturbance with electromagnetic field is indicated by the meter.

7

The cover to the reinforcement shall be noted along with the axis of the reinforcement. The cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent marking pen.

8

Care should be taken to avoid interference from other metallic sources or magnetic material.

9

The cover meter checks shall be carried out by an operator with five years experience.

10

The test report on cover shall include the following information:

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13.2.4

(a)

date

(b)

time and place of test

(c)

description of the structure or component under investigation

(d)

location of test areas

(e)

make and type of cover meter used

(f)

date of last laboratory calibration of cover meter

(g)

details of site calibration of cover meter, indicated values of cover

(h)

estimated accuracy of quantitative measurements

(i)

configuration of steel reinforcement

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ULTRASONIC PULSE MEASUREMENTS

13.4.1

General

1

The ultrasonic velocity test equipment shall be capable of measuring the transit time of a pulse vibration through concrete. The length of the pulse part between the transducer equipment shall be measured, and the pulse velocity calculated.

2

Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS EN 12504-4.

3

Velocities shall be measured at a number of locations around a structure and a velocity contour of the structure established. A minimum of 40 velocities shall be measured for each structural element.

13.4.2

Selection of Test Locations

1

Wherever possible direct transmission arrangements shall be used. The transducers shall be mounted on a specially formed moulded surface.

2

The minimum path length shall be 100 mm for concrete in which the nominal maximum size of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than required to detect small regions of bad concrete.

3

Where concrete contains steel the pulse velocity shall be adjusted in accordance with the requirement of BS EN 12504-4.

4

Locations that contain reinforcement directly along or close to the pulse paths shall be avoided.

5

Where repositioning is not possible the semi-direct transmission measurement, where transducers are placed on adjacent faces of the concrete, may be used.

13.4.3

Execution of Tests

1

Positions chosen for the test locations shall be clearly and accurately marked on the surface of the concrete.

2

The surface of the concrete shall be shall be cleaned and free from grit and dust. Path lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease) applied to each of the test points.

3

Pulse transit times shall be measured by a skilled operator, with a minimum of five years experience in the use of the equipment.

4

Pulse velocity measurement equipment shall be in accordance with the requirements of BS EN 12504-4.

5

Test results shall be examined and any unusual readings repeated carefully for verification or amendment.

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13.4

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Estimated In-Situ Cube Strength

1

A correlation shall be established between the cube crushing strength of the particular mix used in the structure and the pulse velocity.

2

Where it is not possible to obtain cubes with the same mix design as the original structure a combination of coring and ultrasonic pulse velocity testing may be carried out at the direction of the Engineer, where the cores are used to provide the correlation information required for the interpretation of the ultrasonic pulse velocity tests.

13.5

RADIOGRAPHY OF CONCRETE

1

Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects: The testing shall be carried out in accordance with the requirements of BS 1881-205 or equivalent.

13.6

SURFACE HARDNESS

13.6.1

General

1

Testing of concrete surfaces for hardness using rebound hammers shall be carried out in accordance with BS EN 12504-2.

2

The rebound hammer shall only be used for estimation of concrete strength where a specific correlation is carried out of the concrete from the structure being tested; this shall be from works test cubes or cores taken from the structure.

3

The correlation between concrete strength and the rebound number shall be carried out in accordance with BS EN 12504-2. The precision of the correlation curve between the mean rebound number and strength shall be stated and this shall be used when reporting any strength interpretations from surface hardness readings. The use of general manufacturers’ correlation or calibration curve for strength shall not be used.

4

It should be noted that the rebound hammer number only provides information on a surface layer of approximately 30 mm in depth of the concrete and that this should be quoted in the test report.

5

The rebound hammer maybe used to establish the uniformity of the finish products or similar elements in a structure at a constant age, temperature, maturity and moisture condition.

13.6.2

Method of Test

1

A minimum of 12 readings shall be taken to establish a single surface hardness at a particular location.

2

The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not exceeding 300 mm by 300 mm.

3

The mean of each set of readings shall be calculated including abnormally high and abnormally low results unless there is good reason to doubt the validity of a particular reading.

4

The coefficient of variation and the standard deviation of the readings shall be reported.

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13.4.4

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Equipment

1

The rebound hammer shall be a proprietary type that has been used successfully and serviced for a minimum of five years.

2

The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact with the surface.

3

The manufacturers’ literature shall identify the impact energy and contact area of the plunger for the hammer.

13.6.4

Reporting

1

The test report shall affirm that the hardness was determined in accordance with BS EN 12504-2 and shall provide the following information:

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13.6.3

date time and place of test

(b)

description of structure and location of test

(c)

details of concrete

(d)

type of cement

(e)

cement content

(f)

type of aggregate

(g)

type of curing

(h)

age of concrete

(i)

type of compaction of concrete

(j)

forming of surface

(k)

moisture condition of the surface

(l)

carbonation state of surface

(m)

any suspected movement of the concrete under test

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direction of test

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(a)

(o)

any other factors that are considered significant in influencing the hardness readings.

2

The details of the rebound hammer correlation with strength including the mean, range, standard deviation and coefficient and variation of each reading shall also be included.

13.7

CHEMICAL CONTENT

13.7.1

Sampling

1

The Engineer shall instruct the depth increments over which the dust samples are to be taken, the types of chemical testing to be carried out and the quantity of sample required.

2

The depth of sample shall not be less than the concrete cover to the reinforcement and at least 50 mm from the surface of concrete. In presence of reinforcement, the chemical content shall be tested at least at two levels before and after the depth of reinforcement from the surface of concrete.

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To provide uniform samples of cement matrix and aggregate, three separate holes shall be drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

4

Care shall be taken to discard the material from any render or finish unless this is specifically required under the investigation.

5

Care shall be taken to ensure that dust increments are accurately measured by marking the drill bit.

6

The dust samples increments shall be carefully transferred to plastic bags and sealed to avoid contamination. Each sealed bag shall be uniquely identified by the sample identification and depth increment.

13.7.2

Laboratory Testing

1

Residual split samples of dust from the field investigation shall be retained until the Engineer has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried out on certain samples.

2

Chloride testing of concrete dust samples shall be by an acid soluble method in accordance with BS 1881 Part 124. The results shall be reported to two decimal places.

3

Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124, using an acid soluble method.

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END OF PART

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Page 1

PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2

14.1 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Preinstallation and Co-ordination 4 Delivery, Storage and Handling 4 Protection 4 General Requirements for all Treatments 5 Final Inspection 5

14.2 14.2.1 14.2.2 14.2.3 14.2.4

EPOXY COATING ................................................................................................... 5 General 5 Surface Preparation 5 Materials 6 Application 6

14.3 14.3.1 14.3.2 14.3.3 14.3.4

WATERPROOF MEMBRANE ................................................................................. 6 General 6 Materials 7 Waterproof Membrane 7 Application 7

14.4 14.4.1 14.4.2 14.4.3 14.4.4

PENETRATIVE PRIMER ......................................................................................... 8 General 8 Material 8 Surface Preparation 8 Application 8

14.5 14.5.1 14.5.2 14.5.3 14.5.4

PROTECTIVE COATING ........................................................................................ 9 General 9 Surface Preparation 9 Material 10 Application 10

14.6 14.6.1 14.6.2 14.6.3 14.6.4 14.6.5 14.6.6 14.6.7 14.6.8 14.6.9 14.6.10 14.6.11

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11 General 11 Shop Drawings and Submittals 11 Liner Material Requirements 11 Plastic Sheet Liner Strip Properties 12 Basic Sheet Dimensions 12 Liner Details 12 Installation 13 Testing Requirements 13 Special Requirements 14 Joints in Lining for In-Situ Concrete Structures 15 Testing and repairing damaged surfaces 15

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14

PROTECTIVE TREATMENTS FOR CONCRETE

14.1

GENERAL

14.1.1

Scope

1

This Part covers the materials and application requirements for coatings for concrete surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective coatings, and coatings and treatments for specialist applications where there is a harsh environment.

2


References

1


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This Section Part 1, ............. General

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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers Tension ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents

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ASTM D570 ................Test Method for Water Absorption of Plastics ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)

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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting

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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for Electrical and Electronic Applications

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ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting

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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion Testers ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials

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ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover BS 1881......................Testing Concrete BS EN 12350..............Testing fresh concrete CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments. ISO 9000 ....................Quality management and quality assurance standards ISO 9001 ....................Quality systems - Model for quality assurance in design, development, production, installation and servicing 14.1.3

Submittals

1


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The Contractor shall submit samples of all materials to be used in the works before delivery of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples of liquid components shall be a minimum of one litre.

3

The Contractor shall submit comprehensive test results for the protective coating system as per the tests in the specification which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

4

The Contractor shall clearly state the chemical composition of the material and the process by which protection is given to the concrete.

5

In addition to the test methods identified in this clause of this specification, the Engineer may require the Contractor to carry out further tests to different standards.

6

If the Contractor wishes to propose a material which has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test, criteria for assessment etc.

7

The Contractor shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include: project name, type/grade of material used, quantity of material used, name of client, name of consultant, name of Contractor. If requested by the Engineer, the Contractor shall supply the contact details of the client, consultant or Contractor where the material was previously installed.

8

The Contractor shall submit a guaranty for the protective coating system and the workmanship. The guaranty shall be worded to reflect the required performance of the material and shall be approved by the Engineer. The guaranty shall be worded to include the phrase ‘the Contractor shall, at the convenience of the Employer, effect all repairs and replacements necessary to remedy defects all to the complete satisfaction of the Engineer’. Unless stated otherwise in the contract specific documentation, the performance guaranty shall be for a period of ten years except for the penetrative primer which shall be for a period of five years.

9

The use of alternatives may be considered by the Engineer. If the Contractor wishes to propose such systems, a technical submission shall be made which shall include a comprehensive justification giving an explanation of why the proposed system is equivalent or superior to the one designated.

14.1.4

Quality Assurance

1

The protective coating system shall be supplied by a manufacturer who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 series certificate that clearly states the scope of the certification.

2

The protective coating system shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on Site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

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The protective coating system shall be applied by a contractor or subcontractor who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification. the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the applicator works to a quality system that is approved by the Engineer.

4

The works shall be executed by an approved specialist subcontractor having a minimum of 5 years successful experience in the installation of the specified material. Only tradesmen experienced with the installation of the materials specified shall be used.

14.1.5

Preinstallation and Co-ordination

1

After approval of all materials and before installation, a prework conference with the Engineer shall be held at the Site. The meeting shall be attended by representatives of the Engineer, Contractor, subcontractor, and manufacturer.

2

The parties shall:

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review drawings, specifications and approved materials

(b)

correct conflicts, if any, between approvals and specification requirements

(c)

examine Site conditions, including inspection of substrate, material labels and methods of storing materials

(d)

review installation procedures and scheduling

(e)

review protection methods for finished work from other trades.

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(a)

Before applying the coating system to the permanent works the Contractor shall carry out a small trial of the coating system for the review and approval of the Engineer.

14.1.6


1

Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly labelled with the manufacturer's name, brand name, and number and batch number of the material where appropriate. Materials and equipment shall be stored as directed in a neat and safe manner.

2

Storage areas shall comply with the manufacturers requirements with regard to shade, ventilation and temperature limits and shall be located away from all sources of excess heat, sparks or open flame. Containers of liquid material shall not be left open at any time in the storage area.

3

Materials not conforming to these requirements will be rejected by the Engineer and shall be removed from the Site and replaced with approved materials.

4

The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and at such times as to permit proper co-ordination of the various parts.

14.1.7

Protection

1

The Contractor shall protect the protection system installation from damage during the construction period so that it will be without any indication of abuse, defects or damage at the time of completion.

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Page 5

The Contractor shall protect the building/structure from damage resulting from spillage, dripping and dropping of materials.

3

The Contractor shall prevent any materials from running into and clogging drains.

4

Materials and plant shall not be stored on any newly constructed floor without the permission of the Engineer.

5

Impervious membranes shall be laid as protection to all concrete surfaces in contact with the soil and shall consist of tanking or similar accepted material, based on soil investigation report.

6

All foundations shall be provided with protection such as epoxy coatings or similar other accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

14.1.8

General Requirements for all Treatments

1

Protective treatments shall be applied where designated in the contract specific documentation.

2

All protective coating systems to be used shall be applied strictly in accordance with the manufacturers recommendations.

3

The Contractor shall take all necessary precautions against fire and other hazards during delivery, storage and installation of flammable materials specified herein and comply any regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect of the storage and use of hazardous materials required under this section.

4

The Engineer shall specify the required final colour of the coating and the Contractor shall submit samples showing the colour before ordering the materials.

14.1.9

Final Inspection

1

Upon completion of the installation, an inspection shall be made by a representative of the material manufacturer in order to ascertain that the system has been properly installed.

14.2

EPOXY COATING

14.2.1

General

1

The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in two coats to a dry film thickness of 200 m minimum.

14.2.2

Surface Preparation

1

The surface of the concrete shall be free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds. All surface contamination and surface laitance shall be removed by high pressure water jetting or sweep blasting.

2

Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with the product manufacturer’s recommendations.

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Where surface cracking is apparent these cracks shall be chased, by an approved mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased section and providing a flush finish with the concrete surface. A minimum period of 24 h shall be allowed before applying any subsequent protective coating systems.

14.2.3

Materials

1

External above ground coating materials shall provide protection against chlorides and carbonation, and be UV and abrasion resistant.

2

The above ground coating shall be applied over the below ground coating and shall continue for a minimum of 150 mm above the ground level.

3

The epoxy coating shall be UV stable.

4

The finished coating shall be pinhole free and have a total minimum dry film thickness of 200 m.

5

The materials used in the coating system shall comply with the following requirements:

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> 85 % -20 C to 70 C 4 MPa 6 MPa greater than 3.5 MPa 90 MPa (neat resin) 6-8 % (neat resin) Nil 50 mg 97 MPa @ 7 days -6 46.8 x 10 mm/mm/degree C

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Solids content Service temperature Tensile strength (DIN 53504) Resistance against crack (DIN 53515) Adhesion to concrete (ASTM D-4541) Compressive strength (ASTM D-695) Tensile elongation (ASTM D-638) Water absorption (MIL D-24613) Abrasion resistance (ASTM C-501) Compressive strength (ASTM C-579) Thermal coefficient of expansion (ASTM C-531) Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be treated with the material.

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4

In all operations of storage, mixing and application, the Contractor is to comply with the health and safety recommendations of the manufacturer and governing authorities.

14.3

WATERPROOF MEMBRANE

14.3.1

General

1

This Subpart covers the use of waterproof membrane for general protection to buried concrete.

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14.2.4

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Where indicated on the Drawings or directed by the Engineer, concrete in contact with the ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

3

The laying, lapping and sealing of the membrane shall be in accordance with the manufacturer’s instructions.

14.3.2

Materials

1

The material shall be an externally applied waterproof membrane shall be an impervious, cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with silicone coated release paper.

2

Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

3

Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured from selected aggregates, bound in modified bitumen encased between two layers of strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm wide.

14.3.3

Waterproof Membrane

1

The material shall be suitable for use in the Gulf region the compound shall be specially formulated for hot climates and shall have proven experience in the Middle East.

2

The waterproofing material shall conform to the standards detailed in Table 14.1

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Table 14.1 Waterproof Membrane Property Requirements

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Property

Standard ASTM D638

Tear resistance

ASTM D1004

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Elongation Film

Value Longituduial 210 % Transverse 160 % Longitudinal 340 MPa Transverse 310 MPa

Adhesion to primed concrete

ASTM D1000

1.8 MPa

Elongation compound

ASTM D1000

1.8 MPa

Puncture resistance

ASTM E154

220 N over 65 mm

Water resistance

ASTM D570

After 24 h. 0.14 % After 35 d 0.95 %

Environmental resistance Moisture vapour transmission rate

ASTM D543 ASTM E96

Minimum thickness

2

0.3g/M 24 h 1.0 mm.

14.3.4

Application

1

Waterproofing membranes placed on vertical concrete faces shall be protected by preformed asphalt board.

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Boards shall be bonded onto position with high quality solvent borne contact adhesive based on polychloroprene rubber.

3

The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains, equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

4

Areas where waterproofing is applied shall be protected from all traffic and where necessary backfilling. All damage to finished portions of the waterproofing membrane shall be either repaired or replaced, or both, in a manner acceptable to the Engineer.

14.4

PENETRATIVE PRIMER

14.4.1

General

1

The system shall be a penetrating hydrophobic treatment that protects concrete from both water and chloride intrusion, while permitting water vapour transmission.

2

The treatment shall significantly reduce the absorption of water and water borne salts but allow the transmission of water vapour from the substrate.

3

The treatment shall not produce any discoloration of the substrate and shall have excellent resistance to weathering.

14.4.2

Material

1

The material shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

2

The material shall be resistant to petrol, oil, and atmospheric contaminants such as car exhaust fumes and industrial exhausts.

14.4.3

Surface Preparation

1

The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae growth and curing compounds.

2

If the concrete surface is newly cast and has a very smooth finish, the surface shall be roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer shall decide if this means of preparation is required.

3

Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in accordance with the manufacturer’s recommendations.

4

Concrete finishing required shall be completed before the application of the treatment.

5

Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturer’s recommendations.

14.4.4

Application

1

Unless directed otherwise by the Engineer the treatment shall be applied a minimum period of 24 h after the wet curing period, and shall be surface dry.

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The Contractor shall carry out tests to verify the depth of penetration of the material. These tests shall be carried out on specimens of the actual mix design and shall use coloured dyes to trace the penetration of the material.

3

Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats' of the treatment shall be applied before the main treatment.

4

The application of the material on surfaces shall be by a low pressure spray direct from the can. Under no circumstances should thinning of the material be carried out.

5

The rate of application shall ensure that the surface is completely saturated. The impregnated coating shall be applied to two or more flood coats each flood coat shall be a 2 minimum of 0.4 l/m .

6

The material shall be applied strictly in accordance with the manufacturers instructions and as follows:

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the material shall be applied by a fine nozzle spray

(b)

application will not be permitted when the ambient air temperature is above 35 C or in windy conditions

(c)

the surface shall be cleaned by a stiff brush or compressed air to remove all loose deposits

(d)

concrete to be treated shall be surface dry for a minimum period of 24 h before impregnation

(e)

membranes, joint sealers and cast in concrete ancillaries shall be masked off before treatment

(f)

application shall be made by saturation flooding

(g)

the interval between application shall be at least 6 h

(h)

treated areas shall be protected from sea water and rain for 6 h after treatment.

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(a)

PROTECTIVE COATING

14.5.1

General

1

The coating system shall be used for the protection of new or existing reinforced concrete structures against carbonation or chloride induced corrosion.

2

The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat system to minimise ingress of acidic gases, chlorides and water.

14.5.2

Surface Preparation

1

Before application, all surfaces must be dry and free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds.

2

All such contamination and laitence must be removed by the use of grit blasting, high pressure water jetting or equivalent mechanical means.

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14.5

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Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may be affected by the application of the coating shall be fully masked and, in particular, flora and fauna shall be protected.

4

Blow holes and areas of pitting shall be made good with a one part modified cementitious material and allowed to cure in accordance with the manufacturer's recommendations. In particular, the application shall be in accordance with the manufacturer's recommendations, with respect to the maximum application thickness.

14.5.3

Material

1

The materials are required to provide in-depth protection against carbonation and chloride penetration whilst permitting water vapour transmission from the concrete.

2

The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

3

The material employed for the coating shall comply with the following requirements:

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400 µm 200 µm R Value at 325 microns > 161 metres.

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Wet film thickness Dry film thickness Carbon Dioxide diffusion resistance (Taywood Engineering Laboratories) Water vapour transmission (Taywood Engineering Laboratories) Reduction in chloride ion penetration (BS 1881 : Part 124) Tear Resistance (ASTM D624) Crack bridging (BRE Method) Chloride Ion Diffusion (Taywood Engineering Labororatories)

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Shall be more than 13 g/m .d 94 % minimum at 28 d 7.3 kN/mm 5.1 mm

2

-10

3.63 x 10

2

cm /sec.

Where test methods are not specified, the procedure for establishing compliance with the above criteria shall be agreed with the Engineer.

5

The Contractor is required to adhere strictly to the manufacturer's recommendations regarding the use, storage, application and safety rules in respect of the approved materials.

14.5.4

Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials. These trial areas shall be noted on the Drawings and shall be carried out using the type of materials, mixing procedures and applications that will be used on the contract and shall be approved by the Engineer before the Contractor commences with the general work.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be conditioned by the application of a penetrating hydrophobic treatment. The primer shall be allowed to dry in accordance with the manufacturer's requirements.

3

The Contractor shall then apply two coats of pigmented topcoat in accordance with the manufacturer's instructions. The finished coating shall be pinhole free and have a total minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the Engineer.

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5

In all operations of storage, mixing and application the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

14.6

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1

General

1

This Subpart covers the supply and installation of sheet liners in reinforced concrete structures.

2

The liner must be continuous and free of pinholes both across the joints and in the liner itself.

3

All work for and in connection with the installation of the lining in concrete pipe and structure, and the field sealing and welding of joints, will be done in strict conformity with all applicable specifications, instructions, and recommendations of the lining manufacturer.

14.6.2

Shop Drawings and Submittals

1

The Contractor shall submit to the Engineer for approval the following:

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liner schedule

(b)

material certifications

(c)

test results

(d)

material samples

(e)

the manufacturer of the lining will submit an affidavit attesting to the successful use of its material as a lining for sewer pipes and structures for a minimum period of five years in service conditions recognised as corrosive or otherwise detrimental to concrete.

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(a)

Liner Material Requirements

1

The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and other components necessary to make a material of permanent flexibility suitable for a liner in concrete pipes and structures in sewerage service. The weld strips and the joint strips shall be made from like material. For PVC and PE sheet liners, the actual resin used in manufacture must constitute not less than 99 % of the resin used in the formulation.

2

Copolymer resins will not be permitted.

3

All plastic sheets including locking extensions, all joints and welding strips shall be free of cracks, asperities and other defects that may affect the protective properties of the material.

4

The properties of PVC and PE sheet are shown in Table 14.2

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14.6.3

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Table 14.2 Properties of PVC and PE Sheet Liners Property

Test Method

PVC Elongation at break Tensile Strength Low Temp. Brittleness PE Elongation at break Tensile Strength Low Temp. Brittleness

Requirement


300 % 15 MPa 0°C


Exceeds 600 % 10-20 MPa -75 °C

Plastic Sheet Liner Strip Properties

1

Except at shop welds, all plastic sheet liners and strips shall have the properties shown in Table 14.3 when tested at 25 °C.

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14.6.4

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Table 14.3 Properties of Plastic Sheet Liner Strips

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Property

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Shore Durometer

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Weight change

15 MPa 200 % 1 s 50 - 60 5 (with respect to 10 s 35 - 50 5) 1.5 %

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Tensile strength Elongation at break

Requirement

Basic Sheet Dimensions

1

The minimum thickness of the material shall be as shown in Table 14.4

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14.6.5

Table 14.4 Plastic Sheet Liner Minimum Dimensions

Material Thickness

Sheet with locking extensions Sheet, plain Joint strip Weld strip

Structures 4.0 mm 2.3 mm 1.9 mm 2.4 mm

14.6.6

Liner Details

1

Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be integrally extruded with the sheet.

2

Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

3

Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall be repaired and retested.

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14.6.7

Installation

1

Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall be performed in accordance with the recommendations of the manufacturer.

2

The lining to be held snugly in place against inner forms by means of steel banding straps or other means recommended by the manufacturer.

3

Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a careful manner to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

4

In removing forms care shall be taken to protect the lining from damage. In particular:

(b)

when forms are removed, any nails that remain in the lining to be pulled, without tearing the lining, and the resulting holes clearly marked.

(c)

form tie holes to be marked before ties are broken off and all areas of serious abrasion or damage shall be marked.

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sharp instruments not to be used to pry forms from lined surfaces.

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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched as follows: patches made entirely with welding strip to be fused to the liner over the entire patch area

(b)

larger patches may consist of smooth liner sheet applied over the damaged area with adhesive

(c)

all edges must be covered with welding strip fused to the patch and the sound lining adjoining the damaged area.

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(a)

Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

7

The Contractor shall take all necessary measures to prevent damage to the installed lining from equipment and materials used in or taken through the work.

14.6.8

Testing Requirements

1

Samples taken from sheets, joints or weld strips shall be tested to determine material properties. Determination of tensile strength and elongation shall be in accordance with ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with ASTM D 2240 using a Type D Durometer, except that a single thickness of material and indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of specimens shall be the thickness of the sheet or strip.

2

The measurement of initial physical properties for tensile strength, weight, elongation and indentation hardness shall be determined before chemical resistance tests.

3

Chemical resistance tests shall be carried out to determine the physical properties of the specimens after exposure to chemical solutions. Test specimens shall be conditioned to constant weight at 43 °C before and after submersion in the solutions detailed in Table 14.5 for a period of 112 d at 25  3 °C.

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Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals, specimens shall be removed from each chemical solution and tested. If any specimen fails to meet the 112 day exposure, the material will be subject to rejection.

5

Pull test for locking extensions: Liner locking extensions embedded in concrete shall withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a period of 1 min, without rupture of the locking extensions or withdrawal from embedment. This test shall be made at a temperature between 21 °C to 27 °C inclusive.

6

Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together, shall be a least equal to the minimum requirements of the liner for thickness, corrosion resistance and impermeability. Welds shall show no cracks or separations and shall be tested for tensile strength. Tensile strength measured across the welded joint in accordance with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25  3 C and the measured minimum width and thickness of the reduced section shall be used.

7

Spark test: All liner shall be shop tested for holes with a spark tester set to provide from 15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before shipment from the manufacturer’s plant.

8

The Contractor shall provide the Engineer with certified copies of test reports before the shipment of the product to the Site.

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Table 14.5 Chemical Resistance Tests

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Chemical Solutions Sodium Hydroxide Nitric Acid

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Soap

5% 1% 1%

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Ferric Chloride

5%

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Ammonium Hydroxide

20 %

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Sulphuric Acid

Concentration

0.1 %

Detergent (Linear alkyl benzyl sulphonate or LAS)

0.1 % BOD not less than 700 mg/l

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Bacteriological

Phosphoric Acid 14.6.9


1

Liner sheets to be closely fitted and properly secured to the inner forms.

2

50 %

(a)

sheets that are to be cut to fit curved and warped surfaces shall use a minimum number of separate pieces

(b)

a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt joints to prevent wet concrete from flowing around the edges.

Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the surfaces of contact between the concrete structure and items not of concrete and (a)

the same procedure will be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete

QCS 2014


Page 15

(b)

at each return, the returned liner will be sealed to the item in contact with the plastic lined concrete with an adhesive system

(c)

if the liner cannot be sealed with this adhesive because of the joint at the return being too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 50 mm and finish with a minimum of 25 mm of an approved corrosion resistant material.

14.6.10 Joints in Lining for In-Situ Concrete Structures Field joints and Lining at joints shall be free of all mortar and other foreign material and shall be clean and dry before joints are made.

2

All welding is to be in strict conformance with the specifications of the lining manufacturer.

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all welds shall be physically tested by a non-destructive probing method

(b)

all patches over holes, or repairs to the liner wherever damage has occurred.

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Each transverse welding strip which extends to a lower edge of the liner will be tested by an approved testing agency at the cost of the Contractor. the welding strips will extend 50 mm below the liner to provide a tab.

(b)

a 5 kg pull will be applied to each tab. The force will be applied normal to the face of the structure by means of a spring balance

(c)

liner adjoining the welding strip will be held against the concrete during application of the force

(d)

the 5 kg pull will be maintained if a weld failure develops until no further separation occurs.

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(e) (f)

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All surfaces covered with lining, including welds, will be tested with an approved electrical holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

defective welds will be retested after repairs have been made tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed inspection.

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14.6.11 Testing and repairing damaged surfaces

(g)

inspection will be made within two days after joints has been completed in order to prevent tearing the projecting weld strip and consequent damage to the liner from equipment and materials used in or taken through the work.

END OF PART

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Page 1

HOT WEATHER CONCRETING ............................................................................. 2

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definition of Hot Weather 2 System Description 3 Submittals 3

15.2

PLACING TEMPERATURE ..................................................................................... 3

15.3

PLANNING CONCRETING ..................................................................................... 4

15.4

MIX DESIGN ........................................................................................................... 4

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6

TEMPERATURE CONTROL ................................................................................... 4 General 4 Aggregates 4 Water 5 Cement 5 Addition of Ice 5 Liquid Nitrogen 6

15.6

BATCHING AND MIXING ........................................................................................ 6

15.7

TRANSPORTATION ............................................................................................... 6

15.8

PLACING AND FINISHING ..................................................................................... 6

15.9

CURING AND PROTECTION.................................................................................. 7

15.10

INSPECTION AND TESTING .................................................................................. 7

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HOT WEATHER CONCRETING

15.1

GENERAL

15.1.1

Scope

1

This Part covers the precautions to be taken for hot weather concreting for all structural concrete except blinding concrete, where a minimum compressive strength is specified.

2


15.1.2

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This Section Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8 .............. Transportation and Placing of Concrete Part 10 ............. Curing

.

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References

ta

ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

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ASTM C1064 ..............Measuring the Temperature of Concrete

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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for buildings

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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods

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BS EN 934..................Admixtures for concrete, mortar and grout Definition of Hot Weather

1

The requirements of the following clauses of the specification are applicable during the hot weather period in Qatar.

2

The hot weather period shall be defined as starting when the maximum ambient air shade temperature on the Site exceeds 35 C for three consecutive days. The end of the hot weather period shall be defined as the period when the maximum air shade temperature is below 35 C on three consecutive days.

3

The Contractor shall establish a thermometer on Site that records the ambient air shade temperature. The thermometer shall be established at a position to provide representative air temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange for the calibration of the Site thermometer.

4

Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as:

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15.1.3

(a)

High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer),

(b)

High concrete temperature,

(c)

Low relative humidity,

(d)

High wind speed

QCS 2014


(e)

the rate of evaporation exceeds 0.75 kg/m /h

Page 3

2

15.1.4

System Description

1

The Contractor shall undertake hot weather concreting procedures that are effective in controlling the following potential problems associated with concreting in hot weather: increased water demand of the mix

(b)

increased rate of slump loss

(c)

increased rate of setting

(d)

increased tendency for plastic shrinkage cracking

(e)

decreased long-term strength

(f)

increase tendency for drying shrinkage and cracking

(g)

increased tendency for differential thermal effects with consequent cracking

(h)

decreased durability from cracking where there is increased permeability.

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(a)

Submittals

1

The Contractor shall prepare weekly in advance his proposed concreting programme showing the quantities to be placed and the anticipated placing hours.

2

At least one month before the start of the hot weather period the Contractor shall submit his specific proposals for the control of the concrete temperature for the constituent materials; cement, water aggregates.

3

Where required the Contractor shall submit to the Engineer his proposals for the use of liquid nitrogen for cooling which shall include details of previous project application and the intended methods to be used and quantities of liquid nitrogen.

15.2

PLACING TEMPERATURE

1

This Subpart of the specification applies at all times of the year and at all times of the day.

2

Maximum fresh concrete temperature (at placement) shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

3

Concrete shall not be placed if the shade temperature exceeds 40ºC.

4

The temperature of each truck of concrete shall be measured using either a glass, dial type or electronic thermometer, just before the placing of the concrete and the temperature recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire load of concrete in the truck or conveyer.

5

The Contractor shall allow for the increase in concrete temperature in the period from dispatch from the plant while in transportation or whilst awaiting placement on Site and take adequate measures to ensure the maximum temperature is not exceeded.

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15.1.5

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PLANNING CONCRETING

1

During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall plan concreting operations such that no concreting takes place between the hours of 10:00 hours and 17:00 hours.

2

The Contractor shall arrange concrete pours such that the programme of works can be achieved without concreting during the period from 10:00 hours to 17:00 hours.

3

The Contractor shall nominate one member of his staff to be the co-ordinator for the supply of concrete. The co-ordinator’s responsibilities shall include ensuring the batched rate matches that of delivery and placement and the preparations needed before commencing a concrete pour.

15.4

MIX DESIGN

1

In the hot weather period, the Contractor shall review all concrete mix designs to ensure that the design slump or workability specified is achieved without increase in the mix water content. The Contractor shall make modifications to the mix design to allow for increased slump loss during transportation in hot weather.

2

This shall be achieved by adjusting the proportion of admixture, plasticiser or super plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix design with nominal values for cold weather and hot weather use.

3

Under no circumstances will the addition of extra water that increases the water cement ratio be permitted during hotter weather.

4

All concrete materials and proportions used in periods of hot weather shall be those that have a satisfactory record of use in such conditions.

15.5

TEMPERATURE CONTROL

15.5.1

General

1

The Contractor’s specific proposals for the control of the concrete temperature shall include extent and type of shading of aggregates, method of chilling mix water and procedures for batching and mixing, transportation, placing and finishing, curing and protection.

2

These shall include calculations in accordance with ACI 305R, clause 3.1 “estimating concrete temperature”. The Contractor shall calculate the temperature of freshly produced concrete based on the input temperatures of the constituent materials and the weights from particular mix designs. The calculations shall make allowance for the rise in temperature between mixing and placing due to the transportation and waiting period. The calculations shall successfully demonstrate that the temperature can be maintained below 32 C at the point of placing.

15.5.2

Aggregates

1

All practical means shall be employed to keep the aggregates as cool as possible.

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15.3

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Page 5

Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is not incident on the aggregates. Shades shall be constructed to allow access for mechanical shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool the aggregate.

3

Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall not be permitted.

15.5.3

Water

1

Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

2

The water shall be chilled by the use of proprietary chillers or the addition of ice to the water tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited directly into the mixer.

3

Water shall not be chilled below a temperature of 5 C.

4

Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and painted white.

5

The mechanical refrigeration equipment and insulated water storage shall be adequate for the anticipated hourly and daily production rates of concrete during the hot weather period.

6

Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank, such procedures shall be to the approval of the Engineer.

7

Ice shall be completely melted in mixing water prior to adding water to the mixer.

15.5.4

Cement

1

The use of freshly ground cement at very high temperatures is not permitted.

2

The cement shall be kept below the temperature which there is a tendency of false set.

3

Under no conditions shall the temperature of the cement exceed 75 C when it enters the mixture.

4

The Contractor shall make arrangements for storage on Site to allow cooling of freshly ground and delivered cement.

15.5.5

Addition of Ice

1

Crushed shaved or chipped ice can be used as part of the mixing water for reducing the concrete temperature.

2

The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted before the completion of mixing of the concrete in the pan.

3

To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of the batch water requirement.

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Page 6

Crushed ice shall be stored at a temperature that will prevent lumps from forming by refreezing of particles.

5

The batching plant shall incorporate a mechanical system for correctly proportioning and weighing the ice to be added to the mixture.

6

The quantity of ice shall be deducted from the total batch water.

7

The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated storage on the Site at the plant to meet the anticipated daily and hourly production rates of concrete during the hot weather period.

15.5.6

Liquid Nitrogen

1

Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

2

Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not frozen.

3

The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and injection facility for the batching plant or one or more injection stations for truck mixers.

4

The system may be set up at the Site for injection just before placing.

5

Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.

15.6

BATCHING AND MIXING

1

The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.

2

Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with water and the drum flushed out with cold water before batching. Care shall be taken to ensure all water is removed from the drum before batching.

3

The temperature of the concrete shall be checked after discharge from the mixer and written on the delivery ticket. Temperature check shall be carried out at the plant on the concrete 3 floor for every 50 m produced or every hour which ever is the minimum.

4

A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN 480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature conditions.

15.7

TRANSPORTATION

1

The transportation, placing, compaction and finishing of concrete shall be at the fastest possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of placement and compaction.

15.8

PLACING AND FINISHING

1

If the temperature of the first truck of concrete of a particular pour is above the specification maximum temperature limit then placing shall not commence.

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Page 7

If a pour is in progress and the temperature of a particular truck exceeds the maximum permitted temperature the placing may be allowed to continue at the discretion of the Engineer in order to avoid the possible development of a cold joint.

3

However, no further concreting pours shall take place until the Contractor has submitted revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the maximum temperature will not be exceeded in the future. Before beginning new pours the temperature of the concrete constituent materials shall be monitored to verify that they meet the assumptions of the calculations.

15.9

CURING AND PROTECTION

1

Curing and protection shall conform to the requirements of Part 10 of this Section.

2

Evaporation shall be minimised, particularly during the first few hours subsequent to placing concrete, by suitable means such as applying moisture by fog spraying or any other means acceptable to the Engineer.

15.10


1

All thermometers used for the measurement of concrete temperature shall be calibrated weekly against a glass mercury thermometer. Calibration shall be carried out over the temperature range of 10 C to 100 C using a water bath with ice or heating.

2

The method used to determine acceptance of temperature controlled concrete should be in accordance with ASTM C1064.

3

All concrete test specimens for strength or other purposes shall be carefully protected and cured.

4

Specimens shall be protected from accidental damage by plant personnel or equipment on Site.

5

Specimens shall be kept moist by the addition of water or covering by suitable curing materials.

6

The exact time of preparation of the specimen on Site shall be noted and the time when it is transferred to the laboratory. These times shall be written on the test report.

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END OF PART

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Page 1

MISCELLANEOUS .................................................................................................. 2

16.1 16.1.1 16.1.2


16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.2.5 16.2.6 16.2.7 16.2.8

PAVEMENT QUALITY CONCRETE ........................................................................ 3 Scope 3 Mix Designs 3 Cement 4 Water 4 Aggregates 5 Admixtures 5 Air content 5 Density 5

16.3 16.3.1 16.3.2 16.3.3

CEMENTITIOUS GROUT ........................................................................................ 6 General 6 Material 6 Workmanship 6

16.4 16.4.1 16.4.2

SCREEDS ............................................................................................................... 7 Scope 7 General 7

16.5

CELLULAR CONCRETE ......................................................................................... 9

16.6 16.6.1 16.6.2 16.6.3

REPAIR OF CONCRETE ........................................................................................ 9 General 9 Honeycombing or Spalling 9 Crack injection 11

16.7

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13 General 13 Resin 13 Minimum strength 14

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16.7.1 16.7.2 16.7.3

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16

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Page 2

16

MISCELLANEOUS

16.1

GENERAL

16.1.1

Scope

1

This Part deals with miscellaneous items related to concrete works including pavement quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair of concrete and guniting.

2


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Part 2, .............. Aggregate Part 3, .............. Cementitious Material Part 4, .............. Water Part 5, .............. Admixture Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Placing of Concrete Part 9, .............. Formwork Part 10, ............ Curing Part 15, ............ Hot Weather Concreting.

.

This Section

References

1


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16.1.2

ACI 506, .....................Guide to Shotcrete

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ASTM C989 –10, ........Standard Specification for Slag Cement for Use in Concrete and Mortars

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BS 146,.......................Portland-blast furnace cement

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BS 812,.......................Testing aggregates BS 1881,.....................Testing concrete

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BS 2782,.....................Methods of testing plastics BS 3892,.....................Pulverised fuel ash BS 4551,.....................Methods of testing mortars, screeds and plasters BS 5075,.....................Concrete admixtures BS 6319,.....................Testing of resin and polymer / cement compositions for use in construction BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement. BS 8203,.....................Code of practice for installation of resilient floor coverings. BS 8500,.....................Concrete BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for common cements BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2, 4, 5, 6, 8, 10, 11, and 12) BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6) BS EN 998,.................Specification for mortar for masonry

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Page 3

BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis BS EN 12350,.............Testing fresh concrete BS EN 12390-5, .........Flexural strength of test specimens BS EN 12620,............. Aggregates for concrete EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 12350, ..................Testing fresh concrete EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis

.

GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

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SHW 1000 ..................Specification for Highway Works – UK ROAD PAVEMENTS – CONCRETE MATERIALS

PAVEMENT QUALITY CONCRETE

16.2.1

Scope

1

This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement bound granular material used as a roadbase or sub-base or as a backfill material for excavations.

16.2.2

Mix Designs

1

Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1 below, in accordance, with the pavement design shown on the Drawings or as directed by the Engineer.

2

All concrete for use in pavements shall be designed mixes or equivalent standard mixes in accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where otherwise specified.

3

Prescribed mixes may be used for rapid construction with the approval of the Engineer.

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16.2

Table 16.1 Pavement Grades Pavement Layer


Surface Slabs Unreinforced Concrete

C40

Jointed Reinforced Concrete ( JRC )

C40

Continuously Reinforced Concrete Pavement ( CRCP )

C40

Continuously Reinforced Concrete Roadbase ( CRCR )

C40

Ground Anchorage Beam

C40


QCS 2014


Page 4




C20

ST4


C15

ST3


C10

ST2


C7.5

ST1

Pavement Layer

Cement

1

The general term 'cement' in this Part means the materials shown below.

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16.2.3

Complying with

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Cement

EN 197-1

Specification for pozzolanic pulverised-fuel ash cement (grades C20 or below)

BS 6610

BS 146 or EN 197-4

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Cement. Composition, specifications and conformity criteria for common cements Portland blast furnace cement

The use of a combination of Portland cement and ground granulated blast furnace slag is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix.

3

The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix. PFA shall be in accordance with BS 3892.

4

The use of microsilica in the mix designs will be permitted if approved by the Engineer.

5

The Engineer will stipulate the minimum combined cementitious material content required for the mix where PFA or GGBFS are used.

6

The maximum proportion of ground granulated blastfurnace slag with Portland cement shall be as per Table 6.6 of Part 5.6.

7

In combination with Portland cement, the proportion of PFA by mass to the total cement shall be as per Table 6.6 of Part 5.6.

8

The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

9

The minimum cement content for concrete pavements shall be preapproved by Qatar Standards.

16.2.4

Water

1

Water for use in the making and curing of concrete shall conform to the requirements of Part 4 of this Section.

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Page 5

The water content shall be the minimum required to provide the agreed workability for full compaction of the concrete to the required density, as determined by trial mixes or other means approved by the Engineer..

16.2.5

Aggregates

1

The requirements of Part 2 of this specification will govern, except as modified below.

2

Aggregates for all pavement concrete shall be complying with BS EN 12620

3

Alternatively coarse aggregate of recycled and secondary aggregate materials may be used to replace up to 50% by mass of coarse aggregate

4

The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not exceed 20 mm.

5

If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate combination to check for the possibility of alkali silica reaction. Such tests shall be carried out in accordance with the procedure laid down in Part 2 of this Section.

16.2.6

Admixtures

1

Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN 934. Admixtures containing calcium chloride shall not be used.

2

Other chloride-free admixtures may be used with the approval of the Engineer.

16.2.7

Air content

1

The total quantity of air in air-entrained concrete as a percentage of the volume of the mix shall be 5  1.5 % for mixes of nominal aggregate size 20 and be 4  1.5 % for mixes of nominal aggregate size 40.

2

The air content shall be determined at the point of delivery by a pressure type air meter in accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at least six times per day whichever is the greater, in conjunction with tests for workability and strength. For areas less than 300 m2, the rate shall be at least one determination to each 20 m length of slab or less constructed at one time or at least three times per day. If the air content is outside the specified limits, a further determination shall be made immediately on the next available load of concrete before discharging. If the air content is still outside the limit, the Contractor shall immediately adjust the air content of the concrete to improve its uniformity, before further concrete is used in the Works.

3

The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure uniform distribution of the agent throughout the batch during mixing.

16.2.8

Density

1

The density of concrete Grades greater than C30 shall be such that without air-entrainment the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.

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The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the theoretical maximum dry density.

16.3

CEMENTITIOUS GROUT

16.3.1

General

1

This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be used to where it is necessary to eliminate shrinkage when filling the void between a base plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including masts, anchor bolts and fence posts.

2

The grout shall be supplied by a reputable construction chemical company as a single pack prepackaged cement based product which is chloride free.

3

For a particular application, the Contractor shall submit a method statement detailing how the formwork will be placed and the points where the grout will be poured.

4

Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of the materials and methods with the suppliers representative being present to train the Contractor’s personnel in the correct use of the material.

16.3.2

Material

1

The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing and non shrink.

2

Positive volumetric expansion shall take place while the grout is plastic by means of gaseous expansion to avoid shrinkage and cracking.

3

The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.

4

The grout shall exhibit a high early strength gain yet not be subject to cracking or other detrimental effects.

5

At ambient temperatures above 35 C, cool water shall be used for mixing the grout before placing.

16.3.3

Workmanship

1

The storage handling and pouring of the grout shall be in strict accordance with the manufacturer’s instructions.

2

The substrate surface shall be free from oil grease or loose or partially bonded material.

3

If the concrete surface is defective or has laitance it shall be cut back to a sound base.

4

Bolt holes and fixing pockets shall be blown clean of dirt or debris.

5

The substrate shall be soaked with fresh potable water before grouting, although immediately before grouting, free water shall be removed and blown out of bolt holes or pockets.

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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide. For larger base plates or flow areas the manufacturers instructions shall be followed.

7

Base plates and metallic items shall be clean and free from oil, grease, or scale.

8

Vent holes shall be provided to allow the release of air from isolated spots.

9

Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between the constructive formwork and joints. Formwork shall extend above the required pour height and if necessary shall be extended to allow a hydrostatic head to aid placement.

10

The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

11

The quantity of water to be added to the preweighed bags shall be enough to give the desirable consistency as trowelable or flowable.

12

Mixing shall take place for a minimum of 5 min.

13

The grout shall be placed within the time limit specified by the manufacturer depending on the actual application temperature.

14

Grout shall be poured from one side and it shall be verified that the grout has flowed under all of the base plate with no voids. Pouring from several sides shall not be permitted.

15

Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.

16.4

SCREEDS

16.4.1

Scope

1

This Subpart covers screeds that provide by means of a layer of mortar a level surface in flooring applications and to provide falls on flat concrete roofs.

16.4.2

General

1

Screeds shall be suitable for application onto a concrete substrate.

2

The screeds shall be suitable for receiving surface finishes which may arrange from thin flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

3

Screed mortars shall generally comprise sand and cement modified by additives or substituted by other materials such as polymers in order to provide specific performance requirements.

4

For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of 10 mm aggregate.

5

Aggregates used for screeds shall not contain deleterious materials such as coal or iron particles which may affect the finish the surface of the screed.

6

Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening and shall comply with the appropriate part of BS EN 480 and BS EN 934.

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7

Polymer based additives may be used to improve adhesion and strength of thin or featured screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or acrylic polymers.

8

Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

9

Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used strictly in accordance with the manufacturers’ instructions.

10

The interface of the screed in the concrete substrate shall be specified as one of the following options by the Engineer: Monolithic with the concrete base: The screed shall be applied within 3 hours of placing the concrete base.

(b)

Bonded to the concrete base: Screed shall be laid onto a concrete base which is hardened and is subsequently been prepared to receive the screed, the minimum thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

(c)

As an unbonded screed: The screed shall be laid on a separating layer.

(d)

As a floating screed: The screed shall be laid on an insulating material.

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The cement and sand screed mix shall have the minimum amount of water added to give sufficient workability and allow the material to be thoroughly compacted.

12

Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water and admixtures shall ensure a thorough homogeneous mixture with no balling up of the cement.

13

Screeds shall be laid either between carefully levelled and trued batons or between strips of screed laid and compacted to a finished level.

14

For bonded screed where a high degree of bond is required the surface laitance of the concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer of neat cement grout shall be applied to the prewetted or dampened concrete and the screed applied and compacted while the grout is wet.

15

Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints around the perimeter shall be particularly well compacted to avoid breaking out and curling.

16

Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be kept protected by waterproof sheeting for at least 7 days after laying.

17

Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and necessary strength achieved.

18

If requested by the Engineer the Contractor shall carry out a soundness and impact test in accordance with BS 8203.

19

Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction or movement joints shall be provided as appropriate, where shown on the drawings or as directed by the Engineer. Bays shall be laid alternatively.

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Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick screed.

16.5

CELLULAR CONCRETE

1

Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing, hardening and most important "ageing ". CC infinitely increases its strength by hydration as long as exposed to humidity in the atmosphere.

2

CC offer more thermal insulation and a substantially higher fire-rating than conventional concrete.

3

Minimum compressive strengths shall be 4.0 MPa.

4

The required density and strength of the CC shall be specified on the drawings and approved by the Engineer.

5

The method of production of Cellular Concrete shall be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the CC along with a list of previous projects where the particular system has been used.

6

After source approval of the material and system the Contractor shall submit a mix design for the CLC for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

7


8

Cellular Concrete shall not be used for structural reinforced members.

16.6

REPAIR OF CONCRETE

16.6.1

General

1

The extent and nature of the defects in concrete shall be established in accordance with Part 15 of this Section. Based on these results the Engineer shall confirm the acceptability of the work and whether remedial works are required.

2

If remedial works are required the Contractor shall submit a detailed method statement identifying the specific materials to be used and the sequence of activities for the repair.

3

Only proprietary proven materials that form part of a standard repair system shall be used.

16.6.2

Honeycombing or Spalling

1

Where there is honeycombed concrete or concrete damaged by physical forces such as impact that has caused spalling, the concrete shall be replaced using a high strength free flowing cementitious micro-concrete.

2

The areas of repair shall be marked out and agreed with the Engineer.

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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until sound concrete is reached. Due account shall be taken of propping or other instructions given by the Engineer regarding sequences of removal and repair.

4

The equipment and methods used to break out the concrete shall be such that no reinforcing steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened or damaged unless so directed by the Engineer.

5

Where the removal of concrete by mechanical means is difficult due to reinforcement congestion, then the use of high pressure water jetting shall be considered and necessary provisions for protecting the rest of the structure shall be made.

6

The prepared void shall be profiled so that entrapment of air is avoided during the repair process using fluid micro-concrete.

7

The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be accepted.

8

The prepared concrete surface shall be sound and clean and free of loose particles, dust and debris.

9

Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose millscale.

10

Reinforcement damaged during the removal of concrete or the preparation process shall, if required by the Engineer, be repaired or replaced.

11

Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair material without distortion or movement during placement.

12

The formwork shall be watertight at all joints between panels and between the formwork and the existing concrete surface so as to prevent grout leakage.

13

The formwork shall be constructed from appropriate materials as agreed with the Engineer to achieve the required finish.

14

Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated with a suitable mould release agent. This shall be used in accordance with the manufacturer's recommendations.

15

The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled completely and no air remains entrapped.

16

Where necessary, provision shall be made for controllable bleed points to prevent air entrapment and enable the extent of flow of the repair material to be assessed.

17

The formwork shall be inspected by the Engineer and, if approved, filled with clean water which demonstrates that the formwork is grout-tight and saturates the prepared concrete surfaces. The formwork shall be then be completely drained and resealed

18

In situations where the completed repair will be subjected to constant immersion an epoxy bonding agent shall be applied in accordance with the manufacturers’ instructions.

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19

Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18 and tested at 20 oC

20

The thermal conductivity and the elastic modulus of the repair material shall be compatible with the host concrete.

21

If requested by the Engineer, recent test results of the material for the following properties shall be submitted: (a)

thermal conductivity

(b)

elastic modulus, BS 1881

(c)

expansion characteristics, ASTM C 827, CRD 621-82A

(d)

flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

The micro-concrete shall be mixed and placed in accordance with the manufacturer's recommendations, particularly with regard to water content, mixing equipment and placing time.

23

As far as possible the placing of the micro-concrete shall be continuous. The mixing operation shall be timed so that there is minimal interruption in the material flow. If, however, placing is interrupted, the operation shall recommence as soon as possible while the repair material retains its flow characteristics.

24

The formwork shall not be removed until the repair micro-concrete has achieved a compressive strength of at least 10 MPa or as directed by the Engineer.

25

Immediately after removal of the formwork the repair area shall be cured in accordance with Part 10 of this Section.

26

The repair material shall:

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22

be shrinkage compensated in both liquid and cured states

(b)

contain no metallic expansion system

(c)

be prepacked and factory quality controlled

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be a free-flowing cementitious material that has a coefficient of thermal expansion fully compatible with the host concrete and which complies with the requirements of Table 16.3.

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(a)

Table 16.3 Property requirements of micro concrete Property

Test Method

Minimum Value


BS EN 12390-3 @ 28 d

50 MPa

Flexural strength

BS 4551 @ 28 d

10 MPa

Anchorage bond

BS 8110

Passes

16.6.3

Crack injection

1

This clause of the specification covers non-active cracks within concrete elements caused by shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.

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Page 12

Before to starting the injection operation it shall be established by testing and investigation work that cracks manifest within concrete elements due to either or both shrinkage or structural movement are non-active.

3

The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be filled shall be marked out in detail on the concrete elements by the Contractor and agreed with the Engineer before proceeding.

4

The extent of the work may be adjusted by the Engineer as the project proceeds, according to the conditions found.

5

Grease, oil or other contaminants shall be removed. Algae and other biological growth shall also be removed by scrubbing with bactericide or detergent and clean water. If necessary, wire brushes shall be used.

6

Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within the marked out scope of the work shall be removed.

7

All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

8

The injection nipples shall be fixed at intervals along the length of each crack. The distance between each nipple will depend on the width and depth of the crack.

9

Spacing shall be close enough to ensure that the resin will penetrate along the crack to the next point of injection. This will normally be between 200 mm and 100 mm.

10

Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant shall be supplied in two pans (liquid base and hardener system). The two components shall be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.

11

The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall be pressed firmly into place and held for several seconds until secure. The mixed sealant shall be applied around each embedded nipple, ensuring a complete seal is made. In this way, all the nipples shall be fixed along the length of the crack.

12

In the case of a wall or slab which is cracked all the way through, nipples shall be located on both sides with those at the back placed at midway points between those it the front.

13

The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to 40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or slab shall be sealed in this way.

14

The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures (5 °C to 12 °C) the curing time will be extended and the Contractor shall ensure that the surface sealant has adequately cured before continuing.

15

One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to either end of horizontal cracks.

16

Each crack shall be treated in a single, continuous operation. Sufficient material shall therefore be made ready before the commencement of the work.

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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of the mixed material.

18

The preparation, mixing and application of the materials shall be undertaken in strict accordance with the manufacturer's recommendations. The Contractor is to ensure that all necessary tools and equipment are on Site.

19

Both the compressive strength and flexural strength shall be tested at 7 d.

20

The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the failure shall be in the concrete and not at the interface.

21

The injection resin shall be of a prepackaged or preweighed type and only the use of full units will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

22

In all operations of storage, mixing and application, the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

23

The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this time.

24

The nipples and bands of surface sealant shall then be removed and damaged areas made good to the satisfaction of the Engineer.

25

The injection material shall be compatible with the host concrete and shall have the properties shown in Table 16.4 when tested in accordance with the relevant standards.

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Property

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Table 16.4 Property Requirement for Epoxy Crack Injection Material Method

BS 4551, BS 2782 BS 6319

Flexural strength

BS EN 12390-5

70 MPa

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Minimum Value

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE

16.7.1

General

1


2


16.7.2

Resin

1


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2

The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method D648. The resin content shall not be less than 7 % of the weight of the sample as determined by Test Method D2584.

16.7.3

Minimum strength

1

The minimum strength classes for different pipe shapes are given below. Table 16.4

.

Minimum strength classes for pipes designated PRC-OC or PRC-TC Strength class Sc Nominal size N/mm DN PRC-TC

150 ≤ DN ≤ 500

180

180

600 ≤ DN ≤ 1000

145

1200 ≤ DN≤ 3000

120

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160

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145

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Table 16.5 Minimum strength classes for pipes designated PRC-OE or PRC-TE Strength class Sc N/mm

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PRC-TE

300/450 ≤ WN/HN ≤ 600/900

180

180

700/1050 ≤ WN/HN ≤ 1000/1500

145

160

120

145

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1200/1800 ≤ WN/HN ≤ 1400/2100

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Table 16.6 — Minimum strength classes for pipes designated PRC-OK or PRC-TK Strength class Sc N/mm

Nominal size DN

PRC-OK

PRC-TK

800 ≤ DN ≤ 1000

145

160

1200 ≤ DN ≤ 1800

120

145

END OF PART

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 1

STRUCTURAL PRECAST CONCRETE .................................................................. 2

17.1 17.1.1 17.1.2 17.1.3 17.1.4 17.1.5 17.1.6 17.1.7 17.1.8 17.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Qualifications 4 Quality Assurance 4 Quality Control 5 Testing 6 Delivery, Storage and Handling 7 Design Loadings, Actions and Structural Members Selection 7

17.2 17.2.1 17.2.2 17.2.3 17.2.4

MATERIALS ............................................................................................................ 8 General 8 Reinforcing Bars 8 Bearing Pads 8 Embedded Steel 8

17.3 17.3.1 17.3.2

FORMING ............................................................................................................... 8 General 8 Tolerances 9

17.4 17.4.1 17.4.2 17.4.3 17.4.4 17.4.5 17.4.6 17.4.7 17.4.8

INSTALLATION ....................................................................................................... 9 General 9 Survey 9 Guying, Bracing and Shoring 9 Adjustment and Correction 9 Erection Tolerances 10 Welding 10 Grouting 10 Field Cutting 10

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STRUCTURAL PRECAST CONCRETE

17.1

GENERAL

17.1.1

Scope

1

The work included in this Section comprises furnishing all plant, labour, equipment, appliances and materials and performing all operations in connection with Structural Precast Concrete Work.

2


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This Section Part 2 ............... Aggregates Part 3 ............... Cementitious materials Part 5 ............... Admixtures Part 6 ............... Property requirements Part 7 ............... Concrete Plants Part 8 ............... Transportation and placing of concrete Part 9 ............... Formwork Part 10 ............. Curing Part 11 ............. Reinforcement Part 15 ............. Hot weather concreting

.

17

References

1


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AASHTO ....................Standard Specification for Highway Bridges, Section 25 ACI 523.2R .................Guide for Precast Cellular Concrete Floor, Roof, and Wall Units

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ACI 533R ....................Guide for Precast Concrete Wall Panels

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ACI 533.1R .................Design Responsibility for Architectural Precast-Concrete Projects ACI 543R ....................Design, Manufacture, and Installation of Concrete Piles

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ACI 550.1R-09............Guide to Emulating Cast-in-Place Detailing for Seismic Design of Precast Concrete Structures ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures ACI 318-11 .................Building Code Requirements for Structural Concrete BS 8110......................The structural use of concrete. BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for buildings ISO 9000, ..................Quality management systems. Fundamentals and vocabulary Prestressed Concrete Institute (PCI) , Manual 116

QCS 2014


17.1.3

Submittals

1

Manufacturer's Literature: (a)

2

the Contractor shall provide copies of manufacturer's specifications and installation instructions for each item of proprietary material to be used, showing compliance with this specification. Information on equipment, embedded items and other accessories shall also be provided.

Design Mixes: (a)

copies of mix designs with support material

(b)

the requirements of the mix design shall be in accordance with Parts 6 and 7 of this Section.

Product Design Criteria:

initial handling and erection stresses

(ii)

all dead and live loads as specified on the contract drawings or as required

(iii)

all other loads specified for the member where they are applicable.

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Product Design Calculations: (a)

the design calculations shall be performed by a Structural Engineer experienced in precast concrete design. They shall cover all stages of handling, transportation and erection. The design shall be carried out in accordance with the requirements of BS EN 1992-1-1 or relevant ACI codes, and shall be accepted by the Engineer.

(b)

calculations for the design of precast members shall be supported by a statement explaining the principle of design and type of analysis adopted

(c)

the influence of individual members in achieving the overall stability of the structure should be considered

(d)

computer programmes used in the designs shall be fully described and details of input and printout shall be presented in a manner which can be readily understood and the following requirements shall be met:

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loadings for design:

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(a)

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programme manuals and instructions to programme users shall be made available to the Engineer upon request

(ii)

where such programme cannot be demonstrated by the Contractor to have been fully checked or where the Engineer considers it necessary, the Contractor shall run such test examples as the Engineer may choose, in order to verify the completeness and accuracy of the programme

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(i)

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(e)

members that are exposed to the weather shall be designed to provide for the movement of components without damage, failure of joint seals, undue stress on fasteners or other detrimental effects when subject to seasonal or cyclic day/night temperature ranges

(f)

precast systems shall be designed to accommodate construction tolerances, deflection of other building structural members and the clearance of intended openings

(g)

calculate structural properties of framing members in accordance with BS 8110 or BS EN 1992-1-1, or relevant ACI codes.

Shop Drawings. The Contractor shall provide the following information for the approval of the Engineer: (a)

layout plans and detailed fabrication and placement drawings for each structural precast element

QCS 2014

(b)

size, grade, profile and dimensions of all materials used

(ii)

connection and anchorage details

(iii)

lifting devices, locations and handling limitations

(iv)

steel reinforcement details

(v)

all openings, sleeves, inserts and other provisions in full co-ordination with all trades in the Contract

(vi)

identification marks.

.

detailed outline of sequence and methods of erection including but not limited to types, capacities and numbers of cranage, methods of support and transportation.

(ii)

date of pour

(iii)

concrete test results

(iv)

shop drawing reference number

(v)

type and duration of curing

(vi)

date of delivery to Site

(vii)

date of fixing in position.

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copies of all testing and inspection reports.

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the Contractor shall produce trial panels in accordance with the requirements of Part 10 of this Section. trial panels shall be retained for reference purposes for the acceptance of the production work.

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type and number

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(i)

Trial Panels: (a)

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A record shall be kept for every piece of precast element produced showing the following:

Test Reports: (a)

9

(i)

Fabrication Records: (a)

8

shop drawings are to include the following information:

Erection Procedures: (a)

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17.1.4

Qualifications

1

Structural precast work shall be executed by an approved specialist Subcontractor for casting and also for transportation, handling and erection.

2

The Contractor may execute this work himself if he can satisfy the Engineer that he has sufficient experience and expertise in this field. As a minimum the Contractor shall: (a)

provide satisfactory evidence that his tradesmen and their supervisory personnel engaged in such work have successful experience with work comparable to that shown and specified

(b)

provide details of organised quality control and testing procedures.

17.1.5

Quality Assurance

1

The precast concrete supplier shall have a quality assurance scheme that meets ISO 9000 or equivalent.

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Page 5

All work shall be performed to secure for the project homogeneous concrete having the required strength, surface finish, materials, durability, and weathering resistance, without planes of weakness or other structural defects, and free of honeycombs, air pockets, voids, projections, offset of plane and other defacements of concrete.

3

No alterations or substitutions of the structural systems shown on the Drawings are permitted unless otherwise specified.

4

The Contractor shall supervise and co-ordinate all phases of the structural precast concrete construction process and be responsible for the complete manufacturing process.

5

All methods of manufacture and practices of handling raw materials and manufactured concrete shall be reviewed by the Engineer before execution of the structural precast concrete work, at least 14 days before the beginning of precasting work.

6

Only materials of known quality shall be incorporated in the work.

7

All materials shall be properly selected, reviewed and approved by the Engineer before use, and maintained during shipment, storage and use.

8

Construction systems and techniques shall be properly selected, reviewed and approved by the Engineer before use, and maintained throughout the complete structural precast concrete construction phase.

9

Adequate spare equipment, parts, additional components and repair facilities shall be available for all tools and equipment.

10

Regardless of approvals by the Engineer, the Contractor shall be responsible for all materials and methods of structural precast concrete work.

11

If work does not meet the specified requirements, the Contractor shall at no additional cost to the Employer:

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implement removal, replacement or remedial work

(b)

revise procedures or materials to prevent recurrence of unacceptable work.

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(a)

Quality Control

1

The Contractor shall prepare and provide his quality control programme for structural precast concrete work with particular attention to details, pre-checking processes, procedures and close supervision, and in particular the Contractor shall:

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17.1.6

2

(a)

in order to assure that proper work is performed to prevent later corrective actions, assign at least one experienced supervisor full time to provide quality control for structural precast concrete work

(b)

the assignment will not relieve the Contractor's other quality control personnel of their duties relative to the quality control of the structural requirements and surface finish of the structural precast concrete work.

The Contractor shall arrange for the training of his quality control personnel who will perform quality control of structural precast concrete work and whose training shall include but not be limited to: (a)

materials evaluation

(b)

special mix design techniques

(c)

mix placement

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(d)

vibrator selection and use

(e)

formwork details formwork protection

(f)

release agent use

(g)

reinforcing steel

(h)

detailing and installation

(i)

finishing equipment and techniques

(j)

corrective procedures and protection of completed work.

Page 6

The Contractor's quality control personnel shall be responsible for verifying all details necessary to produce the final structural design objectives.

4

The Contractor's quality control personnel shall also verify the quality of the structural precast concrete work and guide the production of results which will be within acceptable physical tolerances

17.1.7

Testing

1

Concrete shall be tested as specified in Part 6 of this Section.

2

The Contractor shall:

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furnish labour required to facilitate testing

(b)

inform the Engineer with at least one day's advance notice when concrete is to be placed

(c)

provide storage facilities for concrete test cubes

(d)

provide material samples and access to materials as required for testing.

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(a)

Should the batching plant be located more than 500 meters away from the site offices, the Contractor shall provide suitable transport acceptable to the Engineer, for the sole use of the Engineer's staff.

4

The Contractor shall station a qualified technician at the casting site to continuously test, inspect and report on the following:

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(a)

that concrete testing is being carried out in accordance with the requirements of Part 6 of this Section

(b)

check the following and verify conformance with specified requirements and approved shop drawings:

(c)

5

(i)

all reinforcing bars

(ii)

all embedded items

(iii)

all formwork

check all openings and provisions for co-ordination with all trades in the Contract as shown on approved shop drawings.

The Contractor shall provide facilities and equipment for the conducting of all tests specified herein except for the strength test which should be carried out by an approved independent testing agency.

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1

The structural precast elements shall be removed from the form without damaging or over stressing and stored or placed for transportation on a stable bed that will not allow distortion of the member.

2

Separate stacked members with suitable battens and bracing.

3

Mark each member with an identifying reference or piece mark, and the date of casting.

4

All piece marks are to be correlated with test reports and plan layouts or erection drawings.

5

The structural precast element shall be transported with sufficient battens, bracing, and supports so as to prevent over-stress by vibration or impact loadings. The Contractor shall submit his proposed method of transportation to the Engineer for approval.

6

Structural precast units shall be stored, handled and transported in a manner that will avoid undue strains, hair cracks, staining, or other damage.

7

The Contractor shall deliver the units from the casting site to the project Site in accordance with schedule and proper setting sequence.

8

Structural precast units shall be stored free of the ground and protected from wind or rain splashes.

9

The units shall be covered and protected from dust, dirt or other staining materials.

10

During fabrication, construction and after erection, the Contractor shall protect the castings to avoid the possibility of damage.

17.1.9

Design Loadings, Actions and Structural Members Selection

1

The provisions of this Clause shall apply if the Contractor is responsible for the design of the structural precast units.

2

The precast elements shall be designed to withstand all loading conditions against which strength and serviceability must be measured.

3

Vertical loads shall include the self-weight of precast elements, floor coverings and live loads as indicated on the contract drawings.

4

The wind loads shall be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.

5

Account shall be taken of the loads and deformation caused by temperature and time dependent deformations. For such purpose 55 °C temperature variation and 90 % relative humidity should be considered for all members, except exterior elements and facade o elements shall consider 85 C.

6

Precast elements shall be designed in accordance with BS EN 1992-1-1 or relevant ACI code. Design tensile stresses should not exceed the design flexure tensile stress of concrete, at the particular age of the concrete.

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17.1.8

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Nominal cover to steel including links must meet the durability requirement of severe condition of exposure and to meet requirement for 2 h period of fire resistance, as provided for in BS EN 1992-1-1 or relevant ACI code.

8

Total deflection of precast elements should be limited to 1/350 of the span of this element.

9

Plan and design for openings for building services, where required or necessary.

17.2

MATERIALS

17.2.1

General

1

The Contractor shall obtain cement, aggregates and water from a single source, sufficient to complete the entire structural precast concrete work to assure regularity of appearance and uniformity of colour.

2

The Contractor shall provide all materials in accordance with and meet all applicable requirements of this section.

17.2.2

Reinforcing Bars

1

Reinforcing bars shall conform to the requirements of Part 11 of this Section

17.2.3

Bearing Pads

1

These shall be Elastomeric neoprene, conforming to AASHTO Standard Specifications for Highway Bridges (Section 25) with the following stipulations: use unfactored loads for design

(b)

maximum compressive stress, 0.70 MPa

(c)

maximum shear stress, 0.07 MPa

(d)

maximum shear deformation, 1/2 thickness

(e)

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maximum compressive strain, 15 %

17.2.4

Embedded Steel

1

All embedded items shall be of stainless steel Grade 316L.

17.3

FORMING

17.3.1

General

1

Forms and casting beds are to be firmly seated so as not to deflect or be displaced under concreting or tensioning loads.

2

Correct for thermally induced strains or forces.

3

For member penetrations larger than 150 mm, coring or field cutting is not permitted unless approved by the Engineer.

4

Clean and coat forms with release agent before installation or reinforcing or embedments.

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17.3.2

Tolerances

1

Permissible deviations of formed surfaces are not to exceed tolerances outlined in PCI Manual 116, with items as summarised or modified in Table 17.1

Table 17.1 Tolerances for Structural Precast Concrete Description

Tolerance

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5 mm 3 mm Stem 3 mm; Flange 2.0 mm. 0.2 % 3 mm. for 300 cm 3 mm

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Dimensions Length: Width: Thickness: Embedment or penetration location: Straightness: End squareness:

INSTALLATION

17.4.1

General

1

The Contractor’s erection responsibilities include the safe and proper placing, aligning, and levelling of the structural precast elements on the accepted bearing surfaces and affecting their proper fastening.

17.4.2

Survey

1

Before placement of the structural precast elements the Contractor shall survey and maintain all temporary supports shown or required to control alignment, and deflection.

2

Temporary supports shall be retained until framing elements braced thereby have attained integral stability in accordance with the design.

17.4.3

Guying, Bracing and Shoring

1

The Contractor shall install in proper sequence and maintain all temporary supports shown or required to control alignment, deflection and stress levels.

2

Temporary supports shall be retained until framing elements braced thereby have attained integral stability in accordance with the design.

17.4.4

Adjustment and Correction

1

The Contractor shall compensate and correct for the misaligning affect of temperature, draw from welding, bolting or erection sequence or grouting.

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17.4

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17.4.5

Erection Tolerances

1

The following erection tolerances shall apply unless otherwise specified in the Contract: (a)

Variations from plumb

6 mm in 6 m run; 12 mm total in a12 m or longer run

(b)

Variation from level or elevation

6 mm in runs; 12 mm in 12 m run; maximum 12 mm at single locations 12 mm maximum.

(c)

Variation from position in plan

(d)

Offsets in alignment of adjacent 1.5 mm in 3 m run, 6 mm maximum.

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Welding

1

Where permission for welding is given by the Engineer, the following shall apply:

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17.4.6

welding shall not take place until all adjacent elements to be connected have been aligned, firmly seated and braced

(b)

control of heat build-up by limiting voltage, electrode size, and rate

(c)

spalled or heat damaged concrete around weldments shall not be acceptable.

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(a)

Grouting

1

Joints, gaps and connections shall be filled with grout as shown on the Drawings and as approved by the Engineer.

17.4.8

Field Cutting

1

Field cutting of holes may be done only with the Engineer's concurrence, and only with power saws or core drills. Steel reinforcement or prestressing strand shall be avoided, where the reinforcement or strand is damaged the unit shall be repaired to the satisfaction of the Engineer, or rejected.

2

The maximum hole size shall be 150 mm diameter or as limited by member size or strand location

3

Any cracks, spalls and sharp corners created by field cutting are to be ground, eased, and patched with epoxy type bonding and patching compounds.

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17.4.7

END OF PART

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 1

PRESTRESSED CONCRETE ................................................................................. 2

18.1 18.1.1 18.1.2 18.1.3 18.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Storage and Handling 3

18.2 18.2.1 18.2.2 18.2.3 18.2.4 18.2.5 18.2.6 18.2.7 18.2.8 18.2.9

PRESTRESSING .................................................................................................... 3 General 3 Wires and Strands 4 Sheaths, Cores and Ducts 5 Anchorages 5 Jacking Equipment 5 Tensioning 6 Grouting 7 Grout Mixer 7 Grout Trials 8

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18

PRESTRESSED CONCRETE

18.1

GENERAL

18.1.1

Scope

1

This section describes the requirements for prestressed post-tensioned concrete, including materials and procedures for installation, stressing and grouting.

2


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ACI 325.7R ------------- Recommendations for Designing Prestressed Concrete Pavements ACI 343R ---------------- Analysis and Design of Reinforced Concrete Bridge Structures ACI 350.3R ------------- Seismic Design of Liquid-Containing Concrete Structures ACI 358.1R ------------- Analysis and Design of Reinforced and Prestressed-Concrete Guideway Structures ACI 372R ---------------- Design and Construction of Circular Wire- and Strand-Wrapped Prestressed-Concrete Structures ACI 373R ---------------- Design and Construction of Circular Prestressed Concrete Structures with Circumferential Tendons ACI 423.3R ------------- Recommendations for Concrete Members Prestressed with Unbonded Tendons

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Part 2 ............... Aggregates Part 3 ............... Cementitious Material Part 4, ........... Water Part 5, ........... Admixtures Part 6, ............ Property requirements Part 7, ........... Concrete Plants Part 8, ............ Transportation and placing of concrete Part 9, ........... Formwork Part 10, ........... Curing Part 11, ........... Reinforcement Part 15, ........... Hot weather concreting Part 16, ........... Miscellaneous

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This Section

ASTM A881/A881M -- Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties ASTM A882/A882M--- Standard Specification for Filled Epoxy-Coated Seven-Wire Prestressing Steel Strand ASTM A641/A641M – Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire ASTM A416/A416M-10 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete AWWA D110-------------Wire- and Strand-Wound, Circular, Prestressed Concrete Water Tanks BS 1881......................Testing Concrete. BS EN 12350,.............Testing fresh concrete

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BS EN 12390,.............Testing hardened concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS EN 1992

Eurocode 2: Design of concrete structures

GSO ISO 1920, .......... Testing of concrete 18.1.3

Submittals

1

Samples

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Technical details of the proposed materials and equipment shall be submitted. Details of the jack type and size shall be submitted to allow for clearances to be checked. A calibrated stress-recording device shall be used. Design Data. The Contractor shall submit:

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(c)

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(b)

a 1 m length sample of strand shall be taken from every 1000 m of strand to be installed in the works with a minimum of one sample of strand per reel, on Site in the presence of the Engineer for strength test at an independent laboratory approved by the Engineer. A reel shall only be accepted if both the breaking load and the 0.1 % proof load of the sample exceed the characteristic load given in BS 5896 Table 6 a minimum of three samples of strand shall be taken at random from each reel of prestressing steel on Site in the presence of the Engineer. The reels on Site shall only be accepted if the relaxation values determined by the tests are equal to or lower than the specified relaxation class of BS 5896. Sample requirements and frequency for prestressing wire shall meet the requirements of AWWA D110 and ACI 372R.

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(a)

(b)

tendon extension calculations

(c)

vent pipe spacing and location details.

(d)

detailed execution and shop drawings

(e)

calculation notes

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details of the proposed grout mix design

Other Submittals. The Contractor shall also submit:

Safety procedures, including warning signs, barricades and communication between different stressing locations

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(b)

Curriculum vitae and experience record of the supervisor proposed, who shall have a minimum of five years experience in such a position

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(a)

(c)

The name of the proposed the prestressing company, giving details of previous projects.

18.1.4

Storage and Handling

1

Prestressing steel shall be stored on palettes at least 300 mm above the ground, and be protected from contamination by wind blown sand or rain.

2

Prestressing strand shall be in coils of sufficiently large diameter to ensure that the strand pays off straight.

18.2

PRESTRESSING

18.2.1

General

1

Prestressing operation shall be carried out only under the direction of an experienced and competent supervisor and all personnel operating the stressing equipment shall have been properly trained in its use.

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Page 4

In addition to the normal precautions against accident, which should be taken at all times for the whole of the Works, special care shall be taken when working with or near tendons which have been tensioned or are in the process of being tensioned.

3

The system of prestressing used shall be a system approved by the Engineer. Such system shall be used strictly in accordance with the recommendations of the system manufacturer.

4

Under no circumstances shall equipment or fittings designed for use with one system of prestressing be used in conjunction with equipment and fittings designed for use with another system.

5

Prestressing components shall be stored in clean dry conditions. They shall be clean and free form loose rust and lose mill scale at the time of fixing in position and subsequent concreting. Slight rusting of the steel, which can be removed by moderate rubbing, is acceptable, but the surface shall not show signs of pitting.

18.2.2

Wires and Strands

1

All prestressing strands shall be seven-wire super stabilised low relaxation strands with a Guaranteed Ultimate Tensile Strength (GUTS) of not less than 1770 MPa, complying with BS 5896 or relevant ASTM standards.

2

All prestressing wire shall be cold-drawn, high-carbon wire meeting the requirements of ASTM A821/A821M, Type B having a minimum ultimate tensile strength of 1,448 MPa (210,000 psi) prior to galvanizing. Zinc coating for galvanizing shall meet the requirements of ASTM A641/A641M, with a minimum weight per unit area of uncoated wire surface of 259 g/m2 (0.85 oz/ft2). The minimum ultimate strength of the wire after galvanizing shall be no less than 1,241 MPa (180,000 psi).

3

All wires or strands to be stressed at the same time shall be taken from the same parcel. The coil numbers of the steel used for each tendon shall be recorded.

4

Welding of tendons shall not be permitted.

5

All cutting of strands shall be carried out using a high-speed abrasive cutting wheel or friction saw at not less than one diameter from the anchor. Cutting shall take place only after the Contractor has submitted the stressing records and the Engineer has approved them in writing. Flame cutting will not be permitted.

6

Tendons shall be built into the Works strictly in accordance with the system which is being employed.

7

Sufficient strand shall project from the anchorage to allow jacking to take place at the stressing end of the tendon.

8

The cable (tendons) or individual strands comprising the cable shall not be kinked or bent. No strand that has become unravelled shall be used.

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Sheaths, Cores and Ducts

1

Sheaths shall be accurately located both vertically and horizontally as described in the Specific Project Specification. Unless otherwise described in the Specific Project Specification the tolerance in the location of the centre line of the sheath shall be within 5 mm.

2

All sheaths and cores shall be maintained in their correct positions during the placing of the concrete. Unless otherwise agreed with the Engineer, sheaths shall be rigidly supported at points not less than 50 mm and not more than 500 mm apart. The method of support shall be to the approval of the Engineer.

3

Where sheaths are used, the number of joints shall be kept to a minimum and sleeve connectors shall be used for jointing. Each joint shall be adequately sealed against the ingress of material. Joints in adjacent sheaths shall be staggered by at least 300 mm

4

Sheaths shall be kept free of matter detrimental to the bond between the grout and the sheath and, except for material sealing a sheath joint, between the sheath and concrete.

5

Within 24 hours of the concrete being placed the Contractor shall satisfy the Engineer that the tendons are free to move if they are in ducts or that the ducts are free from obstruction.

6

The number and position of grout vents for entry and outlet points and for checking that the entire length of duct has been adequately grouted, shall be agreed with the Engineer before the ducts are formed.

7

Vents shall be provided at low points in the tendon profile to allow the disposal of water that may have collected as a result of rain or curing, for example. The vents shall be sealed before grouting operations beginning.

18.2.4

Anchorages

1

Anchorages, end blocks and plates shall be positioned and maintained in position during concreting so that the centre line of the duct passes axially through the anchorage assembly.

2

All bearing surfaces shall be clean before concreting and tensioning.

3

Anchoring of prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.

18.2.5

Jacking Equipment

1

All jacking equipment used for stressing operations shall be of the type applicable to the system adopted.

2

Jack and pumps shall be calibrated at an independent facility, in the presence of the Engineer, before beginning stressing operations. Calibration of the equipment shall take place at six-month intervals for equipment permanently present on Site. Whenever new equipment is brought to the Site, or equipment is removed and returned, or serviced, recalibration of the equipment as described will be required.

3

All gauges, load cells, dynamometers and other devices used for measurement shall have a reading accuracy of within 2 %.

4

Stressing equipment for prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.

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18.2.3

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Page 6

Tensioning

1

The Contractor shall submit details of the proposed stressing loads and stressing sequence to the Engineer for approval.

2

Tensioning shall be carried out only in the presence of the Engineer or his representative unless permission has been granted to the contrary.

3

The Contractor shall ensure that personnel carrying out the stressing are provided with particulars of the required tendon loads, order of stressing and extensions.

4

Immediately before tensioning, the Contractor shall prove that all tendons are free to move between jacking points.

5

Unless otherwise permitted in the Contract, concrete shall not be stressed until it has reached at least the age at which two test cubes taken from it attain the specified transfer strength. The cubes shall be made and tested as described in BS 1881 , BS EN 12350, BS EN 12390 or GSO ISO 1920. They shall be cured in similar conditions to the concrete to which they relate to, and in a manner approved by the Engineer.

6

The friction factors assumed for the calculation of tendon extension shall be verified by on Site measurement of the force-extension relationship of a typical sample of installed tendons.

7

The Contractor shall establish the datum point for measuring extension and jack pressure to the satisfaction of the Engineer.

8

The tendons shall be stressed at a gradual and steady rate until they attain the force required.

9

The maximum force exerted on the shall not exceed 75 % of the GUTS of the strand. For the purposes of cable detensioning, where the installed strand is to be discarded the jacking force may be increased to 80 % GUTS.

10

The force in the tendons shall be obtained from the readings on a load cell or pressure gauge and the extension of the tendons measured. The two readings shall conform to the limits set by the Engineer but in all cases the force in the tendon as computed from the extension measurement shall be within +5 % to -2 % of the force indicated by the gauging system.

11

When stressing from one end only the pull in at the dead end shall be accurately measured and the appropriate allowance made in the measured extension at the live end.

12

If the calculated and measured extensions vary from each other by more than 6 % then corrective action shall be taken. This may involve detensioning and retensioning of the tendons if required by the Engineer.

13

When the required force, including overloads of short duration, has been applied to the satisfaction of the Engineer, the tendons shall be anchored. The jack pressure shall then be relieved in such a way as to avoid shock to the anchorage or tendons.

14

If the pull-in of tendons at the completion of anchoring is greater than that acceptable to the Engineer, the tendons shall be detensioned and the tendon tensioned again.

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18.2.6

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Page 7

The Engineer may direct that the force in any tendon be tested by rejacking. This will only be instructed if there is doubt that the calibration of tensioning equipment is accurate. Care shall be exercised by the Contractor during the retensioning to ensure that the jacking load does not exceed more than 80 % of the GUTS of the strand.

16

If it is necessary to crop the tendons to enable the ducts to be grouted, this shall be delayed as long as is practicable up to the time of grouting. In all other cases, unless otherwise agreed with the Engineer, the tendons shall not be cropped less than three days after grouting.

17

The Contractor shall keep full records of all tensioning operations, including the measured extensions, pressure gauge or load cell readings and the amount of pull-in at each anchorage. Copies of these records, on suitable forms, shall be supplied to the Engineer within 24 hours of each tensioning operation.

18

Tensioning prestressing wires shall meet the requirements of AWWA D110 and ACI 372R

18.2.7

Grouting

1

Grouting shall take place only with the written approval of the Engineer.

2

All ducts shall be thoroughly cleaned by means of compressed air and all anchorages shall be sealed before grouting.

3

Ducts shall be grouted as soon as practicable after the tendons in them have been stressed and the Engineer’s written permission to commence has been obtained. Grout shall be injected in one continuous operation and allowed to flow from the vents until the consistency is equivalent to that being injected. The maximum time between mixing and injection shall not exceed 30 min.

4

The ducts shall be completely filled with grout.

5

Vents shall be sealed consecutively in the direction of flow and the injection tube sealed under pressure until the grout has set. The filled ducts shall be protected to the satisfaction of the Engineer to ensure that they are not subject to shock or vibration for one day.

6

Two days after grouting, the level of grout in the injection and vent tubes shall be inspected and made good if necessary.

7

The Contractor shall keep full records of grouting including the date each duct was grouted, the proportions of the grout and admixtures used, the pressure, details of interruptions and topping up required. Copies of these records shall be supplied to the Engineer within three days of grouting.

8

Prestressing wires shall be protected against corrosion and other damage by a shotcrete cover coat meeting the requirements of AWWA D110 and ACI 372R

18.2.8

Grout Mixer

1

The grout mixer shall produce a grout of colloidal consistency. The grout injector shall be capable of continuous operation with a sensibly constant pressure up to 0.7 MPa and shall include a system of circulating or agitating the grout whilst the actual grouting is not in progress. All baffles to the pump shall be fitted with sieve strainers size BS 14.

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The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be fitted with a nozzle which can be locked off without loss of pressure in the duct.

3

The pressure gauges shall be calibrated before they are first used in the Works and thereafter as required by the Engineer. All equipment shall be thoroughly washed with clean water at least once every three hours during grouting operations and at the end of use for each day.

4

The Contractor shall ensure that standby grouting equipment is available in the event of a breakdown.

18.2.9

Grout Trials

1

The Contractor shall carry out grouting trails to the satisfaction of the Engineer before actual grouting taking place.

2

Unless otherwise directed or agreed as a result of grouting trials, the grout shall:

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consist only of ordinary Portland cement, water and an approved expansion agent

(b)

have a water: cement ratio as low as possible consistent with the necessary workability. Under no circumstances shall the water: cement ratio exceed 0.4

(c)

not be subject to bleeding in excess of 2 % after 3 h or 4 % maximum when measured o at 18 C in a covered glass cylinder approximately 100 mm diameter with a height of approximately 100 mm and the water shall be reabsorbed after 24 h.

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(a)

Admixtures containing chloride or nitrates shall not be used. Other admixtures shall be used only with the written permission of the Engineer and shall be used strictly in accordance with the manufacturer’s instructions.

4

The grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is obtained.

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END OF PART

QCS 2014

Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 1

TESTING OF WATER RETAINING STRUCTURES................................................ 2

19.1 19.1.1 19.1.2 19.1.3 19.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 General 2

19.2 19.2.1 19.2.2

TESTING ................................................................................................................. 2 General 2 Cleaning 3

19.3 19.3.1 19.3.2 19.3.3

TESTING PROCEDURE ......................................................................................... 4 Walls 4 Roofs 5 Disposal of Water Used for Testing 5

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TESTING OF WATER RETAINING STRUCTURES

19.1

GENERAL

19.1.1

Scope

1

This Part of the specification applies to the testing of structures that are designed with the intention of retaining water.

2


References

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19.1.2

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This Section Part 1 ............... General Part 13 ............. Inspection and Testing of Hardened Concrete Part 14 ............. Protective Treatments for Concrete

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BS 8007......................Code of Practice for Design of concrete structures for the retaining of aqueous liquids Submittals

1

The Contractor shall record and submit to the Engineer within 24 hours the results of the watertightness tests carried out.

19.1.4

General

1

Water retaining structures shall be watertight when subjected to external groundwater pressures or to tests as specified in this Part.

19.2

TESTING

19.2.1

General

1

The Contractor shall test watertightness of water retaining structures including storage reservoirs and other miscellaneous structures that require to be watertight.

2

All water used for testing shall be potable or irrigation water and the Contractor shall make arrangements for the supply and disposal of this water.

3

Water retaining structures shall be tested for watertightness after completion, in accordance with the following method or as directed by the Engineer:

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19.1.3

(a)

the structure shall be filled with potable or irrigation water in stages not exceeding 1 m in 24 h held at each water level for such time as the Engineer may require. Should dampness or leakage occur, the water shall be drawn off and the defects remedied to the satisfaction of the Engineer

(b)

in the case of structures which are subdivided into individual tanks, each individual tank shall be tested separately. In the case of underground or partially underground structures, the testing shall take place before application of water proofing membrane, liner material or perimeter drain, filter material or backfilling is placed against the walls

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Page 3

in the case of hopper bottomed tanks, this shall be taken to mean that no material is placed against the vertical external walls of the tank, the sloping walls of the hopper bottoms of the tanks being assumed built directly against the excavation apart from the blinding concrete

(d)

no placing of material against the walls shall take place until the Engineer has given his written approval and acceptance of the water retaining structures as watertight

(e)

filling shall not take place earlier than 28 d after the casting of the final sections of the structure which will be stressed by the filling of the structure.

(f)

testing shall not be undertaken until the structure to be tested has been; completed structurally including roof, if any, and has been passed by the Engineer in writing as satisfactory in all respects other than watertightness, especially in regard to the final finish of the work

(g)

not withstanding the satisfactory completion of the seven day test, leakage, cracks, and damp patches and sweating visible on the outside faces of the structure shall be rectified from the water face by an injection system to the approval of the Engineer

(h)

repair making the outer face only watertight wall not be accepted, this applies to bobbin holes also

(i)

the structure shall be retested until the watertightness is approved by the Engineer.

(j)

should the structure fail a test in the above respects, the Contractor shall immediately take such steps as may be necessary to:

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(c)

ascertain the nature and positions of defects or leakage's

(ii)

empty the structure

(iii)

remedy the defects in a manner approved by the Engineer, employing workers who are specialists in this class of work

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(i)

when the remedial work has been completed in the manner approved by the Engineer, the testing and if necessary rectification shall be repeated until a satisfactory test is achieved.

(l)

if necessary, in extreme cases of lack of watertightness, the Engineer may reject the structure or portions thereof.

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(k)

Cleaning

1

All water retaining structures shall, on completion, be carefully cleaned of all debris, to the complete satisfaction of the Engineer as follows:

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19.2.2

(a)

shall be brushed down on all internal faces with a stiff broom while still dry

(b)

all resulting debris removed

(c)

all associated reservoir pipe work shall be cleaned in accordance with the specified requirements

(d)

the structure shall then be flooded with approximately 75 mm of clean water

(e)

whole of internal faces shall be carefully brushed down with stiff brooms using the water continuously until all faces are clean

(f)

water shall then be drained off

(g)

walls and floors hosed and flushed with clean water until perfectly clean.

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TESTING PROCEDURE

19.3.1

Walls

1

After completion and cleaning of the structure and all associated pipe work, if any, the Contractor shall fill the structure up to the top water level and leave for a stabilising period of 21 d in order to allow for absorption and autogenous healing to take place.

2

Water shall be added over this period to maintain the top water level.

3

The Contractor shall ensure that all pipes and specials are available in ample time ahead of testing.

4

Two sets of evaporation trays shall be provided along with two sets of rain gauges.

5

Levels in the trays and structure shall be made and recorded by a hook gauge with vernier attachments.

6

Before and during testing, flows in the structure under drainage, if any, shall be monitored, measured and recorded.

7

Each under drain shall be numbered and observations reported by under drain number to facilitate analysis of the data.

8

All leaks shall be repaired within one month of their detection.

9

On the twenty-second day, two shallow watertight evaporation trays of area 0.4 m2 shall be filled with 75 mm of water and placed to float in the structure.

10

The water level in the structure shall be recorded and the test commenced and carried out over the next 7 d.

11

Readings of water levels in the structure and trays shall be made and recorded every 24 h over this period.

12

If the water level in the tank falls by more than indicated by the evaporation trays, or other sign of leakage occurs by the end of the test period then the Contractor shall search and mark all areas of defect.

13

The structure shall then be emptied and the defects made good as specified herein.

14

After completion of remedial measures the structure shall be refilled and the test repeated.

15

This process shall be repeated until the structure is watertight to the satisfaction of the Engineer.

16

The fall of water level in the structure over the test period of 7 d, minus the fall accounted for by evaporation and rainfall shall not exceed 1/500 of the average water depth of the full structure or 10 mm whichever is less.

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19.3

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Roofs

1

The roofs of structures shall be tested for watertightness before laying of roof membrane.

2

Roof and fittings shall be hosed down vigorously and this shall be repeated in such a way as to keep the roof wet for three successive days.

3

Roof and fittings shall be deemed satisfactory for watertightness if no discernible leaks or damp patches show in the soffit.

4

Roof covering shall be completed as soon as possible after testing.

19.3.3

Disposal of Water Used for Testing

1

The Contractor shall provide suitable means for disposal of water used for testing, such that no damage results to facilities, structures or property.

2

These means shall be subject to the approval of the Engineer and local authorities.

3

Details shall be submitted to Engineer on request.

4

The Contractor shall be responsible for damage caused by his filling, testing, flushing and wastewater disposal operations.

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19.3.2

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END OF PART

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 1

AGGREGATES ....................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 3 Source Approval 4 Sampling 4

2.2

QUALITY AND TESTING ........................................................................................ 5

2.3

STORAGE AT CONTRACTOR PLANT ................................................................... 5

2.4

FINE AGGREGATE FOR CONCRETE AND MORTAR ........................................... 7

2.5

COARSE AGGREGATE FOR CONCRETE............................................................. 8

2.6

COMBINED AGGREGATE FOR CONCRETE......................................................... 8

2.7

WASHING AND PROCESSING .............................................................................. 9

2.8

LIGHTWEIGHT AGGREGATES.............................................................................. 9

2.9

COARSE RECYCLED AGGREGATES ................................................................... 9

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AGGREGATES

2.1

GENERAL

2.1.1

Scope

1

This part covers the requirements of aggregates for use in structural concrete.

2


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References

ASTM C33 ..................Standard Specification for Concrete Aggregates

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ASTM C40 ..................Test Method for Organic Impurities in Fine Aggregates for Concrete

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ASTM C88 ..................Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C123 ................Test Method for Lightweight Pieces in Aggregate ASTM C127 ................Test Method for Specific Gravity and Absorption of Coarse Aggregate

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ASTM C128 ................Test Method for Specific Gravity and Absorption of Fine Aggregate

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ASTM C131 ................Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse Aggregate ASTM C142 ................Test Method for Clay Lumps and Friable Particles in Aggregates.

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This Section..... Part 3, .............. Cementitious Materials Part 4, .............. Water Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Planning of Concrete Part 15, ............ Hot weather Concreting Part 17, ............ Structural Precast Concrete Part 18, ............ Prestressed Concrete

.

2

ASTM C535 ................Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C702 ................Standard Practice for Reducing Samples of Aggregate to Testing Size ASTM D75 ..................Standard Practice for Sampling Aggregates BRE Digest 330-2.......Alkali-Silica Reaction in Concrete – Detailed Guidance for New Construction. BS 933-3 ....................Tests for geometrical properties of aggregates Determination of particle shape. Flakiness index BS 933-7 ....................Tests for geometrical properties of aggregates Determination of shell content. Percentage of shells in coarse aggregates BS 933-9 ....................Tests for geometrical properties of aggregates Assessment of fines. Methylene blue test

QCS 2014


Page 3

BS 933-11 ..................Tests for geometrical properties of aggregates Classification test for the constituents of coarse recycled aggregate BS 1097-6 ..................Tests for mechanical and physical properties of Determination of particle density and water absorption

aggregates

BS 8500 part 2 ...........Concrete. Complementary British Standard to BS EN 206-1. Specification for constituent materials and concrete BS EN 12620 ..............Aggregates for concrete BS EN 1744-1 ............Tests for chemical properties of aggregates, Chemical analysis BS EN 1744-5 ............Tests for chemical properties of aggregates. Determination of acid soluble chloride salts aggregates. of drying

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BS EN 1367-2 ............Tests for thermal and weathering properties of Magnesium sulphate test. BS EN 1367-4 Determination shrinkage BS EN 933 ..................Tests for geometrical properties of aggregates

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BS EN 1097-2 ............Tests for mechanical and physical properties of aggregates. Methods for the determination of resistance to fragmentation

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BS EN 1097-6 ............Tests for mechanical and physical properties of aggregates. Determination of particle density and water absorption

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BS EN13055-1 ...........Lightweight aggregates. Lightweight aggregates for concrete, mortar and grout. BS PD 6682-1 ............Aggregates for concrete. Guidance on the use of BS EN 12620

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BS PD 6682-4 ............Aggregates Lightweight aggregates for concrete, mortar and grout. Guidance on the use of BS EN 13055-1

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EN 13139 ..................Aggregates for mortar EN 998-1 ...................Specification for mortar for masonry Rendering and plastering mortar

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EN 998-2 ...................Specification for mortar for Masonry mortar ISO 9001:2008 ...........Quality management systems -- Requirements

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ISO 17025 ..................General requirements for the competence of testing and calibration laboratories RILEM AAR1 ..............RILEM Recommended Test Method AAR-1 “Detection of potential alkali-reactivity aggregates”, Petrographic method RILEM AAR3 ..............RILEM Recommended Test Method AAR-3 “Detection of potential alkali-reactivity - 38°C test method for aggregate combinations using concrete prisms 2.1.3

Definitions

1

Aggregate: granular material used in construction and may be natural, manufactured or recycled.

2

Natural aggregate: aggregate from mineral sources which has been subjected to nothing more than mechanical processing.

QCS 2014


Page 4

Manufactured aggregate: aggregate of mineral origin resulting from an industrial process involving thermal or other modification.

4

Recycled aggregate: aggregate resulting from the processing of inorganic material previously used in construction.

5

Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding 2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.

2.1.4

Source Approval

1

The Contractor shall use only those imported materials sourced from an Accredited Quarry Producer or Accredited Supplier and which have been approved by Qatar Standards or their representatives.

2

The accredited aggregate suppliers shall provide the source name(s) for every shipment of aggregates delivered to the concrete supplier.

3

The source of material supply may be changed by the Contractor during the project, provided that the replacement materials shall be sourced from an Accredited Quarry Producer and the replacement materials are not significantly different in terms of physical and chemical properties, thus ensuring that the resultant concrete continues to comply fully with the specified requirements.

4

When considering whether an aggregates supplier and aggregates producer are suitable to be Accredited, preference will be given to organisations with a proper quality management system, such as ISO 9001 or another quality management system approved by Qatar Standards.

5

When requested by the engineer, the aggregate supplier shall provide a geotechnical analysis on the rock samples before blasting and grinding to ensure the proper quality of materials.

6

The aggregates shall be properly stocked and labelled without intermingling at any storage area.

7

When requested by the engineer, the aggregates supplier shall provide data for the past 6 months that shows the consistency of materials and conformity with this specification.

8

The supplier shall verify the compliance of aggregates as per QCS by an independent qualified testing agency accredited to ISO 17025, and approved by Qatar Standards.

2.1.5

Sampling

1

The Contractor shall provide samples of both fine and course aggregate to the Engineer, in accordance with the requirements of relevant standards in QCS for sampling, sample reducing and testing of Aggregates, for testing at least two weeks before beginning deliveries to the Site.

2

All samples shall be taken in the presence of the Engineer or an approved testing agency assigned by the Engineer.

3

Aggregate sampling and testing shall be conducted by qualified staff.

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QUALITY AND TESTING

1

Aggregates shall consist of tough, hard, durable and uncoated particles containing no harmful material in quantities sufficient to adversely affect the concrete or reinforcing steel, and shall contain no materials likely to cause staining or otherwise disfigure the concrete surface.

2

Aggregates shall be obtained from a source approved by the Engineer.

3

Aggregate shall meet the requirements given in Table 2.1. Additional tests detailed in BS EN 12620 with BS PD 6682, EN 13139, EN 998-1, EN 998-2, or relevant ACI and ASTM standards and codes of practice may be required by the Engineer to satisfy certain requirements.

4

Contractor shall provide all data as specified in QCS.

5

Sampling of the aggregates shall be carried out in accordance with the requirements of BS EN 12620, BS EN 933, or ASTM D75 and ASTM C702.

6

Fine aggregates shall be natural sand or manufactured crushed rock sand. Crushed rock sand shall be the direct product of a manufacturing process, not the by-product of coarse aggregate production.

7

Beach sand shall not be permitted for use in concrete mixes.

8

The use of clean Dune Sand, blended with coarser sand, may be permitted providing it can be shown that the sand is free from contaminants. The use of local Dune sand shall be preapproved by the Ministry of Environment.

9

Samples of aggregates shall be taken in accordance with the requirements of Table 1.1- Part 1.

10

Frequency of routine testing shall meet the requirements as listed in Section 2. Frequency of testing may be increased by the engineer’s request if testing results show inconsistency, and frequency may be reduced if approved by the engineer if materials are highly consistent.

11

Mineralogical tests are to be carried out as instructed by the Engineer.

12

No aggregate deliveries shall be made to the Site until the Engineer has approved the samples as complying with this specification.

2.3

STORAGE AT CONTRACTOR PLANT

1

Aggregate shall be stored as follows:

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2.2

(a)

each nominal size of coarse aggregate and fine aggregate shall be kept separated and clearly labelled at all times.

(b)

The height of stockpiles shall be controlled to prevent harmful segregation and breakage of the aggregate.

(c)

stockpiles shall be on hard and clean surfaces with not more than 5 % slope

QCS 2014


Page 6

(d)

contamination of the aggregates by the ground or other foreign matter shall be effectively prevented at all times

(e)

each heap of aggregate shall be capable of draining freely

(f)

stockpiles shall be protected from direct sunlight

(g)

unloading of aggregate shall be controlled to prevent harmful segregation and breakage.

2

The Contractor shall maintain the stockpiles of coarse aggregate in separate gradings.

3

At the construction site, the preparation, location and size of any stockpile shall be approved by the Engineer.

Test Methods Requirement BS / EN

Permissible Limits

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No.

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Table 2.1 Limits for Physical, Chemical and Mechanical Properties of Aggregates for Normal Concrete

ASTM

Fines

Coarse

933-1

2. Natural: materials finer than 0.063 mm.

933-1

Crushed rock: materials finer than 0.063mm. 3. Fines quality a) Structural concrete Sand Equivalent (%)

933-8

60% min

933-9

2% max

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1. Grading

Non-structural concrete Methylene blue adsorption 3 value (0/2mm)

Standard

Standard

3% max 7% max

2% max 2% max

2

C142

5. Lightweight pieces

C123

0.5% max

0.5% max

C40

NA

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4. Clay lumps and friable particles

1.0 (g/kg) max 2% max

7. Water absorption (saturated surface

1097-6

Colour standard not darker than 4 plate No. 3 2.3% max

8. Particle density for normal weight

1097-6

2.0 min

2.0 min

9. Shell Content:

933-7

3% max

3% max

10. Flakiness index

933-3

11. Acid-soluble chlorides:

1744-5

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6. Organic impurities for fine aggregates

2.0% max

concrete

35% max

a) Reinforced and mass concrete

0.06% max

0.03% max

b) Prestressed concrete and steam 5 cured structural concrete

0.01%

0.01%

QCS 2014


Page 7

Test Methods No.

1

Permissible Limits

Requirement BS / EN

ASTM

Fines

Coarse

12. Acid-soluble sulphate

1744-1

0.4% max

0.3% max

13. Soundness by magnesium sulphate (5

1367-2

15% max

15% max

cycles)

Resistance to fragmentation: Los

1097-2

30% max

15. Drying shrinkage

1367-4

0.075% max

.

14. Angeles abrasion

16. Potential reactivity:

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See Note 6 below

Notes:

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3. 4.

Use of BS EN or relevant GSO standards. If the Sand Equivalent value is less than 60% and greater than or equal to 50%, the sand shall be considered non-harmful and is accepted provided that the Methylene Blue value is less than or equal to 1.0 (g/kg). Not required when the fines content in the fine aggregate, or in the all-in aggregate, is 3% or less. Organic impurities: use of a fine aggregate failing in the test is not prohibited, provided that: a. The discoloration is due principally to the presence of small quantities of coal, lignite, or similar discrete particles. b. When tested for the effect of organic impurities on strength of mortar, the relative strength at 7 days, calculated in accordance with ASTM C87, is not less than 95 %. If the chloride content is higher than 0.01% the following steps may be taken: a- The aggregates may be washed by suitable water (Sec 5 Part 4) before mixing to lower the chloride content to the specified value (0.01%). b- If the washing process does not reduce the chloride content to the required value, then the Acid Soluble Chloride content in the concrete ingredients (the sum of the contributions from the constituent materials) shall be tested as mentioned in BS 8500-2. The allowable Acid Soluble chloride content limit shall not exceed the values given in Section 5, Part 6, Para 6.5.3. The alkali-aggregate reactivity shall be assessed at source in accordance with BS 206-1 and BS 85002. Certification shall be obtained from the aggregate source indicating absence of deleterious expansion of concrete due to alkali aggregate reactivity.

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1. 2.

2.4

FINE AGGREGATE FOR CONCRETE AND MORTAR

1

Fine aggregate consist of natural clean sand, stone screenings or a combination and can be produced from natural disintegration of rock or gravel and/or by the crushing of rock or gravel or processing of manufactured aggregate or artificial, conforming to the requirements of physical and chemical properties complying with Table 2.1 and subject to the Engineer's acceptance.

2

Crushed fine aggregates may be blended with local washed sand provided that the final aggregate complies with the requirements in Table 2.1.

3

The gradation of fine aggregate for concrete and mortar shall be in accordance with the gradation designations in BS EN 12620 with BS PD 6682, EN 13139 , EN 998-1 , EN 998-2, or relevant ACI and ASTM standards and codes of practice and subject to the Engineer’s acceptance.

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Page 8

4

Each batch of aggregate delivered to the Site shall be kept separate from previous batches, and shall be stored to allow for inspection and tests to be carried out.

5

Local natural sand shall be mechanically washed to remove salts and other impurities in order to meet the specified requirements.

6

The storage area for the clean washed sand shall be shaded from the direct rays of the sun and shall be screened for protection from dust. The area in the neighbourhood of stockpile/mixing plant shall be watered as necessary, to reduce the rising of dust.

7

The usage of Dune sand shall be accepted as governed by the regulations of Qatar Ministry of Environment and shall be: Not used for any reinforced concrete

(b)

Used only for blocks, block mortar, plasters, soil cement, shotcrete and insulation concrete.

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COARSE AGGREGATE FOR CONCRETE

1

The coarse aggregate is granular material and may be natural, manufactured, recycled or a combination. It shall be free from deleterious matter and conforming to the requirements of physical and chemical properties in Table 2.1 as a minimum requirements and subject to the Engineer's acceptance within BS EN 12620, BS PD 6682 or ASTM C33

2

For imported aggregate, Qatar Standards may publish more requirements and stringent limits than specified in Table 2.1.

3

For other types of concrete mixes and subject to Engineer's acceptance, coarse aggregate shall comply with the relevant BS EN or relevant ACI and ASTM standards and codes. The nominal maximum size of coarse aggregate shall be not larger than: (a) 1/5 the narrowest dimension between sides of forms, nor (b) 1/3 the depth of slab, nor (c) 3/4 the minimum clear spacing between individual reinforcing bars or wires, bundles of bars, individual tendons, bundled tendons, or ducts.

4

These limitations shall not apply if, in the judgment of the licensed design professional, workability and methods of consolidation are such that concrete can be placed without honeycombs or voids.

5

As requested by the Engineer, the Contractor shall mechanically wash the aggregates to remove salts and other impurities in order to meet the requirements specified.

2.6

COMBINED AGGREGATE FOR CONCRETE

1

The material passing the 0.063mm sieve shall not exceed 3.0 % of the combined aggregate

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2.5

(by weight). The combined aggregate gradation used in the work shall be as specified, except when otherwise approved or directed by the Engineer. 2

Changes in the approved gradation shall not be made during the progress of the works unless approved or directed by the Engineer.

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Page 9

WASHING AND PROCESSING

1

Where aggregates have been washed shortly before delivery to the Site, or if stockpiles have been sprayed to cool them, samples of the aggregate shall be taken frequently to determine the correct amount of water to add to the mix.

2.8

LIGHTWEIGHT AGGREGATES

1

Lightweight aggregates are those having particle densities not exceeding 2,000 kg/m3 or 3 loose bulk densities not exceeding 1200 kg/m .

2

Lightweight aggregates include natural aggregate, aggregate manufactured from natural materials and/or a by product of industrial processes, and some recycled aggregate.

3

Lightweight aggregates shall be in accordance with BS EN13055-1 and BS PD 6682-4, or equivalent ASTM standards.

2.9

COARSE RECYCLED AGGREGATES

1

Excavation Waste (EW), coarse recycled aggregates (RA), and coarse recycled concrete aggregates (RCA) shall meet with the requirements of Table 2.1, with the exception that water absorption shall not exceed;

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2.7

3% for structural concrete

(b)

4% for non-structural concrete.

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(a)

For structural concrete EW and/or RCA may be used in designated concrete of maximum C30. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

3

For non-structural concrete, such as crash barriers and soakaways, EW and/or RCA may be used in designated concrete of maximum C40. Its proportion shall be not more than a mass fraction of 50% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

4

For non-structural concrete RA may be used in designated concrete of maximum C25. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

5

When the composition of coarse RCA and coarse RA is tested in accordance with BS EN 933-11, the test result obtained for each type of particle shall not exceed the maximum value specified in Table 2.2.

6

EW aggregate shall meet the same requirements for RCA, as given in Table 2.2.

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Table 2.2 Requirements for coarse RCA and coarse RA, (mass fraction, %)

RCA

1, 3

5.0

5.0

0.5

5.0

1.0

1.0

100

3

1.0

10.0

-4

Maximum acid soluble sulphate (SO3)

1.0

Where the material to be used is obtained by crushing hardened concrete of known composition that has not been in use, e.g. surplus precast units or returned fresh concrete, and not contaminated during storage and processing, the only requirements are those for grading and maximum fines. Material with a density less than 1,000 kg/m3 The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates blended with the listed constituents. The appropriate limit and test method needs to be determined on a case-by-case basis (see Note 6 to 4.3 of BS 8500-2).

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4.

Maximum Asphalt

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2. 3.

Maximum lightweight 2 material

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1.

Maximum fines

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RA

Maximum masonry content

Maximum foreign material e.g. glass, plastic, metals

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Type of Aggregate

1

.

Requirement

3

The floating material (FL) content, as per BS EN 933-11, shall not exceed 5.0 cm /kg.

8

RCA should be treated as highly reactive aggregate. The alkali contribution from RCA shall be determined as given in BS 8500-2.

9

For manufacturing of masonry concrete blocks, the usage of recycled aggregates is permitted up to 100% as given in Sec. 13 in accordance with ACI 555.

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END OF PART

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Page 1

PERSONNEL QUALIFICATIONS AND CERTIFICATIONS ..................................... 2

20.1

GENERAL ............................................................................................................... 2

20.2

AUDITORS .............................................................................................................. 2

20.3 20.3.1 20.3.2

READY MIXED CONCRETE COMPANIES ............................................................. 2 Technical Department 2 Production and Operation Department 4

20.4 20.4.1

TESTING LABORATORIES .................................................................................... 5 Concrete Laboratory Department 5

20.5 20.5.1

CONTRACTORS ..................................................................................................... 6 Concrete Construction Department 6

20.6 20.6.1 20.6.2

CONSULTANTS ...................................................................................................... 7 Site Supervision Department 7 Site Supervision / Design Office Department 7

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PERSONNEL QUALIFICATIONS AND CERTIFICATIONS

20.1

GENERAL

1

The qualification requirements given in this part are optional unless otherwise mentioned below. The purpose of the qualifications is to prepare the industry to cope with the required quality of construction. The requirements will become compulsory as and when stated by Qatar Standards.

2

Qualifications shall be approved by Qatar Standards or their representatives.

20.2

AUDITORS

1

Qatar Standards auditors and their approved representatives shall be qualified for inspecting concrete ready mix plants and testing laboratories.

20.3

READY MIXED CONCRETE COMPANIES

20.3.1

Technical Department

1

Position:

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Technical Manager / QC Manager

Qualifications:

Concrete specification review and concrete mixture proportioning

(b)

Concrete constituent materials, their characteristics, and effects on concrete properties

(c)

Fresh and hardened concrete properties

(d)

Durability of concrete

(e)

Production and delivery of Ready Mixed Concrete

(f)

Handling, placing and curing of concrete

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Specifying and evaluation of concrete strength Testing of concrete and its constituents

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(a)

2

(i)

Quality control procedures and statistical analysis

(j)

Hot weather concreting

(k)

Troubleshooting concrete problems

Position:

Site Supervisor

Qualifications: (a)

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

BS EN 12350-1 ..........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete

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Page 3

BS EN 12350-2 ..........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete 3

Position:

Lab Supervisor

Qualifications:

BS EN 12350-1 .........Testing fresh concrete - Sampling

.

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh and hardened concrete tests:

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(a)

ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-6 .........Testing fresh concrete – Density

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BS EN 12350-2 .........Testing fresh concrete – Slump test

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BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

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BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests

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ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 ..........Testing hardened concrete - Compressive strength of test specimens

se

BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

ov

er

BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content) BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

o

BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids

Position:

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4

et it

ASTM C566 – ............Method of determination of moisture content

Site Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

QCS 2014

5


Position:

Page 4

Lab Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh and hardened concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

.l. l

.

BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

rw

BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens BS EN 932-1 .............Aggregates - Methods of sampling

ta

BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

qa

BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content) BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

as


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Production and Operation Department

1

Position:

ov

20.3.2

Plant/Production/Operation Manager and/or Supervisor

Materials management

m

(b)

Properties of concrete and its constituents

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(a)

o

Qualifications:

2

(c)

Plant design, function and maintenance

(d)

Batching operations, procedures and dispatching

(e)

Materials management and inventory

(f)

Safety regulations and procedures

Position:

Plant Operator

Qualifications: (a)

Basic concrete properties and characteristics of its constituents

(b)

Scales, meters and batching sequence and control system

(c)

Central mixing and discharging

(d)

Tolerances, overweight/underweight controls

QCS 2014


(e)

Troubleshooting scales, gates and other plant components

(f)

Safety procedures

20.4

TESTING LABORATORIES

20.4.1

Concrete Laboratory Department

1

Position:

Page 5

Laboratory Manager / QC Manager

Qualifications: Concrete specification review and concrete mixture proportioning

(b)


(c)


(d)


(e)


(f)


(g)

Evaluation of concrete strength

(h)

Testing of concrete and its constituents

(i)


(j)


(k)


Position:

Supervisor

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh and hardened concrete tests:

et it

(a)

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Qualifications:

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(a)

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method) BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content)

QCS 2014


Page 6

BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids ASTM C566 – ............Method of determination of moisture content

3

Position:

Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh and hardened concrete tests:


.l. l

BS EN 12350-6 .........Testing fresh concrete – Density

rw

BS EN 12350-2 .........Testing fresh concrete – Slump test

.

ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete

BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

ta

BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests

qa

ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens

as

BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

se

BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content)

er

BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

ov


o


CONTRACTORS

20.5.1

Concrete Construction Department

1

Position:

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20.5

Site Engineer

Qualifications: (a)

The site engineer shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method) BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

QCS 2014

2


Position:

Page 7

QC Manager/ QC Engineer/ Material Engineer

Qualifications: Concrete specification review and concrete mixture proportioning

(b)


(c)


(d)


(e)


(f)


(g)

Specifying and evaluating of concrete strength

(h)


(i)


(j)


(k)


20.6

CONSULTANTS

20.6.1

Site Supervision Department

1

Position:

se

Site Inspector/ Material Inspector

er

Qualifications:

The site engineer shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

ov

(a)

as

qa

ta

rw

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.

(a)

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et it

ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test

m

BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

20.6.2

Site Supervision / Design Office Department

1

Position:

Material Engineer

Qualifications: (a)

Concrete specification review and concrete mixture proportioning

(b)


(c)


(d)


QCS 2014


(e)


(f)


(g)

Specifying and evaluating of concrete strength

(h)


(i)


(j)


(k)


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END OF PART

Page 8

QCS 2014

Section 05: Concrete Part 03: Cementitious Materials

Page 1

CEMENTITIOUS MATERIALS................................................................................. 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Terms and Definitions: 3

3.2

SOURCE APPROVAL ............................................................................................. 3

3.3

SAMPLING .............................................................................................................. 3

3.4

QUALITY AND TESTING ........................................................................................ 3

3.5

DELIVERY, STORAGE AND HANDLING ................................................................ 4

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3

QCS 2014


Page 2

3

CEMENTITIOUS MATERIALS

3.1

GENERAL

3.1.1

Scope

1

This Part covers the requirements for the testing and use of cement in structural concrete.

2


3.1.2

References

1


.

Property Requirements

.l. l

Part 6

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ASTM C10 ..................Standard specification for natural cement ASTM C91 ..................Specification for Masonry cement

ASTM C114 ................Test methods for chemical analysis of Hydraulic Cement

ta

ASTM C115, ...............Test method for fineness of Portland cement by the Turbidimeter

qa

ASTM C150 ................Standard specification for Portland cement

as

ASTM C183 ................Standard Practice for sampling and the amount of testing of Hydraulic cement ASTM C188 ................Test method for density of Hydraulic cement

se

ASTM C186 ................Test method for heat of hydration of Hydraulic cement ASTM C204 ................Test method for fineness of Hydraulic cement by air permeability

er

ASTM C348 ................Test method for flexural strength of Hydraulic cement mortar

ov

ASTM C349 ................Test method for compressive strength of Hydraulic cement mortar using portion of prism broken in flexure

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ASTM C430 ................Test method for fineness of Hydraulic cement by the 45mm (No.325)

et it

ASTM C595 ................Standard specification for blended Hydraulic cement

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ASTM C618 ................Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete ASTM C845 ................Specification for Expansive Hydraulic cement ASTM C989 ..............Standard Specification for Slag Cement for Use in Concrete and Mortars ASTM C1157 ..............Standard performance specification for Hydraulic cement ASTM C1240 .............Standard Specification for Silica Fume Used in Cementitious Mixtures ASTM C1328 ..............Specification for plastic cement (Stucco) ASTM C1329 ..............Specification for Mortar cement BS 146 ........................Portland blast furnace cement BS 1370 ......................Low heat Portland cement BS 4027 ......................Sulphate-resisting Portland cement BS EN 196, .................Methods for testing cement

QCS 2014


Page 3

BS EN 197-1, .............Cement, Composition, specifications and conformity criteria for common cements. BS EN 197-4 .............Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements Terms and Definitions:

1

Cementitious Materials: Portland cement in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, silica fume and Metakaolin; subject to compliance with requirements of this specification.

2

PC: shall mean Portland cement or CEM I.

3

FA or PFA: shall mean fly ash or pulverised fuel ash.

4

GGBS: shall mean ground granulated blast furnace slag.

3.2

SOURCE APPROVAL

1

The Contractor shall submit to the Engineer for approval full details of the proposed source of cement. These sources of cement supply shall be regularly and thoroughly investigated to ensure that the quality of the material supply is satisfactory and that it does not deteriorate during the performance of the project.

2

The cement source shall not be changed without the Engineer's acceptance.

3

The Contractor shall supply the Engineer with the manufacturer’s test certificates certifying that the cement is in compliance with the relevant standards.

4

For imported cement the manufacturer’s test certificates shall be provided with each consignment. The Contractor shall submit to the Engineer the date of manufacture and proof that the specifications have been complied with, certified by an independent agency in the country of origin.

5

Cement manufacturers shall label their packaging and delivery documents and shall provide, where applicable, information on the packing/dispatch date, storage conditions and the storage period appropriate to maintaining the activity of any reducing agent and to keeping the content of soluble chromium (VI) below the 2 ppm limit. The Engineer has the right to test the cement for presence of chromium at the contractor’s expense.

3.3

SAMPLING

1

The methods of obtaining samples of cement for testing shall be carried out as described in EN 196 or ASTM C183

3.4

QUALITY AND TESTING

1

The cementitious material shall fully comply with the relevant standard(s) from the following list:

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3.1.3

ASTM C150 ................Standard specification for Portland cement ASTM C595 ................Standard specification for blended Hydraulic cement

QCS 2014


Page 4

ASTM C618 ...............Standard specification for coal fly ash and raw natural pozzolan for use in concrete ASTM C989 ...............Standard specification for ground granulated blastfurnace slag for use in concrete and mortars ASTM C1157 ..............Standard performance specification for Hydraulic cement ASTM C1240 ..............Standard specification for silica fume used in cementitious mixtures BS 146 ........................Portland-blast furnace cement BS 1370 ......................Low heat Portland cement BS 4027 ......................Sulphate-resisting Portland cement BS EN 197-1, ............minimum grade 42.5

.

BS EN 450 .................Fly ash for concrete.

rw

.l. l

BS EN 15167 .............Ground granulated blastfurnace slag for use in concrete, mortar and grouts. EN 12363 ..................Silica fume for concrete.

ta

Relevant GSO

The water-soluble chromium (VI) content shall not exceed 2ppm (0,0002%) by total dry weight of cementitious materials.

3.5

DELIVERY, STORAGE AND HANDLING

1

Cement shall be delivered to the Site in sealed and branded bags, or in the manufacturer’s containers, bearing the manufacturer’s name, cement type and date of manufacture, in batches not exceeding 100 tons.

2

Cement shall be stored at the site in such a manner, as to prevent its deterioration, intrusion of moisture and foreign matter. It must be kept dry at all times. Immediately upon arrival at the Site the Contractor shall store the cement in

dry, weather tight and properly ventilated structures with floors raised a minimum of 450 mm above the ground with adequate provision to prevent absorption of moisture.

m

(b)

bins or silos designed for the purpose. It shall be tight and provide for free movement to discharge opening, or

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(a)

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2

3

All storage facilities shall be subject to the approval of the Engineer, and shall be such as to permit easy access for inspection and identification. Prolonged storage of cement at site is to be avoided.

4

For bagged cement, each consignment of cement shall be kept separately, and the Contractor shall use the consignments in the order in which they are received.

5

The Contractor shall keep records of the various consignments of cement in store, giving quantities received and used, and the sections of the work in which the cement has been used, on a daily basis and make a weekly return to the Engineer accordingly. Cement used in the Works shall be free flowing and free from lumps.

6

In no case shall bagged cement be stored in stacks more than eight bags high.

QCS 2014

7


Page 5

A free passage of at least 1 m shall be left between the cement and the side walls of the structure. Different types of cement shall be kept in clearly marked separate storage facilities.

9

Cement delivered to Site in drums or bags by the supplier or manufacturer shall be stored in the drums or bags until used in the Works.

10

Any cement in drums or bags which have been opened shall be used immediately.

11

Cement that has partially or fully caked in storage will not be permitted in work and shall be immediately removed from the storage area. Any bag or package or sample of cement which has been damaged, or rebagged or in any way has deteriorated shall be rejected either as an individual bag or package or as the whole consignment in which such bag, package or sample is contained, as advised by the Engineer.

12

Where Site limitations preclude the storage of cement on Site, cement shall be stored at a central location and shall be delivered daily as required to specific job sites.

13

The Contractor shall provide weighing machines which shall be kept permanently in each shed for checking the weight of the bags or barrels of cement. The weighing machines shall be calibrated by an independent agency. The Engineer shall have access at all times to the cement storage sheds.

14

During transport and storage the cement shall be fully protected from all weather elements.

15

Any consignment of cement not used within two months from the date of manufacture and cement which in the opinion of the Engineer is of doubtful quality shall not be used in the Works until it has been retested and test result sheets showing that it complies in all respects with the specification and relevant standards have been delivered to the Engineer.

16

Cement stored for longer than 28 days shall be tested for “loss on ignition" prior to use to check for deterioration, and any cement which fails the test shall not be used in the works.

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8

END OF PART

QCS 2014

Section 05: Concrete Part 04: Water

Page 1

WATER ................................................................................................................... 2

4.1 4.1.1 4.1.2


4.2 4.2.1 4.2.2 4.2.3 4.2.4

QUALITY OF WATER ............................................................................................. 3 General 3 pH of Water 3 Permissible Temperatures 3 Supply and Storage 3

4.3 4.3.2

TESTING AND SAMPLING ..................................................................................... 3 Health and Safety 5

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4

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Page 2

4

WATER

4.1

GENERAL

4.1.1

Scope

1

This Part includes water used for concrete mixtures, washing of aggregates and equipment, wetting of surfaces or ponding during curing or for wetting formwork and washing reinforcement.

2


ta

rw

.l. l

.

This Section Part 2, .............. Aggregates Part 6, .............. Property Requirements Part 9, .............. Formwork Part 10, ............ Curing Part 11, ............ Reinforcement References

1


qa

4.1.2

se

as

ASTM C109 ................test Method for Compressive Strength of Hydraulic Cement Mortars (using 2-in or 50 mm Cube Specimens) BS 1377 ......................Methods of test for soils for civil engineering purposes.

er

BS 2690 ......................Methods of testing water used in industry

ov

BS 6068 ......................Water quality

o

BS EN ISO 9963-1 .....Determination of total and composite alkalinity

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BS EN ISO 9963-2 .....Determination of carbonate alkalinity

m

EN 196-1 ....................Determination of strength EN 196-2 ....................Methods of testing cement - Part 2: Chemical analysis of cement EN 196-3 ....................Determination of setting time and soundness EN 1008 .....................Mixing water for concrete, Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete SM 5220 B ................. Chemical Oxygen Demand (COD) SM 4500 ....................Standard Methods for the Examination of Water and Wastewater ISO 7890

...............Water quality -- Determination of nitrate -- Part 1: 2,6-Dimethylphenol spectrometric method

SM 3125B (ICP/MS) ...Metals by Inductively Coupled Plasma/Mass Spectrometry

QCS 2014


Page 3

QUALITY OF WATER

4.2.1

General

1

Potable water is suitable for use in concrete, while water of other origin such as underground water, natural surface water, recovered water, as well as municipal treated water or mixed water shall be tested to prove that its quality shall conform to water quality requirements as given below in 4.3.

2

On site, where a permit is issued for Municipal Treated Effluent use for concrete, the effluent shall be treated by tertiary treatment stage: Reverse Osmosis (R.O.), and disinfection (Ultraviolet Radiation, or ozonation).

3

The water shall be examined in accordance with the test procedures stated in Table 1, EN 1008. Water not conforming to one or more of the requirements in Table 1, EN 1008 may be used only, if it can be shown to be suitable for use in concrete, in accordance with the physical tests of Table 1 below.

4

The site health and safety services and Treated Effluent Quality shall fulfil the requirements of 5

4.2.2

pH of Water

1

The pH of water used in concrete works shall be as shown in Table 4.2.

4.2.3

Permissible Temperatures

1

Temperature of water for concrete shall not be less than 5 °C and not more than 40 °C

2

Water may be cooled to not less than 5 °C by the gradual addition of chilled water or ice as

(b)

alternatively, flaked ice may be used ice to be used shall be crushed and shall be a product of frozen water which complies with the acceptance criteria of Tables 4.1 and 4.2 and 4.3.

m

(c)

no ice particles shall be present in the mix

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(a)

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follows:

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.

4.2

3

Every effort should be made to protect water pipes and tanks from the sun; e.g., burying, shading, insulation or painting white.

4.2.4

Supply and Storage

1

The Contractor shall make his own arrangements and obtain the approval of the Engineer for the supply of water.

2

Storage of water should be such that contamination is prevented from occurring. Any measures taken to avoid contamination of the water shall be to the approval of the Engineer.

4.3

TESTING AND SAMPLING

1

Whenever required to do so by the Engineer, the Contractor shall take samples of the water being used, or which it is proposed to use, for mixing concrete and test them for quality.

QCS 2014

2


Page 4

Samples of water of not less than 5 l shall be taken, sealed and sent for testing at an approved independent laboratory, prior to the approval of any water source, and whenever the sources of water is changed periodically during the continuance of its use.

3

Water of questionable quality should comply with the physical tests of Table 4.1 and chemical limitations listed in Table 4.2 & Table 4.3.

4

No source of water shall be used until the required tests have demonstrated its suitability for concreting.

5

The use of water from a municipal or government supply does not preclude the requirement for testing.

rw

Test Method

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Table 4.1 Acceptance Criteria and Physical Tests for Mixing Water

EN 196-1

Setting time, max. deviation from control, (h:min)

EN 196-3

90 % from 1:00 early to 1:30 later

as

qa

ta

Compressive strength at 7 d, min % of control

Limits

er

BS 6068-1.37 (ISO 9297)

(a-1) for Prestressed concrete.

500

(a-2) for reinforced concrete.

1000

(a-3) for concrete without reinforcement.

4500

(b)

m

(c)

Alkali

2-

Sulphates (as SO4 )

(c-1) Alkali carbonates and bicarbonates

(c-2) Alkali equivalent sodium oxides (d)

Total dissolved ions, including a, b and c above

EN 196-2

pH

2000

BS 6068-2.51 BS EN ISO 9963-1 BS EN ISO 9963-2

500

EN 196-2

1500

BS 1377 : Part 3

1000 2000 5000

(d-1) for prestressed concrete (d-2) reinforced concrete. (d-3) for concrete without reinforcement. (e)

Maximum Limit, mg/l

o

Chloride (as CI)

Test Method

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(a)

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Parameter

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Table 4.2 Chemical Limitations for Mixing Water

BS 6068-2.50

6.5 - 9.0

QCS 2014


Page 5

Table 4.3 Maximum limit of Harmful Contaminants Parameter

Test Method

Maximum Limit, mg/l

SM 5220 B

50

Phosphate; expressed as PO4 - P

SM 4500 P B, C, SM 4500 PD by subtraction

30

ISO 7890-1

100

Lead; expressed as Pb

SM 3125B (ICP/MS)

2+

100

SM 3125B (ICP/MS)

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Zinc; expressed as Zn

2+

.l. l

-

Nitrate; expressed as NO3 -N

.

COD

100

qa

ta

SM: Standards Methods for the Examination of Water and Wastewater.

Health and Safety

1

On site, where a permit is issued for Municipal Treated Water use in construction works, the effluent should be treated by tertiary treatment stage including filtration and disinfectant (Chlorine alone, or Ultraviolet Radiation, or ozonation). Furthermore, the following site health and safety services and the Treated Effluent Quality shall be fulfilled:

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4.3.2

Residual chlorine level shall be within the range of 0.5 – 1.0 mg/l. For water to be used for concrete, the disinfectant shall be Ultraviolet Radiation, or ozonation.

(b)

Coliform level shall fulfil one of the following:

o

ov

(a)

Fecal Coliform < 200 CFU/100 ml, in case there is no direct exposure on site labour.

(ii)

Total Coliform < 23 CFU/100 ml, in case there is direct exposure on site labour.

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(i)

(c)

The site shall be facilitated by health and safety guidelines signs, where it is indicated by Arabic, English, and any other languages where there are 5 workers or more on the site, that “Water not for Human Consumption”

(d)

The site shall be facilitated by health and safety equipment, as well as, personal health and safety protection equipment.

(e)

Labour shall follow health and safety guidelines and instructions and use their health and safety personal protection equibment.

END OF PART

QCS 2014

Section 05: Concrete Part 05: Admixtures

Page 1

ADMIXTURES ......................................................................................................... 2

5.1 5.1.1 5.1.2 5.1.3 5.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 2 Submittals 2

5.2 5.2.1 5.2.2

USE OF ADMIXTURES ........................................................................................... 3 General 3 Trials 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7

WATER PROOFING ADMIXTURES ....................................................................... 3 General 3 Water resisting admixtures 4 Permeability reducing admixture 4 Submittals 4 General 4 Organic Corrosion Inhibitors 4 Inorganic Corrosion Inhibitors 5

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5

ADMIXTURES

5.1

GENERAL

5.1.1

Scope

1

This Part includes materials added to the concrete materials during mixing.

2


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This Section Part 1 ............... General Part 6 ............... Property Requirements Part 7 ............... Concrete Plants Part 16 ............. Miscellaneous References

1


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5.1.2

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ACI 212.3R-10............Report on Chemical Admixtures for Concrete ACI 302 ......................Guide for Concrete Floor and Slab Construction

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ACI 305 ......................Hot Weather Concreting

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ACI 308 ......................Standard Practice for Curing Concrete ASTM C494, ...............Standard Specification for Chemical Admixtures for Concrete

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ASTM C1582, .............Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete BS EN 934 ..................Admixtures for concrete, mortar and grout (Parts: 2, 6) BS EN 196, ................Methods of testing cement

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BS EN 14889 .............Fibres for concrete Polymer fibres. Definitions, specifications and conformity

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NSF ............................ Standard 61

5.1.3

Definitions

1

Admixtures are materials added during the mixing process of concrete to modify the properties of the concrete mix in the fresh and/or hardened state.

5.1.4

Submittals

1

In addition to the specified general requirements for approval of materials, approval of admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing arrangements and performance.

QCS 2014


Page 3

5.2

USE OF ADMIXTURES

5.2.1

General

1

Admixtures are materials added to the concrete materials during the mixing process to modify its properties in the fresh and/or hardened state.

2

Where approved and or directed by the Engineer, admixtures shall be used as a means of: enhancing concrete durability

(b)

increasing workability of the concrete without increasing the water:cement ratio

(c)

controlling retardation and setting time.

(a)

water reducing/plasicizing admixture

(b)

high range water reducing/plasticizer admixture

(c)

set retarding admixtures

rw

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.

Admixtures shall comply with the following BS EN 934 – 2 requirements or the equivalent ASTM C494:

ta

3

(a)

The methods and the quantities of admixture used shall be in accordance with the manufacturer’s instruction and subject to the Engineer’s approval after evaluation in trial mixes and shall in no way limit the Contractor’s obligations under the Contract to produce concrete with the specified strength, workability and durability.

5

The effects of accidental overdose of the admixture and measure to be taken if an overdose occurs shall be provided by the Contractor to the Engineer.

6

No admixtures containing chlorides shall be used. In particular, the use of acceleration admixtures containing calcium chloride shall not be used.

7

The use of the admixtures shall be controlled; i.e., strict quality control to ensure correct dosages as prescribed by the manufacturer and justified by trial mixes to be used. A calibrated dispenser or flowmeter shall be used for the addition of the admixture.

5.2.2

Trials

1

In addition to the standard requirements for the approval of materials, approval of admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing arrangements and performance, when a proven history of performance cannot be provided to the satisfaction of the Engineer.

5.3

WATER PROOFING ADMIXTURES

5.3.1

General

1

The admixture shall be suitable for use in the Gulf condition, and specially formulated for higher ambient temperature.

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The admixture shall be added as per manufacturer’s datasheet. Approved third party laboratory verification shall be conducted prior to use of material for the works. The manufacturer’s technical representative shall be present to ensure proper dosage of admixture during the trial mix.

5.3.2

Water resisting admixtures

1

Water resisting admixtures may be used with the permission of the Engineer and shall comply with the requirements of BS EN 934-2.

2

The admixture is to be added as per the Manufacturer’s supplier data sheet at the time of mixing. An approved lab verification shall be made prior to use,

5.3.3

Permeability reducing admixture

1

The admixture shall be a permeability reducing admixture for Non-Hydrostatic Conditions (PRAN) and for hydrostatic conditions (PRAH) as indicated by ACI 212.3R-10, or crystalline waterproofing admixture.

2

For PRAH, independent testing shall be performed according to NSF Standard 61 and approval for use of waterproofing material on structures holding potable water shall be evidenced by NSF certification.

5.3.4

Submittals

1


2

The Contractor shall submit comprehensive test results for the water proofing admixture as per the tests in the specification, and evidence of their ability to meet all the requirements specified.

3

The Contractor shall submit a guarantee for the water proofing admixture. The guarantee shall be worded to reflect the required performance of the material and shall be approved by the Engineer.

4

CORROSION INHIBITING ADMIXTURES

5.3.5

General

1

Where reinforced concrete structures are exposed to aggressive environment such as underground and marine structures, the use of a corrosion inhibiting admixture shall be used.

2

Corrosion Inhibiting Admixtures shall comply with ASTM C1582 Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete.

5.3.6

Organic Corrosion Inhibitors

1

The admixture shall be based on either aqueous emulsion of amines and esters or amine carboxylates and shall be capable of forming a protective corrosion resistant film around the steel reinforcement.

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The corrosion inhibitor shall be capable of effecting protection to the steel where concrete has cracked and allows access to the elements responsible for corrosion.

3

Organic corrosion inhibitors have a fixed dosage rate independent of chloride levels and shall be incorporated at the dosage rate recommended and tested by the Manufacturer.

5.3.7

Inorganic Corrosion Inhibitors

1

Inorganic corrosion inhibitors shall be based on calcium nitrites capable of oxidizing steel to a more stable form increasing its passivity in the presence of chlorides.

2

Dosage of inorganic corrosion inhibitors ranges from 10 to 30L/m3 depending on the expected chloride levels as defined by ACI 212 Table 13.1.

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END OF PART

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 1

PROPERTY REQUIREMENTS ............................................................................... 2

6.1 6.1.1 6.1.2 6.1.3 6.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions: 6 Submittals 7

6.2 6.2.1 6.2.2

EXPOSURE CLASSES ......................................................................................... 10 General 10 Reinforcement corrosion and sulphate classes 10

6.3 6.3.1

FRESH CONCRETE ............................................................................................. 12 General 12

6.4

GRADES OF CONCRETE..................................................................................... 13

6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7

DURABILITY REQUIREMENTS ............................................................................ 13 General 13 Maximum acid soluble chloride content 14 Type of cementitious material 14 Resistance to alkali-silica reaction 15 Recommendations to resist reinforcement corrosion 15 Recommendations to resist sulphate attack 16 Durability-Related Properties 16

6.6 6.6.1

DESIGN OF CONCRETE MIXES .......................................................................... 17 Concrete 18

6.7

TRIAL MIXES ........................................................................................................ 25

6.8 6.8.1 6.8.2 6.8.3 6.8.4

QUALITY AND TESTING ...................................................................................... 27 General 27 Tests for Concrete 27 Hardened Tests for Fiber-Reinforced Concrete 29 Quality Control charts 29

6.9

WORKS TEST CUBES ......................................................................................... 30

6.10 6.10.1 6.10.2

REJECTION OF CONCRETE MIXES ................................................................... 30 Rejection of Concrete Mixes: 30 Unsatisfactory Concrete Works 31

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PROPERTY REQUIREMENTS

6.1

GENERAL

6.1.1

Scope

1

This Part includes Grades 15 MPa and above of concrete to be used in the civil works, with the requirements for workability, permeability, and drying shrinkage.

2


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This Section Part 2, ........... Aggregates Part 3, ........... Cementitious Materials Part 4, ............ Water Part 5, ........... Admixtures Part 7, ............ Concrete Plants Part 8, ........... Transportation and Placing of Concrete Part 9, .............. Formwork Part 13, ............ Inspection and Testing of Hardened Concrete

.

6

References

1

The following standards are referred to in this Part. The designer along with contractor are responsible to use the latest update standard as published by the organization:

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ACI 207.1R .................Guide to Mass Concrete

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ACI 207.2R .................Report on Thermal and Volume Change Effects on Cracking of Mass Concrete ACI 207.5R .................Roller - Compacted mass concrete

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ACI 213, .....................Guide for Structural Lightweight-Aggregate Concrete

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ACI 214, .....................Evaluation of Strength Test Results of Concrete

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ACI 221, .....................Guide for Use of Normal Weight and Heavyweight Aggregates in Concrete ACI 237R 07 ..............Self Consolidating Concrete ACI 301, .....................Specifications for Structural Concrete ACI 304, .....................Guide for Measuring, Mixing, Transporting, and Placing Concrete ACI 304.2, ..................Placing Concrete by Pumping Methods ACI 318, .....................Metric Building Code Requirements for Structural Concrete & Commentary ACI 506, ....................Guide to Shotcrete ACI 506.1, ..................Guide to Fiber-Reinforced Shotcrete ACI 506.2, ..................Specification for Shotcrete ACI 555, .....................Removal and Reuse of Hardened Concrete ASTM A 820, ..............Specification for Steel Fibers for Fiber-Reinforced Concrete ASTM C 31, ................Practice for making and curing concrete test specimens in the field ASTM C 33, ...............Specification for Concrete Aggregates

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ASTM C 39, ................Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C 42, ................Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete ASTM C 94, ................Specification for Ready-Mixed Concrete ASTM C192, ...............Practice for Making and Curing Concrete Test Specimens in the Laboratory ASTM E 119, ..............Test Methods for Fire Tests of Building Construction and Materials ASTM C 138, ..............Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete ASTM C 150, .............Specification for Portland Cement ASTM C 172, ..............Practice for Sampling Freshly Mixed Concrete

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ASTM C 173, ..............Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

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ASTM C 231 ...............Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

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ASTM C 232, .............Test Methods for Bleeding of Concrete

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ASTM C 311, .............Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

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ASTM C 387, ..............Specification for Packaged, Dry, Combined Materials for Mortar and Concrete ASTM C 597, ..............Test Method for Pulse Velocity through Concrete

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ASTM C 617, .............Practice for Capping Cylindrical Concrete Specimens

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ASTM C 618, .............Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

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ASTM C 637, ..............Specification for Aggregates for Radiation-Shielding Concrete Constituents

of

Aggregates

for

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ASTM C 638, .............Descriptive Nonmenclature of Radiation-Shielding Concrete

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ASTM C 803, .............Test Method for Penetration Resistance of Hardened Concrete ASTM C 805, .............Test Method for Rebound Number of Hardened Concrete

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ASTM C 856, .............Practice for Petrographic Examination of Hardened Concrete ASTM C 900, .............Test Method for Pullout Strength of Hardened Concrete ASTM C 989, ..............Standard Specification for Slag Cement for Use in Concrete and Mortars ASTM C 1018, ............Test Method for Flexural Toughness and First-Crack Strength of FiberReinforced Concrete ASTM C 1116, ...........Specification for Fiber-Reinforced Concrete ASTM C 1140, ............Practice for Preparing and Testing Specimens from Shotcrete Test Panels ASTM C 1152 .............Standard Test Method for Acid-Soluble Chloride in Morter and Concrete. ASTM C 1218 .............Standard Test Method for Water-Soluble Chloride in Morter and Concrete. ASTM C 1231, ............Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

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ASTM C 1240, ............Specification for Silica Fume Used in Cementitious Mixtures ASTM C 1385, ............Practice for Sampling Materials for Shotcrete ASTM C 1399, ............Test Method for Obtaining Average Residual-Strength of FiberReinforced Concrete ASTM C 1480, ............Specification for Packaged, Pre-Blended, Dry, Combined Materials for Use in Wet or Dry Shotcrete Application ASTM C 1550, ............Test Method for Flexural Toughness of Fiber Reinforced Concrete (Using Centrally Loaded Round Panel) ASTM C 1604, ............Test Method for Obtaining and Testing Drilled Cores of Shotcrete ASTM C 1609, ............Test Method for Flexural Performance of Fiber-Reinforced Concrete (Using Beam With Third-Point Loading) ASTM C 1611, ............Test Method for Slump Flow of Self-Compacting Concrete

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ASTM C 1666, ............Specification for Alkali Resistant (AR) Glass Fiber for GFRC and Fiber-Reinforced Concrete and Cement

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ASTM D 5759, ............Guide for Characterization of Coal Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

BRE digest 433, .........Recycled Aggregates

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ASTM D 6942, ............Test Method for Stability of Cellulose Fibers in Alkaline Environments

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BS 4027, ....................Specification for Sulphate-Resisting Portland Cement

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BS 6073-2:2008, ........Precast concrete masonry units. Guide for specifying precast concrete masonry units

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BS 8500, ....................Concrete, Complementary British Standard to BS EN 206-1.

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BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete BS EN 206-1, ............Concrete. Specification, Performance, Production And Conformity

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BS EN 450,.................Fly Ash for Concrete. Definition, Specifications And Conformity Criteria

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BS EN 771-3, .............Specification for masonry units. Aggregate concrete masonry units (dense and light-weight aggregates

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BS EN 772-2, ............. Methods of test for masonry units. Determination of percentage area of voids in masonry units (by paper indentation) BS EN 12350,.............Testing Fresh Concrete BS EN 12350-1, .........Testing fresh concrete - Part 1: Sampling BS EN 12350-2, .........Testing fresh concrete - Part 2: Slump test BS EN 12350-3, .........Testing fresh concrete - Part 3: Vebe test BS EN 12350-4, .........Testing fresh concrete - Part 4: Degree of compactability BS EN 12350-5, .........Testing fresh concrete - Part 5: Flow table test BS EN 12350-6, .........Testing fresh concrete - Part 6: Density BS EN 12350-7, .........Testing fresh concrete - Part 7: Air content - Pressure methods BS EN 12390,.............Testing Hardened Concrete BS EN 12390-1, .........Testing hardened concrete - Part 1: Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2, .........Testing hardened concrete - Part 2: Making and curing specimens for strength tests

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BS EN 12390-3, .........Testing hardened concrete - Part 3: Compressive strength of test specimens BS EN 12390-4, .........Testing hardened concrete - Part 4: Compressive strength Specification for testing machines BS EN 12390-5, .........Testing hardened concrete - Part 5: Flexural strength of test specimens BS EN 12390-6, .........Testing hardened concrete - Part 6: Tensile splitting strength of test specimens BS EN 12390-7, .........Testing hardened concrete - Part 7: Density of hardened concrete BS EN 12390-8, .........Testing hardened concrete - Part 8: Depth of penetration of water under pressure BS EN 12620,.............Aggregate For Concrete

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BS EN 15167 .............Ground Granulated Blast Furnace Slag For Use In Concrete, Mortar And Grout. Conformity Evaluation

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BS EN 1744, ..............Tests For Chemical Properties Of Aggregates

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BS EN 1992-3:2006 ...Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN 1992-3:2006 ...UK National Annex to Eurocode 2. Design of concrete structures. Liquid retaining and containment structures

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BS PD 6682-1, ...........Aggregates for Concrete. Guidance on the Use of BS EN 12620

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Concrete Society Report No. 31, Permeability testing of site concrete EN 1011, .................... Welding. Recommendation for welding of metallic materials

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EN 1992-1-1, ..............Eurocode 2: Design of concrete structures. General rules and rules for buildings

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GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – part 2: properties of fresh concrete

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GSO ISO 1920-3 ........Testing of concrete – part 3: Making and curing test specimens. GSO ISO 1920-4 .......Testing of concrete – part 4: strength of hardened concrete. GSO ISO 1920-5 .......Testing of concrete – part 5: properties hardened concrete other than strength. GSO ISO 1920-6 ........Testing of concrete – part 6: sampling, preparing and testing of concrete core . GSO ISO 1920-7 .......Testing of concrete – part 7: Non –destructive test on hardened concrete. ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of concrete for samples prepared in the field or in the laboratory ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete cylinders in compression ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of elasticity in compression

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CSTR11......................Concrete core testing – The concrete Society RILEM CPC 11.3 .......Absorption of water by immersion under vacuum The Concrete Society CS163. Guide to the design of concrete structures in the Arabian Peninsula. The European Guidelines for Self-Compacting Concrete Specification, Production and Use 6.1.3

Definitions:

1

Exposure conditions will apply as follows: Class X0: No risk of corrosion or attack. Non saline conditions. Blinding concrete, nonreinforced concrete or slab on ground.

(b)

Class X1: Mild exposure – Non saline conditions (dry or wet, rarely dry) External concrete at least 3m above ground level, internal concrete in dry conditions, concrete permanently submerged in non-saline water or non-aggressive groundwater.

(c)

Class X2: Moderate exposure – Non saline conditions (Cyclic wet and dry). External reinforced concrete less than 3m above ground level, water-retaining structures exposed to fluctuating water levels.

(d)

Class X3: Aggressive exposure – Permanently submerged or wet (rarely dry) Concrete in contact with groundwater including capillary rise zone, concrete containing or permanently exposed to saline water.

(e)

Class X4: Severe exposure – Moderate humidity External concrete within 1km from the sea or in contact with high saline water table or sabkhas. Concrete not affected by condensation, irrigation or leakage, which are more than 3m above ground level.

(f)

Class X5: Extreme exposure – Cyclic wet and dry, external concrete within 1km from the sea or in contact with high saline groundwater or sabkhas. Concrete affected by condensation, irrigation or leakage, which are less than 3m above ground level or within capillary zone. Concrete surfaces exposed to sea water splash or in sea water tidal zone.

(g)

Sulphate exposure classes S1 to S4: the exposure classes are related to sulphate attack in relation to sulphate and pH of the ground water.

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(a)

Concrete is a mixture (mix) of cementitious materials, coarse and fine aggregate, and water, with or without admixtures, which develops its properties by cement hydration.

3

"Cementitious Materials": Portland cement in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag and silica fume; subject to compliance with requirements of this specification.

4

“Water/Cementitious Ratio” shall mean the ratio between the total weight of water in the concrete (less the water absorbed by the aggregate) and the weight of cementitious materials, expressed as a decimal fraction.

5

“Admixtures” shall mean a material other than water, aggregate, cementitious materials or fiber reinforcement, used as an ingredient of concrete or mortar. Admixtures are added during the mixing process of concrete to modify the properties of the concrete mix in the fresh and/or hardened state.

6

“Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as: a. High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer), b. High concrete temperature, c. Low relative humidity, d. 2 High wind speed and e. whenever the rate of evaporation exceeds 0.75 kg/m /h

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“Mass concrete” is defined as any volume of concrete with dimensions large enough to require that measures be taken to cope with generation of heat form hydration of the cement and attendant volume change to minimize cracking. Reinforced Massive concrete structures include pile caps, transfer plates, and structural members where the least dimension exceeds 1.5 meters.

8

“Coarse Aggregate” shall be considered as that size passing a 20mm sieve (or larger sieve size) and predominately retained on a 4mm sieve.

9

“Fine Aggregate” shall be considered as that size predominately passing a 4mm sieve and predominately retained on a 0.063mm size.

10

“PC” shall mean Portland cement or CEM I.

11

“FA” shall mean pulverised fuel ash or fly ash.

12

“GGBS” shall mean ground granulated blastfurnace slag.

13

“SF” shall mean silica fume. Other names are condensed silica fume and microsilica

14

“Gap-graded aggregate” shall mean graded aggregate without one or more of the intermediate sizes.

15

“Single-size aggregate” shall mean aggregates containing a major proportion of particles of one sieve size.

16

“Target Mean Strength” shall mean the specified characteristic strength plus the margin.

17

“Margin” shall mean the difference between the specified characteristic strength and the target mean strength.

18

“Acceptable or Accepted” shall mean acceptable or accepted by the Engineer.

19

“Approval or Approved” shall mean approval from the Engineer.

20

“All-in” aggregate shall mean the materials composed of a mixture of coarse and fine aggregates.

21

Self-Compacting Concrete (SCC): concrete that is able to flow and consolidate under its own weight, completely fill the formwork even in the presence of dense reinforcement, whilst maintaining homogeneity and without the need for any additional compaction.

6.1.4

Submittals

1

The Contractor shall submit details of mix designs to the Engineer for approval.

2

Material Safety Data Sheet MSDS or equivalent for all products. test results and other information as required to prove compliance with the specification shall be submitted to the Engineer for approval according to the relevant sections of QCS on at least the following products

3

Cement:

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(a)

Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

(b)

Manufacturer's certificates shall also be supplied for each batch of production of cement or on a weekly basis, whichever is more frequent, certifying compliance with the BS EN 197 or other equivalent standard.

QCS 2014

(c)

Page 8

The early compressive strength of each consignment of cement shall conform to the requirements of QCS part 3 at the independent site laboratory. Deviation of more than 10% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer. Testing at an independent laboratory shall be as instructed by the Engineer.

GGBS: (a)


(b)

Manufacturer's certificates with all information necessary to verify compliance shall also be supplied for each consignment of GGBS or on weekly basis, whichever is more frequent.

(c)

The early compressive strength of each consignment of GGBS shall be determined in accordance with BS EN 197 and BS EN 15167 or ASTM C989 at the independent site laboratory based on a blend of 50/50 % GGBS and CEM 1. Deviation of more than 5% in strength from either the previous consignment value or the rolling average shall be immediately reported to the Engineer. Testing at an independent laboratory shall be in accordance with per BS EN 197 and BS EN 15167 standards, and approved by the Engineer.

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FA:

Recent independent test results acceptable to the Engineer confirming compliance with specified requirements of BS EN 450 or ASTM C618.

(b)

Manufacturer's certificates with all information necessary to verify compliance with internationally recognized standards shall also be supplied with each consignment of FA.

(c)

The materials shall comply with QCS part 3. Deviation of the strength factor by more than 5% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer and the Technical Manager of the premix company.

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(a)

Silica fume:

Manufacturer's certificates with all information necessary to verify compliance with internationally recognized standards shall also be supplied with each consignment of silica fume.

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(b)

Recent independent test results acceptable to the Engineer confirming compliance with specified requirements and referenced standards.

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(c)

7

8

7 day pozzolanic activity test in accordance with BS EN 13263-1 or ASTM C 1240 on each consignment of silica fume at the Independent site laboratory. Deviation of the activity index by more than 5% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer and the Technical Manager of the premix company.

Aggregates: (a)


(b)

Full details of the proposed sources of aggregates.

Water: Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

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9

Admixtures: Manufacturer’s technical specifications and recommendations. Recent trial results acceptable to the Engineer illustrating the efficiency of the product for its particular application. Tests on specific gravity and solids content shall be conducted at the Independent site laboratory on each consignment.

10

Mix Designs: Submit concrete mix designs for each type and strength of concrete required at least thirty (30) days before placing concrete.

11

New mix designs, with historic data less than 6 months, shall be verified by an approved independent testing laboratory in accordance with requirements of QCS Part 05 and shall be coordinated with design requirements and Contract Documents.

12

Submit complete mix design data for each separate mix to be used on the Project in a single submittal with at least the following information: Type of cement*.

(b)

Portland cement content*.

(c)

Cementitious content* (GGBS, FA, natural pozzolan, rice husk ash and/or silica fume).

(d)

Max. aggregate size*.

(e)

Combined grading curve for coarse aggregate

(f)

Quantities of all individual materials*

(g)

Type of admixture(s)*

(h)

Target slump/slump flow (at discharge)* as per BS EN 12350-2

(i)

Initial and final concrete setting time for each mix design as per ASTM C403 or equivalent BS EN standards, if specified

(j)

Fresh density of concrete as per BS EN 12350-6

(k)

Air content as per BS EN 12350-7

(l)

Target temperature*

(m)

Bleeding, if specified

(n)

Chloride and sulphate (SO3) contents

(o)

Details of calculated water/cementitious material (w/c) ratio*

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Compressive strength grade* Hardened density

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(a)

(r)

Water absorption (%) and water penetration (mm), if specified

(s)

Rapid chloride permeability - Coulomb value, if specified

(t)

Chloride migration coefficient (m /sec), if specified

2

*Include on delivery ticket as a minimum 13

Data shall be from the same production facility that will be used for the Project.

14

Mix Design data shall include but not be limited to the following: (a)

Locations on the Project where each mix design is to be used corresponding to Structural General Notes on the Drawings.

(b)

Proportions: Concrete constituent materials shall be proportioned to yield 1 m

(c)

Submit strength test records, mix design materials, conditions, and proportions for concrete used for record of tests, standard deviation calculation, and determination of required average compressive strength, if required by the Engineer.

3

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(d)

If early concrete strength is required, contractor shall submit trial mixture results as required.

(e)

Test records to support proposed mixtures shall be no more than 12 months old and use current cement and aggregate sources. Test records to establish standard deviation may be older if necessary to have the required number of samples.

(f)

Manufacturer's product data for each type of admixture.

(g)

Manufacturer’s certifications that all admixtures used are compatible with each other.

(h)

All information indicating compliance with Contract Documents including method of placement and method of curing.

Mass Concrete: (a)

Submit mix design for mass concrete elements in conformance with requirements of ACI 301 Section 8. The concrete mix design shall not be designed with a high early strength unless otherwise demonstrated by the Contractor for capability of maintaining proper temperature and approved by the Engineer.

(b)

Submit proposed methods of temperature control, including cementitious material content control in mix design to reduce heat-generating potential of concrete, precooling of ingredients to lower concrete temperature as placed, and methods to protect mass concrete elements from excessive temperature differentials.

(c)

Submit analysis of anticipated thermal development within mass concrete elements with the proposed mix design for these elements. Results of the analysis, using methods in ACI 207.1R and ACI 207.2R such as the Schmidt model and site specific data, shall address the maximum differential temperature and the maximum temperature during curing

(d)

Submit proposed number and locations of temperature monitoring devices to record temperature development between the interior and the exterior of mass concrete elements.

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EXPOSURE CLASSES

6.2.1

General

1

The exposure classes are related to the environmental conditions surrounding the concrete in service.

2

The concrete may be subject to more than one of the classes described below, and the environmental conditions to which it is subjected need to be expressed as a combination of exposure classes.

3

Where two or more aggressive characteristics lead to the same class, the exposure shall be classified into the next higher class; unless a special study for this specific case proves that it is not necessary.

4

For a given structure, different concrete elements may be subject to different environmental classes.

6.2.2

Reinforcement corrosion and sulphate classes

1

The classification system described below is based on the approach in BS EN 206-1, BS 8500-1, and the Concrete Society CS 163.

2

The exposure classes related to reinforcement corrosion are associated with carbonation and chlorides as per Table 6.1.

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3

The exposure classes related to sulphate attack are given in Table 6.2 in relation to sulphate and pH of the ground water.

4

The sulphate content as S04 mg/l shall be determined as per BS EN 196-2.

5

The pH shall be determined as per ISO 4316. Table 6.1. Exposure classes for reinforcement corrosion Exposure Class

Class description No risk of corrosion or attack. Non saline conditions. Blinding concrete, non-reinforced concrete or slab on ground

X1

Mild exposure – Non saline conditions (dry or wet, rarely dry). External concrete at least 3m above ground level, internal concrete in dry conditions, concrete permanently submerged in non-saline water or nonaggressive groundwater (Class S1).

X2

Moderate exposure – Non saline conditions (cyclic wet and dry). External reinforced concrete less than 3m above ground level, water-retaining structures exposed to fluctuating water levels.

X3

Aggressive exposure – Permanently submerged or wet (rarely dry). Concrete in contact with groundwater including capillary rise zone, concrete containing or permanently exposed to saline water.

X4

Severe exposure – Moderate humidity. External concrete within 1km from the sea or in contact with high saline water table or sabkhas. Concrete not affected by condensation, irrigation or leakage, which are more than 3m above ground level.

X5

Extreme exposure – Cyclic wet and dry. External concrete within 1km from the sea or in contact with high saline groundwater or sabkhas. Concrete affected by condensation, irrigation or leakage, which are less than 3m above ground level or within capillary zone. Concrete surfaces exposed to sea water splash or in sea water tidal zone.

et it

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ta

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.l. l

.

X0

Table 6.2. Sulphate exposure classes

m

Sulphate and magnesium

Exposure class

2:1 water/soil or groundwater SO4 (mg/l)

Mg (mg/l)

Natural soil Static water pH

Mobile 2 water pH

Brownfield Static water pH

1

Mobile 2 water pH

S1

< 1500

> 3.5

Not mobile

> 5.5

Not mobile

S2

1500-3000

> 3.5

Not mobile

> 5.5

Not mobile

S3

3001-6000

≤ 1000

> 3.5

Not mobile

> 5.5

Not mobile

S4

> 6000

≤ 1000

> 3.5

> 5.5

> 5.5

> 6.5

S5

> 6000

> 1000

> 3.5

> 5.5

> 5.5

> 6.5

Notes 1. 2.

Brownfield sites are those previously occupied and contain chemical residues into the ground or groundwater The mobility of water shall be determined as described in the Concrete Society CS 163.

QCS 2014


Page 12

6.3

FRESH CONCRETE

6.3.1

General

1

Where adequate workability is difficult to obtain at the maximum water/cementitious ratio allowed, the use of plasticisers or water reducing admixtures may be considered. Alternatively an increase in cementitious content may be considered where this will not adversely affect the durability of the concrete.

2

Cementitious contents in excess of 400 kg/m shall not be used unless special consideration has been given to the effect for heat of hydration and reduce thermal stress in the concrete, and approval has been obtained from the Engineer. The maximum cementitious content shall not exceed 500kg/m³

3

The proportioning, mixing and placing of the mixture shall be in accordance with Parts 7 and

.l. l

.

3

Temperature (at placement):

Maximum fresh concrete temperature shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

(b)

For mass concrete, the concrete producer shall demonstrate that temperature of concrete due to hydration shall comply with the maximum fresh concrete temperature specified. The supplier may use in his demonstration testing heat sensors and simulation technologies which measure the concrete heat of hydration and its rate versus concrete curing age.

ta

(a)

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4

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8 of this Section

The Contractor is responsible for ensuring that the concrete is able to be fully compacted within the concrete element regardless of reinforcing density or other limitations. This may involve reducing the maximum aggregate size, increase the level of concrete workability or use self-compacting concrete.

6

Where the consistence of concrete is to be determined, it shall be measured either by means of:

m

et it

o

ov

5

(a)

Slump test conforming to BS EN 12350-2

(b)

Flow table test conforming to BS EN 12350-5

7

The consistence of concrete shall be determined at the time of use of the concrete or in the case of ready-mix concrete, at the time of delivery.

8

The tolerances for the different consistence tests and target values are given in Table 6.3. Table 6.3. Tolerances for target values of consistence Slump*

Flow diameter*

Target value (mm)

≤ 40

50 to 90

≥ 100

Tolerance (mm)

-30, +40

-40, +50

-50, +60

Target value (mm)

All values

Tolerance (mm)

-60, +70

* For spot samples taken from initial discharge.

QCS 2014


Page 13

6.4

GRADES OF CONCRETE

1

Where strength is classified with respect to compressive strength, Table 6.4 gives the concrete grade with the requirements for w/c ratio and cementitious content.

2

The characteristic compressive strength at 28 days of 150mm cubes (f ck, cube) or 150mm diameter by 300mm cylinders (fck, cyl) may be used for the classification.

3

Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing shall be requested at 56 days, or 90 days as approved by the Engineer.

(N/mm )

B 15

15

12

B 20

20

16

C 25

25

20

C 30

30

C 35

35

C 40

40

C45

45

C 50

50

3

qa

(kg/m )

Maximum

Water : Cementitious Ratio

(w/c)

-

-

-

260

0.60

300

0.58

28

320

0.55

32

335

0.50

35

355

0.47

40

370

0.45

60

50

380

0.40

75

60

390

0.35

se

as

-

o

ov

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25

m

C 75

2

et it

C 60

2

rw

(N/mm )

Minimum cementitious content

ta

Concrete Grade

Minimum characteristic cylinder strength (fck, cyl)

Minimum characteristic cube strength (fck, cube)

.l. l

.

Table 6.4: Concrete grades and composition requirements

6.5

DURABILITY REQUIREMENTS

6.5.1

General

1

Constituent materials shall not contain harmful ingredients in such quantities as may be detrimental to the durability of concrete or cause corrosion of the reinforcement.

2

For reinforced concrete in the ground, the need for protection from chlorides must be balanced against the need for protection from sulphates.

3

Protective measures include the use of surface treatment, alternative reinforcement and increasing the concrete cover. In every case, the need for good quality concrete with low permeability is paramount.

QCS 2014


Page 14

6.5.2

Maximum acid soluble chloride content

1

The chloride content of the concrete, expressed as the percentage of chloride ions by mass of cementitious materials, shall not exceed the values given in Table 6.5.

2

Calcium chloride and chloride based admixtures shall not be used in concrete containing steel reinforcement or other embedded metal.

3

The determination of the chloride content in the concrete shall be conducted by the sum of the contributions from the constituent materials as described in BS EN 206-1 and BS 8500-2. Table 6.5. Maximum chloride content of concrete (by weight of cementitious materials) Concrete made with sulphate resisting Portland cement

Concrete made with other cementitious materials than SRPC

Reinforced concrete

0.15 %

0.3 %

Pre-stressed concrete

0.08 %

rw

.l. l

.

Concrete type

ta

0.10 %

Type of cementitious material

1

Different types of cementitious materials offer different resistance to sulphate attack and penetration of chlorides

2

The minimum cementitious content for different concrete grades is given in Table 6.4.

3

Table 6.6 gives the different types of cementitious materials and their combinations.

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6.5.3

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Table 6.6. Cementitious materials and combinations

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Cementitious material

Percentage of components 100% PC

Sulphate-resistance Portland cement

100% SRPC

m

Portland cement

PC/fly ash

PC/ground granulated blastfurnace slag

Triple blend PC/FA/SF

65-79% PC 35-21% FA 35-65% PC 65-35% GGBS 55-70% PC 35-25% FA 10-5% SF 30-45% PC

Triple blend PC/GGBS/SF

60-50% GGBS 10-5% SF

BS EN 197-1 designation

ASTM standard

CEM I

Type 1

-

Type 5

CEM II/B-V

CEM III/A

QCS 2014


Page 15

Resistance to alkali-silica reaction

1

Alkali-silica reaction is the most common form of alkali-aggregate reaction.

2

Dry concrete is not prone to cracking by alkali-silica reaction, as it needs an external source of water to develop sufficiently to cause cracking.

3

Where aggregate contain varieties of silica susceptible to attack by alkalis from cement and other sources and the concrete is exposed to humid conditions, actions shall be taken to prevent deleterious alkali-silica reaction using recommendations and procedures given in BS EN 206-1 and BS 8500-2.

6.5.5

Recommendations to resist reinforcement corrosion

1

Durability design should start at the concept design stage, continuing through the design, detailing, specification and execution phases.

2

This section covers the concrete grade, cementitious type, and minimum concrete cover for various exposure classes as given in Table 6.1.

3

Table 6.7 provided recommended values of concrete grade and cover thickness to resist reinforcement corrosion at different exposure classes.

qa

ta

rw

.l. l

.

6.5.4

se

as

Table 6.7. Recommended durability requirement to resist reinforcement corrosion

Mild

X2

Moderate

X3

ov

X1

25

o

No risk of corrosion

All

40

35

30

-

50

45

40

35

Aggressive

-

70

65

60

55

  

PC/FA PC/GGBS Triple blend

X4

Severe*

-

75

70

65

60

  

PC/FA PC/GGBS Triple blend

X5

Extreme*

-

80

75

70

65



Triple blend

C30

C40

C50

C60

C75

m

45

et it

X0

Cementitious type (Table 6.6)

Minimum concrete cover (mm)

er

Exposure Class

Minimum concrete grade



All

All

*High level of cement replacement is required for severe and extreme exposure conditions. Other protection measures such as coated reinforcement or surface treatment may be considered.

QCS 2014


Page 16

Recommendations to resist sulphate attack

1

The exposure classification shall be identified based on the sulphate and magnesium contents in the ground and groundwater, pH and mobility of groundwater as given in Table 6.2.

2

The recommended concrete specification requirements in terms of concrete grade and cementitious type are given in Table 6.8.

3

Unless stated otherwise by the Engineer or project designs, all concrete below ground shall have surface protection to prevent the movement of moisture from the ground, through the foundations into the superstructure. The method of protection shall be in accordance with Section 15 of the QCS or as approved by Qatar Standards.

.

6.5.6

Minimum concrete grade

S1

C35

C50

Triple blend SRPC, PC/FA, PC/GGBS

as

SRPC, PC/FA, PC/GGBS

C60

er

C75

ov

1

Triple blend

C50

C60

S4

All

se

S3

S5

qa

C40

S2

Cementitious type

ta

Exposure class

rw

.l. l

Table 6.8 Recommended durability requirement to resist sulphate attack

See Note

Triple blend See Note

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o

Note: 1 S5 requires special treatment when the sulphate content exceeds 6000 mg/l and the magnesium content exceeds 1000 mg/l. Durability-Related Properties

1

The durability of concrete is greatly influenced by the ability of the concrete cover to resist the movement of liquid and gas through concrete.

2

The commonly used test for assessing the transport properties of concrete are listed in Table 6.9 together with typical values. Lower value indicates more durable concrete.

3

No values are currently specified for various exposure classes, but may be requested by the Engineer. Table 6.9 gives the recommended durability-related properties and typical values for the development of mix design and comparative performance as given in the Concrete Society CS163.

4

For Severe and Extreme exposures, it is recommended to use high durable concrete (Table 6.9)

m

6.5.7

QCS 2014


Page 17

Table 6.9 Recommended properties and typical values for concrete Concrete property

Age range between 28 and 90 days

Test method

Water absorption Water penetration, Rapid chloride permeability (RCP), Chloride migration

High durability

Minimum durability

BS 1881: Part 122

2%

4%

BS EN 12390-8

5 mm

30 mm

ASTM C 1202

500 coulombs

NT Build 492

2.0 x10

-12

2

(m /s)

4000 coulombs 9.0 x10

-12

2

(m /s)

1. Concrete shall be tested for any of the transport properties when requested by the Engineer and shall be tested at 28 days.

2. Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing

.l. l

.

shall be requested at 56 days, or 90 days.

DESIGN OF CONCRETE MIXES

1

At the start of the construction period, the Contractor shall design a mix for each grade of concrete as stated hereafter.

2

Each mix design shall be such that:

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ta

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6.6

the aggregate shall comprise fine aggregate and coarse aggregate with size specified in Section 5, Part 2.

(b)

the combined aggregate grading shall be continuous

(c)

the aggregate quantity shall be calculated by weight.

se

as

(a)

Where a concrete production facility has strength test records not more than 12 months old, a sample standard deviation, Ss, shall be established. Test records from which Ss is calculated shall consist of at least 30 consecutive tests or two groups of consecutive tests totalling at least 30 tests

4

Where a concrete production facility does not have strength test records meeting requirements of 6.6 (3) above, but does have test records not more than 12 months old based on 15 to 29 consecutive tests, a sample standard deviation Ss shall be established as the product of the calculated sample standard deviation and modification factor of Table 6.10

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3

Table 6.10 Modification Factor for Sample Standard Deviation When Less Than 30 Tests Are Available No. of tests

Modification factor for sample standard deviation

Less than 15

Use para 7. Below

15

1.16

20

1.08

25

1.03

30

1.00

1- Interpolate for intermediate number of tests 2- Modified sample standard deviation, Ss, to be used to determined required average strength f’cr

QCS 2014


Page 18

5

To determine the correction factor between cube strength and cylinder strength, the contractor shall establish at least 30 consecutive strength tests from each proposed mix design. This correction will remain valid thru the project providing that no change in the properties of the materials and no change in source occurred.

6

Required average compressive strength (Target Mean Strength) f’cr used as the basis for selection of concrete proportions shall be determined from Table 6.11 using the sample standard deviation, Ss

Required average compressive strength, Target 2 Mean Strength, N/mm or MPa

.l. l

strength,

rw

Specified compressive N/mm2 or MPa

.

Table 6.11: Required Target Mean Strength when data are available to establish a sample Standard Deviation

F’cr = f’c + 1.34Ss ------------------ Eq. 1

ta

F’c < 35 MPa --- see footnote

qa

F’cr = f’c + 2.33Ss – 3.5 ---------- Eq. 2 F’c > 35 MPa --- see footnote

F’cr = f’c + 1.34Ss ------------------ Eq. 1

as

F’cr = 0.90f’c + 2.33Ss ------------ Eq. 3

When a concrete production facility does not have field strength test records for calculation of Ss, Required average strength (Target Mean Strength) f’cr shall be determined as follow:

ov

er

7

se

Note: Use the larger value computed from any equation

F’cr = f’c + 8.5 MPa when 20 < f’c < 35 MPa

(b)

F’cr = 1.10f’c + 5 MPa when f’c > 35 MPa

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(a)

Concrete

1

Portland cement concrete shall consist of a mixture of cementitious materials, fine aggregate, coarse aggregate, water, and additives (when required). It shall be classified as in Table 6.4 unless otherwise stated hereafter and requested by the Engineer.

2

Blinding concrete

m

6.6.1

(a)

Blinding concrete shall be of minimum Grade C15 and above.

(b)

The thickness of the blinding concrete shall be as shown on the Drawings, but shall in no instance be less than 75 mm.

(c)

The surface finish to blinding concrete shall be Class U4 as specified in Clause 9.3.1 of Part 9 of this Section or as directed by the Engineer.

QCS 2014

3

Page 19

Mass Concrete (a)

The fresh concrete temperature at placing shall not exceed 21°C to minimise thermal cracking. A higher temperature of up to 27°C may be accepted with a demonstration of the satisfactory performance of concrete including mock up and thermal calculations. The maximum allowable differential temperature between the interior and the exterior of the mass concrete element shall not exceed 20 ° C. The maximum temperature in any location within the mass concrete structure during curing shall not exceed 70 °C. The drop in concrete surface temperature during, and at the conclusion of the specified curing period, shall not exceed 11 °C in any 24 hour period.

Self-Compacting Concrete (a)

General: Self-Compacting Concrete (SCC) is a special concrete that requires minimum or no vibration for placing and compaction. It is able to flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested reinforcement. The hardened concrete is dense, homogeneous and has the same engineering properties and durability as traditional vibrated, fully compacted concrete.

(b)

Self-Compacting Concrete Supplier: SCC shall be supplied by a competent concrete producer with a record of successfully producing this type of concrete at considerable volume and with high consistency.

(c)

Constituent Materials, General: The constituent materials for SCC are the same as those used in traditional concrete conforming to EN 206-1, as specified in part 2 of this section.

(d)

To achieve these requirements the control of the constituent materials needs to be increased and the tolerable variations restricted, so that daily production of SCC is within the conformity criteria without the need to test and/or adjust every batch.

(e)

Recommended Test Requirements for SCC:

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ta

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.l. l

.

4


Field Tests

600 – 750 mm

550 – 750 mm

6 – 25 sec

N.A

L-Box (3 bars)

> 0.80

N.A

J-Ring

< 10mm

N.A

o

Laboratory tests

et it

Slump-flow

m

V-Funnel

5

(f)

Concrete specimens shall be moulded in single layer without rodding and tapping

(g)

Slump flow and VSI testing shall be performed as outlined in the European Guidelines for SCC, BS EN 12350-8 and BS EN 12350-9 or ACI 237R 07 and ASTM C 1611/C 1611M

Pile Concrete 3

(a)

The cementitious content shall not be less than 380 kg/m , as specified in Section 4.

(b)

The water-cementitious ratio shall not exceed 0.45

QCS 2014

Page 20

(c)

The concrete mixture shall be designed of high slump not less than 150 mm allowing proper free fall with excellent homogeneity. When concrete mixture requires slump of greater than 230 mm, it shall be designed as Self-Compacting Concrete or as instructed by the Engineer.

(d)

The concrete slump shall have adequate workability retention using approved type of retarder and shall be submitted in the design mix.

(e)

The increase in workability shall not permit any decrease in the specified design strength

(f)

The concrete in a pile shall, if at all possible, be placed in one continuous operation.

Underwater Concrete Shall comply with ACI 304 Chapter 8

(b)

The Cementitious content shall not be less than 390 kg/m

(c)

The water-cementitious ratio must not exceed 0.40

(d)

Fine aggregate contents of 45 to 55% by volume of total aggregate and air contents of up to approximately 5% are generally specified.

(e)

Concrete shall be more cohesive and less prone to washout of cement or fines from the concrete during placement. Antiwashout admixtures or alternative concrete mix shall be used for underwater concrete.

(f)

Trial placements shall be conducted to verify that the concrete proportioned with the antiwashout admixture can maintain adequate slump life and can flow for the required distance.

(g)

The concrete mixture shall be designed of high slump not less than 150 mm allowing proper free fall with excellent homogeneity. The use of air-entraining admixture shall be evaluated as it increases the workability. When concrete mixture requires slump of greater than 230 mm, it shall be designed as Self Compacted Concrete. The increase in slump shall be made using proper admixtures.

(h)

.l. l

.

(a)

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3

o

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6


The increase in workability shall not permit any decrease in the specified design strength

m

(i)

The concrete slump shall have adequate retention using approved type of retarder and shall be submitted in the design mix.

7

(j)

The concrete shall be placed in one continuous operation

(k)

The final selection of a concrete mixture shall be based on test placements made under water in a placement box or in a pit that can be dewatered after the placement. Test placements shall be examined for concrete surface flatness, amount of laitance present, quality of concrete at the extreme flow distance of the test, and flow around embedded items, if appropriate.

Shotcrete (a)

The classification of shotcreting shall be in accordance to the process used (wet-mix or dry-mix) and the size of aggregates used.

(b)

All materials shall be as per QCS except for aggregate where gradation shall be as per ACI 506R and 506.2R

QCS 2014


Page 21

(c)

Steel and synthetic fibers will be used to reduce propagation of cracks. Fibers shall be as per Manufacturer supplier data sheet and shall conform to ASTM A 820 for steel fibers and ASTM C1116 for synthetic fibers.

(d)

The nozzle operator should be certified (refer to ACI CP-60) and have completed at least one similar application as a nozzle operator on a similar project. The nozzle operator should also be able to demonstrate, by test, an ability to satisfactorily perform the required duties and to apply shotcrete as required by specifications

(e)

Before shotcreting the surface shall be prepared and maintained before and during shotcrete application. Surface preparation shall conform to ACI 506 R chap. 5

(f)

The cementitious content shall not be less than 360 kg/m where wet-mix is applied the slump shall be in the range of 40 to 80 mm

(g)

Normal testing ages for compressive strength are 7 and 28 days; however, shorter periods may be required for particular applications or conditions as directed by the 3 Engineer. Testing shall be on daily production or every 30 m whichever is greater.

(h)

Sampling and testing, however, should be varied according to the size and complexity of the project. Sampling should be done in accordance with ASTM C 1385. Making extra cylinders or panels shall be at the request of Engineer if testing results vary.

(i)

Testing for water absorption and drying shrinkage shall be at the request of the Engineer.

(j)

Fiber-reinforced shotcrete requires fiber washout tests or flexural toughness testing according to ASTM C 1018.

(k)

Acceptance of shotcrete should be based on results obtained from drilled cores or sawed cubes (ASTM C 42). The use of data from nondestructive testing devices, such as impact hammers or probes (ASTM C 805, ASTM C 803), ultrasonic equipment (ASTM C 597), and pull-out devices (ASTM C 900) may be useful in determining the uniformity and quality of the in-place shotcrete. These tests, however, may not provide reliable values for compressive strength.

(l)

Core grading is a method used to evaluate encasement of reinforcement. Core grading shall be used for nozzle operator evaluation. Core grading should not be used to evaluate structures.

o

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No-Fines Concrete and Pervious concrete

m

8

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.

3

(a)

No-fines concrete shall be made using a coarse aggregate conforming QCS section 5 part 3

(b)

Proportion of aggregate, cement and water shall be determined by trial mixes by the Contractor and to be accepted by the Engineer.

(c)

All the aggregate particles are to be coated with a film of cement grout.

(d)

No-fines concrete when placed shall contain no layers of laitance.

(e)

No-fines concrete shall not be mixed by hand.

(f)

Mechanical vibration shall not be used to compact no-fines concrete.

(g)

Three test cubes of no-fines concrete shall be made of each preliminary mix.

(h)

Minimum crushing strength of the chosen mix shall be 5 MPa at 28 days.

QCS 2014

(i)


Page 22

The porosity of no-fines concrete shall be such that water will pass through a slab 2 300 mm thick at the rate of not less than 7 l/m • s of slab with a constant 100 mm depth of water on the slab. Where a slab incorporating vertical weep holes or drain holes is casted above a layer of no-fines concrete; any polyethylene sheeting shall be pierced below the pipes forming such drain holes and the edges of the sheeting sealed to the lower end of the pipe to prevent the ingress of grout and fine particles from the slab concrete into the no-fines concrete.

(k)

The limit for the maximum height of drop while placing is not applicable for no fines concrete.

(l)

Formwork shall remain in place until the no fines concrete has gained adequate strength to support itself as per the requirements of Part 10 of this Section.

(m)

Curing shall be carried out in accordance with the provisions of Part 11 of this Section

(n)

The fresh density of Pervious concrete shall be tested as per ASTM C1688 and the infiltration rate shall be tested as per ASTM C1701 and to follow ACI 522.1R for testing and quality control scheme.

qa

Concrete with recycled aggregates shall be generally approved once the source of recycled aggregates is identified based on type and approved by the Engineer. The recycled aggregates shall meet with BS EN 12620 and QCS requirements.

(b)

The concrete made with recycled aggregates shall be limited to design strength of C40 MPa cube strength; unless otherwise accepted by the Engineer. BS EN 206-1 shall be the code of practice and guide for the usage of recycled concrete aggregates in concrete or ACI 555 and BRE digest 433.

(c)

The Water-cementitious ratio shall not exceed 0.50

(d)

To determine a target mean strength on the basis of a required strength, a higher standard deviation (increased by 40%) shall be used when designing a concrete with recycled aggregates of variable quality than when recycled aggregate of uniform quality or virgin aggregates are used

as

(a)

Specific gravity, unit weight, and absorption of aggregates should be determined before mixture proportion studies

m

(e)

et it

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9

ta

rw

.l. l

.

(j)

10

(f)

The mixture proportion should be based on the measured density of the recycled aggregates intended in the job concrete

(g)

Trial mixes shall be made to verify the requirements with project specification and QCS.

Heavyweight and radiation shielding concrete (a)

The quality of the aggregates should comply with the requirements of QCS for normal weight aggregates, ASTM C 637 for heavyweight aggregates and ASTM C638 for aggregates to be used in radiation-shielding concrete.

(b)

When ferrophosphorous aggregates are used, tests shall be made to determine if gases (nontoxic) might be released during construction.

(c)

Aggregates shall be checked for every delivery to ensure that they conform completely with purchase specifications

QCS 2014


Page 23

Aggregates shall be frequently evaluated for the effects of deleterious substances or aggregate coatings on concrete strength or the promotion of corrosion in metallic aggregates or embedment’s

(e)

The chemical properties of all high-density aggregates must be provided to the Engineer for evaluation before use with due consideration given to chemical reactivity, particularly in highly alkaline environment as found in cement paste.

(f)

Tests for alkali-aggregate reactivity shall be determined from each source and supplier and shall be made every 3 months.

(g)

The fresh density of high-density concrete shall be made from each truck

(h)

Lead shot concrete shall not be use for structural concrete.

(i)

Thermal conductivity, elastic behaviour and shrinkage, hardened density, strength as well as other hardened concrete properties shall be tested and verified before the use of concrete.

ta

Classification of fiber-reinforced concrete shall be made based on the material type of the fiber incorporated: Type I Steel Fiber-Reinforced Concrete—Contains stainless steel, alloy steel, or carbon steel fibers conforming to Specification of BS EN 14889-1 or ASTM A820 /A820M .

(ii)

Type II Glass Fiber-Reinforced Concrete—Contains alkali-resistant (AR) glass fibers conforming to Specification C 1666/C 1666M.

(iii)

Type III Synthetic Fiber-Reinforced Concrete— Contains synthetic fibers for which documentary evidence can be produced confirming their long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures and shall conform to BS EN 14889-2

(iv)

Type IV Natural Fiber-Reinforced Concrete— Contains natural fibers for which documentary evidence can be produced confirming their long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures. Test Method ASTM D 6942 shall be used to determine the susceptibility of these fibers to deterioration as a result of exposure to alkalis in concrete

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(i)

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(a)

rw

Fiber-Reinforced Concrete

m

11

.l. l

.

(d)

(v)

(b)

When the purchaser chooses to permit the use of fibers other than those complying with the above classifications, the manufacturer or supplier shall show evidence satisfactory to the purchaser that the type of fiber proposed for use shows long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures

The contractor shall submit: (i)

Type of fiber-reinforced concrete required

(ii)

Designated size, or sizes, of coarse aggregates

QCS 2014


Page 24

Slump or time of flow required at the point of delivery, or when appropriate the point of placement, subject to the tolerances hereinafter specified Slump shall be specified when it is anticipated to be 50 mm or more. Except as otherwise specifically permitted by the Engineer, cement, supplementary cementitious materials, fine and coarse aggregates, mixing water, and admixtures shall be measured in accordance with the applicable requirements of QCS

(d)

Fibers shall be measured by mass. When the fibers are to be measured by mass, bags, boxes, or like containers are acceptable provided that such like containers are sealed by the fiber manufacturer and have the mass contained therein clearly marked. No fraction of a container delivered unsealed, or left over from previous work, shall be used unless weighed.

(e)

Prepackaged, dry, combined materials, including fibers, shall comply with the packaging and marking requirements of Specification ASTM C 387 or C 1480 and shall be accepted for use provided that after addition of water, the resulting fiber reinforced concrete meets the performance requirements of this specification

(f)

Batching plant used for the preparation of continuously mixed fiber-reinforced concrete shall comply with the applicable requirements of NRMCA. Fiber-reinforced concrete shall be added directly to the concrete at the time of batching in amounts in accord with approved submittals for each type of concrete required. Mix concrete in strict accord with fiber-reinforced concrete manufacturer, instructions and recommendations

(g)

Fiber-reinforced concrete shall be free of fiber balls when delivered

(h)

The manufacturer of the fiber-reinforced concrete shall furnish to the purchaser a delivery ticket or statement of particulars on which is printed, stamped, or written, information with details of the type, brand, and amount of fibers used.

(i)

The contractor shall afford the inspector all reasonable access, without charge, for the procurement of samples of freshly mixed fiber-reinforced concrete at the time of placement to determine compliance with the requirements of this specification.

(j)

Samples of batch-mixed fiber-reinforced concrete shall be obtained in accordance with Practice ASTM C 172 or C 1385/C 1385M for shotcrete as appropriate, except that wet-sieving shall not be permitted. Sampling for uniformity tests shall be in accordance with specification ASTM C 94/C 94M If the measured slumps, time of flow, or air content fall outside the limits permitted by this specification, make a check test immediately on another portion of the same sample. If the results again fall outside the permitted limits, the material represented by the sample fails to meet the requirements of this specification

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(c)

(l)

The following shall apply to all forms of fiber-reinforced concrete except dry-mix shotcrete. When applicable, the slump shall be in tolerance with this section para 6.4.2.5 (a) and (b).

(m)

The time of flow shall be in the tolerances as follow: (i)

When the project specifications for time of flow are written as a “minimum” or “not less than” requirement

Plus Tolerance Minus Tolerance

Specified time of flow If 15sec or less If more than 15 sec 5s 10s 0s 0s

QCS 2014

Section 05: Concrete Part 06: Property Requirements (ii)

When the project specifications for time of flow are not written as a “minimum” or “not less than” requirement: For specified time of flow 8 to 15 s More than 15 s

Tolerances for time of flow Tolerance + 3s + 5s

Finishability - Pre-project trials shall be utilized to determine acceptable surface finishability by the Engineer. The manufacturer shall provide the services of a qualified technician to instruct the concrete supplier in proper batching and mixing of materials to be provided.

(o)

Provide fibers for concrete reinforcing capable of achieving a two hour fire resistance rating when tested under ASTM E 119. Fire tests must be certified.

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Lightweight concrete

This clause of the specification refers to lightweight concrete with improved insulation properties where the practical range of densities is between about 300 and 1850 kg/m3.

(b)

The required density and strength of the lightweight concrete will be specified on the drawings or directed by the Engineer.

(c)

The method of production of lightweight concrete will be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the lightweight concrete along with a list of previous projects where the particular system has been used.

(d)

After source approval of the material and system the Contractor shall submit a mix design for the lightweight concrete for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

(e)


(f)

Iightweight concrete shall be made with lightweight aggregates as approved in part 2 of section 05 in QCS for its use in concrete

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The performance of lightweight concrete shall follow ACI 213R

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6.7

TRIAL MIXES

1

As soon as the Engineer has approved the concrete mix design for each grade of concrete and during or following the carrying out of the preliminary tests, the Contractor shall prepare a trial mix of each grade in the presence of the Engineer at least 35 days before commencement of concreting. Trial mix shall be mixed and handled by means of the same plant which the Contractor proposes to use in the Works. The trial mix shall comprise not 3 less than 50% from the central mixing drum capacity but not less than 3.0 m of concrete. The trial mix can be exempted if concrete supplier provides through an independent approved testing agency adequate history on strength:

2

(a)

Not less than 30 strength test results as in para 6.6 of this specification

(b)

The results shall valid by no more than 6 months from the date of approval

Batch the field concrete trial mixture within -5°C of the proposed maximum allowable fresh 3 concrete temperature in a truck-mixer with a minimum batch size of 3 m .

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Page 26

The concrete mixture shall be held in the mixer for 120 minutes, unless otherwise specified by the Engineer. During the entire 120-minute period, agitate the mixer at 1 to 6 rpm. At the end of 120 minutes, mix the concrete mixture at full mixing speed designated by the manufacturer (6 to 18 rpm) for 2 minutes.

4

For each trial mix, a plant production trial shall be carried out and the slump of the concrete checked immediately after discharge from the mixer and thereafter at 30 min intervals up to the maximum time period envisaged for delivery and standing on site. Based on this trial the mix design shall identify any adjustments to the range of plasticiser for acceptable workability for different times after batching. Where ready mix concrete is being used, the above requirement may be waived at the discretion of the Engineer if the Contractor has documented previous experience of a particular mix design with test results available.

5

The proportions of cement, aggregate and water shall be carefully determined by weight in accordance with the Contractor's approved mix design (or modified mix design after preliminary tests).

6

Each sample shall consist of at least 9 specimens for strength analysis where 3 specimens for each age will be tested to determine the concrete strength at the required age.

7

If either or both the average value of the strength of the three cubes tested at 28 d is less than the required strength (target strength) or the difference between the greatest and the least strengths is more than 15 % of the average strengths, as per BS EN 206-1, the Contractor shall take measures as deemed necessary such as:

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Propose new mix design

(b)

Provide new materials and prepare and test further trial mixes until specified requirements are achieved.

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(a)

Additionally, the Contractor shall measure the temperature, workability of concrete in each batch.

9

When requested by engineer, a mock-up of 2x2x2 m shall be made at jobsite and full scale tests of the workability of each trial mix shall be made by the Contractor in the presence of the Engineer. The following tests shall be made on the Site by filling trial moulds to confirm the suitability of:

3

(a)

mix for the works type of plant used for mixing

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(c)

face intended for use in the works

(d)

type of form oil

(e)

type of protective coatings.

10

Redesign of the concrete mixes and trial mixes of concrete shall be repeated for each grade of concrete until the concrete meets the requirements in this specification and it is verified by full scale mockup test as described above.

11

Approval of the job-mix proportions by the Engineer or his assistance to the Contractor in establishing those proportions, in no way relieves the Contractor of the responsibility of producing concrete which meets the requirements of this Specification.

12

All costs connected with the preparations of trial mixes and the design of the job mixes shall be borne by the Contractor.

13

The Contractor shall declare any change in the source of the material and any changes in the cement content consumption greater than 20.0kg/m³ from that used in the trial mixes.

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QUALITY AND TESTING

6.8.1

General

1

In order to ensure that the quality of materials and mix proportions are maintained throughout concreting operations, sampling and testing shall be carried out using the relevant standard procedures and all other relevant codes quoted in this specification in accordance with a routine testing program that shall be agreed with the Engineer before the start of concrete work.

2

The Contractor, through a third party approved testing agency, shall supply all necessary tools for tests, shall cast all concrete specimens, strip and store them in water as stated in BS EN 12390-2. The Contractor shall also arrange for the transport of samples to the place of testing and shall supply the Engineer with duplicate copies of all test certificates.

6.8.2

Tests for Concrete

1

Unless the Engineer directs otherwise, the program shall include at least the tests specified below.

2

Tests on aggregates shall be as described in Part 2 of this Section.

3

Concrete shall be tested in accordance with the requirements of this specification by qualified field testing technicians or engineer. Concrete testing laboratory personnel shall be certified from a recognised Institution. Field personnel’s in charge of sampling concrete; testing for slump, and temperature; and making and curing test specimens shall be certified from a recognised Institution too.

4

Slump tests (and VSI testing when applicable) shall be carried out at the rate of one test per 3 load of concrete delivered to the Site, or one test per 10 m whichever is the lesser for the 3 3 first 50 m of concrete then at a rate of 1 slump test for every 50 m if concrete was consistent during production. In the event of inconsistent slump values, the Engineer may instruct the Contractor to check the slump test on each truck of concrete at the plant. The Contractor shall carry out an investigation to establish the cause of the high variation in slump and shall take any necessary corrective measures. The slump requirements for the fresh concrete are to be approved by the Engineer.

5

The adjustment for the slump of concrete to fit the job requirement can be conducted only one time using a proper additive at jobsite provided that such addition does not increase the water-cement ratio and setting time above the maximum permitted by the specifications. This addition will only be made at the approval of Engineer.

6

Concrete shall be available within the permissible range of slump for a period of 30 min starting either on arrival at the job site or after the initial slump adjustment as permitted 3 above, whichever is later. The first and last quarter m discharged are exempt from this requirement. If the user is unprepared for discharge of the concrete from the vehicle, the producer shall not be responsible for the limitation of minimum slump after 30 min have elapsed starting either on arrival of the vehicle at the prescribed destination or at the requested delivery time, whichever is later.

7

When air-entrained concrete is desired the purchaser shall specify the total air content of the concrete. The air content of air-entrained concrete when sampled from the transportation unit at the point of discharge shall be within a tolerance of +1.5% of the specified value.

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6.8

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Concrete strength test: (a)

Each concrete strength sample shall consist of at least seven specimens, two to be tested at 7 days, three at 28 days and two to be tested at the discretion of the Engineer. Additional samples may be prepared as directed by the Engineer to be tested at the discretion of the Engineer for strength and/or durability.

(b)

When concrete cylinders have been specified, the concrete specimens shall not be capped using sulphur for environmental effect. The Contractor shall follow one of the following procedures and as approved by the Engineer: (i)

Cap the specimens in accordance with ASTM C617 using neat cement paste and/or High-strength gypsum cement paste

(ii)

Saw cut and Grind the surface of the concrete to the desired planeness and perpendicular

(iii)

Test the concrete cylinders using Unbonded Caps in accordance with ASTM C1231

(iv)

For field specimens, the contractor has the right to either use the conversion listed in EN 206 or determine the conversion factor for each specified concrete mix design by testing at least 36 comparative specimens (i.e. 18 cubes versus 18 cylinders sampled from 3 consecutive batch trial mix).

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A minimum of one sample shall be taken of each mix every day the mix is used

(d)

Samples shall be taken at the average rate of the followings:

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One sample every 30 m3, if the pour is less than or equal to 90 m

(ii)

One sample every 100 m3, if the pour is greater than 90m and equal to or less than 2000 m3,

(iii)

One sample every 200 m3, if the pour exceeds 2000 m .

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Test specimens for compressive strength testing shall be prepared and cured in accordance with BS EN 12390-2. The compressive strength of the specimens shall be determined in accordance with BS EN 12390-3.

(f)

A test shall be the average of the strength of the specimens tested at the age specified. If a specimen shows definite evidence other than low strength, of improper sampling, moulding, handling, curing, or testing, it shall be discarded and the strength of the remaining cubes shall then be considered the test result. Identity criteria of concrete strength shall be assessed for each individual test result and the average of non-overlapping results as per BS EN 206-1 and explained below:

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(i)

The average strength tests (average of two specimens or more) shall be equal to or greater than the characteristic (fck) + 2 MPa, and

(ii)

Any individual test result shall be equal to or greater than fck – 4 MPa. The test result shall be that obtained from the average of the results of two or more specimens made from one sample for testing at the same age.

If works test specimens fail at 28 days the Contractor shall suspend concreting operations and shall not proceed further without approval. The Contractor shall carry out in-situ testing of the suspect concrete in accordance with Part 13 of this Section, in the presence of the Engineer. All defective work shall be replaced and retested to the satisfaction of the Engineer.

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Page 29

Hardened Tests for Fiber-Reinforced Concrete (a)

When post-crack flexural performance is used as the basis for acceptance of fiberreinforced concrete, make, condition, and test sets of test specimens in accordance with Test Method ASTM C1399, C1550 or C1609/C1609M as specified.

(b)

When flexural strength is used as the basis for acceptance, make and test sets of at least three test specimens in accordance with the requirements for sampling and conditioning given in Test Method ASTM C1609/C1609M. Test specimens representing thin sections, as defined in C1609/C1609M, or specimens representing fiber-reinforced shotcrete of any thickness, shall be tested as cast or placed without being turned on their sides before placement on the support system. Acceptance shall not be based on flexural strength alone when post-crack performance is important. Test Method C1609/C1609M provides for the determination of first peak flexural strength when required by the purchaser. For many type-amount fiber combinations, the first peak flexural strength is not significantly greater than the peak strength in flexure.

(c)

When compressive strength is used as part of the basis for acceptance of fiberreinforced concrete, make sets of at least two test specimens in accordance with the applicable requirements of Practices ASTM C31/C31M and C192/C192M and as specified in this section, or Test Methods C42/C42M or C1604/C1604M and condition and test in accordance with Test Methods BS EN 12390, C39/C39M, C42/ C42M, or C1604/C1604M. Acceptance shall not be based on compressive strength alone.

(d)

The frequency of tests on hardened fiber-reinforced concrete shall be in accordance with the following requirements:

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6.8.3


Batch-Mixing: Tests shall be made with same frequency as in conventional concrete. Each test shall be made from a separate batch. On each day fiberreinforced concrete is mixed, at least one test shall be made for each class of material.

(ii)

When fibers are added, subject for approval of the Engineer, at the truck mixer 3 the tests shall be made for each 20 m or fraction thereof, or whenever significant changes have been made in the proportioning controls. On each day fiber-reinforced concrete is mixed, at least one test shall be made for each class of material.

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(i)

(iii)

3

For Shotcrete: Tests shall be made for each 38 m placed using specimens sawed or cored from the structure or from corresponding test panels prepared in accordance with Practice ASTM C1604 and C 1140. On each day fiberreinforced shotcrete is prepared; at least one test shall be made for each class of material.

6.8.4

Quality Control charts

1

The Contractor shall submit a continuous statistical analysis, on a monthly basis, for strength showing the potential strength of the concrete, variations in measured strength by determining the standard deviation (margin), batch-to-batch variations of the proportions and characteristics of the constituent materials in the concrete, the production, delivery, and handling process, and climatic conditions; and variations in the sampling, specimen preparation, curing, and testing procedures (within-test).

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Page 30

The Contractor shall provide in his analysis the mean strength, calculated standard deviation, the normal distribution of concrete strength and the frequency histogram. The Contractor shall draw the upper and lower lines for warning line (Target mean strength + 2 x standard deviation) and control line (Target mean strength + 3 x standard deviation)

3

The contractor shall use the methods, of computing standard deviation along with coefficient of variation and factors for computing within-test standard deviation from range, addressed in ACI 214

4

This recalculated margin, if adopted by the Engineer, becomes the current margin for the judgement of compliance with the specified characteristic strength of concrete

6.9

WORKS TEST CUBES

1

Test cubes shall be taken as specified from fresh mixed concrete which is being used in the Works and which has been prepared in the normal way.

2

Cubes shall be numbered sequentially and marked: Time, date and name of individual

(b)

Section of work from which samples are taken

(c)

Mix reference and delivery note number

(d)

Name of technician

(e)

and any other relevant information.

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Tests for slump, as per BS EN 12350-2, and temperature shall be made and recorded whenever samples are taken.

4

The cube manufacture shall be in accordance with BS EN 12390-2.

5

When Self Compacting Concrete is used, the concrete specimens shall not be consolidated in moulds and it shall be placed in a single lift then levelled with minimum manipulation.

6

All samples shall be moulded at jobsite on a levelled surface area to within 20 mm per meter

7

Immediately after moulding and finishing, the specimens shall be stored for a period up to 48 ° h in a temperature range from 20 to 26 C and in an environment preventing moisture loss from the specimens

8

Specimens shall not be transported or handled until at least 14 h after casting

9

Transportation time from site to laboratory for final curing and strength testing shall not exceed 4 hours. Specimens shall be protected from direct sun or rapid evaporation and placed on cushion layer to reduce vibration

6.10

REJECTION OF CONCRETE MIXES

6.10.1

Rejection of Concrete Mixes:

1

Concrete mixes shall be rejected if they fail to meet one or more requirements, which cannot be brought into compliance as related to any of the following:

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QCS 2014


(a)

Improper class or grade of concrete

(b)

Slump or temperature not within specified limits

(c)

Oversized aggregate

(d)

Maximum water-cementitious ratio is exceeded

Page 31

Concrete shall not be rejected unless it has been visually inspected by the Engineer or representatives.

6.10.2

Unsatisfactory Concrete Works

1

A test shall be the average of the strengths of the specimens tested at the age specified. If a specimen shows definite evidence other than low strength, of improper sampling, moulding, handling, curing, or testing, it shall be discarded and the strength of the remaining specimens shall then be considered the test result and where the range of the test values is more than 15 % of the mean, the results shall be disregarded unless an investigation reveals an acceptable reason to justify disregarding an individual test value. To conform to the requirements of this specification, strength tests representing each class of concrete must meet the following requirements:

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The average of any three consecutive strength tests shall be equal to, or greater than, the specified strength, f ‘c, and

(b)

When the specified strength is 35 MPa or less, no individual strength test (average of at least two specimen tests) shall be more than 3.5 MPa below the specified strength, f ‘c

(c)

When the specified strength is greater than 35 MPa, no individual strength test (average of two specimen tests) shall be less than 0.90 f ‘c.

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(a)

Should any of the test results be unsatisfactory, the Engineer may order the work to be stopped pending his further instructions. Executed work for which test results are unsatisfactory shall be liable to rejection and if so advised the work shall be rebuilt at the Contractor's expense.

3

In the case of the 7-day works cube tests proving unsatisfactory, the work may be stopped liable to rejection pending the result of the 28-day test. If the test results fail to comply with the requirements, the work represented shall be immediately liable to rejection.

4

The cost of all such cuttings, preparation of specimens, transportation and testing, and of making good the portions of the structure affected shall be borne by the Contractor.

5

Regardless of satisfactory test cube results, any concrete work which, in the Engineer's opinion, is excessively honeycombed or in any other way is defective, shall be liable to rejection. Minor defects apparent on stripping the formwork must be made good at the Contractor's expense. No such repair work shall be carried out until after inspection by the Engineer and his acceptance of the proposed treatment has been given. Work which has not been previously inspected but which shows signs of such treatment shall be liable to rejection as defective work.

6

The cost of all delays on site due to faulty concrete work shall be met by the Contractor.

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END OF PART

QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 1

CONCRETE PLANTS.............................................................................................. 2

7.1 7.1.1 7.1.2


7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

BATCHING .............................................................................................................. 3 General 3 Plant Type 5 Bins and Weight Batchers 5 Tolerances of Measuring Equipment 5 Batching Tolerances 6 Charging the Mixer 7

7.3 7.3.1 7.3.2 7.3.3 7.3.4

MIXING.................................................................................................................... 7 Charging Concrete Materials 7 Mixing Time for Stationary Mixers 7 Mixing 8 Limitation of Water : Cement Ratio 8

7.4 7.4.1

READY-MIXED CONCRETE ................................................................................... 9 General 9

7.5

APPENDIX A: CONCRETE PLANT INSPECTION – CHECKLIST ........................ 11

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7

CONCRETE PLANTS

7.1

GENERAL

7.1.1

Scope

1

This Part covers batching and mixing of concrete together with inspection of concrete plants.

2


References

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ACI 304 ......................Guides for Measuring, Mixing, Transporting, and Placing Concrete

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ASTM C94 ..................Specification for ready-mixed concrete

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BS 1881......................Testing concrete

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BS 8500......................Concrete Specification complementary to EN 206 BS EN 12390..............Testing of hardened concrete

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BS EN 12390-1:2000 .Testing hardened concrete — Part 1: Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2:2000 .Testing hardened concrete — Part 2: Making and curing specimens for strength tests

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Part 1 ............... General Part 2 ............... Aggregates Part 3 ............... Cementitious materials Part 4 ............... Water Part 5 ............... Admixtures Part 6 ............... Property Requirements Part 8 ............... Transporting and Placing of Concrete Part 15 ............. Hot Weather Concreting Part 16 ............. Miscellaneous

.

This Section

BS EN 12390-3:2000 .Testing hardened concrete — Part 3: Compressive strength of test specimens BS EN 12390-4:2000 .Testing hardened concrete — Part 4: Compressive strength Specification for testing machines BS EN 12390-5:2000 .Testing hardened concrete — Part 5: Flexural strength of test specimens BS EN 12390-6:2000 .Testing hardened concrete — Part 6: Tensile splitting strength of test specimens BS EN 12390-7:2000 .Testing hardened concrete — Part 7: Density of hardened concrete BS EN 12390-8:2000 .Testing hardened concrete — Part 8: Depth of penetration of water under pressure BS EN 12350..............Testing fresh concrete BS EN 12350-1:2000 .Testing fresh concrete - Part 1: Sampling

QCS 2014


Page 3

BS EN 12350-2:2000 .Testing fresh concrete - Part 2: Slump test BS EN 12350-3:2000 .Testing fresh concrete - Part 3: Vebe test BS EN 12350-4:2000 Testing fresh concrete - Part 4: Degree of compatibility BS EN 12350-5:2000 Testing fresh concrete - Part 5: Flow table test BS EN 12350-6:2000 Testing fresh concrete - Part 6: Density BS EN 12350-7:2000 Testing fresh concrete - Part 7: Air content - Pressure methods GSO EN 206-1, ..........Concrete. Specification, performance, production and conformity GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – part 2: properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – part 3: Making and curing test specimens.

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GSO ISO 1920-4 ........Testing of concrete – part 4: strength of hardened concrete.

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GSO ISO 1920-5 ........Testing of concrete – part 5: properties hardened concrete other than strength.

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GSO ISO 1920-6 ........Testing of concrete – part 6: sampling, preparing and testing of concrete core.

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GSO ISO 1920-7 ........Testing of concrete – part 7: Non–destructive test on hardened concrete.

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ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of concrete for samples prepared in the field or in the laboratory

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ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete cylinders in compression

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ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of elasticity in compression

BATCHING

7.2.1

General

1

During measurement operations, aggregates shall be handled in a manner to maintain their desired grading, and all materials shall be weighed to the tolerances required for the desired reproducibility of the selected concrete mix.

2

The coarse aggregate shall be controlled to minimize segregation and undersized material. Fine aggregate shall be controlled to minimize variations in gradation, giving special attention to keeping finer fractions uniform and exercising care to avoid excessive removal of fines during processing

3

Avoid blending two sizes of fine aggregate by placing alternate amounts in bins or stockpiles or when loading cars or trucks. Satisfactory results are achieved when different size fractions are blended as they flow into a stream from regulating gates or feeders. A more reliable method of control for a wide range of plant and job conditions, however, is to separate storage, handling, and batching of the coarse and fine fractions

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Page 4

Stockpiling of coarse aggregate shall be kept to a minimum because fines tend to settle and accumulate. When stockpiling is necessary use of correct methods minimizes problems with fines, segregation, aggregate breakage, excessive variation in gradation, and contamination. Stockpiles shall be built up in horizontal or gently sloping layers, not by end-dumping. Trucks, loaders, and dozers, or other equipment shall not be operated on the stockpiles because, in addition to breaking the aggregate, they frequently track dirt onto the piles

5

Stockpiles located to prevent contamination; arranged to assure that each aggregate as removed from its stockpile is distinct and not intermingled with others. The concrete supplier is asked to separate storage bins or compartments for each size and type of aggregate properly constructed and charged to prevent mixing of different sizes or types

6

Sequencing and blending of the ingredients during charging of the mixers shall be carried out in such a way as to obtain uniformity and homogeneity in the concrete produced as indicated by such physical properties as unit weight, slump, air content, strength and air-free mortar content in successive batches of the same mix proportions and as stated in ASTM C94 Annex A.

7

The mix recipe for the mixes to be produced shall be readily available to the mixer operator. Only authorised personnel shall be allowed to make changes to the mix design.

8

All cement bags shall be stored in weathertight, properly ventilated structures to prevent absorption of moisture.

9

Storage facilities for bulk cement shall include separate compartments for each type of cement used. The interior of a cement silo shall be smooth, with a minimum bottom slope of 50 degrees from the horizontal for a circular silo and 55 to 60 degrees for a rectangular silo. Silos shall be equipped with non-clogging air-diffuser flow pads through which small quantities of dry, oil-free, low-pressure air can be introduced intermittently at approximately 3 to 5 psi (20 to 35 kPa) to loosen cement that has settled tightly in the silos. Storage silos shall be drawn down frequently, preferably once per month, to prevent cement caking.

10

Each bin compartment from which cement is batched shall include a separate gate, screw conveyor, air slide, rotary feeder, or other conveyance that effectively allows both constant flow and precise cutoff to obtain accurate batching of cement

11

Fly ash, ground slag, or other pozzolans shall be handled, conveyed, and stored in the same manner as cement. The bins, however, shall be completely separate from cement bins without common walls that could allow the material to leak into the cement bin.

12

All bins and silos shall be properly tagged at silos, bins and near charging hose.

13

Bags of cement should be stacked on pallets or similar platforms to permit proper circulation of air. For a storage period of less than 60 days, stack the bags no higher than 14 layers, and for longer periods, no higher than seven layers.

14

The water batcher and the water pipes should be leak-free. If ice is used, the ice facilities, including the equipment for batching and transporting to the mixer, should be properly insulated to prevent the ice from melting before it is in the mixer.

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Plant Type

1

Manual control batching. Manual plants are acceptable for small jobs having low batching 3 3 rate requirements, generally for jobs up to a total concrete quantity of 1000 m and 10 m /h.

2

Semi-automatic control batching. In this system, aggregate bin gates for charging batchers are opened by manually operated push buttons or switches. Gates are closed automatically when the designated weight of material has been delivered.

3

Automatic control batching. Automatic batching of all materials is electrically activated by a single starter switch. However, interlocks shall interrupt the batching cycle when the scale has not returned to 0.3 % of zero balance or when weighing tolerances detailed in Clause 7.2.5 of this Part are exceeded.

7.2.3

Bins and Weight Batchers

1

Batch plant bins shall be of sufficient size to effectively accommodate the production capacity of the plant. Compartments in bins separate the various concrete materials, and the shape and arrangement of aggregate bins shall prevent aggregate segregation and leakage.

2

Weight batchers shall be charged with easy-operating clam shells or undercut radial-type bin gates.

3

Gates used to charge semi-automatic and fully automatic batchers shall be power operated and equipped with a suitable in flight correction to obtain the desired weighing accuracy. They shall be calibrated by the plant supplier for the types of aggregate used at the standard range of moisture contents.

4

Weigh batchers shall be accessible for obtaining representative samples, and they shall be arranged to obtain the proper sequencing and blending of aggregates during charging of the mixer.

5

The amount of concrete mixed in any one batch shall not exceed the rated capacity of the mixer.

6

All mixing and batching plants shall be maintained free of set concrete or cement and shall be clean before commencing mixing.

7

For each different type of cement at use at the plant a separate silo shall be provided.

7.2.4

Tolerances of Measuring Equipment

1

Scales for weighing concrete ingredients shall be accurate when in use within 3 % and 1.5 % for additives. Standard test weights shall be available to permit the checking of scale accuracy.

2

Testing of the weighers shall be at three-month intervals. If water is dispensed by flow meter the frequency of testing shall be at three-month intervals. Such testing shall be undertaken by a calibration company approved by the Central Materials Laboratory, and calibrated to recognized international standards.

3

Test certificates shall be displayed in the plant in prominent positions.

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7.2.2

QCS 2014


Page 6

Batching Tolerances

1

Operation of batching equipment shall be such that the concrete ingredients are consistently measured within the following tolerances. The plant shall have the ability to flag values that are outside these limits. The operator shall make manual adjustments to the batching and the final weights shall be within the given limits stated in table 7.1. Any adjustments shall be displayed on the batch weight printouts.

2

Cementitious materials shall be measured by mass. When supplementary cementitious materials are used in the concrete mixtures, the cumulative mass is permitted to be measured with hydraulic cement, but in a batch hopper and on a scale which is separate and distinct from those used for other materials.

3

Aggregate shall be measured by mass. Batch mass measurements shall be based on dry materials and shall be the required masses of dry materials plus the total mass of moisture (both absorbed and surface) contained in the aggregate

4

Mixing water shall consist of water added to the batch, ice added to the batch, water occurring as surface moisture on the aggregates, and water introduced in the form of admixtures. The added water shall be measured by weight or volume.

5

Added ice shall be measured by weight. In the case of truck mixers, any wash water retained in the drum for use in the next batch of concrete shall be accurately measured; if this proves impractical or impossible the wash water shall be discharged prior to loading the next batch of concrete

6

Chemical admixtures in powdered form shall be measured by mass. Liquid chemical admixtures shall be batched by mass or volume

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7.2.5

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Table 7.1 Typical batching tolerances Ingredient

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Typical batching tolerances Ingredient

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Cement and other cementitious Materials

Water (by volume or weight), %

Batch weights greater than 30% of scale capacity

Individual Cumulative batching batching ±1% of required mass or ±0.3% of scale capacity, whichever is greater ±1

Not recommended

Batch weights less than 30% of scale capacity Individual batching

Cumulative batching

Not less than required weight or 4% more than required weight

±1

Not recommended

Aggregates, %

±2

±1

±2

±0.3% of scale capacity or ±3% of required cumulative Weight, whichever is less

Admixtures (by volume or weight), %

±3

Not recommended

±3

Not recommended

QCS 2014


Page 7

Cement supplied in bags shall be placed directly from the bag into the intake of the mixing plant and each batch must contain one or more complete bags of cement. No mixer having a rated capacity of less than a one-bag batch shall be used and the mixer shall not be charged in excess of its rated capacity.

7.2.6

Charging the Mixer

1

Each batch shall be so charged into the mixer that some of the water will enter in advance of the cement and aggregates. Controls shall be provided to prevent batched ingredients from entering the mixer before the previous batch has been completely discharged.

2

The first batch of concrete through the mixer shall contain an excess of cement to allow for coating of the inside of the mixing drum without reducing the required mortar content of the mix.

3

Mixing plant that has been out of action for more than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed in it.

4

When a change of mix is made to one using a different type of cement, the mixing plant shall be thoroughly cleaned of all traces of the previously used cement, whatever is the time interval between successive mixes.

7.3

MIXING

7.3.1

Charging Concrete Materials

1

Water shall enter the mixer first with continuous flow while other ingredients are entering the mixer. Water charging pipes must be of the proper design and of sufficient size so that water enters at a point well inside the mixer and charging is completed within the first 25% of the prescribed mixing time and where concrete uniformity shall be verified by approved inspector.

2

Admixtures shall be charged to the mixer in accordance with the instructions of the manufacturer. Automatic dispensers shall be used.

7.3.2

Mixing Time for Stationary Mixers

1

The mixing time required shall be based upon the ability of the mixer to produce uniform, homogeneous, consistent mixture throughout the batch and from batch to batch.

2

Final mixing times shall be based on the results of mixer performance tests made at the start of the project and the time fixed unless a change is authorised by the Engineer. The time shall however not be less than 60 Sec unless otherwise verified as stated hereafter. Where no mixer performance tests are made, the acceptable mixing time for mixers having 3 capacities of 0.75 m or less shall be not less than 1 min. For mixers of greater capacity, this minimum shall be increased 15 s for each cubic meter or fraction thereof of additional capacity.

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Page 8

Where mixer performance tests have been made on given concrete mixtures in accordance with the testing program ASTM C94 Annex A and NRMCA certification, and the mixers have been charged to their rated capacity, the acceptable mixing time is permitted to be reduced for those particular circumstances to a point at which satisfactory mixing defined in ASTM C94 and NRMCA certification for central mixing plants shall have been accomplished. When the mixing time is so reduced the maximum time of mixing shall not exceed this reduced time by more than 60 s for air-entrained concrete. The mixing time shall be measured from the time all ingredients are in the mixer.

4

Batch mixers with audible indicators used in combination with interlocks which prevent mixer discharge prior to completion of a preset mixing time shall be provided on automatic plants and are also desirable on manual plants.

5

The mixer shall be designed for starting and stopping under full load.

7.3.3

Mixing

1

All structural concrete to be placed in-situ shall be manufactured in a computer controlled batching plant of the types described in Clause 7.2.2 of this Part.

2

The plant shall be complete with suitable water chilling or ice making facilities, or both, to ensure concrete temperatures are maintained as specified in Parts 6 and 15 of this Section.

3

Concrete shall be mixed in batches in plant capable of combining the aggregates, cement and water (including admixtures, if any) into a mixture of uniform colour and consistency and of discharging the mixture without segregation.

4

Automatic moisture content probes, set in the hoppers shall be used to continuously determine the moisture content of the aggregates.

5

Contractor shall make due allowance for the water contained in the aggregates when determining the quantity of water to be added to each mix.

6

The amount of water added to each mix shall be adjusted to maintain the constant approved water : cement ratio of the mixed concrete.

7.3.4

Limitation of Water : Cement Ratio

1

No concrete shall exceed the water : cement ratio as given in Part 6 of this Section.

2

The quantity of water used in mixing shall be the least amount that will produce a workable homogeneous plastic mixture which can be worked into the forms and around the reinforcement.

3

Excess water over the maximum allowed by the mix design shall not be permitted and any batch containing such excess will be rejected.

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7.4

READY-MIXED CONCRETE

7.4.1

General

1

The manufacture of readymix concrete for use in government projects may only be carried out in batching plants that have an approval certificate issued by the Central Materials Laboratory. When this certificate is under renewal process by the readymix concrete manufacturer, other certificate such as NRMCA shall be considered by the Engineer as approval on the uniformity and consistency of the facility. The engineer may request to revalidate the uniformity tests under his supervision. In addition, the use of readymix concrete in any part of the work shall require the Engineer’s written approval.

2

The Contractor shall satisfy the Engineer on the following: materials used in ready-mixed concrete comply with the specification in all respects

(b)

manufacturing and delivery resources of the proposed supplier are adequate to ensure proper and timely completion.

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(a)

The specified requirements as to the sampling, trial mixing, testing and quality of concrete, of various grades as described in Part 6 of this Section, shall apply equally to ready-mixed concrete.

4

Every additional facility, including but not limited to testing equipment, labour, laboratory facilities and transport, which the Engineer or persons authorised by him may require for the supervision and inspection of the batching, mixing, testing and transporting to Site of readymixed concrete shall be provided by the Contractor at no extra cost.

5

Copies of all delivery notes shall be submitted to the Engineer in duplicate, on computer generated forms and shall include at least the following information.

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name of supplier, serial number of ticket and date

(b)

truck number

(c)

name of Contractor name of Contract and location of office grade of concrete

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(a)

(f)

specified workability

(g)

type and source of cement

(h)

source of aggregate

(i)

nominal maximum size of aggregate

(j)

quantity of each concrete ingredient

(k)

type of admixture and quantity

(l)

water content

(m)

time of loading and departure from ready-mix plant

(n)

arrival and departure times of truck

(o)

time of completion of discharge

QCS 2014

(p)


Page 10

notations to indicate equipment was checked and found to be free of contaminants prior to batching.

A copy of the delivery note shall be given to the Engineer's site representative for each load.

7

Unless approved otherwise in advance of batching all concrete of single design mix for any one day's pour shall be from a single batch plant of a single supplier.

8

Ready-mix concrete shall conform to BS 8500 in addition to GSO EN 206-1, except materials, testing and mix design shall be as specified in this Section.

9

Transit mixers equipped with automatic devices for recording the number of revolutions of the drum shall be used.

10

Excess water over the maximum allowed by the mix design shall not be added.

11

Each mixer truck shall arrive at the job site with its water container full.

12

In the event that a container is not full or concrete tests give a greater slump than acceptable, the load shall be rejected.

13

Shade temperature and concrete temperature shall be recorded at the point of discharge of the mixer and at placement for each load of concrete delivered to site.

14

Maximum and minimum temperatures and wet bulb temperatures shall be recorded daily.

15

Slump tests shall be performed in accordance with BS EN 12350 or relevant GSO standard at the point of placement as stated in Part 6.

16

No water shall be added at the Site.

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6

END OF PART

QCS 2014

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APPENDIX A: CONCRETE PLANT INSPECTION – CHECKLIST

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7.5


Qatar General Organization for Standards and Standardization

CONCRETE PLANT INSPECTION CHECK LIST

New Approval

☐

☐

Renewal

Regular Inspection

1.0 GENERAL INFORMATION OF PLANT

:

1.3

Plant Location

:

1.4

Plant No/s

:

1.5

Plant Manufacturer

:

1.6

Plant ID No.

:

1.7

Approval Certificate No :

1.8

Contact a Plant

AM / PM

.

Inspection Date

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1.2

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:

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Company Name

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1.1

2.0 FACTORY CONDITION

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:

Yes ☐ No ☐

Concrete Floor Under Mixer and silos

2.2

Concrete floor with Slope under materials

2.3

Hard and stable surface for Access and ramps

2.4

Floors Clean

2.5

Cleaning plan implements

Yes ☐ No ☐

2.6

Drainage System

Yes ☐ No ☐

2.7

Separated Place of Waste materials

2.8

Separated Place of wash tank

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Yes ☐ No ☐ Yes ☐ No ☐

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Yes ☐ No ☐

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Yes ☐ No ☐ Yes ☐ No ☐

3.0 MATERIAL STORAGE AND HANDLING 3.1

Cement and Cementations materials (including blended cements, fly ash, GGBS, silica fume..)

3.1.1 The Silos of Cement ☐ No

☐

A.

Outside Cleaning for Cement silo

Yes

B.

Cement scale calibration

Current ☐ Expired ☐

C.

Reflective color for cement silo

Yes

☐ No

☐

D.

Board clarify the cement type

Yes

☐ No

☐

3.1.2 The silos of cementations materials A.

Outside Cleaning for Cementations silo

Yes

☐ No

☐

Page 12 of 15

☐

Cementations scale calibration


C.

Reflective Color for Cementations Silo

Yes

☐ No

☐

D.

Board Clarify the Cementations Type

Yes

☐ No

☐

E.

All Cementations Materials Excess of use protected under shad

Yes

☐ No

☐

3.2

Aggregates:

A.

Aggregate Shading

Yes

☐ No

☐

B.

Aggregate Separation under shad

Yes

☐ No

☐

C.

Aggregate Separation in bins

Yes

☐ No

☐

D.

Aggregate scale calibration


E.

Cover for Conveyer Belts

Yes

☐ No

F.

Board Clarify the Aggregate Type

Yes

☐ No

G.

Effective method for checking the level of material inside the bins

Yes

☐ No

☐

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Yes

☐ No

☐

Yes

☐ No

☐

Yes

☐ No

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Water supply Water pipe insulated

B.

Chiller using

C.

Ice plant or Nitrogen cooling

D.

Water gauge calibration

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A.


Admixture supply

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4.2

☐

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4.0 Water & Admixture Supply 4.1

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B.

☐

Additive storage silos

B.

Additive Gage calibration

C.

Board Clarify the Admixture Type

Yes

☐ No

☐

D.

All admixture excess of use protected under shad

Yes

☐ No

☐

E.

Agitation system for all storage tanks or silos more than 5000 liter

Yes

☐ No

☐

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Yes

☐ No

A.

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5.0 Requirements of the Concrete batching plant 5.1

Certificate validity

Yes

☐

No

☐

5.2

Computer controlled

Yes

☐

No

☐

5.3

Plant type

Wet mix ☐

5.4

Computer printout

Yes

5.5

Calibration validity

Current ☐

5.6

Cleaning of plant blades

Yes

☐

☐

Dry mix ☐ No

☐

Expired ☐ No

☐

Page 13 of 15

6.0 Laboratory Records for raw materials and cube tests Frequency of Tests

Was Test Performed?

Yes ☐ No ☐

6.1.3 Fines quality

Yes ☐ No ☐

6.1.4 Clay lumps and friable particles

Yes ☐ No ☐

6.1.5 Lightweight pieces

Yes ☐ No ☐

6.1.6 Organic impurities

Yes ☐ No ☐

6.1.7 Water Absorption

Yes ☐ No ☐

6.1.8 Particle density

Yes ☐ No ☐

6.1.9 Shell Content

Yes ☐ No ☐

6.1.10 Flakiness Index (%)

Yes ☐ No ☐

6.1.11 Chloride content (%)

Yes ☐ No ☐

6.1.12 Sulphate content (%)

Yes ☐ No ☐

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Yes ☐ No ☐

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6.1.13 Soundness (%)

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6.1.2 Fines content (%)

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Yes ☐ No ☐

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6.1.1 Grading

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.

D

Comments of Inspection

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Required Tests to QCS 2014

qa

6.1

Yes ☐ No ☐

6.1.15 Moisture Content (%)

Yes ☐ No ☐

6.1.16 Compressive Strength

Yes ☐ No ☐

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6.1.14 Los Angeles abrasion

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6.1.17 Other test*

*Such as recycled aggregate

6.2

Specimens testing at inspection time ITEMS

CASE

6.2.1 Method of slump test

Yes ☐

No ☐

6.2.2 Curing of samples

Yes ☐

No ☐

6.2.3 Water Temperature Of Curing Tank Yes ☐

No ☐

6.2.4 Concrete Temperature at plant

Yes ☐

No ☐

6.2.5 Concrete Slump at plant

Yes ☐

No ☐

COMMENTS

Page 14 of 15

6.3

Laboratory equipment calibration EQUIPMENT

CASE

COMMENTS

6.3.1 Compression Testing Machine

Yes ☐

No ☐

6.3.2 Sieves

Yes ☐

No ☐

6.3.3 Balance

Yes ☐

No ☐

6.3.4 Thermometers

Yes ☐

No ☐

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8.0 Plant representative information

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Name of representative Contract number

: :

Signature

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9.0 Inspector team

:

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Signature

Inspected by

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7.0 Recommendations

Page 15 of 15

QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 1

TRANSPORTATION AND PLACING OF CONCRETE ............................................ 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ............................................................................................................... 2 Scope of Work 2 References 2 Submittals 2

8.2 8.2.1 8.2.2 8.2.3

TRANSPORTATION ............................................................................................... 3 General 3 Pumped Concrete 3 Records 4

8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5

PLACING CONCRETE ............................................................................................ 4 General 4 Preparation 4 Placing 5 Compaction 7 Continuity of Concrete Work 8

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8

QCS 2014


8

TRANSPORTATION AND PLACING OF CONCRETE

8.1

GENERAL

8.1.1

Scope of Work

1

This part deals with the transportation, placing and compaction of concrete.

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8.1.2

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This Section Part 1 ............... General Part 7, .............. Concrete Plants Part 9, .............. Formwork Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous

Page 2

References

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ACI 304, ............. Guide for Measuring, Mixing, Transporting, and Placing Concrete ASTM C94, ......... Specification for ready-mixed concrete BS 8500,............. Concrete, Complementary British Standard to BS EN 206-1. BS EN 206-1, ..... Concrete. Specification, performance, production and conformity EN 1992-1-1 ....... Eurocode 2: Design of concrete structures. General rules and rules for buildings Submittals

1

Should the Contractor propose to use concrete pumps for the transportation and placing of concrete, he shall submit details of the equipment and operating techniques he proposes to use for the approval of the Engineer.

2

A method statement shall be submitted for approval for major concrete placements, which shall address

(b)

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8.1.3

(c)

number of trucks

(d)

number and positioning of pumps

(e)

pour sequence

(f)

quality control measures

(g)

spare equipment

(h)

any other factors that might affect the placing of concrete.

the planned rate of placing number of batching plants

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(a)

3

The method statement should be submitted at least three days in advance of the planned pour. If required by the Engineer or any other concerned party a prepour planning meeting may be arranged with representatives from the ready-mix supplier, Contractor and Engineer.

4

The Contractor shall submit to the Engineer for approval details of his proposed operations and standby equipment.

QCS 2014


Page 3

TRANSPORTATION

8.2.1

General

1

Transportation delivery and handling shall be in accordance with the requirements of BS 8500 and BS EN 206-1.

2

Concrete shall be conveyed from the mixer to its place in the Works as rapidly as possible by methods which will prevent segregation or drying out and ensure that the concrete is of the required workability at the point and time of placing.

3

Should segregation occur in the concrete then the materials shall be remixed to the satisfaction of the Engineer or discarded. Furthermore the cause of the segregation shall be determined and further occurrences prevented.

4

The Contractor shall ensure that the time between placing of different lifts or layers of concrete is short enough to prevent the formation of cold joints. The Contractor shall ensure that there is a back up plant that can be used in the event of a breakdown, and that adequate provision has been made for the number of delivery trucks.

5

The concrete shall be transported to the site in an approved type of truck mixer or agitator truck which apart from the cab and chassis shall be painted white and kept clean at all times. The discharge chute and other dirty areas shall be washed down after delivery to prevent spillage on the roads.

6

If a truck mixer or a truck body with an agitator is used for central-mixed concrete, limit the volume of concrete charged into the truck to 80% of the drum or truck volume as per ASTM C94 and NRMCA requirements. if shrink mixing is approved by the engineer limit the volume of concrete charged into the truck to 63% of the drum volume.

7

All trucks shall be rotated 30 revolutions at mixing speed before discharging concrete to assure uniformity.

8

The insides of concrete mix trucks shall be inspected periodically, and any build up of concrete removed that may impair the efficiency of the mixing action. All trucks shall be NRMCA certified or any equivalent certification

9

Discharge of the concrete shall be completed within 90 min, or before the drum has revolved 300 revolutions, whichever comes first, after the introduction of the mixing water to the cement and aggregates or the introduction of the cement to the aggregates. These limitations are permitted to be waived by the purchaser if the concrete is of such slump or slump flow after the 90 min time or 300-revolution limit has been reached that it can be placed, without the addition of water, to the batch. In hot weather, or under conditions contributing to quick stiffening of the concrete, a time less than 90 min is permitted to be specified by the Engineer

8.2.2

Pumped Concrete

1

Access for the pump shall be checked prior to the pour. If access cannot be assured, the Contractor shall not continue with concreting operations.

2

If approval is obtained for pumped concrete, the Contractor shall ensure that shock is not transferred from the pipeline to the formwork and previously laid concrete.

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Page 4

During placing concrete by pumping the end hose must never reach into the concrete. All measures shall be taken to avoid blockage of the delivery hose system. The Compaction of concrete shall be carried out as per standard practice procedures.

4

Grout shall be pumped through the concrete pump to provide initial lubrication. The initial discharge of any pumped concrete shall not be incorporated in the permanent works.

5

Where concrete is conveyed by chuting or pumping the plant shall be of a size and design to ensure continuous flow in the chute or pipe. The slope of the chute or the pressure of the pump shall allow the concrete to flow without the use of any water additional to that approved by the Engineer to produce the required consistency and without segregation of the ingredients. The delivery end of the chute or pipe shall be thoroughly flushed with water before and after each working period and kept clean. The water used for this purpose shall be discharged outside and away from any permanent works.

8.2.3

Records

1

Within 24 h of delivery, the Contractor shall provide the Engineer with delivery notes giving the information required under Paragraph 7.4.1.5 of this Section.

8.3

PLACING CONCRETE

8.3.1

General

1

The Contractor shall obtain the approval of the Engineer to his proposed arrangements before beginning concreting.

2

All placing and compacting of concrete shall be carried out under the direct supervision of a competent member of the Contractor’s staff with a minimum of five years of experience in concreting works, and in a manner to produce a watertight concrete of maximum density and strength.

3

For night concreting operations, the Contractor shall arrange adequate suitable lighting.

4

The Contractor shall provide safe secure access for all personnel on concreting operations.

5

Where the thickness of the concrete section exceeds 600 mm the Contractor shall adopt

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special precautions, to be approved by the Engineer, to avoid thermal cracking due to external and core temperature differentials. 6

Concrete shall not be placed in adverse weather conditions such as dust storms or heavy rain.

8.3.2

Preparation

1

No concrete shall be placed until the Engineer has inspected and approved in writing the surfaces upon which the concrete is to be placed, the formwork, and reinforcing steel. The Contractor shall give the Engineer at least 24 hours notice to enable this inspection to be carried out. If concrete is not placed within 24 hours of approval being given, approval shall be obtained again before concreting. An inspection shall be made immediately prior to concreting to check the cleanliness of the forms.

QCS 2014


Page 5

Wood forms, unless lined, shall be oiled or wetted with water in advance of placing concrete so that joints will tighten and prevent seepage of cement grout from the mix.

3

The reinforcement shall be sprayed with a small amount of water prior to starting the pour. Reinforcement shall be secured in position, inspected, and accepted by the Engineer before placing the concrete.

4

All inserts, anchor bolts, sleeves and other embedded items shall be accurately located, using templates where appropriate, and held securely to prevent displacement during the placing of the concrete. Aluminium items shall be completely covered and protected when embedded in the concrete.

5

Except where shown on the drawings, no fixtures shall be attached to the concrete by shot fixing or drilling without acceptance by the Engineer. Notwithstanding any such authorisation, the Contractor shall be responsible for all damage so caused to the concrete and make good at his own expense.

6

Water shall be removed from excavations before concrete is deposited. Any flow of water shall be diverted through proper side drains and shall be removed without washing over freshly deposited concrete. All dewatering works shall be continued as long as required. Hardened concrete, debris, and foreign materials shall be removed from interior of forms and from inner surfaces of mixing and conveying equipment.

7

Runways or other means accepted by the Engineer shall be provided for wheeled equipment to convey the concrete to the points of deposit. Equipment used to deposit concrete shall not be wheeled over reinforcement nor shall runways be supported on reinforcement.

8

Before depositing new concrete on or against concrete that has set, existing surfaces shall be thoroughly roughened and cleaned of laitance, foreign matter and loose particles. Forms shall be re-tightened and existing surfaces slushed with a grout coat of mortar consisting of cement and fine aggregate in the same proportion in the mix, but not leaner than one (1) part cement to two (2) parts fine aggregate, after the existing surface has been moistened. New concrete shall be placed before the grout has attained initial set. Horizontal construction joints shall be given a brush coat of grout consisting of cement and fine aggregate in the same proportion as concrete to be placed, followed by approximately 75mm of concrete of regular mix, except that the proportion of coarse aggregate shall be reduced 50%.

9

High strength grout for precision support of machine base and soleplates, including equipment subject to thermal movement, tanks, column baseplates, bridge seats, anchor bolts and dowels, etc., shall be a non-shrink, ready-to-use, fluid precision grout material, proportioned, premixed and packaged at the factory, delivered to the job site to be placed with only the addition of water, formwork, and curing shall be as specified.

8.3.3

Placing

1

Concrete shall be placed in its final position before initial set has commenced and shall not be subsequently disturbed. All concrete shall be placed within 15 min of mixing unless carried in purpose made agitators.

2

Concrete shall be carefully placed in horizontal layers which shall be kept at an even height throughout the work. The depth of layers and time between placement of layers shall be such that each layer can be properly merged into the preceding layer before initial set takes place, the depth of layer shall be determined from the type of plant the Contractor proposes to use.

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3

Concrete shall be allowed to slide or flow down sloping surfaces directly into its final position from skips, down pipes or other placing machines or devices or, if this is not practical, it should be shovelled into position, care being taken to avoid separation of the constituent materials.

4

Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be tipped into the face of the previously placed concrete.

5

Concrete dropped into place shall be dropped vertically. It shall not strike the formwork between the point of its discharge and its final place in the Work, and except by approval of the Engineer it shall not be dropped freely through a height greater than 1.5 m. Chutes and

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conveyor belts shall be also designed so that there is no segregation or loss of mortar and shall be provided with a vertical tapered down pipe, or other device, to ensure that concrete is discharged vertically into place. Concrete shall not be placed in standing water in the formwork.

7

Concrete that has attained its initial set or has contained its water content for more than 1.5 hours or 300 drum revolutions, whichever comes first, shall not be deposited in the work.

8

Cold weather concreting shall be in accordance with EN 1992-1-1 or CIRIA Report 67 and ACI 306.

9

Hot weather concreting shall be in accordance with Part 15 of this section.

10

Special care shall be taken to protect new concrete from the harmful effects of drying winds.

11

During wet weather, the concrete shall be adequately protected as soon as it is in position.

12

No concreting shall be carried out during periods of continuous heavy rain unless it is completely covered during mixing, transporting and placing.

13

No concrete shall be carried out during dust storms.

14

Underwater placing of concrete is allowed only for unreinforced components, the placing being effected exclusively with stationary tremies or with a bottom-opening watertight boxes and shall be in accordance with the requirements of design or equivalent as accepted.

15

Underwater concrete is to be placed continuously without interruption. For water depths up to 1 m the concrete may be placed without tremie. In the case of water depths exceeding 1 m the concrete is to be placed in such a way that it does not fall freely through the water. The tremies must at all times dip sufficiently far into the freshly placed concrete to ensure that the concrete emerging from the tremie does not come into contact with the water.

16

All work connected with the placing of concrete under water shall be designed, directed and inspected with due regard to local circumstances and purposes. Work shall not proceed until all phases and methods to be used in the placing operations have been accepted by the Engineer.

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Stops in concrete, at the end of a period of work, shall be made only at construction joint locations shown on the drawings and/or positions accepted. Where the positions of construction joints are not indicated on the drawings, these may be assumed, for estimating purposes, to occur at 5 metre intervals in foundations and retaining walls and at one-third to one-quarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres.

18

At construction joint location the surface of the completed concrete shall be prepared by spraying, wire brushing or chipping so that it is free from all laitance, scum and loose material and shows a slightly roughened texture and tips of the coarse aggregate exposed. Before continuing concreting the exposed concrete face shall be thoroughly wetted.

19

In the ground floor slab (where ground bearing), construction joints, crack inducer joints, contraction joints and expansion joints shall be incorporated into the work as appropriate. The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings

20

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, the slab shall be cast in strips not more than 4.0 metres wide, in alternating sequence, across the width of the building. A minimum of 3 days shall elapse between the casting of adjacent strips. Within each strip, crack induced joints shall be provided at not more than 5.0 metre spacing, and contraction joints shall be provided at not more than 15.0m spacing. Across the width of the building, construction joint shall be provided between adjacent strips th with contraction joint at every 4 construction joint.

21

Wherever necessary and as required by the Engineer, waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

22


23

Waterstops shall be carefully maintained in position prior to concreting on accurately profiled stop boards to create rigid conditions.

24

The type of waterbar to be used shall suit the joint and purpose according to water bar manufacturers recommendations

8.3.4

Compaction

1

Concrete shall be thoroughly compacted by vibration during the operation of placing and thoroughly worked around the reinforcement, around embedded fixtures and into corners or the formwork to form a solid mass free from voids.

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When vibrators are used to compact the concrete, vibration shall be applied continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation of the constituents of the concrete.

3

Immersion type vibrators shall be capable of producing not less than 10000 cycles per minute, and external vibrators not less than 3000 cycles per minute.

4

A sufficient number of vibrators in serviceable condition shall be on site to ensure that spare equipment is always available in the event of breakdown.

5

Immersion type vibrators shall be inserted into the uncompacted concrete vertically and at regular intervals. Where the uncompacted concrete is in a layer above freshly compacted concrete the vibrator shall penetrate vertically for about 100 mm into the previous layer. Vibrators shall not come into contact with the reinforcement or the formwork. They shall be drawn back slowly from the mass concrete so as to leave no voids. Internal type vibrators shall not be placed in the concrete in a random or haphazard manner nor shall concrete be moved from one part of the work to another by means of the vibrators.

6

Operators shall be trained in the use of vibrators. Foremen shall have a minimum of five years of experience in the supervision of placing concrete

7

Vibration of the concrete shall not be applied by way of the reinforcement.

8

Compaction shall commence as soon as there is sufficient concrete to immerse the vibrator and continue during the placing operations so that at no time shall there be a large volume of uncompacted concrete in the formwork.

9

The duration of vibration shall be limited to that required to produce satisfactory compaction without causing segregation. Vibration shall on no account be continued after water or excess grout has appeared on the surface.

10

During the placing of all reinforced concrete, a competent steel fixer and a competent carpenter shall be in attendance on each concreting gang. They shall ensure the reinforcement embedded fittings and forms are kept in position as work proceeds.

8.3.5

Continuity of Concrete Work

1

Whenever instructed by the Engineer, the Contractor shall carry out the work in such a manner that the placing of the concrete in any particular section of the structure shall be executed without any interruption whatsoever from the beginning to the end of the operation.

2

Casting of concrete shall not begin until a sufficient quantity of approved material is at hand to ensure continuity of operation, nor shall work begin until there is sufficient equipment in reserve in case of breakdown.

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END OF PART

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FORMWORK ........................................................................................................... 2 GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 FORMWORK MATERIALS ...................................................................................... 5 General 5 CLASS OF FINISH AND MATERIALS: .................................................................... 5 Unformed surfaces 5 Surface Finish Classifications 7 Formwork Materials 7 Exposed Concrete Surface Finishes 7 Form Ties 8 Coating and Accessories 8 FORMWORK EXECUTION ..................................................................................... 9 General 9 Trial Panels 9 Formwork Face in Contact with Concrete 9 Sloping Surfaces 10 Temporary Openings 10 Form Windows 10 Co-ordination 10 Conduits 10 Ties and Bolts 11 Chamfers 11 Cambers 11 Exterior Angles 11 Surface Retarders 11 Detection of Movement During Concrete Placement 11 Building in Pipes 12 Working Platform 12 Safe Access 12 Kickers 12 Cover Spacers 12 Water Bars 12 REMOVAL OF FORMWORK................................................................................. 13 General 13 Stripping of Formwork 13 Holes to be Filled 14 Repair to Damaged Concrete Surfaces 14 DELIVERY AND STORAGE .................................................................................. 14 Delivery 14 Storage 14 TOLERANCES ...................................................................................................... 15 EARLY LOADING .................................................................................................. 15

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9 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.2 9.2.1 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.4.10 9.4.11 9.4.12 9.4.13 9.4.14 9.4.15 9.4.16 9.4.17 9.4.18 9.4.19 9.4.20 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.6 9.6.1 9.6.2 9.7 9.8

Section 05: Concrete Part 09: Formwork

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9

FORMWORK

9.1

GENERAL

9.1.1

Scope

1

This Part includes permanent forms, temporary formwork, and falsework for structural and architectural cast-in-place concrete including form liners, coatings, and accessories.

2


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management/administration

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prevention

system

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Section 11: Health and Safety Part 1, ............. Regulatory document Part 2, ............. Safety and accident (SAMAS)

.

This Section Part 8, .............. Transportation and Placing of Concrete Part 10, ............ Curing Part 17, ............ Structural Precast Concrete.

References

1

The following standards and other document are referred to in this Part:

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ACI Committee 117 ....“Standard Tolerances for Concrete Construction and Materials” (ACI 117-90), American Concrete Institute, Detroit, 22 pp.

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ACI Manual of Concrete Practice, Parts 2 and 5. BS 8500......................Concrete

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BS 5975......................Code of practice for false work

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BS EN 12812..............Falsework. Performance requirements and general design CP3 chapter V-2: 1972

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EN 1992-1-1 ...............Eurocode 2: Design of concrete structures. General rules and rules for buildings GSO EN 206-1 ...........Concrete. Specification, performance, production and conformity Concrete Society Technical Report No. 13 9.1.3

Submittals

1

Shop drawings shall include plans and sections, giving the following minimum information for each level: (a)

details of individual panels

(b)

position, size and spacing of adjustable steel shores

(c)

position, size and spacing of joists, soldiers, ties

(d)

details of formwork for columns, beams, parapets, slab and kickers

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details of construction joints and movement joints

(f)

details of retaining walls and deep beams showing the position and size of ties, joints, soldiers and sheeting, together with detailed information on erection and casting sequences and construction joints

(g)

general assembly details

(h)

full calculation sheets

(i)

proposals at all penetrations through the concrete

(j)

proposed sequence of shoring and reshoring beams and slabs for different spans and floor heights and number of floors shored, and the stripping time for supported and suspended structural elements, clearly identifying the supported element and suspended element.

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(e)

details: 1:1, 1:5, 1:10, 1:20

(b)

construction: 1:50, 1:100

(c)

layout and Site Plan: 1:100 or 1:200

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(a)

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Scales of shop drawings shall be as follows:

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The Contractor shall submit samples of all proposed formwork materials and samples of ties proposed for use in general situations above the water table and for fair faced concrete.

4

The Contractor shall allow 14 days for Engineer’s review of submittals or samples.

5

Supply and delivery of built-in pipework should be clearly shown on the detailed construction program to be submitted by the Contractor.

6

Method Statements for erection and removal of formwork shall be submitted by the Contractor before the start of the works for the Engineer’s review and approval. The Method Statement shall include the Risk Assessments related to the activity.

7

When the formwork is to be carried out by a sub-contractor, then the pre-qualification documents shall be submitted for the Engineer’s review and approval.

9.1.4

Quality Assurance

1

Formwork shall comply with the requirements of BS 5975 and EN 1992-1-1

2

The erection of formwork and associated falsework shall be executed and supervised by fully qualified personnel having a minimum of five years experience.

3

The Contractor shall obtain approval to load any particular section of the works from the Engineer.

4

Formwork design shall be carried out in accordance with the Concrete Society Technical Report No. 13.

5

The erected formwork shall be watertight from the ingress of external liquids and the egress of internal liquids. Adjustable steel supports and shores shall allow formboards and framework to be accurately adjusted to line and level. The Contractor shall ensure that adequate ground support for falsework is available, and if not shall take measures to make them suitable.

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Formwork shall be designed to be sufficiently rigid to maintain the correct position, shape and profile so that the final concrete structure is within the dimensional tolerances specified Subpart 9.7 of this Part.

7

Formwork shall be designed to be demountable without causing shock, disturbance or damage to the concrete.

8

Soffit formwork, properly supported on shores only, shall be capable of being retained in position during the concrete maturing period.

9

The design shall allow free movement and accessibility under the formwork.

10

Shores for abnormal ceiling heights shall be specially designed.

11

The forms shall be designed to incorporate 20 mm chamfers on exposed corners of columns, walls and beams.

12

The design of formwork shall take into account the following:

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height and rate of pour

(b)

thickness of the member

(c)

concrete slump and density

(d)

placing temperature

(e)

texture of finish

(f)

construction joints

(g)

wind load

(h)

on soffit forms (in addition to concrete weight)

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(ii)

if a motorised cart is used, an additional live load of 3.75 kPa

minimum design load for combined dead and live load

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(i)

(ii)

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an additional live load of 2.5 kPa, or

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(a)

6.50 kPa if a motorised cart is used, 7.75 kPa

the worst combination of: (i)

self-weight

(ii)

formwork forces

(iii)

reinforcement weight

(iv)

wet concrete weight

(v)

construction loads

(vi)

wind loads,

(vii)

incidental dynamic effects caused by placing, vibrating and compacting concrete

(viii)

the use of externally applied vibrators

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(k)

method of concrete discharge

(l)

access for concrete placement and vibration.

Before beginning related formwork operations the Contractor shall erect a job mock-up, to a reasonable size including all items such as sheeting, stiffeners, soldiers, ties etc. (and including release agents, where used) for the following types of formwork, and shall obtain the approval the Engineer before proceeding: (a)

columns

(b)

slabs and beams

(c)

staircases

(d)

fair-faced concrete (show method used to conceal tie holes) cove ties not required.

Upon prior consultation, agreement of location and approval, the job mock-ups may remain as part of the finished work.

9.2

FORMWORK MATERIALS

9.2.1

General

1

Forms shall be of wood; metal or other material acceptable to the Engineer.

2

The design of formwork shall be the responsibility of the Contractor.

3

Formwork shall conform to the requirements of EN 1992-1-1

4

Form oil and form sealer shall be of quality as acceptable to the Engineer.

9.3

CLASS OF FINISH AND MATERIALS:

9.3.1

Unformed surfaces

1

Unformed surfaces shall be classified as either: U4, timber trowel finish

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(b)

U3, steel trowel finish

(c)

U2, brush finished

(d)

U1 other finish designated by the Engineer, such as: (i)

Screeded Finish - Where the floor slab is to receive a screeded finish, the slab shall be laid to the slopes and levels shown on the drawings and the top surface shall be tamped whilst unset, to produce a suitable keyed surface for the receipt of the appropriate finishing materials.

(ii)

Floated Finish - Where a floated finish is required to the floor slabs the top surface shall be leveled and floated whilst unset to an uniform finish to the slopes and levels shown on the drawings. The floating shall be done in such a manner as not to bring an excess of mortar to the surface.


Page 6

Dustproof Finish - Where concrete surfaces are required to provide a dustproof finish these shall be treated with two coats of accepted material. Each coat shall be applied with a soft brush on a clean and dry surface in accordance with the manufacturer's printed instructions.

(iv)

Non-slip Finish - Concrete surfaces described on the drawings as having a nonslip finish shall be treated with carborundum dust, evenly sprinkled on whilst the concrete is still green, at a rate of 1½ kg/m² and lightly trowelled in before final finishing. Alternatively, the carborundum dust may be incorporated into the finish by means of a mechanical power float.

(v)

Hardened Finish - Where a hardened finish is required to the floor slabs these shall be treated with three coats of accepted material. Each coat shall be applied with a soft brush on a clean and dry surface in accordance with the manufacturer's printed instructions.

(vi)

Finishing Unformed Surfaces - Finishing unformed surfaces shall be tamped, floated, trowelled or brushed as defined below and shown on the drawings.

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(iii)

1.

Type T - Tamped surfaces shall be formed by levelling and tamping the concrete to produce a uniform plain or ridged surface, surplus concrete being struck off by a straight edge immediately after compaction. It is also the first stage of the following finish.

2.

Type F - Floated surfaces shall be uniform surface which has been worked no more than is necessary to remove screed marks by hand with a wood float or by power float of a type acceptable to the Engineer. The surface shall not be floated until the concrete has hardened sufficiently.

3.

Type ST - Steel trowelled shall be a hard, smooth finish, free from trowel marks and formed with a steel trowel under firm pressure. Trowelling shall not commence until the moisture film has disappeared and the concrete has hardened sufficiently to prevent excess laitance from being worked to the surface. If laitance is brought to the surface it shall be removed. Type BR - Brushed shall be formed before the concrete has hardened by drawing a wire broom over the concrete surface at right angles to the traffic flow to give an average texture depth of 1mm.

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QCS 2014

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5.

For ground slab concrete shall be treated with sodium silicate or a similar dust preventive coating. This must be applied in accordance with the manufacturer's instructions.

2

The type of finish will be specified on the drawings or as directed by the Engineer. Before beginning any concrete pour with unformed surfaces, the Contractor shall obtain confirmation of the type of finish required from the Engineer.

3

Initial finishing of unformed surfaces shall commence immediately after the placing and compaction have taken place.

4

Suitable access boards or platforms shall be provided to allow access to all parts of unformed surfaces to be finished.

5

Where a protective treatment or topping layer is to be applied to the concrete the manufacturers and suppliers recommendations shall be followed concerning the required finish.

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6

Brush to finish shall be obtained by carrying out a steel trial finish and then using a suitable stiff nylon brush dragged lightly across the surface.

7

The addition of small quantities of water to the finishing trowel will be permitted to aid finishing.

9.3.2

Surface Finish Classifications

1

Finishes to formed surfaces of concrete shall be classified as F1, F2 and F3, or such other special finish as may be designated.

2

Where the class of finish is not designated: all internal concrete shall be finished to Class F3

(b)

external concrete below ground shall be finished to Class F1

(c)

where surfaces are to be tanked by covering with paint or sheeting, the formwork shall be capable of achieving a finish suitable for the proposed tanking as directed by the Engineer.

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(a)

Formwork Materials

1

Formwork for Class F3 finish shall be lined with as large panels as possible of non-staining material with a smooth unblemished surface such as sanded plywood or hard compressed fibre board, arranged in a uniform approved pattern and fixed to back formwork by oval nails.

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9.3.3

the same type of lining shall be used throughout any one structure

(b)

unfaced wrought boarding or standard steel panels shall not be permitted.

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(a)

Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or plywood arranged in a uniform approved pattern free from defects likely to detract from the appearance of the surface.

3

Formwork for Class F1 finish shall be constructed of timber, or of any suitable materials which will prevent loss of grout when the concrete is vibrated.

9.3.4

Exposed Concrete Surface Finishes

1

Exposed concrete surfaces shall have a Class F3 finish.

2

Care shall be taken to ensure that the finish to the exposed concrete on the external and internal surfaces are of the highest quality to produce a smooth concrete surface of uniform texture and appearance without visible imprint of grains, steppings or ridges.

3

The resulting concreting shall be free from honeycombing, stains, fins, lipping, nail and screw marks, raised grain marks or any other imperfections and shall be of a uniform surface texture and colour. Only very minor surface blemishes caused by entrapped air or water will be accepted provided that they do not exceed 0.5% by area of each square metre considered separately and in addition they shall not be concentrated in a manner such that they are noticeable.

4

Formwork to the wetted surfaces of water retaining structures shall be Class F3

5

All exposed concrete corners and edges shall have 20 mm by 20 mm chamfers.

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6

Grooves in exposed concrete shall be formed by attaching tapered planed timber battens accurately aligned to the face of formwork.

9.3.5

Form Ties

1

Form ties shall conform to the following requirements: factory-fabricated

(b)

adjustable in length

(c)

use removable or snap-off metal form ties

(d)

designed to prevent formwork deflection and to prevent spalling concrete surfaces on removal

(e)

no metal shall be left closer than the applicable level of cover to the surface of the concrete

(f)

holes larger than 10 mm diameter in the concrete surface, when using snap ties shall not be permitted

(g)

form ties shall have a factor of safety not less than 1.5.

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(a)

Coating and Accessories

1

Form coatings shall be commercial formulation form-coating compounds that will not bond with, stain, nor adversely affect concrete surfaces requiring bond or adhesion, nor impede the wetting of surfaces to be cured, shall be used. The use of form coatings shall be strictly in accordance with the manufacturer instructions.

2

Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil to prevent adherence of the concrete.

3

Forms for exposed surfaces shall be coated with oil before reinforcement is placed. Forms for unexposed surfaces may be thoroughly wetted with water in lieu of oiling, immediately before placing of concrete except during freezing weather.

4

Excessive oiling of the forms shall not be permitted in order to prevent discoloration of the cement plaster. Where concrete surface is to be painted, the form-oil must not affect the bond between concrete and paint.

5

Care shall be taken to prevent the oil from coming in contact with reinforcement or with concrete at construction joints. Any oil on reinforcing steel shall be removed.

6

Release agents shall not be used where concrete surfaces receive special finishes or applied coatings which may be affected by the agent, unless approved by the Engineer.

7

Fillet and chamfer strips shall be PVC or timber to the approval of the Engineer.

8

Tapes to be used to seal joints of formwork panels for smooth finish concrete shall be plastic faced adhesive tape to the approval of the Engineer.

9

Precast concrete moulds shall be rigid steel, wood or fibreglass moulds.

10

Flashing reglets shall be galvanised steel of the longest possible length.

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9.3.6

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FORMWORK EXECUTION

9.4.1

General

1

Where formwork to external faces will be permanently exposed, all horizontal and vertical formwork joints shall be so arranged that joint lines will form a uniform pattern on the face of the concrete.

2

Where the Contractor proposes to make up the formwork from standard sized manufactured formwork panels, the size of such panels shall be approved by the Engineer before they are used in the construction of the Works.

3

The finished appearance of the entire elevation of the structure and adjoining structures shall be considered when planning the pattern of joint lines caused by the formwork and by the construction joints to ensure continuity of horizontal and vertical lines.

4

Masonry nails or similar items shall not be used to fix formwork of the like to permanent concrete works.

9.4.2

Trial Panels

1

The trial panels shall comprise surfaces that have unformed surfaces and formed surfaces F1, F2 and F3.

2

The concrete cast from the job mock-up shall be used to assess the acceptability of the Contractor’s workmanship for finishing.

3

If the finishing is deemed unacceptable by the Engineer, the Contractor shall prepare a further mock-up with a particular class of finish.

4

The job mock-ups shall be retained during the course of the works to allow comparative inspection, with production concreting and finishing and for the purpose of colour comparison to ensure colour consistency.

9.4.3

Formwork Face in Contact with Concrete

1

Faces of formwork in contact with concrete shall be free from adhering foreign matter, projecting nails and the like, splits or other defects, and all formwork shall be clean and free from standing water, dirt, shavings, chippings or other deleterious matter.

2

Joints between forms and tie holes shall be watertight to prevent the escape of mortar or the formation of fins or other blemishes on the face of the concrete.

3

The Contractor shall verify lines, levels and measurement before proceeding with formwork erection.

4

The formwork surface shall be made clean and free from any foreign and deleterious matter, prior to start the concrete pour.

5

In hot weather, the surface of the formwork shall be sprayed with water in order to lower the temperature, prior to start the pour.

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9.4

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Sloping Surfaces

1

Formwork shall be provided for the top surfaces of sloping work where the slope exceeds 15  from the horizontal (except where any such top surface is specified as a spaded finish).

2

The formwork shall be anchored to enable the concrete to be properly compacted and to prevent flotation.

3

Care shall be taken to prevent air being trapped under the sloping formwork.

9.4.5

Temporary Openings

1

The Contractor shall provide temporary openings for inspection of the inside of the formwork and for the removal of water used for washing down. The openings shall be formed as to be easily closed before placing concrete.

2

Temporary opening shall be avoided in the case of fair faced concrete.

9.4.6

Form Windows

1

The Contractor shall provide windows in forms wherever directed by the Engineer or necessary for access for concrete placement and vibration.

2

The windows shall be of a size adequate for tremies and vibrators spaced at maximum 1.8 m centres horizontally.

3

Any windows shall be tightly closed and sealed before proceeding to place concrete at a higher level.

9.4.7

Co-ordination

1

The Contractor shall ensure that the work of other trades in forming and setting openings, slots recesses, chases, sleeves, bolts, anchors and other inserts is fully co-ordinated.

9.4.8

Conduits

1

Conduits or pipes shall be located so as not to reduce the strength of the construction.

2

In no case shall pipes other than conduits be placed in a slab 125 mm or less in thickness.

3

Conduits embedded in a concrete slab shall not have an outside diameter greater than one-third the thickness of the slab nor be placed below the bottom reinforcing steel or over the top reinforcing steel.

4

Conduits may be embedded in walls provided they are not larger in outside diameter than one-third the thickness of the wall, are not spaced closer than three diameters on centre, and do not impair the strength of the structure.

5

Embedded pipes and conduits shall be supported independently from reinforcing steel in a manner to prevent metallic contact and thereby prevent electrolytic deterioration.

6

Pipes and conduits where embedded shall be placed as nearly as possible to the centre line of the concrete section.

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9.4.4

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Conduits, piping, and other wall penetrations or reinforcements shall be subject to the Engineer’s review and approval.

8

Conduits shall be fixed properly to avoid any displacement during concreting and prevent coming in contact with the forms.

9.4.9

Ties and Bolts

1

The position of ties passing through concrete shall be subject to the approval of the Engineer.

2

Ties, bolts or other devices shall not be built into the concrete for the purpose of supporting formwork without the prior approval of the Engineer. The whole or part of any such supports shall be capable of removal so that no part remaining embedded in the concrete shall be nearer to the surface than the cover required for reinforcement.

9.4.10

Chamfers

1

Chamfer moulding strips shall be positioned on the exposed corners of columns and beams.

9.4.11

Cambers

1

If required, cambers shall be as shown on the Drawings.

2

The depth of beams at all points in the span, where cambers are used, shall be as shown on the Drawings.

3

Allowance shall be made for compression and settlement of the formwork on line and level.

9.4.12

Exterior Angles

1

All exterior angles to concrete exposed to view in the completed structure shall be cast to the true angles evenly throughout the length.

2

Care shall be taken to ensure that no waviness occurs along the angle and that no spalling occurs to the concrete on removal of the formwork.

9.4.13

Surface Retarders

1

Surface retarders shall not be used on any formwork surface in contact with concrete unless expressly authorised by the Engineer.

9.4.14

Detection of Movement During Concrete Placement

1

Devices of telltale type shall be installed on supported forms and elsewhere as required to detect formwork movements and deflection during concrete placement.

2

Where required slab and beam cambers shall be checked and correctly maintained as concrete loads are applied on forms.

3

Workmen shall be assigned to check forms during concrete placement and to promptly seal all mortar leaks.

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The forms shall be checked during concreting in order to identify any displacement and provide corrective actions immediately.

9.4.15

Building in Pipes

1

Pipes and pipe specials through concrete walls and floors shall as far as possible be positioned and built in during construction. They shall be located exactly in the positions shown on the Drawings and shall be true to line and level.

2

The Contractor shall take particular care to ensure that fully compacted concrete is in contact with the pipe at all points.

3

Where it is not practicable to cast pipes and specials in the concrete, boxholes shall be formed in the shuttering.

4

The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger in size than will give adequate clearance for the subsequent positioning and grouting in of the pipe. The sides of the boxhole shall be provided with a tapered central annular recess to provide a positive key. The boxhole shall be provided with a grout hole and, at the top of the central annular recess, a vent hole. The boxhole shall be stripped with the main shuttering and the concrete surface thoroughly cleaned and roughened.

5

When the pipe is later fixed, the remaining hole shall be reshuttered and filled with non-shrink epoxy grout or non-shrink concrete. In the case of water retaining structures, the Contractor shall ensure that the measures adopted shall provide a finished joint which is resistant against and free from leakage.

9.4.16

Working Platform

1

Safe working platform shall be provided according to Section 11 (Health and Safety).

9.4.17

Safe Access

1

Safe access shall be provided for the workers, inspectors, and other users according to Section 11 (Health and Safety).

9.4.18

Kickers

1

Kickers shall be provided for walls and columns

2

The kickers shall be water tight in order to prevent any grout loss.

9.4.19

Cover Spacers

1

Cover spacers shall be used in order to maintain the required cover between the formwork and reinforcement.

9.4.20

Water Bars

1

In the case of watertight constructions water bars or equivalent, as approved by the Engineer, shall be used at joints.

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REMOVAL OF FORMWORK

9.5.1

General

1

The Engineer shall be notified in writing before the removal of any formwork.

2

The Contractor, under no circumstances, shall strike the formwork until the concrete has attained adequate strength to resist damage, in particular to arises and features.

3

Concrete shall be thoroughly wetted as soon as the forms are first loosened and shall be kept wet during the removal operations and until the curing media is applied.

4

A potable water supply with hoses having fine fog spray attachments shall be ready at each removal location before operations are commenced.

5

The forms after removal shall be cleaned and prepared for subsequent use.

9.5.2

Stripping of Formwork

1

The period of time elapsing between the placing of the concrete and the striking of the formwork shall be approved by the Engineer after consideration of the loads likely to be imposed on the concrete and shall in any case be not less than the periods shown in Table 9.1

2

Stripping of the formwork within the time limits listed above does not relieve the Contractor from successfully crushing test cubes and achieving the specified compressive strength results.

3

Notwithstanding the foregoing the Contractor shall be held responsible for any damage arising from removal of formwork before the structure is capable of carrying its own weight and any incidental loading.

4

Where finished surfaces have re-entrant angles, the formwork shall be removed as early as possible, within the time limits set above, to avoid shrinkage cracks.

5

The formwork shall be carefully stripped to avoid sudden shocks from the removal of wedges, or vibration which might cause damage to the concrete.

6

Reshoring to beams and slabs shall be placed immediately after stripping formwork.

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9.5

Table 9.1 Stripping Times of Formworks Type Of Formwork

Minimum Period Before Stripping (Times Are From Concrete Placement)

Beam sides, walls and column Soffits of slabs (props left under) Soffits of beams, joists and girders (props left under) Props to slabs Props to beams

1d 4d 10 d 11 d 15 d

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Holes to be Filled

1

Holes formed in concrete surfaces by formwork supports or the like shall be filled neatly with non-shrink grout.

2

The Contractor shall clean and scarify any hole that is to be filled with non-shrink grout.

9.5.4

Repair to Damaged Concrete Surfaces

1

Where the concrete surface has been damaged, the Contractor shall break out any loose, broken or cracked concrete or aggregate.

2

The concrete surrounding the hole shall be then be thoroughly soaked after which the surface shall be dried so as to leave a small amount of free water on the surface. The surface shall then be dusted with ordinary Portland cement by means of a small dry brush until the whole surface that will come into contact with the dry-pack mortar has been covered and darkened by absorption of the free water by the cement. Any dry cement in the hole shall be removed

3

Dry-pack material shall then be placed and packed in layers having a compacted thickness in accordance with the manufacturer’s instructions. Compaction shall be carried out by the use of a hardwood stick and a hammer and shall extend over the full area of the layer, particular care being taken to compact the dry-pack against the side of the hole. After compaction the surface of each layer shall be scratched before further loose material is added

4

The hole shall not be over-filled and the surface shall be finished by layering a hardwood block against the dry-pack fill and striking the block several times. Steel finishing tools shall not be used and water shall not be added to facilitate finishing.

5

The surface of the concrete shall be rubbed down smooth with carborundum and water in an approved manner within three days of removing the formwork. Holes left after removal of such supports shall be neatly filled with non-shrink grout of a suitable consistency and matching colour.

9.6

DELIVERY AND STORAGE

9.6.1

Delivery

1

The delivery of formwork materials shall be done in such a manner that damage can be prevented.

9.6.2

Storage

1

Formwork should be stored, after cleaning and preparing for reuse if used before, in such a manner that access to all different materials is available.

2

Materials which can be affected by weathering shall be stored in appropriate buildings or under cover.

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9.7

TOLERANCES

1

The concrete work shall be constructed to an accuracy which shall permit the proper assembly of components and installations and shall be compatible with the finish. The accuracy of the work shall be within the tolerances shown on the Drawings or specified elsewhere and, in the absence of any other requirements, shall comply with the following: 5 mm 5 mm

All laying out dimensions Sections of concrete members

10 mm

Top surfaces of foundations, bases and piers

20 mm

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5 mm 10 mm 5 mm

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Surface level of floor slabs (5m straight edge) Surface level of floor slabs to datum Plumb of columns and walls in storey height

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5 mm

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Inside faces of elevator shafts in storey height

20 mm (1/1000) of height  150 mm

10 mm (0.5/1000) of height  75 mm

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EARLY LOADING

1

The Contractor should note that the loading from the falsework and wet concrete, during the construction of a floor, will not exceed the permissible loading on the floor immediately below. Consequently two of the floors immediately below the one being constructed will need to be used, to share the loading.

2

While propping through two floors, the Contractor shall ensure, that the props beneath the floor last constructed are released over its full extent as soon as the concrete has achieved sufficient strength to support itself plus any superimposed loading, but not sooner than the periods given in Table 9.1. The props shall then be re-tightened so that these may be used to share the construction loading from the floor above.

3

Not withstanding the requirements of this Section for the removal times for formwork, the following provisions shall apply to early loading of concrete.

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Concrete shall at no time be subject to loading including its own weight which will induce a compressive stress in excess of 0.33 of the actual compressive strength of the concrete at the time of loading or 0.33 of the specified 28 d characteristic strength whichever is the lower. For the purpose of this clause the assessment of the strength of the concrete and the stress produced by the loads shall be subject to the agreement of the Engineer.

5

If, due to his method of construction, the Contractor wishes to place an imposed load on the structure, he shall arrange for additional cubes to be cast at the point of the structure to be loaded and these cubes will be crushed to monitor the compressive strength in accordance with BS EN 12390-3 Compressive strength of test specimens. The Contractor shall submit calculations showing the stresses induced by any proposed temporary loads to be placed on the structure.

6

No superstructure load shall be placed upon finished piers or abutments until the Engineer has given his approval in writing and in no case shall any load be placed until the curing period is complete.

7

Deck slabs of bridges shall only be opened to traffic or construction equipment and plant when authorised by the Engineer and in no case until the curing period is complete.

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END OF PART

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Section 06: Road Works Part 01: General

Page 1

1

GENERAL ............................................................................................................... 2

1.1 1.2

RELATED DOCUMENTS & REGULATIONS ................................................ 2 BENCH MARKS AND MONUMENTS............................................................ 2

1.2.1 1.2.2 1.2.3

General Permanent Monuments Setting Out

1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

EXISTING GROUND LEVELS....................................................................... 3 MATERIALS TESTING .................................................................................. 4 NUCLEAR DENSITY TESTING DEVICES .................................................... 5 TEMPORARY FENCING ............................................................................... 5 ROAD OPENING ........................................................................................... 5 CONCRETE WORKS .................................................................................... 5 STANDARDS AND CODES OF PRACTICE ................................................. 6 TRAFFIC MANAGEMENT ............................................................................. 6 ARMED FORCES .......................................................................................... 6

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GENERAL

1.1

RELATED DOCUMENTS & REGULATIONS

1

The information given in this Part is supplemental to QCS Section 1 - General. Reference should be made to Section 1 – General prior to referring to the clauses in this part of the specification which cover specific requirements for roadworks and are additional to Section 1 - General.

2

The Government specifications, regulations, notices and circulars mentioned in QCS Section 1 – General are amended and complemented by this Specification as detailed hereafter. In the case of any ambiguity or discrepancy the provisions of this Specification shall prevail over the provisions of the aforementioned Government published specifications.

1.2

BENCH MARKS AND MONUMENTS

1.2.1

General

1

The Contractor shall consult the Survey Section of the Ministry of Municipal Affairs and Agriculture prior to any earthworks or site clearance to determine if the work is likely to disturb survey marks.

2

If the survey section require a survey mark to be moved the Contractor will be responsible for recreating the survey mark to an approved design and specification, and for re surveying the point using survey companies approved by the Survey Section.

3

On the Practical Completion of the Works the Survey Section will issue a certificate stating that all survey marks, whether disturbed or otherwise, by the Contractor have been reinstated or protected to the satisfaction of the Survey Section.

4

In the event of failure to comply with the requirements of this Clause the Government, without prejudice to any other method of recovery, may deduct the costs of any remedial work after the Practical Completion date, carried out by Survey Section from any monies in its hands due to or which may become due to the Contractor.

5

All pertinent levels, lines and locations must be checked and verified by the Contractor before commencing the Works.

1.2.2

Permanent Monuments

1

At the time of substantial completion of the whole of the works, a schedule and plan drawings of all remaining Project related and supplementary bench marks and monuments shall be prepared and transmitted to the Engineer. All project related bench marks and monuments made permanent as above will be shown on the as-built plans, including the co-ordinates and level information for each.

2

Certain bench marks and monuments determined by the Engineer shall be made into permanent bench marks and monuments.

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Fabrication and installation of bench marks and monuments shall be as shown on the drawings or in the specifications and shall include attaching warning reflectors and painting if required. Each bench mark and monument shall be set accurately at the required location and elevation and in such manner as to ensure its being held firmly in place.

4

The Contractor may request the Engineer's approval for concrete monuments, markers and posts supplied by an established commercial manufacturer, whose capability of producing survey monuments has been well established by both testing and performance. Written approval shall be obtained prior to installation of the units on the project.

1.2.3

Setting Out

1

The level datum for the works shall be the Qatar Datum as defined by the PWA.

2

The works shall be set out to the Qatar national grid as defined by the PWA. The Contractor will be supplied with the details and grid reference of setting out monuments.

3

The works shall be set out in accordance with the standard specification of the PWA.

4

Before commencing the works the Contractor shall obtain from the Engineer all information pertaining to project related bench marks and monuments bearing local grid co-ordinates.

5

After the Contractor takes possession of the Contract Drawings and has noted all the existing bench marks, he shall carry out at his own expense the setting out of the works, definition of levels, centre lines and slopes, all in accordance with the Drawings.

6

The Contractor shall be responsible for the true and proper setting out of the work in relation to original points, lines and levels of references given in the Drawings and for the accuracy of the positions, levels, dimensions and alignment of all parts of the work, and for any delay or loss resulting from errors made in completing the setting out of the work.

7

The Contractor shall protect, preserve and be responsible for all existing bench narks, pegs and boundary marks and shall keep these in place or replace them when necessary either in their positions or in other approved positions.

8

Setting out shall be approved by the Engineer before commencing the Works, but such approval shall in no way relieve the Contractor of his responsibility for the correct execution of the works.

1.3

EXISTING GROUND LEVELS

1

The Contractor will survey cross-sections of the site prior to the commencement of works in any section.

2

The Contractor shall include in his critical path programme the date by which survey work should be completed in each section of the site. No works may commence in any section prior to the programme date without the written approval of the Engineer.

3

Sections will be prepared at such intervals as are necessary to give a representative record of existing conditions and in no case will the intervals exceed 50 metres.

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The Engineer may choose to carry out his own survey of the site and in such cases will give the Contractor 48 hours notice of his intention to carry out survey work in any particular section of the Site.

5

The Contractor may nominate a representative to be present to observe the survey. If, having been given such notice, the Contractor fails to appoint a representative or if the representative should fail to be present during the survey work, the Engineer shall proceed with the survey which shall be deemed to have been prepared in the presence of the Contractor.

6

The Contractor shall prepare drawings showing the various cross-sections obtained from the above survey.

7

The original of the drawings shall be signed by the Engineer and the Contractor as an agreed record of the existing ground levels.

8

A copy transparency of each original drawing will then be given to the Engineer. These drawings shall be deemed to be the Contract Drawings replacing the original.

1.4

MATERIALS TESTING

1

Reference should be made to the requirements for the provision of facilities and equipment for the testing of materials given in Section 1.

2

In addition to these requirements the Contractor shall provide a fully equipped site laboratory or shall arrange for materials and samples to be transported to the Ministry of Environment (MOE) for testing or otherwise specified by the Engineer or the Project Documentation.

3

In addition the Contractor shall provide suitable facilities at the asphalt batching plants to enable the Engineer to carry out all necessary tests on the raw materials and mixes. Such facilities will be subject to the Engineer's approval and the preparation of asphalt mixes shall not be allowed until the facilities have been approved by the Engineer.

4

Approved equipment shall be maintained on site at all times to: Determine the laying and rolling temperature of bituminous materials.

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(b)

Check surface tolerance by using a straightedge and wedges or rolling straightedge.

(c)

Carryout soil grading shape, classification, moisture content and compaction tests, as required.

(d)

Carryout in situ dry density tests.

(e)

Carryout bitumen extraction.

5

Equipment shall also be made available when required by the Engineer to take 150 mm diameter cores from the carriageway.

6

The Engineer may require samples of materials to be delivered to the MOE for additional tests.

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1.5

NUCLEAR DENSITY TESTING DEVICES

1

No person or company will be permitted to determine in-situ density by mean of a nuclear density measuring device without complying with the following regulations: (a)

Each device shall have a valid Calibration Certificate issued by the MOE.

(b)

Persons operating the device shall hold a valid authorised user certificate issued by the MOE.

(c)

During the operation of the device the person operating it and any assistants shall wear a suitable film badge or a personal radiation warning alarm. Copies of radiation exposure report of the film badges should be submitted on monthly basis to the MOE.

TEMPORARY FENCING

1

Temporary fencing shall be appropriate to the usage of the adjoining land and unless otherwise described on the drawings may be of a type selected by the Contractor taking into account the usage of the adjoining land subject to the approval of the Engineer.

2

As soon as the Contractor is placed in possession of any part of the site he shall immediately erect fencing on the boundaries of the land as shown on the Drawings. In places where permanent fencing cannot be erected immediately or where none is required, the Contractor shall erect, and when and where required re-erect and maintain, temporary fencing and subsequently take down and remove as necessary.

3

The Contractor shall not use barbed wire in areas accessible to the general public. Access shall be made in temporary fencing as necessary for the use of the occupiers of adjacent lands.

4

If temporary fencing is removed temporarily for the execution of any part of the Works it shall be reinstated as soon as possible and in the meantime, subject and without prejudice to the Conditions of Contract, the gap in the fencing shall be patrolled so that no unauthorised entry onto adjoining land takes place.

5

Temporary fencing shall remain in position either until it is replaced by permanent fencing or until its removal on completion of the Works, unless otherwise described in the contract or directed by Engineer.

1.7

ROAD OPENING

1

Road openings shall be carried out in accordance with the procedures laid down in The Code of Practice and Specification for Road Openings in the Highway, prepared by the Ministry of Industry and Public Works, January 1992.

2

Newly compacted bituminous courses shall not be opened to traffic until they have cooled to ambient temperature. Longer periods may be applied during the summer months for heavily trafficked roads at the discretion of the supervising engineer

1.8

CONCRETE WORKS

1

All concrete works shall be carried out in accordance with the requirements of Section 5.

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Concrete works shall include; mass concrete, reinforced concrete, in-situ concrete, precast concrete and prestressed concrete.

3

Concrete works shall be deemed to include reinforcement, formwork and all the other materials procedures and requirements covered by Section 5 - Concrete.

1.9

STANDARDS AND CODES OF PRACTICE

1

The standards, codes of practice and other reference documents referred to in the roadworks section of the specification are listed in the first clause of each of the parts of the specification.

2

Unless otherwise agreed with the Engineer a full set of these documents shall be provided by the Contractor within 30 days of the commencement of the contract. These documents shall be kept at the site and shall be available at all times for the use of the Engineer and his staff.

1.10

TRAFFIC MANAGEMENT

1

The Contractor shall comply with all instructions given by the Qatar Traffic Police in relation to traffic management and road safety.

1.11

ARMED FORCES

1

The Contractor shall comply with all reasonable instructions given by the Qatar Armed Forces to allow them access to the Works and with the PWA.

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END OF PART

QCS 2014

Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 1

10

VEHICLE CRASH BARRIERS ....................................................................... 2

10.1

GENERAL REQUIREMENTS ........................................................................ 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6

Scope References Performance Requirements Submittals Quality Assurance Maintenance

10.2

STEEL WIRE ROPE BARRIERS .................................................................. 5

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8

General Component Ropes Tail Rope Safety Check Rope Posts Anchorage Frames Other Components Installation

10.3

TENSIONED CORRUGATED BEAM SAFETY FENCE ................................ 9

10.4

UNTENSIONED CORRUGATED SAFETY FENCE .................................... 10

10.5

OPEN-BOX BEAM SAFETY FENCE ........................................................... 11

10.6

TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE ......................................................................................................... 12

10.7

MARKERS FOR BARRIERS ....................................................................... 12

10.8

CRASH CUSHIONS AND TERMINALS ...................................................... 12

10.9

VEHICLE BARRIER UNITS (VBU) .............................................................. 13

10.10

TEMPORARY CONCRETE BARRIERS ...................................................... 13

10.11

ALUMINIUM BRIDGE PARAPET ................................................................ 14

5 5 6 6 6 7 7 8

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10

VEHICLE CRASH BARRIERS

10.1

GENERAL REQUIREMENTS

10.1.1

Scope

1

This section of the specification covers the supply, installation and foundation requirements of the following representative types of vehicle crash barriers. The definition of each type of barrier is given in the relevant section of the specification. steel wire rope barriers.

(b)

tensioned corrugated beam safety fence

(c)

untensioned corrugated beam safety fence

(d)

open box beam safety fence

(e)

tensioned rectangular hollow section safety fence

(f)

permanent concrete barriers

(g)

temporary concrete barriers

(h)

aluminium bridge parapet.

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(a)

This section of the specification does not cover the design criteria for deciding on the type of barrier to be applied in a particular situation.

3

Related Sections and Parts

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Fencing

Section 5

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This Section Part 12

References

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BS 4............................Structural steel sections BS 302........................ Wire ropes for cranes, excavators and general engineering purposes BS EN 13411-1 ..........Specification for Thimbles for wire ropes BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles BS 970........................Wrought steels for mechanical and allied engineering purposes BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes BS 1490......................Aluminium and aluminium ingots for engineering purposes BS EN ISO 2081 & BS EN ISO 2082, Electroplated coatings of cadmium and zinc on iron and steel BS EN 10264..............Round carbon steel wire for wire ropes BS 3416......................Bitumen based coatings for cold application BS EN 1011................MIG Welding of aluminium and aluminium alloys BS 4320......................Metal washers for general engineering purpose BS 4464......................Spring washers for general engineering and automobile purposes BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners BS 6579......................Safety fences and barriers for highways

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BS EN 1317................"Highway parapets for bridges and other structures. Part 1. Specification for vehicle containment parapets of metal construction BS EN 10025..............Hot rolled products of non-alloy structural steels - Technical delivery conditions. DTP, Manual of contract documents for highway works - volume 1 specification series 400 DTP, Manual of contract documents for highway works - volume 3 standard details ASTM D 1248 .............Specification for Polyethylene Plastics Moulding and Extrusion Materials US, Department of Transportation Research Report NCHRP, No. 230. ISO 9002 ....................Quality assurance system for production and installation Performance Requirements

1

The vehicle crash barriers shall present a continuous smooth face to an impacting vehicle so that the vehicle is redirected without turning on its side or rolling over to a course that is nearly parallel to the barrier face and with a lateral deceleration which is tolerable to the vehicle occupant. The vehicle shall be redirected without rotation about either its horizontal axis (spinning out) or vertical axis (overturning) and the rate of lateral deceleration shall be such as to cause minimum risk of injury to the passengers.

2

The vehicle shall be directed so that no part of the vehicle crosses the line parallel with and 4 m from the original alignment of the traffic face of the fence or barrier within a distance of

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10 m from the last point of initial impact in the direction of the adjacent traffic flow. On impact the safety fence or barrier shall contain and redirect a vehicle of a certain mass travelling at a certain velocity at an angle of incidence of 20 degrees to the fence or barrier.

4

The level of vehicle containment shall be lower, normal or higher as designated, with the following value for vehicle mass and vehicle speed.

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Vehicle Mass, kg 1500 1500 5000

Vehicle Speed, km/h 113 80 80

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Containment Normal Lower Higher

The centre of gravity of the test vehicle prior to impact shall be 500 mm above the ground. 5

All the components of a vehicle crash barrier shall be designed to achieve a serviceable life of not less than 20 years except for the use of temporary concrete barriers where the nominal service life shall not be less than 10 years.

10.1.4

Submittals

1

The Contractor shall submit details of previous installations of the vehicle crash barrier over a 10-year period, indicating the system, its location and the type of highway.

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For the particular crash barrier system proposed, the Contractor shall submit a detailed report giving the results of vehicle impact tests, and may include photographs and video recordings. The report shall be from an internationally recognised laboratory approved by the Engineer. The report shall describe in detail the arrangements for the test including vehicle weight, speed, impact area, full details of the test vehicle guidance and measuring systems and speed measurements. The report shall include photographs showing the results of the test. The report shall give full details of the actual vehicle speed, approach angle, vehicle interaction and fence movement of vehicle and roll, yawl and pitch of the vehicle movement after exit from safety fence. The report shall include details of the safety fence damage and the vehicle damage.

3

Crash cushions and terminals. The Contractor shall make a detailed technical submission that will include drawings indicating the layout for the system at different locations. The Contractor shall also submit design calculations for the system for head on impact and side impact. These calculations shall indicate the reduction in G force or all vehicles of specified weight and speed. The submission shall contain the precise specification of the individual elements of the system, installation procedures, fixing details and fully dimensioned scale layout drawings. The Contractor shall submit reports from the highway authority where the particular barrier system has been used showing details of vehicle collisions and the results of such collisions.

4

The Contractor shall submit calculations to show that post foundations can withstand an overturning moment of 6.0 kNm.

5

The Contractor shall submit full technical details of the safety fence system proposed including post to beam connection details of beam joints and post to beam connection details of posts, and details of tensioning assembly.

6

The Contractor shall submit calculations showing the required size and details of the lifting eyes for permanent and temporary concrete barriers for the designated barrier details.

10.1.5

Quality Assurance

1

Vehicle crash barriers shall have been tested by an approved Testing establishment such as the UK Transport and Research Laboratory. The Engineer shall decide what is an approved Testing establishment.

2

The manufacturer shall operate an approved quality assurance system complying with ISO 9002 for the fabrication and supply of components used in the vehicle safety barriers. Only components complying with the manufacturer’s specifications may be used.

3

The supplier shall submit certification showing that tensioned rectangular hollow section safety fence systems have been tested in accordance with the requirements of the UK Transport and Research Laboratory.

4

Crash cushion and terminal systems shall have been satisfactory tested following the procedures set down in the US Department of Transportation Research Report NCHRP, No. 230. The installation of the system shall be supervised by a representative of the manufacturer with a minimum of five years of experience in the use of the system.

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10.1.6

Maintenance

1

For vehicle crash barriers, crash cushion and terminal systems the Contractor shall supply: (a)

four copies of the installation and maintenance manual

(b)

a relevant spare parts list for the system showing the recommended set of spare parts needed to restore one system to its original condition after a head on impact

(c)

if specified elsewhere in the Contract the Contractor shall supply spare parts for the system

(d)

current prices of spare parts

(e)

profile of a local agent

STEEL WIRE ROPE BARRIERS

10.2.1

General

1

Steel wire rope safety fence barriers shall be supplied and installed in accordance with the designated dimensions and details shown on the contract drawings. The post details, spacing, anchorage, size shapes and general layout shall be as per the details shown on the contract drawings.

2

Wire rope barriers shall consist of either two or four, tensioned, galvanised, steel-wire ropes. The type of system to be specified shall be as shown on the contract drawings.

3

Four wire rope barriers shall consist of two upper ropes located in a slot at the top of the steel posts and two lower ropes interwoven along the fence between each pair of ropes. The ropes shall be joined and tensioned by means of screws at the designated intervals.

4

The ends of the ropes shall be attached to anchor blocks and embedded in the ground. Steel posts may be located in the ground either as driven posts or in concrete footings. In the case of any obstruction, the Contractor shall propose an alternative steel post, surface mounted to the equivalent of strain. Steel posts shall be removable and replaceable.

5

The supply and installation of steel wire safety fence barriers is to be carried out in accordance with BS 6579, except as modified herein.

10.2.2

Component Ropes

1

Component ropes shall consist of steel wire ropes fitted with end terminals.

2

The rope shall be 19 mm diameter, 3 x 7 (fill) galvanised wire rope generally to BS 302: Part 1 with a minimum breaking force of 173.6 kN. All wire used in the rope shall be to BS EN 10264 galvanised normal duty. Various galvanised wire finishes may be used by agreement with the Engineer.

3

The rope shall be prestressed by applying a cyclic loading until all initial extension has been removed. After prestressing the rope will exhibit a minimum modulus of elasticity of 8300 kg/mm2 based on an area of 283 mm2.

4

The complete component rope shall have terminals, one end right-hand thread and the other left-hand thread.

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The fittings shall be attached to the rope whose length measured over the extreme ends of the threaded portion of the fittings shall be 153.35 m, -0/+25 mm. Other special lengths of rope with identical construction may be detailed as necessary for specific applications.

6

All threaded terminals shall be made from steel to BS 970: Part I Grade 65SM13 and either cadmium plated to BS EN ISO 2081 & BS EN ISO 2082 class B or alternatively galvanised to BS EN ISO 1461. A test will be carried out to destruction on a threaded terminal test piece consisting of a terminal and a length of rope such that the minimum test length is 600 mm. This assembly shall have a minimum breaking force of 164.6 kN.

10.2.3

Tail Rope

1

Tail ropes shall be short lengths of rope fitted with threaded terminals at both ends that are used to connect component ropes to anchors. Tail ropes shall be supplied to the site prefabricated.

2

Tail ropes are of identical construction and specification to the component ropes but of different overall length. These ropes must also be prestressed.

3

The length of the fitted rope measured over the extremities of the threaded portions of the screwed terminals shall be 6 m  10 mm.

4

Tail ropes shall be terminated in one of two ways using identical terminals to those specified for component ropes: with right-hand terminations on both ends, or with a right-hand at one end and a left-hand termination at the other.

10.2.4

Safety Check Rope

1

Safety Check Ropes are steel wire ropes fitted with end terminations. The rope itself shall be 8 mm diameter 6 x 19 (9/9/1) IWRC galvanised wire rope to BS 302 with a minimum breaking

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The rope shall have a galvanised heart-shaped thimble to BS EN 13411-1 capable of accepting a 38 mm diameter pin fitted by using a pressed ferrule on one end and a forked

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force of 40.3 kN. All wires used in the rope shall be to BS EN 10264 grade normal duty, galvanised to class 'A' finish.

terminal on the other end. 3

The length of the rope between the centre of the 38 mm pin hole and the 9 mm pin hole shall be 1.8 m –0/+20 mm.

10.2.5

Posts

1

There are three types of posts with variations for embedded style or surface mounting: line, deflection and surface.

2

All posts shall be manufactured from 6 mm section cold rolled mild steel plate to BS EN 10025 grade Fe 50A, having a minimum yield strength of 355 N/mm2. All posts shall be galvanised to BS EN ISO 1461. Dimensions and tolerances of the types of posts shall be as designated.

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Post foundations and anchor blocks shall be as per the dimensions and details designated by the supplier.

10.2.6

Anchorage Frames

1

A range of anchorage frames must be available for various locations and applications. These are: on the median, verge and for end/intermediate and embedded/surface mounted fixings. The anchorage frames shall comply with the requirements of clause 4.3 of BS 6579.

2

End anchorage frames shall be constructed from weldable structural steel as defined in BS EN 10025 Grade Fe 430A with steel plate to section 4, and steel bar to section 6. Rolled steel channel to BS 4. All materials shall be galvanised to BS EN ISO 1461.

3

Intermediate anchorage frames are double sided frames. All materials and finishes shall be as defined above.

4

The intermediate anchor frames may be surface mounted.

10.2.7

Other Components

1

Sockets for post foundation shall be constructed from 3 mm steel to BS EN 10025 Grade Fe 430A. Galvanised to BS EN ISO 1461.

2

Excluders shall be produced from high-density polyethylene type iii class C Cat 4, ASTM D 1248

3

Rigging screws shall be used to connect component ropes together and component to tail ropes. The rigging screws shall be the body of a rigging screw manufactured to BS 4429. Except for the threads which are to be right and left hand M24 x 3-7H. Each rigging screw shall be hot dipped galvanised to BS EN ISO 1461.

4

Steel pins used in the fork terminal on the safety check rope shall be made from BS 970 Grade 045M10.

5

Split cotter pins shall be in stainless steel 2.5 mm x 16 mm to BS 4320 and shall have a retaining pin.

6

Nuts used to secure the threaded rope terminal to an anchor frame shall be M24 thread in zinc electroplated condition. Steel washers shall be M 24 to BS 4320 and fitted over the threaded terminal and between the nut and anchor frame.

7

Locating hooks shall be made in stainless steel to BS 970 Part I. Nuts (for hooks) shall be M6

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to BS 3692 Grade A2. 8

Caps for posts shall be high-density polyethylene Type III class c cat 4, ASTM D 1248

9

Ordinary thimbles shall be size 9, fitted to safety check rope made to BS EN 13411-1.

10

The fork terminal shall be fitted to the safety check rope shall be made to BS 970 Grade 45 M10.

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11

All ropes, terminals, rigging screws, posts and anchor frames are to be clearly marked with the manufacturers identification and the date of manufacture and the standard of construction.

10.2.8

Installation

1

Steel wire ropes safety fences shall not be used where the length of fence at full height would be less than 37.5 m

(b)

on horizontal kerb at radius less than 600 m

(c)

on vertical sag curves of radius less than 300 m

(d)

on medians having a width of less than 3.14 m

(e)

where the height of any kerb at the edge of the adjacent surface exceeds 100 mm

(f)

where high mast lighting columns are situated within 10m of the edge of the paved surface

(g)

where the fence has to be connected to any other fence or building

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(a)

All components shall be suitably protected and supplied in packaging that prevents any permanent damage particularly to threaded components. Damage to metallic coating shall be prevented by appropriate means. Any damage found on inspection prior to installation shall be made good to the satisfaction of the Engineer.

3

Component ropes and tail ropes shall be supplied on reels with a bar of diameter not less than 450 mm.

4

Ropes shall not be twisted or kinked.

5

Driven line posts shall be installed to the alignment and level shown on the drawing without damage to the slot on the top of the post.

6

The top of the post shall be capped with a black polypropylene excluder.

7

The length of the line rope between any two adjacent anchors shall be not greater than 627m.

8

Tensioning between any two limits shall not proceed until the Engineer is satisfied that each limit is anchored sufficiently securely to resist the load effects due to tensioning.

9

The tension shall be measured using a device approved by the Engineer.

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The ambient air temperature shall be noted at the time of tensioning and adjusted as follows;

AMBIENT TEMPERATURE C

14.00 16.75 19.50 22.25 25.00 27.75 30.50 33.25 36.00

45 40 35 30 25 20 15 10 5

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ROPE TENSION kN

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TENSIONED CORRUGATED BEAM SAFETY FENCE

1

Except as modified herein, tension corrugated beam safety fences shall comply with the DTP Manual of Contract Documents for Highway Works Specification - Volume 1, specification series 400.

2

Tensioned corrugated beam safety fences are for use on high speed roads at the road edge or on the central median in one of the following forms:

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10.3

Single sided for road edges.

(b)

Double sided for medians.

(c)

Dual single sides for medians .

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(a)

In the event of an accident, the support post shall give away while the safety fence remains in tension absorbing the impact energy while protecting the traffic on the opposite carriageway. The angle of deflection shall be reduced and as the vehicle decelerates it shall be redirected towards the carriageway.

4

The barrier shall consist of a strong corrugated steel beam section mounted and tensioned on steel universal posts. End posts shall be set in concrete and intermediate posts can be driven or set in concrete.

5

Surface mounted posts may be used where there are obstructions. In all cases the end posts which are attached to barriers must be set in concrete.

6

The layout and the positioning of the barrier shall be as shown on the contract drawings. The details and sizes and spacing of the various components shall be as shown on the contract drawings.

7

The height of the centreline of the barrier shall be 610 mm above the edge of the carriageway unless shown otherwise on the contract drawings.

8

There is no maximum length for installation. Where the line of the barrier is interrupted for an obstacle or gap, additional end anchorages shall be provided.

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Page 10

Where a barrier protects an individual short obstacle the barrier should extend from at least 30 m in front of the obstacle to at least 7.5 m or more beyond it. A minimum clearance of 1.2 m behind the barrier shall be allowed for deflection.

10

Circular installations shall be at a radius of not less than 120 m. Tighter radii than this shall not be used without the written approval of the Engineer. Tensioners shall consist of two longitudinal bulbs installed in brackets and shall be positioned in intervals along the barrier and bolted to the corrugated beam.

12

Beams shall be connected by lap joints using screws nuts and washers. Beams shall be spliced by lapping with the edge facing away from the direction of traffic. Longitudinal clearance between screws and slotted holes in the beams shall be removed by prising apart the beams. The nuts shall be tightened to a torque approved by the supplier.

13

Tensioning between any two limits shall not proceed until the Engineer is satisfied that each limit is anchored sufficiently securely to resist the load effects due to tensioning. Tensioning shall be carried out strictly in accordance with the system manufacturer’s recommendations. Adjustments to the tensioning shall be made for the ambient temperature at the time of tensioning strictly in accordance with the system manufacturer’s recommendations.

14

The beam shall be completely formed, punched with holes for mounting and splicing and ready for assembly when delivered. It shall be uniform corrugated section straight or curved sections, galvanising shall be carried out after fabrication and each element and end sections shall be marked at the point of fabrication with the manufacturer’s name or trade mark, gauge and heat ( steel batch ) number and with the coating lot referenced.

15

The barrier system shall be supplied with all required terminals and approach flares for the particular installation situation.

16

Safety barriers shall be erected to present a flowing alignment, with the alignment in plan not more than ± 30 mm from the prescribed alignment and no deviations in a 10 m length by

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more than ± 15 mm from the prescribed alignment. The height of the beam shall not depart from the prescribed height by more than ± 30 mm nor deviate in any 10 m length from the

m

prescribed height by more than ± 10 mm.

10.4

UNTENSIONED CORRUGATED SAFETY FENCE

1

Untensioned corrugated safety fences shall meet the requirements of the tensioned corrugated safety fence except as modified herein and the fence shall not be tensioned.

2

Untensioned corrugated safety fences can be used in low-speed situations to prevent vehicles crossing median and for protection at the verge.

3

Beams shall be shaped so that there are no sharp edges protruding into traffic. Beams shall be connected by lap joints made in the direction of the traffic flow. The beams shall be formed from a 3 mm steel strip to give a corrugated cross-section. On curves less than 45 m radius, the beam shall be provided in preformed curves, internal or external, without any reduction in strength.

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At terminations, the end rails shall be sloped down at a slope of approximately 1 in 6 to terminate just above ground level. Anchorage shall be provided by an end post set in concrete. Unless otherwise designated the centreline of the beam shall be 610 mm above the edge of the carriageway or hard shoulder.

10.5

OPEN-BOX BEAM SAFETY FENCE

1

Open box beam safety fences shall meet the requirements of the DTP - Manual of contract documents for highway works - volume 1 specification series 400 except as modified herein.

2

The open-box beam barrier shall be used on high-speed roads where a stiffer barrier than the tensioned corrugated beam is required. The open-box barrier can be used for a double sided installation in a median.

3

The layout, positioning, post spacing and all dimensions of the system shall be as designated.

4

The systems shall comprise a main traffic section rail element with a traffic face 150 mm wide. This shall be ground mounted on relatively weak Z-section posts or with hexagonal energy absorbing brackets bolted to a reinforced concrete wall or bridge pier. The traffic face shall be set to a height of 610 mm at the centreline of the rail.

5

There is no limit to the length of the installation, but end rails shall be taken down to ground level and bolted to end posts to form anchors which are set in concrete.

6

Where the installed barrier exceeds 100 m in length, expansion joints are to be inserted in

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4

The standard section length shall be 4.8 m unless otherwise designated, and this value shall

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be used on curves of radii down to 335 m. For radii between 335 m and 107 m special fish plates shall be used.

9

For radii between 107 m and 50 m, 2.4 m rail lengths shall be used with special fish plates.

10

Z-section intermediate posts shall be connected to the main rail by shear bolts and clamp plates into the back of the rail section.

11

Rail sections shall be butt jointed together connected by fish plates and bolted in connection.

12

Where a non-standard situation arises in the use of the crash barrier, the supplier shall obtain recommendations from the UK Transport Research Laboratory.

13

In particularly hazardous locations where vehicles with a high centre of gravity are in use, the open box barrier may be installed to a double height with two protective rails. The horizontal centreline of the second rail shall be positioned 1 m above the adjacent carriageway. The

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two box section rails shall be connected together with vertical straps or a single shear bolt in the centre of each connection of the rails to longer intermediate posts.

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10.6

TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE

1

Tensioned rectangular hollow section safety fences shall be installed as designated. The position, layout dimensions and details shall be as designated.

2

The barriers shall be used where protection is required for bridge piers lighting columns and other obstructions.

3

The size of the rectangular hollow section shall be 100 mm wide x 100 mm high or 100 mm wide x 200 mm high.

4

The minimum recommended curve for the barrier shall be 120 m radius. Tensioners shall be fitted at a maximum spacing of 70.5 m and the first tensioner shall be within 50 m of the

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anchorage.

When supplied the system shall include a detailed packing list with each component referenced and clearly marked to the standard of manufacture and the manufacturer’s name and date of manufacture.

10.7

MARKERS FOR BARRIERS

1

To ensure that the vehicle crash barriers are clearly delineated, reflectorized markers shall be fixed to the barriers. The work shall consist of the fabrication supplied and fixing of reflectorized markers to vehicle crash barriers and other road side obstructions.

2

Reflectorized markers shall consist of two retro-reflective faces of minimum area 4000 mm2 on a weather proof durable backing capable of being fixed to the barrier. All metal fixings and fittings shall be galvanised or stainless steel and approved by the Engineer.

3

Reflectorized faces shall consist of a minimum of 210 glass beads set in a 3 mm thick tough durable plastic backing. The two faces of the marker shall be of the colour specified in the Qatar Traffic Manual unless shown otherwise in the drawing or instructed otherwise by the Engineer.

4

Reflectors shall be fixed to safety barriers and other structures where designated. Stainless steel fixings complying with BS EN ISO 3506 grade A4 shall be used to attach markers to concrete. Plastic isolation washers shall be used if the marker is galvanised.

10.8

CRASH CUSHIONS AND TERMINALS

1

Where designated, permanent or portable energy absorbing terminal systems shall be provided for protection of traffic as shown on the drawings.

2

Proposed systems shall have a proven record of satisfactory performance of at least five years in a number of locations.

3

The system shall be able to withstand head on and side impacts within the specified design criteria. The system shall have the performance characteristics of a conventional metal beam guard rail for strength durability and redirectional properties.

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All of the components and materials of the system shall be suitable for use in the climatic conditions of Qatar and shall not be liable to damage or deterioration in high temperatures or by prolonged exposure to direct sunlight.

5

The system shall be such that most major components can be reused after a typical impact.

6

All metal work used in the system shall be galvanised or stainless steel.

7

All concrete used in the system shall meet the requirements of Section 5.

8

No work or fabrication of the system or ordering of the materials shall be carried out until the Engineer has given formal approval in writing to the Contractor’s detailed submission.

10.9

VEHICLE BARRIER UNITS (VBU)

1

Vehicle barrier units and their foundations shall be as per the details and dimensions shown on the drawings.

2

Vehicle barrier units shall be mass concrete of grade C25

3

The barriers shall be cast in-situ in nominal 6 m length units unless designated otherwise.

4

All the concrete materials and procedures including any steel reinforcement for the barriers shall comply with Section 5.

5

Forms shall be smooth and tight-fitting which can be held rigidly to the line and grade during the placing of concrete.

6

At the option of the Contractor, the barriers may be precast in sections not exceeding 6 m in

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length. In such cases the barrier shall be reinforced to ensure that information technology can be safely handled and have 2 no. lifting eyes of galvanised steel cast in at the top. The method of casting, handling and placing of barrier sections shall be proposed by the Contractor for approval by the Engineer. The joints between the barriers shall be as per the details shown on the drawings.

8

Vehicle barrier units shall be cast onto blinding concrete laid onto compacted subgrade

10.10

TEMPORARY CONCRETE BARRIERS

1

Temporary concrete barriers shall be used for traffic management at road diversions or detours where there is slow moving traffic.

2

Temporary concrete barriers shall be as per the designated detailed dimensions. The barriers shall be either double or single sided.

3

The barriers shall be cast in nominal 6 m length units unless otherwise designated.

4

Each barrier shall have cast in at the top two lifting eyes of galvanised steel.

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Where adjacent barriers are put together two galvanised steel wire eyes shall be cast in to the ends to allow a steel pin to be placed through the eyes and into the road surface to secure the barrier laterally.

6

The Contractor shall propose the reinforcement in the precast barriers which shall be adequate to resist the forces and moments induced during lifting and handling.

7

All the concrete work including any steel reinforcement for the barriers shall comply with Section 5 of this specification.

8

The method of casting, handling and placing of barrier sections shall be proposed by the Contractor for approval by the Engineer.

10.11

ALUMINIUM BRIDGE PARAPET

1

The aluminium alloy parapets for installation on the bridges and retaining walls shall be designed to the requirements of BS EN 1317 "Highway parapets for bridges and other structures. Part 1. Specification for vehicle containment parapets of metal construction".

2

The parapet shall be designed for normal level of containment as defined by the standard i.e. that required to resist penetration from the following vehicle’s impact characteristics:

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Saloon Car 1500 kg 600 mm 2 degrees 113 km/h

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Vehicle Mass Height of centre of gravity Angle of impact Speed

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5

The parapet proposed for use shall be a three rail system of an established design the prototypes of which have been subjected to full scale dynamic testing. The parapet design which shall therefore be considered exempt from further dynamic testing shall be taken from the list in Appendix G of BS EN 1317.

4

The parapets supplied to the project shall be certified by the supplier as a normal containment system complying with one of the following.

5

That it complies in all respects with the design of parapet that successfully met the requirements of Clause 26.1 or 26.5 (concerning dynamic testing) of BS EN 1317 as appropriate.

6

That any modifications that have been made to the tested design comply with Clause 26.6 or 26.7 of BS EN 1317 as appropriate.

7

The parapet construction materials shall be as follows:

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Extruded sections Castings

Aluminium alloy 6082-T6 to BS 1474 Aluminium alloy LM6M to BS 1490

8

The finish of the parapets shall be high quality defect free mill finish and as cast finish for extrusions and castings respectively.

9

All aluminium welds shall confirm to BS EN 1011 and the requirements of BS EN 1317.

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All setscrews and nuts are to be stainless steel to BS EN ISO 3506 material grade A4. Setscrews are to be strength class 80. Washer material is to be stainless steel to BS 1449: Part 2 conforming to grade A4 or A2 as defined in BS EN ISO 3506.

11

Rail attachment and rail joint screws are to be M12 x 30 long hexagon head each complete with one spring washer to BS 4464 type B, and one plain washer to BS 4320 form A.

12

Holding down bolts are to be M20 hexagon head bolts of sufficient length to give the engagement required in BS EN 1317.

13

Bottom mesh fixing screws if required, are to be to the M8 long hexagon head set screws each complete with one spring washer, two plain washers and one M8 nut where appropriate.

14

The holding down arrangement shall be in accordance with the requirements of BS EN 1317.

15

Loctite grade 270 (or similar approved) to be applied on erection to all rail joint and rail attachment setscrews. At the holding down bolts, contact between the stainless steel and aluminium baseplate shall be avoided by the use of a suitable "top-hat" insert manufactured from an inert material.

16

Underside of baseplates are to be given at least two coats of an alkali resistant bitumastic paint or pitch complying with BS 3416.

17

Mesh, if required, shall be 10 gauge welded steel wire in accordance with BS EN 1317, where appropriate. It may be galvanised, or any other finish as directed by the Engineer.

18

Rivets shall consist of Avdel drive rivets, code 5141 or 06 37 or similar approved. Where there is no substantial backing Avdel chrobert rivets, code 1125 06 13 with sealing pins code 1182 06 07 or similar approved, shall be used.

19

Full details of the proposed supplier with his technical specification in English covering materials, main dimensions and sizes shall be submitted to the Engineer for approval before the Contractor places an order.

20

Two copies of detailed shop drawings shall be submitted and the Engineer's approval obtained before manufacture is commenced.

21

During erection, parapets shall be securely held in their correct position until all connections and fastenings are complete and the post fixings have attained adequate strength to the Engineer's approval.

22

The finished parapets shall be true to line and level throughout their length.

23

Panels and members shall be free from twist, and posts shall be truly vertical.

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END OF PART

QCS 2014

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 1

KERBS, FOOTWAYS AND PAVED AREAS............................................................ 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2

11.2 11.2.1 11.2.2 11.2.3

KERBS .................................................................................................................... 3 General 3 Materials and Manufacture 3 Laying 5

11.3

PRECAST CONCRETE PAVING BLOCKS ............................................................. 6

11.4

LAYING PRECAST CONCRETE PAVING BLOCKS ............................................... 7

11.5

PRECAST CONCRETE PAVING SLABS ................................................................ 8

11.6

CAST-IN-PLACE CONCRETE PAVED AREAS....................................................... 9

11.7

BITUMINOUS PAVED AREAS ................................................................................ 9

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11

KERBS, FOOTWAYS AND PAVED AREAS

11.1

GENERAL

11.1.1

Scope

1

Highway kerbs, edging kerbs for footways and other paved areas. Precast concrete paving slabs and precast interlocking concrete block areas.

2

Related Sections and Parts:

.

Earthworks Unbound Pavement Materials Asphalt Works

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This Section Part 3 Part 4 Part 5

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Section 5, Concrete

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Section 13, Masonry References

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11.1.2

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BS 812........................Testing Aggregates

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BS 1377......................Methods of test for soil for civil engineering purposes BS 7533......................Code of practice for laying precast concrete units

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BS 7533-3 ..................Laying precast concrete paving blocks and conformity criteria for

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BS EN 197-1 ..............Cement composition specifications comments cements BS EN 1338................Precast concrete paving blocks

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BS EN 1339................Concrete paving flags

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BS EN 1340................Concrete kerbs unit BS EN 12620..............Aggregates for concrete

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BS EN 12878..............Pigments for the colouring of building materials

11.1.3

Submittals

1

The Contractor shall submit samples of the various types of concrete kerbs and other pavement materials for approval by the Engineer before beginning the work.

11.1.4

Quality Assurance

1

Tests shall be carried out on the concrete mix before beginning manufacture of precast kerbs and other items to ascertain the strength and surface finish requirements can be met. If the required strength and surface finish are not obtained, the Engineer may order revisions to be made in order to achieve the designated requirements.

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2

The Engineer shall, at all reasonable times, have access to the place where paving blocks and other items and their constituent materials are manufactured and stored, for the purpose of examining and sampling the materials and finished blocks, inspecting the process of manufacture and marking the blocks.

3

The laying of paving blocks shall comply with the requirements of the Code of Practice for Laying Precast Concrete Block Pavements and BS EN 1338 except where otherwise designated.

KERBS

11.2.1

General

1

The following are the types of precast kerbs to be constructed where designated together with associated channels, edgings and quadrants: Non-mountable.

(b)

Dropped.

(c)

Flush.

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The dimensions and shapes of the different kerb types shall be as per the details in BS EN 1340 unless otherwise shown on the drawings or designated in the contract.

3

The bedding and support for such units shall be as shown on the drawings.

4

Except as modified in this Part, all precast concrete kerbs, channels, edgings and quadrants shall be hydraulically pressed complying with BS EN 1340.

5

Kerbs shall be laid and bedded in accordance with BS 7533 on the concrete pavement slab, a mortar bed, the road base, or on a concrete foundation while it is still plastic or after it has set. All precast units shall be backed with concrete as per the designated details.

6

The use of cast-in-situ concrete for kerbs will not be permitted except with the express written approval of the Engineer.

11.2.2

Materials and Manufacture

1

Constituent concrete materials for kerbs shall conform to the requirements designated in Section 5. Kerbs shall be prepared with a concrete mixture containing not less than 400 kg/m3 of sulphate resisting Portland cement.

2

Testing of concrete kerbs shall be carried out in accordance with the requirements of BS EN 1340.

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The aggregate shall meet the designated requirements and conform to the following gradation. Table 11.1 Aggregate Gradation for Kerb Concrete % Passing by Weight

19

100

13.2

76-100

9.50

60-80

4.75

40-60

2.36

22-42

1.18

12-32

0.6

7-23

0.3

4-15

.l. l

rw

0.15

2-10 0-2

ta

0.075

The 28-day compressive strength of the concrete shall be not less than 30 N/mm2

qa

4

.

Sieve mm

determined on 150 mm cube specimens, and not less than 75 % of this figure after seven

as

days.

Non-mountable kerb, dropped kerb, flush kerb and heel kerb elements shall only be precast from concrete produced in a fully automatic batching plant.

6

Before approval of elements of commercial manufacture, cores shall be taken from a random sample to ascertain that the concrete strength is not less than 25 N/mm2 at 7 days.

7

Elements shall be manufactured to the designated dimensions as standard 900 mm lengths unless specified otherwise in the contract documents.

8

Non-mountable and dropped precast kerbs shall be formed by elements 500 mm long where required to be laid in straight lines but may be reduced to 250 mm long where required to be laid to curves, depending on the radii of the curves.

9

The finished product shall be of solid appearance with clean planar faces, be free of segregation, honeycombing, pits, broken corners or other defects and there shall be no evidence of external rendering.

10

Bull-nosed and curved faces shall be of constant radius with a smooth change from radius to straight.

11

Tolerances of manufacture shall be 3 mm in any one dimension and end faces shall be truly

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5

perpendicular to the base.

QCS 2014

12


Page 5

Transverse strength requirements shall be assessed in accordance with BS EN 1338 appendix B. The loads at failure shall not be less than the appropriate value given in Table 11.1A. Table 11.1A Transverse strength of kerbs, channels and edgings Width as tested (mm)

Load at failure (kN)

150

305

22.2

125

150

8.0

125

255

13.3

50

255

50

205

50

150

Dropper kerbs 125

255 to 150

ta

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5.1 4.5

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3.3

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10.3

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Water absorption requirements shall be assessed in accordance with BS EN 1338 appendix C. The water absorption shall not exceed the appropriate value given in Table 11.1B.

er

13

.l. l

.

Depth as tested (mm)

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Table 11.1B Water absorption of kerbs, channels and edgings

o

Water absorption in % by mass Edgings

3.0

3.6

m

et it

Kerbs, channels and quadrants

11.2.3

Laying

1

Elements shall be set on to the designated lines and grades. Under no circumstances shall it be permitted for levels to be set by direct measurement from pavement layers.

2

Unless otherwise indicated, elements shall be laid either directly onto a wet-concrete base or onto a sand/cement (3:1) mortar bedding, 25 mm thick, on a previously laid concrete base or approved subbase. The dimensions of the base and concrete class shall be as designated.

3

After kerb units have been laid, a contiguous backing of concrete shall be poured for the elements using steel forms, unless otherwise designated. Lateral resistance shall be provided to the kerbs by placing dowel bars in the backing concrete in not more than 500mm intervals.

QCS 2014


Page 6

4

No pavement layers shall be laid against kerbing until such time as the backing is completed, backfilled and approved by the Engineer.

5

Joints between kerbs, shall have a width of 4 mm. These joints shall be filled completely with fluid sand cement mortar approved by the Engineer and the joints shall be formed again. Immediately after any concrete is in place, and for seven days thereafter, the kerbs, base, and backing shall be fully cured and protected from drying out and against the harmful effects of weather, including rain and rapid temperature changes. The method of protection shall be subject to the Engineer's approval. The use of coloured curing membranes will not be permitted. Concrete not properly cured and protected will be rejected and shall be removed from the site.

7

At every 10 m interval movement joint 20 mm thick shall be formed through the concrete bed and backing. The joint filler shall be bitumen impregnated cork board. The filler shall extend through the kerb, bed, backing and channel, and shall be trimmed to the finished shape of the kerb and channel.

8

At access points, the kerbs, including the bed backing shall be dropped to show a face of 25 mm or as otherwise designated.

9

At the termination of any kerb run, the end kerb section shall be sloped down to ground level, if applicable, and angled away from the road at 30 degrees in accordance with BS 7533.

10

All kerbs shall be thoroughly cleaned of all extraneous materials.

11

Kerbs shall be laid within a tolerance of  3 mm, at each end of an element, to the designated

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ta

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.

6

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lines and grades.

PRECAST CONCRETE PAVING BLOCKS

1

Standard rectangular precast concrete paving blocks shall have a work size length of 200 mm and a work size width of 100 mm. Paving blocks of any other shape may be made provided they fit within a 295 mm square co-ordinating space. The preferred work size thicknesses are 60 mm, 80 mm and 100 mm for all types of paving blocks.

2

The actual sizes of the paving blocks as determined in accordance with BS EN 1338 shall not deviate from the work size dimensions by more than the following tolerances:

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11.3

Length

 2 mm

Width

 2 mm

Thickness

 3 mm

3

The binder used in making the paving blocks shall be Ordinary Portland Cement, Sulphate Resisting Portland Cement or Moderate Sulphate Resisting Portland Cement which complies with BS 4027 or ASTM C150; respectively.

4

The aggregates used in making the paving blocks shall be Gabbro, and they shall comply with section 5 of QCS.

QCS 2014


Page 7

The water used in the manufacturing of the blocks shall be of drinking quality or shall be in conformance with section 5 of the QCS.

6

The pigments, which are used to give colour to the paving blocks, shall comply with BS EN 12878.

7

The average tensile splitting strength of 16 paving blocks tested in accordance with BS EN 1338 shall not be less than 3.6MPa and the strength of any individual block shall not be less than 2.9MPa and the failing load not lower than 250N/mm.

8

The average water absorption of three tested samples shall not exceed 5% and no individual block shall have a water absorption greater than 6%.

11.4

LAYING PRECAST CONCRETE PAVING BLOCKS

1

The paving blocks shall be laid generally in accordance with BS 7533-3 and to a pattern approved by the Engineer.

2

A laying course consisting of fine aggregates (sand), which complies with the corresponding grading requirement given in Table 11.2, shall be constructed. The fine aggregates shall be placed in a moist but not a saturated condition and shall be compacted so that a laying course thickness of 50 mm approximately is formed. This sand layer shall be placed on a compacted aggregate subbase or base as indicated in the project specifications/drawings.

3

The paving blocks shall be laid on the laying course and compacted using a plate compactor with a plate area of not less than 0.25 m2, transmitting an effective pressure of not less than 75 kN/m2 of plate at a frequency of vibration in the range of 75 Hz to 100 Hz.

4

A maximum deviation for the block paving from design levels of  6 mm shall be maintained.

5

The joints between the paving blocks shall be filled with dry jointing sand by spreading it over the surface and brushing it into the joints. The dry sand shall be natural and shall comply with the corresponding grading requirement given in Table 11.2. The block paving shall be vibrated to ensure that the joints have been completely filled.

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ta

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.l. l

.

5

Table 11.2 Grading for laying course & jointing sand % Passing

Sieve Size Laying Course Sand

Jointing Sand

10 mm

100

5 mm

90-100

100

2.36 mm

75-100

95-100

1.18 mm

55-90

90-100

600 m

35-70

55-100

300 m

8-35

15-50

150 m

0-10

0-15

75 m

0-3

0-3

QCS 2014

11.5


Page 8

PRECAST CONCRETE PAVING SLABS

1

Precast concrete paving slabs shall be hydraulically pressed, complying with BS EN 1339.

2

The dimensions of precast concrete paving slabs shall be as per Table 3 of BS EN 1339 unless shown otherwise on the contract drawings.

3

Where permitted by the Engineer as an alternative, slabs 450 mm x 450 mm and smaller may be bedded on a layer of clean sharp sand complying with BS EN 12620 Grading C or M, 25 mm  10 mm thick. On circular work where the radius is 12 m or less, all slabs shall be radially cut on both edges to the required line.

5

Transverse strength and water absorption requirements shall be assessed in accordance with BS EN 1339 - appendix B and appendix C; respectively. The loads at failure shall not be less than the appropriate value given in Table 11.3 and the water absorption shall not exceed the limit given in the aforementioned Table.

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4

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ta

Table 11.3 Transverse strength and water absorption of flags Minimum load at failure for thickness (kN)

as

65 mm

70 mm

12.7

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-

-

er

Flag type

-

16.9

-

-

-

-

-

18.8

9.1

-

-

15.4

-

9.6

13.8

-

-

-

60 mm

A

8.3

-

B,C,D

11.1

E

9.6

F G

63 mm

4.0

et it

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ov

50 mm

Maximum water absorption in % by mass

The mortar bed shall be spread only after the base has been approved by the Engineer. The subbase shall be tested for density and the minimum density shall be greater than 95% of the maximum dry density.

7

Slabs shall be laid in accordance with BS 7533 to the designated cross-section and with joints at right angles to the kerb.

8

Slabs shall be bedded on a sand/cement (3:1) mortar bedding not less than 10 mm and not more than 40 mm thick.

9

Unless designated elsewhere paving slabs shall be laid with close joints of between 2 to 4 mm. After laying the joints shall be filled with sand complying with clause 8.3.3.

10

Where designated paving slabs shall be laid with open joints of between 5 to 10mm laid in accordance with BS 7533.

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QCS 2014

11.6


Page 9

CAST-IN-PLACE CONCRETE PAVED AREAS Cast-in-place concrete for footways and paved areas shall only be permitted for small areas where it is awkward or impractical to use one of the alternative paving materials specified in this part of the specification.

2

The use of steel reinforcement bars or mesh in cast-in-place concrete slabs is not permitted.

3

Paving shall be cast in sizes to avoid the formation of shrinkage cracks. The actual maximum size of area to be cast at one time will be advised by the Engineer based on the mix design and layer thickness shown on the drawings. The Contractor may be permitted to cast larger areas at one time if non-metallic fibres are added to the concrete mix to eliminate cracking. In such cases the maximum pour size shall be proposed by the Contractor and approved by the Engineer.

4

Cast-in-place concrete for footways and paved areas shall be mixed, laid and cured as described in Section 5.

5

The grade of concrete, layout, thickness, position of joints and surface finish shall be as designated.

6

Cast-in-place concrete shall be laid on a designated sub-base in accordance with Part 4.

BITUMINOUS PAVED AREAS

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11.7

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.

1

Flexible surfacing for footways and paved areas shall be made and laid in compliance with Part 5.

2

The type of mix and the surface treatment/finish to the paving will be as designated..

3

Surfacing shall be laid to true levels and crossfalls and be of the designated thickness.

4

Surfacing shall be laid on a designated sub-base in accordance with Part 4.

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1

END OF PART

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 1

12

FENCING ....................................................................................................... 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 Scope 12.1.2 References 12.1.3 Submittals

2 2 3

FENCING GENERALLY ................................................................................ 3

12.3

CHAIN LINK FENCING.................................................................................. 4

12.3.1 12.3.2 12.3.3 12.3.4 12.3.5

General Materials Gates Finish to Components Construction

12.4

STRAINED WIRE FENCING ......................................................................... 7

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.

12.2

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ta

12.4.1 General 12.4.2 Materials 12.4.3 Installation

4 4 5 6 6 7 8 10

PEDESTRIAN GUARD-RAIL ....................................................................... 11

12.5.1 12.5.2 12.5.3 12.5.4

Aluminium Guard Rails Galvanised Steel Rails Materials and Fabrication Installation

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12.5

11 12 12 13

QCS 2014


Page 2

FENCING

12.1

GENERAL

12.1.1

Scope

1

This part of the specification covers the materials and installation requirements for the following permanent fence types. The definition of each type is given in the relevant section of the specification.

(b)

strained wire fencing.

(c)

pedestrian guard-rail.

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chainlink fencing.

as

References

BS 4............................Structural steel sections

se

BS 970........................Wrought steels for mechanical and allied engineering purposes BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip

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BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes

ov

BS 1490......................Aluminium and aluminium ingots for engineering purposes BS 1722-2 ..................Strained wire fences

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BS 1722, Part 1 ..........Chain link fences

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BS 1722, Part 2 ..........Rectangular wire mesh and hexagonal wire netting fences BS 4102......................Specifications for steel wire and wire products for fences BS 4320......................Metal washers for general engineering purpose

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12.1.2

ta

This Section Part 1 General Part 10 Vehicle Crash Barriers Section 5, Concrete

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qa

2

(a)

.

12

BS 4464......................Spring washers for general engineering and automobile purposes BS 4652......................Specifications for zinc rich priming paint BS EN 1011................Welding BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners BS EN 10210-2 ..........Hot finished structural hollow sections of non alloy and fine grain steels BS EN 10244-2 ..........Steel wire and wire products ASTM A53 ..................Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless ASTM A193 ................Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature

QCS 2014


Page 3

ASTM A240 ................Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels ASTM B108 ................Specification for Aluminium-Alloy Permanent Mould Castings ASTM B221 ................Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes ASTM D4364 ..............Practice for Performing Accelerated Outdoor Weathering of Plastics Using Concentrated Natural Sunlight ASTM Dl499 ...............Standard practice for filtered open-frame carbon-arc exposure of plastic ASTM G152................Standard practice for operating open flame carbon-arc light apparatus for exposure of non-metallic materials

.l. l

.

ASTM G153................Standard practice for operating endorsed arc light apparatus for exposure of non-metallic materials.

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ASTM G23..................Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type) With and Without Water for Exposure of Non-metallic Materials

ta

AASHTO M181...........Chain link fence

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USA Federal Salt Spray Test (Test Standard 141 Method 6061) Submittals

1

For all fencing systems, the Contractor shall submit the following for the Engineer’s approval, before an order is placed with the manufacturer:

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12.1.3

Name and address of the factories at which the required materials will be manufactured.

(b)

Technical submittals accompanied by a completed specification in the English language, catalogues and a tabulation showing the overall dimensions of each type and size of the required materials.

(c)

Programme of delivery certified by the manufacturer and supplier.

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Detailed drawings.

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(d)

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(a)

(e)

Material composition certificates.

(f)

Technical information for the materials and system.

2

The submittals shall clearly show the standard to which the material complies. All materials shall meet the requirements of the relevant BS. The Engineer may accept materials that comply to a comparable international standard if the contractor demonstrates that the standard is equivalent.

12.2

FENCING GENERALLY

1

All permanent fencing, unless otherwise designated shall be erected to present a flowing alignment both in plan and elevation following approximately the level of the finished ground along the line of the fence. The Contractor shall trim or fill the ground along the line of the fence when required. The fencing shall be neatly and effectively joined to existing fences and to other structures and parapets.

QCS 2014


Page 4

Where designated, existing fences, gates and stiles, with posts shall be carefully taken down, laid aside, removed or later re-erected. Fences, gates, stiles and posts which are to be reerected shall be handled carefully to avoid any damage.

12.3

CHAIN LINK FENCING

12.3.1

General

1

This work consists of the supply and installation of all plastic coated chain link fencing complete with all necessary hardware and appurtenances as designated and in conformity with the lines and grades directed by the Engineer.

2

All materials to be furnished and installed shall conform to all requirements of BS1722: Part 2 except as otherwise designated.

12.3.2

Materials

1

The base metal for the manufacture of posts and braces shall conform to the requirements of BS1722: Part 1, except that the carbon content of steel posts shall not be more than 0.4 % if welding is required. Posts and braces shall be galvanised in accordance with BS EN ISO 1461.

2

Fence posts and braces and gate frames shall be pipe conforming to the requirements of Table 12.1 unless otherwise designated:

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.

2

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Table 12.1 Fence posts and braces and gate frames requirements

End, Corner, Pull Posts

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Line Posts

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Location

Minimum Weight, kg/m

60.3

5.43

48.3

4.05

42.2

3.38

Posts for each side of gates shall be pipe conforming to the requirements of Table 12.2:

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Braces

Minimum O.D., mm

Table 12.2 Post dimensions for chain link fences

Gate Opening, m

Minimum O.D., mm

Minimum Weight, kg/m

1.5

60.3

5.43

4.0

73.0

8.62

4

All fence and gate posts (including all end and corner posts) shall be fitted with plastic or vinyl coated aluminium tops designed to fit securely over the posts and crowned to shed water.

5

Changes in line where the angle of deflection is 15° or more shall be considered as corners and corner posts shall be installed.

QCS 2014


Page 5

6

Extension arms, stretcher bars, and other required fittings and hardware shall be steel, malleable iron or wrought iron and shall be hot dipped galvanised. All required fittings and hardware shall be fastened to the posts in the proper manner.

7

Chain link fence fabric shall be galvanised steel fabric conforming to the BS1722: Part 1. The base metal for the fabric shall be medium high carbon hot-dip galvanised steel wire. All chain link fence fabric shall be woven into approximately 50 mm mesh such that in a vertical dimension of 600 mm along the diagonals of the openings there shall be at least 7 meshes. Between posts, chain link fabric shall be fastened to a top and bottom tension cable. The tension cable shall be 10 gauge galvanised steel.

9

Tie wires and post clips shall be at least 9 gauge galvanised steel.

10

Turnbuckles and truss tighteners shall be fabricated of steel, malleable iron, or wrought iron and shall be hot dipped galvanised. The truss tighteners shall have a strap thickness of not less than 6 mm.

11

The class of concrete for post footings shall be as designated.

12.3.3

Gates

1

Gate frames shall be constructed of not less than 42.2 mm galvanised pipe weighing

as

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ta

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.l. l

.

8

3.38 kg/m and conforming to ASTM A53. Gate frames shall be cross trussed with 9 mm

er

se

adjustable truss rods. The corners of gate frames shall be fastened together and reinforced with a malleable iron fitting designed for the purpose or by welding. All welds shall be ground smooth. Chain link fence fabric designated for the fence shall be attached to the gate frame by the use of stretcher bars and the tie wires as designated for fence construction, and suitable tension connectors shall be spaced at approximately 300 mm intervals.

3

The gates shall be hung by at least two steel or malleable iron hinges not less than 80 mm in

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2

m

width, so designed as to securely clamp to the gate post and permit the gate to be swung back against the fence. The bottom hinge shall have a socket to take the bail end of the gate frame. 4

Gates shall be provided with a combination steel or malleable iron catch and locking attachment of approved design. Stops to hold gates open and a centre rest with catch shall be provided where required.

5

All gates shall be provided with standard hardware and heavy duty padlocks with four keys each, the type and details of which shall be to the approval of the Engineer.

QCS 2014


Page 6

12.3.4

Finish to Components

1

All posts, gate frames, rails and similar materials shall have a coating thickness of 254 to 356 micron of a polyvinyl chloride (PVC) which has been chemically bonded to the metal surface with an appropriately cured primer. Final finish colour shall be as designated.

2

Chain link fence fabric shall have a vinyl coating of minimum wall thickness of 0.559 mm over the galvanised substrate. The vinyl coating shall be continuously extruded (not sprayed or dipped) over the galvanised steel wire by the thermal extrusion process under pressures to 352 kg/cm2 to ensure a dense and impervious covering free of voids, having a smooth and lustrous surface appearance. The wire shall be vinyl-clad before weaving and shall be free and flexible at all joints.

4

Colours shall be stabilised and have a light fastness that shall withstand a minimum WEATHER-O-METER exposure time of 4000 h without any deterioration in accordance with ASTM Dl499 and G23, Type E. Alternatively a sample of fencing may be subject to an

rw

.l. l

.

3

ta

exposure time of 2000 h at 85 °C humidity in a humidity oven. The sample shall exhibit no

5

qa

colour loss, cracking, peeling, blistering or other deterioration. The vinyl-clad wire shall withstand an accelerated ageing test of 2000 hours at 62 °C without

as

cracking or peeling.

The vinyl covering shall, in addition, resist attack from prolonged exposure to dilute solutions of most common mineral acids, sea water and dilute solutions of most salts and alkali.

7

The pipe resin formulation shall meet the standard ASTM D4364, minimum 5000 h

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6

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WEATHER-O-METER requirement without cracking, blistering, or loss of adhesion. The protective resin coating shall withstand an impact resistance test (Gardner Test Method) of a minimum of 1850 mm/kg. Certified abrasion resistance shall be in excess of a ten minute blast of 5.6 kg/cm2 at 305 mm at 25 °C with S230 shot at an impingement angle of 90 ° without exposing the steel substratum. It shall not support combustion and shall be self-extinguishing; and shall withstand a salt spray test (Federal Test Standard 141, Method 6061 of greater than 10,000 h with no

m

8

perceptive deterioration to coating or evidence of metal corrosion for unscored samples. For scored samples after exposure of 1000 h, under-cutting shall not exceed 5 mm. The protective resin coating shall exhibit a chemical resistance after prolonged exposure at 24 °C to fumes. 12.3.5

Construction

1

Line posts shall be spaced at not more than 3.0 m intervals, measured from centre to centre of posts, in general, in determining the post spacing, measurement will be made parallel to the slope of the natural ground, and all posts shall be placed in a vertical position, except in unusual locations where the posts shall be set perpendicular to the ground surface if so directed by the Engineer.

2

All posts shall be set in concrete footings conforming to the designated details.

QCS 2014

3


Page 7

End, corner, pull and gate posts shall be braced to the nearest line post with galvanised diagonal or horizontal braces used as compression members and galvanised 9 mm steel truss rods with turnbuckles or truss tighteners used as tension members.

4

Pull posts shall be placed at locations agreed by the Engineer. They shall be placed at 200 m intervals between posts to which the ends of the fabric are clamped or midway between such posts when the distance is greater than 40 m but less than 200 m. Chain link fabric shall be fastened on the side of the posts designated by the Engineer.

6

The fabric shall be stretched and securely fastened to the posts, and between posts the top and bottom edges of the fabric shall be fastened to the tension wires. Tension wires shall be stretched tight, the bottom tension wire shall be installed on a straight grade between posts by excavating at the high points of ground and in no case will filling of depressions be permitted.

7

The fabric shall be fastened to end, corner and gate posts tall with minimum 10 mm diameter steel stretcher bars and not less our than 3 mm by 18 mm stretcher bar bands spaced at maximum or 300 mm intervals. The fabric shall be fastened to line posts ends and tension

ta

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.l. l

.

5

qa

wires with tie wires or post clips. The fasteners shall be spaced at maximum intervals of 500 mm.

STRAINED WIRE FENCING

12.4.1

General

1

Strained wire general and dropper fences shall be as designated and they shall comply with BS 1722-2 with the following amendments.

2

This part of the specification covers the requirements for materials and workmanship for strained wire fences of the general pattern and of the dropper pattern. Droppers are defined as intermediate and vertical stiffeners between some or all of the wires that are used to maintain the spacing of the wires. The droppers are not connected to the ground.

3

Strained wire fences comprise of tensioned horizontal steel wires fixed between vertical straining posts with support angle struts and connected to intermediate posts. Posts shall be constructed of either steel or precast reinforced concrete and anchored in concrete foundations.

4

Wire dropper fencing shall be provided at locations where it is necessary to restrict the access of vehicles, and camels and wandering animals.

5

Strained wire general and dropper fences shall be of one of the types shown in Table 12.3

6

The strained wire fences shall be coded according to the type dependant on the number of line wires, whether droppers are used, material used for the posts, these type references are given in Table 12.3. The first letter indicates that it is either a general pattern or a dropper pattern strained wire fence, the second letter indicates the type of posts that are used, the numbers give an indication of the height of the fence e.g. DC90 indicates a 0.9m high fence with concrete posts and droppers.

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12.4

QCS 2014

7


Page 8

For the sake of uniformity quoted heights of those to the top wire and exclude any variation in ground clearance to the base, the third letter where present indicates the number of line wires. Table 12.3 General Characteristics of Strained Fences - Fence Types With Concrete Posts Dropper Pattern

General Pattern

Dropper Pattern

General pattern

Dropper Pattern

SC105A

DC 90 DC105A

SS90 SS105A

DS90 DS105A

SW90 SW105A

DW90 DW105A

m 0.90 1.05

No. 3 5

SC105B

SS105B

SS105B

DS105B

SW105B

DW105B

1.05

6

SC120

DC120

SS120

DS120

SW120

DW120

1.20

6

SC135A

DC135A

SS135A

DS135A

SW135A

DW135A

1.35

7

SC135B

DC135B

SS135B

DS135B

SW135B

DW135B

1.35

8

SC135C

DC135C

SS135C

DS135C

SW135C

DW135 C

1.35

9

DW180

1.80

11

DW210

2.10

16

DC210

er

Spacing between horizontal wires, from the top wires mm 330,330 250,250,230,150 250,250,230,150, 100 250,250,230,150, 150 250,250,230,150, 150,150 250,250,230,150, 150,150,100 250,225,225,150, 125,125,100,75 225,225,200,175, 175,175,150,150, 125,100 100,100,100,100, 100

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DS210

ta

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as

DS180

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DC180

With Wooden Posts

.

General Pattern

Height of Top Wire & Number of Wires

With Steel Posts

Materials

1

The sizes stated for components are the minimum requirements and it is permissible to use larger sizes except where this would adversely affect the fit of the components or where replacement parts need to match those already present.

2

Line wire shall comply with BS 4102 and shall be one of the following:

3

Zinc coated low carbon steel with a nominal wire diameter of either 4.5 or 5mm

4

Zinc coated high tensile wire with a nominal wire diameter of 3.15mm

5

Plastic coated high tensile wire having a tensile strength of 1050 N/mm2 with a Zinc coated core of 3.15mm nominal core diameter and a 4 .0mm overall diameter.

6

Stirrup wire shall comply with BS4102 and shall be of zinc coated low carbon steel with grade A plastic coated low carbon steel and should have a nominal wire core diameter of 2.5 mm.

7

Barbed wire shall comply with BS 4102, shall be zinc coated and made from either low carbon steel or high tensile steel wire.

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12.4.2

QCS 2014


Page 9

The materials, protective treatment, tolerances on size and general construction details of steel posts and struts, for strained wire fences shall comply with the requirements for chain link fences, except that components shall not be plastic coated unless specifically required under the contract documentation.

9

The materials and tolerances on precasting of all concrete components shall comply with the relevant parts of section 5.

10

The minimum concrete grade for posts shall be C25 and the minimum cement content should be 350 kg.

11

The mixing, placing and compaction of the concrete shall be as per Section 5.

12

All inserts and holes cast into precast concrete components with posts shall be adequate for the bolts or appurtenances to be fitted.

13

All holes shall be free from obstructions and accurately positioned.

14

The minimum grade of concrete to be used for posts shall be C25 and the minimum cover to embedded steel in posts shall be 50mm.

15

The dimensions of concrete fence posts and struts shall be as given in Table 12.4.

16

Posts shall be reinforced with 4 steel reinforcing bars of the size given in Table 12.4.

17

Straining posts and struts shall not be tapered.

18

The dimensions and details of the foundations shall be as shown in the contract drawings. Concrete for foundations for the bases of posts and struts shall comply with the requirement of section 5 of the specification and shall be grade C15.

19

Straining posts shall be provided with a firm bearing struts at a point within the top of the length of the string posts, measured above the ground level.

20

Straining posts shall be provided with holes for the attachment of straining fittings.

21

Where line wires are to be passed through them, struts shall be provided with either holes or slots.

22

Intermediate posts shall be tapered to 75mm x 75mm at the top and shall be holed to allow the attachment of line wires.

23

High bolt strain shall consist of bolts of 250mm overall length, not less than 9.5mm diameter with an eye at one end. They should be threaded and fitted with nuts and washers.

24

2 way eye bolt strainers shall be fitted with ring nuts. They shall be hopped and galvanised to BS EN ISO 1461. Widening brackets intended for attachment to the post shall be manufactured from mild steel flat not less than 25mm x 3mm and shall be fitted with a widening bolt 12mm minimum diameter with a friction type ferrule or ratchet winder.

25

Hair pin staples shall be of not less than 3mm diameter round wire or sectional wire of the same cross sectional area and shall have a zinc coating complying with BS EN 10244-2.

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QCS 2014

26


Page 10

Droppers shall be at least 65 mm longer than the distance between the top and bottom wires covered by them and shall be made of steel of the section not less than 0.0066 kg/m or steel wire or galvanised in accordance with BS EN ISO 1461. Table 12.4 Concrete Fence Posts and Struts Strain Posts

Reinf. Dia.

Length

m

m

mm x mm

mm

m

0.90

1.57

100 x 100

1.57

1.05

1.72

100 x 100

1.87

1.20 1.35a and b 1.35c 1.80 2.10

1.87

125 x 125

2.02

mm x mm 100 x 100 or 125 x 125 100 x 100 or 125 x 125 125 x 125

2.02

125 x 125

2.17

125 x 125

2.17 2.62 2.92

125 x 125 125 x 125 125 x 125

2.32 2.77 3.07

150 x 150 200 x 200 200 x 200

Reinf. Dia.

Length

mm

m

qa

as

Section

Reinf. Dia.

1.98

mm x mm 75 x 75 or 100 x 75 75 x 75 or 100 x 75 100 x 75

8

2.13

100 x 75

6

10 12 12

2.13 2.73 3.03

100 x 75 100 x 100 100 x 100

6 8 8

5 or 8 5 or 8 8

ta

Section

1.50

mm

6

.

Section

.l. l

Length

Struts

1.83

rw

Intermediate Posts Height

6 6

Installation

1

Droppers shall be securely fixed to all the line wires covered by them and be of sufficient strength to maintain the spacing of the line wires and spread the load between them in use.

2

The post shall be adequately braced in both directions after insertion into the wet concrete and support shall be maintained till the concrete is fully hardened.

3

Excavation for foundations for post and struts shall be of the minimum stipulated dimensions at the base of the hole.

4

When erecting fence posts the concrete shall be placed in position before the commencement of the initial set.

5

The entire foundation hole shall be filled with concrete, the use of partly backfilled holes shall not be permitted. Straining posts shall be provided at the ends and corners of changes of direction or acute variations in level and at intervals not exceeding 150m for mild steel line wire or 300m for high tensile line wire in straight lengths of fence.

6

Struts shall be provided at each straining post.

7

Where there is a change in plan direction of the fence two struts shall be provided.

8

Intermediate posts shall be provided at intervals measured centre to centre of posts not exceeding 3.5m.

9

The number of line wires shall be as given in Table 12.3.

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12.4.3

QCS 2014


Page 11

The top wire shall be secured with approximately 75mm below the top of the posts, each line wire shall be strained tightly and secured to each straining posts by either widening brackets attached to the post with fixing bolts or high bolt strainers passing through a hole in the post and secure with a nut and washer.

11

If barbed wire is specified it shall be attached to the straining posts and intermediate posts by the same method as the line wire.

12

Attachment to intermediate posts with the exception of the high tensile line wire for which stirrups are not permitted each line wire shall be secured to each intermediate posts by one of the following means;

13

A wire stirrup pass through a hole in the posts secured to the

14

a hairpin stapled post through a hole in the post and the ends twice bent over

15

A line wire pass through a hole in the post

16

Small areas of hot dipped galvanised coating damaged by welding cutting or by excessively rough treatment during the transit and erection shall be renovated either by the use of melting point zinc alloy repair rods or powders made specifically for this purpose or by the use of at least 3 coats of good quality zinc paint as per BS 4652. Sufficient material shall be applied to provide a zinc coating at least equal in thickness.

17

Droppers shall be attached after all wires have been strained and secured in position.

18

The interval between dropper and the posts or between adjacent droppers shall not exceed the following:

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10

For full length droppers 2m.

(b)

For sectional droppers, bottom wires 2m.

(c)

Top wires 2.5m.

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(a)

Where sectional droppers are used the ends of all droppers or adjacent levels of wire shall be fixed to at least one wire common to both levels.

20

When measured within 14 days of erection the settled tension in the line wire between straining posts at 100 m apart shall be at least 1.6 kN

21

The method of approximately measuring the tension shall be as described in appendix F to BS 1722-2.

12.5

PEDESTRIAN GUARD-RAIL

12.5.1

Aluminium Guard Rails

1

This Sub-section covers the requirements for the supply and installation of aluminium pedestrian guard-rails and accessories.

2

Guard-rails shall be constructed to the designated line and grade and shall not reflect any unevenness in the founding construction. Unless otherwise designated, railing posts shall be vertical. For bridges, railing shall not be placed on a span until centring or falsework has been removed, rendering the span self-supporting.

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QCS 2014


Page 12

The foundation details for the fence shall be as per the designated details and dimensions.

12.5.2

Galvanised Steel Rails

1

Galvanised steel pedestrian guard rails shall comply with the strength requirements of BS 3049 Clause ‘A’ and shall be fabricated to the dimensions shown on the drawings from hot rolled steel section and bars to BS EN 10210-2 and BS 4360, Grade 43C.

2

The following Minimum steel section thickness shall be used: : :

2.5 mm 4.0 mm

Posts - Sealed hollow sections Other sections

: :

3.0 mm 5.0 mm

.l. l

Rails - Sealed hollow section Other sections

.

3

Joints shall be welded by metal arc welding to BS EN 1011 except where shown otherwise on the drawings.

4

The guard rails and components shall be fabricated such that no burrs or sharp edges occur, that the finished work is free from distortion and cracks and that welded joints are fully bonded, form accurate fit and are finished smooth and flush with adjacent surfaces.

5

The guard rail components shall be fixed to the posts at the lower joints by 12 mm diameter, 80 mm long galvanised steel bolts with one galvanised steel washer through 40 x 40 x 6 mm cleats. End units shall be purpose made to project over the posts with a rounded end.

6

Posts shall be closed at the top with a 6 mm plate having two 12.5 mm, 25 mm long dowels welded thereto. The holding down plate at the bottom of the post shall be a minimum of 20 x 100 x 6 mm thick.

7

All steel posts shall be hot dip galvanized both inside and outside to BS EN ISO 1461. “-end of specification addition.

12.5.3

Materials and Fabrication

1

Material for cast aluminium guard-rail posts shall conform to the requirements of AASHTO M193 and ASTM B108, alloy S7A - T4 (A444 - T4).

2

Aluminium alloy extruded rail shall conform to the requirements of ASTM B221 alloy, 6061-T6 or 6351-T5 with a minimum yield strength of 2466 kg/cm2, a minimum tensile strength of 2677 kg/cm2 and an elongation of 10 % in 50 mm.

3

Stainless steel hardware for aluminium railings shall be machine bolts or cap screws conforming to ASTM A193, grade B8, Class 2.

4

Stainless steel flat washers and lock washers shall conform to the requirements of ASTM A240, Type 302.

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QCS 2014

5


Page 13

Material 12.7 mm thick or less may be cut by shearing, sawing or milling. Material over 12.7 mm thick shall be sawed or milled. Cut edges shall be true and smooth and free from excessive burrs or ragged breaks. Re-entrant cuts shall be filleted by drilling before cutting. Flame cutting will not be permitted. Material may be heated to a temperature not exceeding 240 °C for a period not exceeding 30 minutes to facilitate bending unless cold bending is required to retain the original mechanical properties of the material furnished.

6

Rivet and bolt holes shall be drilled to finished size or stub punched smaller than the nominal diameter of the fastener and reamed to size. The amount by which the diameter of a stub punched hole is smaller than that of the finished hole shall be at least one-quarter the thickness of the piece. The finished diameter of circular holes shall be not more than 7 % greater than the nominal diameter of the fastener. Slotted bolt holes to take care of expansion shall be provided as designated. Anchor-bolt holes may be up to 25 % greater

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than the nominal bolt diameter with a maximum of 12.7 mm greater than the nominal bolt diameter. Installation

1

The Contractor shall co-ordinate and space the rail posts to miss any items which may be furnished and installed under this Contract. The Contractor shall also co-ordinate and space the rail posts to miss lighting poles and any other existing obstructions.

2

Where aluminium alloys come in contact with other metals, except stainless steel, the contacting surfaces shall be thoroughly coated with an aluminium-impregnated caulking compound, or a synthetic rubber gasket may be placed between the two surfaces. Aluminium alloys shall not be placed between the two surfaces. Aluminium alloys shall not be placed in contact with copper, copper base alloys, lead or nickel.

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12.5.4

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END OF PART

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 1

13

TRAFFIC SIGNS, MARKINGS AND STUDS ................................................. 2

13.1

GENERAL ...................................................................................................... 2

13.1.1 13.1.2 13.1.3 13.1.4

Scope References Definitions for Reflective Traffic Studs Submittals

13.2

TRAFFIC SIGNS ........................................................................................... 3

13.2.1 13.2.2 13.2.3 13.2.4 13.2.5

Scope of Work Sign Foundations Traffic Sign Materials Installation Requirements for Traffic Signs Advance and far Advance Directional Signs

13.3

PAVEMENT MARKINGS ............................................................................. 10

13.3.1 13.3.2 13.3.3 13.3.4 13.3.5

Scope of Work Materials for Pavement Markings Application of Thermoplastic Performance Requirements and Testing Protection of Pavement Markings

13.4

TEMPORARY ROAD MARKING ................................................................. 14

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13.4.1 ROAD MARKING PAINT 13.4.2 ADHESIVE ROAD MARKING STRIP 13.4.3 REMOVAL OF ROAD MARKINGS

.

2 2 2 3 3 4 5 7 8 10 10 12 13 14 14 15 15

REFLECTIVE STUDS ................................................................................. 15

13.5.1 13.5.2 13.5.3 13.5.4

General Reflectors Reflectivity Installation of Reflective Studs

13.6

NON-REFLECTIVE STUDS ........................................................................ 19

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13.5

13.6.1 General 13.6.2 Materials and Manufacture 13.6.3 Installation

15 16 17 18 19 20 21

QCS 2014


Page 2

13

TRAFFIC SIGNS, MARKINGS AND STUDS

13.1

GENERAL

13.1.1

Scope

1

This Part covers the supply and installation of traffic signs (complete with posts and foundations), thermoplastic road marking, road marking paint for temporary roads and diversions, reflectorised studs and non-reflective studs.

2

Related Sections and Parts: Traffic Signals

Section 5,

Concrete

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This Section Part 16,

References

1

The following manuals and standards are referred to in this Part:

ta

13.1.2

qa

Qatar Traffic Control Manual

BS 381C .....................Colours for identification purposes

as

BS 873........................Road traffic signs

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BS 1470......................Wrought aluminium for general engineering purposes; plate sheet and strip

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BS 1474......................Wrought aluminium for general engineering purposes; bar, extruded round tubes and sections

ov

BS 1490......................Aluminium and aluminium alloy ingots for general casting purposes BS 2000, Part 58 ........Determination of softening point of bitumen (ring and ball)

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BS 3262,(Part 1) l989 .Hot applied thermoplastic road marking materials

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BS 6088 1981.............Solid glass beads for Road Marking BS EN ISO 591-1 .......Titanium dioxide pigments

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BS EN ISO 1461 ........Hot dipped galvanising ASTM A307 ................Steel anchor bolts ASTM C373 ................Standard test methods for water absorption ASTM C424 ................Test methods for crazing resistance CML 14-97..................Standard Method of test for determination of appearance, shape, dimensions and compressive strength of ceramic non-reflecting road studs. TRL Road Note 27 .....Skid resistance portable tester. 13.1.3

Definitions for Reflective Traffic Studs

1

Entrance Angle: The angle in the horizontal plane between the direction of incident light and the normal (perpendicular) to the leading edge of the stud.

QCS 2014


Page 3

Observation Angle: The angle at the reflector between observer's line of sight and the direction of the light incident on the reflector.

3

Specific Intensity (S.I.): The candle-power of the returned light at the chosen observation and entrance angles for each foot candle of illumination at the reflector on a plan perpendicular to the incident light.

13.1.4

Submittals

1

Within three weeks of acceptance of the manufacturer's tender, the Contractor shall submit for approval working drawings for signs posts and base plates. Fabrication shall not begin until approval has been given.

2

The Contractor shall submit detailed drawings of the foundations proposed for traffic signs.

3

The Contractor shall submit samples of the proposed materials for approval on request by the Engineer before delivery to Site, at his own cost.

4

The Contractor shall submit to the Engineer for approval three copies of his working drawings for all traffic sign faces both in Arabic and English. Size and style of lettering shall be as designated. No order shall be placed without written agreement of the Engineer and the Concerned Authorities.

5

Before proceeding with drilling holes for sign foundations, the Contractor shall submit to the Engineer for approval; the type of plant proposed for drilling holes, details of any temporary metal casings, proposed method of concreting and the proposed method of conduit installation.

13.2

TRAFFIC SIGNS

13.2.1

Scope of Work

1

This work shall consist of furnishing and installing road signs and posts assemblies as designated. All sign faces and lettering shall be in accordance with the Qatar Traffic Control Manual. The required post sizes for different sign sizes shall be as tabulated in the Qatar Traffic Control Manual. Where in this section of the specification the term “designated” is used, this refers to the contract drawings and the Qatar Traffic Control Manual.

2

The minimum depths and sizes for sign foundations shall be as per the requirements of the Qatar Traffic Control Manual. For each of the signs the Contractor shall submit design calculations for the proposed foundations.

3

The following documents should be specifically referred to for this work;

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4

(a)

BS 873

(b)


Permanent traffic signs shall be reflectorised or non reflectorised illuminated and shall, in respect of quality, comply with the requirements of the latest editions of; (a)

BS 873

(b)


QCS 2014


Page 4

In the case of conflict with these specifications and the above documents, the matter shall be referred to the Engineer.

6

All foundations, framing and fixings for information signs shall be suitable for local conditions. The design calculations shall be submitted to the Engineer for approval. The wind loads shall be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.

7

A positive system of identification of signs, posts and all fittings shall be adopted. The reference number of the sign together with the date of manufacture shall be indicated by selfadhesive numbers on the reverse side of the sign in the bottom left hand corner and in a consistent and readily visible position on all posts and fittings. The manufacturer's name of trademark will not be permitted on the face of the sign. It may be affixed on the back of the sign, provided approval to the size and colour of the mark has been obtained from the Engineer. Any previously marked reference number should be transferred to new signs on replacement.

8

All road signs shall be guaranteed by the Contractor against any defect in material and workmanship for a period of five years from the date of completion of the Works under the Contract. If any defect should arise due to poor material or workmanship, it shall be rectified by the Contractor.

13.2.2

Sign Foundations

1

Sign foundations shall either be reinforced concrete columns in drilled holes or shallow reinforced concrete spread footings. The dimensions and details of the foundations shall be as designated.

2

The number of anchor bolts and bolt locations and anchor bolt dimensions shall be as designated. All anchor bolts nuts and washers shall be hot dipped galvanised to BS EN ISO 1461. Any protruding parts to the bolt thread or nut shall be further protected by the application of a wax or grease impregnated tape. Any conduit cast into the foundation for cable access shall be mild steel, hot dipped galvanised after fabrication to BS EN ISO 1461. The minimum bend of conduit shall be 600 mm radius.

3

All concrete and reinforcing steel used in the sign foundations shall be of the designated grade and type and shall comply with the requirements of Section 5. Anchor bolts shall 2 comply with the requirements of ASTM A307 with a minimum tensile strength of 414 N/mm .

4

Each bolt shall be supplied with two hexagonal nuts for levelling purposes complete with washers.

5

If an obstruction is encountered whilst drilling the foundation hole the Contractor shall inform the Engineer. The Contractor may elect to bore or drill through the obstruction depending on its nature or may propose to reallocate the signs slightly to avoid the obstruction subject to the approval of the Engineer. In either case the work is deemed to be included in the scope covered by this Part.

6

The sides of excavation shall be vertical and any additional excavations carried out beyond that designated, for the particular post and sign being erected, shall be filled with concrete or granular material as directed by the Engineer.

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QCS 2014


Page 5

7

The reinforcement cage shall be securely fixed centrally about the axis of the foundation, any electrical conduit shall be securely fixed in position as designated before replacement of concrete.

8

The top of the concrete foundation shall be finished with a steel trowel to a smooth finish.

9

The top of the concrete foundation shall not extend more than 100 mm nor less than 50 mm above the finish grade level unless otherwise designated. All backfilling and compaction shall be completed before the erection of any sign on the structure.

11

All excavations shall be approved by the Engineer before the sign is erected and before backfilling with fill or concrete as designated.

13.2.3

Traffic Sign Materials

1

Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC - 1/2H, NS33/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11 swg) or from extruded aluminium plank sections to BS 1470, HE 9-WP, HE 9P or HE 30-WP or extruded aluminium alloy plank sections to BS 1474, HE 9 TE and HE 30 TF. However information signs shall be constructed in extruded aluminium planks, which will either be self-locking or rear fixing, and the aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent International standard.

2

All sign plates shall have clean, smooth edges cut to the required shape of the sign, and shall be etched and degreased to the sign sheeting manufacturer's specifications before application of the sheeting.

3

Illuminated signs shall be covered with "Super Engineering Grade" reflective sheeting.

4

Reflective signs shall be covered over the whole front face with "High Intensity" reflective sheeting. The sheeting shall be of the designated colour and shall have a manufacturer's guarantee of not less than five years. The rear faces shall be non-reflective grey and should give a similar life span to the sign face.

5

The reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in accordance with the sheeting manufacturer's instructions.

6

Sign faces shall be formed from a single piece of reflective sheeting, but if for any reason the sign face must be fabricated from more than one piece of material all joints in the material shall be overlapped by not less than 6 mm and where sheeting is applied to extruded

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10

sections it shall extend over the top and bottom edges of the sections by not less than 3 mm. No butt joints shall be permitted and in horizontal joints the overlap shall be from the top. 7

The corners of all direction signs shall be rounded to a radius of 75 mm.

8

Signs constructed of aluminium sheet shall, when recommended by the Traffic Signs Manual, be framed on all edges using hot dipped galvanised steel angle or angle-channel of equivalent section.

QCS 2014


Page 6

Signs constructed from extruded aluminium plank sections are to present the same flanged appearance on all edges of the sign by fitting an aluminium end capping to the exposed ends of the plank section on both sides of the sign.

10

Where the designated sign width requires the use of more than one length of plank section, support beams shall be provided and positioned as approved by the Engineer.

11

For plank type signs supported on two posts the plank rails and support beams shall be manufactured from one length of extruded aluminium section. One tie bar shall be fitted between the bottom two plank rails (or the plank rail and support beam) at the centre of the span between the mounting posts.

12

Where plank type signs are supported on more than two posts, and the designated sign width is wider than the plank rail and support beams, the plank rail and support beam may comprise two or three lengths provided butt joints occur at an inner post. One tie bar shall be fitted between the bottom plank rail and support beam at the centre of the span between the mounting posts.

13

All stiffening and framing shall be continuous and shall prevent the sign from twisting.

14

All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or other material approved by the Engineer and shall have a sufficient cross-sectional area to prevent failure from thermal stresses or wind pressure or such other stresses as may be designated.

15

All rivet and bolt holes shall be edge-sealed with clear lacquer after the application of the plastics sheeting.

16

Rivets shall be spaced at not more than l50 mm apart, around the outside edge of the sign plate and on cross braces the spacing shall be not more than 300 mm.

17

Any rivet brought through the sign face shall be coloured to match the sign face. Any rivet or other device fixing sign plates to their frame work shall have a protective washer of nylon or other approved insulating material inserted where they would be in contact.

18

All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates to support posts shall be manufactured from stainless steel. For plank type signs, brackets and clips shall be extruded aluminium alloy section.

19

Saddles shall be aluminium alloy or other material approved by the Engineer and shall be provided with a nylon strip or other approved insulating material.

20

There shall be full adhesion of all sheeting material including letters, symbols and borders and there shall be no air bubbles, creases or other blemishes.

21

All panels, cut-out letters, numbers, borders, symbols and back grounds on reflective sheeting shall be carefully matched for colour at the time of sign fabrication to provide uniform appearance both by day and night. The sheeting manufacturer's recommendations on colour matching methods shall be observed. Non-uniform shading or undesirable contrast between reflective sheeting on any one sign will not be accepted.

22

The edges of all applied sheeting materials including edges of all plates which make up a sign, letters, symbols and borders shall be sealed as designated by the manufacturer.

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QCS 2014


Page 7

Where required by the sheeting manufacturer the face of the sign plate shall have a coat of clear lacquer of a type designated by him.

24

The top of sign support posts shall be capped with a plastic cap.

13.2.4

Installation Requirements for Traffic Signs

1

All sign faces shall be of the designated type, colour and size.

2

Signs delivered for use in the project shall be in new and unused condition, except where otherwise designated; and shall be stored off the ground and under cover in a manner approved by the Engineer. Any sign damaged, discoloured or defaced during transportation, storage or erection shall be rejected.

3

The position and mounting height of each sign shall be as designated.

4

Designated post lengths are approximate only. When progress of the work is at the appropriate stage the Engineer will authorise the location of each sign, with the chainage and offset distance from the edge of the road pavement. The Contractor shall be responsible for determination of the exact post lengths to provide the designated vertical clearance. Field cutting of posts shall be performed by sawing. Welded posts will not be permitted.

5

All posts shall be erected vertically and where two or more posts are provided for any sign the faces of these posts shall be lined up and their deflection angle checked for compliance with this Part before concreting in.

6

For a period of 14 days after concreting in position, all posts shall be suitably braced to prevent movement. Sign faces should not be fixed to posts until after the bracing has been removed and the Engineer has inspected and approved the post stability and foundations.

7

All posts shall be of the designated type and shall be protected against corrosion by hot dip galvanising to BS EN ISO 1461.

8

Unless otherwise designated, all signs shall be erected so that the edge and face of the sign are truly vertical and the face is at an angle of 95  to the centreline; that is, facing slightly

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23

m

away from the centreline of the lane which the sign serves. Where lanes divide or are on sharp curves, the Contractor shall refer the orientation of the sign face to the Engineer for his instruction. 9

All sign supports shall be plumbed vertical.

10

The distance between the lower edge of the signs and the road surface shall be as designated.

11

Signs shall be fastened to sign supports in accordance with the designated requirements and the recommendations of the sign manufacturer to the satisfaction of the Engineer.

12

The Contractor shall at his own expense, immediately after erection and approval by the Engineer cover the sign in order to prevent misleading information being displayed. The covering shall be close weave hessian securely fixed over the face of the sign using a lacing of nylon cord so as not to damage the sign. The Contractor shall maintain such coverings in good order until receipt of the Engineer's instruction for their removal.

QCS 2014


Page 8

13

Signs shall be thoroughly cleaned immediately before being handed over. The type of detergent used shall be approved by the Engineer.

13.2.5

Advance and far Advance Directional Signs

1

The face of the sign shall be completely covered with 3M Diamond Grade or similar approved reflective material complying with the following Table 13.1A for retro-reflectivity. Table 13.1A Minimum Coefficients of Retro-Reflection 2

(b)

30° Entrance Angle

2

0.33°

0.5°

1.0°

430 350 110 45 20

300 250 75 33 15

250 200 60 25 10

80 65 20 10 4.0

0.33°

0.5°

1.0°

150 130 30 18 7

170 140 40 19 7

50 40 13 5 2.5

0.5° 35 30 10 3.5 1.5

1.0° 20 17 6 2.0 0.7

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Observation Angle

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0.2°

235 190 60 24 11

1

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White Yellow Red Green Blue

.

0.2°

as

White Yellow Red Green Blue

1

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Observation Angle

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4° Entrance Angle

ta

(a)

(c)

90° Orientation, 40° Entrance Angle

2

Observation Angle

White Yellow Red Green Blue 1

0.2° 150 125 40 15 6

0.33° 85 75 25 8 4

1

Observation (Divergence) Angle – the angle between the illumination axis and the observation axis 2 Entrance (Incidence) Angle – The angle from the illumination axis to the retroreflector axis the retroreflector axis is perpendicular to the retroreflective surface.

QCS 2014


Page 9

3

Values for screened red colour on white sheeting may be significantly lower.

2

The material also shall satisfy the requirements of the following Tables 13.1B & 13.1C with regard to colourimetric and photometric performance. Table 13.1B Chromacity factors 1

3

4

Limit Y (%)

Y

X

Y

X

Y

X

Y

Min

Max

White

.035

.305

.355

.355

.335

.375

.285

.325

40

-

Yellow

.487

.423

.545

.454

.465

.534

.427

.483

24

45

Red

.690

.310

.595

.315

.569

.341

.655

.345

3

15

Green

.030

.398

.166

.364

.286

.446

.201

.794

3

9

Blue

.078

.171

.150

.220

.210

.160

.137

.038

1

10

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.

X

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ta

Colour

2

Table 13.1C Minimum Luminance Factors Factor 0.03 0.24 0.01 0.40 0.01

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Red Yellow Blue White Green

as

Colour

All plastic sheeting shall be fixed in accordance with the sheeting manufacturer’s instructions.

4

Unless otherwise agreed by the Engineer, sign faces shall be formed from a single piece of plastic sheeting.

5

Where, with the agreement of the Engineer, more than one sheet is used the number of sheets shall be kept to a minimum.

6

Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be overlapped by not less than 6 mm. The overlap on the horizontal joints shall be from the top; but joints in plastics sheeting shall not be permitted. The number of joints shall be kept to minimum.

7

Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top and bottom edges of these sections by not less than 3mm.

8

All materials comprising the sign face, including the background, border and legends shall be carefully matched for colour at the time of sign fabrication to provide uniform appearance both by day and night. The sheeting manufacturer’s recommendations on colour matching methods shall be observed.

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Letter, numerals, symbols and borders shall be of material compatible with the sheeting to which they are applied. They shall be applied in accordance with the sheeting manufacturer’s instructions.

10

Sheeting materials including letters, numerals, symbols and borders shall be fully adhered with a pre-coated heat activated adhesive using a vacuum applicator equipped with a temperature controller and there shall be no air bubbles, creases, cracks or other blemishes. Application of the material shall be made using equipment specifically designed and manufactured for the purpose by the sheeting manufacturer and maintained according to his instructions. Where the sheeting manufacturer requires the assembly materials to be provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be applied at the time of fabrication of the sign face and shall be of a type specified or supplied by the sheeting manufacturer.

11

Details of the graphic designs, Arabic and English legends to be used on directional and certain informatory signs are given on the Contract Drawings. The Contractor shall submit design drawings detailing the proposed layout of all such signs for the approval of the Engineer prior to their manufacturer. Otherwise, the signs shall be in accordance with the specified regulatory, warning and informatory signs detailed in the Qatar Traffic Manual, Volume 1.

13.3

PAVEMENT MARKINGS

13.3.1

Scope of Work

1

This Work shall consist of the supply and application of thermoplastic road marking paint for marking of the pavement as outlined herein. It shall include the marking of the centreline, the shoulder strip or edge, the barrier lines, the cross walks and any other markings required on the pavement for the control and direction of the traffic.

2

Where designated, thermoplastic road marking paint shall be used in the construction of rumble strips and jiggle bars. In such cases the requirements of this Part will apply except that the thickness and profile of the thermoplastic will be as per the designated details.

3

The pavement markings shall be painted on the road to the dimensions and in the locations designated on the drawings as per Qatar Traffic Control Manual.

4

The Contractor shall set out the markings and obtain the Engineer's approval before beginning the work.

13.3.2

Materials for Pavement Markings

1

The material used shall conform to the superimposed type British Standard Specification for Road Marking Materials BS 3262: Part 1. Where the materials do not conform to the BS the deviations shall be clearly given in reference to the relevant tables and paragraphs of BS 3262: Part 1.

2

Ballotini shall comply with the requirements of BS 6088.

3

The material shall consist of light coloured aggregate, pigment and extender, bound together with hard wearing resins, plasticised with oil as necessary in approximately the proportions by weight as Table 13.1.

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Table 13.1 Composition of Thermoplastic Material

Composition

Aggregate

40 %

Ballotini

10 - 20 %

Pigment and Extender

20%

Binder

20 %

The Contractor shall be responsible for blending the material to ensure that the performance requirements of this part of the specification are met. This approximate composition of the material as indicated above shall include the sprayed on ballotini.

5

The grading of various ingredients shall be such that the final product, when in a molten state, can be sprayed on the surface at a nominal 1.5 mm thickness.

6

The aggregate shall consist of white silica sand, crushed calcite, calcined flint or quartz, or other approved aggregate, and the colour shall comply, with the requirements laid down in paragraph 4b of BS 3262: Part 1.

7

Ballotini incorporated in the mixture shall be reasonably spherical, and free from flaws and not less than 80 % shall be transparent glass. The grading of the ballotini shall be as stated in

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4

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BS 6088.

The pigment shall be titanium dioxide in accordance with paragraph 6a (I) of BS 3262: Part 1 and shall be not less than l0 % by weight of the mix.

9

The extender shall be whiting in accordance with paragraph 6b of Part 1 of BS 3262.

10

For yellow material sufficient suitable yellow pigment in accordance with BS 3262 shall be substituted for all or part of the titanium dioxide to comply with the performance requirements of this specification.

11

The binder shall not contain more than 5 % of resin or other acidic material. It shall consist

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8

mainly of hydrocarbon resins plasticised with mineral oil. 12

The resins used shall be of a colour at least as pale as Grade WG resin. It shall have an acid value not greater than 2, and must pass the heat stability test described below.

13

The oil used as plasticiser shall be a mineral oil with colour and viscosity as defined in paragraph 7a (ii) of BS 3262: Part 1; i.e., at least as pale as grade 4 on the P-R-S- Shellac and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 C viscosity. In addition, when heated for 16 hours at 150 C it shall not darken excessively.

14

The softening point of the binder shall be used only as a guide to quality control, and the behaviour of the thermoplastic shall be judged from the performance tests described below.

15

The viscosity of the melted binder at the spraying temperature must be such as to produce a thermoplastic mix of the required spraying properties.

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Page 12

The temperature limits imposed by BS 3262: Part 1 for materials based on resin shall not apply. Temperatures up to 220 C may be used; at these temperatures the material shall not discolour in the time required for its use. Containers shall be made of a material which does not contaminate the contents and will protect the contents from contamination.

18

The capacity of each container shall be not less than 25 kg or more than 100 kg.

19

Each container shall be clearly marked with the manufacturer's name, batch number and date of manufacture.

20

Testing for the composition of the material and the grading of the aggregate shall be carried out in accordance with the methods in BS 3262 except as modified by this part of the specification. The composition of the laid material as found on analysis shall comply with Table 13.2 & Table 13.3; Table 13.2 Proportion of Constituents

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.

17

ta

Percent by Weight

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Constituent

as

Binder

Maximum

18

22

78

82

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Aggregate, pigment and extender and ballotini

Minimum

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Table 13.3 Grading of Combined Aggregate Pigment and Extender

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Sieve (mm)

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BS

Percent by Weight Minimum

Maximum

0.850

100

-

0.600

75

95

0.300

35

65

0.075

25

35

13.3.3

Application of Thermoplastic

1

Application shall be by mobile sprayer, either hand-propelled or self-propelled.

2

The road surface shall be dry, and free of loose, detritus mud, or other extraneous matter.

3

All existing markings of more than 1 mm thick shall be removed completely before new markings are applied.

4

A tack coat should not be necessary when the thermoplastic is applied to carriageways. Where it is considered necessary to use a tack coat, this shall be rubberised type recommended by the manufacturers of the thermoplastic material.

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In addition to the ballotini included in the mix, an additional quantity of glass beads shall be sprayed on to the hot thermoplastic line at the time of application. The rate of application 2 shall be at the rate of about 0.5 kg/m .

6

The thermoplastic material shall be applied in intermittent or continuous lines of thickness 1.5 mm  0.3 mm.

7

For special lettering, arrows or symbols the material shall be applied by hand methods.

8

The finished lines shall be free from raggedness at all edges and be true in place with the road surface.

9

The upper surface shall be level, uniform and free from streaks, blisters, lumps and other defects.

13.3.4

Performance Requirements and Testing

1

The thermoplastic material shall meet the requirements of Table 13.4:

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5

Property 3

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Table 13.4 Properties of Thermoplastic Material Maximum

2.0 approx. 230 95 65 45 No Slump 45

105 25 0.3 -

Testing of thermoplastic material shall be as described below. All specimens shall be prepared by carefully heating a representative sample to a temperature of (softening point + 50 C) whilst stirring thoroughly to avoid segregation. The molten material shall be used

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Density, g/cm Open flashpoint °C Softening point (ring and ball BS 2000 Part 58), °C Luminance Luminance (Yellow) Flow resistance Flow resistance after 48 h at 40 °C Abrasive wear 9/100 revs Skid resistance

Minimum

without delay. 3

Heat Stability Luminance Test: The material shall be cast on to a suitable flat, glossy surface coated with a colourless release agent to give a slab 100 mm square by 3 mm thick. The luminance of the cast face, with reference to that of a block of magnesium oxide (luminance factor l00) shall be measured with the sample illuminated by a tungsten light source at an angle of 45  viewed at right angles by a selenium barrier layer photoelectric cell.

4

Flow Resistance Test: The material shall be cast into a conical mould having an apex angle of 60  and a vertical height of 100 mm. After cooling and setting for 24 h the cone shall be removed from the mould, placed on a flat level surface and maintained at a temperature of 23 C ± 2 C for 48 h.

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Page 14

Impact Test: A 3 mm thick coating of material shall be prepared as a screed on a Monel alloy panel 1.25 mm thick, previously coated with rubberised bitumen emulsion. The impact instrument, a 4.7 kg weight, shall be dropped vertically through 250 mm on to the surface of the panel, striking the surface with a hemispherical indentor of radius of 6 mm. The panel shall be retained by a metal block drilled to allow the indentor to strike the panel, with the depth of indentation limited to 2 mm. Five panels shall be tested and no fracture shall result from impact. A crack not longer than 2 mm will be accepted provided there is a smooth indentation in the material.

6

Abrasive Test: A 3 mm thick coating of material shall be screeded on to a Monel alloy panel and subject to wet (water lubricated) abrasion at 23 C on a Taber Model 503 standard

7

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abrasion tester using H-22 Calibrade wheels, refaced between tests. The loss in weight after two successive tests of 100 revolutions shall be recorded and the average taken as the abrasive wear. The abrasive wear shall be less than the figure in Table 13.4. Skid Resistance: A 100 mm wide line of material 1.5 mm thick shall be screeded on to a flat,

ta

level base for a minimum length of 800 mm. After cooling to ambient temperature the skid

as

qa

resistance shall be measured using the TRRL Portable Tester as described in Road Note 27. Measurements shall be made on different parts of the specimen, corrected for temperature effects, and the average recorded. Protection of Pavement Markings

1

The Contractor shall control the traffic in such a manner as to protect the freshly marked surface from damage. The traffic control shall be so arranged as to give minimum interference to the travelling public. Signs, barricades, flagmen and control devices shall be supplied by the Contractor and a system of spaced warning flags or blocks shall be used to protect the fresh marking until it has dried as required. Any lines, stripes or markings which become blurred or smeared by the traffic shall be corrected by the Contractor.

13.4

TEMPORARY ROAD MARKING

13.4.1

ROAD MARKING PAINT

1

The use of road marking paint shall be restricted to traffic diversions or for other uses as directed by the Engineer.

2

Road marking paint shall be by an approved manufacturer. It shall be suitable for applying by brush or mechanical means to cement, concrete or bituminous pavement to give a chemically stable film of uniform thickness and shall be chlorinated rubber, one pack epoxy or alkyd based.

3

White paint shall contain not less than 6 % by mass of titanium dioxide as a pigment,

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13.3.5

conforming to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1 4

Yellow paint shall be standard colour BS 381C No. 355, except where an alternative shade has been designated, and contain not less than 6 % by mass of a suitable yellow pigment.

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The paint shall be supplied fresh and ready for use in sealed containers and stored in accordance with the manufacturer's instructions. The paint shall be applied without the use of thinners or other additives.

6

Paint shall be applied at a covering rate recommended by the manufacturer and approved by the Engineer.

7

Where markings are to be reflectorised with ballotini it shall be sprayed uniformly on to the 2 wet paint film at the rate of 400-500 g/m . Ballotini shall be graded to comply with the requirements of BS 6088.

8

Road marking materials shall only be applied to surfaces which are clean and dry. Markings shall not be ragged at their edges and shall be uniform and free from streaks. Carriageway lane and edge lines shall be laid by approved mechanical means to a regular alignment.

13.4.2

ADHESIVE ROAD MARKING STRIP

1

For temporary diversions the use of self adhesive proprietary marking strips will be permitted.

2

Self adhesive proprietary road marking strips shall be of the details and dimensions shown on the drawings.

3

The strips shall have a metallic backing that peels of and shall have reflective properties by the incorporation of ballotini.

13.4.3

REMOVAL OF ROAD MARKINGS

1

Where it is necessary to remove existing thermoplastic road markings the material shall be completely removed by sand blasting or other abrasive methods.

2

Care shall be taken to avoid damaging the wearing course surface during this operation.

3

Any damage caused to the wearing course shall be made good to the satisfaction of the engineer.

4

The painting over of old road markings with black paint shall not be permitted.

13.5

REFLECTIVE STUDS

13.5.1

General

1

Reflective road markers shall be smooth, pressure moulded aluminium alloy, complying with BS 1490 with lenses to meet the performance requirements of this specification. They shall be capable of withstanding the climatic conditions of Qatar and be maintained free. A performance guarantee of five years is required.

2

The Road stud shall measure 130 mm x 115 mm x 25 mm when seated on the road surface.

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5

Exact size of the road stud shall be as designated. 3

The shaft shall be "Anti-Twist/Hot-Tite", 76 mm long.

4

The slope of the reflecting face shall be 20.

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5

The enveloping profile of the head of road studs shall be smooth and the studs shall not present any sharp edges to traffic.

6

The body of the stud shall be constructed in one integral part.

7

The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel flats, the flats on the alternative ribs being at 90  to each other to prevent rotation of the stud when located in the road surface.

8

The studs shall be constructed in aluminium alloy to BS 1490 to provide a robust and durable location for the lenses. The alloy shall have the characteristics listed in Table 13.5.

.l. l

-

0.1 13.0 0.6 0.5 0.1 0.1 0.1 0.1 0.5 Remainder

rw

Maximum (%)

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as

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Copper Silicon Iron Manganese Nickel Zinc Lead Tin Titanium Aluminium

Minimum (%)

ta

Composition

.

Table 13.5 Composition of Alloy for Road Studs

Reflective studs mechanical and physical properties shall comply with the Table 13.6 requirements:

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9

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The Contractor shall submit mill certificates for the material showing the actual composition.

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Table 13.6 Mechanical and Physical Properties of Reflective Studs

m

Mechanical Properties

0.2 proof stress test, N/m 2 Tensile Strength, N/mm . Elongation, mm

2

Physical Properties Specific gravity

Minimum 120 280 2-5 Minimum 2.65

Method of Casting

Injection

Corrosion rating

Excellent

Brinell hardness number

55 - 60

13.5.2

Reflectors

1

The reflectors shall be rectangular in shape. The rectangular reflective unit shall be firmly located into a recess within the body of the stud such that the reflective face is established at the correct orientation. A sample of the proposed reflective studs shall be submitted for the Engineer’s approval.

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Page 17

The Optical Performance (specific intensity) of each crystal reflecting surface shall not be less than the values listed in Table 13.7. Table 13.7 Optical Performance of Reflectors Observation Angle, °

0.3

0.5

1.0

2.0

Entrance Angle, °

5

10

10

15

Specific Intensity

160

100

27

3

Specific Intensity

120

72

20

2

For yellow reflectors the specific intensity shall be 50% of the value for crystal. For red and green reflectors the specific intensity shall be 20% of the value for crystal.

4

The colour limits of the reflector(s) when illuminated by CIE standard illumination A, with an entrance angle V= 0 , H= 5  L or R, and an observation angle of 0.3  shall comply with the

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3

ta

requirements given in the following paragraphs.

White (uncoloured) reflectors shall not produce a selective reflection; that is to say, the trichromatic co-ordinates X and Y of the standard illuminant A used to illuminate the reflector shall undergo a change of more than 0.91 after reflection by the reflector.

6

Red reflectors shall have chromaticity co-ordinates which lie within the area formed by the straight lines defined by the following pairs of points, 1 and 2, 2 and 3, the spectrum locus, and the line joint the ends of the spectrum locus:

er

Point 2 0.657 0.335

Point 3 0.730 0.262

Amber reflector shall have chromaticity co-ordinates which lie within the area formed by the straight lines defined by the following pairs of points, 1 and 2, 2 and 3, 3 and 4, and the spectrum locus:-

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Point 1 0.665 0.335

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Co-ordinate X Y

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5

m

Co-ordinates X Y

Point 1 0.330 0.385

Point 2 0.228 0.351

Point 3 0.321 0.493

Point 4 0.302 0.692

8

Compliance with the colorimetric requirements shall normally be verified by means of a visual comparison test. If any doubt remains after this test, compliance shall be verified by the determination of the trichromatic co-ordinates as defined in the proceedings of the 1951 meeting of the International Commission (CIE).

13.5.3

Reflectivity

1

A sample of the road stud shall be submitted by the Contractor and relevant technical information, catalogues supplied by the manufacturers shall accompany the sample.

2

The reflectivity of the stud when new shall well exceed minimum standard as laid down in BS 873 and meet typical values as shown below:

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Table 13.8 White Reflectors Tested to BS 873

Orientation

CIL Value (mod/1x)

CIL Value (mod/1x)

Typical

Minimum

5-7.5 26.5-30 59-93 100-190

2 10 15 20

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Table 13.9 Amber Reflectors Tested to BS 873

.

Observation angle 2  Entrance Angle 15  L and 15  R. Observation Angle 2  Entrance Angle 10  L and 10  R Observation Angle 0.5  Entrance Angle 10  L and 10  R Observation Angle 0.3 Entrance Angle 5  L and 5  R

Orientation

CIL Value (mod/1x)

Typical

Minimum

3-4 10-20 20-50 30-90

1.0 5.0 7.0 10.0

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ta

Observation angle 2  Entrance Angle 15  L and 15  R. Observation Angle 1  Entrance Angle 10  L and 10  R. Observation Angle 0.5  Entrance Angle 10  L and 10  R. Observation Angle 0.3  Entrance Angle 5  L and 5  R.

CIL Value (mod/1x)

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Table 13.10 Red Reflectors Tested to BS 873

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Orientation

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Observation angle 2  Entrance Angle 15  L and 15  R Observation Angle 1  Entrance Angle 10  L and 10  R Observation Angle 0.5  Entrance Angle 10  L and 10  R Observation Angle 0.3  Entrance Angle 5  L and 5  R.

CIL Value (mod/1x)

CIL Value (mod/1x)

Typical

Minimum

1.5-2.0 4.5-7 10-20 16-35

2.0 10.0 15.0 20.0

13.5.4

Installation of Reflective Studs

1

Reflective studs shall be installed and anchored to the pavement as follows: (a)

Drill a hole into the asphalt pavement to the dimensions recommended by the manufacturer. Ensure that the hole is free of dust and also the pavement surface within a radius of 200 mm of the hole is free from debris and dust.

(b)

Fill the hole to overflow with the two part epoxy adhesive of the type specified in clause 10.6.2.

QCS 2014


Page 19

(c)

Immediately after pouring the grout, the road stud shall be inserted into the hole and the reflective face aligned to the oncoming traffic. The road stud shall be firmly embedded into the ground ensuring a good bed of grouting compound under the road stud and solid fixing. Protect the installed marker until the epoxy adhesive has completely set.

(d)

Clean off any surplus grouting and protect the road stud from traffic for approximately 60 minutes.

NON-REFLECTIVE STUDS

13.6.1

General

1

Non-reflective road studs shall be ceramic and of approximately 100 mm diameter at the base, the studs shall consist of a heat-fired, vitreous ceramic base and a heat fired opaque smooth matte surface.

2

The colour of the studs shall be white unless otherwise designated. The base of the stud shall have a rough surface to ensure a good bond to the road.

3

The adhesive used for the installation of non-reflective ceramic studs shall be a two part epoxy or other material recommended by the manufacturers and tested under the climatic and traffic conditions prevalent in Qatar.

4

The non-reflective ceramic studs shall conform to the dimensions and shapes shown on the drawings and shall be installed at the location indicated on the drawings or where designated by the Engineer.

5

The studs shall be ceramic manufactured and shall consist of a heat-fired, opaque, glazed surface. The glazed surface shall not be present on the bottom of the studs which will be cemented to the road surface. The outer surface of the studs shall be smooth except for purpose of identification, and all edges exposed to traffic must be convex and the radius nearest the edge may be less. Any change in curvature shall be gradual. The bottom surface of the marker shall be of a roughness comparable to at least that of a fine grade of sandpaper, and shall be substantially free form gloss or substance that may reduce its bond to the adhesive.

6

The body of the marker shall be white.

7

Brightness will be measured with equipment conforming ASTM E97 using a Brightness Standard of 75%. The minimum weight of the marker shall be 125 grams.

8

A random sample of 5 buttons shall be subjected to the compressive load test. The average compressive strength of the 5 buttons shall not be less than 680 kg and no individual button shall have a compressive strength less than 544 kg. The button shall be centered base down, over the open end of a vertically positioned hollow metal cylinder. The cylinder shall be 25.4 mm high, with an internal diameter of 76.2 mm and a wall thickness of 6.4mm. A load necessary to break the button shall be at speed of 2.5 mm per minute to the top of the button. In the event that the bottom of the marker is dimpled, a 2 mm layer of wood shall insert between the base of the maker and the hollow cylinder. Should any of the samples tested for strength fail to comply with this specification, 10 additional samples will be tested. The failure of any one of the additional samples shall be cause for rejection of the entire lot or shipment represented by the samples.’

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13.6

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Materials and Manufacture

1

The studs shall be produced from a combination of intimately mixed clays, shales, flints, feldspars or other inorganic material which will ensure the required properties are met. All studs shall be thoroughly and evenly matured and free from defects which affect appearance or serviceability.

2

The studs shall be of uniform composition and free from surface irregularities cracks, chipping, peeling spoiling, crazing and any other physical damage. The studs shall be precast in the form of a single based spheroidal segment terminating in a rounded or squared shoulder.

3

The height of the studs above road level shall be between 18 mm and 20 mm.

4

Compliance of the studs with respect to appearance, shape, dimensions and compressive strength shall be determined in accordance with CML Method 14-97. In particular, they shall exhibit an average compressive load at failure for each sample of 5 studs of not less than 680 kg and no individual value shall be less than 544 kg. Furthermore, the water absorption shall not exceed 1.0% when tested in accordance with ASTM C373. And the glazed surface of the stud shall not craze, spell, or peel when subjected to one cycle of the Autoclave test at 250 psi when tested in accordance with ASTM C424.

5

The adhesive for reflective studs and non-reflective studs shall be a two component epoxy. Each component shall be supplied in separate clearly marked containers and the time of use the contents of the two parts shall be thoroughly redispersed by mixing. Only complete containers of each part shall be used and these shall be mixed thoroughly until a uniform colour is achieved with no streaks of individual colours. The blend of the two components of epoxy thoroughly mixed together shall meet Table 13.11.

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13.6.2

Property

Value

Gel time

5 to 30 minutes

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Table 13.11 Specification for Epoxy Adhesive

Minimum Tensile strength of 1.6 mm film between steel blocks cured 24 h at 21 °C tested at 21 °C

7 N/mm

Shore hardness on 24 h sample at 21°C

70 to 80

Shore hardness on 24 h sample at 49 °C

30 minimum

Deformation temperature, °C

49 minimum

2

6

The Contractor shall submit recent test results that confirm the above properties of the supplied adhesive are met.

7

The epoxy shall be used strictly in accordance with the manufacturer’s recommendation for storage preparation, mixing and application. Any differences from the manufacturer’s recommendations and this specification shall be referred to the Engineer.

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The final colour of the epoxy adhesive shall be uniform grey unless designated otherwise.

13.6.3

Installation

1

All sand, dirt and extraneous material shall be removed from the mark location and the surface cleaned and abraded. Cleaning shall be by compressed air. In the case of adhering material the application of heat or sand blasting will be required.

2

The surface shall be completely dry for the application of the adhesive.

3

The base of the supplied stud shall be free of any wax or grease from the manufacturing process. Any such wax or grease shall be sanded off the bottom of the marker.

4

The adhesive components shall be stored at the temperature recommended by the manufacturer both before use and during application. The two components of the adhesive shall be added to each other just before use, any unused mixed adhesive shall be discarded when catallic actions cause stiffening and reduction of workability or balls of gelled resin formed in the container.

5

The mixed adhesive shall be applied to the prepared pavement area to be covered by the marker and the stud pressed onto the adhesive so as to squeeze out a small bead of adhesive around the periphery of the stud.

6

The Contractor shall carry out a trial outside of the permanent works to establish the approximate amount of adhesive required per marker and application on the works shall be carried out to this quantity.

7

The studs shall not be fixed to the pavement where asphalt has been laid within the last 14 days unless otherwise directed by the Engineer. The studs shall be spaced and aligned as designated or as per the Qatar Traffic Control Manual. The tolerance for placing shall be not more than  10 mm.

8

Where studs are to be applied to pavement where the road is to be opened to public traffic shortly after placing, the preheating of the roadway surface to permit a rapid set is permitted. In such cases, the procedure followed shall be as recommended by the supplier of the epoxy adhesive and as approved by the Engineer.

9

On roadway sections that are not opened to public traffic no preheating of the studs or road 2 surface is required as long as the required bond strength of 12 kg/cm can be achieved in

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less than 3 h.

END OF PART

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 1

14

WORKS IN RELATION TO SERVICES ........................................................ 2

14.1

GENERAL ...................................................................................................... 2

14.1.1 14.1.2 14.1.3 14.1.4

Scope References Submittals Notification to Service Authorities & Statutory Bodies

14.2

SERVICES GENERALLY .............................................................................. 3

14.2.1 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6 14.2.7 14.2.8 14.2.9

General Safety Marking Services Location of Existing Services Protection of Services Relocation of Services Services Ducts Excavation for Ducts Bedding and Laying of Ducts

14.3

PARTICULAR REQUIREMENTS .................................................................. 8

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14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC (ENA) 14.3.2 Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC (WNA) 14.3.3 Telecom Provider 14.3.4 Qatar Petroleum (QP) and Qatar Gas 14.3.5 PWA, Storm water and Groundwater

3 4 4 5 5 6 7 7 8

8 10 10 12 13

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WORKS IN RELATION TO SERVICES

14.1

GENERAL

14.1.1

Scope

1

This Part includes the provision of new services and the seeking, protection, diversion and relocation of the existing services for the following service authorities:

General Earthworks Road Drainage

Section 1 Section 5 Section 20

General Concrete Drainage Works For Buildings

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Qatar General Electricity & Water Corporation (QGEWC) Telecom Provider Qatar Petroleum (QP) and Qatar Gas Public Works Authority (PWA) Urban Planning and Development Authority (UPDA) Local Municipality

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14

References

1

The following standards and reference documents are referred to in this Part:

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BS 1377......................Methods of tests for soils for civil engineering purposes BS 2484......................Straight concrete clayware cable covers

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BS 2782......................Methods of testing plastics.

Submittals

1

The Contractor shall prepare and submit records and sketches showing position, levels and types of each existing service including manholes, joint boxes, inspection chambers and connections. These records shall be maintained in the form of a daily diary.

2

The Contractor shall prepare and submit shop drawings for utility protection work and obtain the approval of the appropriate Authority before beginning construction.

3

Samples of proposed ducts shall be submitted to the Engineer for his approval beforehand.

4

The Contractor shall prepare and maintain up-to-date drawings for each service authority giving details of each duct laid including precise location, level, number and type, and these drawings are to be submitted to the Engineer.

5

The Contractor shall keep accurate records of the arrangement, positions and details of all works constructed by him as Record Drawings. The details, format, extent and procedures for the preparation and submission of the record drawings shall be in accordance with Section 1.

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14.1.3

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Notification to Service Authorities & Statutory Bodies

1

All works in relation to services shall be carried out by a contractor or subcontractor prequalified and approved by the concerned service authority. Proof of such approval shall be required in writing before the start of Works on the Site. The name of any subcontractor to be used shall be as designated.

2

No work concerning services will be started without having first informed and obtained approval of the concerned service authorities. Before opening the ground for any purpose, the Contractor must notify all concerned parties by issue of formal "Notice of Intent" and must obtain information by formal notice regarding the location of all services. The complete responsibility for obtaining this information rests with the Contractor. "Notices of Intent" shall be circulated to all concerned parties including those listed in Clause 11.1.1:

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Qatar General Electricity & Water Corporation (QGEWC) Telecom Provider Qatar Petroleum (QP) and Qatar Gas Public Works Authority (PWA) Urban Planning and Development Authority (UPDA) Local Municipality

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14.1.4

Prior to commencing any work on excavation in a roadway the Contractor shall obtain the approval of the Traffic Police. All excavations in a roadway shall be carried out in accordance with PWA road opening procedures.

4

Drawings and notices shall be sent in duplicate one of which shall be retained by the addressee and the other returned to the sender duly marked to show underground services. "Notice of Intent" will be given 14 days in advance of starting the proposed Works. In the event that the work is not started within eight weeks of the date of the "Notice of Intent", it will be deemed to have lapsed. A further Notice of Intent will then be submitted. The Contractor shall furnish copies of the above Notices of Intent to the Engineer.

5

The Contractor's attention is particularly drawn to the procedures to be followed concerning existing services and service diversions laid down in all current administrative orders of the service authorities.

14.2

SERVICES GENERALLY

14.2.1

General

1

The Contractor shall acquaint himself with the position of all existing services and shall obtain clearance from the concerned service authority before commencing any work in a particular area. Written evidence of such clearance shall be provided to the Engineer by the Contractor.

2

The position, types of ducts, pipes, cables, manholes and related structures are designated, but the final location will be determined on site by the Contractor and submitted to the Engineer for approval after having consulted with the concerned service authorities.

3

All concrete works shall conform to the requirements of Section 5.

4

The Contractor will be fully responsible for ensuring observance of the requirements of this clause by his subcontractors.

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Where any utility or service works are to be constructed under a separate contract by the Engineer within the Site and concurrent with the execution of the Works, the Contractor shall co-operate with the other contractor and shall co-ordinate his construction operations to avoid interference with the other contractor's operations.

6

Any public or private service for water, electricity, drainage, or other utility, affected by the Works shall not be interrupted without the written permission of the Engineer. Such permission will be withheld until suitable approved permanent or temporary alternative services have been provided by the Contractor or by the owner of the utility or his agents.

7

For temporary traffic diversions as may be required for the construction of road crossings, full liaison with the Municipality and Police shall be required as well as compliance with the requirements of the PWA road opening procedures.

8

The Contractor shall be responsible for following each service authorities inspection and testing procedures.

9

The Contractor shall be responsible for liaison with each service authority to obtain their approval for the completion of the works.

14.2.2

Safety

1

The Contractor shall be responsible for public safety during execution of work. He shall take all measures, including, where necessary, the provision of ropes, picket fences, and other temporary barriers on the sides of trenches and excavations with warning lights.

2

The Contractor shall arrange for night watchman and any other measures required to ensure the safety of the public.

3

The Contractor will be held responsible for any damage to property or injury to persons due to his negligence. Any instruction from the Engineer concerning the safety aspects of the work must be carried out immediately, but the Contractor shall remain responsible for the adequacy of the safety measures.

4

The Contractor shall take into account the current laws regarding the safety of service lines, together with any amendment or additions thereto. The Contractor shall be responsible for locating or verifying the location of existing services, liaison with the various service authorities and complying with the above.

14.2.3

Marking Services

1

All services shall be provided with continuous warning tapes with the requirements of the following paragraphs.

2

The Contractor shall install approved warning tapes during backfilling work over buried pipes, cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for identification according to the requirements of the concerned service authority.

3

Warning tape shall be approved high quality, acid and alkali-resistant polyethylene film 250 mm wide, and with a minimum thickness of 150 microns. Tape shall have a minimum

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tensile strength of 125 kg/cm2 longitudinally and 105 kg/cm2 laterally with an elongation factor of 350 %.

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Page 5

Tape shall be printed with 50 mm high black lettering, alternatively in Arabic and English. The complete wordings shall be repeated every 2 m along the tape. The colours shall be vivid, glossy and permanent with a life expectancy of 40 years. Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape relating to the top of service shall be in accordance with the requirements of the concerned service authority.

6

Warning tapes over non-metallic services shall be backed with aluminium foil to facilitate detection.

14.2.4

Location of Existing Services

1

The positions of all designated public and privately owned services have been based on the records of various service authorities and must be regarded as approximate.

2

The positions designated for existing services are for informational purposes only and do not necessarily show exact locations, depths, spacings, or the presence and location of smaller services such as house connections which are not normally designated.

3

The Contractor shall verify this information and satisfy himself as to the exact nature and position of all such apparatus. The Engineer does not guarantee the accuracy of the designated information, and no warranty is given or implied.

4

The Contractor shall verify the position of services by digging trial trenches and pits. If ducts, pipes, cables and manholes which are not designated are found, the Engineer and the concerned service authority shall be informed as soon as possible. The concerned service authority will then instruct on the action to be taken, if any.

5

The Contractor shall excavate by hand, take trial pits at regular distances and also at all road intersections to locate existing services, their number, depth and route direction. As these services are located the Contractor shall prepare record drawings indicating the aforementioned information which shall be submitted to the Engineer.

14.2.5

Protection of Services

1

The Contractor shall take any and all measures reasonably required by any public or concerned service authority for the support and full protection of all mains, pipes, cables and other apparatus during the progress of the Works, and shall construct and provide to the satisfaction of the concerned service authority, all works necessary for the prevention of damage or interruption of services.

2

The protection of the existing services shall be carried out before the earth work starts in the vicinity of the services to be protected.

3

If some services have already been protected by the various Departments, no protection will be carried out under this Contract, but such protection can be extended or upgraded as instructed by the Engineer on Site after having consulted with the concerned service authority.

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If in the execution of the Works, by reason of any subsidence caused by, or any act of neglect or default of the Contractor, any damage to any apparatus or any interruption of, or delay to, the provision of any service is caused, the Contractor shall report it to the Engineer immediately and bear and pay the cost reasonably incurred by the service authority concerned in making good such damage and shall make full compensation to the authority for any loss, sustained by reason of such interruption or delay.

5

All protected services, existing ducts found or newly laid ducts shall be marked with markers of approved of size and type as designated. The location of markers shall be as designated. No asphalt course will be laid unless the ends of the ducts or protected services have been exposed and marked with markers.

6

The Contractor shall, at all times during the progress of the works, afford facilities to properly accredited agents of any concerned service authority for access to all or any of their apparatus situated in or under the site, as may be necessary for inspecting, reporting, maintaining, removing, renewing or altering such apparatus in connection with the construction of the Works or any other purpose whatsoever.

14.2.6

Relocation of Services

1

The Contractor shall relocate certain utilities to service reservation areas as designated. This work may only include constructing necessary protective housing such as box culverts, slabs, and concrete encased sleeves in the service reservation areas for utility lines to be relocated. Or this work may include necessary protective housing as described above and, in addition, the relocation of specific utility lines to the service reservation areas.

2

In both cases the Contractor shall complete the necessary survey to establish the lines and levels, prepare shop drawings and submit them to the Engineer for his review. The Contractor shall obtain approval from the concerned service authority before commencing this work.

3

After existing services, according to the Engineer's instruction, have been exposed and if according to the opinion of the Engineer and after approval of the concerned service authorities it is found necessary to proceed with the lowering or diversion thereof, the Contractor shall proceed with the relevant excavation in co-ordination with the said authorities.

4

The Contractor shall maintain records of such excavation in a form acceptable to the Engineer. Two copies of such records shall be submitted to the Engineer on a weekly basis or as agreed with by the Engineer.

5

All materials removed shall be disposed of by the Contractor as designated.

6

When directed by the Engineer, all such excavations shall be backfilled with suitable material, placed and compacted as designated.

7

The Contractor shall place fill material and compact with care to avoid damage to the existing services. The Contractor shall be responsible for any and all damages caused by his construction operations.

8

The works relevant to the lowering of existing services will be started as soon as, according to the Engineer, all the necessary precautions have been taken to prevent any injury to person or damage to property or services.

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The excavation for lowering existing services shall be performed by hand down to the elevation indicated by the Engineer and the concerned service authority.

10

At all times the Contractor shall provide and maintain access to the adjoining properties to the satisfaction of the Engineer.

14.2.7

Services Ducts

1

Service ducts shall be provided as designated so that future services can pass through them without disturbing road construction.

2

The Contractor shall supply, unless otherwise designated, and install all the necessary service ducts required for the project. The duct material shall be as designated.

3

Road crossing ducts shall extend beyond the road or shoulder line at each side of the road as designated.

4

To prevent earth blocking the ducts, the openings at both ends are to be protected with appropriate blanking caps.

5

In general, all duct laying work is subject to the approval of the Engineer and any particular requirements of the concerned service authority.

6

The Contractor shall after completing each duct, make the necessary arrangements with the service authority for testing and acceptance of the work. As a minimum this shall involve the verification of the duct by rodding or pulling through a mandrel.

14.2.8

Excavation for Ducts

1

The trench shall be excavated to the designated width and depth.

2

When appropriate, the excavation for the road crossing and laying of ducts, concreting and related work shall only be carried out on half the width of the road at one time, the other half being left available for traffic. In this case the necessary traffic warning signs on selfsupporting tripods or cones shall be provided well ahead of the duct crossing work and all care and attention exercised to avoid risk of traffic accidents during preparation and execution of the work.

3

All trenches and other excavation shall be maintained in a dry condition and the Contractor shall arrange a suitable dewatering system for any dewatering involved, in agreement with the Engineer, to keep the working place clean and dry.

4

The sides of pits and trenches shall be vertical and adequately supported at all times. Excavations may if considered necessary be battered with a safe slope, but only with the Engineer's written permission.

5

Where ducts are laid under any area of the road construction, the bottom of the excavation shall be completed to a density of 95 % of the maximum dry density, as determined by BS

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1377 Test 13 or as otherwise approved by the Engineer. 6

Excavated material shall, if found unsuitable as defined in Part 3 of this Section, be disposed of to an approved tip and replaced with suitable material. All surplus suitable excavated material shall be used in road construction or disposed of in an approved manner.

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7

Where split ducts are required for existing services crossing the Works, hand excavation shall be carefully undertaken until the position of the service to be protected is fully exposed.

14.2.9

Bedding and Laying of Ducts

1

As soon as possible after trench excavation, ducts of the required diameter shall be laid and jointed as designated and in accordance with the manufacturer's instructions.

2

Ducts shall be laid to the designated lines and levels with the required depth of cover. Where the designated minimum cover cannot be achieved, or as otherwise directed by the Engineer, they shall be bedded and surrounded with 150 mm of grade 20 concrete.

3

Unless surrounded in concrete, ducts shall be bedded on a 150 mm thick layer of well graded

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above the duct barrel, well packed and tamped. Filling with suitable material above this level shall be free from large stones. For multiple ducts, the spaces between ducts are to be filled with compacted sand and the ducts surrounded to a depth of l50 mm above the uppermost

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layer. Trench backfill shall be compacted to the designated requirements. Ducts shall be cut by the Contractor as necessary only at right angles to their length using a saw in a simple cutting guide. The inside cut edges Shall be thoroughly rounded off or dressed before installation to prevent damage to cables drawn through the ducts.

5

In kerbed areas of new roadway duct markers shall be used. Duct marker shall be of concrete construction, in-situ or precast depending on the location, as per the designated details complete with approved abbreviation cast thereon. The finished product shall be solid in appearance, free of segregation, honeycombing broken edges and other defects.

14.3

PARTICULAR REQUIREMENTS

14.3.1

Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC (ENA)

1

All of the works associated with electricity supply shall be carried out in accordance with the latest specifications for materials, excavation and backfill, cable laying and jointing, as issued by the QGEWC (ENA). Contractors are deemed to be in possession of the latest QGEWC (ENA) specifications.

2

All QGEWC (ENA) MV, HV and EHV works shall be carried out by a Contractor or subcontractor prequalified and approved by the QGEWC (ENA). Proof of such approval shall be required in writing before the start of Works on the Site, and the name of any subcontractor to be used shall be as designated. All cable jointers to be used on the Contract shall be required to undertake and pass a trade test conducted by QGEWC (ENA).

3

The Contractor shall comply with all requirements of the Police Department for marking, lighting and protecting excavation. It is the responsibility of the Contractor to ascertain the requirements of the Police Department and to comply fully with these requirements.

4

Where carriageway works and road crossings are performed the Contractor shall provide steel plates of sufficient size and quality to permit the safe passage of traffic and the plates shall be so placed (and if necessary fixed) to permit reasonable traffic flow.

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All doorways, gates and entrances shall be kept clear with full access. Where excavations impede pedestrian access crossing boards shall be provided. Crossing boards shall be 1250 mm wide with a handrail on both sides 1 m in height and guard-rails on both sides at vehicular and pedestrian access to premises. Ducts will not be installed at entrances to premises except on the express instruction of the Engineer.

6

Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not possible, the material shall be removed from site and returned for backfilling on completion of cable laying. In cases where the excavated material is not to be used for backfilling trenches it must be removed from site on the same day as it is excavated.

7

QGEWC (ENA) will require to carry out inspections at the following stages: Completion of excavations.

(b)

Completion of bedding of trench before cable installation.

(c)

Cable installation.

(d)

Completion of surround over cables and installation of cable tiles.

(e)

Upon completion of reinstatement.

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(a)

The Contractor must not progress from one stage to the next of the above without the approval of QGEWC (ENA) and the Engineer. The Contractor shall be responsible for arranging inspections by QGEWC (ENA) to suit his programme of works.

9

Where materials are to be supplied by the Contractor, the requirements described in the following paragraphs shall apply.

10

Materials shall be ordered in accordance with the specifications issued by QGEWC (ENA).

11

For works involving the use of high voltage overhead cables Contractors shall comply with the requirements of QGEWC circular no 6.

12

Specifications and the details of the proposed supplier shall be submitted to QGEWC (ENA) for approval before a firm order being placed.

13

On delivery of materials to Qatar, QGEWC (ENA) inspectors shall be given the opportunity to inspect the materials before their use.

14

The Contractor shall supply all cables and jointing materials for the works unless expressed stated to the contrary in the contract documentation. Cleaning materials, protection tiles, warning tape, and other materials shall be supplied by the Contractor.

15

The Contractor is responsible for all liaison with QGEWC (ENA) in respect of programming the installation and commissioning of the complete electrical system. He shall ensure that QGEWC (ENA) are at all times kept informed of the current progress of the civil works on the Site and that his approved electricity supply subcontractor programs the cable laying works in the designated sequence in accordance with the approved programme.

16

The Contractor shall provide and install concrete cable tiles over all 66 kV cables. The cable tiles shall be of the designated size and form. Samples must be provided for approval by QGEWC (ENA) and the Engineer, and satisfy a test of impact strength in accordance with BS 2484.

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17

For cables of 132KV and above the measures for protection of the cable shall be as per the requirements of QGEWC.

18

Cable tiles shall be installed over all 11,000 volt cables. Cable tiles shall be manufactured from recycled polyethylene or similar with a minimum thickness of 12 mm, length 1 m, width (minimum) 24 mm, tensile strength 8.40 N/mm2 as per BS 2782, Method 320 C. The tiles shall be marked as designated. The cable tiles must be supplied complete with any pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC (ENA) and the Engineer for approval before use.

20

The Contractor shall liaise directly with QGEWC (ENA) regarding the removal of existing cables and shall not, under any circumstance, commence removal of cables until QGEWC (ENA) have verified such apparatus as being redundant.

21

Removal of cable shall only be carried out in the presence of a QGEWC (ENA) engineer.

22

The Contractor shall arrange uplift of empty cable drums from QGEWC (ENA) Stores and shall return all recovered cables neatly coiled on the drums provided.

23

Ducts are to be supplied by the Contractor. They shall be of high impact resistant PVC of internal diameter 150 mm or 100 mm as designated, minimum wall thickness 3.6 mm (for

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150 mm) or 2.4 mm (for 100 mm). Samples must be provided for approval by the Engineer

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before use.

Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC (WNA)

1

All of the works associated with water supply shall be carried out in accordance with the latest General Specifications for Main Laying Contracts and Main Laying Materials, as issued by the QGEWC (WNA) except as modified in this Part. Contractors are deemed to be in possession of the latest specifications.

2

All QGEWC (WNA) Works shall be carried out by a Contractor or subcontractor prequalified and approved by the QGEWC (WNA). Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

3

The supply of the materials required to carry out the Works shall be as designated in the contract documents. The Contractor will be responsible for the conveyance of all materials to the site of the works.

14.3.3

Telecom Provider

1

All Telecom Provider works shall be carried out strictly in accordance with the Telecom Provider Standard Specifications Telecom Provider WRK 4001 Underground Duct Laying And Associated Works. Contractors are deemed to be in possession of the latest version of the specifications.

2

All Telecom Provider works shall be carried out by a Contractor or subcontractor approved by Telecom Provider. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

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Telecom Provider will supply as 'free issue" all ducts for Road Crossings projects only. Other projects will be charged for the ducts. All other materials required for any type of project shall be supplied by the Contractor.

4

Trenches for Telecom Provider ducts through rock fill shall be lined with geotextile, complying with the requirements of Part 16, Geosynthetics.

5

The Telecom Provider specification S. 006 shall be modified as described in the following paragraphs.

6

The Supervising Officer shall mean the Civil/Cable Engineer from Telecom Provider, for the purpose of superintending the work, or, where the context permits, the representative of such officers.

7

The concrete quality classes specified in Clause 202 of the Telecom Provider specifications shall be of the comparable classes in Section 5 as designated by the Engineer.

8

Clause 105 of Telecom Provider Standard Specifications Telecom Provider WRK 4001 ‘Underground Duct Laying And Associated Works’ should be read as:

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“Backfill materials” means earth free from stone or loose earth, compacted in two equal layers above the protection dune sand, and shall not leave voids to form a water course.

105 (b)

“Sand bed and surround” means dune sand, 75 mm below, above and around the duct.

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105 (a)

The Contractor shall consult Telecom Provider not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed works, in which event the Contractor shall make all necessary arrangements with Telecom Provider to safeguard the installations.

10

The Contractor shall give at least one week's notice in writing to Telecom Provider of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by Telecom Provider. Such operations of work shall only be carried out in the presence at Telecom Provider unless notice shall be obtained in writing from Telecom Provider that they do not require to be present.

11

Telecom Provider may require work to be executed on their installations during the period of the Contract. The Contractor shall allow access to Telecom Provider’s Contractor or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of Telecom Provider and his own activities and when necessary shall amend his programme of working to suit all requirements of Telecom Provider in connection with their diversion work and shall keep the Engineer informed in writing of all arrangements made.

12

The Contractor shall locate and mark with suitable posts all Telecom Provider underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times. The Contractor shall advise Telecom Provider’s agent of any installation not found where designated, or found but not shown or found damaged or subsequently damaged.

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Qatar Petroleum (QP) and Qatar Gas

1

All of the works associated with Qatar Petroleum and Qatar Gas shall be carried out in accordance with their latest specifications except as modified in this Part. Contractors are deemed to be in possession of the latest specifications. Before beginning any work the Contractor shall approach Qatar Petroleum and Qatar Gas and obtain a copy of their latest specification relating to the Works.

2

All Qatar Petroleum and Qatar Gas Works shall be carried out by a Contractor or subcontractor prequalified and approved by Qatar Petroleum and Qatar Gas. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

3

When working near existing QP Gas/Oil facilities the following conditions shall be adhered to. All notices to be given to the Contractor shall be in writing and delivered by hand.

4

A permit to work must be obtained for all work within fifteen (15) meters distance from all boundaries of existing facilities. These permits can be obtained from QP and twenty four (24) hours notice should be given to prevent delays.

5

Mechanical or hydraulic rock breakers shall not be used adjacent to gas, oil or NGL pipelines.

6

Should jackhammers be required within two (2) meters of any buried pipelines and between any pipelines running in the same easement all round pipe protection must be provided before commencement

7

Pilot holes to locate existing lines shall be dug by hand tools only, before allowing mechanical equipment to operate within five (5) meters of a QP live gas, oil or NGL pipelines.

8

Prior to exposure of any live pipeline the Contractor shall erect a suitable and substantial barrier to prevent any damage to QP pipelines. This is particularly important where there are heavy vehicles in the vicinity and the possibility that removal of the bond for trenching operations opens up an illegal vehicle crossing.

9

When backfilling an exposed section of pipeline, naturally occurring soft dune sand shall be used and the pipeline shall be covered and re-bedded all round with 150 mm minimum of sand. The remaining height of the bund will be made up of selected desert fill with particle size not exceeding 150mm from organic material. QP engineer shall witness the backfill work, particularly the soft sand bedding operations.

10

When trenching between pipelines in the same easement, vehicle access between the pipelines must be maintained.

11

The maximum length of exposed unsupported pipeline must not exceed seven (7) meters. When it exceeds five (5) meters, a central substantial wooden support shall be installed within a minimum 10 mm thick rubber “shoe” contacting the pipe.

12

When the bund is removed from any existing line its buried route shall be clearly indicated by pegs and warnings.

13

Any damage to the pipe external protecting wrapping caused by the Contractor will be repaired in strict accordance with QP procedures at the Contractor’s cost.

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Provision of a permit-to-work by QP does not release the Contractor from obligation of obtaining relevant permits to expose or work near utilities/facilities not under QP area of responsibility. Examples – QGEWC, Telecom Provider etc.

14.3.5

PWA, Storm water and Groundwater

1

This subclause of the specification covers; stormwater and groundwater drainage, foul water drainage and treated sewage effluent systems.

2

All of the material submission, inspection & testing, preparation of record sheets, preparation of record drawings for works associated with PWA shall be carried out in accordance with the requirements of this part of the specification.

3

Where it is necessary to make a connection to an existing water service this shall be in accordance with Part 14 of this Section.

4

Works shall be in accordance with the latest PWA standard details except as modified in this Part. Contractors are deemed to be in possession of the latest standard details. Before beginning any work, the Contractor shall approach PWA and obtain a copy of their latest specification & standard details relating to the Works.

5

All work shall be carried out by a contractor or subcontractor prequalified and approved by PWA. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

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END OF PART

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 1

ROAD LIGHTING .................................................................................................... 4

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5 15.1.6

GENERAL ............................................................................................................... 4 Scope of Works 4 References 5 Approved Contractors 6 Supply of Materials 6 Programme of Work 7 Technical Requirements 7

15.2 15.2.1

APPROVAL OF EQUIPMENT ................................................................................. 7 General 7

15.3

STORAGE OF PLANT AND EQUIPMENT .............................................................. 9

15.4

SPECIAL REQUIREMENTS .................................................................................... 9

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6 15.5.7 15.5.8 15.5.9 15.5.10 15.5.11 15.5.12 15.5.13 15.5.14 15.5.15 15.5.16 15.5.17 15.5.18

HIGH MAST LIGHTING ......................................................................................... 10 General 10 High Mast Column 10 High Mast Head Frame 11 High Mast Luminaire Ring 11 Multi Core Mast Rising Cable 12 Raising and Lowering Equipment 12 Raising and Lowering Winch System 13 Finish 14 High Mast Luminaires 14 High Mast Distribution Equipment 15 Aircraft Obstruction Light 15 Earthing and Lightning Protection 16 High Mast Foundations Construction Requirements 16 High Mast General Requirements 16 High Mast Approval 17 Maintenance Requirements 17 High Mast Portable Cage for Maintenance 17 High Mast Lighting Performance 18

15.6 15.6.1 15.6.2 15.6.3 15.6.4 15.6.5 15.6.6 15.6.7 15.6.8 15.6.9

LIGHTING COLUMNS ........................................................................................... 18 General 18 Design Criteria for Columns 18 Details of Column 18 Details of Bracket 19 Doors and Base Compartments for Columns 20 Details of Base Flange Plate 20 Details of Column Foundation 21 Passively Safe Lighting Columns 21 Decorative Lighting Columns 23

15.7 15.7.1

LIGHTING UNITS .................................................................................................. 24 General 24

15.8 15.8.1

CONTROL GEAR .................................................................................................. 25 General 25

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LAMPS .................................................................................................................. 25 General 25

15.10 15.10.1 15.10.2 15.10.3 15.10.4 15.10.5 15.10.6 15.10.7 15.10.8

LIGHTING SYSTEM FOR UNDERPASSES .......................................................... 26 General 26 Vehicular Underpass 26 Pedestrian Underpass 26 Animal Underpass 26 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses 27 Underbridge or Undercrossing Lantern and Installation 28 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps 29 Underpass, Underbridge or Undercrossing Isolating Box 30

15.11 15.11.1 15.11.2 15.11.3 15.11.4 15.11.5 15.11.6 15.11.7 15.11.8 15.11.9

LED LIGHTING UNITS .......................................................................................... 30 Lighting Units 30 Lighting Performance 31 Thermal Management 32 Testing 33 In Situ Temperature Measurement Test (ISTMT) 34 Control Gear 34 LED Lamps 36 Quality Criteria for LED Lighting 37 LED manufacturers data 38

15.12 15.12.1 15.12.2 15.12.3 15.12.4

OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION ............................. 38 General 38 Sign Gantry Lantern 39 Sign Gantry Lantern Control Gear and Lamps 40 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables 41

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15.9 15.9.1

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15.13 PHOTO ELECTRIC CONTROL CELL ................................................................... 41 15.13.1 General 41

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15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS ........................................... 42 15.14.1 General 42 FEEDER PILLAR ................................................................................................... 43 General 43 Cabinet 43 Components of Feeder Pillars 44

15.16 15.16.1 15.16.2 15.16.3

ROAD LIGHTING CABLES ................................................................................... 45 Underground Cables 45 Packing of Cables 45 Insulated PVC Sheathed Circular High Temperature (85°C) 46

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15.15 15.15.1 15.15.2 15.15.3

15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES .................................. 46 15.17.1 General 46 15.17.2 Material & Quality 46 15.18 MARKER POSTS .................................................................................................. 46 15.18.1 General 46

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15.19 EARTHING ............................................................................................................ 46 15.19.1 General 46

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TESTING AND COMMISSIONING ON SITE ......................................................... 53 General 53 Electrical Tests 53 Photometric Performance Testing 54

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15.21 15.21.1 15.21.2 15.21.3

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15.20 INSTALLATION ..................................................................................................... 47 15.20.1 General Requirements 47 15.20.2 Temporary Lighting 48 15.20.3 Removal of Existing Columns 48 15.20.4 Detailed Drawing for RCC foundation 49 15.20.5 Road lighting Column/Lantern Installation 49 15.20.6 Road lighting Feeder Pillar Installation 50 15.20.7 Road lighting Cable Installation 50 15.20.8 Road Crossing Ducts 51 15.20.9 Backfilling and Re-instatement 52 15.20.10 Road lighting Cable Terminations and Testing 52 15.20.11 Electrical Power Supply 53

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15.22 RECORD DRAWINGS .......................................................................................... 55 15.22.1 General 55

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15

ROAD LIGHTING

15.1

GENERAL

15.1.1

Scope of Works

1

Work related to the road lighting installation provided for in this specification shall include the supply, installation, testing, commissioning and putting into satisfactory operation any or all of the following systems as required by the project drawings. Road lighting (L.V) cables and terminations.

(b)

Road lighting Feeder Pillar and internal associated control equipment including photocell control.

(c)

Road lighting column/lantern assemblies.

(d)

High mast lighting mast/lantern assemblies.

(e)

Roadway Lighting System control, adaptive, smart or remotely managed

(f)

Lighting network earthing, including electrical grounding.

(g)

Installation testing including lighting performance verification.

(h)

Provision of equipment technical and maintenance data.

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(a)

The Contractor shall provide the shop drawings and supporting calculations required by the specification, as well as the provision of all required supporting technical literature and samples in connection with the approval of proposed equipment.

3

The equipment supplied shall include all necessary items for a complete installation according to the specification requirements in order to provide for satisfactory operation, not withstanding errors and omission. The equipment listed in the Contract documents are, therefore, indicative and not limitative.

4

On satisfactory completion and commissioning of the lighting installation the Contractor shall be responsible for the maintenance of the whole system for a period of 400 days. This will include for the free replacement of any component or lamp that fails during that period of time. In addition, the Contractor shall be responsible for the rectification of any fault that occurs within the cabling network. As part of this rectification work no cable joints will be permitted.

5

All of the works associated with the road lighting installation shall be carried out in accordance with the "Regulations for the Lighting of Roads for Motorised Traffic" and the latest specifications issued by the PWA including The Qatar General Electricity & Water Corporation “KAHRAMAA” Regulations for the Installation of Electrical Wiring, Electrical Equipment.

6

The Contractor is deemed to be in possession of these regulations and the latest specifications.

7

The luminaire shall be suitable for connection to the low voltage single phase supply of the main network grid in The State of Qatar.

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15.1.2

References

1

The following standards and other documents are referred to in this Part: ANSI/IESNA RP-008 ..Roadway Lighting BS HD 60269-2 ..........Low Voltage Fuses. Supplementary requirements for fuses by authorized persons (fuses mainly for for industrial application) BS 302........................Specification for higher breaking load ropes BS 791........................Solid-stem calorimeter thermometers BS 1011......................Process of arc welding of carbon and carbon manganese steels BS 2484......................Straight concrete clayware cable covers BS 4343......................Plugs, socket-outlets and couplers for industrial purposes

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BS 4360......................Weldable structural steels

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BS 4533......................Luminaires

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BS 4800...................Colour chart

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BS 5467......................Cables with thermosetting insulation for electricity supply for rated voltages of up to and including 600/1000 V and up to and including 1900/3300 V BS 5489......................Road lighting

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BS 5649......................Lighting columns

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BS 5486......................Low voltage switch gear and control gear assemblies

BS 5972......................Photoelectric Control Units for Road Lighting

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BS 6121......................Mechanical Cable Glands for Elastomer and Plastic Insulated Cables BS 6141......................PVC insulated PVC sheathed circular flexible cables

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BS 6346......................PVC-insulated Cables for electricity Supply

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BS 6360......................High conductivity stranded copper shaped conductor with XLPE insulation

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BS 6622......................Cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3800 / 6600 V up to 19 000 / 33 000 V BS 6746......................Extruded black PVC over sheath

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BS 6977......................Specification for insulated flexible cables for lifts and other flexible connections BS 7430......................Code of practice for earthing BS 7671......................Requirements for electrical installations BS EN 40.................Lighting Columns BS EN 295..................Vitrified clay pipes, fittings and pipe joints for drains and sewers BS EN 1011................Welding BS EN ISO 1461 ........Hot dip galvanized coatings on iron and steel articles BS EN1559-1 ............Founding. Technical conditions of delivery. General. BS EN1559-4 ............Founding. Technical conditions of delivery. Additional requirements for aluminium alloy castings. BS EN1676.................Aluminium and aluminium alloys. Alloyed ingots for remelting BS EN 10137..............Plates and wide flats made of high yield strength structural steels

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BS EN 10210..............Hot-finished hollow sections BS EN 12767...........Passive Safety of Support Structures BS EN 60529..............Degrees of protection provided by enclosures BS EN 60898..............Miniature and moulded case circuit breakers BS EN 60947-3 ..........Air-break switches, air-break disconnectors, air-break switch disconnectors and fuse combination units for voltages up to and including 1000 V ac and 1200 V dc. BS EN 62305..............Protection against the lighting IEC 60598 ..................Luminaires for roadway lighting CIE 126-1997 ............Guidelines for minimizing sky glow.

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EN62262:2002 ..........(IEC62262:2002) Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts.

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The Qatar General Electricity & Water Corporation “KAHRAMAA” Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment.

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The Qatar Highway Design Manual (QHDM). Current edition.

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WEEE Directive (2002/96/EC). RoHS Directive (2002/95/EC).

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Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety

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Institution of Lighting Engineers (ILE), Technical Report No 7 ‘High Masts for Lighting and CCTV’

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ISO 9001, Quality Management Systems

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Institution of Electrical Engineers (IEE), Wiring Regulations

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State of Qatar, Qatar Wiring Regulations

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American Association of State Highway and Transportation Officials (AASHTO) “Roadside Design Guide” 15.1.3

Approved Contractors

1

All road lighting works shall be carried out by a contractor or sub-contractor approved by the PWA. Proof of such approval shall be required in writing prior to the works commencing on site and the name of any sub-contractor to be engaged shall be entered in appropriate forms during tender submittal.

15.1.4

Supply of Materials

1

The Contractor shall supply all the materials required to carry out the Works as specified in the Contract Documents and Drawings. No materials will be supplied by the Owner or the PWA.

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Programme of Work

1

The Contractor is responsible, with the agreement of the Engineer, for all liaisons with the respective department within PWA, in respect of programming the installation and commissioning of the complete road lighting system. In addition to the Engineer, he shall also ensure that relevant departments within the PWA are at all times kept informed of the current progress of the road lighting works on site and that his approved sub-contractor programme works are in the specified sequence in accordance with the overall approved Works programme.

15.1.6

Technical Requirements

1

All works carried out on the installation shall be in accordance with the requirements of these specifications so that their true meaning and intent are fulfilled. Minor deviations from the drawings may be made to accomplish this but no change shall be made without written approval of the Engineer and in consultation with the relevant departments within the PWA.

2

In addition to all the regulations, codes of practice and standards referred to within this specification, all the lighting and associated electrical works shall comply with the current Qatar wiring regulations and the requirements of PWA.

3

Where applicable, any associated work involving other authorities in the State of Qatar their relevant standards and specifications, as issued by them, shall be complied with.

4

All equipment and materials supplied for the project shall be manufactured in strict compliance with the latest standard of BS, IEC, EN their equivalent AASHTO or other standards and regulations specifically referred to in this specification. Here in after they are referred to as the “Standards”.

5

Acceptance tests shall conform to those referred to in the above mentioned “Standards”.

15.2

APPROVAL OF EQUIPMENT

15.2.1

General

1

All materials shall be approved by the Engineer. The Contractor shall be responsible to ensure that, where applicable, for nominated items of equipment only the type and manufacturer approved by the PWA, as detailed in their List of Approved Manufacturers are submitted for incorporation into the works. In addition, written approval must be obtained from the PWA, prior to ordering. Contractors shall note that only products with a proven record of performance, efficiency and long life will be considered for approval.

2

The Contractor shall not order any equipment for the incorporation into the Works before receipt of formal approval in writing. The approval procedure shall be as follows:

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15.1.5

(a)

The Contractor shall submit four copies of his equipment proposals to the Engineer. This submission shall be comprehensive and clearly state any manufacturer’s deviations from the specification. Manufacturer’s literature associated with the submission shall be originals and not photocopies. Specific reference to the compliance of certain specification requirements shall be identified.

(b)

The Engineer shall review this submission. The Engineer’s approval shall be as follows.

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(i)

With the Engineer’s comments and recommendations attached, a copy of the submission shall be forwarded to the departments concerned within the PWA, to obtain their approval.

(ii)

Where minor deviations exist from the specifications but do not affect the performance of the equipment or installation the Engineer’s recommendations to accept such deviations, his approval together with a copy of the submission shall be forwarded to the departments concerned within the PWA, to obtain their approval.

(iii)

Approval shall be transmitted to the Contractor in writing once the approval of the relevant departments within the PWA, has been given.

All submissions shall give clear, unambiguous details and performance data of the equipment proposed, together with all supporting calculations where necessary. Clear catalogue identification references shall be provided. Documents shall be in English.

4

The Engineer reserves the right to direct the Contractor to provide equipment of a make and type that is essential to achieve the Contract design criteria.

5

Approval of samples by the Engineer in consultation with the relevant departments within the PWA, does not in any way relieve the Contractor of his contractual obligation in respect of the suitability of the equipment or their final performance once installed, and the co-ordination with all the elements of the lighting works into a fully operational installation.

6

After receipt of equipment the Contractor shall arrange for them to be examined and approved by the Engineer’s Representative in consultation with the relevant department within the PWA, prior to installation.

7

Column and Mast Fabrication Requirements

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3

Specific Requirements for Columns

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In paved or walkways areas Enclosure plate is required. The Enclosure plate shall be cast Aluminium or Galvanized steel, comprising two removal halves per base with size matching the base plate. It shall be painted to match pole finish. Provided with backup plate to one halve of Enclosure Plate and with tapped holes to accept stainless steel screws countersunk into other half of Enclosure Plate.

The gap between base plate and top of foundation shall be grouted. Means of discharging any accumulated moisture shall be provided at the pole base and provision shall be made for adequate drainage. 9

Testing and Factory Visits The contractor shall facilitate authorised Engineer representatives, and/or their appointed representative, to examine the test and manufacturing facilities and witness manufacturing processes and sample testing related to the luminaire and associated components submitted for evaluation, at no cost to Ashghal or their appointed representative.

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Saving Energy Lamp’s Luminaire specification data sheet arrangement or each model of luminaire the manufacturer shall produce a data sheet providing a detailed and comprehensive description of the luminaires characteristics and component parts. The data sheet will contain adequate information for the reader to select and specify a particular model from the luminaire range. This will include; (a)

luminaire diagram external dimensions, weight and windage

(b)

optical arrangement (lens and reflectors types and settings)

(c)

driver type (drive current, system power consumption)

(d)

luminaire output (lm)

(e)

luminaire efficiency (lm/W)

(f)

glare rating

(g)

control and switching options (photocell, programmed stand alone, CMS, etc.)

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STORAGE OF PLANT AND EQUIPMENT

1

All plant and equipment shall be stored off the ground under weatherproof cover ready for incorporation in the works. All electrical apparatus shall be examined and cleaned before installation. All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the ingress of foreign matter. All drums with cables shall be protected from direct sunlight.

15.4

SPECIAL REQUIREMENTS

1

All notices from the Contractor shall be in writing and delivered by hand.

2

The Contractor shall consult the Engineer not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the Contractor shall make all necessary arrangements with the Engineer to safeguard the installation. It will be the Contractors responsibility to liaise with the utility authorities and to arrange for all road opening notices

3

The Contractor shall give at least one week's notice in writing to the utility authority’s Engineer of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the utility authority’s Engineer. Such operations of work shall only be carried out in the presence of the utility authority’s Engineer unless notice shall have been in writing from the utility authority’s Engineer that they do not require to be present.

4

The utility authorities may require work to be executed on their installation during the period of the Contract. The Contractor shall afford all facilities to the utility authority’s contractors or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of the utility authorities and his own activities and when necessary shall amend his programme of working to suit all requirements of the utility authorities in connection with their diversion work and shall keep the Engineer informed in writing of all arrangements made.

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15.3

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The Contractor shall locate and mark with suitable posts all the utility authority’s underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times. The Contractor shall advise the utility authority’s agent of any installation not found where shown on the Drawings, or found but not shown or found damaged or subsequently damaged.

15.5

HIGH MAST LIGHTING

15.5.1

General

1

This work shall consist of the supply, installation upon prepared foundations, connections, commissioning and putting into satisfactory service the high masts complete with the operating mechanisms, luminaire support ring or bracket, luminaries, control gear, wiring and distribution equipment.

2

The mast luminaire support ring shall be designed to provide for the appropriate distribution of lighting either in one direction or in many directions thus making it possible to concentrate the required number of luminaires on any zone and fix them rigidly in any direction desired. Prepared foundations are specified in other sections of this specification.

15.5.2

High Mast Column

1

The high mast column shall be of the height specified on the Drawings, hot dipped galvanized to BS EN ISO 1461 or BS 791 of multi-sided cross-section with a continuous taper made of formed sheet steel in accordance with BS 4360 grade 43C and electrically welded. They shall be delivered to the site in manageable sections of not greater than 12 metres and be joined by means of pressure over-lapping or slip-joints, which shall have a minimum length of 1.5 times diameter of the joint. Site welding will not be allowed.

2

The walls of the masts shall have a minimum thickness of 6mm for the base section, 5mm for the central section and 4mm for the top section. The steel used shall have tensile strength between 490 and 630 MN/sqm and minimum yield strength of 355 MN/sqm.

3

The mast cross-sections shall be so designed that once installed and fully equipped, it shall have safety factors in accordance with Technical Report No. 7 of the Institute of Lighting Engineers – London and shall be capable of withstanding wind load resulted from the wind speed provided in Section 1 Part 1 Clause 1.5.2, and blowing in the most unfavourable direction at a height of ten meters above ground level. Appropriate reinforcement shall be provided where necessary to increase the strength. Its behaviour under wind induced oscillation shall be such that it shall not fail due to fatigue and the design should ensure that these oscillations be damped to a minimum of zero.

4

The maximum deflection at the top of the mast shall not exceed 2.5% of the mast height at the minimum wind speed provided in Section 1 Part 1 Clause 1.5.2.

5

A steel flange plate of adequate thickness and free from laminations shall be welded above and below the base of the mast developing fully the strength of the section. In addition supplementary gussets shall be provided between bolt holes if deemed necessary.

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An access door shall be provided in the base of the mast of adequate dimensions to permit clear access to the back plate installed for the mounting of the circuit breaker assembly and junction box, winch, etc. The backboard shall be made of steel or other non-hydroscopic material. The door shall be completely weatherproof fitted with a hidden hinge and a heavy duty lock. The door area shall have appropriate reinforcement.

7

A stainless steel earthing 12mm diameter bolt shall be welded inside the mast near the access door and shall be complete with stainless steel washers and nuts.

15.5.3

High Mast Head Frame

1

The head frame shall be hot-dipped galvanized steel attached to the mast by means of a steel slip-fitter and secured by at least four stainless steel set screws. It shall be composed of spun aluminium or other approved weatherproof cover, housing the required number of steel cable sheaves and associated accessories for the operation and powering of the luminaire ring.

15.5.4

High Mast Luminaire Ring

1

The high mast luminaire support ring or carriage shall be constructed of hot dipped galvanized steel channel fitted with the appropriate number of luminaires, lamp gear mounting brackets, wiring chamber and mounting plate. It shall be in two halves joined by bolted flanges to permit removal from the erected mast. The luminaire shall be mounted on the luminaire rings by means of either a specially designed bracket allowing it to be swiveled in any desired direction or rigid bracket arm assembly. It shall be possible to lock each luminaire firmly in position, thus preventing any rotation or falling while moving the luminaire ring.

2

The carriage assembly shall be arranged to locate firmly against stops when in the secure position and these shall be of adequate strength to ensure that they cannot be damaged by over winding of the winch.

3

A shaped protective aesthetic canopy, designed to give a coordinated appearance of head frame with the luminaire ring, shall cover the head frame.

4

For masts fitted with a mobile luminaire ring, rollers with a centering mechanism shall be provided to ensure a perfect alignment of the luminaire ring both axially and in azimuth, while ascending or descending the mast. Rollers shall be made of water resistant non-marking composition material with oil-impregnated bronze brushings. All shafts and washers shall be stainless steel.

5

A weatherproof wiring chamber or terminal box shall be provided constructed from a corrosion resistant material or aluminium alloy and installed on the luminaire ring. It shall be equipped with the high temperature shrouded terminal blocks and neutral bar or block and shall include facilities on the luminaire ring to allow testing of luminaires while in the lowered position. The wiring chamber shall be fitted with an earthing stud accessible from inside and out for earthing connections. The housing shall be completely weatherproof.

6

The cables installed in the luminaire ring connecting each luminaire to the wiring chamber shall be factory pre-wired avoiding the need for field wiring, and shall have single core copper conductors with neoprene or cross-linked polythene or approved equivalent insulation and 2 sheath. Cables shall be either single core or 3 core 2.5mm with copper conductors and colour coding of the different phases being in conformity with the relevant cabling standards.

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Cables from the terminal box shall run in PVC duct or metal duct fixed to or within the luminaire carriage to each luminaire from the wiring chamber.

15.5.5

Multi Core Mast Rising Cable

1

The cable connecting the MCCB assembly at the base of the mast to the wiring chamber on the luminaire ring, shall be a flexible multicore copper cable with conductors and neoprene or approved equivalent high temperature resistant insulation and sheath in accordance with BS 6977.

2

The colour coding of the different phases of the cable shall conform to the relevant cable standards. Each luminaire shall have its own neutral conductor connected to the neutral bar or block.

3

The mast cable shall consist of a circular multi core cable to BS 6977 600/1000V grade. Each conductor core shall be insulated with ethylene propylene rubber (EPR) and the complete core is sheathed with heavy duty polychloroprene (PCP).

4

A multicore electrical power cable shall be provided terminating in the base compartment with a special multi-pin plug and socket coupler fitted with a guard, and at mast head connected to the wiring chamber fixed to the luminaire ring. It shall be suitable for the bending, flexible and load carrying stresses involved.

5

The cable shall be fitted with a correctly rated multi pin weatherproof plug and socket within the base compartment of the mast which will enable the cable to be disconnected before lowering the luminaire carriage. The socket must be connected to the supply side of the circuit and may either be free cable coming from the fuse box or be fixed to the fuse box in the base compartment.

6

The wiring shall be such that the plug and socket can be isolated before disconnecting.

7

The cable shall be suitably restrained to prevent its own weight from causing the terminal box to energise the lanterns.

15.5.6

Raising and Lowering Equipment

1

The pulleys located within the headframe shall be of non- corrosive cast aluminium alloy material grooved to exactly suit the steel rope and cable diameters, and fitted with stainless steel shafts. The pulleys shall be housed in a chassis integral with a sleeve, which slopes over the top of the mast and is secured axially and in azimuth. The complete chassis assembly shall be hot dipped galvanized. A guard is to be provided for the separation of the wire rope and power cable before entering in the pulley and the locating of the steel wire rope and power cables in their groves when operating either loaded or slack. An arrangement shall be provided to ensure that the electric and steel cables are separated before passing over their respective pulleys, and close fitting guides shall ensure that the cables cannot disengage the pulley during operations.

2

The luminaire carriage shall have the provision made on it for supporting and gripping the weight of the supply cable without damage of the cable sheath.

3

The luminaire ring shall be supported by 3 steel ropes coupled to 2 steel ropes and suspended from the double drum winch by means of a manufactured steel coupling unit. A divider bar shall ensure the separation of the steel ropes during raising and lowering.

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An MCCB providing overload protection shall be incorporated to stop the ring when the effort required by the winch becomes superior to the nominal load.

9

The winch shall be fitted with suitable equipment to allow the winch to stop in a safe manner, without damage to the mast finish, in the event of a supply failure to the power tool. The winding mechanism should then be capable of being operated by hand.

10

Each winch supplied shall be uniquely identified. In addition it shall have its own individual test certificate recording the safe working load. Lubrication details shall also be permanently recorded on its housing for future maintenance purposes.

15.5.8

Finish

1

All welds shall be smooth with the splatter removed and the interior and exterior surface of the mast and ring shall be cleaned by pickling or blasting and shall be free of any grease.

2

All components shall be hot dipped galvanized by total immersion in a bath of molten zinc after completion of the fabrication. No further levelling up, finishing or modifications shall be carried out after completion of the galvanizing process. The minimum thickness of zinc coating shall be 450 gm/sqm on the inside and outside surfaces of the mast and ring. The galvanizing shall conform to BS EN ISO 1461.

3

Any damage to the galvanizing shall be rectified during erection by wire brushing the affected area and treating with an approved zinc restorative. Sufficient materials shall be applied to provide a zinc coating at least equal in thickness to the galvanized layer.

4

If required by the Engineer the underside of the flange plate and internal surface of the mast to a height of 0.5m shall be given a coat of heavy duty bitumen paint prior to erection.

15.5.9

High Mast Luminaires

1

The high mast luminaire shall have a ‘cut off’ distribution. It shall be of the side entry mounting type, with toughen a flat glass protector and integral control gear suitable for the operation of either a 400W with lumens per watt rating of no less than 48,000, or 600W with lumens per watt rating of no less than 88,000, 220-240V, 50Hz. High Pressure Sodium tubular lamp of E-40 base, as defined for the contract.

2

The luminaires to be adopted shall be high performance street lighting lanterns currently used for conventional roadway lighting routes to BS 5489 or equivalent suitable for use at a mounting height of 25 or 30 metre. It shall comply with IEC 60598 or other approved equivalent norms. The body shall be made of die-cast aluminium and shall be divided into two separate compartments.

3

The first compartment of the luminaire shall house the optical system with polished and anodized pressure aluminium reflector. The second compartment shall contain the electrical accessories (control gear) cable feed terminals and side entry mounting socket. This separation shall protect the electrical accessories from the direct radiant heat emitted by the lamp. The optical compartment shall be protected by a toughened flat glass protector and shall be dust and watertight to a protection rating of IP65.

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4

The access to the optical compartment shall be by tilting the protector frame around the hinge without tools. A heat resistant gasket fitted on the frame shall ensure the tightness of the optical compartment. The accessories such as ballast, ignitor, and capacitor shall be rewired and pre-assembled by a metallic plate that is mounted and fixed into the rear compartment. Special care shall be taken to allow easy maintenance and quick replacement of the accessories and to minimise the risk of falling.

5

The cable feed terminal and the earth-screw shall be fixed to the metallic compartment, a cable holder shall be mounted near the terminals. The side entry mounting sockets should accept a 125 mm. long spigot and 50 mm diameter OR adjustable from 42 to 60 mm dia. Exterior side of both compartments should be with grey colour in finish.

15.5.10 High Mast Distribution Equipment The high mast base compartment shall be fitted with a power control and distribution assembly installed in a pre-wired weatherproof box opposite the access door inside the base of the mast.

2

The assembly shall consist of a surface mounted sheet steel weatherproof box with a cover enclosing:

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One 3-pole main 60Amp MCCB together with a neutral link for luminaire circuits. The ratings of the MCCB shall be in accordance with the QGEWC regulations and suitable to the connected load and cable.

(b)

One single pole 20 Amp MCB with neutral link for each luminaire circuit of a suitable current rating.

(c)

One-pole MCCB with neutral link connected to the incoming supply and serving a 16A250 V DIN socket outlet complete with 3-pin plug to suit the raising and lowering mechanism.

(d)

A multi-pin plug and socket outlet with guard fitted with cable outlet for connection to the multi-core electric power cable provided from the MCCB to the luminaire ring wiring chamber.

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The MCCB’s shall be de-rated and calibrated to provide over-current and short circuit protection when used in an ambient temperature of 50oC and shall have the required breaking capacity. The incoming side of the triple pole MCCB with the neutral links shall be fitted with a 4-way, line-tap type terminal block, with each terminal capable of accepting 2 x 2 35mm copper conductors.

4

The multi-pin coupler for supply to the portable raising and lowering power tool shall be connected to the MCCB via a flexible connection to ensure accessibility.

5

Where an high mast assembly supplies a ground sign lighting unit or equivalent it shall be equipped with an additional 15 Amps circuit breaker to supply the sign lighting installation. The circuit breaker shall be installed inside the mast distribution box.

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15.5.11 Aircraft Obstruction Light 1

Where required by Civil Aviation Authorities, two red luminaires within cast aluminium bodies shall be fitted at the top of each high mast attached to the movable luminaire ring with a purpose made bracket and arranged to project through the canopy.

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2

The luminaires shall be provided with a change over relay such that, in the event of lamp failure, the second lamp is automatically connected. Lamps shall be GLS Rough Service 100 watt suitable for an E.S. (E27) lampholder.

3

The obstruction lights shall be wired on a separate circuit protected by a separate SP & N circuit breaker with terminals to accept separate incoming cables.

15.5.12 Earthing and Lightning Protection All masts shall be provided with a separate system for earthing as a protection against lightning. This shall comply with BS EN 62305.

2

High masts shall be equipped with an air terminal of the correct height to provide the required zone of protection for the mast head frames and fixtures. The air terminal shall be bonded to the mast to ensure the discharge is dissipated via the earth ground terminal without damage to the steel winch ropes or electrical cables.

3

Separate earthing shall be provided for each item of control equipment within the mast assembly and connected to a central earthing point.

4

A 12mm diameter stainless steel or brass stud with nuts and washers in the base compartment connected to the main body of the mast structure shall be provided.

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15.5.13 High Mast Foundations Construction Requirements High masts shall be installed on concrete bases as detailed on the Drawings. The foundation design and construction shall be as based on the high mast manufacturers recommendations according to the ground and climatic conditions that exist at the site location. The erection of high masts and the assembly of the luminaire, head frame with raising and lowering gear shall be carried out strictly in accordance with the manufacturers’ instructions. The Contractor shall before commencement of the construction work confirm by means of structural calculations that the foundations proposed are suitable for use with the high mast installation he proposes to install. Holding down bolts and plumb adjustment nuts, washers, locknuts or nyloc nuts shall be galvanized steel or cadmium plated.

2

The holding down bolt/nuts complete with the anchor plate for casting into the foundation shall be provided by the high mast manufacturer together with a mild steel anchor bolt template with tube holes to ensure correct vertical and precision made horizontal bolt alignment.

3

The anchor bolts shall be of guaranteed performance high tensile steel.

4

All buried external surface of the high mast foundation shall be protected by brush painted tanking membrane and hard board protection.

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15.5.14 High Mast General Requirements 1

Final setting and adjustment of the luminaires shall only be carried out after all the masts along a route, junction or interchange are complete and operational.

2

Each high mast metal work shall be bonded to a separate earth rod as indicated on the Drawings and also to the separate earthing cable connected to the distribution system earth bar.

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The high mast shall be of specified height carrying luminaires as indicated on the Drawings. Each luminaire shall be fitted with the specific lamp or lamps arranged to be separately oriented to give the correct illumination at designated locations along the road surfaces.

15.5.15 High Mast Approval For the approval of the Engineer before manufacturing commences the Contractor shall submit detailed calculations and supporting data to show that the mast meets the design criteria detailed and shall include the following information: The deflection at the top of the mast at the designed wind speed.

(b)

The neutral frequency of the mast.

(c)

The critical wind speed for resonance.

(d)

The damping characteristics of the mast.

(e)

The steel stressed under resonant conditions.

(f)

The acceleration at the top of the mast under resonant conditions.

(g)

Welding procedure.

(h)

Procedure to ensuring that the flange plate is not laminated.

(i)

Details of the joints between the mast sections and between the bottom section and the flange.

(j)

Details of the base compartment with the method of reinforcement at the door area and means adopted for making the door weather and tamperproof.

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15.5.16 Maintenance Requirements

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The following items must be provided for the Engineer at the time of the commissioning of any high mast assembly: Power tools – 1 No.

(b)

‘L’ hooks – 6 No.

(c)

Operating handles – 2 No. Foundation Bolt/Nut and Head frame Nut/Bolt Spanners – 2 No. Sets.

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15.5.17 High Mast Portable Cage for Maintenance 1

The high mast system shall incorporate a mobile luminaire ring such that it is suitable for utilising a purpose made portable cage for maintenance purposes.

2

The cage shall be obtained from the high mast supplier and shall be capable of carrying two persons plus servicing equipment.

3

A safety system shall be provided for use with the cage according to the manufacturer’s recommendations. One safety cage per project shall be allowed within the pricing structure offered by the Contractor for the future use of the Engineer.

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15.5.18 High Mast Lighting Performance 1

The Contractor must provide guaranteed lighting performance data as part of his technical submission to confirm the minimum light values that will be maintained at each location and where specifically identified by the Engineer or representatives from the relevant departments within the PWA.

2

The minimum light levels that must be obtained shall be: Horizontal illumination Diversity Factor (Ave/Min)

30 LUX 4:1

LIGHTING COLUMNS

15.6.1

General

1

All columns and brackets shall be produced by ISO 9001 certificated lighting column manufacturers registered and certified for the manufacture, supply and certification of lighting columns under their quality assessment schedule.

2

All columns of the same mounting height and with the same arrangement shall be identical in construction.

3

Road lighting columns shall be hot dip galvanized steel, octagonal, multisided, tubular and stepped shape, of height as detailed in the Contract specification and drawings, complete with bracket of outreach, number of arms and of shape all again as detailed in the Contract specification or on the drawings.

15.6.2

Design Criteria for Columns

1

For all columns and masts the stress and deflection calculations shall be based on the maximum bracket and luminaire projection, on the bracket arm, with projected area, length and weight as designated.

2

In still air conditions, loaded with the designated luminaire positioned in any of the variable locations, there shall be no appreciable deflection of the column.

3

The maximum permissible deflection in the column or mast shall be 1° in any 1m length with

4

Columns must be designed to withstand the wind force.

5

The "K" factor for columns over 8 m in height shall be 2.2.

6

Columns shall be designed to support lanterns with the data given by the Engineer.

15.6.3

Details of Column

1

The column shall be made from hollow sections to BS EN 10210 in steel to BS 7613 grade 43C or any approved equivalent norms. The hollow sections shall have a minimum tensile strength of 430 N/mm² and minimum yield strength of 255N/mm².

2

Columns shall be in one piece tubular (round), stepped shape or multi-sided sheet steel and be of the flanged (bolted) type.

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Columns should be designed in accordance with BS 5649 in steel and finished with hot dip galvanized internally and externally with no other treatment in accordance with BS EN ISO 1461 or equivalent.

4

The jointing of the column shall be carried out by reducing the diameter of the base section to form an interface fit with the bore of the upper section. The upper section shall be heated and pushed over the lower section. The thermal shrinkage shall ensure a complete bond over the full area of the joint and develop the full strength of column at the transition. The final operation is to weld the lower section to the upper section and dress the weld to a smooth profile. Welding shall be carried out in accordance with BS 1011.

5

Strengthening shall be provided at the door opening. Care shall be taken to ensure that rounded edges are provided at the corners of the door opening to avoid stress concentrations.

6

The top of the column should be designed and provided as suitable to fix the bracket arm collar with the top of the column as shown in the Contract drawings.

7

All dimensions for the column shall be in accordance with the latest requirements of the PWA, and, if applicable, as detailed on the drawings. Modifications to suit the particular foundation/support details proposed by the manufacturer shall be submitted to the Engineer for approval prior to incorporation.

15.6.4

Details of Bracket

1

Brackets shall be formed of hollow sections to BS EN 10210 in steel to BS EN 10137 Grade 43C or equivalent.

2

The column bracket arms and spigots shall be so designed that when assembled with the shaft the design altitude of the arm and projection shall be as detailed in the contract requirements.

3

Welding on bracket arm shall be carried out in accordance with BS EN 1011.

4

Brackets shall be hot dip galvanized to BS EN ISO 1461 or equivalent. The bracket arm shall be so designed that when assembled on the column shaft the altitude of the arm and spigot shall be 5° above the horizontal unless otherwise stated in the Contract documents.

5

Length of the luminaire fixing spigot unless otherwise designated to suit the luminaire shall be 150mm, outside diameter of spigot shall be 42mm, thickness shall, be 4mm.

6

The securing arrangement of the bracket arm to the column shall be positive so as to ensure that the arm does not rotate and shall be such that the bracket can be fixed in any of four 90 degree positions in relation to the column door opening. 8 No. socket set screws of size M10 x 16mm or approved equivalent arrangement shall fix the bracket onto the columns using stainless steel screws.

7

The luminaire shall be securely fixed to the mounting post or bracket by means of a clamping system that will prevent movement in high winds. All component parts shall be manufactured from non-corrosive materials.

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Doors and Base Compartments for Columns

1

Each column and mast shaft shall have a base compartment large enough to offer easy access to the equipment therein.

2

The weatherproof door provided for each opening which shall be interchangeable between columns of the same mounting height. To avoid accidental spillage of water from irrigation of flooding the bottom of the door shall be at least 0.5m above the top of the foundation.

3

A stainless steel durable non-corroding tamper-proof lock device shall be provided of the triangular headed screw type, unless designated otherwise. Where applicable, door lock recess shall incorporate adequate drainage such that they are unlikely to become blocked and so form a water trap.

4

Door openings are to be kept to the minimum size consistent with the cable termination units and any control gear.

5

When installing lighting columns on a single carriageway the column doors shall be located at 90° to the kerb line and in such a location that the maintenance operative faces the oncoming traffic and to ensure that the door can be opened at all times without encroaching onto the highway. In the case of installing lighting columns within the central median the column door shall be located perpendicular to the road such that the maintenance operative will be facing across the line of the carriageway. The door openings shall be free from any irregularities and burrs.

6

Keys are to be provided with the first consignment of columns at the rate of 10 % of the total number of columns.

7

A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely fixed in each compartment and shall be of sufficient size to accommodate the cable termination unit.

8

Single purpose earth terminals shall be provided in a readily accessible position, preferably on the left hand side of the opening and on the column door.

9

The baseboard shall be fixed using brass or stainless steel nut and bolt arrangement.

10

All door lock hinges and catches shall be greased before handover.

15.6.6

Details of Base Flange Plate

1

The base flange plate shall be manufactured from steel plate that is free from laminations. The main shaft of the pole shall penetrate the full depth of the base plate and is to be welded above and below using a semi automatic MIG shielded arc process. Additional strength shall be provided by gusset plates located between hole positions.

2

4 No. slots allowing for adjustment shall be provided in the flange plate of suitable size so as to accommodate the foundation bolt specified to fix the column on the RCC foundation.

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15.6.5

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Details of Column Foundation

1

The manufacturer of the road lighting column shall submit the dimensions and specification of his proposed foundation including the steel reinforcement details to the Engineer for approval.

2

The foundation shall accommodate 4 No. holding down bolts of size 25mm x 800mm for columns up to 10 metres high and 33mm x 900mm for 12 and 16 metres high columns, supplied with two nuts and two washers to each bolt.

3

Foundations shall be constructed such that they avoid being a hazard to pedestrians and bicyclists on footways and shared use paths. The top surface of concrete column foundations on pathways shall not be higher than ground level, and shall not be higher than 50 mm above ground level on all other surfaces.

15.6.8

Passively Safe Lighting Columns

1

Design Criteria

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15.6.7

All Passively Safe lighting Columns shall comply with BS EN 12767 – Passive safety of support structures for road equipment – requirements, classification and test methods, 2007 or all road lighting columns within the clear zone (as AASHTO Roadside Design Guide Table 3.1 or Chapter 10 Roadside Safety Urban or Restricted Environments) shall be protected by an approved barrier system.

(b)

Each Passively Safe Lighting Column shall be anodized aluminium or galvanized steel as specified in the Contract Documents. Design of aluminium columns shall comply with BS EN 40, Part 6 and its incorporated references. Design of steel columns shall comply with BS EN 40, Part 5 and its incorporated references.

(c)

In addition to section 15.6.2-1 the passively safe columns in still air conditions, loaded with the designated luminaire positioned in any of the variable locations, there shall be no appreciable deflection of the column. The maximum permissible deflection for passively safe poles shall not exceed 4% of the total length of the pole when furnished with bracket arm, and 2% of the total length of pole with no bracket arm. Columns must be designed to withstand a base wind speed of 30 metres/second. Columns shall be designed to support lanterns with the data given by the Engineer.

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(a)

(d)

Per BS EN 12767, Annex F, passively safe tubular hollow section steel or aluminium posts provided shall have a nominal diameter less than or equal to 89 mm, and a nominal wall thickness of 3.2 mm. Where steel poles are specified in the Contract Documents, steel grade S355J2H shall be provided.

(e)

Aluminium columns shall be finish coated with an anodized aluminium finish providing resistance to fading, peeling, cracking or corrosion. The guarantee provided by the manufacturer shall be a minimum of 10 years against fading, peeling, cracking or corrosion of the finish.

(f)

The maximum mass of combined luminaire support and fixtures attached to breakaway supports shall be limited to 450 kg and the maximum column height shall not exceed 18.0 metres.

(g)

Where slopes are greater than 6:1, no passively safe support shall be used without the approval of the Engineer. Passively safe supports shall not be used on any columns mounted on median barriers, concrete or otherwise. No slip base mechanisms may be used on Qatar roadways.

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Columns shall be certified by the manufacturer to comply with BS EN 12767 and shall achieve the Passive Safety Performance Classes as indicated in Table 15.1. Table 15.1 – Passive Safety Performance Classes

Pole Support Requirement Roadway Posted Speed

CBD Other

100:HE:1-3 100:NE:1-3

CBD – Central Business District

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Term Descriptions

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Where columns may fall on other carriageways below (i.e. flyovers).

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(a) 70:HE:1-3 (b) 100:HE:1-3 (c) 70:LE:1-3 (d) 100:LE:1-3

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≤ 40 kph

˃ 40 kph

Impact Speed Class*/ Energy Absorbing Type / Occupant Safety Level**

Location

100:HE:1-3

HE – High Energy Absorbing LE – Low Energy Absorbing NE – Non-Energy Absorbing

Certification of breakaway support shall be collected from the manufacturer and submitted for Engineer approval prior to procurement. Certification documentation shall confirm the Impact Speed Class, Energy Absorbing Type and Occupant Safety Level of the supplied luminaires.

The column shall be rated to support Cloth Banners up to the length, width and height as required in the Contract Documents. Each column shall be provided with a 240V earthed outlet rated for outdoor conditions in compliance with Section 21 Part 10.2.2 herein.

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* Poles shall be procured in order of class per availability from the manufacturer. ** The Occupant Safety Level (OSL) provides for increasing levels of safety by reducing impact severity. The preferred level of safety is OSL 3 and shall be procured as first choice when available from the manufacturer.

(b)

3

When required by the provisions of the Contract Documents, all poles, whether aluminium or steel in type, shall be supplied with a frangible element or breakaway base tested and certified to provide passive safety elements as to be in compliance with BS EN 12767, with special attention to National Annex (informative) to BS EN 12767:2007.

Lighting System Requirements (a)

Work related to the Passively Safe Lighting Column installation provided for in this specification shall include the supply, installation, testing, commissioning and putting into satisfactory operation all systems as required by the Contract Documents and the Specification.

(b)

Electrical connections for lighting columns shall be quick disconnect type at ground level, such that they provide for electrical isolation within 0.4 seconds upon impact of the lighting pole, and be furnished as required by BS EN 12767:2007 NA.8.

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(c)

Prior to procurement, the Contractor shall provide shop drawings and supporting calculations required by the Specification, as well as the provision of all required supporting technical literature and samples in connection with the acceptance of proposed equipment approved by Ashghal’s authorized representative.

(d)

Due to the long lead times of such equipment, the Contractor shall order the poles within 1 week of shop drawing approval. The equipment supplied shall include all necessary items for a complete installation in accordance with the Specification and other Contract Documents in order to provide for specified luminaire operation.

(e)

Contractor shall provide all necessary accessories, wiring and equipment from lamp to base, feeder pillar to last luminaire, to complete a functional lighting system regardless of their inclusion in the Contract Documents.

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Lighting Columns (i)

The Passively Safe Lighting Columns shall be procured from an Ashghalapproved manufacturer. The manufacturer shall submit no less than three references for contact on past performance, supplying previous installed contract’s contact person, title, agency or company name, phone number and e-mail address to Ashghal Design’s and Ashghal Operation and Maintenance’s authorized representatives as part of the approval process.

(ii)

Columns shall be constructed with their anchor bolts at no more than 100 mm above ground level. Anchor bolts furnished with the column support shall be galvanized steel or stainless steel in type.

Luminaire

(c)

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Each luminaire fitted on the Passively Safe Lighting Columns shall meet all illumination requirements set forth by Ashghal and the photometric specifics as outlined in the Contract Drawings.

Foundations

Contractor shall submit the dimensions and specification of proposed foundations for support of the Passively Safe Lighting Columns. Drawings and specifications shall be prepared and sealed by a licensed structural engineer. The structural engineer shall provide certification that the proposed foundation design supports the performance of the breakaway mechanism, and is designed properly to prevent movement or rotation in the surrounding soil.

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15.6.9

Decorative Lighting Columns

1

Decorative lighting systems are non-standard, themed luminaire and pole styles. The luminaires range from ornate globes known as acorns to four-sided glass fixtures having a distinct character. The luminaires are mounted on the decorative lighting columns in a postmounted arrangement or with a bracket arm. The Contractor shall coordinate final decorative lighting column and foundation placement with the Engineer to avoid problems related to the placement of trees, other street furniture and underground utilities.

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Each Decorative Lighting Column shall be anodized aluminium or galvanized steel as specified in the Contract Documents. Design of aluminium columns shall comply with BS EN 40, Part 6 and its incorporated references. Design of steel columns shall comply with BS EN 40, Part 5 and its incorporated references. Galvanized steel columns shall be supplied with aluminium cladding sufficient to provide the decorative features when detailed as such in the Contract Documents.

3

Galvanized steel columns shall be supplied with aluminium cladding sufficient to provide decorative features when detailed as such in the Contract Documents.

15.7

LIGHTING UNITS

15.7.1

General

1

Road lighting luminaires (light fitting) shall be semi cut-off or cut off and side entry mounting type complete with bowl and integral control gear of rating 100W, 150W, 250W, or 400W, 220-240V, 50Hz as specified in 15.9.

2

All types of lamps shall be energy saving lamps (LED (light emitting diode), Induction lamps) manufactured according to International Electrotechnical Commission IEC or International Standards, and accepted or approved by Qatar Standards.

3

The luminaires for roadway lighting shall be to IEC 60598 and shall be capable of achieving the lighting performance specification requirements set out in the Contract specification in accordance with BS 5489 , EN 13201 and ANSI/IESNA RP-008 at the mounting heights identified within the Contract.

4

Luminaires shall be side entry mounting and semi cut-off or cut off type with integral control gear for use with either 1x 100W, 1x 150W or 1 x 250W, 220- 240V, 50Hz, high pressure sodium tubular lamp of E-40 base. The E-40 lamp shall have a porcelain skin. The lamp supports shall ensure that the lamp position in respect of the optical system remains fixed throughout its operation. The body shall be made of die cast aluminium and shall be divided into two compartments. The first compartment shall house the optical system with a pressed high purity one piece aluminium reflector that is anodized and polished. The positioning of the reflector shall be such that should it nsslished. Tt lector

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The accessories such as ballasts, starters, capacitors etc., shall be pre-wired and preassembled in the rear compartment on a detachable metallic gear tray fixed securely to the main body of the luminaire in such a way as to ensure effective earth continuity.

6

Special care shall be taken to allow easy maintenance and quick replacement of the accessories and to minimise the risk of falling.

7

The incoming cable feed terminal block and the earth-screw shall be fixed to either the gear tray or metallic compartment. A cable restraining device shall be mounted near the incoming terminal block. All metal parts shall be effectively earthed to the luminaire earth-screw that shall be readily visible and accessible once access is obtained to the rear compartment. The spigot entry socket of the luminaire shall be compatible with the column bracket and able to accept a 125mm long by 50mm diameter or adjustable from 42mm to 60mm diameter spigot.

15.8

CONTROL GEAR

15.8.1

General

1

All items of control gear shall be fitted with shrouds over all terminals to prevent accidental contact during lamp replacement or routine equipment maintenance. All control gear shall have a clearly marked circuit diagram to show its terminal connections in relation to all other components. Control gear (choke, capacitor, ignitor etc.) shall be suitable to withstand temperatures up to 86°C and shall have a purpose made earth terminal. Internal connections shall be with heat resistant non-hydroscopic insulated stranded copper conductors, cleated and with porcelain connectors.

2

Ballast (choke) shall be closed type polyester filled can. It shall be suitable for single phase voltage operation and silent in operation. All tappings shall be brought to suitably marked standard terminals to which the lamp and supply connections shall be made.

3

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of + or – 10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the capacitor when fitted. Where the capacitor has an aluminium body it shall be provided with a separate earth terminal.

4

Ignitors shall be mounted within the control gear compartment of the luminaire. Each ignitor shall be fitted with a device that will detect the presence of a faulty lamp and automatically limit the generation of HV pulses. The ignitors shall be suitable for use with the lamp, ballast and power factor correction capacitor included within the control gear circuit.

15.9

LAMPS

15.9.1

General

1

Lamps shall be energy saving lamps with clear tubular hard glass envelope with E-40 base suitable for use on 220 - 240 V, 50Hz, AC. Lamps shall be manufactured according to International Electrotechnical Commission IEC or International Standards, and accepted or approved by Qatar Standards.

2

Energy saving lamps ( that have a minimum of 50% energy saving than the standard high pressure sodium vapour gas lamps)shall be:

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(a)

High Intensity Discharge (HID) ,

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(b)

Induction lamp types;

(c)

Light Emitting Diodes (LED)

(d)

and any other types of energy saving lamps accepted and approved by Qatar Standards .

These lamps shall either have a built in or an external ignitor. Initial Lumen output for High Intensity Discharge (HID) lamps shall be no less than 4,500 lumens/watt for the 50 watt lamps, no less than 6,500 lumens/watt for the 70 watt lamps, no less than 12,500 lumens/watt for the 100 watt lamps, no less than 17,500 lumens/watt for the 150 watt lamps, no less than 33,150 lumens/watt for the 250 watt lamps or no less than 48,000 lumens/watt for the 400 watt lamps,

15.10

LIGHTING SYSTEM FOR UNDERPASSES

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The basis for the lanterns for use within both the lighting of the vehicular, pedestrian and animal underpasses pertains to lanterns designed for cornice surface mounting within each underpasses, complete with lamp, fuse and associated control gear. The lighting arrangement within each type of underpass shall be based on the use of a common lantern designed such that it can incorporate either a multi lamp or single lamp luminaire arrangement of a variable wattage.

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15.10.1 General

The lanterns for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt equivalent to the above wattages, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.2 Vehicular Underpass

The lanterns for pedestrian underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps or energy saving lamps, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.3 Pedestrian Underpass

15.10.4 Animal Underpass 1

The lanterns for animal underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps, or energy saving lamps complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses An underpass lantern shall consist of housing, front cover, reflector, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its optical housing shall have protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

2

The optical seal which shall include the reflector mounting shall be adequate to maintain this degree of protection. With the exception of the reflector, lamp holder mounting and associated cable all other equipment shall be housed at the rear of the optical system and shall be readily accessible by access through the lantern front plate. These components shall include the lantern control equipment, associated cable and isolating fuse. The cable connections to the lampholder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

3

The housing and front cover shall be made of stainless steel.

4

The reflector shall be made of aluminium sheet of such grade and quality that :

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The reflecting surface shall have a specular finish.

(b)

The reflecting surface shall have a dense protective coating of oxide not less than 1.2 2 mg/cm , applied by the anodic oxidisation process.

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(a)

The reflector shall be of such material and construction as to provide low brightness and minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer. The seal of the optical system shall be accomplished with a gasket material that will not deteriorate with age. This gasketing shall be continuous and shall ensure a heat and weatherproof seal. Suitably located knockouts to suit the cable conduit shall be provided in the housing. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

6

The fascia plate of the lantern shall be manufactured from toughened glass protected, if necessary due to a high incidence of vandalism by means of the manufacturers purpose made wire mesh guard.

7

Between adjacent luminaries a stainless steel ‘in fill’ plate shall be provided such that the whole assembly gives the appearance of a continuous cornice arrangement. The main sub circuit cables interconnecting each underbridge luminaire from the underpass isolating control box shall be routed between fittings within the luminaire or ‘in fill’ plate by means of a purpose made cable tray arrangement. Within the structure the cabling shall be routed via galvanized steel conduit cast within the underpass walls and soffit of size suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. The cabling shall be either single core or multi core 6mm² copper conductors within high temperature grade double insulated or flexible cable.

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15.10.6 Underbridge or Undercrossing Lantern and Installation The lantern for use within both the underbridge and undercrossing lighting shall be designed for directly mounting immediately above the kerb edge of the carriageway and shall be complete with lamp, fuse and associated control gear. The lighting arrangement shall be such that it can incorporate either a single lamp of a variable wattage.

2

The underbridge or undercrossing lantern shall consist of housing, cover, reflector, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its optical housing shall have protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

3

The optical seal which shall include the reflector mounting shall be adequate to maintain this degree of protection. With the exception of the reflector, lamp holder mounting and associated cable all other equipment shall be housed at the rear of the optical system and shall be readily accessible by access through the lantern front plate. These components shall include the lantern control equipment, associated cable and isolating fuse. The cable connections to the lampholder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

4

The housing and front cover shall be made of stainless steel.

5

The reflector shall be made of aluminium sheet of such grade and quality that :

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The reflecting surface shall have a specular finish.

(b)

The reflecting surface shall have a dense protective coating of oxide not less than 1.2 2 mg/cm , applied by the anodic oxidisation process.

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(a)

The reflector shall be of such material and construction as to provide low brightness and minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer. The seal of the optical system shall be accomplished with a gasket material that will not deteriorate with age. This gasketing shall be continuous and shall assure a heat and weatherproof seal. Suitably located knockouts to suit the conduit shall be provided in the housing. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

7

The fascia plate of the lantern shall be manufactured from toughened glass protected, if necessary due to a high incidence of vandalism by means of the manufacturers purpose made wire mesh guard.

8

The main sub circuit cables interconnecting each underbridge or undercrossing luminaire from the underbridge or uncrossing isolating control box Within the structure the cabling shall be routed via galvanized steel conduit cast within the underbridge or structure walls and soffit of size suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. The cabling shall be either single core or multi core 10mm² copper conductors within high temperature grade double insulated or flexible cable.

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15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps The control gear shall be designed to operate the lamp of the power rating and type indicated and it shall be able to start the lamp and control it continuously for ambient temperatures up to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage. Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear operating more than one lamp shall not be employed.

2

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of +/– 10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the capacitor when fitted and, if metallic, shall be provided with a separate earth terminal. The permitted operating temperature of the capacitor shall be marked on its case.

3

Each lamp shall operate using only one choke and one capacitor. Any combination of two or more capacitors having the equivalent value of capacitance will not be accepted.

4

Chokes and capacitors shall comply with the relevant British Standard Specification or an acceptable International equivalent and shall be fully compatible with the complete associated operation lamp circuit.

5

The ignitor for energy saving lamp shall be of the electronic solid state type and shall be arranged so that the ignitor circuit stops working after the lamp has started. It shall be totally enclosed. The circuit shall include a shunt capacitor to isolate the mains from high frequency start pulses; this capacitor may also be used for power factor correction. The length of wiring between the ignitor and the lamp shall not exceed that recommended by the Manufacturer for satisfactory lamp ignition and re-ignition of an extinguished lamp.

6

The control gear shall meet the following specifications:

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It shall be suitable for 50 Hz, 240 V AC + 10% operation.

(b)

It shall regulate the output power to 12% for the input voltage noted above.

(c)

It shall have an overall power factor of at least 0.85 when operated under rated lamp load.

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It shall operate the lamp without affecting adversely the lamp life and performance as specified herein.

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(e)

It shall withstand a 2500 V dielectric test between core and windings.

(f)

The choke shall be encapsulated in an approved resin compound and totally enclosed.

7

The lamps for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt equivalent to the above wattages, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

8

The lamps for pedestrian or animal underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, LED or energy saving lamps with Lumen/Watt-equivalent, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.8 Underpass, Underbridge or Undercrossing Isolating Box 1

At each underpass, underbridge or undercrossing location an isolating box assembly shall be provided to control and isolate the respective lighting. This assembly shall be constructed from either galvanized steel or stainless steel with a hinged vandal resistant lockable front cover complete with sealing gasket protection against the ingress of moisture and dust to degree IP54 of IEC529 under all operating conditions providing. A three phase mcb isolator shall be located within this housing to control the power supplies to each lighting sub circuit. The galvanized steel conduit providing the cabling routing within the structure shall be secured at the isolating box assembly by means of a locknut arrangement.

15.11

LED LIGHTING UNITS

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15.11.1 Lighting Units The degree of Ingress Protection provided by the luminaire, including the facility for a switching device, shall be rated at least IP66 in accordance with EN60529 (IEC529). Specification for degrees of protection provided by enclosures (IP code). This shall be certified by an independent IP testing and examination laboratory accredited by UKAS or equivalent accreditation body.

2

The degree of Impact Protection provided by the luminaire against external mechanical impact shall be rated at least IK10 (metals and plastics) and IK08 (glass) in accordance with EN62262:2002 (IEC62262:2002) Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code). This shall be certified by an independent IK testing and examination laboratory accredited by UKAS or equivalent accreditation body.

3

The luminaire assembly shall be tested and approved by an independent ENEC (European Norms Electrical Certification) national Certification Body and awarded the ENEC mark or equivalent international standards. Contractor shall provide verifiable certificate featuring contact information of Certification Body.

4

The luminaire shall be designed and suitably rated to ensure correct operation and continuous trouble free service under the prevailing climatic conditions. The luminaire shall be designed to withstand the effects of direct sun exposure during the day and dusty weather conditions including the occasional sandstorm. The luminaire manufacturer shall guarantee the performance and life time claims of lumen maintenance and luminaire life of the luminaire under the stated climatic conditions.

5

The luminaire housing shall be constructed from corrosion resistant marine grade aluminium alloy conforming to BS EN 1676, 1559-1, 1559-4 and 1706 and powder coated by an Akzo Nobel approved applicator, or equivalent, conforming to EN12206-1:2004 Paints and varnishes. Coating of aluminium and aluminium alloys for architectural purposes. Coatings prepared from coating powder.

6

The manufacturer shall supply a RAL colour chart depicting the range of powder coat colours available for the external finish of the luminaire. Luminaire colour shall be specified at the time of ordering.

7

The optical assembly and control gear components shall be integral to the luminaire body.

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For maintenance the luminaire shall allow tool-less access and incorporate quick disconnect features and universal fittings. All component parts shall be easily accessible and securely mounted to prevent accidental falling and manufactured from corrosion resistant materials or treated to prevent corrosion. The luminaire cover shall include an optional security feature to enable locking by means of a tool. The cover shall also incorporate a safety switch to disconnect power on opening and any upward rising hinged canopy shall be secured in an open position by means of a brace to prevent accidental closing.

9

The luminaire shall be procured from a prominent luminaire manufacturer that publishes product specifications measured in compliance with the IEC/PAS performance requirements or equivalent.

10

The complete luminaire shall be at least 98% recyclable.

11

The luminaire shall be vandal resistant. The ingress of insects through any system vent or aperture shall be prevented by means of a filter.

12

The luminaire shall be compliant with the Waste Electrical and Electronic Equipment (WEEE) Directive (2002/96/EC) and the Restriction of the use of certain Hazardous Substances in electrical and electronic equipment (RoHS) Directive (2002/95/EC).

13

Each luminaire shall have a barcode securely attached internally within the gear compartment identifying the luminaires reference/catalogue number, total wattage and LED current setting and other attributes as required by Ashghal and as required of the Enterprise Asset Management System (EAMS). The barcode type shall be compatible with the handheld device authorized for use by Ashghal.

14

All internal and external wiring of the luminaire shall comply with EN60598-1:2008 Luminaires, General requirements and tests and shall be flexible and suitably rated and insulated to withstand the voltages and temperatures encountered in service.

15

Any luminaire wiring passing through metal shall have suitable grommets or otherwise be protected to avoid abrasion of the insulation.

16

All luminaire terminals and supply connections shall comply with EN60598-1:2008. The conducting material of any terminal block shall be made of brass and shall have screw down plates bearing on the wires. Terminals where screws bear down directly on wires will not be acceptable.

17

Luminaires shall be earthed in accordance with EN60598-1:2008. An earth terminal forming part of the luminaire body shall be provided. All parts of an earth terminal shall be made of brass.

18

Luminaires shall be “future proofed” by allowing the LED modules to be upgraded easily in situ, as LED efficiency improves. Upgrading of luminaires, or replacement of faulty components, with manufacturer approved components shall not have any detrimental impact whatsoever on the luminaires’ manufacturer warranty. Prototypes shall not be accepted.

15.11.2

Lighting Performance

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Highway luminaires shall be suitable to achieve the lighting class standards as detailed in the Qatar Design Management Manual, as referenced in ANSI/IESNA RP-008, and as applicable to Primary, Secondary and Tertiary roads in The State of Qatar, under the control of Ashghal and other areas as required.

2

The luminaire shall be compliant with EN60598-1:2008 Luminaires. General requirements and tests, and EN60598-2-3:2003 Luminaires. Particular requirements. Luminaires for road and street lighting.

3

The luminaire shall be able to restrict glare and control obtrusive light in accordance with the full “cut-off” and “semi cut-off” concepts and associated luminous intensity classes defined in ANSI/IESNA RP-008 or an equivalent, Ashghal-authorized standard. Individual project contract drawings and design specifications shall detail the luminous intensity class requirement.

4

The luminaire shall control light output to limit light pollution and minimise sky glow in accordance with Commission Internationale de l'Éclairage (CIE) 126-1997 Guidelines for minimizing sky glow and meet the requirements therein for maximum permissible upward light output ratio (ULOR) expressed as the percentage of luminous flux acceptable in each of four different Environmental Zones.

5

The efficacy of the luminaire is given by the total lumen output divided by the power into the system and shall be equal to or greater than 100 lm/w (lumens per watt) operating within the climate conditions as stated herein. The contractor shall obtain a statement from the luminaire manufacturer declaring that quoted performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the manufacturer’s warranty agreement.

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15.11.3 Thermal Management

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The luminaire shall be capable of withstanding severe climate conditions, as stated in Section 21, Part 1. General Provisions for Electrical Installation, clause 1.1.14.

2

As a minimum, manufacturers shall use 50 ˚C as the night time ambient temperature with 95% humidity.

3

The luminaire shall be designed to provide satisfactory heat dissipation for any powered component parts and maintain safe operating temperatures at all times under the stated climatic conditions. Heat dissipation shall be by passive thermal management, active or mechanical cooling is not acceptable.

4

All materials used in the luminaire shall be resistant to high temperature UV (ultra violet) exposure and be 90% UV-stable.

5

The luminaire shall incorporate a passive thermal management system, active cooling such as fan assisted systems will not be accepted. The manufacturer shall demonstrate that the luminaire is suitable for continuous operation in the Qatar environment. Within the stated climate conditions the LED junction temperatures shall be shown to remain within the range required to limit the risk of accelerated degradation of the LEDs based on the stated life expectancy of the luminaire.

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Junction temperature cannot be measured directly and must be derived using calculation formulae and temperature measurements read from a thermocouple device attached to a series of defined reference points (thermal pads) on the outer casing (package) of the LED. Thermal verification testing is carried out as a laboratory based operation with ambient conditions simulated.

7

The luminaire manufacturer shall submit a statement declaring that quoted LED performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

8

The maximum allowable ambient temperature for the LED lighting shall be stated, in which the LED lighting can operate without adversely affecting any components life, luminaire light output or colour stability. This shall take into consideration the maximum case temperature of the driver and the design LED junction temperature.

9

Manufacturers shall state the predefined critical temperature level at which the dim down and switch off protection events occur and relate to junction temperature and ambient temperature. The luminaire shall be constructed in such a way that this protection method shall not occur during climate conditions stated within this specification.

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15.11.4 Testing

LED Luminaire lighting performance shall be measured using an independent photometric testing laboratory accredited by UKAS or equivalent accreditation body. The test procedure and measurements shall be carried out in accordance and compliance with IES_LM-79-08 Approved Method: Photometric Measurements of Solid State Lighting Products. The photometric test report shall list all significant data for each SSL product tested together with performance data and also pertinent data concerning conditions of testing, type of equipment, and reference standards. The photometric test procedure shall also be used to calculate correction factors in allowance of the stated climate conditions.

2

Photometric data for each luminaire optical setting shall be available in electronic file format in accordance and compliance with IES_LM-63-02 Standard File Format for Electronic Transfer of Photometric Data and Related Information and EN130321:2004+A1:2012 Light and lighting. Measurement and presentation of photometric data of lamps and luminaires. Measurement and file format. The photometry files shall be compatible for use with industry recognised road lighting design software packages or as requested by Ashghal and include applied correction factors specific to the declared ambient conditions.

3

Lighting performance of the LED luminaire in terms of design spacing’s relative to a specified road lighting class should be comparable to a modern HID lamp based luminaire with similar lumen output.

4

The luminaire manufacturer shall submit a statement declaring that quoted photometric performance figures correspond to the stated ambient air temperature (not LED junction temperature) and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

5

The luminaire shall be tested in accordance and compliance with EN62471:2008 (IEC62471:2006) Photobiological safety of lamps and lamp systems or an equivalent standard. Any assumptions made during testing shall be clearly stated.

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The luminaire LED light source shall be tested in accordance and compliance with IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources. The LM-80-08 test report produced for the LED light source shall meet the eligibility criteria necessary for submission to the U.S Department of Energy (DOE) Energy Star Program Requirements for Solid State Lighting Luminaires.

15.11.5 In Situ Temperature Measurement Test (ISTMT) In order to relate the LM-80 test to the luminaire and stated climatic conditions, testing shall be completed that simulate this application. This shall be achieved by In Situ Temperature Measurement Test (ISTMT) which follows ANSI/UL 1598-2004 Luminaires.

2

The luminaire manufacturer shall provide a written undertaking to the satisfaction of Ashghal\s authorized Engineer to warranty the materials and performance as follows: LED arrays shall have a written warranty for a minimum of 50,000 hours at the ambient temperature specified herein and shall be replaced on a one for one basis upon failure. An LED array will be deemed to have failed when:

(b)

equal to or greater than 10% of the individual LED chips in an array has failed or an array does not provide the required lumen maintenance (L70).

(c)

Drivers shall have a written warranty for a minimum 50,000 hours and shall be replaced on a one for one basis.

(d)

Luminaire housing and all external components such as; lenses, gaskets & fastenings and the fixture finish shall have a written warranty for a minimum twenty (20) years against the deterioration of, but not limited to, mechanical failure, UV degradation, corrosion, yellowing, blistering, chalking, cracking, peeling or fading.

(e)

The Warranty shall be transferable without limitations in its entirety to Ashghal, Public Works Authority, Qatar.

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(a)

Equivalent or more onerous standards can be proposed, by the manufacturer, as an alternative to the detailed standards, with the exception of Qatar documents. Evidence shall be submitted detailing the equivalent or more onerous sections that deviates from the intended standard.

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15.11.6 Control Gear 1

The luminaire control gear (driver) shall be produced by a prominent manufacturer of semiconductor components and comply with IEC 62384 DC or AC supplied electronic control gear for LED modules - Performance requirements. The manufacturer shall confirm that the packaged driver assembly is fabricated from high quality integrated circuit components including long-life electrolytic capacitors and provide data relating to the reliability of the device, in the climatic conditions stated in this specification.

2

The drivers shall be encapsulated / potted and Class II double insulated (IEC61140) and have a minimum energy efficiency of 85% and power factor ≥0.9 (full load). The control gear shall feature Surge Protection Device (SPD) for lightning strikes (IEC62305), short-circuit protection and transient overvoltage protection (IEC61643-1 / IEC61000-4-5).

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The LED drivers shall be housed on a removable gear tray accessible with the luminaire cover open and be compatible with the Qatar power supply. The supply cable shall pass through the mounting post, or bracket, directly into the luminaire through an M20 cable gland located at the base of the luminaire mounting socket.

4

For protection in the event of temperatures reaching predefined critical levels, both LEDs and drivers shall have thermal protection, which will initially dim down and eventually switch off the light. Manufacturers shall state the predefined critical temperature level at which the dim down and switch off protection events occur and relate to junction temperature and ambient temperature. The luminaire shall be constructed in such a way that this protection method shall not occur during climate conditions stated within this specification.

5

The driver system shall be compatible with Lighting Control Systems / Lighting Management Systems (LMS), using both analogue (1-10V) and Digital Addressable Lighting Interface (DALI) protocols including WiMAC or other similar Ashghal-approved driver system. The driver system shall also be capable of being configured for single, and multi-stage, stand-alone dimming configurations when not connected to a CMS.

6

The drivers shall be programmable and permanently configured to operate under the principle of “constant flux” output or maintenance factor harvesting or similar, Ashghalapproved configuration method. During this process light output is initially dimmed to an equivalent end of life level value and then the operating current is gradually increased throughout service life to compensate for lumen depreciation and maintain a constant lighting level. The advantage of this system is to give energy savings and improve LED life and reliability. The manufacturer shall provide details of how this facility is maintained following replacement of a faulty driver or LED array.

7

The driver shall be capable of operating within the climate conditions previously described and shall have documentation and certification supporting the claimed minimum life expectancy of 50,000 hours in the stated conditions within this specification.

8

The driver manufacturer’s device data sheet will provide specification details and the maximum permissible ambient temperature range in which the driver can operate (free air convection) at the defined driver current. The luminaire manufacturer shall demonstrate that the LED driver is suitable for continuous operation in the Qatar environment. Within the stated climate conditions the driver compartment enclosure shall be shown to remain within the range required to limit the risk of driver failure during operation based on the stated life expectancy of the luminaire.

9

The luminaire manufacturer shall submit a statement declaring that quoted driver performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

10

The luminaire shall conform to CE marking directives including the European Electromagnetic Compatibility (EMC) Directive EN 61000-3-2:2009 (IEC 61000-32:2009) Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions (equipment input current ≤ 16 A per phase)

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15.11.7 LED Lamps The LEDs shall be produced by a Ashghal Approved manufacturer of solid state lighting (SSL) components and comply with the related standards and guidelines set by the Illuminating Engineering Society of North America (IESNA) and the JEDEC Solid State Technology Association and approved by Qatar Standards.

2

The light source is required to control light output with the aim of optimising luminaire performance and efficiency in relation to the specific lighting application. The luminaire, or luminaire series, shall provide the facility for varying luminous flux output ranging from 5klm up to at least 40klm using an appropriate number of LEDs and a suitable control method for each different lumen package.

3

The luminaire LED module shall comply with International Electrical Commission Publicly Available Specification IEC/PAS62717 LED modules for general lighting – Performance requirements.

4

The LED arrays shall be capable of operating within the climate conditions previously described and shall have documentation and certification supporting the claimed minimum life expectancy of 50,000 hours at L70 in the stated conditions as within this specification.

5

Technical details shall be provided of the light source optical system and range of optics or optical settings available for each model of luminaire including performance characteristics. The optical system is required to control light output with the aim of optimising luminaire performance and efficiency in relation to the specific lighting application. The system should meet the lighting requirements of most rights of way types and configurations and maximise the “light output ratio” (LOR) of the luminaire.

6

The inadvertent failure of any LEDs during the life of the luminaire shall not bring about any reduction in uniformity of light output. Therefore, the multi-layer method of light distribution shall take precedence over multiple spot methods.

7

Diffuser systems may be required for some lighting applications to eliminate the effect of multiple-source shadows.

8

Chromaticity tolerance and associated colour consistency of luminaire LED modules shall be measured in terms of the CIE 1931 chromaticity diagram and the CCT quadrangles defined by the American National Standards Institute (ANSI) C78.3772008 Specifications for the Chromaticity of Solid State Lighting Products for Electric Lamps. The ANSI quadrangle is made up by smaller quadrangles, commonly referred to as bins. The x y chromaticity components of each LED module shall be enclosed by one bin and the bin size shall not exceed a 4-step MacAdam ellipse. The binning process shall be in compliance with National Electrical Manufacturers Association (NEMA) SSL 3:2010 High-Power White LED Binning for General Illumination.

9

The chromaticity shift shall be measured and reported in accordance with IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources.

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For highway lighting the Correlated Colour Temperature (CCT) of the light emitted from the luminaire shall be in the range ≥4000K with a Colour Rendering Index (CRI) of ≥60. The manufacturer shall state the CCT ranges available with a ±275K warranted window. The CCT and CRI shall include the effects of colour shift over the life of the luminaire. Other CCT ranges may be applicable to individual projects and manufacturers shall be notified as required.

11

Lumen maintenance (L) is the luminous flux emitted by the light source at any specified time during its operational life and is expressed as a percentage of the luminous flux emitted at the start of life (L%). The rated lumen maintenance life of the LED light source shall not exceed L70, or 30% lumen depreciation at the specified temperature conditions.

12

The luminaire manufacturer shall define the estimated service life of the light source in terms of operating hours and rated lumen maintenance. The minimum standard expected shall be 50,000 operating hours at L70 at the temperature conditions specified herein.

13

The method of deriving rated lumen maintenance life beyond the limits of lumen maintenance determined from actual measurements shall be demonstrated. The method for projecting the lumen maintenance of LED light sources from the data obtained by the procedures found in IES document LM-80-08 shall be in accordance and compliance with IES_TM-21-11 Projecting Long Term Lumen Maintenance of LED Light Sources.

14

In combination with rated life predications the reliability of the LED modules shall also be expressed in terms of the percentage (fraction) of failures in accordance with IEC/PAS 62722-2-1:2011 Luminaire performance - Part 2-1: Particular requirements for LED luminaires. The failure fraction (Fy) corresponds to the percentage of LED‟s that fail before end of rated life. This failure fraction expresses the combined effect of all components of a module including mechanical, as far as the light output is concerned. The effect of the LED could either be less light than claimed or no light at all.

15

The failure fraction shall also be expressed in terms of its component parts, gradual failure fraction (By) and abrupt failure fraction (Cy). The reliability curve relative to operating hours is calculated using statistical formulae and data gathered under test conditions during luminaire monitoring periods.

16

Luminaire maintenance factors (LMF) to follow model used in BS5489-1:2003+A2:2008 Annex D Table D1 with figures extrapolated to extend cleaning cycle interval up to 6 years and also adjusted to take account of environmental conditions specified herein.

17

Lamp flux maintenance factor (LFMF) shall be calculated by the manufacturer in accordance with calculated lumen depreciation relative to a predefined cleaning cycle interval. Currently the perceived cleaning interval is biannually due to the intense dust laden atmosphere.

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15.11.8 Quality Criteria for LED Lighting 1

Manufacturers shall submit data in accordance with IEC/PAS 62717 Performance requirements – LED modules for general lighting and IEC/PAS 62722 Performance requirements – LED luminaires for general lighting.

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15.11.9 LED manufacturers data Manufacturer shall provide a standardised set of quality criteria, measured in compliance with the appropriate standard. The performance claims shall be matched against traceable data. The performance data required is summarised below and shall be headed Quality Criteria: (a)

Rated input power (in W)

(b)

Rated luminous flux of the luminaire (in lm)

(c)

luminaire efficacy (in lm/W)

(d)

Luminous intensity distribution

(e)

Photometric code Rated Colour Rendering Index (CRI)

(ii)

Correlated Colour Temperature (CCT in K)

(iii)

Rated chromaticity co-ordinate values (initial and maintained)

(iv)

Maintained luminous flux

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Rated life (in h) of the module and the associated rated lumen

(g)

maintenance (Lx)

(h)

Failure fraction (Fy), corresponding to the rated life of the module in the

(i)

luminaire

(j)

Ambient temperature (ta) for the luminaire

(k)

Power Factor

(l)

Intensity Distribution

(m)

Drive Current

(n)

Optical Risk Group

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This data shall be submitted on an Ashghal-approved form. Forms shall be submitted to Ashghal for approval prior to submitting data for consideration. Further data shall be provided to evidence compliance with all aspects of this specification. Additional data shall be provided as and when requested by Ashghal.

15.12

OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION

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15.12.1 General 1

The basis for the lanterns for use on the overhead sign gantries or bridges for the illuminating of overhead guide signs mounted on the sign support structure or on the gantry sign walkway supported on the gantry sign support brackets. The lanterns shall be complete with lamp, isolating fuse and associated control gear.

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15.12.2 Sign Gantry Lantern The lanterns shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500 lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500 lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than 33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. At half life, the maintained luminous flux shall be a minimum of 75% of the initial luminous flux.

2

The lantern shall provide efficient illumination, be optically sealed, mechanically strong and easy to maintain.

3

The reflector mounting, wiring terminals and control gear components shall be readily accessible. When closed for operation, the optical assembly shall be sealed to provide protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

4

The seal between the refractor and the housing shall be adequate to maintain this degree of protection. The refractor shall be held in such a manner as to allow for expansion and contraction of the refractor. Cable connections to the lamp holder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

5

The optical system shall consist of a hydroformed aluminium primary beam reflector which shall be precisely profiled and contoured to distribute light across the inner surface of the refractor. The prismatic refractor shall be of moulded borosilicate thermal shock-resistant glass. The inner surface shall have an intricate array of prisms to direct light across the face of the sign. The outer surface shall be smooth to facilitate self-cleaning. The reflector shall be of a retro-dispersing type designed to eliminate the halo of excessive luminance to assure more uniform sign luminance.

6

The terminal board shall be located beneath the reflector at the conduit entry and shall 2 accommodate 10 mm electric cables.

7

The reflector shall be fastened to the housing by means of a minimum of four stainless steel screws with keyhole slot to facilitate easy removal and replacement. Levelling pads are to be provided on the inside and bottom of the main housing to permit accurate installation.

8

There shall be mounting within of the stainless steel housing to permit the lantern to be mounted directly to the supporting structure.

9

The refractor shall be form-fitted to the stainless steel door frame and shall have a single piece gasket with a sealing pad to effectively seal the assembly and housing. The assembly shall be fastened to the housing by means of separable hinges at the front and spring tempered, stainless steel at the rear. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

10

The terminals of all ballasts, capacitors and control gears shall be shrouded.

11

Each sign lighting system shall be subject to the approval of the Engineer. Particular attention shall be given to the mechanical strength of all components, and to the security of their method of the sign supports.

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15.12.3 Sign Gantry Lantern Control Gear and Lamps The control gear shall be designed to operate the lamp of the power rating and type indicated and it shall be able to start the lamp and control it continuously for ambient temperatures up to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage. Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear operating more than one lamp shall not be employed.

2

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of + or –10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the shell and be provided with a separate earth terminal. The permitted operating temperature of the capacitor shall be marked on its case.

3

Each lamp shall operate using only one choke and one capacitor. Any combination of two or more capacitors having the equivalent value of capacitance will not be accepted.

4

Chokes and capacitors shall comply with the relevant British Standard Specification or an acceptable International equivalent and shall be fully compatible with the complete associated operation lamp circuit.

5

The control gear shall meet the following specifications:

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It shall be suitable for 50 Hz, 240 V AC + 10% operation.

(b)

It shall regulate the output power to 12% for the input voltage noted above.

(c)

It shall have an overall power factor of at least 0.85 when operated under rated lamp load.

(d)

It shall operate the lamp without affecting adversely the lamp life and performance as specified herein.

(e)

It shall withstand a 2500 V dielectric test between core and windings.

(f)

The choke shall be encapsulated in an approved resin compound and totally enclosed.

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(a)

The lamps shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500 lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500 lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than 33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. At half life, the maintained luminous flux shall be a minimum of 75% of the initial luminous flux.

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15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables At each sign gantry location an isolating (safety) shall be provided at walk way level of the structure. It shall be fabricated galvanized steel complete with a vandal resistant hinged access door. A three phase mcb isolator shall be located within this housing to control the power supplies to each lighting sub circuit. The galvanized steel conduit, secured to the gantry structure by means of purpose made saddles to suit the size of conduit, providing the cabling routing within the structure shall be secured at the isolating box assembly by means of a locknut arrangement. The size of the conduit shall be suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. A 3-phase mcb isolator shall be located within the isolating (safety) switch to control the lighting sub circuit upon each gantry structure. The cabling shall be either single core or multi core 10mm² copper conductors within high temperature grade double insulated or flexible cable.

15.13

PHOTO ELECTRIC CONTROL CELL

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15.13.1 General

Photo electric control cells shall comply with the requirements of BS 5972 and offer a Class II protection from electric shock as defined in IEC 60598.

2

Unit must be completely weatherproof, hermetically sealed against the ingress of moisture. It shall be resistant to vibration or change in temperature. It shall be housed in a strong impact resistant low profile translucent housing, the surface of which shall be non- oxidizing and impervious to deterioration.

3

The photo electric control unit (PECU) shall be guaranteed for a period of not less than six years, failures within that period of time to be replaced free of charge.

4

They will be capable of working in an ambient temperature of up to + 60 C.

5

The operation level should be preset to ON 80/100 Lux the ratio of ON to OFF should be approximately 1:2. There shall be no means of manual adjustment to the PECU’s calibration and it shall not need to be orientated to operate as required.

6

There should be a minimum 15 second delay to prevent the unit from functioning due to short period high illumination such as lightning etc.

7

The power supply to the PECU shall be 240V 50Hz. A.C with a contact output rating of 30A at 240V (resistive).

8

The PECU and associated relay or switching device shall have pre matched responses and housed in the same envelope. The contact rating shall be 1500-Watts (1800 V.A) and should be fitted with a snap action to prevent chatter. In the case of the load to be switched then the PECU can switch directly, a contactor shall be used.

9

The photocell shall be located within the road lighting feeder pillar such that it can be easily removed. It shall be housed within a small compartment with an acrylic fascia plate set into the surface of the feeder pillar for the satisfactory operation of the photocell. The control circuitry for the correct switching of the road lighting will be housed within the adjacent feeder pillar. The associated specification requirements will be dealt with within that section of the specification.

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10

The upper LED luminaire cover shall have the facility for installation and wiring of one of the following devices: an integral miniature photocell, NEMA socket (detachable photocell), telemetry device. This facility shall be included within the IP testing.

15.14

ROAD LIGHTING COLUMN CUTOUT / ISOLATORS

15.14.1 General 1

Cutouts in columns shall be phenolic moulded, three phase, and suitable for looping two 4 Core 25 mm XLPE/SWA/PVC cables.

2

Cutouts shall : Incorporate miniature circuit breakers complying to BS EN 60898 with a minimum breaking capacity of 4kA.

(b)

Be of the combined single phase and neutral type.

(c)

Incorporate an earth terminal.

(d)

Be suitable for concentric or PVC armoured cables of up to 25mm2 cross-sectional area with capacity for looping in and out.

(e)

Have all metal parts tinned.

(f)

Be provided with a minimum of 2 fixing screws.

(g)

Be manufactured from material which is non-hygroscopic and non-tracking.

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Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for the use of miniature circuit breakers 6 A, 10A or16 A ratings, selected from the Table 15.2 below:

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Wattage

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Table 15.2 Ratings of Miniature Circuit Breakers

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For 1 Lamp

For 2 Lamps

50W

70W

100W

150W

250 W

400 W

6

6

6

6

10

10

6

6

6

10

16

16

The cutouts shall comply with the 16th Edition of the IEE Wiring Regulations.

5

A cutout used as a means of isolation shall have the facility for padlocking.

6

The service cutout shall have a moulded enclosure, offering a minimum protection of IP22, capable of withstanding severe impact.

7

Separate terminals shall be provided for live, neutral and earth conductors complete with terminal shields to prevent accidental contact with all live conductors.

8

Cutouts shall be sized to accommodate the designated cables, but with a minimum of 25mm2 cables.

9

Cable armouring shall be bonded as an integral part of the cutout, and complete with cable armour clamp shrouds.

10

The cutout shall be suitable for mounting on a wooden backboard or DIN rails.

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11

Where there is a requirement for the use of an isolator they shall incorporate in-built fused loop terminals for the feeds to signs, bollards etc.

12

All isolating devices shall be double pole for single-phase systems and four poles for three phase systems.

13

All isolators shall be rated to suit the local environmental conditions of Qatar where these differ from those stated in BS EN 60947-3

15.15

FEEDER PILLAR

15.15.1 General Road lighting feeder pillars shall be totally enclosed weatherproof with fibreglass reinforced polyester cabinet of ground mounting type complete with accessories suitable for mounting outdoor..

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15.15.2 Cabinet

The feeder pillar cabinet, unless previously approved by the Engineer, shall be of fibreglassreinforced polyester and ultra violet ray resistant. The cabinet surface shall be totally weather and corrosion resistant with a completely smooth exterior. The outer 0.5mm - 1.0mm should consist of pure polyester. The colour of the cabinet shall be grey. The colour shall be completely light stabilised and impregnated from the surface through the thickness of the material.

2

Pillars shall be ground mounting type by means of a steel frame with concrete foundation. The cabinet shall have a base frame with a minimum ground clearance of 200mm between the body and the mounting area (bottom). The base frame shall have at least four holes to bolt down the pillar to the concreted steel frame. The cabinets base frame shall be removable. The feeder pillar shell shall incorporate lifting devices for the safe movement of the feeder pillar.

3

The cabinet top (canopy) shall be arranged so as to prevent the ingress of rainwater and provide air circulation.

4

The cabinet shall be provided with a front door complete with internal hinges and fixing screws fixing at top and bottom. A tamper proof lock will be provided centrally and all locks shall operate by a standard master key. Two keys for each pillar shall be provided. The door closing will have a perfect weatherproofing arrangement. The enclosure shall have a designated IP rating of IP54 in accordance with IEC 60529.

5

Approximate cabinet size shall be 1000mm high by 620mm length by 300mm width..

6

Natural ventilation shall be provided to limit the temperature rise to the manufacturer’s recommendations. Such ventilation shall not reduce the stated IP rating of the cabinet and shall be screened to prevent the entry of vermin. Where recommended by the manufacturer dust filters shall be provided.

7

A data plate shall be fixed to the inside of the pillar detailing information as deemed necessary by the PWA and/or the Engineer.

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Detailed distribution board schedules are to be provided within the each feeder pillar these to be located on the inside of the cabinet and stored in a weather protected plastic pocket securely fixed to the shell of the housing.

15.15.3 Components of Feeder Pillars 1

1 No. 200Amp mains breaker (MCCB) of three phase 415V - interrupting capacity according to BS 3871: 240V – 85kA 415V – 35kA A facility to lock off the assembly in the open position shall be provided. 1No. 200Amp 4 pole magnetic contactor, three phase with coil voltage of 240V within an IP 54 enclosure. The contacts of the contactor shall be fitted with a snap action to prevent chatter.

3

A control circuit shall be provided connected to the control coil of the contactor. The circuit shall be protected by means of a 4A HRC control fuse within a weatherproof enclosure. The control circuit shall be such that in the event of a failure of the photocell control unit a time switch identified below will override the operation. In addition a manual override switch shall be provided to operate the road lighting at times outside the periods during which the lights are normally operational.

4

The time switch shall be a 24-hour dial time switch motor driven single phase 30 Amp. 220 240V 50 Hz. with a clock accuracy of + or – 5minutes/year and shall have a 48-hour synchronous spring reserve to maintain clock operation and output switching during power supply failure or disconnection. Time switch should be protected with a HRC fuse or MCB. Arrangement for connecting a photoelectric control switch shall also be made within the pillar.

5

A 3-phase MCB metal clad or plastic distribution board complete with single pole 240V MCB’s of interrupting capacity according to BS EN 60898. The number and size of the outgoing circuits shall be as per the feeder pillar schedules. Terminations shall be capable of accommodating sub circuit cable of size 25mm2. There shall be at least 25% spare outgoing circuit capacity.

6

MCB’s and protective devices shall be rated to withstand a minimum short-circuit current of 9kA.

7

Neutral terminal bar shall be provided separately. Neutral conductors shall be insulated from earth to allow use on TN-S systems. The neutral connections shall have separate connections for each outgoing cable. Where a neutral busbar is provided it shall be mounted in parallel with the phase busbars and arranged so that each neutral connection is physically identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of the feeder pillar and shall be of sufficient length to accommodate a connection for each circuit including 25% spare capacity. The neutral busbar shall be coloured black and the earth busbar coloured green and yellow.

8

Busbars shall be of full rating having taken into account any holes, they shall be constructed from high conductivity copper and mounted on insulators and mounted at the rear of the feeder pillar. Busbars shall be insulated with non-hydroscopic, non-tracking insulation. All live parts shall be screened.

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Insulated dividing barriers shall be provided between both phase contact assemblies and between phase and neutral.

10

Each feeder pillar shall accommodate at least 1No. brass cable gland with locknut, earth tag and PVC shroud for the incoming supply cable together with individual brass cable glands 25mm CW gland according to BS 6121 complete with lock nuts, earth tags and PVC shrouds for all outgoing cables, including an allowance for spare capacity, for stranded copper cables up to 25mm² 4 core XLPE SWA PVC.

11

Colour-coded leads shall identify all wiring for phase and neutral cables. Outgoing circuits shall be labelled with the circuit reference and circuit breaker rating. Wherever possible all internal wiring shall be enclosed in trunking or conduit.

15.16

ROAD LIGHTING CABLES

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15.16.1 Underground Cables

Underground road lighting cable shall be copper stranded 10/16/25mm² x 4 core XLPE SWA PVC cable of stranded copper conductor 600/1000 VAC.

2

Cables shall be low tension 600/1000 volt multi core stranded copper conductors, insulated with XLPE compound, core laid-up, extruded PVC tape bedded, steel wire armoured and PVC sheathed overall underground cables to BS 5467: 1977.

3

The cable shall be capable of withstanding vigorous climatic conditions of ambient temperature up to 50°C (the temperature can be accompanied by a relative humidity of up to 100% at 30°C).

4

It should also be noted that cables can be buried in sand and laid partly in ducts at a depth of up to 600mm in footpaths and 750mm in roadways. The ground temperatures can vary from 35-40°C in summer to 8-12°C in winter. Cable drums may be stored in the open for up to 1 year and will be exposed to direct sunlight. Accordingly, cables shall be designed to withstand such conditions without deterioration of the electrical or mechanical properties.

5

Cables shall have the following construction details: Conductors:

High conductivity stranded copper - shaped conductors shall comply with BS 6360: 1981 with XLPE insulation.

(b)

Bedding:

Bedding shall be an extruded layer of XLPE compound.

(c)

Colour of Cores:

Red, Yellow, Blue and Black.

(d)

Armouring:

Single layer of galvanized steel wire.

(e)

Finish (over sheath): Extruded black PVC over sheath which conforms to BS 6346:

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1987 for thickness and to BS 6746: 1987 for properties. The external surface shall be embossed with the voltage designation, cable size and manufacturers name 15.16.2 Packing of Cables 1

Underground cables shall be packed in sealed wooden cable drums each of 500 metres length with a plate stating the following details: (a)

Manufacturer's name and country of origin

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(b)

Cable type and size

(c)

Length of cable per drum

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15.16.3 Insulated PVC Sheathed Circular High Temperature (85°C) 1

Flexible cable should be of conductors of high conductivity copper stranded wires, 2.5 sq. mm, insulated with high temperature PVC compound, three cores, green or yellow, blue and brown, twisted together, filled and sheathed with high temperature PVC compound, 300/500V.A.C. according to BS 6141, Table 15 or equivalent norm.

15.17

MARKER TAPE FOR UNDERGROUND POWER CABLES

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Marker tape shall be installed wherever cables are to be directly buried in the ground to warn of the presence of power cables.

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15.17.2 Material & Quality

The marker tape shall be of low density polyethylene, of thickness at least 100 micron. Its width shall be 40cm and be yellow in colour, with black marking indicating the presence of road lighting cable in both English and Arabic. Its location in respect of the cable position is identified within the Contract documentation.

2

The material shall be colour fast, and resistant to chemical action in typical ground conditions experienced in Qatar. These may vary from extremely wet to extremely dry, and with very high salinity. The ground temperature may vary from 0 to 40°C.

3

The material shall be mechanically durable. The manufacturer shall demonstrate the samples complying with this specification have been tested for compliance with BS 2782, Part 3, Method 326A to 326C or an equivalent standard.

15.18

MARKER POSTS

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15.18.1 General 1

Where instructed by the Engineer, the Contractor shall install marker posts and slabs. These shall be of reinforced concrete, steel or heavy duty plastic of an approved type suitable for use in Qatar. Unless instructed otherwise pre-cast reinforced concrete or equally approved marker posts or slabs shall be installed at intervals of not more than 50m along all underground cable routes, joint pits (if any), at all changes of direction and at both ends of road crossings.

15.19

EARTHING

15.19.1 General 1

The integrity of the earthing system within the road lighting network shall be maintained.

2

Each item of equipment shall be individually effectively earthed within each lighting assembly and feeder pillar by means of a dedicated earth to a central earthing point. This shall be regardless of any other terminals available. All connections shall use crimped terminations.

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Page 47 2

For circuit conductors of 16mm and 25mm a circuit protective conductor of cross-section 2 not less than 16mm shall be incorporated.

4

All removable metal doors or metal frames shall be earth bonded.

5

Within the feeder pillar the central earthing point shall be connected to the incoming earth provided by QGEWC.

6

At each feeder pillar location an earth rod shall be installed complete with an approved earth pit and cover plate. It shall have a resistance to true earth of not more than 10 ohms. The size of the earth rod shall be 16mm by 2.5m in length. It shall be driven to a depth that penetrates the summer water table by at least 1m. It shall be connected to the central earthing point of the feeder pillar via a bare stranded copper conductor of cross-sectional 2 area 70mm .

7

At the end of each lighting sub circuit an additional earth electrode as detailed above shall be connected to the central earthing point within the last lighting column base compartment. The connection between the earth electrode and the column central earth terminal shall be via a 2 bare stranded copper conductor of cross-section 16mm .

8

Routing of the earth cable to the ground conductor within the last column of each feeder pillar outgoing subcircuit shall be via a 100mm. PVC duct within the column foundation.

15.20

INSTALLATION

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15.20.1 General Requirements

The Contractor is responsible for all liaisons, through the Engineer, with the departments concerned within the PWA, in respect of programming the installation and commissioning of the complete road lighting system. He shall also ensure through the Engineer that the relevant departments within the PWA are at all times kept informed of the current progress of the work. Throughout the road lighting installation works the engineering representative from the relevant departments within the PWA, must be invited to carry out periodic inspections of the works. The Contractor shall ensure that his approved subcontractor programmes works are in the designated sequence in accordance with the approved programme. On completion of each phase of the works progress to the next phase will be subject to the approval of the Engineer’s Representative and/or the relevant departments within the PWA.

2

A qualified person having a thorough experience in road lighting and associated equipment shall supervise the execution of all electrical work.

3

Only workmen who have had experience in the erection of road lighting shall be employed on the work of erection.

4

Before carrying out any electrical works to existing services, authorisation must be obtained in writing from all relevant authorities.

5

The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in the ILE Code of Practice for Electrical Safety.

6

Where an existing installation has been extended the relevant parts of the existing system and equipment earthing shall be inspected and tested for compliance with the IEE Wiring Regulations.

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A completion certificate as detailed in the IEE Wiring Regulations shall be issued following the inspection and testing of the installation and any corrective action found necessary.

15.20.2 Temporary Lighting Where the existing installation is to be disconnected during the Contract Period, temporary lighting shall be provided. Any temporary lighting proposals must have the approval of the PWA prior to installation.

2

At no time shall design road lighting standards be lower than those existing prior to the start of the Contract.

3

The Engineer must approve any form of temporary lighting and associated lighting levels.

4

Temporary lighting shall not be removed or disconnected until the permanent installation has been inspected and approved by the Engineer and has been energised.

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15.20.3 Removal of Existing Columns

Prior to any work being undertaken the Contractor shall obtain from the relevant departments within the PWA a copy of the latest revised record drawing of the existing lighting network within the contract limits. The Contractor is to identify from these records those columns affected by the Contract and require removal or relocating. A copy of any record obtained shall be forwarded to the Engineer for his use.

2

Existing columns shall be removed under supervision of the Engineer’s Representative in consultation with the relevant department within the PWA. Existing cables shall be disconnected, made safe and protected to the satisfaction of the Engineer in consultation with the relevant departments within the PWA prior to removal of the columns.

3

No existing road lighting shall be switched off, dismantled or removed without the prior approval of the Engineer and the relevant departments within the PWA. Where the existing road lighting has been removed the Contractor, to ensure safe vehicular and pedestrian movement within the designated area, shall provide necessary temporary lighting complete at his cost. Existing signs shall also be relocated at the Contractors cost to ensure compliance with the current traffic regulations.

4

All lamps, luminaries and fittings shall be removed before excavating around the column prior to its removal. Tie ropes shall support the columns at all times.

5

The Contractor shall carefully excavate existing material from around the column base, including concrete taking care not to damage any adjacent cables or services. No assembly shall be removed until it has been fully excavated.

6

The columns shall be lifted from the foundation by means of a crane approved by the Engineer. The foundation shall be backfilled with suitable approved material and temporarily reinstated.

7

All columns, cables, lamps and luminaries to be removed under the Contract shall be taken to store as directed by the Engineer and remain the property of the PWA. Where such items are instructed to be taken to the stores of the PWA, proof of delivery should be obtained by means of a signed receipt from the relevant departments within the PWA and witnessed by the Engineer’s representative.

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Existing road lighting, where it is to be relocated within the Contract, shall be carried out in accordance with the relevant sections of the contract specifications, as if new. Prior to reinstalling all equipment it shall be inspected and any damage reported to the relevant departments within the PWA, via the Engineer.

15.20.4 Detailed Drawing for RCC foundation The foundation for the 3 metre to 12 metre lighting columns shall be in accordance with the details provided within the Contract Documents. The reinforcement detail shall be detailed by the Contractor based on the recommendations of the column manufacturer to meet the column assembly design criteria detailed in paragraph 15.6.7 of this specification. Contractor shall consider the use of augured foundations in areas where soil and lighting utility reservation necessitate it, as per the Contract Documents.

2

The foundation detail for the lighting columns or masts between 16 metres to 30 metres will be as recommended by the column manufacturer for the climatic conditions applicable to the State of Qatar taking due consideration of the equipment to be supported. Contractor shall consider the use of augured foundations in areas where soil and lighting utility reservation necessitate it, as per the Contract Documents.

3

Final configuration of the proposed foundation will be subject to the approval of the Engineer and the PWA.

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15.20.5 Road lighting Column/Lantern Installation

Road lighting columns shall be erected on pre-constructed bases offset from the carriageway, as defined in the contract Specification, via anchor bolt arrangement.

2

Prior to erection of the lighting pole no bracket arm or lighting fixtures shall be mounted on the column shaft.

3

Only purpose made cranes with nylon slings will be accepted for the purpose of lifting the columns onto the anchor bolts. Metal chains are not acceptable.

4

The bottom securing nut/washer arrangement or shims shall be used to align the lighting column vertical. The location of the base compartment door shall be agreed prior to the installing of the column shaft, but unless notified otherwise the door opening shall be located such that any operative working within the column shall face the on-coming traffic.

5

Once installed, the final alignment and verticality of the column shall be checked in two directions at 90 degrees to each other by theodolite or other approved method. The final verticality is to be approved by the Engineer’s Representative prior to the column bracket and luminaire as specified being installed and commissioned.

6

The underground cables shall be terminated into the cut-out/isolator assembly mounted within the lighting pole base compartment. An additional length of 500mm shall be allowed at each incoming cable termination and shall remain underground for future reconnections.

7

Wiring between the terminal block in the luminaire and the components in the base of the column or each unit shall be using high temperature 3 core, green or yellow, blue and brown, 2.5mm2 copper flexible cables to BS 6141.

8

All installation requirements described in the ILE Code of Practice Clause 11 shall apply.

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A double insulated 6.0mm2 stranded copper earth wire with clamped tag bonded to earth lug on column and the column door earth terminal shall be provided.

10

All cable routes shall be clear of control gear and limited to horizontal and vertical runs. Cables entering terminals shall show no bare wire nor shall the insulation be taken into the electrical conducting part of the terminal. All cable shall be neatly bunched together and securely taped.

11

Terminal blocks shall be clearly marked and the wiring shall be so arranged that the luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without any electrical wiring disconnections.

12

After installation each lighting column shall be identified by a reference number in accordance with the requirements of the PWA.

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15.20.6 Road lighting Feeder Pillar Installation

The road lighting feeder pillar shall be erected on pre-constructed base off set to the carriageway, as defined in the Contract specification, via anchor bolt arrangement.

2

Prior to erection no internal equipment shall be installed which could be damaged either in transit to site or during the erection phase.

3

The bottom securing nut/washer arrangement or shims shall be used to align the feeder pillar vertical.

4

The electrical installation within the feeder pillar shall be undertaken as detailed elsewhere in the specification.

5

All underground cables when terminated shall allow for a minimum length of 500mm to be left underground to allow for future reconnections

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15.20.7 Road lighting Cable Installation 1

The installation of all cables shall be in accordance with the requirements of QCS Section 21.

2

Excavation of Road lighting Cable trenches for cable size from 10mm to 35mm x 4 core are to be of the following dimension:

2

m

2

Depth: 600mm Width: 500mm 3

Cable trenches shall be cleared of all stone and sharp projections and shall be drained. All cables shall be laid on a bed of 150mm approved fine aggregate sand or quarry scalping. Cabling to and between columns will be by means of copper stranded 4core XLPE.SWA.PVC cable. (Size as indicated and based on the connected electrical load and length of cable from power source) and shall be at the depth of 450mm. A layer of 150mm dune sand or quarry scalping is to cover the cable. No joints in Cable shall be permitted.

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LV cables laid shall be laid straight between lighting columns with an allowance for 500mm spare underground cable adjacent to each column. Cables can be placed in the same trench with a lateral spacing between cables of 50mm. In the event of HV cables being placed in the same trench then there shall be a separation of at least 300mm. All cables shall have a clearance of at least 300mm from all other services including telephone or communication cables.

5

The Contractor shall arrange for inspection of the cable, trenches and cable installations by the Engineer’s Representative, in conjunction with the relevant departments within the PWA prior to backfilling.

6

All cables shall be handled, installed and terminated in accordance with the manufacturer’s recommendations. The manufacturer’s recommended ambient temperature limitations for the handling of cables shall be strictly adhered to.

7

All cables, once removed from the cable drum, shall be immediately laid in position. No cable shall remain laying on the surface for more than is practicably possible.

8

Cabling is to be looped into each column and terminated by means of an approved lighting column cut out.

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Underground ducts shall be provided where cables

Cross roads or other paved areas with vehicular access.

(b)

Cross unpaved areas regularly used by vehicles.

(c)

Enter buildings.

(d)

Vehicular entrances to properties.

(e)

Pass through corrosive soils or elsewhere as designated, they shall be drawn into underground pipe ducts.

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15.20.8 Road Crossing Ducts

A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run immediately after its installation. A 2m surplus shall be left at each end of each run, neatly coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct.

3

Underground pipe ducts shall be heavy gauge unplasticised PVC (high impact resistant PVC, 3.6mm wall thickness) conduits with tapered sleeve or spigot and socket joints encased in concrete as detailed in the Contract drawings and in accordance with the requirements of the PWA.

4

All ducts shall have a nominal internal diameter of 150 mm unless designated otherwise.

5

The internal diameter of ducts used to provide cable entries into structures shall have a space factor less than 25 %, unless otherwise designated.

6

All dual systems shall be installed so that no undue strain is placed on cables when pulled in. Cable manufacturer’s recommendations shall be followed.

7

All underground cable ducts shall, so far as possible, be run in straight lines.

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Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis of the road. They shall be laid at a depth of 800mm backfilled and reinstated in accordance with QCS.

9

Except in the case of short isolated duct runs such as road crossings, underground cable duct runs shall terminate in suitable drawpits.

10

Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded with concrete of grade SRC 30 as per the standard detail.

11

Ducts shall be laid so as to drain naturally towards one or both ends, where adequate provision for drainage shall be made. Adequate precautions shall be taken to prevent the cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of 1 in 200 shall be provided for drainage purposes.

12

Any work carried out requiring the use of split ducts shall be carried out in such a manner as to preserve the withdrawability of the cables concerned.

13

Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be installed on a concrete bed as designated above, but without concrete surround.

14

If two or more cables are to be installed in the same duct, the aggregate of their crosssectional areas shall not exceed 30 % of the cross-sectional area of the duct.

15

All trenches excavated for the laying of cable ducts shall be completely backfilled and rammed before cable installation work begins.

16

Immediately following the installation of any duct run, the interior of the duct shall be thoroughly cleaned by twice drawing through the ducts a mandrel, once in each direction. Following this, the ends of each run shall be sealed with a suitable hardwood or plastic sealing plug which shall be left in position until cable laying is about to begin.

17

The polished hardwood mandrel shall be 300mm long having spherical ends and a diameter 6mm less than the nominal duct diameter.

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15.20.9 Backfilling and Re-instatement 1

All trenches and pole pit/foundations shall be backfilled, compacted and re-instated in accordance with the QCS requirements.

15.20.10 Road lighting Cable Terminations and Testing 1

Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where applicable, and shall be of a design appropriate to the type of cable being terminated.

2

Glands for cables with metallic inner sheaths shall incorporate a bonding connection.

3

Except where it is impracticable to do so, the cable cores shall be taken through the terminating box directly to the terminals of the equipment, without crosses, and shall be made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped socket.

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4

Terminations for armoured cable shall incorporate a method of rating off the armour which ensures a permanent earth bond between the cables terminated to the satisfaction of the Engineer. The cable armour shall be bonded to the earth terminal block in each column.

5

All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in the appropriate colours, to indicate the disposition of the phase and neutral conductors within them.

6

Compression glands installed externally shall be classified IP66 and be provided with closefitting PVC shrouds.

15.20.11 Electrical Power Supply Upon the completion of the associated work, arrangements will be made via the Engineer to provide the electrical power to each road lighting feeder pillar based on a 415V 50Hz supply. Once available, and after inspection, the lighting system shall be tested prior to connection. The Engineer shall arrange for full consultation with the relevant departments within the PWA during this phase of the lighting works.

15.21

TESTING AND COMMISSIONING ON SITE

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15.21.1 General

In addition to the requirements of the Contract Specific Specification all testing and commissioning shall be carried out according to the requirements of the relevant BS , CP, IEE regulations, or other standards and regulations as may be stated or implied in this Specification.

2

Each completed system with the installation shall be tested as a whole under operating conditions to ensure that each component functions correctly in conjunction with the rest of the installation.

3

The Contractor shall afford access at all times to the relevant departments within the PWA to enable them to inspect work during and after erection and to be present at all tests.

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15.21.2 Electrical Tests 1

As soon as is practicable after the completion of installation the tests described below, together with such other tests and measurements to prove compliance with the contract requirements shall be made.

2

An insulation tester shall be used to measure the insulation resistance between each conductor and the remaining conductors and between each conductor and the metallic sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V.

3

The above tests shall be carried out both before and after any pressure tests and the insulation resistance shall not be less than the figures in the appropriate BS.

4

A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix 88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable.

5

Proposals for the appropriate test in respect of other types of cable shall be submitted for approval.

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An earth continuity test shall be carried out to verify that the cable armouring and metal sheath, if any, have been properly bonded to earth.

7

Phase rotation and phase correspondence shall be tested to prove that the cables have been correctly connected.

8

Where a new cable has been jointed to an existing cable with the express permission of the Engineer, the voltage test designated above may be carried out at a reduced voltage if the existing cable has been in service for more than five years. In such a case the test voltage shall be determined by applying a factor K to the value given in the appropriate British Standard as referred to above.

9

The Contractor shall afford access at all times to the representatives of QGEWC and the relevant departments within the PWA to enable them to inspect work during and after erection and to be present at all tests.

10

Upon completion of laying and terminating underground cable runs, the Contractor, in the presence of the Engineer or his duly authorised representative, shall carry out pressure tests in accordance with relevant British Standards. The Contractor shall provide all apparatus and labour required for such tests and within a reasonable time thereafter shall present the Engineer with certificates of the tests.

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A certificate of Initial Lighting Performance of Installation shall be issued when tests have been passed as follows: The initial photometric tests shall be made after the installation has been in lighting operation for between l00 and 150 hours

(b)

The location of test positions shall be distributed along the length of the installation and shall be as directed by the Engineer. All service tests throughout the testing period shall be made at these positions.

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15.21.3 Photometric Performance Testing

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Readings shall be taken with a portable calibrated luminance meter holding a current valid calibration certificate. The measurements in accordance with the procedures laid down by the CIE and shall be taken by a qualified lighting engineer who shall confirm that the lighting performance data as identified in the contract specification has been satisfactorily obtained.

3

Measurement of the supply voltage at adjacent lighting columns and posts shall be taken at the time of each test and the illumination measurement shall be adjusted for any variation from the supply voltage value declared in the contract specification. Allowance shall be made for the use of control gear taps if necessary immediately before the initial tests are made. The lamps and all components of the luminaire that may affect the optical performance shall be cleaned and correctly adjusted.

4

The Engineer shall witness all photometric testing, unless otherwise notified in writing. A minimum of 7-days’ notice shall be given to the Engineer before testing begins. After testing the certificates shall be submitted to the Engineer for approval. Representatives from the relevant departments within the PWA shall be invited to witness the lighting performance testing.

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RECORD DRAWINGS

15.22.1 General Within thirty days from the date of completion of the whole or any section of the lighting works the Contractor shall provide fully detailed "as built" drawings and schedules in respect of all sections of work completed together with all relevant operating and maintenance instructions. The drawings shall: Fully indicate with accurate dimensions the sizes, types and position of equipment, cables, ducts, joints, feeder pillars etc., with particular regard for the need to accurately locate buried cables after completion.

(b)

Show the circuit arrangements for the relevant section of the road lighting installation.

(c)

Show full details, ratings and function of each item of equipment.

(d)

Include any other relevant information to ensure the safe and satisfactory operation of the particular section of the road lighting works.

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1

The Contractor shall submit, within the time stated above, two copies of the Record Drawings for the approval of the Engineer. Upon and after receipt of such approval the Contractor shall provide records in both digitised and hard copy format of reproducible transparent negative drawings, and two sets of prints on paper to the Engineer for his retention.

3

In addition to the foregoing, the Contractor shall provide in each feeder pillar and distribution unit a good quality print on paper showing the road lighting distribution line diagram of that particular section. These prints shall be mounted on the inside of the door of each feeder pillar and distribution unit and shall be covered in clear plastic to prevent undue deterioration.

4

In order to achieve accurate Record Drawings all relevant information relating to the lighting works shall be entered on to the stated drawings and kept for immediate use once the work has been carried out. The marked prints shall be available for inspection at the Contractor's site office at any reasonable time during the progress of the lighting works.

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END OF PART

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 1

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16 TRAFIC SIGNALS ......................................................................................... 2 16.1 GENERAL ...................................................................................................... 2 16.1.1 Summary 2 16.1.2 References 2 16.1.3 Submittals 2 16.1.4 Quality Assurance 3 16.1.5 Delivery, Storage and Handling 3 16.1.6 General Project/Site Conditions 4 16.1.7 Warranties 4 16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT .............................................. 4 16.2.1 General 4 16.2.2 Identification of Equipment 5 16.2.3 Traffic Signal Posts 5 16.2.4 Traffic Signal Gantries 5 16.2.5 Three-Aspect Traffic Signal Heads 6 16.2.6 Two-Aspect Pedestrian Signal Heads 7 16.2.7 Traffic Signal Controllers 8 16.2.8 Pedestrian Operated Push-Buttons 10 16.2.9 Flexible Traffic Signal Cable 10 16.2.10 Armoured Traffic Signal Cable 10 16.2.11 Loop Cables 11 16.2.12 Loop Feeder Cables 11 16.2.13 Pulling Chamber Cover 11 16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 12 16.2.15 General Compatibility 12 16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT ................................. 12 16.3.1 General 12 16.3.2 Poles, Gantries and Signal Heads 12 16.3.3 Installation of Traffic Signal Controller 13 16.3.4 Cabling 13 16.3.5 Circuit Protection and Earthing Requirements 14 16.3.6 Permanent Electrical Power Supply 15 16.3.7 Inductive Loops for Vehicle Detection 16 16.4 TESTING AND COMMISSIONING .............................................................. 20 16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT ............................................................................................... 21 16.5.1 General 21 16.5.2 Operational Maintenance 21 16.5.3 Emergency Maintenance 23 16.5.4 Contractor’s Vehicles 23 16.5.5 Contractor’s Equipment 23

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TRAFIC SIGNALS

16.1

GENERAL

16.1.1

Summary

1

This Part includes the provision of traffic signal equipment and related street furniture at controlled roadway junctions and pedestrian crossings.

2

Related Sections

16.1.2

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Section 1 Section 5 Section 9 Section 10 Section 21

.

16

References

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The following standards are referred to on this Part: BS 1361......................Cartridge fuses for a..c circuits in domestic and similar premises BS 381C .....................Specifications for colours for identifications BS 5493......................Code of practice for protective coatings of iron and steel structures against corrosion. BS 7430......................Code of practice and regulations for earthing BS 7671......................Requirements for electrical installations BS 88..........................Cartridge fuses for voltages up to and including 1000 Vac and 150 Vac

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BS EN 1011................Process of arc welding carbon and carbon manganese steels BS EN 12368..............Road traffic signals BS EN 13108..............Fine cold asphalt BS EN 60529..............Degrees of protection provided by enclosures BS EN ISO 146 ..........Hot dip galvanised coatings on iron and steel articles

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AASHTO Standard specification for supports for highway signs, luminaires, traffic signals DIN 40050 ..................Enclosures for electrical equipment DIN 6163 Part 5..........Diffusion lenses for traffic signals QGEWC (E) Regulations for Electrical Installations QGEWC (E) Regulations for Protective Multiple Earthing 16.1.3

Submittals

1

The Contractor shall submit to the engineer for approval shop drawings for each type of signal pole, gantry and mounting frame for signal heads to be provided under the Contract along with structural calculations. The drawings shall show materials specification and finishes for each component proposed for use. All weld types and sizes shall be identified on the shop drawings.

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Page 3

The Contractor shall submit to the engineer for approval design calculations for the proposed signal poles and gantries. The design calculations shall be carried out in accordance with the AASHTO Standard specification for supports for highway signs, luminaires, and traffic signals

3

The Contractor shall propose a design for the foundations for each type of signal pole and gantry and shall submit design calculations and drawings to the Engineer for approval.

4

The Contractor shall submit to the engineer for approval a schematic wiring diagram for all the installations. The Contractor shall also submit a wiring layout drawing for the cable loops and the cross-sectional details of the cut in the road surface.

16.1.4

Quality Assurance

1

Contractors for the works shall be experienced specialists in the field of traffic control systems with a minimum of 5 years experience of the installation, commissioning and testing

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of such systems in a similar environment.

The Contractor shall submit a technical submission for the proposed subcontractor giving details of previous installations date installed, client, technical data for proposed materials, and experience record of proposed installation staff, supervisors and management.

3

Installation of traffic signal equipment shall only be conducted by approved specialist subcontractors. The specialist subcontractors shall be approved by the PWA.

4

The performance and design requirements work shall be in compliance with QGEWC Regulations for Electrical Installations.

5

All equipment supplied shall, in general, conform to the same style, colours and functions as that already in place in Qatar. The supplier may be required to provide, at his own expense, samples of his proposed equipment.

6

All equipment and installation shall be in accordance with the latest edition of the Qatar Traffic Manual. For all signalled intersections and pedestrian signal control crossings the timing sequence of signals displayed to drivers during phases shall be as per information given by the PWA and/or Traffic Police.

16.1.5


1

Before delivering a traffic signal controller to site, the Contractor shall arrange a factory acceptance test in his workshop. The programmed and internally complete controller shall be connected to a labelled light board capable of simulating all traffic signal aspects controlled by that particular controller. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with operational requirements. The factory acceptance test shall consist of the following checks:

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(a)

visual check of internal wiring and controller assembly

(b)

operation of green conflict monitor

(c)

intergreen times

(d)

group times

(e)

detector logic (where applicable)

(f)

stage to stage change logic

(g)

lamp switching.

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2

The Contractor shall be responsible for the delivery of all items to the project site or to any site as required by the Engineer.

16.1.6

General Project/Site Conditions

1

All equipment and associated components shall be designed and suitably rated to ensure proper maintenance, continuous trouble free service under the prevailing climatic conditions. All equipment and installation shall operate satisfactorily in a temperature range of 0 C to +55 C and under humidity conditions ranging from 10 % to 100 %. Warranties

1

All warranties and guarantees for traffic signal equipment shall commence from the day of commissioning. The warranty period shall be that as designated by the manufacturer but shall in any case not be less than 400 days

16.2

SUPPLY OF TRAFFIC SIGNAL EQUIPMENT

16.2.1

General

1

It shall be the Contractor’s responsibility to ensure that all equipment supplied is approved. The Engineer will advise on approved suppliers.

2

It shall be the Contractor’s responsibility to honour the designated warranty periods..

3

The Contractor, shall make himself aware of any lead times required for delivery of equipment and programme his works accordingly. It shall be the Contractor’s responsibility to ensure that equipment is available as needed, any delays to works resulting from the unavailability of equipment shall be deemed to be the responsibility of the Contractor.

4

The Contractor shall be responsible for the correct delivery, storage and handling and storage of all equipment up to the time it is commissioned.

5

All equipment shall comprise of units of a type that have been used successfully in other installations in a similar environment, from a minimum period of six months and shall be subject to approval of the engineer. Particular attention shall be given in the selection and design of equipment and components to the exclusion of water, moisture and dust.

6

Components and materials that may perish and deteriorate in the climatic conditions of Qatar shall be avoided. All equipment shall be so constructed as similar units that shall be readily available and completely interchangeable both mechanically and electrically.

7

The location layout of each installation and the number of phases and stages for each traffic controller shall be as designated Controllers shall provide the signal sequences and phasing designated for each installation.

8

The structural design and traffic signal posts and traffic signal gantries shall be in accordance with provisions of AASHTO standard specification, Supports for Highway Signs, Luminaires, Traffic Signals, or an approved alternative.

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16.1.7

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Identification of Equipment

1

The Contractor shall mark or clearly label all modules, units and main parts of a system with a functional code or title, type number, serial number as approved by the Engineer.

2

Marking shall maintain legibility throughout the life of the equipment under the prevailing environmental conditions.

3

The labelling system shall comply with the GIS system (as defined in the data dictionary) used by the Government of Qatar and the PWA.

16.2.3

Traffic Signal Posts

1

Traffic signal poles shall be of the tubular steel type with a flanged base, having an internal electrical termination point accessible through a lockable inspection window. The supply of a traffic signal pole shall include; holding down bolts, nuts, washers and shims required for erection; pole; terminal block; locking cover for inspection window complete with three sets of keys; all grommets; glands and cable anchor points.

2

Traffic signal poles shall have dimensions conforming to those given in the contract Drawings.

3

The traffic signal poles shall be of mild steel construction. Corrosion protection shall be through the use of a hot dipped galvanised coating conforming to the requirements of British Standard BS 5493 and BS EN ISO 1461, depth of galvanised coating shall be 85 microns. All welded connections shall conform to British Standard BS EN 1011.

4

The termination point shall consist of a terminal block positioned internally within the traffic signal pole. The terminal block shall be fully accessible through a lockable inspection window. The terminal block shall be securely fixed to the traffic signal pole.

5

The terminal block shall be electrically isolated from the traffic signal pole and shall have a minimum capacity of 2 x 20 No. connectors. Each connector shall have a minimum rated capacity of 100 watts at 240 volts.

6

The connectors on the terminal block shall be in compliance with the requirements of the QGEWC.

7

The traffic signal pole shall have the facility to secure incoming cables at a point prior to them being connected to the terminal block

8

The traffic signal pole shall be fitted with an electrical earthing stud, such that at least four earth connections can be made to it.

16.2.4

Traffic Signal Gantries

1

Traffic signal gantries shall be of the tubular steel type with a flanged base, having an internal electrical termination point accessible through a lockable inspection window. The supply of a traffic signal gantry shall include: holding down bolts, nuts, washers and shims required for erection; pole caps; terminal block; locking cover for inspection window complete with three set of keys; all grommets, glands and cable anchor points. Traffic signal gantry shall be styled in accordance with Contract Drawings.

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16.2.2

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The traffic signal gantries shall have minimum dimension conforming to those given in the Drawings. The design of the gantries is open to submission by the supplier.

3

The supplier shall provide full details of the materials used and the method of construction employed when quoting for this item, this shall include workshop fabrication drawings, material specifications and calculations pertaining to the structural design of the gantry. The gantry shall be capable of supporting three aspect traffic signal heads, each having a total weight of 25 kg, inclusive of mountings. The number and position of heads are to be as designated.

4

With regard to termination points, cable anchor points and earthing points, these shall be as specified in Section 6 Part12 of this Specification

5

The supplier shall furnish full details of the foundation requirements for his proposed gantry, this shall include details of dimensions, reinforcement, quality of concrete and fixings. Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanized to BS EN ISO 1461.

6

The gantry and foundation design shall be such that the gantry is completely detachable from the foundation, should this be required.

7

The gantry shall have a system such that it can be adjusted subsequent to installation, to allow for leveling and turning.

8

The supplier shall furnish full details of the proposed foundation for his proposed gantry, this shall include details of dimensions, reinforcement, quality of concrete and fixings. The gantry and foundation design shall be such that the gantry is completely detachable from the foundation, should this be required. Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanised to BS EN ISO 1461. The gantry shall have a system such that it can be adjusted subsequent to installation, to allow for levelling and truing.

9

The electrical termination point shall consist of a terminal block positioned internally within the gantry. The terminal block shall be fully accessible through a lockable inspection window. The terminal block shall be securely fixed to the gantry.

16.2.5

Three-Aspect Traffic Signal Heads

1

Three-aspect traffic signal head dimensions shall be as designated. The Contractor shall submit drawings of the proposed units.

2

Signal heads shall comprise of a polycarbonate body containing three traffic signal aspects, coloured red, amber and green and shall include:

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(a)

lamps

(b)

reflectors

(c)

lenses

(d)

transformers

(e)

visors

(f)

anti-phantom devices (if designated)

(g)

brackets, frames and all fixtures and fittings required for mounting

(h)

backing board.

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Page 7

3

Signal heads shall be constructed, in as far as is possible, out of high quality polycarbonate plastic. Any metal fittings shall be suitably protected against corrosion.

4

The design and construction of signal heads shall allow for all of the following features: hinged lens panels to allow quick access to the lamps

(b)

flexible, detachable visors

(c)

easily adjustable mounting system

(d)

capability of internally fitting optical arrow mask.

The signal heads shall use, for each aspect, a 10 volt halogen lamp of type SIG 64015/1 50W or SIG 64015 - 50W. The lamp holder and connectors shall be compatible with the type of lamp used. The lamps shall conform to BS EN 12368. The supply voltage to the signal head shall be 240 volts ( 5 %) and shall be converted to the lamp voltage by the use of a standard design transformer (El Type). Each aspect shall have an individual transformer,

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these transformers shall be fitted with noise suppression equipment. The transformers will be required to operate in ambient temperatures up to 60° C. The transformers shall have a minimum operational life of five years with an effective switch-on ratio of 3300: 4380. Signal heads shall be capable of being mounted on the traffic signal pole or gantry as designated or, in the case of traffic signal gantry, as may be proposed by the Contractor. The mounting system used shall be such that no predrilling or permanent attachment of brackets to the signal pole or gantry is required. The mounting system shall be such that the signal head shall be capable of being adjusted through an arc of 30 degrees about its vertical axis. It shall be possible to mount two three-aspect traffic signal heads side by side on a single pole such that the vertical faces being presented to oncoming traffic of each head remain in the same plane. It shall be possible to mount the signal heads asymmetrical from the centreline of the pole. The signal head shall be rendered splash proof by means of an lP54 enclosure. The item description covering signal heads shall include, where necessary, extra mounting brackets to enable the above facilities.

7

The optical reflector shall be made of a high grade aluminium, mirror finished. Diffusion lenses shall be constructed with an internal cobweb pattern and shall be coloured red, amber or green as defined by the colour limits laid down in the DIN Standard DIN 6163 Part 5.

16.2.6

Two-Aspect Pedestrian Signal Heads

1

Two-aspect pedestrian signal heads shall have the designated dimensions. The Contractor shall submit drawings of the proposed units.

2

Signal heads shall comprise of a polycarbonate body containing two pedestrian signal aspects, coloured red and green and shall include:

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(a)

lamps

(b)

reflectors

(c)

lenses

(d)

transformers

(e)

visors

(f)

anti-phantom devices (if designated)

(g)

brackets, frames and all fixtures and fittings required to mount the signal head.

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Page 8

The material, electrical and mounting requirements for the signal head shall be the same as the requirements for the three aspect traffic signal head.

4

The optical requirements for the signal head shall be the same as the requirements for the three aspect traffic signal head with the additional requirement that each aspect of each two aspect pedestrian signal head be supplied with a 'Walking Man' and 'Stopping Man' optical mask.

16.2.7

Traffic Signal Controllers

1

Traffic signal controllers shall be microprocessor based and capable of meeting all the designated requirements. The Contractor shall submit drawings of the proposed units.

2

Supply shall include:

(b)

all required additional modules and circuits

(c)

all internal wiring

(d)

all detector modules and control circuits

(e)

plates, fixings and fastenings, glands, seals and clips.

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basic control hardware including relays housings and cabinets

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The controller shall be provided with the following operational modes: computer control

(b)

standby co-ordinated

(c)

local mode with multi-plan operation

(d)

flashing

(e)

manual mode

(f)

signal on/off mode.

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Means will be provided within the controller housing to select and to test each of these modes of operation.

5

For pedestrian crossings the controller shall be capable of showing a green flashing man before the end of each pedestrian phase.

6

All controllers shall include a dimming feature.

7

Controllers shall be of a manufacturers type approved by the PWA and/or Traffic Police.

8

All equipment supplied shall be compatible with the existing traffic signal controllers in use in the state of Qatar.

9

Where the supplier cannot provide evidence of his equipment having been previously successfully used with the above traffic signal controllers, he shall be required to demonstrate, at his own expense, the compatibility of his equipment.

10

Traffic signal controllers shall be programmed as designated and as agreed with the Engineer. It shall be the Contractor’s responsibility to provide competent personnel to programme the controller.

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Page 9

Each controller shall be supplied with full documentation which shall include : (a)

wiring diagrams

(b)

timing charts

(c)

intergreen tables

(d)

stage diagrams

(e)

any other relevant information relating to the operation.

Three copies of the documentation shall be supplied with each controller. The controller shall be housed in the cabinet of sufficient size to accommodate the controller and all other associated equipment and shall provide easy access for maintenance and test purposes. The controller and associated equipment shall be arranged within the cabinet so that they will not interfere with the entry and exit cables. The cabinet to house signal controllers shall be constructed of aluminium sheet of thickness 3 mm in accordance with BS

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EN 12368 or with non-metallic materials where the properties for abrasion resistance, exposure to the elements are equal or better than aluminium cabinet. Cabinets shall be painted to a colour and specification agreed by the Engineer. The cabinet shall be weatherproof, rain proof and dust proof and be able to maintain proper operation of equipment. The Contractor shall construct a suitable foundation for the cabinet. and it shall allow for the entry and exit of all cables. The cabinet shall be secured to the foundation by anchor bolts. The traffic signal controller shall be micro-processor based and capable of meeting all the requirements of the operational Specification and any further requirements as specified by the Engineer. The supply of a traffic signal controller shall include for: the basic control hardware including relays housings and cabinets, all additional modules and circuits required to meet the operational Specification, all internal wiring, all detector modules and control circuits, plates fixings and fastenings glands, seals and clips.

14

Traffic signal controllers shall be of an approved type and supplied by an approved manufacturer taken from the most recent list prepared by the Public Works Authority.

15

Traffic signal controllers shall be programmed according to the operational Specification and as agreed with the Engineer. It shall be the Contractor’s responsibility to provide competent personnel to programme the controller.

16

The traffic signal controller shall also have the following capabilities:

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(a)

To give a flashing red pedestrian man before switching to a red man at the end of pedestrian cycle.

(b)

The controller shall include a timing feature.

(c)

The controller shall support two power supply inputs coming from two different substations. The purpose is to continuously operate the controller in case of power failure on one substation by automatically transferring to the other power supply input.

(d)

The controller shall be made to ensure that the dual power supply input is stabilized at 240 volts.

(e)

The controller can be operated manually.

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(f)

The controller shall be capable of providing flashing green before switching to yellow/amber at the end of vehicle green phase

(g)

The controller shall be capable of providing continuous flashing yellow/amber in the channelized island.

Each traffic signal controller shall be fully documented, this shall include: wiring diagrams, timing charts, intergreen tables, stage, diagram and any other relevant information relating to the operation. Three (3) No. copies of the documentation shall be supplied with each controller.

16.2.8

Pedestrian Operated Push-Buttons

1

Pedestrian operated push-buttons shall comply with the requirements and regulations of the QGEWC.

2

The push-button shall include traffic signs as per the Qatar Traffic Control Manual either as an integral part, or be mounted separately on the traffic signal pole or gantry.

3

Push-buttons shall comprise of a metal or plastic body containing a push-button switch and an illuminated text panel in Arabic and English.

4

The unit shall have a light that provides confirmation after a pedestrian has pushed the button.

5

The dimensions and position of the push-buttons shall be proposed by the supplier and approved by the Engineer.

6

Push-buttons shall be constructed of metal or high grade plastics.

16.2.9

Flexible Traffic Signal Cable

1

Flexible traffic signal cable shall comprise of four cored, PVC coated, internal core PVC coated, cable. The cable shall be PVC sheathed wiring, catalogue description being NYM-J, page 2/3 or equivalent.

2

The cable shall be of a rated voltage and current carrying capacity suitable for the proposed cable runs. The Contractor shall submit calculations showing the voltage drop for the cable.

3

Cable shall be supplied in 500 metre lengths and wound onto a suitable cable drum.

4

Cable shall have a minimum cross-section area of the conductor in each core of 1.5 mm2

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and the overall diameter of the cable shall be 11 mm. The individual core may be either solid or stranded. Each core shall be uniquely identifiable by coloured PVC sheathing. 16.2.10 Armoured Traffic Signal Cable 1

Armoured traffic signal cable shall comprise of a multi-cored (number of cores as specified), PVC coated, copper wire armoured, internal core PVC coated, cable. Catalogue description being, PVC-CWA-PVC or equivalent.

2

Cable shall be supplied in 500 m lengths, wound onto a suitable cable drum.

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Cable may be supplied in three sizes, 7 core, 12 core or 19 core. The minimum area of the conductor in each core shall be 1.5 mm2. The individual cores may be either solid or stranded. Each individual core shall be uniquely identifiably by either having a uniquely coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.

16.2.11 Loop Cables Loop cables shall consist of a heat resistant coated core cable. Loop feeder cables shall comprise of a communication type cable, PVC coated having six pair of individually coated cores. The Loop shall be manufactured by Never Fail Loop Systems, USA (local representative Traffic Tech (Gulf), P.O. Box 9377, Telephone Number 4621814) or similar approved.

2

Loops shall be constructed from polypropylene conduit with 9.5mm inside diameter and 16mm outside diameter. Conduit shall be filled with hot rubberised asphalt which allows the loop to remain flexible once cooled to prevent incursion of moisture and set the turns of wire firmly in place. Loops shall have 127mm expansion/contraction joints at intervals along the loop to allow for movement. Each expansion/contraction joint shall have a 229mm long schedule 80 polypropylene cover slide to be placed over the joint.

3

Lead-in wires shall be encased in a non-conductive 2250 psi flex hose constructed with a seamless extruded polyester fiber braid reinforcement and a non-conductive, seamless extruded urethane non-perforated jacket. Fill lead-in hose completely with hot rubberised asphalt. Twist wires in all lead-ins with a minimum of three turns per 305 mm for the entire length of the lead-in. Attach lead-ins to loop heads with a sch. 80 CVPC tee.

4

Loop cable shall have one individual core, the conductor of which shall have a crosssectional area of 1.5 mm2. The loop cable such that the coating is able to withstand direct application of temperatures up to 175 °C.

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16.2.12 Loop Feeder Cables

Loop feeder cable shall have six pairs of individual cores, each of which having a conductor of cross-sectional area of 0.6mm2. Each individual core shall be uniquely identifiable by either, having a uniquely coloured PVC-U sheathing or by its PVC-U sheathing having unique, repetitive marking.

2

The use of alternative types of cable may be permitted with the express written permission of the Engineer.

3

Each individual core shall be uniquely identifiable by either having a uniquely coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.

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16.2.13 Pulling Chamber Cover 1

Pulling chamber covers shall be of ductile iron.

2

The pulling chamber covers shall have a square opening of the dimensions shown on the project drawings.

3

The pulling chamber covers shall be inscribed with wording to identify the type of service and the system reference. The exact wording shall be to the approval of the Engineer.

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16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 1

Unplasticised Polyvinyl Chloride shall be supplied in two different sizes, 2 inches diameter or 4 inches diameter (50mm or 100mm). The colour shall be dark gray. The PVC-U shall be either encased burial type or direct burial type. Catalogue description being, PVC-U Electrical Conduit & Tubing and Utility Duct, NEMA TC-6 or NEMA TC-8 or equivalent.

2

Unplasticised polyvinyl chloride ducts shall be supplied in 6 metre lengths with solvent weld socket on one end. The minimum wall thickness shall be 1.52 mm for 2 inches diameter and 2.08 mm for 4 inches diameter.

16.2.15 General Compatibility All equipment supplied shall, in general, conform to the same style, colours and functions as that already in place in Qatar. The supplier may be required to provide at his own expense, samples of his proposed equipment. These samples shall become the property of the PWA, whether or not an order is placed.

2

All equipment supplied shall be compatible with the approved traffic signal controllers and supplied by an approved manufacturer according to the most recent approved list of the PWA.

3

Where the supplier cannot provide evidence of his equipment have been previously used successfully with the above mentioned traffic signal controller, he shall be required to demonstrate, at his own expense, the compatibility of his equipment.

16.3

INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT

16.3.1

General

1

It shall be the Contractor’s responsibility to ensure that all traffic signal installation work is conducted by skilled, competent personnel.

2

The Engineers approval of any subcontractor or individual personnel in no way relieves the Contractor of his responsibility to ensure that traffic signal equipment is correctly installed.

3

The Engineer shall reserve the right to inspect and approve all installation practices.

4

Installation of traffic signal equipment shall only be conducted by approved companies taken from the most recent list prepared by the PWA.

16.3.2

Poles, Gantries and Signal Heads

1

Signal posts and gantries shall be installed onto their prepared foundations, using two levelling nuts or an appropriate fixing method approved by the Engineer. The pole or gantry shall be plumbed square, irrespective of the orientation of surrounding features.

2

The Contractor shall take every precaution to prevent damage to the pole or gantry's protective coating, during installation. Where the protection is damaged or breached the Contractor shall take immediate action to make repairs.

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Where designated, posts and gantries where necessary shall be painted with an approved paint, colour grey (BS 381C) before installation of signal heads and push-buttons..

4

Signal heads and push-buttons shall be installed as shown on the contract drawings. Final positioning and fixing shall not be undertaken without the Engineer’s approval.

5

Signal heads, once fixed, shall be covered with an opaque protective material such that it is clear to motorists that the signals are not in operation.

16.3.3

Installation of Traffic Signal Controller

1

The Contractor shall install the controller housing in the position defined by the Engineer. The Contractor shall ensure that the housing is positioned so that when the access doors are opened to their fullest extent they will not obstruct the sidewalk or cause a danger in any way to members of the public. The housing shall not be positioned adjacent to the kerb as to render it liable to damage by vehicles or so that the safety of persons working on the controller is not endangered.

2

The Contractor shall organise the connection of the electricity supply to the controller housing and any other peripheral equipment requiring an electricity supply by direct liaison with the QGEWC (E) Consumer Section. The Contractor shall ensure that the power supply is contained within its own separate duct, up to the point at which it enters the controller housing. The electrical supply shall at no point share the same ducts or chambers as the traffic signal cabling. The Contractor, where necessary, shall be responsible for providing any housings required for QGEWC apparatus. Where a separate housing is required it shall be positioned directly adjacent to the controller housing.

3

The Contractor shall endeavour to complete as much of the internal wiring of the controller as possible inside his workshop, such that on-site work within the controller housing are kept to a minimum. All external cables terminating within the controller shall be clearly labelled as to their function, destination and nominal voltage. These cables shall, on entering the controller housing, be clamped and supported such that any stress or strain on the cables themselves shall not be transmitted to the controllers internal components. Spare or redundant cables entering the controller housing are to be terminated in such a fashion that they do not interfere in any way with access to the controllers internal components. The conductors of these cables are to be electrically isolated and sealed against the ingress of moisture.

4

It shall be the Contractor’s responsibility to provide all competent personnel and specialist equipment to enable the controller to be programmed.

16.3.4

Cabling

1

The Contractor shall install all cables in the ducts as designated. He shall take all reasonable care to ensure that no undue stress or strain is placed on the cable during installation and shall adhere to the cable manufacturer’s published data with regard to allowable minimum radius of curvature. The Contractor shall ensure that duct drawstrings remain in place subsequent to cable installation.

2

A single dedicated cable shall service each individual traffic signal pole. This cable shall be of the designated size and shall have a minimum of 10 % spare capacity. On entering the signal

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pole the cable shall be firmly anchored to the pole. At least 3 m of spare cable shall be allowed for within the signal pole, over and above that length which is required to reach the termination block.

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Spare or redundant cores within the cable shall be terminated at the termination block and labelled 'Spare'. The core acting as earth protection shall be connected directly to the body of the signal pole by means of the pole’s earthing stud. The cable armouring shall not be used as the protective earth conductor.

4

With the exception of loop cable to loop feeder cable connections, the jointing of cables shall not be permitted. Where jointing of the cables is permitted, this shall be undertaken using a suitable jointing kit of an approved type which allows the integrity of the protective earth conductors to be maintained. Loop cable to loop feeder cable joints shall only be located within an access chamber.

16.3.5

Circuit Protection and Earthing Requirements

1

The Contractor shall provide protection against dangerous earth-leakage currents by the use of fuses or excess-current circuit breakers compliant with the QGEWC (E) Regulations for

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Electrical Installations. The Contractor shall ensure that all installations shall be such as to allow for the operation of the protective devices to operate upon the occurrence of a fault within the time period specified for fixed equipment installations and that all non-current carrying metallic parts shall be connected to the earth terminal in such a manner as to ensure that a hazardous voltage cannot exist on exposed conductive metalwork. All cabinets, posts and other metal hardware comprised by the traffic signalling equipment shall be bonded via protective conductors to the main earth terminal with an earthing conductor to the main terminal by a protective conductor. The main earthing terminal or bar shall comply with QGEWC (E) Regulations for Electrical

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installation and shall be connected to the earthing point provided by the QGEWC (E) with a copper earthing conductor in accordance with the Regulations. It shall have a minimum cross-sectional area of 6.00 mm2 and shall be green/yellow stripe coded. The earthing conductor is defined as a protected conductor connecting a main earthing terminal or bar of an installation to an earth electrode of other means of earthing. Where a residual current circuit breaker is used, the cross sectional area of the earthing conductor shall comply with the requirements of QGEWC (E) Regulations. The connection to metalwork shall be made internally to a secure terminal on a part of the enclosure which is a permanent fixture. The terminal shall be constructed of a material which will minimise chemical corrosion resulting from contact with the protective conductor or other metal part. Conductor terminations shall be by the use of soldered or crimped connectors or screwed terminations, or other approved methods.

4

Earth and other protective conductors shall be selected and installed so that they comply with the QGEWC (E) Regulations for Electrical Installations, the BS 7430, BS 7671 and the Regulations for Protective Multiple Earthing where appropriate. All protective conductors shall be colour coded green/yellow stripe. Where protective conductor is part of a multicore cable and a green/yellow stripe colour coded core is not available, the Contractor shall ensure that the protective conductor is adequately identified. Each cable shall enter the controller housing via a stuffing gland in the gas plinth gland plate. The stuffing gland shall be so designed as to prevent the diffusion of gas and support the cable. The earth stud of the cable terminator shall be correctly bonded to the earth bar in accordance with the QGEWC (E) Regulations, using a 6.00 mm2 conductor (2.50 mm2 for loop feeder cables).

5

The earthing requirements at the head of each traffic signal pole shall be as follows:

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the earth terminal of the gland, shall be connected to the earth terminal of the pole with a protective earth conductor correctly terminated with crimp connectors and having a minimum cross-sectional area of 6.00 mm2

(b)

the protective conductors from each signal head, pedestrian head, push-button unit or other equipment shall be connected together at the head of each pole and connected to the earth terminal in the controller housing by means of one dedicated core of the armoured signal cable servicing that pole

(c)

the earth connection at the head of the pole specified in (b) above, shall be connected to the earth stud of the pole with a bonding conductor having a minimum area of 6.0 mm2 and by means of a crimped connector, or similar

(d)

push-button units fixed to a signal pole shall be earthed to the earth stud of the pole with a separate protective conductor terminated with crimp connectors and having a minimum cross-sectional area of 6.00 mm2

(e)

There shall be electrical connections by means of conductors having a copper equipment cross-sectional area of not less than 6.00 mm2 between the earthing

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terminal and all metal structures, metal pipes and other metalwork (not being metalwork forming part of a telegraphic, telephone or signalling circuit) which

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These connections shall be made as near as practicable to locations where users or maintenance staff approach the facility. Permanent Electrical Power Supply

1

The Contractor shall be responsible for liaison with QGEWC (E) to provide a power supply to the traffic signal controller and shall be responsible for all works required to provide this supply.

2

The electricity supply shall be 240 V AC 50 Hz single phase.

3

The Contractor shall organise, with the approval of QGEWC (E), one of the following earthing systems:

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16.3.6

(a)

TN-S System. Where QGEWC (E) will provide an earthing point which affords a continuous metallic return path to the earth of the supply system. The Contractor’s earthing conductor shall be connected to this point

(b)

TN-C-S System (PME). Where QGEWC (E) will provide a combined neutral earth supply. The earthing Contractor’s earthing terminal and a lead from the earth terminal shall be left available for the QGEWC (E) to connect to the incoming supply. A similar neutral conductor lead shall also be left available for the same purpose

(c)

TT System. Where a means of earthing will not be provided by the QGEWC (E) the earthing terminal will be connected to an effective earth electrode compliant with the QGEWC (E) Regulations for Electrical installations. Where the TT System is provided by the QGEWC (E) the Contractor shall install an earth leakage circuit breaker to comply with the QGEWC (E) Regulations.

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The Contractor shall ensure that the equipment complies in all respects with the regulations and requirements of the QGEWC (E).

5

The Contractor shall be responsible for all cable laying and jointing.

6

It shall be the responsibility of the Contractor to inform the Engineer of the earliest date when he will be ready for the QGEWC (E) to make the service connections.

7

The Contractor shall supply the equipment to be terminated to the QGEWC (E) service with phase and neutral conductors of not less than 4 mm2 and earthing conductor of not less than 6 mm2. The QGEWC (E), shall connect the controller conductors and earth conductor to the terminal provided by the QGEWC (E).

8

The QGEWC (E) cut-out shall incorporate a high breaking capacity fuse carrier and fuse to BS 88 or BS 1361 of the correct rating. The rating shall be specified by the Contractor to comply with the type requirements of the QGEWC (E) Regulations. The maximum permissible earth fault loop impedance shall be those stated in the QGEWC (E) Regulations.

16.3.7

Inductive Loops for Vehicle Detection

1

Slot cutting shall be carried out by a specialist subcontractor. The Contractor shall be responsible for marking out all slot configurations and shall supervise the work of the subcontractor. The slot cutting subcontractor shall make arrangements to provide an adequate water supply to enable him to carry out the necessary works. The approximate position of inductive loops and route of feeder cables will be as designated. The Contractor shall specify the loop configurations at each site, the detailed layout of individual loops and the number of turns per loop. This information shall be supplied to the Engineer. When loop configurations are specified by the Engineer, such information as required will be supplied to the Contractor. In order to obtain a high standard of installation, the Contractor's staff and subcontractors shall be fully briefed by the Contractor and given written instructions describing the technical requirements of this specification and method of installation. This shall cover depth and preparation of slots, backfilling, jointing, ducting under kerbs, earthing and commissioning of equipment.

2

Subsurface detector housings for loop detection equipment are not acceptable to the Engineer. Detector housings shall be positioned so as to reduce the possibility of damage in the event of a road traffic accident and shall not present an obstruction or visual intrusion. In cases of doubt, the advice of the Engineer shall be sought. Positions of detector housings shall be to the approval of the Engineer. Where a remote detector housing is used, each one shall be connected to the controller by 'Twinflex' cable. The cable will be ducted to the controller unless the Engineer's agreement is obtained to cutting a slot in the carriageway. Voltages on this cable shall not exceed 50 V AC or 120 V DC whether between conductors or

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to earth. The Contractor shall provide two sets of keys to all equipment housing supplied as initial issue. The Contractor shall be responsible for removing all surplus materials from site at the completion of the works.

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The cable specified may in exceptional circumstances be replace with an armoured multicore cable (i.e.. triple vehicle extensions with speed discrimination) double vehicle extensions with speed assessment. The cable specified shall be terminated at the controller with a cable gland or castellated bar approved by the Engineer. The gland shall be bonded to the earth point using a 4 mm2 flexible earthing cable terminated with crimp connection tags. The remote end of the cable shall be connected to the plate and 4 mm2 flexible earthing cable terminated with crimp connection tags or by other means approved by the Engineer. In addition one core of the armoured cable shall be used as an earth continuity conductor and shall be bonded to the earth point on the controller and to both the equipment earth and the metalwork of the housing at the remote end of the cable. The cable specified shall be provided with a minimum of 25 percent spare conductor capacity (armoured and nonarmoured multicore cables only).

4

The detector shall operate satisfactorily with a feeder up to 100 metres in length. The feeder is defined as the cable between the loop tails and the detector housing. Where adjustments are required to sensitivity and presence time, these shall be made during initial setting-up and no further adjustments shall be necessary. The equipment, including loop and feeder, shall operate correctly within all carriageways of reasonable condition without any reduction in performance as follows: air temperature (-10°C to 60°C)

(b)

relative humidity up to 100 % (non-condensing)

(c)

carriageway flooded under 1 cm water, or dry

(d)

carriageway subjected to continued heavy use by buses and heavy goods vehicles

(e)

sidewalk and kerbs subjected to misuse by vehicles

(f)

feeder assumed to be buried in soil or sand which may be dry or wet

(g)

the detector shall not operate from electrical noise pick-up on the loop or feeders.

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Slot-cutting operations shall not be conducted in wet weather. Wet weather to be defined as such conditions where the Engineer considers it would be unsafe to carry out slot cutting operations. Slots shall be cut using a motorised machine fitted with a diamond saw blade. The layout of the loop configuration shall avoid areas of poor reinstatement in the road surface caused by other roadworks or works. Slots shall be cut at least one metre from any such disturbance. Slots shall be cut at least one metre from any ferrous objects such as manhole covers. In concrete road surface, the Contractor shall not cut slots less than 1.5 metres from transverse joints between adjacent concrete sections. The depth of loop slots shall be (50 + 7.0 n) mm with a tolerance of + 10.0 mm / - 0.0 mm. In concrete surfaces the depth shall be (25 + 7.0 n) mm with a tolerance of + 5.0 mm / - 0.0 mm where 'n' is the number of cables and the first figure is the minimum depth of cover. The depth of each slot shall be checked with a depth gauge along the whole length of the slot. The Contractor shall ensure that there are no irregularities in the base of the slot. Where an angle more acute than 13 degrees in formed at the junction of two adjacent loop slots, then the slot junction shall be truncated with a saw cut at the apex of the junction; i.e., one blade thickness from the inside edge of the slot corner, and this cut shall be to the same depth as the adjoining slots. The junction shall not be truncated with a cold chisel. Slots cut for feeder cables shall be 20 mm wide (core cables 25 mm) with a tolerance of 3 mm, to give a cover of 65 mm in bituminous surfaces (45 mm in concrete surfaces) with a tolerance of + 10.0 mm / -0.0 mm. Only one feeder cable shall occupy each slot.

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The loop feeder cables shall take the most direct route to the indicated cable chamber. This slot is specified as being 20 mm wide, therefore care shall taken not to obliterate any road markings in whole or part. In the first instance the most direct route from the loop position to the kerb line shall be taken. The loop feeder cables shall be joined in the carriageway only with the approval of the Engineer. The joint slot shall be 10 mm wider and 10 mm longer than the overall dimensions of the completed joint. The depth of the slot shall be sufficient to give a minimum 40 mm cover above the joint. The joint slot shall be positioned either at a traffic lane boundary or at crown of the road so that it is not subjected to the maximum stresses exerted by road vehicles. Each loop shall be separated from adjacent loops by a minimum of 100 mm. The Contractor's supervisory staff shall check the quality of workmanship before laying cable and backfilling. All debris and slit shall be cleared from the base of the slot and the slot blown dry with compressed air before cable laying.

7

For laying loop cables the cable shall be dry before installation. The Contractor shall ensure that the cable lies evenly in the bottom of the slot, and shall secure the cable in such a position if necessary. Sharp implements shall not be used to seat the cable in the slot. Loop tails shall not extend more than 20 metres from the loop before being joined to the feeder cable. Loop tails shall be twisted. Each twisted tail shall have a dedicated slot to the joint with feeder cable. Loop tails shall normally be joined to the feeder cable within cable inspection chambers. Cables shall not be bent to a radius of less than 12 times their diameter or less than a radius recommended by the manufacturer whichever is the greater. Where cables enter the sidewalk a small area of carriageway is to be excavated and a uPVC duct laid through the kerbs for each feeder cable. The duct shall be level with the base of the slot from which the feeder cable emerges. The excavated area shall be backfilled with fine aggregate concrete to the duct invert level. The cables shall then be backfilled with compacted fine cold asphalt and hot oxidised bitumen R85/40. The kerb stone shall be reinstated. Feeder cables in soft verge or beneath sidewalks are to be laid in ducts at a minimum depth of 500 mm below ground level unless otherwise specified by the Engineer. Feeder cables laid unducted in trenches shall be laid on a 75 mm bed of sand free from stones and other sharp materials with a further 75 mm of similar sand placed over the cable. Where feeder cables are laid unducted in soft verges, the cable position shall be indicated with a plastic warning tape laid at a depth of 150 mm to 200 mm from ground level and vertically above the cable. The tape shall be printed with suitable warning message repeated at one metre intervals. Where feeder cables are required to cross French drains or other coarse bed materials in central reservations, the cable shall be looped and protected with flexible plastic ducting. Ducting is to be provided by the installation Contractor.

8

Cable joints shall be approved by the Engineer. Feeder cables shall be electrically connected to the loop tails with insulated crimp connector using a ratchet type of crimping tool. The Contractor shall ensure that the cable conductor has been correctly crimped by visually checking the cable and also by applying a vigorous pull test to the cable on either side of the joint. The electrical connectors shall be encased in a joint approved by the Engineer and the Contractor shall ensure that the connectors are staggered to avoid the possibility of any short circuits. The Contractor shall ensure that any instructions issued by the cable joint manufacturer are provided in writing to his installation and supervisory staff. These instructions shall form part of this specification. The Contractor shall ensure that the joint is waterproof before backfilling. With the exception of cable joints between loop and feeder cables, no other joint shall be permitted in the loop/feeder configuration. Cables shall be terminated in the controller or detector housing using terminal connection blocks which are adequate in size for the diameter of conductors used. Screws shall not bear directly onto conductors, either a protective leaf in the terminal or a crimped pin on the end of the conductor shall be used.

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Immediately before backfilling, the Contractor shall ensure that all slots are clean and dry and that all silt and debris has been removed from the base of the slot. Loop slots shall be backfilled with a low viscosity epoxy resin, approved by the Engineer, to give a minimum of 10 mm cover above the uppermost cable. The resin specified shall be poured at a viscosity of between 500 and 1000 pascal seconds. The Contractor shall provide the Engineer documentary evidence from the resin manufacturer of the temperature necessary to achieve this viscosity. The Contractor shall satisfy the Engineer, before epoxy resin operations commence, that the specialist subcontractor’s on-site equipment is able to raise the epoxy resin and maintain it at the temperature necessary to achieve the viscosity specified. The remaining volume of loop slot shall be backfilled with blown grade hot oxidised bitumen to the level of the road surface. Feeder cable slots shall be backfilled with fine cold asphalt compacted around the cable. The upper 20 mm of the slot shall be filled with hot oxidised

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from an enclosed container which shall be preheated before use. The fine cold asphalt specified shall comply with the requirements of BS EN 13108. The asphalt shall be soft and easily worked when applied, and shall be hand compacted to the satisfaction of the Engineer. Alternative compounds proposed by the Contractor shall be approved by the Engineer. The contractor shall be responsible in determining the exact location of the loops and shall supervise the work of the sub-contractor. The sub-contractor shall mark the locations of the performed inductive loops. Each shall be separated from adjacent loops by a minimum of 100mm and shall be laid on top of the road base or 230mm form the road surface.

11

The cable shall be dry before installation. The sub-contractor shall lay the performed inductive loops and stretch it as per the marked locations. The T-joint of the loops shall be positioned to the nearest chamber/pull box/detector hand hole. The loops shall be fixed by using a clamps and nails to achieve the desired shape

12

The loop wires from the preformed loop to the adjacent chamber/pull box/detector hand hole shall be twisted together into a pair with minimum of three turns per 305mm and encased in polypropylene conduit and/or 2250 psi hydraulic hose between the performed loop and the adjacent chamber/pull box/detector hand hole. Lead-in conduit shall be 100% injected with hot asphalt sealant to prevent the entrance of water at the chamber/pull box/detector hand hole.

13

Asphalt shall be manually laid around the loops to protect it from the pavement machine/equipment.

14

Upon completion of the installation works, the Contractor shall lay the asphalt on the entire carriageways by using the approved pavement machine.

15

Each loop shall be tested sequentially by three methods: by megger (measured by mega ohms), by resistance (in ohms), by inductance (measured in micro henries).

16

In case of existing pavement, a groove shall be cut by using a slot cutting machine. The frames and home-runs shall be placed into the cuts. The cuts shall be filled with hot melted asphalt-rubber sealant conforming to the manufacturer’s recommendations.

17

All the installation works shall conform to the manufacturer’s specifications.

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16.4

TESTING AND COMMISSIONING

1

Before delivering a traffic signal controller to site, the Contractor shall arrange a factory acceptance test in his workshop. The programmed and internally complete controller shall be connected to a labelled light board capable of simulating all traffic signal aspects controlled by that particular controller. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with operational requirements. The factory acceptance test shall consist of the following checks: visual check of internal wiring and controller assembly

(b)

operation of green conflict monitor

(c)

intergreen times

(d)

group times

(e)

detector logic (where applicable)

(f)

stage to stage change logic

(g)

lamp switching.

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(a)

All traffic signal equipment shall be commissioned to the satisfaction of the Engineer.

3

It shall be the responsibility of the Contractor to supply all equipment and personnel required to commission the traffic signal equipment.

4

On completion of installation, and before commissioning, the Contractor shall undertake the following tests to the satisfaction of the Engineer and in accordance with the QGEWC (E) Regulations.

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2

visual inspection

(b)

continuity test of all protective conductors

(c)

insulation resistance test; insulation resistance shall not be less than 100 megaohms

(d)

polarity check

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(e)

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(a)

earth loop impedance test.

Where a residual current circuit breaker is installed, tests in accordance with the QGEWC (E) Regulations shall be complied with. The Contractor shall provide the equipment necessary to complete the tests and shall provide all other test equipment to demonstrate that the installation is compliant.

6

After the traffic signal and controller equipment is installed on site and after it is connected to all its associated equipment, the Contractor shall arrange for a site acceptance test. The site acceptance test will recheck all the points covered in the factory acceptance tests and in addition shall include visual and electrical tests on all posts, gantries, heads, push-buttons and cabling. The Contractor shall ensure that the area of site covered by the installation being tested is cleared of all debris, plant and machinery. The Contractor shall be responsible for the supply of any personnel required to conduct the site acceptance test. The Contractor shall provide any vehicles required to conduct the site acceptance test. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with the operational requirements.

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Page 21

Each loop and feeder configuration of the vehicle detection system shall be tested as follows and the results given in a test certificate for the loop installation. This certificate shall include all pertinent information for the testing. The Contractor shall submit a pro-forma certificate to the engineer before carrying out the commissioning. (a)

With the loop circuit disconnected from the detector, the impedance to earth of the two loop and feeder conductors shall be measured at a test voltage of 500V DC applied for at least one minute. This shall not be less than 10 megaohms. The two ends of the loop circuit shall be connected together for this test

(b)

With the armouring of the feeder cable disconnected from the earth point, the impedance to earth of the armouring shall be measured at a test voltage of 500V DC applied for one minute. This shall not be less than 10 megaohms

(c)

With the armouring of the feeder connected to the earth point of the equipment housing, the impedance to earth of the armouring shall be measured. This impedance shall not be greater than 0.5 ohms

(d)

The inductance of the loop and feeder circuit shall be measured. This shall be comparable with the theoretical value previously supplied to the Engineer

(e)

The frequency of operation of each configuration shall be measured. Where two loop circuits share a common feeder cable their frequency of operation shall be separated by at least 5 kHz

(f)

The Contractor shall adjust the sensitivity and presence time of each detector to the requirements specified by the Engineer. The Contractor shall demonstrate correct operation of the detector at the sensitivity specified

(g)

The Contractor shall ensure that an inductance change caused by vehicles in one loop shall not induce spurious observations in any adjacent loop system.

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Any loop or feeder which fails these tests shall be replaced by the Contractor at his expense.

9

Upon satisfactory completion of the factory acceptance and site acceptance tests, and when the Engineer is fully satisfied that correct installation and adherence to the operational requirements has been attained. The PWA will issue a final commissioning certificate. The installation, or any part thereof shall not be opened to general traffic until this certificate is received.

16.5

GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT

16.5.1

General

1

During the initial maintenance period complete record of component failures shall be kept by the Contractor in order to provide information on the reliability of various components.

16.5.2

Operational Maintenance

1

The Contractor shall provide full operational maintenance coverage for a period of 400 days subsequent to the issuance of the final commissioning certificate.

2

The Contractor shall use only maintenance contractors approved for this work by the PWA.

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Page 22

During the maintenance period, the Contractor shall be responsible for providing coverage for the following: (a)

Replacement or repair and installation of any failed equipment

(b)

Daily corrective maintenance

(c)

Quarterly maintenance Check the cycle length, green time, intergreen time and all other signal timing parameters as given in the timing chart. (ii) Check the timings of the different signal programmes and test the switch over them manually and by time clock. (iii) Test loop detectors for activation and re-tune if necessary. (iv) Test ELCB and any other circuit breakers. (v) Replace any items that show significant wear and/or are operating outside of the manufacturer’s tolerances. (vi) Test operations of pedestrian push buttons (vii) Check timing of Flashing Units (viii) Service controller in accordance with manufacturer’s specifications (ix) All signal heads, reflectors, optical lenses and backing boards shall be cleaned (both internally and externally) in accordance with the manufacturer’s specifications (Bi-annual maintenance - The following works are to be carried out in addition to those described in section (c)

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(d)

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(ii) (iii)

All signal poles and gantries shall be painted and renumbered. The signal poles and gantries shall be coated with primer, red-oxide, and two coats of colour grey paint. The paint specification/colour shall be approved by the Engineer. All inspection chambers shall be cleaned properly. Timings for all signals shall be altered as directed by the Engineer at the beginning and end of the month of Ramadan. Minor changes to the controller’s operational configuration (Changing of phasing /staging, green times and intergreen times) as deemed necessary by the PWA’s traffic signal engineer.

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(i)

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(e)

All protective earth conductors shall be inspected and tested. All lamp fittings and connectors shall be dismantled and cleaned. Signal heads shall be checked for correct alignment and all brackets and clamps tightened. (iv) All electrical connectors are to be checked and cleaned where necessary. Annual maintenance - The following works shall be carried out in addition to those described in sections (c) and (d)

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(i) (ii) (iii)

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(iv)

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The Contractor shall ensure that personnel are available to maintain equipment such that failed equipment shall be replaced or repaired within four hours of notification of the fault. Where controller configuration changes are required, the Engineer shall allow a reasonable period for the Contractor to respond.

5

Failed equipment shall be replaced/repaired within 4 hours of notification of the fault.

6

Where controller configuration changes are required, the Engineer shall allow a reasonable period for the Contractor to respond.

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Page 23

Emergency Maintenance

1

In the case of accidental damage or 'knock downs' or any other equipment failure deemed to be outside of the Contractor’s control, shall not be required to take responsibility for repair or replacement. However it shall be the Contractor’s responsibility to provide the immediate onsite response to a police or the PWA request.

2

Upon the PWA having effected a remedy to any emergency maintenance requirement, it shall be the Contractor’s responsibility to ensure that all repairs or replacements have been conducted to a standard such that no warranties become invalid.

3

If the Contractor feels that any repair or replacement is not of sufficient standard to maintain his warranty he shall notify the PWA with 14 days of any such repair or replacement having been conducted.

16.5.4

Contractor’s Vehicles

1

The Contractor shall arrange a vehicle mounted hydraulic platform with boom and any additional vehicle for the use of his staff whenever required throughout the maintenance period.

2

The vehicles shall be provided with a flashing amber roof light array.

3

The contractor shall be responsible for any cost associated with the vehicles.

4

The hydraulic platform shall be capable of performing the required vertical and horizontal manoeuvres safely and satisfactorily, including adequate platform capacity and boom articulation.

5

The contractor shall gain approval from the Engineer as to the vehicle acceptability prior to supplying the said vehicle.

16.5.5

Contractor’s Equipment

1

The Contractor shall be responsible for supplying any regular or special equipment or tools required for the satisfactory undertaking of the works. In particular this shall include, but not limited to:

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16.5.3

(a)

Specialised commission/testing equipment for all the current traffic signal (Siemens, Futurit, Peek and Tyco) controllers to allow Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT).

(b)

Portable keyboard interfaces to allow interrogation and on-site programming of microprocessor signal controllers for all the traffic signal systems.

(c)

Workshop based aspect simulators to allow for Factory Acceptance Tests.

END OF PART

QCS 2014

Section 06: Road Works Part 17: Road Drainage

Page 1

ROAD DRAINAGE................................................................................................... 2

17.1 17.1.1 17.1.2 17.1.3 17.1.4

GENERAL REQUIREMENTS .................................................................................. 2 Scope 2 References 2 Quality Assurance 3 Delivery, Storage and Handling 3

17.2

DRAINAGE PIPES & PIPELINES ............................................................................ 3

17.3

EXTENDING PIPELINES ........................................................................................ 4

17.4

ROAD GULLIES ...................................................................................................... 4

17.5

MANHOLE COVERS AND GULLY GRATINGS ...................................................... 4

17.6

SOAKAWAYS ......................................................................................................... 5

17.7

SOAKAWAY BOREHOLES ..................................................................................... 6

17.8

TESTING AND CLEANING SURFACE WATER DRAINS ....................................... 7

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17

TRENCH SOAKAWAYS .......................................................................................... 7 General 7 General 7 Pipe 7 Geotextile Fabric 8 Single Sized Coarse Aggregate 8 Catchpit Chambers 9 Road Crossings 9 Geocellular Stormwater Attenuation / Soakaway Trenches 9 The maximum installation depth, to base of units, shall normally not exceed the height of 10 17.9.9 Reinstatement above Trenches 10 17.9.10 Testing 10

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17.9 17.9.1 17.9.2 17.9.3 17.9.4 17.9.5 17.9.6 17.9.7 17.9.8

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17.10 GEOCELLULAR TANKS ....................................................................................... 10 17.10.1 Geocellular Units 10 17.10.2 Geocellular Tank Arrangement 10

QCS 2014


17

ROAD DRAINAGE

17.1


17.1.1

Scope

1

This Part includes: stormwater drainage works draining the road carriageway and directly adjacent areas, including: (i)

road and other pavement gullies and gully pots

(ii)

pipes of minimum 150mm diameter including bedding materials used to connect gully pots to inspection chambers and intermediate manholes

groundwater drainage using filter drains within the road corridor

(c)

soakaways specifically related to road stormwater and groundwater collection and disposal

(d)

connections to stormwater drainage systems including culverts, open channels and closed stormwater drainage pipelines.

(e)

Geocellular attenuation and soakaway trenches and tanks.

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(b)


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This Section

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(a)

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Geosynthetics

Section 5

Concrete

Section 8

Drainage Works

Section 20

Drainage Works for Buildings

Part 3

External Drainage Works

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Part 18

References

1


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17.1.2

BS EN 124 ..................Gully tops & manhole tops for vehicular and pedestrian areas BS 4962 ......................Plastic pipes and fittings for subsoil drainage BS 5911 ......................Concrete pipes ancillary concrete products BS ISO 14654 ............Epoxy coated steel ISO 9001 ....................Quality assurance in production and installation BRE digest 365 - Soakaway Design

QCS 2014


Page 3

Quality Assurance

1

The manufacturer of all manholes and gully gratings shall be accredited to a third party quality system such as ISO 9001. The supplier shall submit a copy of his accreditation showing the scope of products covered.

17.1.4


1

All manhole covers and gullies shall be clearly marked with the technical standard of manufacture, the loading class, the name identification mark of the manufacturer and the mark of the certification body.

17.2

DRAINAGE PIPES & PIPELINES

1

The materials, manufacture, finish, installation inspection and testing of all drainage pipes and fittings for roadworks shall comply with the requirements of Part 3 of Section 20, except as modified by this section of the specification.

2

The type of pipe to be used and the diameter shall be as designated on the drawings or in the project specification.

3

Pipes may be of vitrified clay, concrete, glass reinforced plastic or UPVC. Each of these pipe types shall meet the designated requirements for standards, materials, manufacture, strength, length and dimension of tolerances joints, workmanship and finish, inspection and basis of acceptance given in Part 3 of Section 20.

4

Unless designated otherwise only one type of pipe shall be used within any individual drain or service duct between consecutive chambers.

5

The Contractor shall ensure that plastic pipes are not subject to deterioration due to exposure to sunlight between manufacture and installation in the ground.

6

The excavation, bedding, laying and backfilling around pipelines shall be carried out in accordance with Part 2 of Section 8.

7

Soft spots below the bottom of an excavation shall be removed as directed by the Engineer and the resulting void backfilled with granular material to the approval of the Engineer.

8

Any additional excavation below the bottom of the line required shall be made good with granular material.

9

The pipes shall be laid at the designated levels and gradients. The deviation in level from that designated at any point shall not exceed 20 mm unless agreed otherwise by the Engineer.

10

Pipes shall be laid so that each one is in contact with the bed throughout the length of its barrel.

11

Parts and fittings shall be examined for damage and shall be cleaned immediately before laying. Any pipes that are damaged shall not be used in the works.

12

Measures shall be taken to prevent soil or other material from entering pipes and to anchor each pipe to prevent moving before the work is complete.

13

The pipe bedding material shall be as designated on the project drawings or in the contract documents.

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QCS 2014


Page 4

EXTENDING PIPELINES

1

Where it is designated that existing drains are to be extended and connected to new drain chambers or channel, the connections shall be made during the construction of the new drain. The Contractor shall inform the Engineer in writing of the proposed position for the connection and the detail of the connection. The position of the connection shall be recorded by the Contractor on a drawing.

2

The new connecting pipe shall be aligned such that the angle between the existing pipe and the new pipe is not greater than 60 %.

3

Before entering or breaking into an existing drain, the Contractor shall obtain approval from the authority responsible for the pipeline.

17.4

ROAD GULLIES

1

The type, position, dimensions and clear openings of gullies will be as designated on the drawings or in the project specifications.

2

Gullies shall be constructed so that no part of the spout or trap has a cross sectional area less than 2/3 that of the outlet.

3

Precast concrete gullies shall comply with BS 5911 Part 2.

4

Cast iron and steel gully gratings shall be kerb type gullies complying with BS EN 124 unless

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17.3

otherwise shown on the Contract Drawings. The upper surface of gully gratings shall be flat except where otherwise designated. Slots in gratings or between gratings and frames shall not be orientated parallel to the direction of traffic, except where the slots are less than 150 mm long or less than 20 mm wide.

6

The frames shall be bedded on a 1 to 3 cement sand mortar.

7

Backfilling to precast gullies shall be carried out to formation level with general fill. Where mechanical compaction is impractical, the backfill shall be concrete of the designated grade.

8

Gully connections shall be constructed of minimum 150mm diameter Unplasticised PVC (PVC-U) pipes in accordance with BS 4660 or ESVC pipes in accordance with BS EN 295. Where required by the Engineer, these shall be bedded and surrounded with concrete with movement at the joints permitted by the insertion of compressible material which shall extend to the outside of the concrete surround.

17.5

MANHOLE COVERS AND GULLY GRATINGS

1

Manhole covers and gully gratings shall be formed from ductile iron with an element of graphite spheres to produce a molecular structure that gives the required tensile strength and shock load resistance.

2

Drainage products may be produced from grey iron and shall be hard wearing, inherently stable and highly resistant to flexing.

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Page 5

The type of manhole cover; i.e., square, rectangular, double triangular, single cover shall be as designated on the drawings.

4

During installation the frames shall be properly bedded and levelled to prevent rocking or any lateral movement of the frame.

5

Covers and frames shall be kept together as a supplied unit and interchangeability between various covers and frames shall not be permitted.

6

All castings shall be supplied with a black epoxy coating finish.

7

The tops of all manhole covers shall have a non-slip surface to provide adequate grip.

8

When so designated, the supplier shall arrange for specific lettering to be cast into the top of the covers. The lettering shall be up to a maximum of 4 letters or digits.

9

Manhole covers and gullies shall meet the requirements of BS EN 124, European Standard for access covers of gully tops for vehicular and pedestrian areas.

10

All manholes covers and gullies supplied shall have been verified as being manufactured to BS EN 124 by third party assessment body for both quality procedures and technical

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requirements.

The manholes’ covers or gullies shall meet one of the loading categories specified in BS EN

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Table 17.1

Class

Loading, Tonnes

A 15

1.5

B 125

12.5

C 250

25

D 400

40

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Loading Categories for Manhole Covers on Gullies

12

For a manhole entry to sewer and surface / ground water manholes a minimum of 750mm square clear opening shall be provided. For entry to TSE chambers a minimum of 675mm square opening shall be provided.

13

For manholes situated in the carriageway a three point cover seating shall be adopted to prevent any movement or rocking.

14

Where hinged gully gratings are installed the edge with a hinge shall face the traffic to ensure the cover closes if inadvertently left opened and hit by traffic.

17.6

SOAKAWAYS

1

Soakaways shall be constructed using precast concrete rings. Concrete works shall comply with the requirements of Section 5 of the specification. Concrete shall be Grade C50 for the precast concrete rings and the cover slab, using Sulphate Resisting Portland Cement.

QCS 2014


Page 6

2

The cover slab shall be of the dimensions and contain the reinforcement as shown on the drawings or detailed in the Project Specifications.

3

The structural concrete shall be designed for durability and shall include as a minimum the following specification: (a)

minimum cover 40mm

(b)

all surfaces to be painted with an epoxy protective coating meeting the requirements of Section 5 Part 14 of the specification. The protective coating shall be factory applied to precast elements.

4

The soakaways shall have an internal diameter of 1.8 m unless otherwise designated and

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shall be of a minimum depth of 3 m unless otherwise designated. The precast concrete rings shall be at least 150 mm thick and shall have three evenly spaced

No permanently embedded metal parts shall be left with a cover less than 40 mm from the

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lifting points.

surface. The precast rings shall be constructed with 50 mm diameter holes at 400 mm

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centres in rows spaced 300 mm apart. The holes shall be alternately offset. The bottom ring shall be founded on insitu blinding concrete 200 mm deep.

8

The soakaway shall be surrounded by granular material which shall infill the whole void between the soakaway and the undisturbed ground around the excavation.

9

The granular material shall be laid in tamps in 150 mm layers and shall nowhere be less than

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225 mm in width.

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7

The granular material shall be clean durable, sharp-angled fragments roughly cubical or pyramidal in shape, of un-weathered rock of uniform quality graded and tested in accordance with Tables 14.3, from a source approved by the Engineer

11

Cast iron covers and frames shall be to BS EN 124 of the designated loading class.

12

Geotextile material lining to the outside of the soakaway excavation shall be in accordance with Table 17.2 of this Section. The placing and laying of the material shall be in accordance with the manufacturer’s instructions and Part 15 of this Section.

13

The geotextile material shall not be left exposed to the sun for a period greater than 7 days before burying.

17.7

SOAKAWAY BOREHOLES

1

The Contractor shall drill soakaway boreholes at the locations shown on the drawings. Unless designated otherwise the boreholes shall be 150mm diameter.

2

Boreholes shall be initially taken to a depth of 20 m. At this depth the borehole shall be

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thoroughly flushed clean using compressed air and clean water.

QCS 2014

3


Page 7

The borehole shall then be completely filled with clean water and the rate of dissipation recorded. If the rate of dissipation is found to be less than required by the design criteria given in BRE digest 365 - Soakaway Design then the bore holes shall be deepened in 5 m depth increments and flushed until a satisfactory rate of dissipation is recorded. At the Engineers discretion the rate of dissipation maybe verified by a constant head permeability test using proprietary equipment to monitor and record the flow rate and the variation in water level within the borehole.

TESTING AND CLEANING SURFACE WATER DRAINS

1

Before completing of the road drainage part of the Works the Contractor shall systematically clean the whole road drainage system, in accordance with Section 8, Part 10, including gullies, connecting pipes and soakaways. The entire system shall be clear of debris and silts and in a sound working order.

2

Cast iron covers shall be freed from surfacing materials and pivot points shall be greased. The Contractor shall be responsible for cleaning up any silting of the surface water drainage system caused by other Contractors working within the Site and the approval of the Employer.

3

A CCTV survey shall be carried out of the completed system in accordance with Section 8, Part 10 of QCS.

17.9

TRENCH SOAKAWAYS

17.9.1

General

1

Trench soakaways shall be constructed in accordance with the dimensions and grades shown on the Drawings. The trench soakaway consists of a perforated pipe or geocellular units laid in a trench. A geotextile fabric lines the trench or surrounds the geocellular units, with the remaining voids being filled with single sized coarse aggregate.

2

Reinstatement of trench soakaways shall be in accordance with the Contract drawings.

17.9.2

General

1

Excavation for the trench shall be in accordance to the requirements of Part 3 of this Section.

17.9.3

Pipe

1

The pipe shall be a 300mm UPVC for installations outside the carriageway and 300mm ESVC for installations within the carriageway, perforated pipe supported on single-size coarse aggregate bedding. Pipe perforations shall be 10mm diameter in staggered rows around the circumference of the pipe with a pitch of 40degrees. The longitudinal spacing between each row of holes shall be 200mm.

2

The manufacture, distribution, laying and jointing of perforated pipes shall generally be in accordance with the requirements of Section 8.

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17.8

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Page 8

17.9.4

Geotextile Fabric

1

Filter fabric material lining shall be non-woven geotextile manufactured from UV stabilised, high tenacity, virgin polypropylene fibres that have been both mechanically and thermally bonded and in accordance with Table 17.2.

2

The placing and laying of the material shall be in accordance with the manufacturer’s instructions and Part 15 of this specification.

3

The geotextile material shall not be left exposed to the sun for a period greater than 7 days before burying.

Unit

Mean Value (Applied (a) Tolerance )

kN/m

8.0 (-0.8) 60 (±20) 1500 (-150)

EN ISO 13433

mm

38 (+6)

EN ISO 12956

µm

75 (±20)

EN ISO 11058

l/m s

2

90 (-27)

EN 12224

%

>90

EN 12225

%

No loss

EN 14030

%

No loss

EN 12226

%

>90

mm

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. Test Method

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Table 17.2 Properties of Geotextile Material

Tensile Strength

EN ISO 10319

Tensile Elongation

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Property

%

EN ISO 12236

N

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EN ISO 10319

CBR Puncture Resistance

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Cone Drop

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Pore Size – Mean AOS

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Permeability – (H50)

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Weathering 50MJ/m Exposure (1 month EU)

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Microbiological resistance

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Resistance to acids & alkalis

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Oxidation at 85 days (100 years) Thickness @ 2kPa Note:

(a)

EN ISO 9863-1

Applied tolerances are based on 95% Confidence limits

17.9.5

Single Sized Coarse Aggregate

1

The trench shall be filled by granular material, which shall infill the whole width of the trench between the undisturbed ground trench sides, or between the geocellular units and the undisturbed ground, as shown on the drawings. The granular material shall be laid and tamped in 150 mm layers using mechanical plate compactors. For geocellular unit trenches the backfill shall be brought up in even layers such that the backfill material does not differ by more than 150mm in level between sides.

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Page 9

Where geotextile fabric is required to interface between the trench side walls and subgrade and the soakaway trench fill material, the width of the geotextile must include sufficient material to conform to trench perimeter irregularities and for a 150mm top overlap. When overlaps are required between rolls, the uphill roll should lap a minimum of 500mm over the downhill roll in order to provide a shingled effect. Care shall be exercised to prevent natural or fill soil from intermixing with the trench granular material. All contaminated granular fill shall be removed and replaced with clean material.

3

The granular material shall be clean, durable, sharp-angled fragments roughly cubical or pyramidal in shape, of un-weathered rock of uniform quality and meet the grading limits in Table 17.3. The materials source shall be approved by the Engineer based upon the properties of the materials in accordance with the testing requirements as per Table 17.4. No reactive carbonate rock or sources with indication of local ground water contamination shall be used.

100

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37.5 20

60 - 90 0.2 - 1 0

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5 - 30

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BS sieve size (mm)

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Table 17.3 Grading Limits for Granular Material

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2

Catchpit Chambers

1

Catchpit chambers shall be constructed to the dimensions and at the spacing shown on the drawings.

2

Chambers shall consist of rectangular precast concrete sections with internal dimension 800 x 1500mm. All concrete works shall comply with the requirements of Section 5 of the specification. Concrete shall be Grade C50. Sulphate Resisting Cement shall be used. Chambers shall also conform in all respects to the requirements for surface water drainage manholes in Section 8.

3

All surfaces to be painted with an epoxy protective coating meeting the requirements of Section 5 Part 14 of the specification. The protective coating shall be factory applied to precast elements.

17.9.7

Road Crossings

1

Where the trench soakaway crosses a road then non-perforated pipe shall be used extending 1.0 meters beyond the road kerb line.

17.9.8

Geocellular Stormwater Attenuation / Soakaway Trenches

1

Loads on modular geocellular unitsThe permanent vertical loads to be carried by the units shall be determined by the designer

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17.9.6

(a)

Lateral loads

(b)

Maximum installation depth

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Page 10

17.9.9

The maximum installation depth, to base of units, shall normally not exceed the height of Reinstatement above Trenches

1

Reinstatement material above the trenches shall be of suitable fill, cement bound granular material, foamed concrete pavement materials or asphalt, or as appropriate in accordance with the Contract drawings, and shall be constructed in accordance with QCS Section 6.

17.9.10 Testing On completion of each length of trench soakaway the Contractor shall carry out an infiltration test. The test shall be carried between completed catchpit chambers. The 2 No. upstream outlet pipes within the catchpit chamber shall be sealed and the chamber filled with water to a minimum depth of 1.5 metres. The depth of water shall be recorded each hour for the first twelve hours of the test and subsequently at time intervals as directed by the Engineer.

2

The Contractor shall record the results of the test on a standard proforma and present these to the Engineer on completion.

17.10

GEOCELLULAR TANKS

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Geocellular units used to form storm water attenuation tanks and soakaway tanks shall be in accordance with clause 14.9.8.

Locations for geocellular tanks

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17.10.2 Geocellular Tank Arrangement

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17.10.1 Geocellular Units

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Geocellular tanks made up of geocellular units are suitable for installation in the following locations:

2

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The vehicular access to the tank shall be restricted so as to exclude large vehicles, in excess of the design vehicle load, from the area above the tank.

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(b)

Public open spaces: beneath landscaped areas and paths. The landscaping scheme for the park shall be considered when assessing the loads upon the tank.

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(a)

Loads on modular geocellular units The design of tanks constructed using modular geocellular units shall:(a)

take account of all applied loads, including accidental loading

(b)

be based on appropriate laboratory tests

(c)

use appropriate factors of safety

(d)

analyse all appropriate limit states (or failure modes)

The determination of the loads to be carried by the geocellular units shall be determined in accordance with the requirements of BD 31/01. 3

Permanent loads.

4

Accidental loads

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The risk of accidental loading occurring shall be assessed in the design process. Public parks may be occasionally inadvertently trafficked by HGVs and landscaped area can be used to park cars. Hard paved area shall be assumed liable to support such occasional accidental loading and geocellular tanks shall be designed to support accidental loading without risk of collapse.

Location

Risk

Landscaped area in public park

Specialist vehicles used for maintenance of geocellular tank and any separation system upstream of the tank Illegal parking of private vehicles Movement of delivery vehicles to kiosks in parks

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Large vehicles used for routine maintenance within park

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Specialist vehicles used for erection / maintenance of lighting systems

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Erection of marquees / tents / stages / portable cabins for public events

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Large vehicles delivering equipment for public events Cranes for installation of equipment

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Generators used for public events Planned parking of private vehicles during public events

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Access for emergency vehicles – fire engines

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If the tank has not been designed to carry accidental loading then special precautions may be required to prevent it occurring. In public parks, the area above a tank shall be fenced off or have other barriers / landscaping to prevent vehicle access. Warning signs shall be provided to state that there is an area with limited load bearing capacity and restricted access for vehicles.

5

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The location of the tank and any loading restrictions shall be clearly identified in the operation and maintenance manual for any facility. Lateral loads The lateral loads on the units due to earth and water pressure shall be assessed and allowed for by the designer in accordance with the requirements for the design of retaining walls given in BS 8002:1994. 6

Flotation or uplift Where the tank system is located below the water table, the uplift force shall be resisted by the dead weight of fill above the tank. Other surcharges that are not permanent shall not be included in the assessment. The minimum factor of safety against flotation shall be 1.25.

7

Minimum cover The minimum cover to units shall be as follows:

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Page 12

Landscaped areas: a minimum of 1.0m to allow for suitable planting over the tank. The design of landscaping should be undertaken at the same time as the design of the tank so that the impact of tree roots can be considered. Trees should not be located closer than the canopy width at mature height from the tank. Trees should not be planted directly over a tank or in such a position where maintenance work would require the removal of the tree. 8

Maximum installation depth The maximum installation depth, to base of units, shall normally not exceed the height of three units, plus the cover as assessed in Sub-Clause 15. Limit state design

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END OF PART

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Modular geocellular tanks shall be designed as structural components, using limit state structural design theory in accordance with Section 4.1 of CIRIA Report C680 and BD 31/01. The design philosophy shall follow the requirements for geotechnical design practice as described in Eurocode 7 (BS EN 1997-1:2004).

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QCS 2014

Section 06: Road Works Part 18: Geosynthetics

Page 1

18

GEOSYNTHETICS ........................................................................................ 2

18.1

GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS ........................ 2

18.1.1 18.1.2 18.1.3 18.1.4 18.1.5

Scope References Submittals Quality Assurance Guarantees and Warranties

18.2

REQUIREMENTS FOR GEOTEXTILES ....................................................... 4

2 2 3 3 4

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18.3

.

18.2.1 General Requirements 18.2.2 Drainage Applications 18.2.3 Earthworks Applications

4 5 6

GEOGRIDS ................................................................................................... 7

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18.3.1 General Requirements for Geogrids 18.3.2 Material Requirements for Geogrids 18.3.3 Installation of Geogrids

7 8 9

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18

GEOSYNTHETICS

18.1

GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS

18.1.1

Scope

1

This part of the specification covers the use of geotextiles and geogrids for the;

(b)

reinforcement of embankment foundations over soft or weak soils

(c)

reinforcement of steep earthwork fills

(d)

reinforcement of retaining walls and bridge abutments

(e)

repairs to earthworks embankment failures and landslides

(f)

for erosion control of slopes

(g)

for subsoil and sub-base drainage.

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Related Sections and Parts: This Section Part 3 Part 4 Section 8,

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reinforcement of unbound aggregates for roads, hard standing and airfield pavements

Earthworks Unbound Pavement Materials Drainage Works

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2

(a)

References

1

The following Standards and other documents are referred to in this part:

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18.1.2

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ASTM D 751 ...............Test Methods for Coated Fabrics ASTM D 5034 .............Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test) ASTM D 5035 .............Test Method for Breaking Strength and Elongation of Textile Fabrics (Strip Method) ASTM D 4533 .............Test Method for Trapezoidal Tearing Strength of Geotextiles BS 8006......................Code of practice for strengthened/reinforced soils and other fills BS 2782......................Method of testing plastics BS 3502......................Symbols for plastics and rubber materials BS 4618......................Recommendations for the presentation of plastic design data BS EN ISO 10321 ......Geosynthetics BS EN ISO 10319 ......Geosynthetics DIN 54307 ..................CBR Test DIN 53854 ..................Weight Test DIN 53855 ..................Thickness Test ISO 9001 ....................Quality Management and Quality Assurance Standards Published Document (PD) 6533, Guide to Methods for Assessing the Durability of Geotextiles, British Standards Institute.

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Page 3

18.1.3

Submittals

1

The manufacturer shall submit comprehensive test results for the geosynthetic for the designated tests, which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

2

The manufacturer’s submittal shall clearly state: (a)

the type of material, (whether a polyethylene, propylene or other)

(b)

its structure whether (a monofilament, multifilament or other)

(c)

the element of manufacture by one or combination of the following processes:

.

Heat bonding. Chemical resin bonding Mechanical bonding.

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(i) (ii) (iii)

If the Contractor wishes to propose a material that has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test and criteria for assessment.

4

The manufacturer shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include the project name, contract details, type/grade of material used, quantity of material used, name of the contract, client, consultant, and main contractor.

18.1.4

Quality Assurance

1

The geotextile shall be supplied by a manufacturer who is certified to the ISO 9001. The Contractor shall submit to the Engineer a copy of the ISO 9001 certificate that clearly states the scope of the certification.

2

The geotextile shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

3

Where feasible the jointing of geosynthetics shall be as prefabricated joints manufactured under factory controlled conditions. Joints made during the execution of the work shall be kept to a minimum.

4

Joints shall be tested by the same test methods used for the main material.

5

All joints used in permanent structures designed to carry loads shall be tested in accordance with BS EN ISO 10319 Part 1 or BS EN ISO 10321.

6

In situations where relatively small tensions are developed and, if permitted by the Engineer overlapping joints may be used. These joints shall not be used in the primary tensile direction of reinforced soil structures but can be in secondary tensile directions only.

7

Joints where geotextiles are sewn together shall be with one of the methods showing in figure 5 of BS8006. These joints shall meet the performance characteristics shown in Table 8 BS8006.

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Prior to delivery of the material to site the Contractor shall submit a sample of a sawn joint.

9

Bodkin joints shall have sufficient cross sectional area and strength to avoid excessive deformation. A bodkin joint shall not be so large so as to distort the material causing stress concentrations, bodkin joints shall be pretensioned prior to loading to reduce joint displacement as the components lock together.

10

Any cuts, tears, splits and perforations to geosynthetics during installation shall be made good. The method of remedial work shall be prepared and proposed by the Contractor for approval by the Engineer.

11

The geosynthetics shall be suitable for use in the ambient soil temperature in the State of Qatar.

12

Geosynthetics that are able to ravel shall be heat treated or bonded with an adhesive tape at the cut. The proposed method of sealing the edges of geotextiles shall be proposed by the Contractor and shall fully identify the geotextile material, type of scene, stitch configuration, stitch density, sowing thread and sowing machine to be used.

18.1.5

Guarantees and Warranties

1

The Contractor shall submit a ten-year guarantee for the geotextile material and the workmanship. The guarantee shall be worded to reflect the required performance of the material and shall be approved by the Engineer.

18.2

REQUIREMENTS FOR GEOTEXTILES

18.2.1


1

All geotextiles shall be supplied in manageable roll or unit sizes and shall be robust enough to withstand handling and any treatment received during the installation process.

2

The geotextile shall comply with the minimum properties for geotextile serviceability in Table 18.1 below. The Engineer will direct as to the category that the geotextile shall meet; i.e., very high, high, moderate or low.

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Table 18.1 Minimum Properties for Geotextile Service Ability Property

Very High

High

Moderate

Low

Grab Strength ASTM D 5034

1200

800

600

400

Puncture Strength Modified ASTM D-751/3787, N

500

340

180

135

Burst Strength

3.0

2.0

1.5

1.0

Trapezoidal Tear ASTM D-4533

340

225

180

135

These are the minimum required values below which no test result on production material should fall.

QCS 2014

Page 5

The Engineer may require the Contractor to carry out tests to different standards, in addition to the test methods designated above or in the following clauses: the manufacturer’s recommendations strictly adhered to

concerning the installation process shall be

(b)

all geotextiles shall be suitable for use in the environmental conditions in the State of Qatar

(c)

geotextiles shall be resistant to deterioration on degradation from acids alkalis, bacteria, brackish or saline water. The manufacturer shall submit comprehensive results of tests carried out to demonstrate the durability of the materials under such conditions. These tests shall involve checking the strength properties of the material before and after prolonged exposure to typical groundwater conditions in the State of Qatar

(d)

all geotextiles shall be protected from direct sunlight by storing inside the building or covering with heavy tarpaulins. Geotextiles shall not be exposed to direct sunlight for a duration longer than 48 h

(e)

joints in Geotextiles shall be sewn where load transfer is required

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(a)

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3


Drainage Applications

1

Geotextiles for drainage applications shall be needled polypropylene and meet the performance specifications given in Table 18.2. The performance shall be assessed based on regular tests on the production material. Unless a permitted variation is stated in Table 18.2, the mean test values shall meet the values in the Table.

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18.2.2

Table 18.2

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Performance Specifications for Geotextiles for Drainage Applications International Classification According to CBR Test

2

3

4

4400

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1

CBR test (DIN 54307) mean value 10 %

780

1335

2695

mean value minus standard deviation 10 %

700

1200

2450

deformation %

30

50

60

65

longitudinal direction kN/m 10 %

3

7

12

25

longitudinal direction kN/m 10 %

3

8

14

35

Tensile strength (ASTM D 5035)

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Page 6

International Classification According to CBR Test

1

2

3

4

elongation at rupture %

35/45

50/60

45/55

90/65

Fall cone test hole diameter BS EN ISO 10319

50

32

18

6.5

Water permeability at 2 kPa mech. load 9 x 10

at 10 cm water column l/secm 30 % 2

-2

90

-2

13 x 10

-2

15 x 10

80

45

80

60

45

30

d 90%

110

85

65

40

100

140

250

500

0.6

0.95

1.5

3.4

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d 50%

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Pore size (unvibrated)

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Weight DIN 53854 g/m

-2

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150

8 x 10

.

permeability coefficient cm/s

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Thickness DIN 53855 mm

The manufacturer shall clearly identify to which international classification category the geotextile conforms according to the CBR test.

3

The pore size of the geotextile shall be small enough to prevent the significant loss of soil particles from the retained soil, yet have adequate permeability to allow water transmission normal to the plain of the geotextile.

4

The manufacturer shall submit test results that demonstrate the ability of the geotextile to avoid clogging during water flow due to fine particles. Test results for the US Corps of Engineers gradient ratio test or similar type of test shall be submitted. The test shall be carried out using soil of the type where the geotextile is to be installed. Gradient ratios derived from the test shall be less than 3.

18.2.3

Earthworks Applications

1

Geotextiles for earthworks reinforcement or base use shall be woven polyester multi-filament or multi-filament fabrics with a high rupture strength and low axial strain. The geotextile shall have an adequate high tensile strength in all directions to resist loading imposed by uneven filling.

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QCS 2014


Page 7

The geotextile shall possess the strength for the required design life with minimal increase in strain over time. The average geotextile strain shall be limited to 5 %.

3

Where installed between a sub-base and the underlying soil, the geotextile shall prevent the granular material being pressed into the subsoil and also prevent an intrusion of fines from subgrade into the sub-base.

4

The water permeability of the geotextile shall prevent build up of water pressure under the separation layer. The short- and long-term permeability of the geotextile must be equal to or greater than that of the subsoil. The geotextile must not become blocked.

5

The geotextile shall possess high puncture resistance and a high tearing resistance.

6

Where used as base stabilisation for embankments the type of construction equipment used for spreading and compacting initial fill layers shall be suitable so as to avoid damage to the geotextile. The initial layer of fill placed on the geotextile shall be free from sharp angular or pointed material that may puncture the geotextile.

7

Trucks shall not be permitted to drive over the geotextile. The laying of the material shall be co-ordinated to ensure that trucks do not damage the material.

18.3

GEOGRIDS

18.3.1

General Requirements for Geogrids

1

The geogrid shall be identified as either uniaxial for single dimension loading or biaxial for two dimensional loading.

2

The design of all geotextiles or geogrid applications shall be based on an appropriate in soil temperature for the state of Qatar.

3

The type of geogrid to be used shall be as shown on the drawings or as described elsewhere in the contract documents.

4

The type of polymer used in the manufacture of the geogrid shall be clearly stated.

5

The design shall take into account any possible damage to the material during site installation and a factor shall be introduced into the design.

6

Prior to installing the geosynthetic the Contractor shall prepare a construction trial outside of the permanent works. The construction trial shall utilise similar ground conditions from materials and other factors as the permanent works.

7

If directed by the Engineer the Contractor shall arrange for geotechnical investigation to be carried out in the area where the geosynthetics are to be installed. The range and details of the tests and investigations to be performed shall be directed by the Engineer.

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Material Requirements for Geogrids

1

Geogrids shall be manufactured from a continuous sheet of polyethylene or polypropylene which is punched with a regular pattern of holes. The sheet shall be heated and stretched so that randomly orientated long chain molecules are drawn into an order and align state to increase tensile strength and tensile stiffness.

2

The bars or ribs of the geogrid transverse to the direction of primary loading shall provide a series of bearing points or anchors such that stress is transferred to the grid by surface friction and also interaction.

3

The ribs of the geogrid in both the longitudinal and transverse direction shall be manufactured to a near vertical face to provide good bearing surface for interlocking fill particles.

4

Geogrids shall be resistant to deterioration by aqueous solutions of acids, alkalis and salts, petrol, and diesel fuel.

5

Geogrids shall not be susceptible to hydrolysis, environmental stress, cracking or micro biological attack.

6

The manufacturer shall supply test results for load against strain for the material identifying all test conditions including strain rate and temperature of materials tested and test method.

7

The Contractor shall submit full technical details of the geogrid proposed for use in the works. These details shall include the following:

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18.3.2

grid dimensions

(b)

thickness of longitudinal and transverse ribs

(c)

strength of the material determined as stress strain, at strains of 2 and 5% both

(d)

transverse and longitudinally in accordance with BS EN ISO 10319

(e)

weight in kilograms per metre squared for material

(f)

the supplied roll of dimensions

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the minimum amount of carbon black tested in accordance with BS 2782 Part 4

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(g)

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(a)

(h)

the approximate peak strain , expressed as a percentage

(i)

the creep of the material under load determined in accordance with BS EN ISO 10319 for strain shall not exceed 10%

(j)

the cross sectional shape of the ribs and of the rib joints.

All test results shall be expressed as a lower 95% conference limit in accordance with ISO 2602. 8

The Contractor shall submit test results for the durability of geogrids. Tests shall be in accordance with PD 6533, - Guide To Methods for Assessing the Durability of Geotextiles.

9

The Contractor shall submit laboratory test results for prolonged exposure tests at similar temperatures.

10

For each batch or delivery of the geosynthetic the Contractor shall submit the production quality control test results shall be clearly related to batches delivered to site.

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Page 9

Installation of Geogrids

1

Prior to placing geogrids the Contractor shall prepare a detailed method statement for the sequence of operations.

2

The methods employed shall ensure that the geosynthetic does not suffer deterioration during placing and that any joints are formed effectively.

3

The handling and placement and installation of geogrids shall be carried out strictly in accordance with the manufacturer’s recommendations.

4

Where the geogrid has been protected by a wrapping resistant to ultraviolet lights attack no further protection against sunlight is necessary.

5

For geogrids, jointing shall be by a bodkin whereby two overlapping sections are coupled together using a bar passed through the aperture of the grid. Joints shall be formed at the highest mechanical and durability efficiency possible.

6

If necessary the Contractor shall construct a temporary access road to the site location at a convenient location close to the works, the Contractor shall prepare a clean working platform in storage area to accommodate geosynthetic materials.

7

The geogrid shall extend across the full width of the embankment or area being treated in one continuous piece and no part bits of rolls shall be used. This shall be accommodated by increasing the lap lengths.

8

Prior to installation of the geogrid , the site shall be cleared in accordance with part 2 of this specification

9

Before placing geogrid any abrupt changes in ground profile should be levelled.

10

Any regulating layer of fill placed shall not impair the vertical hydraulic conductivity of the natural ground.

11

Geogrids supplied in rolls shall be supported at a minimum of 2 points to prevent excessive bending unless a central steel tube is used for support.

12

Site handling of geogrids shall ensure that damage to the product such as surface abrasions, splitting, notching or tearing is prevented.

13

The installation of the geogrid shall be consistent with the direction of major stress.

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18.3.3

END OF PART

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 1

19

MISCELLANEOUS ........................................................................................ 2

19.1

STONE PITCHING ........................................................................................ 2

19.1.1 19.1.2 19.1.3 19.1.4 19.1.5

Scope References Submittals Materials Installation

19.2

GABIONS & PROTECTION MATTRESS ...................................................... 3

19.2.1 19.2.2 19.2.3 19.2.4 19.2.5

Scope References General Requirements Specific Requirements for Gabions Specific Requirements for Protection Mattress

19.3

BOLLARDS .................................................................................................... 6

19.3.1 19.3.2 19.3.3 19.3.4

Scope References Concrete Bollards Steel Bollards

19.4

RUMBLE STRIPS .......................................................................................... 7

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3 3 4 5 5 6 6 6 7 7 7 7

SPEED CONTROL HUMPS .......................................................................... 8

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19.5

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19.4.1 Scope 19.4.2 Quality Assurance 19.4.3 Construction

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2 2 2 2 2

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19.5.1 Scope 19.5.2 General 19.5.3 Construction of Speed Humps

8 8 9

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Page 2

19

MISCELLANEOUS

19.1

STONE PITCHING

19.1.1

Scope

1

Stone pitching slope treatment shall consist of the placement and grouting of stone pitching on slopes at the designated locations or at the locations directed by the Engineer to the designated lines, grades, thickness and cross-sections or as directed by the Engineer.

2


19.1.2

References

1

The following standards are referred to in this Subpart:

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Earthworks

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This Section Part 3

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AASHTO T96 .............Resistance to Abrasion by Use of the Los Angeles Machine

qa

BS 812 Part 2 .............Testing Aggregates - physical properties BS 1881......................Methods of testing concrete Submittals

1

Samples of the stone to be used shall be submitted to and approved by the Engineer before any stone is placed. These samples shall be kept on site and used for reference purposes for the quality control of delivered material during the work.

19.1.4

Materials

1

Stone for pitching shall be hard, sound, durable, erosion resistant rock or cobbles.

2

The nominal weight of the stones shall be between 3 to 4 kg (corresponding to a size of about 240mm x 140mm x 100mm). The maximum weight of the stones shall be between 32 kg (corresponding to a size of about 420mm x 230mm x 200mm).

3

Tests for specific gravity and absorption, shall be determined in accordance with BS 812 part 2 Testing Aggregates - physical properties. The minimum apparent specific gravity shall be 2.5 and the maximum absorption shall be 3 %.

4

The stone shall not have an abrasion loss greater than 45 % when subjected to five hundred (500) revolutions in a Los Angeles Abrasion Machine in accordance with AASHTO T96.

5

The size and shape of the stones shall be such to allow for proper placement. The widths of the stone shall be not less than one and one-half times their respective thickness and lengths of not less than two times their respective widths.

19.1.5

Installation

1

The bed upon which the stones are to be placed shall be excavated to the designated grades and lines or as directed by the Engineer.

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19.1.3

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Page 3

Prior to commencing any stone pitching operations the Contractor shall prepare a trial laying of not less than 2 m by 2 m using the materials and methods proposed for the work. The trial laying shall establish the aesthetic appearance of the work and shall be used for comparison purposes for acceptance of the final work.

3

A footing trench shall be excavated along the toe of the slope as designated or as directed by the Engineer. All footing trenches and excavations shall be approved by the Engineer before placement of stones or concrete.

4

Subgrade or base shall be firm and well compacted and approved by the Engineer. A 50 mm thick layer of mortar shall be laid on the subgrade as bedding for the stones.

5

Stones shall be placed so as to provide a minimum number of voids; larger stones shall be placed in the footing trench and on the outside surface of the slope. The flattest face of the stone shall be laid uppermost parallel to the slope. Spaces between larger stones shall be filled with the smaller stones.

6

The surfaces of the stone shall be cleaned of adhering dirt and clay and shall be moistened immediately prior to grouting.

7

The space between stones of stone pitching shall be filled with mortar consisting of one part Portland cement and three parts of fine aggregate, and one-fifth part of hydrated lime with sufficient water to produce a workable mix as approved by the Engineer.

8

Sand and cement shall comply with the requirements of Section 5. The compressive strength of the mortar shall not be less than 15 MPa when tested in accordance with BS 1881 Part 108.

9

Immediately after placing, the mortar shall be spaded and rodded into place with suitable spades, trowels or other approved method. All the voids between stones shall be completely filled.

10

The exposed surface of the rocks shall project not less than 1 cm and not more than 4 cm above the mortar surface. The mortared stone pitching shall be cured by an approved method for a minimum period of four days. Immediately after the expiration of the curing period, the exposed surfaces shall be cleared of all curing mediums.

11

Joints will be provided at a maximum interval of 12 m. Joints shall comprise a gap in the stone pitching of 15 mm. The method of forming the gap shall be to the approval of the Engineer.

19.2

GABIONS & PROTECTION MATTRESS

19.2.1

Scope

1

This work shall consist of supplying, building and placing of stone-filled gabions or protection mattress as slope or watercourse channel protection.

2


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2

This Section Part 3

Earthworks

19.2.2

References

1

The following standards are referred to in this Subpart: BS EN 10244..............Testing zinc coatings on steel wire and for quality requirements

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BS EN ISO 1461.........Hot dip galvanised coatings on iron and steel articles BS 1052......................Mild steel wire for general engineering purposes BS 1722 Part 16 .........Organic powder coating to be used as a plastics finish to components and mesh ASTM G152 and G153-----Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials. General Requirements

1

Gabion boxes and protection mattress shall be made of a hexagonal woven mesh of double twisted hot dip galvanised steel wire. The nominal mesh size shall be 80mm x 100mm. Details of type of mesh proposed for use shall be submitted to the Engineer for approval.

2

Wire shall be coated with a minimum thickness of 0.55 mm of dark green or black PVC complying with BS 1722 Part 16 Organic powder coating to be used as a plastics finish to components & mesh.

3

Wire shall be capable of resisting the effects of immersion in sea water, exposure to ultraviolet light and abrasion, when tested for a period not less than 3000 h in accordance with ASTM G152 and G153.

4

The cages of gabion panels and protection mattress panels shall be selvedged to prevent unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core. Wire for selvedges and lacing shall otherwise comply with the same specification for the wire used in the mesh.

5

Non-metallic material such as extruded polypropylene for gabion boxes may be proposed, for the Engineer's approval. Samples and manufacturer's certificates shall accompany the proposal. The Contractor shall demonstrate that non-metallic materials are suitable for use in the climatic conditions of Qatar.

6

Gabion and protection mattress dimensions shall be as designated. A tolerance of 5 % on width and height, and 3 % on length shall be allowed.

7

Gabions and protection mattress shall have diaphragms at 1 m centres.

8

Wire used in the fabrication of the gabion and protection mattress shall be mild steel to BS 1052 having an average tensile strength, before coating, of 380 to 500 MPa. The core wire diameter shall be 3.0 mm before galvanising. Galvanising shall comply with BS EN 10244.

9

Non-metallic gabion and protection mattress cages of proprietary type shall be constructed according to the manufacturer's instructions.

10

All the fixing and binding wires shall be coated with PVC layer complying with BS 1722 Part 16.

11

All Gabions and mattresses shall be laid over a layer of geotextile membrane Grade 3000 at all times.

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19.2.3

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19.2.4

Specific Requirements for Gabions

1

Stones for gabion filling shall be hard, sound, durable and highly resistant to erosion. The stone size distribution in each individual box shall be as shown in Table 16.1: Table 16.1 Stone Size Distribution of Gabions % of Total (by number)

80 - 125

7 maximum

125 - 200

88 maximum

200 - 250

5 maximum

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Size of Stones mm

Gabions shall be placed and built to the designated lines, levels and patterns on a prepared horizontal foundation surface, excavated as required and compacted as directed by the Engineer.

3

Gabion cages shall be securely wired together at comers and cages, and where there is more than one course of gabions, the upper course cages shall be laced to the lower course. Before filling, the cage shall be in its permanent position and laced to adjoining previously filled cages.

4

Stones shall be packed by hand inside the cages as tight as practicable with the minimum of voids. Tie wires shall be fixed inside the compartments and the units tensioned in accordance with the manufacturer's instructions.

5

The cages shall be overfilled with stones to allow for subsequent settlement and the lid laced down with binding wire to the top of each of the four sides and to the top of the diaphragm panels.

19.2.5

Specific Requirements for Protection Mattress

1

The material shall be supplied as a large sheet with partition panels at 1 m centres to form a cellular structure with the sheet turned up to form the sides. A separate sheet shall form the lid.

2

The cages of protection mattress panels shall be selvedged to prevent unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core. Wire for selvedges and lacing shall otherwise comply with the same specification for the wire used in the mesh.

3

Stones for protection mattress filling shall be hard, sound, durable and highly resistant to erosion.

4

The stone size distribution in each individual box shall be dependent on the design thickness of the mattress as shown on the contract drawings.

5

The protection mattress shall be a special type of rectangular gabion with a large plan area to thickness ratio that is divided into compartments by partition panels fixed to the base.

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The thickness of the protection mattress, the installation slope and the panel size shall be as designated. The Contractor may elect to use a manufacturer’s standard size of mattress that is thicker than that designated.

7

Protection mattress shall be placed and built to the designated lines, levels and patterns on a prepared foundation surface, excavated as required and compacted as directed by the Engineer.

8

Protection mattress cages shall be securely wired together at comers and cages. Before filling, the cage shall be in its permanent position and laced to adjoining previously filled cages. Several assembled units should be placed in position and wired together at their edges with the wire passed continuously through each mesh in turn with a double turn at every second mesh.

9

Stones shall be packed by hand inside the cages as tight as practicable with the minimum of voids. Tie wires shall be fixed inside the compartments and the units tensioned in accordance with the manufacturer's instructions.

19.3

BOLLARDS

19.3.1

Scope

1

Short metal or precast concrete bollards for traffic control in roads or pedestrian areas.

2

Related Sections

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Section 5 Concrete References

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The following standard is referred to in this Part:

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BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles. Concrete Bollards

1

The use of cast in-situ concrete bollards will not be permitted.

2

Precast concrete bollards shall be constructed with the dimensions and details shown in the drawings. The surface finish and colour of the bollards shall be as shown in the drawings, in the Project Specification, per the designated details or as directed by the Engineer.

3

All concrete and steel materials and procedures for the precast concrete bollards shall comply with the requirements of Section 5.

4

The minimum grade of concrete for bollards shall be C40. Bollards shall be constructed using OPC cement to BS EN 197-1.

5

The minimum cover to all embedded steel items in the bollards shall be 50mm with a tolerance of -0 mm and + 10 mm.

6

Where precast concrete bollards are specified the Contractor shall design the bollards such that the durability is ensured for a period of ten years. The Contractor shall submit a performance guarantee for the bollards for a period of ten years. The guarantee shall provide for the replacement of the bollard in the event of any deterioration due to exposure to the elements.

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The supplier shall verify this by a design submission covering the concrete mix design, special admixtures additives, cover to reinforcement type of reinforcement and protective coating. The engineer shall approve the material and design for the bollard based on the particular exposure of the location proposed for use.

8

Prior to production of the precast bollards the Contractor shall cast a trial bollard for approval by the Engineer.

19.3.4

Steel Bollards

1

Metal bollards shall be constructed of steel tube with the dimensions, details, wall thickness and height shown on the drawings or provided in the Project Specification.

2

The top of the bollard shall be ground free of any rough edges and fitted with a tight durable ultraviolet light resistant plastic top.

3

All metal parts shall be hot dipped galvanised to BS EN ISO 1461 after fabrication.

4

All metal parts shall also be painted to the colours and pattern as shown on the drawings or directed by the engineer. The paint system shall be compatible with the hot dipped galvanising and shall provide a service free life for five years.

5

Where designated, bollards shall be removable. This shall be achieved by casting a 4 mm

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thick PVC pipe sleeve into the pavement. The bollard shall be a tight fit into this sleeve. If so designated or directed by the Engineer a locking facility shall be incorporated with the removable bollard.

RUMBLE STRIPS

19.4.1

Scope

1

Rumble strips to provide warning to drivers of vehicles that accidentally stray out of the carriageway.

2

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This Section Part 5

Asphalt Works.

19.4.2

Quality Assurance

1

The Contractor shall arrange for a trial installation of a rumble strip to demonstrate the methods and equipment to be used. Approval to proceed with the construction of the rumble strips will only be permitted after the Engineer has approved this trial in writing.

19.4.3

Construction

1

Rumble strips shall comprise of shallow formed depressions in the wearing course of the road shoulders. The depth, plan size and layout of the rumble strips shall be as designated or as directed by the Engineer.

2

Rumble strips shall be formed by one of the following methods: (a)

cold planing

QCS 2014

(b)


Page 8

Removal shutter boards.

Cold planing of indentations in the wearing course in the shoulder shall be carried out in accordance with the requirements of the cold planing of Part 5. Edges shall be square and true and free from any loose material.

4

Rumble strips may also be formed by the use of removable shutter boards. The boards shall be rigidly located on the base or binder course prior to laying the wearing course. The method of fixing the strip shall be subject to the approval of the Engineer. The laying of the wearing course shall be carried out in accordance with the requirements of Part 5. Care shall be taken to ensure full compaction of material around the edges of the shutter boards. The shutter boards shall be carefully removed not earlier than three days after the laying and compaction of the asphalt.

19.5

SPEED CONTROL HUMPS

19.5.1

Scope

1

Speed control humps to limit the speed of vehicles.

2

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Asphalt Works. Kerbs, Footways & Paved Areas.

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General

1

Speed control humps shall only be installed at the locations designated on the project drawings or specified elsewhere within the contract documents.

2

All speed humps shall be identified by markings on the road surface. The layout of these road markings shall be as the Qatar traffic control manual or as shown on the project drawings or elsewhere in the contract documentation.

3

The profile of the speed hump shall be as shown on the project drawings.

4

The profile shall represent a smooth gradual rise in elevation.

5

Speed humps shall be constructed of the same asphalt mix design as the asphalt wearing course.

6

The use of prefabricated rubber section speed humps or steel checker plate filled with concrete speed humps is not permitted.

7

Speed humps shall be designated as one of two types; for low speed pedestrian areas and for high speed roads. Low speed pedestrian areas speed humps shall comprise of a ramp within elevated section constructed of interlocking concrete paving blocks.

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Construction of Speed Humps

1

The dimensions and construction details of speed hump shall be as shown on the drawings.

2

Prior to installation of the speed hump the surface of the wearing course shall be scabbled or abraded to a rough irregular finish to ensure bond with the speed hump. Tack coat shall be applied at the base.

3

Wearing course shall be hand laid for the speed hump. The wearing course shall be compacted and finished to a smooth profile.

4

All the asphalt work for the speed hump shall comply with the relevant clauses in part 5 of the specification. The final profile speed hump shall comply to the profile on the drawings to within  6mm.

5

Heavy traffic or construction plant shall not be permitted to drive over speed humps until 7 days after the construction unless the engineer permits otherwise.

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END OF PART

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19.5.3

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 1

SITE CLEARANCE .................................................................................................. 2

2.1 2.1.1 2.1.2 2.1.3

GENERAL ............................................................................................................... 2 Scope of Work 2 References 2 Submittals 2

2.2

PROTECTION TO EXISTING SERVICES AND INSTALLATIONS.......................... 3

2.3

RECOVERY OF MATERIALS ................................................................................. 4

2.4

CLEARING AND GRUBBING .................................................................................. 4

2.5

REMOVAL OF STRUCTURES ................................................................................ 5

2.6

REMOVAL OF STREET FURNITURE ..................................................................... 6

2.7

REMOVAL OF FENCES .......................................................................................... 6

2.8 2.8.1 2.8.2 2.8.3 2.8.4

REMOVAL OF EXISTING PAVEMENTS ................................................................. 6 General Requirements 6 Cutting Back Pavement 6 Stockpiling Asphalt Pavement 7 Stockpile Site 7

2.9

MEASURES FOR STATUTORY UNDERTAKERS .................................................. 8

2.10 2.10.1 2.10.2 2.10.3 2.10.4 2.10.5 2.10.6 2.10.7 2.10.8 2.10.9 2.10.10

REMOVAL OR TREATMENT TO BURIED UTILITIES ............................................ 8 General 8 Underground Storage Tanks 8 Removal of Culverts 8 Abandoned Pipes and Culverts 9 Total Removal of Pipelines 9 Grouting of Pipelines 9 Plugging of Pipelines 10 Cut-off Walls and Capping Slabs 10 Manholes and Access Shafts 10 Drainage Inlets and Gullies 10

2.11

DISPOSAL OF MATERIALS.................................................................................. 10

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2

SITE CLEARANCE

2.1

GENERAL

2.1.1

Scope of Work

1

This Part includes:

Page 2

Excavating for, demolishing and removing wholly or in part and disposing of designated redundant pavements, fences, buildings, culverts, manholes, inlets, gullies, pipelines or any other obstructions.

(b)

Associated earthworks to uncover facilities to be demolished, removed or recovered and to backfill and compact all trenches, holes, pits or excavations resultant from demolition, removal and recovery works.

(c)

Recovering designated materials for storage and reuse.

(d)

Removing and, where required, recovery of designated water, gas and sewage pipelines and fittings and of underground cables.

(e)

Disposal of materials not recovered.

(f)

Removal of vegetation and surface boulders and rocks.


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Earthworks Asphalt Works Works in Relation to Services

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Related Parts and Sections are as follows:

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Building Demolition Concrete Sewerage Earthworks Related to Buildings

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BS 5228......................Code of practice for noise control on construction and demolition sites BS 6187......................Code of practice for demolition The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry and Public Works. 2.1.3

Submittals

1

Where existing services are to remain and are in close proximity to the works the Contractor shall submit to the Engineer details of proposed measures to ensure that the existing services are kept in a safe and stable condition for the duration of the Works.

2

Structures and installations to be dismantled or demolished shall be surveyed by the Contractor to ascertain exposed constructional dimensions and details. The Contractor shall prepare sketches of the structures and installations and submit these to the Engineer. This information shall be used by the Engineer to confirm the scope of the dismantling or demolition and confirm materials or equipment to be recovered.

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Page 3

The method of dismantling and demolition including the sequence of operations and any special procedural requirements shall be submitted to the Engineer for consideration not less than seven days before the work is due to begin. Demolition work shall be carried out in accordance with BS 6187, and the submittal shall include information demonstrating the Contractor’s proposed methods to attain compliance.

4

Before any blasting operation the Contractor shall submit a detailed method statement for the work. Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives in Qatar, prepared by the former Ministry of Industry and Public Works. Approvals for blasting work shall be obtained as per the requirements of part 3 of the specification for rock excavation.

5

The Contractor shall submit for approval his proposed method of grouting pipes to be abandoned.

6

Before commencing work on the construction of reinforced concrete cut-off walls and reinforced concrete capping slabs the Contractor shall submit details for the Engineer's approval.

2.2

PROTECTION TO EXISTING SERVICES AND INSTALLATIONS

1

The Contractor shall conduct his operations in such a manner as to avoid hazards to persons, property and vehicles. After work is started on any structure, work on that structure shall be continued to completion promptly and expeditiously.

2

Services to unused installations shall be safely disconnected before demolition. Notification of disconnection shall be given to the appropriate authorities.

3

Drains, manholes and gullies that are to remain shall be protected and kept clear of debris at all times. They shall be left clean and in working order.

4

Details of any underground caverns, chambers, wells or voids discovered during the demolition operation shall be reported to the Engineer. Dangerous openings shall be protected and illuminated.

5

Precautions shall be taken to prevent leakage or formation of flammable, explosive, unhealthy or environmentally hazardous gas or vapour.

6

Pits, drains and manholes shall be checked before entry to ensure that the atmosphere is fit for respiration.

7

The quantity of dust in the atmosphere shall be minimised by spraying the demolition works with water.

8

The recommendations of BS 5228: Part 2 shall be followed in minimising noise and vibration. Silencing devices on plant shall be fitted where practicable and ear defenders shall be provided for site personnel where noisy machinery is used.

9

The location of any survey stations shall be reported to the Engineer. The Engineer may require the Contractor to transfer existing survey stations to new locations and carry out a survey to verify the level and co-ordinates of the new survey stations.

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All existing structures, paving, services, fittings, and other features which are not to be demolished, dismantled, removed or otherwise dealt with shall be protected from damage by a means approved by the Engineer.

11

Adjacent structures shall be surveyed for movement, cracks or deformations before and after demolition. The definition of adjacent structures in this context will be decided by the Engineer dependent on the type of structure to be demolished and the method of demolition proposed by the Contractor and the risk of damaging adjacent property.

12

A photographic record of the adjacent structures before and after demolition shall be taken.

13

Where structures, paving, services, fittings or other features are damaged by the Contractor, they shall be made good to the satisfaction of the Engineer.

2.3

RECOVERY OF MATERIALS

1

Where required the Contractor shall recover designated materials without undue damage, carry out any required cleaning and shall deliver the recovered materials to locations designated by the Engineer and unload and place them into storage.

2

Where on-site reuse is designated recovered materials shall be stored on site before their incorporation in the Works.

3

Materials to be recovered shall be handled and stored in such a manner as to avoid any damage which will impair their reinstallation and reuse. Where the absence of care results in damage, the Contractor shall repair the damage at his expense. If repairs are deemed to be impracticable the Contractor shall provide replacements at his expense.

2.4

CLEARING AND GRUBBING

1

The Contractor shall excavate and remove surface material such as debris, windblown sand, vegetation and any other unsuitable material in the areas and to the thickness instructed by the Engineer. Clearing and grubbing shall be restricted to removal of surface material and debris and shall not include the excavation of natural ground unless directed by the Engineer.

2

The removed material shall be loaded and transported to an approved dumping area.

3

All surface objects, trees, stumps, roots and other protruding obstructions not designated to remain shall be grubbed and cleared as follows:

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(a)

In areas inside of the grading limits of cut and embankment areas, stumps and non perishable solid objects shall be cut off not less than one metre below the subgrade level in the area.

(b)

In areas outside of the grading limits of cut and embankment areas, stumps and nonperishable solid objects shall be cut off not less than 500 mm below finished ground level.

(c)

In areas to be rounded at the top of cut slopes, stumps shall be cut off flush with or below the surface of the final slope line.

(d)

Grubbing of pits and ditches will be required only to the depth necessitated by the proposed excavation within such areas.

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Page 5

(e)

Except in areas to be excavated, stump holes and other holes from which obstructions are removed shall be backfilled with suitable material and compacted.

(f)

Where designated the Contractor shall carefully remove existing trees, plants or shrubs and carefully transport these to a location designated by the Engineer.

REMOVAL OF STRUCTURES

1

Unless otherwise directed the Contractor shall demolish and remove all buildings and structures within the limit of works limits together with all foundations and retaining walls, piers, partitions and columns down to a plane not less than one metre below the finished ground level or one metre below the subgrade level in the area.

2

Upon receipt of notification by the Engineer, the Contractor shall take over all responsibility of the building or buildings then acquired and vacant and shall proceed with the demolition and removal thereof.

3

All structures shall be neatly trimmed off and the reinforcement shall be cut or trimmed off close to the concrete and made safe; basement floor slabs shall be broken into pieces; excess debris and other foundations, concrete floor slabs, sidewalks, driveways, signs, sheds, garages, fences and other facilities shall be removed.

4

The Contractor shall arrange for the discontinuance and disconnection of any services to the structure or structures in accordance with the requirements of the agency concerned. The Contractor shall disconnect and properly seal in an approved manner any sewer outlets that serve any structure he is to remove. The Contractor shall keep the Engineer informed of his plans for the performance of any work in connection with the sealing off of such outlets in order that proper inspection can be provided at the time the work is performed.

5

Any additional small out-buildings or temporary structures even if not shown on the Drawings shall also be removed if directed by the Engineer.

6

Demolition and removal works shall be carried out mechanically or by hand as necessary in such a manner as to cause no undue damage to the public, property, vehicles, pavements, services and structures, and the Contractor shall provide temporary works for protection when necessary, in accordance with any special requirements of the concerned authorities.

7

Blasting or other operations necessary for the demolition and/or removal of facilities which may damage new construction shall be completed before placing the new work, unless otherwise directed by the Engineer.

8

In all cases the Contractor shall be responsible for all claims resulting from damage, of any nature, caused by carelessness or negligence on the part of the Contractor, his subcontractors or agents.

9

Demolition or removal operations for any particular facilities shall not be started until written approval is obtained from the Engineer.

10

Throughout the demolition period the Contractor shall provide and maintain sufficient and adequate temporary supports.

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2.5

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Page 6

REMOVAL OF STREET FURNITURE

1

Where designated, street furniture shall be recovered, cleaned and either delivered to and placed into storage at the stores of the designated authority or set aside for re-erection as part of the Works, or shall be removed and disposed of.

2

The Works shall include the excavation, removal and disposal of all foundations.

3

Before proceeding with the removal of any of the above installations the Contractor shall contact the relevant authority and obtain approval.

4

The recovery of existing street lighting installations shall form part of the Works and shall be in accordance with the requirements of the Public Works Authority.

2.7

REMOVAL OF FENCES

1

Where designated, fencing, including all support posts, gates, other accessories and foundations shall be removed.

2

The Contractor shall provide suitable termination's for remaining fencing whether inside or outside the right-of-way limits.

3

Unless otherwise directed all fencing, posts, gates and other accessories shall remain the property of the Employer and shall be carefully dismantled and delivered to and place into storage on site or at the Employer's stores, the location of which shall be obtained from the Engineer. The supporting posts and supports shall be carefully cleaned of concrete, avoiding damage to the posts.

4

Foundations and sections of fencing which are designated unsuitable for recovery by the Engineer shall be disposed of.

2.8

REMOVAL OF EXISTING PAVEMENTS

2.8.1


1

On sections of redundant existing roadway (and detours and diversions that are no longer needed for traffic) the existing pavement structure together with all kerbs, kerb base and backing, sidewalk paving, edging or kerb to sidewalk paving including base and backing to same and other items shall be broken out and removed.

2

Non-asphaltic pavement, kerbs, kerb base and backing, gutters and other associated debris shall be disposed of unless such items are designated for recovery.

3

Where designated side drainage ditches and excavations shall be filled and the roadway rough graded to restore approximately the original contour of the ground or to produce natural, rounded slopes. After the rough grading is completed, the area of the old roadbed shall be scarified or ploughed to mix the remaining road material thoroughly with earth and then shall be harrowed and smoothed.

2.8.2

Cutting Back Pavement

1

The Contractor shall cut back all existing construction in such a manner to avoid damage to the construction which is to remain.

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2.6

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Page 7

Any damage to the existing pavement and other work areas which are to remain shall be restored to the satisfaction of the Engineer.

3

The details and dimensions of the cutting back of the existing pavement construction shall be as designated subject to a minimum benching step of 300 mm between each pavement course.

4

The method of cutting back all existing construction shall be as approved by the Engineer.

5

Once cut back all pavement edges shall be suitably protected against damage from construction traffic. Any such damage shall be made good before proceeding with pavement construction.

2.8.3

Stockpiling Asphalt Pavement

1

During the recovery and stockpiling operations asphalt pavement containing soil or other debris shall be kept separate from recovered pavement which does not contain soil or other debris.

2

Existing pavement designated for recovery shall be removed and stockpiled by methods which will minimise losses and prevent it being contaminated with other materials. Especially, the Contractor shall ensure that the material is reasonably free of soil and other matter when it is stockpiled.

2.8.4

Stockpile Site

1

The Engineer may direct that removed asphalt or concrete pavement is stockpiled for possible future use and the Contractor will transport all removed asphalt or concrete pavement to the designated stockpile location.

2

The Contractor shall inform the Engineer at least seven (7) days before he is ready to commence stockpiling operations and obtain written approval from the Engineer.

3

If not previously protected, the Contractor shall provide a protective enclosure around the stockpile site to prevent unauthorised dumping by other Contractors and ensure that material is not removed without authorisation. The protective enclosure around the stockpile site shall include a suitable lockable gate for entry.

4

The Contractor shall assure responsibility for maintenance of the stockpile site during the time he is depositing and removing material from the stockpile.

5

Maintenance responsibility shall include but not be limited to:

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(a)

Furnishing plant when directed by the Engineer to spread the material and shape the stockpile as successive loads of salvaged material are delivered.

(b)

Ensuring by whatever means required that no unauthorised dumping is allowed.

(c)

Consolidating and reshaping of stockpile from time to time and when final operations are complete.

When directed by the Engineer the Contractor shall permit other contractors access to the stockpile site to deliver or remove materials.

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Page 8

MEASURES FOR STATUTORY UNDERTAKERS

1

The Contractor shall take all measures required by any statutory undertaker, the management of other publicly owned services, or owners of privately owned services or supplies, for disconnection and proper sealing off of all redundant drains, services and supplies.

2

The Contractor shall observe and comply with all the safety regulations that are in force for work associated with various services.

3

Before commencing work on the removal or treatment to any utilities the Contractor shall contact the statutory undertakers and obtain their written approval.

4

The removal of overhead power lines shall be carried out by the QGEWC or by a specialist contractor approved by the QGEWC.

2.10

REMOVAL OR TREATMENT TO BURIED UTILITIES

2.10.1

General

1

Designated existing underground storage tanks, culverts, box culverts, pipelines, pipes, manholes, inlets, gullies and similar facilities for drainage or other designated utilities shall be totally or partially demolished as designated, all debris removed, the facility thoroughly cleaned out and the resultant void backfilled with suitable material (as defined in Section 6 Clause 3.3) and compacted.

2

Underground utilities, pits, chambers, cesspools and similar facilities shall be demolished to a depth of one metre below the finished subgrade level in the area, and shall be properly cleaned out to full depth and backfilled with approved compacted materials.

3

Where designated, manhole and access shaft covers and frames and drainage inlet covers and frames shall be carefully removed, cleaned and transported to and placed into storage at designated storage areas.

4

Materials not recovered for reuse shall be disposed of.

2.10.2

Underground Storage Tanks

1

Existing underground storage tanks on the site or under structures designated for removal shall be removed and disposed of by the Contractor. The Contractor shall take all necessary precautions during the removal and disposal of any fluid within the tanks and of the tanks themselves.

2.10.3

Removal of Culverts

1

Where the total demolition of a culvert is designated the culvert top slab, walls, base slab and all manhole shafts, shall be broken out and all debris removed and disposed of.

2

Where the partial demolition of the culvert is designated the top slab of the culvert shall be removed together with all manhole shafts. The side walls shall be broken out to the designated level or to a minimum of one metre below the subgrade level or the finished ground level in the area. The walls shall he neatly trimmed off and the reinforcement shall be cut or burned off close to the concrete.

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2.10.4

Abandoned Pipes and Culverts

1

Pipes and culverts no longer required which are designated to be abandoned in place shall either be filled with grout or concrete, as designated by the Engineer.

2

All ends of abandoned pipes with a nominal diameter greater than 100 mm and less than 600 mm and all ends of abandoned culverts with a cross-sectional area of 1.0 m2 or less shall be plugged by either mass concrete or a reinforced blockwork wall. All ends of abandoned pipes with a nominal diameter of 600 mm or greater and all ends of abandoned culverts with a cross-sectional area greater than 1.0 m2 shall be provided with a cut-off wall as designated.

2.10.5

Total Removal of Pipelines

1

Where designated, pipelines, manholes and fittings together with any plain or reinforced concrete bed, haunch or surround shall be broken out, removed and disposed of.

2

Designated pipes and ring fittings to be reused shall be recovered in such a way as to leave them undamaged and suitable for reuse.

3

The method of taking apart the pipes and fittings shall be agreed with the Engineer before the start of the work.

4

Materials damaged in the process of recovery shall be repaired by the Contractor.

5

The pipes and fittings recovered shall have all extraneous material including concrete surround carefully removed, they shall then be thoroughly cleaned and delivered to the designated storage area and placed into storage.

2.10.6

Grouting of Pipelines

1

Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he completely filled with a sand-cement grout.

2

The cement, fine aggregate and water used for the grout shall comply with the requirements of section 5 of the Qatar Construction Specification. The sand used for the grout shall be a fine graded rounded sand that produces a free flowing grout.

3

The grout shall comprise of one part cement to two parts fine aggregate with enough water to produce a free flowing and pumpable mix. The use of admixtures to improve the flow and setting characteristics of the grout will be permitted subject to the prior approval of the Engineer.

4

Each end of the pipe shall be plugged. No grouting shall commence until the Engineer's approval has been obtained.

5

The Contractor may propose alternative methods of filling the pipe for the approval of the Engineer. The Engineer shall retain the right to designate certain pipes that shall be filled with grout irrespective of any approval to alternative methods of filling.

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Plugging of Pipelines

1

Designated pipes shall be plugged by mass concrete as per section 5 of Qatar Construction Specification to a minimum of one metre lateral extent into the pipe.

2

The method of constructing the plug to ensure a solid watertight seal shall be approved by the Engineer.

2.10.8

Cut-off Walls and Capping Slabs

1

Where designated the Contractor shall construct a reinforced blockwork cut-off wall to box culverts and pipelines and a reinforced concrete capping slab to manholes and access shafts.

2

Reinforced blockwork cut-off walls shall extend beyond the edges of the pipe and shall be founded on a mass concrete of grade 20 as per section 5 of Qatar Construction Specification.

2.10.9

Manholes and Access Shafts

1

Unless otherwise designated, manholes and access shafts shall be broken out to a plane not less than one metre below the subgrade level or the finished ground level in the area or to immediately below the manhole and/or access shafts cover slab, whichever is the lower.

2

Manhole and access shaft walls shall be neatly trimmed off and reinforcement shall be cut or burned off close to the concrete and made safe.

3

Manholes and access shafts shall be cleaned out and all debris, sediment and refuse and other unsuitable material disposed of, and backfilled with approved compacted material.

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2.10.7

2.10.10 Drainage Inlets and Gullies

Unless shown otherwise, all redundant drainage inlets, gullies and similar facilities shall be broken out to full depth.

2.11

DISPOSAL OF MATERIALS

1

Materials removed but not recovered shall be disposed of in a lawful manner at approved dumping areas. The Contractor shall be responsible for obtaining the location of the dumping area as well as the necessary permits and approvals from the relevant authorities.

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END OF PART

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 1

EARTHWORKS ....................................................................................................... 3

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

GENERAL ............................................................................................................... 3 Scope of Work 3 References 3 Definitions 4 Submittals 4 Quality Assurance 6

3.2

EARTHWORKS BY OTHERS ................................................................................. 6

3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6

MATERIALS ............................................................................................................ 6 General 6 Unsuitable Materials 7 Fill and Subgrade Materials 7 Rock Fill 8 Water 9 Performance Indicators 9

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8

MAIN PLANT FOR EARTHWORKS ........................................................................ 9 General 9 Compaction Trials 10 Rotary Cultivators 10 Water Sprinklers 10 Bulldozers 10 Motor Graders 11 Shovel Tractors 11 Compacting Equipment 11

3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6

EXCAVATION GENERAL ..................................................................................... 12 Removal of Unsuitable Soil and Soft Spots 12 Excavating High Level Areas 12 Rock Excavation 13 Manual Excavation 13 Excavation for Pits and Trenches 14 Double Handling 14

3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9

FILLING GENERAL ............................................................................................... 14 General 14 Filling Around Utilities 15 Fill Supplied by Qatar National Transport Organization (QNTO) 15 Contractors Imported Fill 15 Rock Fill 16 Compaction 17 Filling of Pits and Trenches 18 Work Over Sabkha 18 Trimming Side Slopes 19

3.7 3.7.1 3.7.2 3.7.3

STRUCTURE EXCAVATION AND FILLING .......................................................... 19 General 19 Excavation Supports 20 Dewatering 20

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Excavation for Structures Use of Materials Cofferdams Backfill Adjacent to Structures

20 21 21 22

3.8 3.8.1 3.8.2 3.8.3

FORMATION PREPARATION............................................................................... 22 Scope 22 Protection 23 Rectification 23

3.9

TOPSOIL ............................................................................................................... 23

3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5

TESTING ............................................................................................................... 23 General 23 Testing Degree of Compaction 24 California Bearing Ratio 24 Testing Levels and Evenness of the Formation 25 Testing Formation Works after Completion 25

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3.7.4 3.7.5 3.7.6 3.7.7

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3

EARTHWORKS

3.1

GENERAL

3.1.1

Scope of Work

1

This Part includes all the earthworks required to construct and maintain the roadway facilities as follows:

(b)

Excavating selected material from the roadway and borrow pits for use as specified.

(c)

Placing and compacting of selected material.

(d)

Structure excavation.

(e)

Backfilling.

(f)

Supplying and placing topsoil (sweet soil).

(g)

Laying and compaction of fill for shallow embankments where additional slope protection measures are not required.

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Removing unsuitable materials.


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(a)

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Drainage Works Earthworks Related to Buildings

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Section 8, Section 12,

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This Section Part 1, .............. General Part 2, .............. Site Clearance Part 4, .............. Unbound Pavement Materials Part 5, ............. Asphalt Works Part 6, ............. Concrete Road Pavements Part 19, ........... Miscellaneous

References

1


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3.1.2

ASTM D1556 .............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1557 .............Standard Test Methods for Laboratory Compaction Characteristics of 3 3 Soil Using Modified Effort (56,000 ft lbf/ft (2,700 kN m/m )) ASTM D4718 .............Standard Practice for Correction of Unit Weight and Water Content for Soils Containing Oversize Particles ASTM D1883 .............Standard Test Method for CBR (California Bearing Ratio) of Laboratory Compacted Soils ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of soils using Sieve Analysis

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ASTM D4429 ..............Standard Test Method for (California Bearing Ratio) CBR of Soils in Place ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM D1140 ..............Standard Test Method for Amount of Material in Soils Finer than No. 200 (75-μm) Sieve ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces Using a Straightedge

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AASHTO T307 ..........Standard Method of Test for Determining the Resilient Modulus of Soils and Aggregate Materials

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BS 1377 - Part 3 ........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests Definitions

1

LSA: Laboratories and Standardization Affairs – Ministry of Environment.

2

Suitable material: material which is acceptable in accordance with Clause 3.3.3.

3

Imported material: suitable material obtained from outside of the Site.

4

Optimum moisture content (OMC): the moisture content of soil at which a specified compaction effort will produce the maximum dry density when determined in accordance with ASTM D1557.

5

Maximum dry density (MDD): The dry density of soil obtained using a specified compaction effort at the optimum moisture content when determined in accordance with the modified compaction test ASTM D1557. Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

6

Subgrade: the compacted existing ground or fill for 500mm beneath formation.

7

Formation: the completed earthworks level shaped in accordance with the Drawings in readiness to receive the sub-base.

3.1.4

Submittals

1

The Contractor shall submit to the Engineer for approval his proposals for the compaction of each type of material to be used in embankments detailing the type of plant, number of passes and maximum loose depth of layer.

2

The contractor shall submit to the Engineer for approval method statements for the following:

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3.1.3

(a)

Materials production, handling, storage, identification, marking and traceability to source of production.

(b)

Quality assurance and quality control plans for all construction activities.

(c)

Quality control testing plan.

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(d)

Equipment and its suitability to fulfill all construction activities to the required quality.

(e)

Personnel capability.

(f)

Safety and environment preservation measures.

Before commencing any structural excavation work greater than 1.5 m in depth, the Contractor shall submit to the Engineer for his review details of proposals for supporting excavated faces.

4

The proposals shall be submitted in the form of calculations and drawings which clearly indicate the extent of excavation at all points along the structure relative to adjacent properties, roads and services.

5

In the case of supported excavations the proposals shall, for the actual soil properties, comprise detailed drawings of the support system stating method of installation and showing support member materials, sizes, spacing and engineering calculations to validate the design of the above, including the maximum theoretical deflections of the support members. The support system shall be designed in such a manner that no support members extend through surfaces exposed in the finished construction and no shoring or bracing is placed under permanent structures.

6

The engineering calculations shall be in English and shall show lateral earth pressures for the full excavation depths, faces at various stages of support during installation and removal and concrete placement, the anticipated equipment loads, anchorage loads of any description, the maximum design loads to be carried by various members of the support system and strut preload forces.

7

If the structure support system proposed includes tie-back anchors, the Contractor's submittal drawings shall show the profile of the soil in which each anchor is to be installed, the design load for the full depth of the excavation, the maximum design and proof loads, surcharge loads of any description; equipment loads, forces at various stages, support during installation and removal, and the criteria proposed for deformations under proof loads.

8

In addition to the approval submittal, shop drawings of the support system are to be submitted. Where a proposed system of tie-back anchors projects onto adjoining property beyond the vertical projection of the designated limits of the Contract, the permission of the owner shall be obtained in writing and documentation of such permission shall be included in the submittal.

9

Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted for review. The submittal drawings shall show the arrangement, location and depths of the proposed dewatering system if required. A complete description of the equipment and materials to be used and the procedure to be followed shall be shown together with the standby equipment, standby power supply, and the proposed location or locations of points of discharge of water. Details of methods of cofferdam construction shall be included in the submittal.

10

The method and the type of equipment to be used for advancing dewatering wellpoints shall be submitted for review.

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Quality Assurance

1

The designs of the structure excavation support systems and the dewatering system shall be prepared by and signed by a professional engineer specializing in this type of design work.

2

Blasting work shall be carried out by a specialist company with the appropriate license as detailed in clause 3.5.3.

3.2

EARTHWORKS BY OTHERS

1

Where earthworks have been carried out by others before commencement of the Works, the Contractor shall carry out all tests he considers necessary to satisfy him that the work already executed complies with this specification.

2

Should the Contractor consider the result of the tests unsatisfactory he shall immediately provide full details of all such tests carried out for the Engineer's review as to the remedial work to be undertaken.

3

The Contractor will be deemed to have satisfied himself as to the adequacy of any previous earthworks when he proceeds with his own work, and he shall be responsible for repairs to or replacement of any defective layer or surface where such failure was due to a fault in the previously executed work which would have been revealed by normal testing procedures.

3.3

MATERIALS

3.3.1

General

1

All excavated material shall be the property of the Owner and shall not be removed from the Site without the written consent from the Owner.

2

Suitable and approved excavated material from any part of the Site shall be hauled and used for filling in any other section of the Site. The Contractor shall store such material when necessary until the need arises for its use in filling as required by the phases of construction, or as directed by the Engineer.

3

Where the amount of suitable material exceeds the amount of fill required for the Works, the Contractor shall dispose of the surplus material at designated locations. The Contractor shall off-load, spread, level, water and carry out other related operations at the disposal site as directed by the Engineer. The Contractor shall ensure that the disposal site has been approved by the Municipality concerned.

4

Any excavation greater than the net volume required for the Works in length or width, shall be made up with suitable compacted fill material at no cost to the Owner and subject to inspection and approval of the Engineer.

5

Any additional excavation to remove unsuitable material at or below the bottom of foundation level or construction layers shall be replaced with mass concrete.

6

Before using material resulting from excavation for filling, the Contractor shall carry out field and laboratory testing to establish the suitability of said material for filling work. Whenever such excavated material indicates a change in characteristics the Contractor shall carry out additional testing.

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3.1.5

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Where the contract provides for the supply of fill material by others the Contractor shall remain responsible for checking each load received to ensure that it is in accordance with the specification requirements and for rejecting unsuitable material. The Contractor shall be responsible for maintaining all records of deliveries and documentation relating to the quality of such material.

3.3.2

Unsuitable Materials

1

Unsuitable materials shall mean materials other than suitable materials and include; Material from marshes.

(b)

Tree and plant stumps.

(c)

Perishable material.

(d)

Deposits of sabkha with more than 5% water-soluble salts.

(e)

Material subject to spontaneous combustion.

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Fill and Subgrade Materials

1

The subgrade material and the material used for filling and compacting below the formation level of the roadway, sidewalks, hard shoulder, drainage ditches and other areas on site shall consist of material approved for filling resulting from the excavation works.

2

In the event that such material is unsuitable or insufficient, the Contractor shall obtain and use filling material from borrow pits.

3

This material shall be clean and free from any unsuitable material and complies with the requirements listed in Table 3.1.

4

The maximum particle size of fill material shall be 75 mm unless the material is classified as rock as per this part of the specification and the placing and compaction are carried out according to the requirements for rock fill.

5

Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

6

When nuclear gauge is used for field density and moisture content testing, 3 readings shall be made at each test location within a radius of 2 meters. The average of the 3 readings is considered to be the density for that test location. Individual density readings shall not be less than the target relative density by more than 0.5%.

7

Recycled aggregate produced from excavating natural ground and from demolition wastes can be used for filling purposes provided that the specifications stated in Section 6 - Part 9 are complied.

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Table 3.1 1 Fill and Subgrade Materials and Construction Specifications Parameter

Standard

Specification Limits

Percent passing the 75mm sieve

ASTM D6913

100%

Percent passing the 0.075mm sieve

ASTM D1140

30% max.

Liquid limit

ASTM D4318 Method A

30% max.

Plasticity Index

ASTM D4318

10 % max.

- Visible change in material

ASTM D6938

In Place Moisture 2 Content

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ASTM D1556

Min. 95% of MDD

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Field Density

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2% max.

 2% of OMC

ASTM D4429

Acid soluble Chloride Content

BS 1377 Part 3

Acid soluble sulphate content

BS 1377 Part 3

3% max.

Organic Matter

BS 1377 Part 3

2% max.

15% min.

- 1 per 200 m layer

2

per

- 1 every 75m per lane per layer 1 per 2000 m

2

1 per 3000 m

3

2% max.

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In Place California Bearing Ratio (CBR)

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15% min. at 95% MDD

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Swelling

Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer. During compaction.

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- Each Source

- 1 per 1000 m

California Bearing Ratio (CBR)

1

Minimum Frequency

Rock Fill

1

Rock shall be defined as any naturally formed solid matter encountered in excavation having 2 2 a crushing strength of not less than 7 N/mm when dry and not less than 4 N/mm after submergence in water for 24 hours.

2

This shall be determined on samples of 100 mm x 100 mm x 100 mm cubes obtained from

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the material (equivalent cores in lie u of cubes may be considered for testing at the discretion of the Engineer and the method of testing and acceptance criteria will be advised by the Engineer in such cases). 3

Individual masses of solid material found in excavation and weighing less than 500 kg shall not be considered as rock.

4

Any artificially formed solid matter such as block work or concrete shall not be considered as rock.

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The Contractor shall supply any equipment and labor necessary to obtain suitable samples and carry out testing of rock or suspected rock. The Engineer shall determine the location and quantity of samples necessary to determine the extent of the rock. These samples shall be taken in the presence of the Engineer.

6

In the event that the tests prove that the material is rock, the Engineer shall determine the extent of such material and shall instruct the Contractor accordingly.

3.3.5

Water

1

Potable or brackish water shall be used for all earthwork operations except that only potable water shall be used for compaction of backfill material within one meter from all surfaces of the structure and for the backfill of all service trenches.

2

Brackish water shall have a maximum total dissolved solids (TDS) of 5000 ppm, a maximum chloride content of 1500 ppm and a maximum sulphate content (as SO3) of 2000 ppm.

3.3.6

Performance Indicators

1

Upon the request of the Engineer, the following performance indicators shall be determined from loose in place materials for verification of the pavement structural design following the AASHTO Mechanistic-Empirical Pavement Design Guide:

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Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture content and maximum density as per ASTM D1557.

(b)

Parameters and moduli required for determining the Permanent Deformation Potential in accordance with AASTHO Mechanistic Empirical Design Guide.

(c)

Parameters and moduli required for measuring the Fatigue Cracking Potential for stabilized and surface layers in accordance with AASHTO Mechanistic Empirical Design Guide.

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3

For performance testing, one sample shall be tested every 10,000 m , and for constructions 3 having less than 10,000 m volume, one sample shall be tested every 50% of the total volume.

3.4

MAIN PLANT FOR EARTHWORKS

3.4.1

General

1

The Contractor shall provide the Engineer with copies of catalogues, technical data and charts of the machinery to be used on site before the commencement of the work.

2

The Engineer will inspect the machinery and tools before the commencement of work. The machinery and tools used in carrying out earthworks and other related works for the road construction and in maintenance of the work shall be in good working condition, and the Contractor shall maintain them in such condition for the whole duration of the Work.

3

The Contractor shall use power screens equipped with clay reject screen with sufficient screen area and clay reject conveyor belt when processing subgrade materials. Static screens shall not be used to produce subgrade materials. Any deviations from this process must be approved by the Engineer.

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The Contractor shall supply an adequate type and number of machines and tools for the proper and timely execution of the Works. The number of machines shall not be limited to the types of equipment or recommended minimum number stipulated in the Contract Documents, which shall be used for guidance purposes only.

5

The Contract is awarded on the understanding that the actual numbers of machines and other plant will not be reduced below the numbers shown in the Contract.

6

No plant shall be removed from the site without the specific written approval of the Engineer.

3.4.2

Compaction Trials

1

Before commencing construction of the permanent works, unless otherwise agreed with the Engineer, the Contractor shall carry out compaction trial, after submitting a method statement, for each type of fill material and construction situation of the earthworks to establish an approved rolling/compaction procedure which shall then be used as a minimum requirement for the permanent works unless otherwise directed or agreed by the Engineer.

2

The compaction trials shall involve all procedures specified for the permanent works including testing and any equipment, processes or procedures as proposed by the Contractor which are not included as a part of these specifications. Compaction trials for each main type of material shall be carried out on areas having dimensions of approximately 50 meters by 10 meters.

3

Construction of the permanent works shall not commence until a compaction procedure has been approved in writing by the Engineer.

3.4.3

Rotary Cultivators

1

Rotary Cultivators shall have axles rotated by a powerful motor and be equipped with metal teeth or plates. They shall be designed in such a way as to ensure proper pulverization and mixing of soil. They must be equipped with apparatus to lift and lower the axles so as to be always to the required depth.

3.4.4

Water Sprinklers

1

Water sprinklers shall be borne by trucks with pneumatic tires and shall be equipped with a pressure pump and water sprinkling distribution equipment. The pump shall be powered in such a manner that the pump pressure will remain uniform regardless of variations in truck speed. The distributors shall be so designed as to allow sprinkling and adding of water to the soil uniformly and in controlled quantities and shall be equipped with an approved gauge to control the quantity of water added during operation. Special spray bar attachments shall be provided and used in order to sprinkle water on sloped sections. The activation of the water system shall be controlled from the cab by the driver.

3.4.5

Bulldozers

1

Bulldozers may be tracked or pneumatic-tire vehicles and shall be equipped with a blade for earth moving and levelling. Ripper attachments shall be provided when necessary. The blade level shall be hydraulically controlled to raise or lower it so that the work surface can be formed and adjusted as required.

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Motor Graders

1

Motor graders shall be pneumatic-tire and shall be equipped such that it is possible to lift, lower and adjust the angle of the blade as required to control the grading operation and to perform grading without making undulations.

3.4.7

Shovel Tractors

1

Shovel tractors shall be tractors equipped with a shovel for earth hauling or moving and may be either on tracks or on pneumatic tires. The shovel shall be hydraulically controlled to raise and lower it as required.

3.4.8

Compacting Equipment

1

Rolling compacting equipment shall consist of pneumatic-tire and steel wheeled rollers as described below:

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3.4.6

Pneumatic-tire rollers shall be equipped with tires of equal size and diameter which shall be uniformly inflated so that the air pressure of the tires shall not vary significantly, from one another. The wheels shall be spaced so that one pass will accomplish one complete coverage equal to the rolling width of the machine. There shall be a minimum of 6mm overlap between the tracks of the front and rear tracking wheels. Self-propelled, pneumatic-tire rollers shall have a minimum weight of 9 tons without ballast and a minimum weight of 18 tons with ballast.

(b)

Steel wheeled rollers shall be of the following types:

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(a)

Three-wheeled rollers shall be self-propelled and equipped with a reversing clutch, a differential drive and with adjustable scrapers to keep the wheel surface clean.

(ii)

Tandem rollers shall be self-propelled and equipped with reversing clutches and adjustable spring scrapers fitted to the driving and steering roller to scrape in both directions.

(iii)

Vibratory steel tandem rollers shall have the requirements of the foregoing steel tandem rollers with a static weight of at least 5000 kg and a vibrating frequency between 1500 and 2000 cycles per minute.

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(iv)

Single drum vibratory steel rollers shall be double axle, self-propelled units with the rear axle equipped with pneumatic flotation wheels, they shall have vibrating frequency capabilities between 1500 and 2000 cycles per minute.

2

Portable vibratory compaction rollers shall be double axle tandem single-drum self-propelled equipped with a vibrating element delivering an impact of not less than 1590 kg at a frequency of about 5000 cycles per minute. The roller shall be easily maneuvered, of adequate width and suitable for rolling ditches with their side slopes having grades of up to 1:3.

3

Hand plate compactors shall be capable of delivering an impact of between 750 to 1500 kilograms.

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EXCAVATION GENERAL

3.5.1

Removal of Unsuitable Soil and Soft Spots

1

If during the progress of the work the soil encountered has characteristics, as determined by tests conducted under the direction of the Engineer, that render it unsuitable for incorporation in the road embankment, the Contractor shall excavate and remove such unsuitable material to the extent directed by the Engineer.

2

Where contractor finds isolated soft spots during excavation, this material shall be removed to the extent directed by the Engineer.

3

No excavated suitable material shall be removed from the Site without the approval of the Engineer. Should the Contractor be permitted to remove suitable material to suit his operational procedure then he shall make good any consequent deficit of fill material arising therefrom.

4

Where the excavation reveals a combination of suitable and unsuitable material the excavation shall, unless otherwise agreed with the Engineer, be carried out in such a manner that the suitable materials are excavated separately for use in the Works without contamination by the unsuitable material.

5

The hauling of excavated material to areas of fill shall proceed only when sufficient spreading and compacting plant are operating at the place of deposition to ensure placing and compaction.

6

Unsuitable excavated material shall be removed and carted away to an approved dumping area after approval from the Engineer.

7

The Contractor shall replace this unsuitable material by other suitable surplus or imported material in layers not exceeding 150 mm compacted thickness to the density specified.

8

If the contractor considers in some situations it is impractical to replace unsuitable material with imported material he may elect to use granular material, which shall comply with the requirements of part 4 of this specification.

9

Granular material placed beneath water shall not require compaction, granular material placed above water shall be compacted and tested as per the requirements of part 4 of this specification.

10

If any solution cavities are found in lime stone material they shall be brought to the attention of the Engineer. The Engineer shall advise what treatment is to be carried out in such situations.

3.5.2

Excavating High Level Areas

1

The Contractor shall excavate high level areas in all materials including rock for the full width of the road construction down to the top of the required subgrade.

2

The Contractor shall then scarify a layer not less than 150 mm deep except that this requirement shall not apply where rock is present.

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The soil shall be pulverized, watered as required, mixed, shaped and compacted to 95 % maximum dry density, as per ASTM D1557, to a depth of 150 mm. In all excavations the groundwater level shall be maintained at least 300 mm below the formation level during the works.

3.5.3

Rock Excavation

1

Excavation in rock shall be as defined in clause 3.3.4 of the specification.

2

Excavation in rock may be carried out by a tracked bulldozer and ripper or by the use of blasting with explosives or any other method approved by the Engineer.

3

Blasting using explosives shall only be permitted if authorized by the civil defense, police and any other statutory authority. The Contractor’s method statement shall be agreed before any blasting operation.

4

Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry and Public Works.

5

For any blasting work involving the use of explosives the Contractor shall use a specialist company, licensed to carry out such work by the former Ministry of Industry and Public Works.

6

The specialist company shall possess the appropriate license for the required scope of work.

7

The purchase and delivery of each consignment of explosives for blasting work should be covered by a separate application for a possession license.

8

The transportation of explosives shall only be carried out after notification to the police and civil defense.

9

For each planned blasting operation the Contractor shall arrange for advance notification to be made to the police and civil defense authorities.

10

After it has been established that the excavated material is rock and after the area where such rock exists has been defined, the Contractor shall incorporate the rock in the embankment.

11

When excavated material contains more than 25 % of rock larger than 150 mm in greatest

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diameter the rock shall be crushed, pulverized and further broken down. The resultant material from the excavation shall be placed on the embankment in accordance with clause 3.6.5. 3.5.4

Manual Excavation

1

The Contractor shall excavate manually in the vicinity of all services, structures, and any other areas, and if necessary uncover them, all as directed by the Engineer.

2

The Contractor shall take all precautions to prevent damages to services, properties and persons, and any damage resulting from the negligence of the Contractor, his agents, or his employees. Any such damage shall be repaired by the Contractor at his own expense.

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Excavation for Pits and Trenches

1

All trenches and pits under roads shall, where possible, be excavated, backfilled and compacted before road construction commences.

2

The sides of the excavation shall be adequately supported at all times.

3

Trenches and pits shall be kept free of water.

4

In tidal and high water table areas the excavation shall be kept free from standing water at all times during construction.

5

Trenches for pipes or ducts shall be excavated to the levels and gradients indicated in the contract documents.

3.5.6

Double Handling

1

It shall be the Contractor’s responsibility to assess at the start of the contract the quantity of suitable material available from an excavation for use as fill material and the requirement for imported fill material.

2

The Contractor shall plan earthworks operations to minimize the handling of fill material and disruption due to dust and noise from transportation operations.

3

The Contractor shall not be entitled to any additional payment for double handling of any excavated material from the site for imported fill.

4

If it is necessary to double handle the material the Contractor shall take all measures to avoid degradation or contamination of fill material.

5

The Engineer may instruct that the tests to assess the properties of the fill material are taken at any point during the transportation, placing and compaction process.

3.6

FILLING GENERAL

3.6.1

General

1

Filling low-level areas shall be to the level of subgrade as designated. After completion of clearing and grubbing, the Contractor shall carry out the necessary levelling in order to control the thickness of the layers of fill.

2

The existing natural ground shall then be scarified in place to a minimum depth of 150 mm for the full width of the embankment except where the material is classified as rock. The scarified material shall be watered as required, thoroughly mixed, shaped and compacted to a minimum of 95 % maximum dry density.

3

Where an existing embankment is being widened, the existing embankment slope shall be trimmed and compacted into benches of minimum width 1m and depth 500mm before placing and compacting each layer of new embankment material unless otherwise directed by the Engineer to suit particular circumstances.

4

The Contractor shall not proceed with filling and compacting any subsequent layer before testing and securing the approval of the Engineer for the previous layer.

5

All fill material for a depth of 500 mm below the formation level must meet the requirements provided in clause 3.3.3.

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Filling Around Utilities

1

Filling around culverts, storm water and sewerage pipes, utility and structures, and between building plot and footpath areas shall be done in accordance with the specific requirements of the relevant utility authority and the following additional requirements.

2

Filling for these areas shall be from surplus excavated material obtained on site and approved by the Engineer. In the case of insufficiency of such material then approved material shall be obtained from borrow pits and filled to the designated levels. The maximum size of particle allowed in the backfill within one meter of culverts, storm water and sewage pipes, utilities and structures shall be 25 mm.

3

The Contractor shall take every precaution to protect bridge columns and lighting equipment when filling between median barriers and any damage to these items arising from the filling works shall be repaired by the Contractor.

4

The Contractor shall agree the type of plant or equipment to be used with the Engineer before undertaking this work.

3.6.3

Fill Supplied by Qatar National Transport Organization (QNTO)

1

If instructed under the projects specification, fill will be imported from other sources using the Qatar National Transport Organization (QNTO).

2

It shall be the responsibility of the Contractor to monitor and control both the quality and the quantity of this imported fill.

3

The Contractor shall ensure that all delivery notes for such material are verified and authenticated and then collated for submission to the Engineer.

3.6.4

Contractors Imported Fill

1

The project specifications shall designate areas for the Contractor to obtain borrow material for use in the construction of the Works. It is the Contractor's responsibility to satisfy himself that there is sufficient borrow material of suitable types.

2

The Contractor may elect to use alternative sources of borrow material.

3

It shall be the Contractor's responsibility to obtain all permits or permission and make any payments that may be required in acquiring the rights to borrow material whether the Contractor uses the designated areas or elects to use alternative areas. The Contractor shall ensure that the source of all borrowed material has been approved by the Municipality concerned.

4

The Contractor shall obtain and supply to the Engineer representative samples from the borrow pits he intends to use. The Engineer will be afforded the opportunity to be present during the sampling operations.

5

The Contractor will carry out the necessary laboratory and, if required, field testing to establish the suitability of the material for filling work and will advise the Engineer of the results. The Engineer will advise the Contractor whether such material is acceptable and whether the borrow pit is an approved source of borrow material.

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3.6.2

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The Contractor will test samples of the approved borrow pits material actually being imported onto the site, and should such material fail to meet the requirements of these Specifications, approval to the use of the borrow pits will be withdrawn and the Contractor shall immediately cease importation from the borrow pits until such time as the Engineer may approve alternative sources of material from within the same borrow pits based on sampling and testing as specified above.

7

The Engineer will decide whether the material already imported from the concerned borrow pits can remain as placed on the site, or whether the Contractor shall remove and replace the said material at his own expense.

8

Overburden and any unsuitable top layers at the borrow pit shall be stripped and stockpiled to the satisfaction of the Engineer. Upon completion of excavation the Contractor shall replace the overburden and unsuitable material, smooth the surface and leave the area clean and tidy to the satisfaction of the Engineer.

9

The Contractor's haul and traffic arrangements will be subject to the Engineer's approval before the work may be commenced.

3.6.5

Rock Fill

1

Material consisting predominantly of rock fragments of such a size that it cannot be placed in layers of the thickness allowed without crushing, or further breaking down, may be placed in the embankment in layers not exceeding twice the average size of the larger fragments.

2

No layer of rock fill shall exceed 800 mm loose thickness.

3

Rock fill shall be placed and spread so that the largest boulders and fragments are evenly distributed, with the voids in-between completely filled with smaller fragments, sand or gravel, watered in if necessary.

4

Each layer shall be bladed and leveled by a track laying tractor.

5

Quality control tests will not normally be performed on this material but each layer must be approved in writing by the Engineer before the next is placed.

6

Embankment layers which consist of material that contains rock but also has sufficient compatible finer material other than rock shall be placed and compacted as for soil embankments. Quality control tests will be made wherever the Engineer determines they are feasible.

7

Compaction shall be carried out by a vibratory roller with the following minimum mass:

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Mass per Meter Width of Vibration Roll (kg/m)

Depth of Fill Layer ( mm )

Minimum number of Passes of the Roller on each Layer

2300 - 2900

400

5

2900 - 3600

500

5

3600 - 4300

600

5

4300 - 5000

700

5

>5000

800

5

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Compaction

1

The Contractor shall carry out the required compaction specified after grading and leveling the surface to be compacted. In areas to be filled, compaction shall include adding necessary soil, water and compacting the first layer in addition to subsequent layers up to the proposed levels.

2

In areas already excavated down to the required level, compaction shall include adding the necessary water, and compacting the surface, in accordance with the procedure outlined in paragraphs 3 to 12 below.

3

After carrying out the grading, leveling, scarifying and pulverizing of the soil layer the Contractor shall add the necessary amount of water to permeate the pulverized soil.

4

The soil shall then be thoroughly turned after each addition of water so as to achieve homogeneous moisture content in the whole thickness of the layer.

5

Before compacting, samples of the pulverized soil shall be tested using a 'Speedy Moisture Device' (ASTM D4944) or similar instrument to measure the moisture content. If the moisture content is not within  2 % of the optimum moisture content as determined by ASTM D1557,

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the area represented by this sample shall be scarified and aerated or water added until the moisture content is within  2 % of the optimum moisture content. The soil shall then be

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primarily leveled in order to commence earth compaction. After primary levelling referred to above, compaction shall be commenced by means of the approved rolling pattern.

7

Filling shall be in layers not exceeding 150 mm compacted thickness.

8

All areas including embankment roadway, medians, shoulders, sidewalks and verges shall be compacted to 95 % of Maximum Dry Density as determined by ASTM D1557 unless

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otherwise specified or directed by the Engineer. The rolling shall be carried out in the direction of the road axis until the soil reaches the required density. In crowned sections, rolling shall start from both edges of the road in the direction of the road axis. If the road is super elevated, rolling shall commence from the lower side and continue to the higher side. In order to compensate for the amount of water loss in evaporation during the course of compaction, additional quantities of water shall be added as required.

10

Each layer shall be levelled and rolled to achieve uniform compaction free from undulations, soft spots and depressions.

11

No layer shall be covered by the next layer until it has been tested, inspected and approved by the Engineer.

12

The Contractor shall be responsible for reinstatement to the satisfaction of the Engineer of any layer damaged or disturbed after compaction and approval, by any means or cause, before placing the next layer.

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Filling of Pits and Trenches

1

The bottom of all excavations shall be formed to the lines and levels shown on the drawings.

2

Any pockets of soft soil or loose rock in the bottom of pits and trenches shall be removed and the resulting cavities and any large fissures filled with suitable material and compacted to a minimum relative compaction of 95 % based on ASTM D1557.

3

Prior to proceeding with filling, the base of the excavation shall be compacted to a minimum relative compaction of 95 % based on ASTM D1557.

4

The full width of the compaction plant shall fit inside the surface area of the backfilling with sufficient space to permit adequate compaction. Under no circumstance shall compaction be carried out with plant straddling backfilled and existing surfaces.

5

Trenches and pits shall be backfilled in layers not exceeding 150 mm compacted thickness unless otherwise directed by the engineer.

3.6.8

Work Over Sabkha

1

Where the road embankment passes over Sabkha areas with a high water table the contractor shall take special precautions during the construction.

2

These precautions shall include but shall not be limited to the construction of suitable temporary haul roads for all construction plant operating in the area.

3

Haul roads shall be constructed using rock fill and geotextiles as necessary to ensure a safe stable surface.

4

The use of geotextiles and geosynthetics shall be in accordance with Part 15 when used for the permanent embankment.

5

If directed by the Engineer the Contractor shall construct embankments over Sabkha areas with a surcharge of excess material that shall remain in place till all appreciable settlement has stopped. The Contractor shall provide a means of monitoring the settlement. The Engineer shall decide when appreciable settlement has stopped.

6

Unless a specific treatment in using geotextiles or geosynthetics is described elsewhere in the contract, work over Sabkha shall comprise of initially stabilizing the existing Sabkha area by laying and rolling rock fill layer type 1 according to Table 3.2. This operation should be continued by adding and rolling type 1 rock fill layer with steel vibratory roller till the layer is completely stabilized.

7

A layer of geotextile fabric should be laid over the compacted type 1 pervious backfill.

8

A layer of 50mm pervious backfill type 2 according to Table 3.2 should be laid over the stabilized layer to protect the geotextile fabric.

9

Layer of 200mm thick rock fill type 1 should be laid over type 2 pervious backfill to receive the required road layers after the above operation.

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Table 3.2 Definition of Type 1 & 2 backfill materials Percentage Passing Size (mm) Type 2

152.0

Max.

-

125.0

85 - 100

-

100.0

75 - 90

-

50.0

45 - 65

-

37.5

35 - 55

-

19.0

20 - 35

100

12.5

10 - 25

95 – 100

9.5

5 - 20

70 – 100

4.75

-

0 – 55

2.36

-

0.075

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Type 1

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0 – 10 0–3

Trimming Side Slopes

1

Embankment side slopes shall be trimmed to the profiles and dimensions shown on the contract drawings.

2

The earthworks shall be trimmed to within  20 mm of the designated profile.

3

The side slopes shall be thoroughly compacted after trimming to ensure a hard surface.

4

Side slopes shall be tested for compaction in accordance with this part of the specification and the minimum density requirement shall be 95% of the maximum dry density as per ASTM D1557.

3.7

STRUCTURE EXCAVATION AND FILLING

3.7.1

General

1

In addition to the work specified, the Contractor shall include all operations necessary to excavate and backfill as required for the construction of any structure’s installations and utilities.

2

This work shall include necessary, pumping, dewatering, draining, sheeting, bracing, and the necessary supply and construction of cribs and cofferdams and their subsequent removal.

3

The Contractor shall take all necessary precautions, to the satisfaction of the Engineer, to prevent loss of natural cementation in the existing subsoil during, and as a consequence of, dewatering operations.

4

This work shall also include the furnishing and placing of approved foundation fill material or concrete to replace unsuitable material encountered below the foundation elevation of structures.

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3.6.9

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Excavation Supports

1

Battered excavation slopes greater than 1.5 m high shall not be used without the express written permission of the Engineer. Where such permission is not granted or where only a part of the overall depth of an excavation is permitted to be with battered slopes all faces of excavations greater than 1.5 m high shall be supported.

2

The Contractor shall submit his proposals for supporting excavated faces.

3

Before commencing any structural excavation work greater than 1.5 m in depth, the Contractor shall obtain the Engineer’s approval of his proposals for supporting excavated faces.

3.7.3

Dewatering

1

At locations where the excavation extends below the groundwater table, a dewatering system shall be provided. This will effectively reduce the hydrostatic pressure and lower the groundwater levels below excavation levels, as required for the safe and proper excavation of the work. It will result in obtaining a stable, dry subgrade for the execution of subsequent operations.

2

The Contractor shall design dewatering methods and settling basins so that no critical amounts of soil, sand or silt are removed during either the initial operations or the construction operations. Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted to the Engineer for his review.

3

The Contractor's submitted drawings shall show the arrangement, location and depths of the proposed dewatering system if required. A complete description of the equipment and materials to be used and the procedure to be followed shall be shown, together with the standby equipment, standby power supply, and the proposed location or locations of points of discharge of water.

4

Any required dewatering system design shall also include the measures taken to prevent damage due to settlement of pavement, utilities, sewers, buildings and other structures outside the excavation but within the area affected by the dewatering procedures.

5

Dewatering shall not be terminated without the approval of the Engineer and in the case of structures retained by ground anchors dewatering shall not be terminated until the ground anchors have been stressed to the full working load and approved by the Engineer.

3.7.4

Excavation for Structures

1

The Contractor shall notify the Engineer sufficiently in advance of the beginning of any excavation so that cross-sectional elevations and measurements may be taken of the undisturbed ground.

2

Trenches or foundation pits for structures or structure footings shall be excavated to the designated lines and grades or elevations. They shall be of sufficient size to permit the placing of structures or structure footings of the full width and length shown. The designated elevations of the bottoms of footings shall be considered as approximate only and the Engineer may order, in writing, such changes in dimensions or elevations of footings as may be deemed necessary, to secure a satisfactory foundation.

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Boulders, logs, and any other unsuitable material encountered in excavations shall be removed from the site.

4

Unless otherwise designated structure excavation shall be carried out for a width of at least 500 mm beyond the horizontal outside limits of the foundation, footing, box culvert or structural member to which the excavation relates. Concrete blinding or sub-foundations are not to be considered as structure for the purpose of defining such excavation.

5

If during the progress of the work, loose or improperly compacted soil or such other material as the Engineer considers would be detrimental to load distribution of new foundations to the underlying soil is encountered below the structure foundation level such material shall be removed within the limits as directed by the Engineer.

6

The resulting void shall be backfilled with either blinding concrete or with suitable material compacted to a density not less than 95 % of the maximum dry density as per ASTM D1557.

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The Engineer shall specify the type of backfill to be employed at each location. After each excavation is completed, the Contractor shall notify the Engineer to that effect, and no footing, bedding material or pipe culvert shall be placed until the Engineer has approved the depth of excavation and the character of the material on which the foundations will bear.

8

All rock or other hard foundation material shall be cleaned of all loose material and cut to a firm surface, either level, stepped, or serrated as directed by the Engineer. All seams or crevices shall be cleaned and grouted. All loose and disintegrated rock and thin strata shall be removed. When the footing is to rest on material other than rock, excavation to final grade shall not be made until just before the footing is to be placed.

3.7.5

Use of Materials

1

All excavated material, so far as it is suitable, shall be used as backfill or roadway fill.

2

All excavated material shall be approved by the Engineer before being used as fill. All surplus excavated material and excavated material rejected by the Engineer for use on the site shall be removed from the site and disposed of in locations approved by the Engineer.

3

Where the Engineer designates a disposal location this shall be within a 50 km radius of the site of the Works.

3.7.6

Cofferdams

1

Suitable and practically watertight cofferdams shall be used wherever water-bearing strata are encountered above the elevation of the bottom of the excavation.

2

Cofferdams or cribs for foundation construction shall, in general, be carried well below the bottoms of the footings and shall be well braced and as nearly watertight as practicable. In general, the interior dimensions of cofferdams shall be such as to give sufficient clearance for the construction of forms and the inspection of their exteriors, and to permit pumping outside of the forms. Cofferdams or cribs which are tilted or moved laterally during the process of sinking shall be righted or enlarged so as to provide the necessary clearance.

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When conditions are encountered which, as determined by the Engineer, render it impracticable to dewater the foundation before placing the footing, the Engineer may require the construction of a concrete foundation seal of such dimensions as he may consider necessary, and of such thickness as to resist any possible uplift. The concrete for such a seal shall be placed as directed by the Engineer. The foundation shall then be dewatered and the footing placed.

4

If weighted cribs are employed and the weight is used to overcome partially the hydrostatic pressure acting against the bottom of the foundation seal, special anchorage's such as dowels or keys shall be provided to transfer the entire weight of the crib to the foundation seal. When a foundation seal is placed under water, the cofferdam shall be vented or ported at low water level as directed.

5

As an alternative to a cofferdam, the Contractor may propose a wellpoint dewatering system, for approval by the Engineer, to keep structural excavation works dry. Such proposal shall include, but not be limited to, sufficient calculations, sketches and drawings, to justify the wellpoint positions and lengths in addition to pumping capacity required. The use of a wellpoint dewatering system may not preclude the use of support or shoring within the excavation to provide adequate stability and safety to the satisfaction of the Engineer.

3.7.7

Backfill Adjacent to Structures

1

Excavated areas around structures shall be backfilled with suitable excavated materials or imported materials as approved by the Engineer. Backfill materials shall be placed in horizontal layers not over 150 mm in depth and compacted to a minimum of 95% of the maximum dry density obtained by ASTM D1557.

2

Material used for backfill adjacent to structures shall have a sulphate content of less than 2.5 g/L when tested in accordance with BS 1377.

3

Each layer shall be moistened or dried as required and thoroughly compacted as specified. The maximum size of particle allowed in the backfill within one meter of structures shall be 50 mm.

4

Backfill and embankment behind walls of any culvert shall not be placed until the top slab of the culvert has been placed and cured.

5

Backfill to culvert walls shall be carried out simultaneously behind opposite walls.

3.8

FORMATION PREPARATION

3.8.1

Scope

1

This work shall consist of the preparation of the graded formation upon which sub-base, base course or pavement materials are to be placed, all in accordance with these Specifications.

2

All subgrade shall be compacted to the previous requirements of these Specifications.

3

Preparation and surface treatment of the formation shall be carried out after all duct and pipe installations in the subgrade have been completed.

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Any non-compliant subgrade material shall be excavated, replaced, and compacted to the required density.

3.8.2

Protection

1

Once prepared, the formation shall be maintained in the finished condition until the first succeeding course of sub-base, base, or asphalt pavement material has been placed.

2

The Contractor shall take all precautions necessary to protect the formation from damage: hauling over finished subgrade shall be limited to that which is essential for construction purposes.

3

Any equipment used for hauling over the prepared subgrade which in the opinion of the Engineer is causing undue damage to the prepared subgrade or to the underlying materials shall be removed from the Works at the request of the Engineer.

4

All cuts, ruts and breaks in the surface of the subgrade shall be repaired by the Contractor before placing any subsequent layer. The Contractor shall protect the prepared subgrade from both his own and public traffic.

5

The Contractor shall maintain the subgrade by blading and rolling as frequently as may be necessary to preserve the subgrade in a completely satisfactory condition.

3.8.3

Rectification

1

Any surface area of the formation which is too high shall be graded off, scarified and recompacted to the full depth of the affected layer.

2

Any surface area of the formation which is too low shall be scarified and corrected by the addition of subgrade material of the same classification and moisture content.

3

The Contractor shall carry out additional testing as required by the Engineer to ensure that the standard of compaction is satisfactory through the full depth of a layer or previously placed layers.

3.9

TOPSOIL

1

Topsoil (sweet soil) shall be fertile, free draining, non-toxic soil capable of sustaining healthy plant growth.

2

The material proposed for use as topsoil shall be approved by the Agricultural Department of the Ministry of Municipal Affairs and Agriculture.

3

Topsoil shall be loosely placed at the designated thickness.

3.10

TESTING

3.10.1

General

1

For verification of material, moisture content, compaction, thickness and other properties of the materials or workmanship the Engineer shall at all times have access to all portions of the works and sites. All sampling and testing of material and work shall be carried out under the direction of the Engineer.

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The minimum frequency of testing shall follow the frequencies mentioned in Table 3.1 unless more frequent tests are shown elsewhere in the contract documents or directed by the Engineer. Other testing shall be carried out as directed by the Engineer.

3.10.2

Testing Degree of Compaction

1

Testing shall be done in accordance with ASTM methods of testing, or other approved equivalent test or designated procedure.

2

The density-in-place of earthworks layers shall be tested by the sand replacement method (ASTM D 1556) or nuclear method (ASTM D6938).

3

Nuclear density gauge testing should only be carried out by personnel who have approved user certification issued by the Ministry of Environment.

4

Each in-situ density nuclear gauge shall be calibrated and a calibration form issued. The Contractor shall maintain on site and with the instrument a copy of the Ministry of Environment safety and training manual for the use of nuclear density gauges.

5

When nuclear gauge is used for field density and moisture content testing, the density and moisture content for each material shall be verified by measurements in accordance with ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall be used as the calibration point value for each material.

6

When determining the laboratory maximum dry density the method described in ASTM D1557 shall be applied.

7

No person or company will be permitted to determine in situ density by means of a nuclear type density measuring device without complying with the requirements of the Ministry of Environment. Refer to clause 1.5 of part 1 of this Section.

8

The density of any layer requiring compaction shall be determined in accordance with the specifications mentioned in Table 3.1.

9

If a layer does not conform to the required density, additional tests may be taken to determine the limits of the failing area, after which the Contractor shall rework the area until the specified density is obtained. The Contractor shall allow enough time in his daily work program to permit the performance and checking of the above tests, before he proceeds into any subsequent operations.

3.10.3

California Bearing Ratio

1

The soaked value of the California Bearing Ratio shall be determined on specimens compacted at the optimum moisture content and 95 % of the maximum dry density as per ASTM D1557 after soaking for 4 days in accordance with ASTM D1883. CBR value shall comply with the minimum requirement as per Qatar Highway Design Manual (QHDM).

2

The test surcharge to be used for the equivalent pavement thickness shall be designated by the Engineer.

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Testing Levels and Evenness of the Formation

1

The Engineer shall test the levels and evenness of the finished formation surface to ascertain compliance.

2

The Contractor shall make available to the Engineer a three-meter straight-edge and a crown template of sturdy and approved design and the necessary labor to assist in the checking operations.

3

When tested in accordance with ASTM E1703 by a three-meter straight-edge placed at right angles to, or parallel to, the road centerline or when tested by a crown template placed centrally at right angles to the road centerline, the maximum gap between the road formation surface and the testing edge shall not be greater than 20 mm. Measurements shall be carried out at maximum spacing of 50m of road length for each lane.

4

The subgrade shall be prepared to the levels shown on the contract drawings to a tolerance of between  15 mm and  20 mm when checked by a level instrument.

5

Variation in the falls to cross-sections of the road shall not exceed 0.4 %.

6

These tests shall be made at any point requested by the Engineer. In the event of any failure, the Contractor shall correct the unevenness of the surface and resubmit the area for approval by the Engineer.

3.10.5

Testing Formation Works after Completion

1

All completed works shall be inspected at any time as directed by the Engineer in order to verify the compliance of the executed work to the requirements of the contract as per requirement of Part 5 in Section 3.

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3.10.4

END OF PART

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 1

UNBOUND PAVEMENT MATERIALS ..................................................................... 2

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 3 Submittals 3 Quality Assurance 4

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

MATERIALS ............................................................................................................ 4 Sources of Materials 4 Storage and Handling of Materials 4 Inspection Testing and Control 5 Fine Aggregate 5 Coarse / Combined Aggregate 6 Recycled Aggregate 7 Water 8 Performance Indicators 8

4.3 4.3.1 4.3.2 4.3.3

MAIN EQUIPMENT ................................................................................................. 8 General 8 Paving Machines 9 Central Mixers 9

4.4

MIX DESIGNS ......................................................................................................... 9

4.5

SCREENING AND MIXING ..................................................................................... 9

4.6

SPREADING AND COMPACTION ........................................................................ 10

4.7

CORRECTIVE ACTION......................................................................................... 11

4.8

PROTECTION OF SURFACE ............................................................................... 11

4.9 4.9.1 4.9.2 4.9.3

TESTING ............................................................................................................... 12 General 12 Thickness 12 Evenness and Level 12

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4

UNBOUND PAVEMENT MATERIALS

4.1

GENERAL

4.1.1

Scope

1

This Part includes materials, equipment and construction requirements for unbound layers (aggregate Subbase and Road Base courses).

2

Related Parts are: General Earthworks Asphalt Works

References

1


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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM D1556 ..............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1557 ..............Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))

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ASTM D1883 ..............Standard Test Method for CBR (California Bearing Ratio) of Laboratory-Compacted Soils ASTM D2216 ..............Test Methods for Laboratory Determination of Water (Moisture) Content of Soil and Rock by Mass ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D4429 ..............Standard Test Method for CBR (California Bearing Ratio) of Soils in Place ASTM D4791 ..............Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester

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ASTM D5821 ..............Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of Soils Using Sieve Analysis ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces Using a Straightedge AASHTO T307 ...........Standard Method of Test for Determining the Resilient Modulus of Soils and Aggregate Materials BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests Definitions

1


2

Optimum moisture content (OMC): the moisture content of soil at which a specific compaction effort will produce the maximum dry density when determined in accordance with the ASTM D1557.

3

Maximum dry density (MDD): The dry density of soil obtained using a specified compaction effort at the optimum moisture content when determined in accordance with the modified compaction test ASTM D1557. Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

4

Subgrade: the compacted existing ground or fill for 500mm beneath formation.

5

Formation: the compacted subgrade level shaped in readiness to receive the Subbase or Road Base courses.

6

Subbase: It is the layer between the subgrade and the Road Base. It consists of compacted selected granular materials.

7

Road Base: It is the layer directly beneath the asphalt course layers and above the subbase or subgrade layer. It consists of compacted selected materials. It can be untreated or treated with suitable stabilizing admixtures.

4.1.4

Submittals

1

The Contractor shall submit recent test results for the proposed sources of materials for all quality requirements of the Contract. The Contractor shall submit a test certificate that proves that the raw materials that are purchased/used comply with specifications. The testing may be performed by an approved private laboratory or by the laboratory associated with the plant itself.

2


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4.1.3

(a)

Materials production, handling, storage, identification, marking and traceability to source of production.

(b)

Quality assurance and quality control plans for all construction activities.

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(c)

Materials production, handling, storage, identification and marking, traceability to source of production.

(d)


(e)

Equipment and its suitability to fulfill all construction activities to the required quality.

(f)


(g)


Quality Assurance

1

If requested the Contractor shall arrange for the Engineer to visit the source of the materials and jointly take samples for testing. The Contractor shall carry out testing as directed by the Engineer.

4.2

MATERIALS

4.2.1

Sources of Materials

1

The Contractor shall notify the Engineer of the proposed sources of materials. The Contractor shall ensure that the sources of all aggregates have been approved by the Municipality concerned.

2

The Engineer shall approve the sources before delivery of materials to the site.

3

Where a proposed source of material is not approved, the Contractor shall propose an alternative source of material.

4.2.2

Storage and Handling of Materials

1

Materials shall be so stored and handled as to assure the preservation of their quality and fitness for use in the works. Even after source approval has been given materials may again be inspected and tested before use in the work.

2

Stored material shall be located so as to facilitate prompt inspection.

3

All storage sites shall be restored to their original condition before acceptance of the Works.

4

Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation or contamination of the various sizes. Stockpiles shall be kept flat, and the formation of high cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling aggregates the Engineer may require the use of baffled chutes or perforated chimneys.

5

When trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at a time with trucks depositing their loads as close to the previous load as possible. The use of tractors or loaders to push material deposited at one location to another location in the stockpile shall not be allowed during the construction of the stockpile and their use shall be limited to levelling the deposited material only.

6

The Contractor shall take all necessary protection measures in the storage, handling and stockpiling of materials to prevent contamination of materials by dust. The measures that the Contractor proposes to take shall be subject to the approval of the Engineer.

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4.1.5

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Inspection Testing and Control

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in-place layer.

2

For verification of plant weights and measures, character of materials used in the preparation of the mixes, testing and other quality control requirements, the Engineer shall at all times be provided access to all portions of the mixing plant, aggregate plant, storage yards, crushers and other facilities used for producing and processing the materials of construction.

3

The Engineer shall have authority to take samples and perform tests on any material supplied to the site from any source whatsoever in order to establish compliance and to accept or reject as he deems necessary. Samples shall also be taken from completed work to determine compliance. The frequency of all sampling and testing shall be as designated by the Engineer.

4

The Contractor shall provide suitable facilities at the quarry or plants to carry out all necessary tests on the raw materials and mixes.

5

The Contractor shall arrange for obtaining specimens of materials and samples taken from stockpiles, including the provision of any necessary equipment and plant. This work shall be performed in the presence of the Engineer if so directed by the Engineer.

6

Materials that are not in compliance shall be rejected and removed immediately from the site of the works unless otherwise instructed by the Engineer.

7

Where defects in the materials or the completed work have been corrected, the Contractor shall not proceed with subsequent work until approval has been given by the Engineer.

4.2.4

Fine Aggregate

1

Fine aggregate (passing the 4.75 mm sieve) shall consist of crushed mineral aggregate and/or natural sand.

2

The fine aggregate shall be clean and free from clay-balls and other extraneous or detrimental materials.

3

Where the source of fine aggregate does not meet the requirements listed in Table 4.1, the Contractor may, with the Engineer's approval, add fine aggregate and filler to correct the gradation or to change the characteristics of the material passing the 0.425mm sieve so as to meet the requirements. Such additional material shall be added in a manner which ensures a completely homogeneous material.

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4.2.3

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Table 4.1 Specifications of fine aggregates for Road Base and Subbase layers Specification Limits Parameter

Minimum Frequency

Standard Road Base

Subbase

Liquid Limit

ASTM D4318

25%max.

25% max.

Plasticity Index

ASTM D4318

6 % max.

6 % max.

- Each source - Visible change in material

ASTM D2419

35 min.

25 min.

Organic content

BS 1377 Part 3

0.5% max.

0.5% max.

- 1 test every 1000m

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Sand equivalent

Coarse / Combined Aggregate

1

Coarse aggregate (retained on the 4.75 mm sieve) shall consist of crushed stone or crushed gravel and shall be free from organic matter, clay and other extraneous or detrimental materials.

2

The required properties of coarse aggregates for Road Base and Subbase layers are listed in Table 4.2.

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Table 4.2 Specifications of coarse aggregates for Road Base and Subbase layers Standard

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Parameter

Fractured Faces

ASTM D5821

Specification Limits Road Base

Subbase

50% min.

50% min. - Each source

ASTM D4791

10% max.

15% max.

Loss by Abrasion

ASTM C131 ASTM C535

30% max.

40% max.

ASTM C88

15% max.

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Flat and Elongated Particles (5:1)

Soundness (5 cycles by MgSO4)

Minimum Frequency

- Visible change in material - 1 test every 3000m

3

20% max.

3

Loose materials for testing and acceptance shall be sampled from the un-compacted inplace layer.

4

The required properties of combined aggregate for Road Base and Subbase layers are listed in Table 4.3.

5

Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

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When nuclear gauge is used for field density and moisture content testing, 3 readings shall be made at each test location within a radius of 2 meters. The average of the 3 readings is considered to be the density for that test location. Individual density readings shall not be less than the target relative density by more than 0.5%.

7

When nuclear gauge is used for field density and moisture content testing, the density and moisture content for each material shall be verified by measurements in accordance with ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall be used as the calibration point value for each material.

8

In case abnormally high relative density values are encountered, it will be required to reevaluate the related field and laboratory density values.

9

Gradation requirements of combined aggregate for Road Base and Subbase layers are listed in Table 4.4.

4.2.6

Recycled Aggregate

1

Recycled aggregate produced from excavating natural ground and from demolition wastes can be used in subgrade and subbase layers provided that the specifications stated in Section 6 - Part 9 are complied.

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Table 4.3

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Specifications of combined aggregates for Road Base and Subbase layers

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Standard

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Parameter

Minimum Frequency

Road Base

Subbase

3

2.05 Mg/m min.

2.15 Mg/m min.

ASTM D1557

Gradation

ASTM D6913

Table 4.4

Table 4.4

ASTM D1883 (Soaked)

80% min.

70% min.

Swelling

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ASTM D6938

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Field Density

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California Bearing Ratio (CBR)

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Maximum Dry Density

In Place Moisture 2 Content

ASTM D1556 ASTM D6938 ASTM D4944

- Each source. - Visible change in material - 1 test per 1000m

0.5% max.

1.0% max.

100% of MDD

100% of MDD

- 1 per 200 m per layer

 1.5% of OMC

 2% of OMC

- 1 every 75m per lane per layer 1 per 2000 m

2

1 per 3000 m

3

2

In Place California Bearing Ratio (CBR)

ASTM D4429

80% min.

70% min.

Acid soluble Chloride Content

BS 1377 Part 3

2% max.

2% max.

Acid soluble content

BS 1377 Part 3

sulphate

3

3% max.

3% max.

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.

2

During compaction.

3

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Table 4.4 Gradation limits for Road Base and Subbase layers Road Base

Subbase

50.0 mm

100

100

37.5 mm

95 – 100

90 – 100

19.0 mm

70 – 92

70 – 90

9.5 mm

50 – 70

45 - 75

4.75 mm

35 – 55

30 – 60

0.600 mm

12 – 25

10 – 30

0.075 mm

0–8

0 – 12

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Sieve Size

Water

1

Sea, brackish or saline water shall not be used in the mixing, spreading and compacting operations for Road Base / Subbase layers.

4.2.8

Performance Indicators

1

Upon the request of the Engineer, the following performance related indicators shall be determined from loose in place materials for verification of the pavement structural design following the AASHTO Mechanistic-Empirical Pavement Design Guide:

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4.2.7

Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture content and maximum density as per ASTM D1557.

(b)

Parameters and moduli required for determining the Permanent Deformation Potential in accordance with AASTHO Mechanistic Empirical Design Guide.

(c)

Parameters and moduli required for measuring the Fatigue Cracking Potential for stabilized and surface layers in accordance with AASHTO Mechanistic Empirical Design Guide.

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2

For performance testing, one sample shall be tested every 10,000 m , and for constructions 3 having less than 10,000 m volume, one sample shall be tested every 50% of the total volume.

4.3

MAIN EQUIPMENT

4.3.1

General

1

Unless otherwise stipulated herein the provisions of Section 6, Part 3 (Earthworks), in respect of the main machinery and tools used in earthworks construction, shall be adhered to, subject to the modifications and additions in this clause.

2

The Contractor shall not be allowed to use any equipment or plant before obtaining the approval of the Engineer, and the Contractor shall undertake sound technical methods in operation and to engage skilled and trained operators, mechanics and labor to carry out the works.

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The Engineer shall have the right to stop the use of any equipment or plant which he deems to be inferior to the quality required and to instruct the removal of such equipment and to have it replaced by suitable equipment or to alter the method of operation at any time he so desires.

4

The Contractor shall immediately comply with such instructions without being entitled to any indemnities or extensions as a result of such instructions.

5

The Engineer shall have the right to expel any operators, mechanics or labor and to instruct suitable replacement thereof at any time he deems such action is necessary.

4.3.2

Paving Machines

1

Paving machines shall be self-propelled and shall be capable of spreading the Subbase and Road Base materials in one operation so as to make it ready for compaction with minimum shaping.

2

The paving machines shall be provided with a screed that strikes off and distributes the material to the required width and level.

3

The width of each spread shall not be less than a traffic lane wide.

4

The screed shall be adjustable to the required width being laid.

5

Screed action includes any practical motion that produces a finished surface texture of uniform appearance.

4.3.3

Central Mixers

1

A central mixing plant shall be either of an approved drum or pugmill type with a moisture control system so that the material may be spread without further mixing or processing.

2

Means shall be provided for regulating the flow of material to the mixer. The various feeds shall be calibrated to allow adjustments to the mix design to be carried out.

4.4

MIX DESIGNS

1

Aggregate Subbase and Road Base courses shall consist of crushed mineral aggregates or natural mineral aggregates of the designated gradation and thickness.

2

The maximum dry density and the optimum moisture content of the material shall be ascertained as per the test procedure given in ASTM D1557 and this shall be used to assess the degree of compaction of the mix after rolling.

3

The pavement layer designated as sub-base may be substituted by any of the materials designated to be laid on it subject to the approval of the Engineer.

4.5

SCREENING AND MIXING

1

Screening shall be required for the materials used in Subbase and Road Base courses to ensure that the designated gradation is attained.

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Screens shall be of the size and number required to remove oversize aggregate and to separate the materials into two or more fractions so that they may be combined to meet the required gradation.

3

A central mixing plant shall be used for the mixing of materials.

4

Mixing of separate materials on the roadway by motor grader will not be permitted.

4.6

SPREADING AND COMPACTION

1

Before commencing the construction of the Subbase and Road Base courses, a written approval for the Engineer must be obtained that the subgrade is in compliance.

2

The optimum moisture content of the material shall be noted from the mix design and the actual moisture content determined at the plant after mixing.

3

If the natural moisture content is less than the optimum moisture content, the necessary amount of water must be added to obtain the optimum content.

4

Allowance shall be made for the quantity of moisture which may be lost by evaporation in the process of raking, levelling and compacting, depending on atmospheric temperature.

5

The compacted layer shall have moisture content within  1.5% of the optimum moisture

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content for Road Base layers and within  2% for Subbase layers. The moisture content shall be uniform in all parts of the section where the work is being carried out and in the various depths of the layer thickness.

7

Subbase and Road Base courses shall be laid by a paving machine with a spreader box.

8

Loose samples of materials for testing and acceptance shall be obtained from behind the paving machine upon the approval of the Engineer.

9

Compaction shall start immediately the material has been laid and as per the approved rolling pattern.

10

Work on the Subbase and Road Base courses shall not be permitted during rainy weather.

11

Material shall be spread to a thickness that would result in layers not more than 150 mm thick after compaction. Where the finished compacted thickness exceeds 150 mm placing shall be executed in composite layers each layer not exceeding 150 mm in compacted thickness as directed by the Engineer.

12

The course shall not be rolled when the underlying material is soft or yielding or when the rolling causes a wave-like motion in this course.

13

When the rolling develops irregularities, the irregular surface shall be loosened, then refilled with the same kind of material as used in constructing the course and again rolled.

14

Along places inaccessible to rollers, the Subbase and Road Base courses material shall be tamped thoroughly with suitable mechanical tampers to achieve the required density and finish.

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Page 11

Rolling must continue until a relative density of not less than 100 % of the maximum dry density has been obtained as determined by the moisture-density relationship in ASTM D1557. Care shall be taken so that layers already compacted under the layer being executed are not damaged, or that the formation is not damaged.

17

This aspect must be given special attention in places where rolling equipment makes turns to change direction.

18

Any such damage resulting in mixing the various layers constituting the different subgrades, Subbase and Road Base courses shall be carefully made good by the Contractor at his own expense and to the satisfaction of the Engineer.

4.7

CORRECTIVE ACTION

1

Any material that fails to meet test requirements shall either be reworked or removed and replaced and then retested to check for compliance.

2

Any soft spots, irregularities or depressions that develop in the surface of the Subbase or Road Base courses, shall either be corrected by loosening the surface of such areas and adding further material, or by removing the material in such areas and replacing with further approved material.

3

In the event of heave occurring during compaction, caused either by excessive build-up of pore water pressure or the groundwater table being sufficiently high to affect construction techniques, either of the following procedures shall be adopted subject to the approval of the Engineer:

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16

Sufficient time shall be allowed to elapse enabling the excess pore water to dissipate before further construction or compaction is carried out

(b)

The affected material shall be removed, and approved alternative construction layers substituted.

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(a)

For correction of low density or incorrect level, the top 75 mm shall be scarified, reshaped with material added or removed as necessary and re-compacted to the designated requirement. The area treated shall not be less than 30 metres long and 2 metres wide or such area determined by the Engineer as necessary to attain compliance.

5

Where the surface of the sub-base is covered in a very thin smooth skin composed of fine particles cemented together acting as a barrier to the prime coat the top 75 mm shall be scarified, reshaped, watered if necessary, and re-compacted prior to the application of prime coat.

6

The Contractor shall carry out additional testing if required by the Engineer to ensure that the standard of compaction is satisfactory through the full depth of the layer.

4.8

PROTECTION OF SURFACE

1

The Contractor shall protect the Subbase and Road Base courses so that it shall be maintained sound during work progress, after its completion and before receiving the bituminous layers or before laying the surface overlay thereon.

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Any damage caused to the layer if exposed to traffic or natural conditions resulting in damage to its surface shall be made good at the expense of the Contractor and to the satisfaction of the Engineer.

3

The Engineer has the right to stop all hauling over completed or partially completed Subbase and Road Base courses when in his opinion such hauling is causing damage.

4

Following the completion of the Subbase or Road Base courses the Contractor shall perform all maintenance work necessary to keep the course in a condition for priming.

4.9

TESTING

4.9.1

General

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in-place layer.

2

All testing shall be conducted in accordance with ASTM, AASHTO and BS standards listed in section 4.2.

3

Testing frequency for the properties of Subbase or Road Base layers are listed in Tables 4.1, 4.2 and 4.3.

4

At any stage in the mixing, transportation, spreading or compaction process, the Engineer may instruct that these tests are carried out.

5

Before the application of any prime coat or any other paving course, the aggregate Subbase or Road Base courses shall have been tested for compliance with the requirements of this clause on testing and approved by the Engineer.

4.9.2

Thickness

1

The thickness of the material shall be derived from checking the level by dipping from string lines stretched across the roadway between pins or kerbs. Unless agreed otherwise with the Engineer dipping shall be carried out at intervals of not less than 10m.

2

The thickness of the material shall be measured at the location where the material is removed from the roadway for gradation analysis.

3

Wherever the thickness of compacted aggregate Subbase or Road Base courses is found to vary from the thickness specified in the project drawings or specification by more than 10 %

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2

the area involved shall be satisfactorily corrected to provide the required thickness constructed to the designated grade level. 4.9.3

Evenness and Level

1

The final surfaces of the Subbase or Road Base courses shall be tested by means of a 3 meter long straight edge in accordance with ASTM E1703 and no rises or depressions in excess of 10 mm shall appear in the surface. Measurements shall be carried out at maximum spacing of 30m of road length for each lane.

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2

The finished surface shall also be checked by dips or spot levels and shall be constructed to the designated grade levels to within  10 mm.

3

Where these requirements are not met, the Contractor shall determine the full extent of the area which is out of tolerance and shall make good the surface of the course by scarifying to a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater, reshaping by adding or removing material as necessary, adding water if necessary and recompacting.

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END OF PART

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Section 06: Roadworks Part 05: Asphalt Works

Page 1

ASPHALT WORKS.................................................................................................. 3

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

GENERAL ............................................................................................................... 3 Scope 3 References 3 Definitions 7 Submittals 7 Quality Assurance 8

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10

MATERIALS ............................................................................................................ 8 Unacceptable Materials 8 Fine Aggregate 9 Coarse Aggregate 9 Recycled Aggregate 10 Mineral Filler 10 Asphalt Binder 11 Prime Coat 13 Tack Coat 13 Delivery, Storage and Handling 13 Inspection and Control 14

5.3 5.3.1 5.3.2 5.3.3

MARSHALL MIX DESIGN ..................................................................................... 14 General 14 Marshall Mix Design Criteria 15 Quality Control Testing 17

5.4

DENSE BITUMEN MACADAM .............................................................................. 20

5.5

SUPERPAVE MIX DESIGN ................................................................................... 22

5.6

PERFORMANCE EVALUATION OF ASPHALT CONCRETE ................................ 24

5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.7.8 5.7.9 5.7.10

DELIVERY, SPREADING AND FINISHING ........................................................... 25 Delivery of Mixes 25 Spreading and Finishing 25 Compaction of Mixes 26 Transverse Joints 27 Longitudinal Joints 28 Paving Edges 28 Breakdown Rolling 28 Intermediate Rolling 29 Finish Rolling 29 Protection of Laid Courses 29

5.8

COLD PLANING .................................................................................................... 29

5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5

PRIME COAT ........................................................................................................ 30 General 30 Equipment Required 30 Surface Preparation 30 Application 30 Maintenance and Traffic 31

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TACK COAT .......................................................................................................... 31 General 31 Equipment Required 31 Surface Preparation 32 Application 32 Maintenance and Traffic 32

5.11 5.11.1 5.11.2 5.11.3

THICKNESS AND LEVEL...................................................................................... 32 Thickness 32 Transverse Evenness 33 Evenness and Rideability 33

5.12

PAVEMENT EVALUATION TECHNIQUES ........................................................... 35

5.13 5.13.1 5.13.2 5.13.3 5.13.4 5.13.5 5.13.6

PRODUCTION OF ASPHALT CONCRETE COURSES ........................................ 35 Weather Limitations 35 Equipment Required 35 Survey and Preparation 35 Heating of Asphalt Binder 36 Heating of Mineral Aggregate 36 Proportioning and Mixing 36

5.14

HAULING EQUIPMENT......................................................................................... 37

5.15 5.15.1 5.15.2 5.15.3

OTHER EQUIPMENT ............................................................................................ 37 Spreading and Finishing Equipment 37 Rolling Equipment 38 Liquid Asphalt Distributor 39

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5.10 5.10.1 5.10.2 5.10.3 5.10.4 5.10.5

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APPENDIX .......................................................................................................................... 40

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5

ASPHALT WORKS

5.1

GENERAL

5.1.1

Scope

1

Materials, equipment, and construction of bituminous paving works including prime coating and tack coating.

2

Related Parts

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ASTM C40 ..................Standard Test Method for Organic Impurities in Fine Aggregates for Concrete

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ASTM C50 ..................Standard Practice for Sampling, Sample Preparation, Packing and Marking of Lime and Limestone Products ASTM C51 ..................Terminology Relating to Lime and Limestone (as used by the industry)

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ASTM C88 .................Standard Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C117 ................Standard Test Method for Materials Finer than 75-μm (No. 200) Sieve in Mineral Aggregates by Washing

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ASTM C127 ...............Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

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ASTM C128 ...............Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

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ASTM C131 ...............Standard Test Method for Resistance to Degradation of Small Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C136 ...............Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C142 ...............Standard Test Method for Clay Lumps and Friable Particles in Aggregates ASTM C150 ................Specifications for Portland Cement ASTM C535 ...............Standard Test Method for Resistance to Degradation of Large Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM D5 ....................Standard Test Method for Penetration of Bituminous Materials ASTM D6 ....................Standard Test Method for Loss on Heating of Oil and Asphaltic Compounds ASTM D36 ..................Standard Test Method for Softening Point of Bitumen (Ring-and-Ball Apparatus)

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ASTM D75 .................Standard Practice for Sampling Aggregates ASTM D92 .................Standard Test Method for Flash and Fire Points by Cleveland Open Cup Tester ASTM D113 ................Standard Test Method for Ductility of Bituminous Materials ASTM D140 ...............Standard Practice for Sampling Bituminous Materials ASTM D242 ................Standard Specification for Mineral Filler for Bituminous Paving Mixtures ASTM D402 ................Standard Test Method (Bituminous) Products

for

Distillation

of

Cutback

Asphaltic

ASTM D546 ................Standard Test Method for Sieve Analysis of Mineral Filler for Bituminous Paving Mixtures

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ASTM D946 ...............Standard Specification for Penetration Graded Asphalt Cement for Use in Pavement Construction ASTM D977 ................Standard Specification for Emulsified Asphalt

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ASTM D979 ................Standard Practice for Sampling Bituminous Paving Mixtures

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ASTM D995-95...........Standard Specification for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

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ASTM D1188: ............Standard Test Method for Bulk Specific Gravity and Density of Compacted Bituminous Mixtures Using Coated Samples ASTM D2027 ..............Standard Specification for Cutback Asphalt (Medium-Curing Type)

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ASTM D2041 .............Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures

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ASTM D2042 ..............Standard Test Method for Solubility of Asphalt Materials in Trichloroethylene

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ASTM D2172 .............Standard Test Methods for Quantitative Extraction of Bitumen from Bituminous Paving Mixtures

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ASTM D2419 .............Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate

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ASTM D2726 .............Standard Test Method for Bulk Specific Gravity and Density of Non Absorptive Compacted Bituminous Mixtures

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ASTM D2872 .............. Standard Test Method for Effect of Heat and Air on a Moving Film of Asphalt (Rolling Thin Film Oven Test) ASTM D2950 ..............Standard Test Method for Density of Bituminous Concrete in Place by Nuclear Methods ASTM D2995 ..............Standard Practice for Estimating Application Rate of Bituminous Distributors ASTM D3319 ..............Standard Practice for the Accelerated Polishing of Aggregates Using the British Wheel ASTM D3549 ..............Standard Test Method for Thickness or Height of Compacted Bituminous Paving Mixture Specimens ASTM D4318 .............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D4402 .............Standard Test Method for Viscosity Determination of Asphalt at Elevated Temperatures Using a Rotational Viscometer ASTM D4791 .............Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

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ASTM D5361 ..............Standard Practice for Sampling Compacted Bituminous Mixtures for Laboratory Testing ASTM D5444 ..............Standard Test Method for Mechanical Size Analysis of Extracted Aggregate ASTM D5546 .............Standard Test Method for Solubility of Asphalt Binders in Toluene by Centrifuge ASTM D5581 ..............Standard Test Method for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus (6 inch-Diameter Specimen) ASTM D5821 .............Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate ASTM D6307 ..............Standard Test Method for Asphalt Content of Hot-Mix Asphalt by Ignition Method

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ASTM D6373 ..............Standard Specification for Performance Graded Asphalt Binder

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ASTM D6521 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging Vessel (PAV)

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ASTM D6648 .............Standard Test Method for Determining the Flexural Creep Stiffness of Asphalt Binder Using the Bending Beam Rheometer (BBR)

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ASTM D6723 ..............Standard Test Method for Determining the Fracture Properties of Asphalt Binder in Direct Tension (DT)

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ASTM D6926 .............Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus

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ASTM D6927 ..............Standard Test Method for Marshall Stability and Flow of Bituminous Mixtures

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ASTM D6931 ..............Standard Test Method for Indirect Tensile (IDT) Strength of Bituminous Mixtures

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ASTM D7173 .............Standard Practice for Determining the Separation Tendency of Polymer from Polymer Modified Asphalt

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ASTM D7175 .............Standard Test Method for Determining the Rheological Properties of Asphalt Binder Using a Dynamic Shear Rheometer

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ASTM D7405 .............Standard Test Method for Multiple Stress Creep and Recovery (MSCR) of Asphalt Binder Using a Dynamic Shear Rheometer

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ASTM E11 .................Standard Specification for Woven Wire Test Sieve Cloth and Test Sieves ASTM E274 ................Standard Test Method for Skid Resistance of Paved Surfaces Using a Full-Scale Tire ASTM E303 ................Standard Test Method for Measuring Surface Frictional Properties Using the British Pendulum Tester ASTM E950................. Standard Test Method for Measuring the Longitudinal Profile of Travelled Surfaces with an Accelerometer Established Inertial Profiling Reference ASTM E965 ................Standard Test Method for Measuring Pavement Macrotexture Depth Using a Volumetric Technique ASTM E1926............... Standard Practice for Computing International Roughness Index of Roads from Longitudinal Profile Measurements AASHTO M82.............Standard Specification for Cutback Asphalt (Medium-Curing Type)

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AASHTO M92.............Standard Specification for Wire-Cloth Sieves for Testing Purposes AASHTO M140...........Standard Specification for Emulsified Asphalt AASHTO M208...........Standard Specification for Cationic Emulsified Asphalt (ASTM D239702) AASHTO M320...........Standard Specification for Performance-Graded Asphalt Binder AASHTO M332...........Standard Specification for Performance-Graded Asphalt Binder Using Multiple Stress Creep Recovery (MSCR) Test, Single User Digital Publication AASHTO R28 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging Vessel (PAV)

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AASHTO R35 ............ Standard Practice for Superpave Volumetric Design for Hot-Mix Asphalt (HMA) AASHTO T44 .............Standard Method of Test for Solubility of Bituminous Materials

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AASHTO T48 .............Standard Method of Test for Flash and Fire Points by Cleveland Open Cup

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AASHTO T240 ...........Standard Method of Test for Effect of Heat and Air on a Moving Film of Asphalt Binder (Rolling Thin-Film Oven Test)

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AASHTO T313 ...........Standard Method of Test for Determining the Flexural Creep Stiffness of Asphalt Binder Using the Bending Beam Rheometer (BBR)

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AASHTO T283 ........... Standard Method of Test for Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage

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AASHTO T314 ...........Standard Method of Test for Determining the Fracture Properties of Asphalt Binder in Direct Tension (DT)

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AASHTO T315 ...........Standard Method of Test for Determining the Rheological Properties of Asphalt Binder Using a Dynamic Shear Rheometer (DSR) AASHTO T316 ...........Standard Method of Test for Viscosity Determination of Asphalt Binder Using Rotational Viscometer

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AASHTO T350 ...........Standard Method of Test for Multiple Stress Creep Recovery (MSCR) Test of Asphalt Binder Using a Dynamic Shear Rheometer (DSR)

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AASHTO PP60 ........... Standard Practice for Preparation of Cylindrical Performance Test Specimens Using the Superpave Gyratory Compactor (SGC) AASHTO PP61 .......... Standard Practice for Developing Dynamic Modulus Master Curves for Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester (AMPT) AASHTO TP79 .......... Standard Method of Test for Determining the Dynamic Modulus and Flow Number for Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester (AMPT) BS 812-110 ................Testing aggregates Methods for determination of aggregate crushing value (ACV) BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests BS EN 12697-13 ........Bituminous mixtures. Test methods for hot mix asphalt. Temperature measurement

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Definitions

1


2

Base Course: One or more bituminous layers beneath Wearing Course and above the unbound Road Base Layer. It usually consists of a mixture of aggregates and bituminous materials and functions as a structural portion of pavement.

3

Wearing Course: Top surface bituminous course, which resists skidding, traffic abrasion, and the disintegrating effects of climate.

5.1.4

Submittals

1

The Contractor shall submit for approval a proposed Job Mix Formula (JMF) together with all applicable design data at least one month before beginning the work. The JMF shall give a combined gradation showing a single definite percentage passing each sieve as well as a percentage of each material to be used in the mix. The JMF shall also establish the mixing and compaction temperature values and a compaction reference density. The Engineer will test samples of the materials proposed for use in order to check their quality and to check the proposed mix design. The Contractor shall report all the values obtained in the laboratory design and shall submit these together with a copy of the plotted curves resulting from the tests in an approved form to the Engineer. The Engineer may require verification of the submitted design before giving approval. The Engineer shall approve the optimum binder content based upon the design values submitted by the Contractor and shall notify the Contractor of the value. No asphalt works will be allowed to commence before the Contractor receives written approval from the Engineer for his JMF.

2

The asphalt mix design submission shall include a copy of valid calibration certificates from a calibration service agency approved by the Laboratories and Standardization Affairs (LSA) for the batching plant and the relevant laboratory equipment such as but not limited to balances, proving rings, and load devices. Approval certificates for mix designs will not be issued if the above requirements have not been complied with.

3

Based on the Engineer request, the Contractor shall submit the pertinent certifications of materials, equipment, plants, personnel and processes in relation to the project. Certificates must be issued by a competent authority approved by the Engineer.

4


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5.1.3

(a)

Bituminous and asphalt materials production, storage, transportation, identification and marking procedure and traceability to source of production.

(b)

Quality assurance and quality control plans for laying, compaction and all construction activities.

(c)


(d)

Equipment and its suitability to fulfil all construction activities to the required quality.

(e)


(f)


The Contractor shall provide the Engineer with a complete report on the origin and composition of all stone and/or gravel aggregates to be used in the work (Aggregate Resources Report). All materials shall comply with the specified requirements for the various aggregates.

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Delivery of materials produced from commercial manufacturing process shall be accompanied by the manufacturer’s certification and test reports from local approved laboratory showing the materials compliance with the specification for which it is stipulated.

7

After receiving the approval of specific sources of material the Contractor cannot change these sources without prior written approval of the Engineer.

5.1.5

Quality Assurance

1

The Contractor shall notify the Engineer of the sources of materials and the Engineer shall approve the sources. All materials shall be tested and approved before use.

2

Where the quality of material from a source of material does not comply with the designated requirements, the Contractor shall furnish material that does comply from other sources. Delivery of materials produced from commercial manufacturing processes shall be accompanied by the manufacturer's certification and test report showing that the materials comply with the designated requirements.

3

No change shall be permitted in the source of any of the materials until the technical submissions listed in the specification have been made and approved by the Engineer.

4

All processed materials shall be tested and approved before being stored at the site or incorporated in the works and may be inspected and tested at any time during the progress of their preparation and use. Questionable materials, pending laboratory testing subsequent approval shall not be unloaded and incorporated with materials previously approved and

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accepted.

It is the full responsibility of both the asphalt mixture producer and the Contractor to obtain a certificate which proves that the asphalt binder complies with the specifications. Furthermore, both the asphalt mixture producer and the Contractor shall perform all the required tests in an approved private laboratory to make sure that the asphalt binder being purchased complies with the specifications. The LSA will, at any time, take samples from the asphalt mixtures producer’s plants and test them as part of its quality practice.

5.2

MATERIALS

5.2.1

Unacceptable Materials

1

Materials that do not conform to the designated requirements shall be rejected and immediately removed from the site of the works unless otherwise instructed by the Engineer. No rejected material, the defects of which have been corrected, shall be used until approval has been given by the Engineer.

2

Bituminous paving courses shall consist of coarse aggregate, fine aggregate, filler material, and bitumen binder. Mixture of two different types of rocks, e.g. igneous and sedimentary having different engineering properties shall not be permitted.

3

During execution of works, variations in the specific gravity of any individual fraction of aggregates used in the asphalt mixes by more than 1% shall cause the Engineer to request for evaluation of aggregates consistency and compliance and/or mix design validation.

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Fine Aggregate

1

Fine aggregate is that portion of the mineral aggregate passing the 2.36mm ASTM sieve for the Marshall mix design and passing the 4.75mm sieve for the Superpave mix design.

2

Fine aggregate shall consist of crushed hard durable rock and shall be of such gradation that when combined with other aggregates in proper proportions, the resultant mixture will meet the required gradation. Fine aggregate shall be non-plastic and chemically stable.

3

The source of natural fine aggregate is considered to be the crusher site at which it is produced. Crushed fine aggregate shall be produced by crushing clean coarse aggregate and shall not be thin, flaky or elongated. Sampling of fine aggregate shall be in accordance with ASTM D75.

4

Fine aggregate shall be clean and free from organic matter, clay, cemented particles and other extraneous or detrimental materials.

5

Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

6

The Contractor shall ensure that the sources of all fine aggregates have been approved by the Municipality concerned.

7

The specifications of fine aggregates for asphalt mixtures are listed in Table 5.1.

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5.2.2

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Table 5.1 Fine Aggregate Specifications for Marshall Mixes Standard

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Parameter Plasticity index Sand equivalent value

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ASTM D 4318

Specification Limits 4% max.

Minimum Frequency

(stockpile)

Non Plastic (hot bins) 45% min.

- Each source

ASTM C88

18% max.

Acid soluble chloride content


BS 1377 Part 3

0.1% max.

Acid soluble sulphate content

BS 1377 Part 3

0.5% max.

Clay lumps and friable particles

ASTM C142

None

Organic Impurities

ASTM C40

No Impurities

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ASTM D2419

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Soundness by magnesium sulphate

- 1 test every 2000m

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5.2.3

Coarse Aggregate

1

Coarse aggregate is that portion of the mineral aggregate retained on the 2.36mm ASTM sieve for the Marshall mix design and retained on the 4.75mm ASTM sieve for the Superpave mix design. Coarse aggregate shall consist of crushed natural stones and gravel. Crushed particles shall be cubic and angular in shape and shall not be thin, flaky or elongated. The gradation shall be such that when combined with other aggregate fraction in proper proportions, the resultant mixture will meet the required gradation.

2

The source of crushed aggregate is considered to be the crushing site from which it is produced. Sampling of coarse aggregate shall be in accordance with ASTM D75.

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Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and other extraneous or detrimental material.

4

The specifications of coarse and combined aggregates for asphalt mixtures are listed in Table 5.2.

5

Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

6

If directed by the Engineer, the polished stone value (PSV) should be determined for wearing course aggregates of main lane as per ASTM D3319. The PSV shall not be less than 45.

5.2.4

Recycled Aggregate

1

Recycled aggregate produced from excavating natural ground can be used in asphalt mixtures for temporary roads and for roads, which serve agricultural areas provided that the specifications stated in Section 6 - Part 9 are complied.

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Water absorption Aggregate Crushing Value (ACV)

100% min.

85% min.

85% min.

85% min.

ASTM D4791

15 % max.

15% max.

10 % max.


ASTM C88

15 % max.

15% max.

10 % max.

- 1 test every 3 2000m

30% max.

30% max.

25% max.

2.0% max.

2.0% max.

1.5% max.

25 % max.

25 % max.

20% max.

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ASTM C131 ASTM C535 ASTM C127 BS 812 Part 110

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Los Angeles Abrasion

100% min.

- Each source

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Flat and Elongated Particles (5:1) Soundness (5 cycles by MgSO4)

100% min.

Minimum Frequency

Table 5.7, Job Mix gradation and Table 5.10 tolerances

ASTM C136

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Gradation (Combined)

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One or more Fractured ASTM D5821 Faces 1 Two or more Fractured ASTM D5821 Faces

Specification Limits Base Course Base Course Wearing (Class A) (Class B) Course

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Standard

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Parameter

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Table 5.2 Coarse and Combined Aggregate Specifications for Marshall Mixes

Higher values can be recommended by the engineer based on the design ESAL.

5.2.5

Mineral Filler

1

Mineral filler when separately supplied from an external source shall consist of finely ground mineral matter in accordance with ASTM D242 such as rock dust, hydrated lime, cement or other material which can satisfy the Engineer will produce asphalt mixes of at least equal quality. It shall be free from organic substances and clay, shall be thoroughly dry and free from agglomerations, shall be non-plastic and shall meet the grading requirements shown in Table 5.3.

2

Hydrated lime shall conform to the definitions given in ASTM C51. Sampling, packaging and marking of hydrated lime shall be in accordance with ASTM C50. Storage and use of the hydrated lime shall at all times be such as to protect the material from the weather.

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Table 5.3 ASTM Sieve

% Mass Passing

600 µm

100

300 µm

95 - 100

150 µm

90 – 100

75 µm

70 – 100

The grading of mineral filler shall be carried out in accordance with ASTM D546.

4

When cement is used as mineral filler, it shall meet the requirements of ASTM C150.

5.2.6

Asphalt Binder

1

The asphalt binder specified for use in the asphalt mixes shall be either of the following:

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Penetration grade 60-70: This binder type shall be graded in accordance with ASTM D946. The 60-70 binder specifications are listed in Table 5.4. Sampling shall be in accordance with ASTM D140. The 60-70 penetration graded binder is generally equivalent to PG 64-10 performance graded binder.

(b)

PG 76-10: Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM D6373 specifications in addition to separation test criteria as listed in Table 5.5. Sampling shall be in accordance with ASTM D140.

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(a)

Prior to the commencement of the mix design, the Contractor shall provide a certificate indicating conformance of binder with the specifications stated above. This certificate shall be obtained from an approved laboratory.

3

The asphalt binder shall be prepared by the refining of petroleum and shall be uniform in character. Blending of asphalt binders from different refineries will be permitted only with the written approval of the Engineer.

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Table 5.4 Specifications of Bitumen Penetration Grade 60 – 70 60 – 70 Pen Parameter Standard Minimum Frequency Min. Max. Penetration (0.1 mm) at 25C - Each source ASTM D5 60 70 -100g, 5 Sec - Visible change in material Softening Point Ring & Ball - 1 test per 75t of asphalt ASTM D36 46 Apparatus, C binder per layer Flash Point, Cleveland Open Cup, C

ASTM D92

230

-

Ductility at 25 C, cm

ASTM D113

100

-

Solubility Trichloroethylene, %

ASTM D2042

99

-

Loss on heating, %

ASTM D6

-

0.2

Penetration of Residue of original after TFOT, %

ASTM D5

52

-

ASTM D113

50

-

Ductility of Residue after TFOT at 25 C, 5cm/min, cm

- Each source - Visible change in material - 1 test per 450t of asphalt binder per layer

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Table 5.5 Specifications of Performance Graded Binders / Polymer Modified Binders (PMB) Standard Specification AASHTO ASTM Tests on Original Binder Average 7 days maximum pavement < 76 o design temperature, ( C) Minimum pavement design >-10 o temperature,( C) o Flash Point Temperature, Minimum ( C) T48 D92 230 Rotational Viscosity, Maximum 3 Pa.s, T316 D4402 135 o Test Temperature ( C) Dynamic Shear, G*/sinδ, Minimum, 1.00 T315 D7175 76 o kPa , Test Temperature ( C) at 10 rad/s Solubility, min, % T44 D5546 99 1 Separation Test: Absolute Difference o D7173 20 between G* @ 76 C and 10 rad/s of Top and Bottom Specimens, Maximum, % Requirements of the Rolling Thin Film Oven Residue ( T240 / D2872) Mass Loss, Maximum, Percent T240 D2872 1 Dynamic Shear, G*/sinδ, Minimum, 2.20 T315 D7175 76 o kPa , Test Temperature ( C) at 10 rad/s Pressure Aging Vessel Residue (D6521 / R28) o PAV Aging Temperature , ( C) R28 D6521 110 Dynamic Shear, G*.sinδ, Maximum 5000 T315 D7175 37 o kPa , Test Temperature ( C) at 10 rad/s Creep Stiffness, S, Maximum 300 MPa and m-value, Minimum 0.300 at 60 T313 D6648 0 o seconds , Test Temperature ( C) 2 Direct Tension , Failure Strain, Minimum, T314 D6723 0 1.0% (loading rate of 1.0 mm/min),Test o Temperature( C)

Minimum Frequency

Parameter

- Each source - Visible change in material

- Each source - Visible change in material - 1 test per 450t of asphalt binder per layer

2

Absolute Difference = Abs(100x(top-bottom)/top). If the creep stiffness is below 300 MPa, the direct tension test is not required. If the creep stiffness is between 300 and 600 MPa, the direct tension failure strain requirement can be used in lieu of the creep stiffness requirement. The m-value requirement must be satisfied both cases.

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- 1 test per 450t of asphalt binder per layer

4

Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of AASHTO M332 and will be required to indicate elastic response in percent recovery when tested in accordance with AASHTO T350 / ASTM D7405.

5

Binders modified using Crumb Rubber and other binders containing particulate materials, which are graded according to AASHTO M320 and/or AASHTO M332, shall not include particles with longest dimensions of more than 250μm. In addition, the requirements listed in Table 5.5 shall be satisfied.

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Prime Coat

1

Liquid asphalt for use as prime coat shall be MC-70 medium curing cutback asphalt in accordance with ASTM D2027 or AASHTO M82.

2

The prime coat shall be a cutback consisting of a 60/70 penetration grade bitumen and kerosene. The residue from the distillation test, carried out to 360 C in accordance with ASTM D402, shall be a minimum of 55 % (by volume), as determined by the difference method. Sampling shall be in accordance with ASTM D140. One sample shall be tested every 5 tons.

5.2.8

Tack Coat

1

Emulsified asphalt for use as tack coat in asphalt works may be CSS 1h or CRS-2 cationic emulsified asphalt in accordance with AASHTO M 208 or SS 1h anionic emulsified asphalt in accordance with ASTM D977 or AASHTO M140 unless otherwise designated.

2

Emulsified asphalt shall be of the slow-setting cationic or anionic type of the CSS-1h or SS1h grades respectively and shall conform to the designated requirements. Sampling shall be in accordance with ASTM D140. One sample shall be tested every 5 tons.

5.2.9


1

Materials shall be so stored and handled as to assure the preservation of their quality and fitness for use. Materials, even though approved before storage or handling, may again be inspected and tested before use in the Works.

2

Stored material shall be located so as to facilitate their prompt inspection. All storage locations on land not owned by the Contractor shall be restored to their original condition at the Contractor's expense.

3

Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation or contamination of the various sizes and to prevent contamination of materials by dust. Stockpiles shall be kept flat and the formation of high cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling aggregates, the Engineer may require the use of baffle-chutes or perforated chimneys.

4

Where trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at a time with trucks depositing their loads as close to the previous load as possible. The use of tractors or loaders to push material deposited at one location to another location in the stockpile shall not be allowed during the construction of the stockpile, and their use shall be limited to levelling the deposited material only.

5

Stockpiles of aggregate located at permanent asphalt plant sites shall be separated by bin walls and shall be constructed on asphalt or concrete floors. Stockpile locations and procedures at temporary asphalt plant sites shall be as approved by the Engineer.

6

Intermediate storage of hydrated lime and commercial mineral filler for equipment feeding the asphalt plant shall be silos of adequate size to ensure a minimum of one day's continuous operation.

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5.2.7

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Inspection and Control

1

For verification of weights and measures, character of materials and determination of temperatures used in the preparation of the asphalt mixes, the Engineer shall at all times have access to all portions of the mixing plant, aggregate plant, storage yards, crushers and other facilities used for producing and processing the materials of construction.

2

The Engineer shall have authority to instruct sampling and testing of any material supplied to the site from any source whatsoever in order to establish their compliance and to accept or reject as he deems necessary. Samples shall also be taken from completed work to determine compliance. The frequency of all sampling and testing shall be as designated.

3

The Contractor shall arrange for obtaining specimens of materials, asphalt mixes and samples cut from the paving courses after compaction, including the provision of necessary equipment and plant for obtaining these specimens and samples. This work shall be performed in the presence of the Engineer. The Engineer shall take possession of the samples upon their removal from the roadway unless the Contractor is authorised otherwise

4

In particular, the Contractor shall provide a portable coring machine and bits for taking 150 mm diameter full depth cores of all bituminous paving courses. The coring machine shall be available to the Engineer upon request.

5

In addition to the foregoing, one set of three laboratory compacted specimens and one uncompacted coated sample for each mix type and mixer plant for each day’s production, shall be delivered to LSA no later than 12 hours after compaction of the specimens together with the mix type and project details.

6

Upon the first erection of the batching plant and at least once every three months thereafter, the plant shall be calibrated by a calibration service organisation approved by the LSA.

5.3

MARSHALL MIX DESIGN

5.3.1

General

1

The types of bituminous paving mixes shall be as designated on the project drawings or in the contract documents.

2

The LSA shall act as the engineer for the approval of asphalt mix designs and materials submitted by the Contractor.

3

The contractor shall prepare the mix design with all necessary supporting documentation which shall include the results of the Contractor’s own laboratory procedures.

4

The Contractor shall carry out a trial batching and trial laying of the particular mix design.

5

The testing and sampling of the mix design by the LSA will take place for both the laboratory verification and the trial batching and laying.

6

Based on the results of the trial batching and laying the contractor may be required to make amendments to the mix design. Providing the mix design conforms to the specification the mix shall be approved by the LSA.

7

The LSA shall issue a certification for the job standard mix to the Contractor.

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5.2.10

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The approved Job Mix Formula may be amended as a result of experience in the execution and performance of the permanent asphalt works. Such an amendment may be submitted by the Contractor for the Engineer's approval in which case the Contractor shall submit full details of the proposed amendment together with such data as is necessary to support his submittal. Amendment may also be directed by the Engineer.

9

Approval by the Engineer of the Job Mix Formula or amendments thereto shall in no way relieve the Contractor of his obligations under the Contract, and the Contractor shall be responsible for the soundness of the asphalt paving mixes and the satisfactory execution and performance of the asphalt paving courses.

5.3.2

Marshall Mix Design Criteria

1

The Asphalt Institute MS-2 “Mix Design Methods for Asphalt Concrete and Other Hot-Mix Types” shall be used in designing the bituminous mixtures using Marshall design method.

2

The recommended compacted layer thicknesses are shown in Table 5.6.

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80 to 100 mm

60 to 80 mm

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Base Course (Class B)

Wearing Course(WC) 45 to 55 mm

When tested according to ASTM C136, the combined mineral aggregate shall conform to Table 5.7 for asphalt concrete mixes.

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Base Course (Class A)

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Table 5.6 Recommended Compacted Layer Thicknesses

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Table 5.7 Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes

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ASTM Sieve Size

m

37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm 2.36 mm 0.850 mm 0.425 mm 0.180 mm 0.075 mm

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Percentage Passing (By Weight)

Base Course (Class A) 100 80 - 100 62 - 92 45 - 75 30 - 55 20 - 40 15 - 30 10 - 226 - 15 2-8

Base Course (Class B) 100 80 - 100 63 - 85 57 - 77 40 - 60 25 - 45 15 - 30 10 - 22 6 - 15 2-8

Wearing Course 100 86-100 69 - 87 58 - 78 40 - 60 25 - 45 15 - 30 10 - 22 6 - 15 2-8

The "Laboratory Designed Mixture" for all types of bituminous coated courses shall comply with the requirements given in Table 5.8. Note that any deviation from these requirements shall be approved by LSA.

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Table 5.8 Design Criteria for Marshall Design Mixes Base Course (Class A)

Aggregate Properties

Flow (mm) Marshall Quotient (Stability/Flow) (kN/mm)

75

75

75

3.2 – 4.4

3.4 – 4.4

3.4 – 4.4

9.5 min.

9.5 min.

11.5 min.

2 to 4

2 to 4

2 to 4

4.75 min.

4.75 min.

4.75 min.

4 to 8

4.5 to 8

Voids in Mix (Air Voids) (%) Voids in Mineral Aggregate VMA (%)

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3.2 min.

50 to 75

75 min. 0.8 to 1.5

50 to 75

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50 to 70

Voids in Marshall Specimen at 400 Blows per face at optimum binder content (%) Retained Stability (%) (Filler/Binder) Ratio

5 to 8

Table No.5.9

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Voids Filled with Asphalt VFA (%)

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Stability minimum (kN)

Table 5.7

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Aggregate Grading Number of Compaction blows at each end of specimen (see paragraph 5) Binder Content (% of total mix) inclusive of tolerances

Base Course Wearing Course (Class B) Tables 5.1 and 5.2

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Parameter

3.4 min.

4.0 min.

75 min. 0.8 to 1.5

75 min. 0.75 to 1.35

Note: Relevant ASTM standards shall be used for testing.

Base Course (Class B) and Wearing Course samples shall be prepared and tested using Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while Base Course (Class A) samples shall be prepared and tested in accordance with ASTM D5581. However, based on the Engineer approval, samples having aggregate sizes larger than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the next lower grading sizes.

6

Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with ASTM D6931 shall be obtained for the mix for quality control purposes. The TSR acceptance limits shall be determined at mix design stage and approved by the Engineer.

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Table 5.9 Minimum Percent Voids in Mineral Aggregate (VMA) Minimum VMA, Percent Nominal Maximum 1, 2 Particle Size (mm) 1.18 2.36 4.75 9.5 12.5 19.0 25.0 37.5 50 63

Design Air Voids, Percent 3.0 21.5 19.0 16.0 14.0 13.0 12.0 11.0 10.0 9.5 9.0

4.0 22.5 20.0 17.0 15.0 14.0 13.0 12.0 11.0 10.5 10.0

3

5.0 23.5 21.0 18.0 16.0 15.0 14.0 13.0 12.0 11.5 11.0

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Page 17

1

Standard Specification for Wire Cloth Sieves for Testing Purposes, ASTM E11 (AASHTO M92). The nominal maximum particle size larger than the first sieve to retain more than 10 percent. 3 Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between those listed. 2

7

After the Job Mix Formula has been established and approved, all mixes furnished shall conform thereto within the following tolerances: Table 5.10

Base Course (Class A)

Base Course (Class B)

Wearing Courses

Aggregate retained on 4.75mm sieve or larger

 5%

 4%

 4%

Aggregate passing 4.75mm sieve and retained on 850m sieve

 4%

 3%

 3%

Aggregate passing 850m sieve and retained on 75m sieve

 3%

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Job Mix Tolerances For Field Mixtures

 2%

 2%

 1.0%

 1.0%

 0.2%

 0.2%

Binder Content

 0.3%

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 1.5%

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Aggregate passing 75m sieve

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Description

The ‘Job Standard Mix Density’ shall be obtained by making six standard Marshall specimens from samples of the approved ‘Job Standard Mixture’ determining the bulk specific gravity of each and comparing them with the mean value of the six. Any individual result which differs from the mean by more than 0.015 shall be rejected, and provided that not more than two results are so rejected the mean of the remaining result shall be designated the ‘Job Standard Mixture Density’. The absolute density shall be considered as the theoretical specific gravity calculated in accordance with ASTM D2041.

5.3.3

Quality Control Testing

1

The Contractor shall submit a testing plan to the Engineer for approval that demonstrates how he shall prove compliance with the requirements for compaction, mix composition, level, evenness and all other requirements of Section 6. Each lot shall be approved by the Engineer before placing any subsequent asphalt concrete course. In cases where the asphalt course is laid in more than one layer, each layer shall be tested and approved before placing the subsequent asphalt concrete layer.

2

In addition to the following requirements one set of three laboratory-compacted specimens and one uncompacted coated sample for each mix type and mixer plant for each day’s production shall be delivered to the LSA no later than 12 h after compaction of the specimens. Details of compaction date, time and temperature of mix shall be provided with the specimens together with mix type and project details.

3

The Contractor shall cut samples from each completed asphalt course during the progress of the work and before final acceptance as directed by the Engineer. The Engineer shall determine the location of the samples.

4

When testing for compaction at joints the edge of the core shall not be more than 50 mm or less than 25 mm from the joint.

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Compacted samples shall be taken by coring in accordance with ASTM D5361, for testing by an approved laboratory. The core diameter shall be 150 mm. where the Contractor fails to provide cores as required by the Engineer, the Engineer may arrange for the taking of cores on behalf of the Contractor at his cost. Samples shall be taken of the asphalt mix for the full depth of the course. A sample shall comprise a pair of adjacent cores and the average density of these shall be the density of the sample.

6

Whenever deficiencies are noted in loose mix samples or core samples, the Engineer may direct the taking of additional cores at the Contractor's expense in order to define the area of pavement involved.

7

Hot asphalt mix of the same type shall be placed and compacted in holes left by sampling. The mixture shall be compacted to the percentage compaction required for the layer using a vibrating hammer.

8

Quality control testing of the asphalt mixtures during construction shall follow the frequencies shown in Table 5.12 for Marshall Mixtures:

9

Base Course (Class B) and Wearing Course samples shall be prepared and tested using Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while Base Course (Class A) samples shall be prepared and tested in accordance with ASTM D5581. However, based on the Engineer approval, samples having aggregate sizes larger than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the next lower grading sizes.

10

Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with ASTM D6931 shall be tested for quality control purposes. The TSR acceptance limits shall be based on the mix design obtained limits approved by the Engineer.

11

If it appears from the analysis of samples of loose mix or cores that the asphalt content or aggregate gradation are beyond the permissible tolerances specified for the Job Mix Formula (established for each respective asphalt course mix) and that, such variation affects the characteristics of the asphalt mix conformity to the designated requirements is concerned, this shall be considered a major defect in the work. The portion of the asphalt course represented by these samples shall be rejected.

12

The density of the compacted mixes shall be related to the daily Marshall density determined by making minimum four Marshall specimens from samples collected from behind the paver. The density of each sample shall be determined and compared with the mean value. Any 3 individual result, which varies from the mean by more than 0.015gm/cm shall be rejected. The daily Marshall density shall not differ from the Job Mix Design Density by more than 1.0%.

13

The field density, as determined from each core sample and related to the daily Marshall Density, obtained as shown above, shall be as follows:

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Table 5.11 Layer

Relative Density (%)

Base Course Wearing Course

97 – 101.8 98 – 101.8

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14

The finished road surface shall be inspected visually techniques and if directed by the Engineer the structural ability of the pavement in terms of layer modulus shall be assessed by using the Falling Weight Deflectometer (FWD) and Light weight Deflectometer (LWD).

15

For safety purposes the pavement surface friction shall be measured by the pendulum portable tester or locked wheel tester in accordance with ASTM E303. Table 5.12 Quality Control Testing of the Marshall Mixtures Item / Parameter

Standard


Aggregate conformance

Minimum Frequency

Sections 5.2.1, 5.2.2 and 5.2.3 Section 5.2.5

Every 300t

Section 5.2.7

Tack Coat conformance

Section 5.2.8

Asphalt Binder conformance

Section 5.2.6

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Prime Coat conformance

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Mineral Filler conformance

2

Rate of application for Tack Coat

ASTM D2995

Sampling of bituminous mixtures

ASTM D979

BS EN 12697 Part 13

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2

ASTM D2726 3 ASTM D1188

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Daily Bulk density (See paragraph 12)

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Binder content

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Gradation of extracted aggregates

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Marshall Stability, Flow and Stability/Flow Ratio

Voids in mineral aggregate (VMA) Voids filled with asphalt (VFA) Voids in Mix (Air Voids) (%) Voids in Marshall Specimen at 400 Blows per face at optimum binder content (%) (Filler/Binder) Ratio

In-place air voids

-

 10 C of JMF temperature in truck  135 C min. at paver  120 C min. prior rolling 1.0% of Job Standard Density Table 5.7, Job Mix gradation and Table 5.10 tolerances Job Mix value with Table 5.10 tolerances

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Temperature of bituminous mixture

0.45 – 0.75 kg/m at 60 – 85 C 2 0.15 – 0.38 kg/m at 10 – 60 C

ta

ASTM D2995

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Rate of application for Prime Coat

ASTM D5444 ASTM C117

ASTM D2172 ASTM D6307 ASTM D6927 4 ASTM D5581 ASTM C127 ASTM C128 2 ASTM D2726 3 ASTM D1188 ASTM D2041 2 ASTM D2726 3 ASTM D1188

Table 5.8 Table 5.9

Table 5.8

2

- 1 per 250 m - 1 every 75m per lane Test based

Each truck

Daily

- Each source - Visible change in material - 1 test per 300t per layer for Base Course - 1 test per 150t per layer for Wearing Course

ASTM D2172 ASTM D6307 ASTM C136 ASTM D2041 2 ASTM D2726 3 ASTM D1188

5 – 8%

- 1 test per 600t per layer for Base Course - 1 test per 300t per layer for Wearing Course

QCS 2014


Item / Parameter Retained Stability (%) (Paragraph 16) Field density (nuclear gauge) Field density (2 cores)

5

Page 20

Standard


ASTM D6927 4 ASTM D5581

75 min.

ASTM D2950

Table 5.11

ASTM D5361 2 ASTM D2726 3 ASTM D1188 ASTM D5361 ASTM D3549

5

Thickness

Minimum Frequency 1 test per 3000t per layer At 50m intervals in alternate wheel tracks - 1 test per 200t per layer for Base Course - 1 test per 100t per layer for Wearing Course

Table 5.11 Section 5.11.1

Evenness of surface

Section 5.11.2 & 5.11.3

1

As per polymer manufacturer recommendation and mix design for polymer modified binders If water absorption ≤ 2% 3 If water absorption > 2% 4 For samples containing more than 25mm size aggregates 5 For acceptance of in-situ compaction

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2

The Retained Stability is the percentage of the average stability of 3 samples conditioned for 24 hours at 60  1C water bath and the average stability of 3 samples conditioned for 4 hours in 60  1C air bath. These two sets of samples shall be prepared at the optimum binder content by applying 75 blows and kept at ambient temperature for 17 – 20 hours and shall have similar average densities.

17

Each day the produced mixes shall be tested for checking their compliance with the approved Job Standard Mix criteria. When unsatisfactory results or changed conditions make it necessary, a new job-standard following approval of new mix design shall be established.

5.4

DENSE BITUMEN MACADAM

1

The mix properties for Dense Bitumen Macadam are listed in Table 5.13.

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Table 5.13 Properties of Mix for Dense Bitumen Macadam

Parameter

Number of Compaction blows at each end of specimen

75

75

3.2 – 4.0

3.5 – 4.1

7.5

10.0

2-4

2–4

3.7

4.9

Voids in Mix (Air Voids) (%)

7 - 11

6–9

Voids in Mineral Aggregate VMA (%)

14 - 20

14 - 20

Binder Content (% of total mix) inclusive of tolerances

Stability minimum (kN) Flow (mm) Marshall Quotient (Stability/Flow) (kN/mm), min

2

Specification Limits Base Wearing Course Course

Voids Filled with Asphalt VFA (%)

47 - 60

48 - 60

Retained stability

75 min.

75 min.

When tested according to ASTM C136, the combined mineral aggregate shall conform to Tables 5.14, 5.15 and 5.16.

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Table 5.14 Aggregate Gradation for Dense Bitumen Macadam Road Base (Unbound) B.S Sieve (mm) 50.0 mm 37.5 mm 28.0 mm 14.0 mm 6.3 mm 3.35 mm 0.300 mm 0.075 mm

Aggregate, Crushed Rock or Gravel Percentage by mass passing 100 95 - 100 70 - 94 56 - 76 44 - 60 32 - 46 7 - 21 2- 8

Aggregate, Crushed Rock or Gravel Percentage by Mass Passing for Finished Thickness of Base Course

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70 - 90 mm 100 95 - 100 71 - 95 58 - 82 44 - 60 32 - 46 7 - 21 2 - 8

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50.0 37.5 28.0 20.0 14.0 10.0 6.3 3.35 0.300 0.075

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80 - 100 mm 100 95 - 100 70 - 94 56 - 76 44 - 60 32 - 46 7 - 21 2 - 8

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B.S Sieve (mm)

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Table 5.15 Aggregate Gradation for Dense Bitumen Macadam Asphalt Base Course

50 - 70 mm 100 95 - 100 65 - 85 52 - 72 39 - 55 32 - 46 7 - 21 2 - 8

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Table 5.16 Aggregate Gradation for Dense Bitumen Macadam Asphalt Wearing Course

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B.S Sieve (mm) 28.0 20.0 14.0 10.0 6.3 3.35 1.18 0.075

Aggregate, Crushed Rock or Gravel Percentage by Mass Passing for Finished Thickness of Wearing Course 50 - 60 mm 100 95 - 100 70 - 90 55 - 75 40 - 60 25 - 40 15 - 30 2 - 6

40 - 50 mm 100 95 - 100 70 - 90 45 - 65 30 - 45 15 - 30 2 - 6

30 - 40 mm 100 95 - 100 55 - 75 30 - 45 15 - 30 2 - 6

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SUPERPAVE MIX DESIGN

1

Based on the Engineer approval, the Superpave Mix Design Method can be used to design the asphalt mixtures for Wearing Course and Base Course layers. The design of the Superpave asphalt mixtures shall follow the method outlined in AASHTO R35 and SP-2 “Asphalt Institute Superpave Mix Design Method” in liaison with LSA.

2

The contractor shall prepare the mix design with all necessary supporting documentation which shall include materials production and handling specifications, plant quality procedures, construction quality control and quality assurance procedures, quality control tests, mix acceptance criteria and performance evaluation testing program. All documentations shall be submitted to LSA for review and approval.

3

Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM D6373 specifications and the criteria listed in Table 5.5.

4

Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of AASHTO M332 and will be required to indicate elastic response in percent recovery when tested in accordance with AASHTO T350.

5

Based on the Engineer approval, the guidelines shown in the Appendix can be used for the mix design. Note that software (ePAVE3) shall be validated prior use.

6

The recent editions of the references shown in the Appendix are recommended to be used for preparation of mix design and quality control schemes.

7

Table 5.17 can be used as a guide for sampling and testing frequency for quality control of Superpave mixtures.

8

Performance tests shown in Table 5.18 can be used to evaluate performance of Superpave asphalt concrete mixtures.

9

Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the Engineer for approval, detailed information for each mix which he proposes to furnish. The information shall include, but not be limited to the following:

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5.5

(a)

Copy of mix certificate approval obtained from LSA and the mix design report.

(b)

The source(s) of the aggregate for each mix as well as the pertinent test data and a written certification that the aggregates conform to all of the quality requirements.

(c)

Type of Asphalt modifier intended to be used in the project along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(d)

Pertinent test data on the type and properties of the aggregates, asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(e)

The type and location of plant to be used for mixing each mix.

(f)

Any other support data and information special to the project (e.g. technical data sheets of a polymer in case it was used).

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Page 23

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Table 5.17 Sampling and Testing Frequency of Superpave Field Mixtures Item / Parameter Standard Specification Minimum Frequency Aggregate Conformance Sections 5.2.1, 5.2.2, 5.2.3 and Table 6 - Appendix Mineral Filler conformance Section 5.2.5 Every 300t Prime Coat conformance Section 5.2.7 Tack Coat conformance Section 5.2.8 Asphalt Binder conformance Section 5.2.6 2 0.45 – 0.75 kg/m 2 Rate of application for Prime Coat ASTM D2995 - 1 per 250 m at 60 – 85 C - 1 every 75m per 2 0.15 – 0.38 kg/m lane Rate of application for Tack Coat ASTM D2995 at 10 – 60 C Sampling of bituminous mixtures ASTM D979 Test based  ±10 C of JMF temperature in truck  Min. JMF compaction BS EN 12697 temperature +20 C at Temperature of bituminous mixture Each truck Part 13 paver  Min. JMF compaction temperature prior rolling (sec. 1.5.4 – Appendix) ASTM D2172 Binder content (%) JMF value ±0.40 ASTM D6307 Table 9 Gradation of extracted aggregates ASTM D5444 Appendix Effective Specific Gravity of ASTM D6857 - Each source; Gsb < Gse < Gsa Aggregates (Gse) ASTM D2041 - Visible change in ±1.5 Voids in mineral aggregate (VMA) AASHTO T312 material ASTM D6857 or 1 test per 500t per Voids in Mix (Va) ±1.3 ASTM D2041 layer for Base (Min 2 Gyratory specimens at Ndes) (Eq. 2) Course Density (% of Gmm) at Nmax Table 5 ASTM D2726 - 1 test per 250t per (Min 1 Gyratory specimens at Nmax) Appendix layer for Wearing ASTM D6857 / Course ASTM D2041 Table 5 Dust to binder ratio (P0.075 / Pbe) ASTM D2172 / Appendix ASTM D6307 ASTM D5444 Indirect tensile strength (IDT) ASTM D6931 IDT of JMF min. ASTM D6931 Sec. 1.5.8 Moisture Sensitivity (Retained IDT) Sec. 1.5.8 Weekly Appendix Appendix Dynamic Modulus at 10 Hz, 45 C, Min. 1920 MPa AASHTO PP60 0kPa confinement AASHTO TP79 Every 10,000t Flow Number (Fn) at 54.4 C, 600kPa Procedures A, B Min. 740 deviatory stress, and 0kPa AASHTO PP61 confinement ASTM D5361 - 1 test per 200t per In-place air voids 6 – 8% ASTM D2726 layer for Base Course; - 1 test per 100t per ASTM D5361 Thickness Section 5.11.1 layer for Wearing ASTM D3549 Course At 50m intervals in Field density (nuclear gauge) (%Gmm) ASTM D2950 92 – 94% alternate wheel tracks Evenness of surface Section 5.11.2 & 5.11.3

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5.6

PERFORMANCE EVALUATION OF ASPHALT CONCRETE

1

Based on the Engineer request, the asphalt mixture performance properties can be determined.

2

The performance properties of asphalt mixtures shall be measured for every asphalt concrete layer at least on the following frequencies: Prior asphalt laying on a laboratory prepared sample at the asphalt binder content specified in the JMF.

(b)

Asphalt mix sampled from behind the paver every 10000t of mix.

The purpose of the performance testing is to allow for pavement performance evaluation and verification of pavement structural design through the AASHTO Mechanistic-Empirical Pavement Design Guide. Performance models, references, test conditions are shown in table 5.18 below:

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(a)

Table 5.18

Test Reference

Test Conditions

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Performance Model

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Performance Models Criteria

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100X150mm cylindrical AASHTO PP60, sample under uniaxial Dynamic Modulus TP79 Procedure stress, zero confining Master Curve A, & PP61 pressure and sinusoidal deviator stress AASHTO PP60 100X150mm cylindrical & TP79 sample under triaxial Procedure B stress

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Fatigue Model

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Rutting Model

Aging Model

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AASHTO T321

ASTM D7175

Applications / Use

The E* is used in mechanistic analysis to evaluate the structural responses of the asphalt concrete layers

To evaluate the rutting characteristics of the asphalt mixture in the form of a rutting model or Flow Number (FN)

64x50x380mm beam specimen is subjected to a 4-point bending with free rotation and horizontal translation at all load and reaction points

The initial flexural stiffness is measured at the 50th load cycle. Fatigue life or failure shall be defined as the number of cycles corresponding to 50% reduction in the initial stiffness.

Conduct asphalt binder A-VTS test in the Rheometer (DSR) to measure G* and  in accordance with ASTM D7175 at multiple temperatures

Viscosity-temperature relationship (A-VTS) of the asphalt binder is determined in order to assess the impact of binder aging on the E* property of the asphalt mix at various stages of the pavement life

Modelling methods adopted by Asphalt Institute and Shell or equivalent shall be used. The contractor shall submit a proposal includes performance modelling testing and interpretation procedures to the Engineer for approval.

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DELIVERY, SPREADING AND FINISHING

5.7.1

Delivery of Mixes

1

Sufficient plant capacity, haul vehicles and storage shall be provided so that adequate supplies of mixture are delivered to site to ensure that continuous paving can be achieved.

2

The dispatching of the hauling vehicles to the job site shall be so scheduled that all material delivered may be placed in daylight, unless the Engineer has approved the use of artificial light. Delivery of material shall be at a uniform rate and in an amount well within the capacity of the paving and compacting equipment.

3

All precautions shall be taken to protect the mix from the weather during transit and while waiting to discharge.

4

Hauling vehicles shall not be permitted to carry out tight turns on the laying surface.

5

The mixture at delivery to the paver shall be within 10 C of the Job Mix Formula temperature

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5.7

ta

and above an absolute minimum temperature of 135 C. Material which has fallen below the

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minimum temperature of 135 C before discharge shall be rejected and immediately removed

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from site. Delivery temperature shall not exceed the maximum temperature specified for mixing at the plant Should a significant proportion of the mixture delivered to the paver fail to meet this requirement, or should cold lumps be found in the mixture, the Engineer shall order that paving operations be suspended until measures are taken, to the approval of the Engineer, to ensure compliance.

5.7.2

Spreading and Finishing

1

The Contractor shall prepare a paving plan and obtain approval of the Engineer to ensure adequate equipment and paving sequences.

2

Based on the approved paving plan and prior to the commencement of delivery of the mix the Contractor shall erect and maintain an approved reference guide wire for controlling the levels of the laid mix. The reference guide wire shall be supported at intervals of not more than 5m.

3

The mix shall be laid upon an approved surface and only when weather conditions are suitable and as designated. Upon arrival at the point of use, the asphalt mix shall be spread and struck off to the grade, elevation and cross-section shape intended, either over the entire width or over such partial width as may be required. If the material does not conform to the requirements, it shall not be used and shall be discarded.

4

The laid material shall be compacted as soon as rolling can be effected without causing undue displacement and while the temperature does not fall below 120 C for unmodified

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asphalt mixes. Materials still uncompacted and below this temperature shall be rejected. 5

The compaction temperature for the laid polymer-modified asphalt binder mixes shall be selected based on one of the following: (a)

As specified in the JMF.

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(b) 6


Page 26

As established from the trial section.

The Contractor shall supply accurate calibrated thermometers suitable for measuring the inner and surface temperature of the material. The material temperature shall be checked immediately before rolling and at least every 30 minutes thereafter during forward progress. A record of these temperatures shall be passed to the Engineer at the end of each day’s work. While paving is in progress, the output of the batching plant shall be exclusively reserved for the operations and no mixture shall be supplied to other sites or projects.

8

If during laying, the paver is repeatedly delayed because of lack of mixture or if the paver stands at one location for more than thirty minutes (for any reason), a transverse joint shall be constructed. Paving shall not recommence until the Engineer is satisfied that paving will proceed uninterrupted and until at least four loaded vehicles have arrived at the paving site.

9

The asphalt course shall be constructed to proposed levels and shall be homogeneous, providing after compaction an even surface free from undulations, rises or depressions and within the tolerances stipulated.

10

In no case shall construction of a new asphalt concrete course begin until the previously laid course has been tested and approved.

11

When the same asphalt course is to be laid in more than one layer the second layer shall be placed as soon as practicable after the first layer has been finished, rolled and cooled, and the Engineer may at his discretion request cleaning of the first layer and the application of a tack coat thereon if he so deems necessary.

12

Transverse joints in succeeding layers shall be offset at least 2 m. Longitudinal joints shall be offset at least 300 mm.

13

The use of motor grader or hand spreading of the asphalt mix shall not be permitted except in places where it is impractical to use pavers and shall be only with the specific permission of the Engineer. The asphalt mix shall comply with all conditions regarding trueness of level, thickness, and homogeneity of the mix.

14

Automatic electronic screed controls shall be required on all pavers and shall be used with a 9 m long articulated averaging beam or grade wire control as approved by the Engineer.

5.7.3

Compaction of Mixes

1

At least three rollers shall be required at all times, one self-propelled pneumatic-tire and two self-propelled steel-wheeled. As many additional rollers shall be used by the Contractor as necessary to provide specified asphalt course density and surface characteristics in an orderly, efficient and continuous manner.

2

Before beginning construction of the permanent works, unless otherwise agreed with the Engineer, the Contractor shall carry out compaction trials for each type and thickness of asphalt course to establish an approved compaction procedure which shall then be used as a minimum requirement for the compaction of the permanent works unless otherwise directed or agreed by the Engineer.

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The compaction trials shall involve all procedures specified for the permanent works including testing as specified for the asphalt course under consideration and any equipment, processes or procedures proposed by the Contractor which are not designated. Construction of the permanent works shall not commence until a compaction procedure has been approved in writing by the Engineer. Such approval shall in no way relieve the Contractor of his responsibilities and obligations stipulated in the Contract.

4

Immediately after the asphalt mix has been spread and struck off, the surface shall be checked and any irregularities adjusted and then compacted thoroughly and uniformly by rolling.

5

To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly moistened but excess water shall not be permitted.

6

After the longitudinal joints and edges have been compacted, rolling shall start longitudinally at the sides of the road and shall gradually progress towards the centre. On super elevated sections, rolling shall begin on the low side and progress to the high side, overlapping on successive trips by at least one-half the width of tandem rollers and uniformly lapping each proceeding track. The rollers shall move at a slow but uniform speed with the drive wheels nearest the paver. The speed shall not exceed 4-5 km/h for steel-wheeled rollers or 8 km/h

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for Pneumatic-tire rollers. The operating speed shall be approved by the Engineer. The line of rolling shall not be changed suddenly or the direction of rolling reversed suddenly. If rolling causes displacement of the material, the affected areas shall be loosened at once with hand tools and restored to the original grade of the loose material before being rerolled. Heavy equipment or rollers shall not be permitted to stand on the finished surface before it has been compacted and has thoroughly cooled.

8

When paving in a single width, the first lane placed shall be rolled in the following order:

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Transverse joints.

(b)

Longitudinal joints.

(c)

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Initial or breakdown rolling, beginning on the low side and progressing towards the high side.

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(e)

Intermediate rolling.

(f)

Final rolling.

1

When paving in echelon, 50 mm to 100 mm of the edge which the second paver is following shall be left unrolled. When paving in echelon the edges between the first and the second paver shall not be exposed more than 15 minutes nor 50m by distance without being rolled. Particular attention shall be given to the construction of the transverse and longitudinal joints in all courses.

5.7.4

Transverse Joints

1

Transverse joints shall be carefully constructed and thoroughly compacted to provide a smooth riding surface. Joints shall be checked with a straightedge to assure smoothness and true alignment. Joints shall be formed with a bulkhead, such as a board, to provide a straight line and vertical face.

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If the joint has been distorted by traffic or by other means, it shall be trimmed to line and the face shall be painted with thin coating of emulsified asphalt before the fresh material is placed against it. To obtain thorough compaction of these joints the material placed against the joint shall be tightly pushed against the vertical face with a steel-wheeled roller.

3

The roller shall be placed on the previously compacted material transversely so that not more than 150 mm of the rear rolling wheel rides on the edge of the joint. The roller shall be operated to pinch and press the mix into place at the transverse joint. The roller shall continue to roll along this line, shifting its position gradually across the joint, in 150 to 200 mm increments, until the joint has been rolled with the entire width of the roller wheel. Rolling shall be continued until a thoroughly compacted, neat joint is obtained.

5.7.5

Longitudinal Joints

1

Longitudinal joints shall be rolled directly behind the paving operations. The first lane placed shall be true to line and grade and have a vertical face. The material being placed in the abutting lane shall then be tightly pushed against the face of the previously placed lane. Rolling shall be done with a steel-wheeled roller.

2

The roller shall be shifted over onto the previously placed lane so that not more than 150 mm of the roller wheel rides on the edges of the newly laid lane. The rollers shall then be operated to pinch and press the fine material gradually across the joint. Rolling shall be continued until a thoroughly compacted, neat joint is obtained.

3

When the abutting lane is not placed in the same day, or the joint is distorted during the day's work by traffic or by other means, the edge of the lane shall be carefully trimmed to line, cleaned and painted with a thin coating of emulsified asphalt before the adjacent lane is placed.

4

The longitudinal joints in the surface course shall be along the same line as the traffic lane markers.

5.7.6

Paving Edges

1

The edges of the asphalt course shall be rolled concurrently with or immediately after rolling the longitudinal joint.

2

Care shall be exercised in consolidating the course along the entire length of the edges. Before it is compacted, the material along the unsupported edges shall be slightly elevated with hand tools. This will permit the full weight of the roller wheel to bear on the material to the extreme edges of the mat.

5.7.7

Breakdown Rolling

1

Breakdown rolling shall immediately follow the rolling of the longitudinal joints and edges. Rollers shall be operated as close to the paver as possible to obtain adequate density without causing undue displacement. In no case shall the mix temperature be allowed to drop below 120 C before breakdown rolling.

2

If the breakdown roller is steel wheeled, it shall be operated with the drive wheel nearest the finishing machine. Pneumatic-tire rollers may be used as breakdown rollers.

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Intermediate Rolling

1

Pneumatic-tire rollers or Steel wheeled rollers shall be used for the intermediate rolling.

2

The intermediate rolling shall follow the breakdown rolling as closely as possible and while the paving mix is still hot. Rollers shall be used continuously after the initial rolling until all of the mix placed has been thoroughly compacted. Turning of rollers on the hot paving mix which causes undue displacement shall not be permitted.

5.7.9

Finish Rolling

1

The finish rolling shall be performed with three-axle tandem rollers unless otherwise permitted by the Engineer. Finish rolling shall be accomplished while the material is still warm enough for the removal of roller marks.

2

All rolling operations shall be conducted in close sequence.

3

In places inaccessible for the operation of standard rollers as specified, compaction shall be performed by manual or mechanical tampers of such design as to give the desired density.

4

After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked and any irregularity of the surface exceeding the specified limits and any areas defective in texture, density or composition shall be corrected as directed by the Engineer, including removal and replacement as directed by the Engineer.

5.7.10

Protection of Laid Courses

1

Sections of the newly finished work shall be protected from traffic of any kind until the mix has been properly compacted and cooled. In no case shall traffic be permitted less than 24 h after completion of the asphalt course unless a shorter period is authorised by the Engineer.

5.8

COLD PLANING

1

The cold planing plant shall be to the approval of the Engineer.

2

Cold planing plant shall have sufficient power, traction and stability to maintain the required depth of cut and slope. The control of the depth of cut and the slope shall be by an automatic system based on reference wires.

3

Cold planing shall be carried out to straight crossfalls to the designated thickness. Planing shall be to a tolerance of  5 mm of the designated amount. The average thickness of

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5.7.8

planing achieved shall be at least the thickness designated. 4

In areas where there is severe deformation of the existing pavement, it may be necessary to vary the depth of planing.

5

Existing kerbs, gullies, manholes and other features shall not be disturbed by the planing process. This may require the use of smaller plant or removal by hand tools.

6

Any joints at the edge of planed areas shall be cut vertically and straight using asphalt saws.

7

Cold planing shall be carried out in a longitudinal direction.

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After planing the prepared surface shall be thoroughly brushed and suction swept by mechanical means to the satisfaction of the Engineer. The surface shall be free from gouges, ridges, continuous grooves and shall have a reasonably uniform finish.

9

Cold planing shall be performed so that at the end of a day’s work the termination line does not present a hazard to traffic that may use the road.

10

Any cracks noted in the pavement shall be blown clean with compressed air. The Engineer will inspect the planed surface and may instruct that further work is carried out for treating cracks in the pavement.

5.9

PRIME COAT

5.9.1

General

1

The work shall consist of furnishing and applying liquid asphalt and blotter material, if required, to a previously prepared and approved subgrade or granular base/sub-base course as designated and to the full designated width.

2

Prime coat shall not be applied when the ambient temperature is less than 13 C nor during rain, fog, dust storms or other unsuitable weather.

5.9.2

Equipment Required

1

The equipment used by the Contractor shall include a liquid asphalt distributor as described in clause 5.17.3.

2

If the surface is covered in wind-blown dust or fine aggregate then a power broom shall be provided. The power broom shall be self-propelled and equipped with a cylindrical, rotating nylon bristle brush of not less than 760 mm in diameter and not less than 1800 mm in length. The brush shall be capable of being angled to the right and left with adjustable ground pressure. Where necessary for the proper preparation of the surface, motor graders, rollers and water trucks shall also be provided.

5.9.3

Surface Preparation

1

Immediately before applying the prime coat, all loose dirt, earth and other objectionable material shall be removed from the surface with a power broom of approved design and/or a power blower as required, and any ruts, soft spots or unacceptable irregularities in the surface shall be repaired in accordance with the instructions of the Engineer. If the Engineer so requires, the surface shall be lightly bladed and rolled immediately before the application of the prime coat, in which case brooming or blowing may not be required.

2

Priming will not be permitted when there is free water present on the surface.

5.9.4

Application

1

After preparing the road surface as above, the prime coat shall be applied by means of the distributor at the temperature and rate shown in Table 5.12. Hand-spraying of restricted, inaccessible areas is permitted, subject to the approval of the Engineer.

2

The surface of structures, kerbstones and other appurtenances adjacent to areas being treated shall be protected in such a manner as to prevent their being spattered or marred.

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The prime coat shall usually be applied to 1/3 or 1/2 of the road width at a time. When applied in two or more lanes, there shall be a slight overlap of asphalt material along adjoining edges of the lanes. It should be noted that no overlapping is allowed at the transverse joints and that thick paper shall be used at the joint to protect the previous application and the joining application shall begin on the paper. The paper used shall be removed and satisfactorily disposed of by the Contractor after use. Care shall be taken that the application of prime coat material at the junctions of spread is not in excess of the specified amount. Excess bituminous material shall be removed from the surface.

5.9.5

Maintenance and Traffic

1

Traffic shall not be permitted on the primed surface until the asphalt material has penetrated and dried and, in the judgement of the Engineer, will not be picked up under traffic. If it becomes necessary to permit traffic before that time, but in no case sooner than 48 hours after the application of the asphalt material, blotter material shall be applied as directed by the Engineer and traffic shall be permitted to use the lanes so treated.

2

Blotter material shall be spread from trucks operated backward so that the wheels will not travel in uncovered wet asphalt material. When applying blotter material to an asphalt treated lane that adjoins a lane that has not been treated, a strip at least 200 mm wide along the adjoining edge shall be left devoid of blotter material in order to permit an overlap of asphalt material.

3

The Contractor shall maintain the primed surface in good clean condition and before the application of the next course, any surface irregularities shall be corrected and all excessive blotter material, dirt or other objectionable materials shall be removed.

5.10

TACK COAT

5.10.1

General

1

This work shall consist of furnishing and applying diluted emulsified asphalt to a previously prepared Base or Wearing courses, to provide bond for a superimposed course to the full designated width.

2

Tack coat shall not be applied when the ambient temperature is less than 13C nor during rain, fog, dust storms or other unsuitable weather.

5.10.2

Equipment Required

1

The equipment used by the Contractor shall include liquid asphalt distributor as well as a power broom and a power blower. Power broom shall be self-propelled and equipped with a cylindrical, rotating nylon bristle Brush of not less than 760 mm in diameter and not less than 1800 mm in length. The brush shall be capable of being angled to the right and left with adjustable ground pressure. In addition, the Contractor shall supply and use efficient and approved equipment for diluting the emulsified asphalt with water.

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Surface Preparation

1

The full width of the surface to be treated shall be cleaned with a power broom or power blower to remove dust, dirt or other objectionable materials. All faulty or unsuitable patches, excess cracks or joint filler and all surplus bituminous material shall be corrected in accordance with the instructions of the Engineer. The surface shall be dry when treated.

5.10.4

Application

1

Immediately after cleaning the surface, the tack coat shall be applied by means of the distributor at the temperature and rate directed by the Engineer. Hand spraying of restricted, inaccessible areas is permitted, subject to the approval of the Engineer.

2

The diluted emulsion shall be applied at a rate shown in Table 5.12. The Contractor shall ensure that excessive application of tack coat is avoided.

3

The surface of structures, kerbstones and other fixed objects adjacent to areas being treated shall be protected in such a manner as to prevent their being spattered or marred.

5.10.5

Maintenance and Traffic

1

After application, the surface shall be allowed to dry until it is in a proper condition of tackiness to receive the superimposed course. Tack coat shall be applied only so far in advance of the superimposed course placement as is necessary to obtain this proper condition of tackiness.

2

Until the superimposed course is placed, the Contractor shall protect the tack coat from damage.

3

If the tack coat is unavoidably damaged by rain or dust, it shall be allowed to dry, shall be cleaned again by a power broom or power blower and, if required by the Engineer, a subsequent light application of tack applied to the surface. Where, in the opinion of the Engineer, a tack coat is not necessary between layers of freshly placed courses, he may give instructions in writing to omit the tack coat. Any cleaning required in these areas shall be carried out before the application of the next course.

5.11

THICKNESS AND LEVEL

5.11.1

Thickness

1

Cores shall be taken to determine the thickness of asphalt paving courses. As determined from each core, the thickness of a paving course shall not be less than that specified by more than 5 mm in the case of a single-layered construction. Furthermore, the thickness of the Wearing course shall not be less than that specified by more than 5 mm and the total thickness of all asphalt paving courses combined shall not be less than that specified by more than 10 mm.

2

In addition, the variations in the falls to cross sections of the road shall not vary from the required value by more than 0.3 %. Any asphalt paving course containing deviations or variations exceeding these tolerances shall be corrected or removed and replaced by the Contractor, in accordance with the instructions and to the satisfaction of the Engineer.

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Where any individual course is marginally out of tolerance on the low side, the Engineer may allow adjustment in the succeeding course to correct the overall thickness of the pavement.

4

The tolerances herein specified shall not invalidate the tolerances set forth for the evenness of surface of the asphalt paving course.

5

As directed by the engineer the laid thickness shall be checked by cutting test pits and/or using Ground Penetrating Radar (GPR) for the determination of the structural capacity of the pavement.

5.11.2

Transverse Evenness

1

The Engineer shall test the evenness of surface for each course of the various asphalt paving courses to determine compliance.

2

The Contractor shall put at the disposal of the Engineer a 3m long straight edge and a crown template of sturdy and approved design and enough labour to assist in the checking operations. The maximum allowable differences between the pavement surface and the straight edge shall be 3mm. Transverse measurements shall be carried out every 20m of road length for each lane.

3

Any layer containing deviations or variations exceeding the tolerances specified here shall be corrected or removed and replaced in accordance with the instructions of the Engineer and to his satisfaction.

5.11.3

Evenness and Rideability

1

Smoothness is a measure of the evenness and rideability of the pavement surface. It shall be measured on the driving surface of the completed pavement for all major roads before opening to the traffic.

2

Any section containing deviations or variations exceeding the criteria specified here or by the Engineer shall be corrected or removed and replaced in accordance with the instructions of the Engineer and to his satisfaction at the Contractor’s cost.

3

The minimum length of the rectification work undertaken shall be 100m.

4

All rectified segments shall be re-tested following the completion of rectification work at no additional cost to the client.

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(a)

Evenness

5

The evenness of the driving surface of road pavements shall be measured with a 3m rolling straight edge along any line or lines parallel to the center line of the pavement on sections of 300m selected by the Engineer, whether or not it is constructed in shorter lengths. Sections shorter than 300m forming part of a longer pavement shall be assessed using the number of irregularities for a 300m length prorated to the nearest whole number. Where the total length of pavement is less than 300m the measurements shall be taken in 75m lengths.

6

The number of deviations (from the bottom face of the straight edge) over the length of the section greater than or equal to 4mm shall be counted. None of the measured deviations shall exceed 6mm. The evenness of the driving surface of the tested section shall be within the relevant limits given in Table 5.19.

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Table 5.19 Evenness of Driving Surface

(b)

Section Length (m)

Allowed number of deviations ≥4mm

300

20

75

9

Rideability

For major roads the International Roughness Index (IRI) shall be used to monitor the roughness and condition of the pavement surface. The acceptable IRI for ride quality shall be decided by the Engineer.

8

The rideability of the driving surface of the completed pavement shall be measured in terms of the International Roughness Index (IRI) which shall be tested with a certified and calibrated Inertial Profiler meeting the requirements of ASTM E950–Class 1.

9

The testing method shall be in accordance with ASTM E950. The IRI shall be calculated according to ASTM E1926.

10

Calibration checks on the inertial profiler shall be conducted using test methods in accordance with the manufacturer’s recommendations, at the beginning of the day of operation and at any other time the operator may suspect changes of system performance since the last calibration.

11

Calibration checks on the inertial profiler and all other quality checks shall be submitted in a method statement to the Engineer for approval.

12

The selected measuring speed shall be the posted speed and within the range recommended by the manufacturer and shall remain nearly constant during testing, not to exceed +/-5 km/h of the selected speed.

13

The profiler system shall stabilize at the test speed prior to entering the test sections. This requires bringing the profiler vehicle to the desired test speed at least 100 m prior to the beginning of the test location. Any Features along the test section such as bridges, culverts, milepost or other pertinent information shall be identified. The test shall be conducted in the paving direction.

14

The start and end point of the test section shall be automatically identified by using a photo detector. The coordinates of the test section shall be identified by using a GPS.

15

Three runs of data collection (both wheel tracks in each lane) shall be conducted. The processing of the data for IRI shall include calculating the average IRI value of the three runs for the two wheel tracks. The processed data shall be reported on 25m and 400m subsections calculated using the Moving Average statistical method and applying a 250mm filtering.

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PAVEMENT EVALUATION TECHNIQUES

1

Pavement evaluation tests shall be carried out for the completed pavement structure at any point of the road as directed by the Engineer to assess the serviceability condition of the pavement and verify compliance with specifications.

2

Pavement evaluation methods can be grouped into two main categories, destructive and non-destructive.

3

The Contractor shall allow and provide all necessary arrangements for the execution of all pavement evaluation test required by the Engineer.

4

As directed by the Engineer the structural ability of the pavement in terms of load-deflection response and layer modulus shall be assessed by using the Falling Weight Deflectometer (FWD).

5

The pavement surface friction shall be measured based on the Engineer request using the portable pendulum tester (ASTM E303), locked wheel tester (ASTM E274) or the sand patch method (ASTM E965).

5.13

PRODUCTION OF ASPHALT CONCRETE COURSES

5.13.1

Weather Limitations

1

Production and spreading of asphalt Concrete mix shall not be permitted when the ambient temperature is less than 8 C, nor during rain, fog, dust-storms or other unsuitable weather.

5.13.2

Equipment Required

1

The equipment required for construction of the asphalt concrete courses shall include but not be limited to the equipment mentioned in Clauses 5.3 to 5.6 of this Part, together with such miscellaneous equipment and tools as required for the satisfactory preparation and performance of the work.

2

All equipment shall be checked, calibrated and approved by the Engineer before use. The equipment shall be satisfactorily maintained and shall be used in an approved manner.

3

Adequate equipment and labour shall be used so that there is continual production and distribution of the asphalt course being constructed.

5.13.3

Survey and Preparation

1

The area to be paved shall be true to line and grade and shall have a properly prepared surface before the start of paving operations.

2

When an asphalt concrete pavement course is to be placed on top of an existing pavement, the existing pavement surface shall be prepared as designated by the Engineer.

3

Priming or tacking of surfaces to be paved shall be carried out as designated.

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The surface of kerbs, vertical faces of existing pavements and all structures in actual contact with asphalt mixes shall be painted with a thin and complete coating of tack coat as instructed by the Engineer to provide a closely bonded, watertight joint.

5

All openings or structures in the road for water, drainage and other specified utilities shall be constructed and their positions and levels determined before the start of paving operations.

5.13.4

Heating of Asphalt Binder

1

The 60/70 penetration grade bitumen shall be heated to a temperature of between 150 to 165 degrees centigrade.

2

Bitumen of other penetration grade shall be heated to yield viscosity's in the range of 150 to 300 centistokes (175 to 150 seconds Saybolt-Furol) when delivered to the mixer, as determined from the Temperature Viscosity Chart of the product used.

3

Penetration Graded Asphalt Binders shall not be used if foaming occurs or shall it be heated above 175 C at any time.

4

Polymer-modified binder shall be heated to a temperature specified by the supplier.

5.13.5

Heating of Mineral Aggregate

1

When using 60/70 penetration grade asphalt binder the materials shall be thoroughly dried and heated so that their temperature is 165 to 180 degrees centigrade.

2

When using asphalt binder of other penetration grade the materials shall be thoroughly dried and heated so that their temperature is within ± 8 C of the temperature needed to satisfy the

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viscosity requirements of the asphalt cement. The moisture content of the heated and dried materials shall not exceed 1%.

4

The quantity of materials fed through the drier shall in all cases be held to an amount which can be thoroughly dried and heated within the limits specified.

5

The heated materials shall be screened into sizes such that they may be combined into a gradation meeting the requirements of the Job Mix Formula and the hot aggregate storage bins shall be such as to minimise segregation and loss of temperature of aggregate.

6

Hot bins shall be drawn and cleaned of material at the end of each day's operation.

5.13.6

Proportioning and Mixing

1

The heated ingredients together with the mineral filler and bitumen shall be combined in such a manner so as to produce a mixture which complies with the requirements of the Job Mix Formula. Plant settings, once established, shall not be changed without the approval of the Engineer.

2

Mineral filler, in a cool dry state, shall be proportioned into the mixer either with the aggregate or after the introduction of the bitumen to avoid loss of fines that may occur in dry mixing as a result of turbulence in the mixer.

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In batch type plants a dry mixing period of not less than four seconds shall precede the addition of the bitumen to the mix. Excess wet mixing shall be avoided. Wet mixing shall continue as long as it is necessary to obtain a thoroughly blended mix but shall not exceed 75 seconds nor be less than 30 seconds.

4

Once approved, mixing times shall not be altered unless so ordered or further approved by the Engineer.

5.14

HAULING EQUIPMENT

1

Vehicles used for the transport of aggregates or bituminous mix shall have tight, clean and smooth insulated metal bodies and shall be free from dust, screenings, petroleum oil and volatile or other mineral spirits which may affect the material being hauled. The vehicle metal bed shall, if required, be sprayed with a minimum amount of soapy water or lime solution to prevent the bituminous mix from adhering to the bed. After spraying, the truck shall be raised and thoroughly drained and no excess solution shall be permitted. Use of diesel or other solvents to spray in the truck bed is prohibited.

2

Provision shall be made for covering truck loads with canvas or other suitable material of such size that the bituminous mix is fully covered.

3

Any truck causing excessive segregation of material by its spring suspension or other contributing factors, or that shows oil leaks in detrimental amounts, or that causes undue delays, shall, upon the instruction of the Engineer, be removed from the work until such faults are corrected.

4

End dump trucks shall be equipped with chains on the tail gates for control when dumping the mix into the paving machine. Hauling trucks shall not be routed over wet or muddy access ways such that tires accumulate dirt that is deposited on the laying surface.

5

The Contractor shall provide an adequate number of trucks of such size, speed and condition to ensure orderly and continuous progress of the work all to the approval of the Engineer.

5.15

OTHER EQUIPMENT

5.15.1

Spreading and Finishing Equipment

1

The asphalt mixture shall be fed to the paver by end tipping of the truck or by means of a windrow elevator. The equipment for spreading and finishing the asphalt mixtures shall be of an approved mechanical, self-powered electronic controlled floating screed type, capable of spreading and finishing the mixture true to line, grade and required crown.

2

The pavers shall be self-propelled and equipped with hoppers and distributing screws of the reversing type to place the mixture uniformly in front of adjustable electronic controlled screeds. The pavers shall be so designed to allow a minimum paving width of 2 m, although paving in widths of less than 3 m will require the approval of the Engineer.

3

Pavers shall be equipped with such provisions and attachments to suit paving widths specified for road widening as well to as to suit paving on sloped sections. They shall be equipped with fast and efficient steering devices and shall have reverse as well as forward travelling speeds. The operational speed of the pavers shall be adjustable from 3 to 6 m/min in accordance with the instructions of the Engineer.

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The pavers shall employ mechanical devices as equalising runners, straight edge runners, evener arms or other compensating devices to maintain trueness of grade and to confine the edges of the pavement to true lines without the use of stationary side forms. The equipment shall include blending or joint levelling devices for smoothing and adjusting longitudinal joints between lanes. The assembly shall be designed and operated in such a manner that it will place the material at the required compacted thickness.

5

Electronic screeds shall include automatic feed controls to maintain a constant level of material along the full length of the screed, automatic grade control and automatic slope control. Unless waived by the engineer, on projects with smoothness (IRI) requirements, the paver shall carry minimum 9.0m long average beam equipped with an ultrasonic sensors capable of sensing a pavement section at several spatially separated spots. The automatic slope control shall be equipped with a proportioning manual override to enable smooth transition of changing slope rate. Automatic screed controls shall be approved by the Engineer before use.

6

Screeds shall be provided with devices for heating the screeds to the temperature required for the laying of the mixture without pulling or marring. Pavers shall also be provided with the standard attachable screed extensions. All screeds shall be of the vibrating type that permits material to be tamped into position.

7

The term "screed" includes any cutting, crowning or other physical action that is effective in producing a finished surface of the evenness and texture specified, without tearing, shoving, or gouging.

8

If, during construction, it is found that the spreading and finishing equipment in operation leaves in the pavement surface tracks or indented areas or other objectionable irregularities that are not satisfactorily corrected by scheduled operations, the use of such equipment shall be discontinued and other satisfactory spreading and finishing equipment shall be provided by the Contractor.

5.15.2

Rolling Equipment

1

Rolling equipment shall consist of vibratory steel-wheeled rollers, dead weight steel-wheeled rollers and pneumatic-tire rollers as required for proper compaction and finishing of the asphalt surface. Unless otherwise permitted, rollers shall be equipped with reversible or dual controls to allow operation both forward and backward with the operator always facing in the direction of movement.

2

Steel-wheeled rollers shall be two-axle tandem rollers or three-axle tandem rollers. These rollers shall be self-propelled and equipped with power units of not less than four cylinders and under working conditions shall develop contact pressures under the compression wheels of 45 to 65 kg/cm of width. Each two-axle roller shall have a minimum weight of 10,000 kg each and three-axle roller shall have a minimum weight of 13,000 kg. Vibrating steel-wheeled rollers shall have dual drums with a minimum weight of 7000 kg. Vibrating frequency shall be between 2000 and 3000 cycles per minute with individual controls for each tandem drum. Rollers shall be in good working condition and shall be equipped with a reversing clutch. Rollers shall be equipped with adjustable scrapers to keep the wheel surface clean and with efficient means of keeping them wet to prevent mixes from sticking. These surfaces shall have no flat areas or projections which will mark the surface of the asphalt courses. The three-axle rollers shall be equipped with a centre axle which may be operated either fixed or floating. The three-axle tandem roller shall be so constructed that when locked in a position

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for all treads to be in one plane, the roller wheels are held with such rigidity that, if either front or centre wheel is unsupported the other two wheels will not vary from the plane by more than 6 mm. All steel-wheeled rollers shall be in good condition and the Contractor shall furnish to the Engineer the manufacturer’s technical data for each roller and no roller shall be used except after approval of the Engineer. Pneumatic-tire rollers shall be self-propelled. The rollers shall be equipped with pneumatic tires of equal size and diameter which are capable of exerting varying average contact pressure. Pneumatic-tire rollers shall be in good condition and with enough ballast space to provide uniform wheel loading as may be required. The Contractor shall furnish to the Engineer charts or tabulations showing the contact areas and contact pressures for the full range of tire inflation pressures and for the full range of tire loading for each type and size compactor tire furnished and used in pneumatic-tire rollers. The total operating weight and tire pressure may be varied by the order of the Engineer to obtain contact pressures which will result in the required asphalt course density.

5.15.3

Liquid Asphalt Distributor

1

The liquid asphalt distributor truck shall be of the pressure type with insulated tanks. The use of gravity distributors will not be permitted. The distributor shall have pneumatic tires of such width and number that the load produced on the road surface shall not exceed 100 kg/cm tire width.

2

Spray bars shall have a minimum length of 2.4 m and shall be of the full circulating type. Spray bar extensions shall also be of the full circulating type. The spray bar shall be adjustable to maintain a constant height above the surface to be treated.

3

The spray bar nozzles shall be slotted and shall be of such design so as to provide a uniform unbroken spread of asphalt material on the surface. The valves shall be operated by levers so that one or all valves may be quickly opened or closed in one operation. The distributor shall be equipped with a hose and nozzle attachment to be used for spotting areas inaccessible to the distributor. The distributor and booster tanks shall be so maintained at all times as to prevent dripping of liquid asphalt material from any part of the equipment.

4

The distributor shall be equipped with devices and charts to provide for accurate and rapid determination and control of the amount of liquid asphalt material being applied and with a tachometer of the auxiliary wheel type reading speed in m/min. The spreading equipment shall be provided with a separate power unit for the pump or a variable displacement pump driven by a hydrostatic transmission so that a uniform application of liquid asphalt material, in 2 controlled amounts, may be made ranging from 0.15 to 5.0 kg/m . The distributor shall have satisfactory heating equipment and thermometers in order to provide the full range of application temperatures for the liquid asphalt material being used.

5

Before commencing the work and as required by the Engineer, the liquid asphalt distributor shall be checked and calibrated such that the rate of transverse spread or longitudinal spread shall not vary more than 10 % from the required rate of application.

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APPENDIX

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APPENDIX - ASPHALT WORKS........................................................................... 42

1.1

DEFINITIONS ........................................................................................................ 42

1.2

INTRODUCTION ................................................................................................... 44

1.3 1.3.2 1.3.3

SUPERPAVE DESIGN PARAMETERS ................................................................. 44 Traffic 44 Nominal Maximum Aggregate Size (NMAS) 45

1.4

SELECTION OF HMA PROPERTIES & REQUIREMENTS ................................... 46

1.5 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7 1.5.8 1.5.9

OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS....................................... 47 Step1: Selection of Materials 47 Step2: Selection of a Design Aggregate Structure (DAS) 48 Work Instructions of Step 2 Selection of DAS 50 Step 3: Selection of the Design Asphalt Content 51 Work Instruction of Step 3- Selection of DAC 52 Nmax and Ndes Verification 52 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture 53 Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity 54

1.6 1.6.2 1.6.3

JOB MIX DESIGN PROPOSAL ............................................................................. 54 Acceptance of Job Mix Formula 55 Construction Quality Control: 56

1.7

REFERENCES ...................................................................................................... 57

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1

APPENDIX - ASPHALT WORKS

1.1

DEFINITIONS

1

Superpave: Is an abbreviation of Superior system consist the following steps:

Performing

Asphalt Pavement.

(a)

Performance-Based Asphalt Binder Grading System

(b)

Performance-Based Specifications of Materials & HMA.

(c)

Test methods and practices for material selection & mix design.

(d)

Performance prediction of HMA.

Superpave

Asphalt Binder Content (Pb): the percent by weight of asphalt binder in the total mixture.

3

Initial Trial Asphalt Binder (Pbi): the percent by weight of the asphalt binder in the total mixture for each trial blend in the selection of the Design Aggregate Structure (DAS).

4

Bulk Specific Gravity (G1, 2, to n; … Gsb, Gmb): the ratio of the weight in air of a unit volume of a permeable material (including both permeable and impermeable voids connected to the surface of the aggregate particle) at a stated temperature relative to the weight in air of an equal volume of gas-free distilled water at the stated temperature. This definition generally applies to individual aggregate stockpiles (Gl through Gn), the blended aggregate (Gsb, AASHTO T84, T85 and T100) or the compacted mix (Gmb, AASHTO T166 or T275).

5

Effective Binder Content (Pbe): the volume of the asphalt binder that is not absorbed into the aggregate but remains in the mixture to coat the aggregate particles.

6

Effective Specific Gravity (Gse): the ratio of the weight in air of a unit volume of a permeable material (excluding voids permeable to binder) at a stated temperature relative to the weight in air of an equal volume of gas-free distilled water at the stated temperature.

7

Maximum Specific Gravity (Gmm): the ratio of the weight of a given volume of voidless (Va=0) loose HMA at a stated temperature (usually 77 °F (25°C)) to a weight of an equal volume of gas-free distilled water at the same temperature (AASHTO T209).

8

Voids in Mineral Aggregate (VMA): It is the total space between the aggregate particles in the compacted paving mixture which includes 1) the air voids (Va) and 2) the effective binder volume . The VMA is defined as the volume of void space between the aggregate particles before adding the binder. Note: mineral aggregate is the aggregate which does not include any or organic material but it is the material that consists of minerals and compounds such as calcium, silicon, etc ….

9

Air Voids (Va): The total volume of the small pockets of air between the coated aggregate particles throughout a compacted paving mixture, expressed as percent of the bulk volume of the compacted paving mixture.

10

Voids Filled with Asphalt (VFA): the percentage portion of the volume of intergranular void space between the aggregate particles (i.e. VMA) that is occupied by the effective asphalt binder volume. It is expressed as the ratio of (VMA-Va) to the VMA.

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Volume of Absorbed Binder (Vba): the volume of binder absorbed into the aggregate (equal to the difference in aggregate volume when calculate with the bulk specific gravity and effective specific gravity).

12

Dust to Binder Ratio (P0.075/Pbe): ratio by weight of the percentage of the aggregate passing the 0.075 mm sieve (P200) to the effective binder content (Pbe).

13

Standard Axle: is 8.2 ton (18,000 lb) single axle with dual wheels; the center to center distance of dual wheels is 34.29 cm (13.5 in); the tire pressure is 0.517 MPa (75 psi).

14

ESAL's: is an abbreviation of Equivalent Single Axle Load. The equivalency factor is the number of repetition of the standard axle required to induce the same damage as the given axle. AASHTO Road Test has shown that an equivalent number of the standard axle can represent the damaging effect of the passage of an axle of any mass. This means that the ESAL is the number of applications of the standard axle that is equivalent in the damage to the pavement to an axle of any mass. The relationship is non-linear and is a fourth degree. For example, one application of a 16.2 ton single axle (36,000 lb twice as the standard axel) was found to cause damage equal to approximately sixteen applications of the standard axle; or one application of a 16.2 tons axle were required to cause the same damage or reduction in the pavement serviceability as sixteen applications of the standard axle. Also, one application of a 5.47 ton single axle (12,000 lb two thirds of the standard axel) was found to cause damage equal to approximately 0.2 applications of the standard axle; or five applications of a 5.47 tons axle were required to cause the same damage or reduction in the pavement serviceability as one applications of the standard axle.

15

Standard Sieves: Superpave standard sieve sizes are 50.0, 37.5, 25.0, 19.0, 12.5, 9.5, 4.75, 2.36, 1.18, 0.6, 0.3, 0.15 and 0.075 mm

16

Maximum Aggregate Size (MS): one standard size larger than the nominal maximum aggregate size (This definition applies only to Superpave mix design.)

17

Nominal maximum aggregate size (NMAS): one standard size larger than the first sieve that retains more than 10 percent of the aggregate (this definition applies only to Superpave mix design).

18

Nini, Ndes and Nmax: These are the number of gyrations of the gyratory compactor at three compaction levels simulating the construction traffic for N ini, the design traffic for Ndes and the maximum anticipated densification by the highest traffic for Nmax

19

Design Aggregate Structure (DAS): the aggregate blend meeting all Superpave requirements.

20

Design Asphalt Content (DAC): the percent by weight of the asphalt binder in the total mix selected at 4.0 % air voids in the mix meeting all Superpave requirements.

21

ePAVE3: is a user-friendly menu driven Excel program for the Superpave mix design system. It is a decision making program that includes all the computations, requirements and comparisons to design hot mix asphalt for a given project. ePAVE3 includes Superpave requirements based on the latest (to date) Asphalt Institute Superpave Mix Design – Superpave Series No. 2 (SP-2), third Edition 2001 and last edition of AASTO 2005 including M323 specification "Standard Practice for Designing Superpave HMA", and R35.

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Polymer: An organic substance that is originated from petroleum gases. It is the product of a complicated chemical process. The word “polymer” originally consists of two words “poly” which means numerous and “meros” which means parts; therefore, polymer means the substance with many parts. Polymers can be either copolymers or homopolymers. The most common polymers that are used to modify the asphalt binder for road applications are either “Elastomers” such as SBS or “Plastomers” such as EVA and Polyethylene.

23

Neat and Polymer Modified Binder (PMB): neat binder is a black or dark brown material produced from refining of petroleum oil in petroleum refineries. The polymer modified binder is a neat binder that has been modified by the addition of polymers. The purpose of blending polymer and other chemical substances is to improve the neat binder Rheological properties to achieve the Performance Grade (PG) requirements of Superpave grading system. This process is complicated and involves accurate control of the process parameters such as mixing mechanism, temperature, time, concentration and blending details

1.2

INTRODUCTION

1

This guide, which is based on ref. 1, should be considered as a guide to assist Engineers, consultants and contractors to design Hot-Mix Asphalt (HMA) using Superpave system. It is the contractor full responsibility to select the applicable parameters for his project in liaison with the Engineer and LSA. This system was developed using the last editions of the Asphalt institute “Superpave Mix Design”, 2001, and AASHTO, 2005.

1.3

SUPERPAVE DESIGN PARAMETERS

1

Before starting any HMA design using Superpave system for any project, the mixture and materials specifications and requirement must be identified. Superpave mix design system requires three parameters in order to design a mix. These Parameters are:

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Expected traffic volume in the project.

(b)

Nominal Maximum Aggregate Size (NMAS).

(c)

Location of the project.

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The contract documents shall specify and define the design parameters for the project. A brief description of the basic design parameters is given in the following sections.

1.3.2

Traffic

1

In Superpave, Traffic is defined as the total anticipated project level equivalent single axle load (ESALs) on the design lane for a period of 20 years. To simplify the design process, traffic class designations for each ESALs that appears in the Superpave system is specified herein. If the contract documents do not specify the ESALs applicable to the project, the Engineer can use the information provided in Table 1 to select the traffic classes needed to establish Superpave criteria.

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Table 1 ESAL and Traffic Designation Class Designation

ESALs Range

Applications

Less than 300,000

Agricultural roads with light traffic , local and city streets without trucks

L

Light

300,000 to 3 million

Agriculture, Feeder and collector roads

M

Medium

3 million to 10 million

Main roads and city streets

H

Heavy

10 million to 30 million

Highways and Expressway

Very Heavy

More than 30 million

Heavily trafficked highways, industrial areas ...

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Very Light

VL

Nominal Maximum Aggregate Size (NMAS)

1

Six Nominal Maximum Aggregate Sizes (NMAS) are identified in the Superpave system; these are 37.5, 25.0, 19.0, 12.5, 9.5 and, 4.75 mm as specified in Table 2.

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Table 2 SUAERPAVE Standard NMAS mixtures Maximum Size (MS)

37.5 mm

50.0 mm

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Nominal Maximum Size (NMAS)

37.5 mm

19.0 mm

25.0 mm

12.5 mm

19.0 mm

9.5 mm

12.5 mm

4.75 mm

9.5 mm

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25.0 mm

The selection of design NMAS for a specific layer is based on the general rule that the NMAS does not exceed half to one-third (1/2 to 1/3) the layer thickness. If the contract documents do not specify the NMAS for the project, the Engineer can use the above criteria and the information provided in Table 3 to select the NMAS of the project. Table3 Recommended NMAS for Different Layer Types Layer

Recommended NMAS

Sand Mix

4.75 mm

Wearing coarse

9.5 or 12.5 or 19.0 mm

Base coarse

25.0 or 37.5 mm

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1.4

SELECTION OF HMA PROPERTIES & REQUIREMENTS

1

Based on the specified design parameters (Traffic in ESAL, NMAS, geographic location of the project and location of required layer to be designed), the mixture properties and requirements can be selected. These properties include compaction level, which can be identified from Table 4 and the properties of HMA, which can be identified from Table 5. Table 4 Superpave Gyratory Compactive Effort (SGCE)

Ndes

Nmax

VL (< 0.3)

6

50

75

L (0.3 to 3)

7

75

M to H (3 to < 30)

8

100

VH (> 30)

9

.

Nini

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Traffic (ESAL, million)

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Table 5 Superpave Criteria for the Mixture Design

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Criteria

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Voids in the Mineral Aggregate (VMA %min) Important Note: mixtures with VMA greater than 2.0% above the minimum should be avoided.

Voids Filled with Asphalt, %

VL

Ninitial

< 91.5

L

M

< 90.5 96.0

Nmax

< 98.0

Nominal Maximum Size, mm

H < 89.0

Ndesign

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Required Density (% Gmm)

Traffic Class Designation (or ESAL, million)

37.5

11.0 %

25.0

12.0 %

19.0

13.0 %

12.5

14.0 %

9.5

15.0 %

4.75

16.0%

37.5

64-80

64-78

64-75

25.0

67-80

65-78

65-75

19.0

70-80

65-78

65-75

12.5

70-80

65-78

65-75

9.5

70-80

65-78

65-75

4.75

70-80

65-78

65-75

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Criteria

VL

L

M

H

VH

Dust Proportion (DP) Ratio, if gradation line is above the PCS

For all NMAS DP = 0.6 - 1.2, for NMAS 4.75 DP = 0.9 - 2.0

Dust Proportion (DP) Ratio, if gradation line is below the PCS.

0.8 – 1.6

Average Indirect Tensile Strength of the Dry Set in the Moisture Sensitivity Evaluation, kPa

Report

OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS

1

According to SP-2 and AASHTO R 35, there are four major steps in the volumetric mix design process. These steps consist of

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Material Selection, (Type of binder and aggregate).

(b)

Selection of Design Aggregate Structure (DAS).

(c)

Selection of Design Asphalt Content (DAC).

(d)

Evaluation of Strength and Moisture Sensitivity of the Mix.

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Step 4: Strength and Moisture Sensitivity Evaluation

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Step 2: Selection of DAS

Step 1: Selection of Materials (Binder, Aggregate and Modifiers)

2

ePAVE3 program should be used to assist in the preparation of the mix design and obtain the mix deign report summarizing the computations and test results. ePAVE3 mix design report shall be submitted to the Engineer for acceptance then to LSA for approval.

1.5.2

Step1: Selection of Materials

1

This process includes the selection of the asphalt binder PG (ABPG) and the aggregates that meet all Superpave criteria.

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The selection of ABPG necessitates an understanding of the climatic condition (e.g., temperature) in which the pavement will be constructed and operated. This includes both the average seven-day maximum high temperature and the single-day minimum low temperature for the last twenty years and the latitude for that particular geographic location.

3

To account for traffic volume and speed or both, adjustments should be made to the selected ABPG using AASHTO M332.

4

The requirements of the aggregate are selected based on the anticipated traffic and position of the layer within the pavement. The quality criteria for Superpave aggregates are summarized in Table 6. In order to be used in Superpave mixtures, the aggregate blends must meet two sets of criteria known as source properties and consensus properties. Source property requirements apply to each aggregate stockpile, but consensus properties apply to the combined blend of multiple stockpiles. The consensus properties are mandatory for all Superpave aggregate blends while; source properties are left to the contracts.

(b)

Coarse Aggregate Angularity, (CAA) Fine Aggregate Angularity, (FAA) Flat and Elongated Particles (F&E) Sand Equivalent, (SE)

ASTM D5821 AASHTO T304-Method A ASTM D4791 AASHTO T176

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Source Properties (QCS Requirements):

AASHTO T96 AASHTO T104 AASHTO T112

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Table 6 Superpave Criteria for Aggregate Consensus Properties

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Layer Depth, mm

Property

H(10to<30)

M (3 to<10)

L (0.3 to 3)

VL (< 0.3)

100/100

95/90

85/80

75/-

55/-

< 100 mm

100/100

80/75

60/-

50/-

-/-

> 100 mm

45

45

45

40

-

< 100 mm

45

40

40

40

-

> 100 mm

50

45

45

40

40

SE, % min

10

10

10

10

-

F&E, % max

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CAA, % min. FAA, % min.

Note: CAA values (X/Y) denotes that X% of the coarse aggregate has one fractured face and Y% has two or more fractured faces

1.5.3

Step2: Selection of a Design Aggregate Structure (DAS)

1

Once a group of aggregates has been identified, these aggregates are combined at different percentages to produce at least three distinct blends conforming to Superpave gradation requirements presented in Table 7 according to designed NMAS.

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Table 7 Aggregate Gradation Requirements – Control Points Nominal Maximum Aggregate Size, mm - Control Point (Percent Passing) Sieve Size

25.0 mm

Min.

Max.

50.0 mm

100

-

37.5 mm

90

25.0 mm

Min.

19.0 mm

Max.

Min.

Max.

12.5 mm Min.

9.5 mm

Max.

Min.

Max.

4.75 mm Min.

Max.

-

-

-

-

-

-

-

-

-

100

100

-

-

-

-

-

-

-

-

-

-

90

90

100

100

-

-

-

-

-

-

-

19.0 mm

-

-

-

90

90

100

100

-

-

-

-

-

12.5 mm

-

-

-

-

-

90

90

100

100

-

100

-

9.5 mm

-

-

-

-

-

-

-

90

4.75 mm

-

-

-

-

-

-

-

-

2.36 mm

15

41

19

45

23

49

28

1.18

-

-

-

-

-

-

-

0.075 mm

0

6

1

7

2

8

2

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-

100

95

100

-

90

90

100

58

32

67

-

-

-

-

-

30

60

10

2

10

6

12

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Primary Control Sieve (PCS) shown in Table 8 can be used to determine if the nominated blend is fine or coarse gradation. If the gradation line passes below the PCS, it is considered as coarse graded and it is considered fine gradation if the line passes above the PCS.

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37.5 mm

12.5mm

19mm

25mm

37.5 mm

Nominal Maximum Size

2.36mm

2.36mm

4.75mm

4.75mm

9.5mm

Primary Control Sieve Size

47%

47%

40%

47%

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Table 8 Gradation Classification - PCS Control Points

39%

%Passing PCS

Typically, three blends are developed ranging from the coarse to the fine side of the Superpave control points for a given nominal maximum size (note: control points and PCS differ for different NMAS). After selecting a blend (i.e. from the three trial blends), the aggregate consensuses properties must be confirmed to meeting Superpave criteria by actual testing.

4

The most difficult part of designing an aggregate structure is the creation of the VMA necessary to meet the volumetric criteria. The procedure is typically a trial and error process; however, there are some general guidelines that will assist in obtaining the VMA. The following recommendations may be tried to increase VMA:

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(a)

Move the gradation away from the maximum density line;

(b)

Use highly angular particles;

(c)

Use particles with a rough surface texture;

(d)

Reduce the percent of natural sand and use more percent of the crushed sand;

(e)

Reduce the amount of P200 used in the HMA; and

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Use S-shaped gradation curve.

5

A good design aggregate structure is one that is economical and meets Superpave volumetric criteria.

1.5.4

Work Instructions of Step 2 Selection of DAS

1

To select the design aggregate structure, do the following: Obtain representative hot bin specimens from the plant.

(b)

Determine the consensus properties, water absorption, bulk and apparent specific gravities for each aggregate fraction.

(c)

Grade the specimens using Superpave standard sieve set.

(d)

Input the values from two and three into ePAVE3 or combine manually. to develop three blends that meet the Superpave criteria (i.e. within the control points for the design NMAS)

(e)

Estimate the initial trial asphalt binder content using ePAVE3 or by using formulas presented in ASSHTO R35.

(f)

For unmodified asphalt binders, determine the mixing and compacting temperature for the proposed asphalt binder as follows:

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Measure the rotational viscosity using AASHTO T316 or ASTM D4402 at 135 C and 165 C.

(ii)

Input the measured viscosities into ePAVE3. ePAVE3 will generate the viscositytemperature relationship.

(iii)

From the graph, determine:

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The mixing temperature at a rotational viscosity of 0.17 ± 0.02 Pa.s.

3

The compaction temperature at a rotational viscosity of 0.28 ± 0.03 Pa.s.

For modified asphalt binders, determine the mixing and compaction temperature in accordance with one of the methods presented in NCHRP 648.

(h)

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Prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimens and two specimens to measure the Maximum Specific Gravity (Gmm) for each blend at the estimated initial trial asphalt content. Note: small specimen size of 100 mm is used for mixes having NMAS of 19.0 mm or below.

(i)

Leave the mix in the oven for two hours at the compaction temperature then compact two 150.0 mm (or 100 mm) specimens for each blend using the Superpave Gyratory Compactor (SGC) to Ndes according to AASHTO T312 (minimum number of specimens is six).

(j)

For the specimens that were compacted to Ndes, measure the bulk specific gravity (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor that is automatically recording the specimen height for each gyration.

(k)

Measure the Maximum Specific Gravity (Gmm) for two specimens for each blend according to ASSHTO T209.

(l)

Input the measured values into ePAVE3. ePAVE3 will perform the computations, display results, and check them against the criteria of the project.

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Check the results given by ePAVE3 for the three blends and select the most conforming blend as the DAS; in case none of the three blends meets Superpave criteria, repeat the design by developing additional aggregate blends from the same source ; if the criteria is not met change the sources.

Preparation of the binder and aggregate mixtures for the gyratory compactor (SGC) should be timed such that a minimum of 20 minutes is allowed between batches. Batched specimens should be conditioned in a closed draft oven for a minimum of 2 hours ± 5 minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven aging is performed to permit time for the aggregate to absorb the binder. All specimens including those for SGC and maximum specific gravity tests, should be cured the same amount of time.

1.5.5

Step 3: Selection of the Design Asphalt Content

1

The selected aggregate blend (DAS) will then be mixed with four different proportions of the binder as follows:

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Estimated asphalt binder content corrected to give 4.0% air voids.

(b)

Estimated asphalt binder content corrected to give 4.0% air voids minus 0.5 %.

(c)

Estimated asphalt binder content corrected to give 4.0% air voids plus 0.5 %.

(d)

Estimated asphalt binder content corrected to give 4.0% air voids plus 1.0 %.

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(a)

A sufficient amount of the proposed aggregate blend will need to be prepared to permit two specimens to be compacted in the SGC according to Superpave system for gyrations equal (Ndes), and the maximum specific gravity to be determined at each of the four binder contents.

3

Preparation of the binder and aggregate mixtures for the SGC specimens should be timed such that a minimum of 20 minutes is allowed between batches. Batched specimens should be conditioned in a closed draft oven for a minimum of 2 hours ± 5 minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven aging is performed to permit time for the aggregate to absorb the binder. All specimens including those for SGC and maximum specific gravity tests, should be cured the same amount of time.

4

The procedure used for design in the laboratory will need to closely match the field conditions at the time of construction. Failure to consistently test the materials at the same time interval may result in a highly erratic all specific gravity values and possibly failure to achieve the required VMA. After the necessary testing has been accomplished, the calculation of the volumetric parameters can begin. The averaged results of the various volumetric calculations need to be plotted relative to the corresponding binder content. The design binder content is selected as that which satisfies the specified volumetric criteria at 4 percent air voids (refer to AASHTO R35 for more details).

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1.5.6

Work Instruction of Step 3- Selection of DAC

1

To select the deign asphalt content, do the following: After selecting the most conforming blend (DAS) from step 2, prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimen and two specimens to measure the Maximum Specific Gravity (Gmm) for four trial mixes using DAS of the selected blend and four asphalt binder levels as specified in item (5.5.4) herein.

(b)

Compact two 150.0 mm (or 100 mm) specimens for each mix using the Superpave Gyratory compactor to Ndes according to AASHTO T312 (total number of specimens are eight)

(c)

For the specimens that were compacted to Ndes, measure the bulk specific gravity (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor that is automatically recording the specimen height for each gyration.

(d)

Input the measured values into ePAVE3. The program will perform all calculations, produce the results and compare the results with required mix design properties for the project.

(e)

ePAVE3 will generate the design curves, these are: % air voids vs. asphalt content.

(ii)

% VMA vs. asphalt content.

(iii)

% VFA vs. asphalt content.

(iv)

% Gmm at Nini vs. asphalt content.

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(a)

From the percentage, air voids vs. asphalt content curve determine the design asphalt content (DAC) which corresponds to 4.0 % air voids.

(g)

Use the %VMA vs. asphalt content, %VFA vs. asphalt content % and %Gmm vs. asphalt content graphs to obtain the VMA, FVA and the % Gmm @ Nini values at the design asphalt content.

(h)

Input the DAC, %VMA, %VFA % and Gmm @ Nini into the appropriate cells in ePAVE3. ePAVE3 will perform the computations, display results, and check them against the criteria of the project.

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(f)

(i)

If the mix properties at the design asphalt content conform to the Superpave criteria then go to the Nmax verification; if not then analyze, evaluate and modify the design as needed until the mix properties at the design asphalt content (DAC) conform to the criteria.

1.5.7

Nmax and Ndes Verification

1

After conforming to Superpave criteria, then do the Nmax verification as follows: (a)

Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm) specimens and two Gmm specimens.

(b)

Compact the specimens to Nmax using the gyratory compactor according to AASHTO T312.

(c)

Measure the Gmb at Nmax for the two specimens that were prepared using SGC and measure the Gmm.

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(d)

Input the values into ePAVE3, which will perform the computations, provide the results, and compare them with the Superpave criteria.

(e)

Check the results of ePAVE3, if acceptable then the design is concluded if not then redesign the mix.

After conforming that the mix properties at Nmax meet Superpave criteria, then do the Ndes verification as follows: Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm) specimens and two Gmm specimens.

(b)

Compact the specimens to Ndes using the gyratory compactor according to AASHTO T312.

(c)

Measure the Gmb at Ndes for the two specimens that were prepared using SGC and use the Gmm from the previous step. Obtain the specimen height at Ndes and Nini from the gyratory compactor that is automatically recording the specimen height for each gyration.

(d)

Input the values into ePAVE3, which will perform the computations, provide the results, and compare them with the Superpave criteria.

(e)

Check the results of ePAVE3, if acceptable then the design is concluded if not then redesign the mix.

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2


Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture

1

The identification of the combination of a design aggregate structure and design binder content is now complete. The mixture now needs to demonstrate that it is capable of resisting the moisture induced damage. This evaluation is performed in accordance with AASHTO T283.

2

Moisture sensitivity evaluation requires that a total of six specimens consisting of the proposed aggregate blend and binder at the design binder content, be prepared and compacted to approximately 7 ± 0.5% air voids. This group of specimens is divided into two subsets with three of the specimens being identified as the control specimens and the other three being identified as conditioned specimens.

3

At the end of the conditioning period all of the specimens are loaded to failure in indirect tension. Report the average Indirect Tensile Strength (IDT) of the dry subset in the mix design report (see Table 5); and if the ratio of the average strength of the conditioned subset to the control subset (retained strength) is more than or equal to 80% , then the mixture passes the test. If the retained strength is less than 80%, then the mixture fails. The retained strength can be increased by substituting part of the material finer than 0.075 mm by mineral admixtures or by using chemical anti-stripping agents. Prepare another six (6) specimens and test them as previously described. If this procedure does not improve the retained strength to more than 80%, then the design process should be repeated using different source.

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1.5.8

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1.5.9

Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity

1

To check the Strength and the moisture sensitivity of the designed mix, do the following: Prepare enough hot mix to make six 150 mm (or 100 mm) gyratory compactor specimens using the selected gradation (DAS) and the design asphalt content (DAC).

(b)

Use the Nmax verification densification data to identify the number of gyrations required to achieve 7.0 ± 0.5% % air voids (i.e. %Gmm = 92.5 to 93.5 %).

(c)

Compact six 150.0 mm (or 100 mm) specimens using the Superpave Gyratory Compactor according to AASHTO T312 compactor (total number of specimens are six) to a number of gyrations that will provide approximately 7.0 ± 0.5 % air voids.

(d)

Use ASSHTO T283 to test the six specimens.

(e)

Input the measured values into ePAVE3. ePAVE3 will perform the computations and provide the results and compare them with the Superpave criteria

(f)

Check the results given by ePAVE3. Report the average IDT of the Dry group in the mix design report (see Table 5). If the ratio of the average IDT of the conditioned subset to the control subset is 80% or more, then the mixture passes the test if not consider redesigning the mix and use some additives.

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(a)

JOB MIX DESIGN PROPOSAL

1

A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and submitted to the Engineer and LSA for approval. The JMF shall be prepared by the Contractor in precise compliance with Superpave system. The Contractor shall select his sources of aggregate and bituminous material and, after sufficient quantities have been stockpiled or are available for use, obtain representative specimens of the materials and test to determine if they conform to the requirements of the specifications.

2

Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the Engineer, detailed information for each mix which he proposes to furnish. The information shall include, but not be limited to the following:

The source(s) of the aggregate for each mix.

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(b)

Copy of mix certificate approval obtained from LSA.

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(a)

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(c)

Pertinent test data and a written certification that the aggregates conform to all of the quality requirements specified herein and in section 5.2.

(d)

Type of Asphalt modifier intended to be used in the project. The Asphalt binder modifier shall be an approved modifier; along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(e)

Pertinent test data on the type and properties of the asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(f)

Superpave mix design report in ePAVE3 format.

(g)


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Type of Asphalt modifier intended to be used in the project. The Asphalt binder modifier shall be an approved modifier; along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(i)

Pertinent test data on the type and properties of the asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(j)

Superpave mix design report in ePAVE3 format.

(k)


(l)

The proposed beginning date for producing bituminous concrete mixtures.

(m)

Any other support data and information special to the project (e.g. technical data sheets of a polymer in case it was used).

.

(h)

The Engineer shall be provided access to the materials sampling and testing operations at all times.

4

At the same time that the above information is provided, the Engineer shall obtain one hundred (100) kilogram specimens of each individual aggregate size, eight (8) liters of bituminous material and, when used, sufficient quantities of the mineral filler and the chemical admixture/asphalt modifier to complete two (2) proposed mix design checks, all representing the materials which the Contractor proposes to furnish. The final job mix formula shall be made by using hot-bins aggregate.

1.6.2

Acceptance of Job Mix Formula

1

The Engineer shall review the JMF to determine that it contains all required information. If it does not contain all required information, it shall be returned within seven (7) days to the Contractor for further action and resubmission by the Contractor.

2

If the proposed JMF contains all required information but fails to meet all of the requirements specified, it shall not be accepted by the Engineer and will be returned to the Contractor within fourteen (14) days. The Contractor shall prepare and submit to the Engineer a new JMF conforming to the requirements specified and propose a new date for beginning production of the bituminous mixtures.

3

When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all the requirements of the specifications, he shall order the Contractor to construct a minimum of two hundred (200) meter long field test strip; but, not exceeding one day's production. The test strip is used for three purposes:

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(a)

To check the contractor ability to produce the approved mix within tolerances.

(b)

To check the contractor ability to construct and compact the mix to satisfy job specifications.

(c)

To check the riding quality according to project specifications.

4

The Engineer shall evaluate the test strip as to its constructability and compactability and the mix for conformance to the laboratory tested JMF within the tolerances listed in Table 9. Five (5) specimens shall be obtained from the test strip and tested.

5

If the Engineer is not satisfied with the results of the test strip, he shall state his objections in writing and request a revised JMF and a new test strip.

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When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all requirements of the specifications and the test strip results are acceptable, he will issue written acceptance to the Contractor to begin producing the proposed mixes. Production of bituminous concrete mixtures shall not begin until the Engineer has given written acceptance of the Job Mix Formula.

7

Acceptance of the JMF by the Engineer does not relieve the Contractor of his obligation to produce bituminous concrete mixtures conforming to all specified requirements.

1.6.3

Construction Quality Control:

1

Testing to control the quality of bituminous concrete mixtures produced shall be the responsibility of the Contractor.

2

For each class of bituminous concrete produced and each day's production, the Contractor shall perform one (1) complete Superpave analysis at Ndes including gradation and asphalt binder content, air voids, %VMA, %VFA, DP ratio, Indirect tensile strength on a specimen obtained from the discharge gate or hauling vehicle. In addition, the Contractor shall evaluate on a weekly basis the strength and moisture sensitivity of the mix from a specimen obtained from the discharge gate or hauling vehicle.

3

No mixture conditioning is required when assurance testing on plant-produced mixture.

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Table 9 Superpave Job Mix Formula Tolerances for HMA Plant Mix

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Mix Composition Property

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Asphalt Binder Content (Pb)

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Gradation Passing 4.75 mm and Larger Sieves Gradation Passing 2.36mm to 150μm Sieve

Tolerance Limit ±0.40 ±5 ±4 ±1.2

Air Voids (Va)

±1.3

Voids in Mineral Aggregate (VMA)

±1.5

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Gradation Passing 75μm Sieve

Field Density

92 to 94 (%Gmm)

or

quality

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REFERENCES Hot Asphalt Mix Design System Using Superpave System Detailed in Asphalt Institute SP-2 and the AASHTO 2005 Standards – MOT – Saudi Arabia, 2006.

2)

AASHTO M323: Standard Specification for Superpave Volumetric Mix Design.

3)

(NCHRP) Report 567: Volumetric Requirements for Superpave Mix Design.

4)

(NCHRP) Report 409: Quality Control and Acceptance of Superpave-Designed Hot Mix Asphalt.

5)

(NCHRP) Report 539: Aggregate Properties and the Performance of SuperpaveDesigned Hot-Mix Asphalt.

6)

(NCHRP) Report 513: Simple Performance Tester for Superpave Mix Design.

7)

(NCHRP) Report 648: Mixing and Compaction Temperatures of Asphalt Binders in Hot-Mix Asphalt.

8)

AASHTO T320: Standard Method of Test for Determining the Permanent Shear Strain and Stiffness of Asphalt Mixtures Using the Superpave Shear Tester (SST).

9)

AASHTO T321: Standard Method of Test for Determining the Fatigue Life of Compacted Hot-Mix Asphalt (HMA) Subjected to Repeated Flexural Bending.

10)

AASHTO T322: Standard Method of Test for Determining the Creep Compliance and Strength of Hot-Mix Asphalt (HMA) Using the Indirect Tensile Test Device.

11)

AASHTO T340: Standard Method of Test for Determining the Rutting Susceptibility of Hot Mix Asphalt (APA) Using the Asphalt Pavement Analyzer (APA).

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1.7


END OF PART

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 1

CONCRETE ROAD PAVEMENTS .......................................................................... 3

6.1 6.1.1 6.1.2 6.1.3

GENERAL REQUIREMENTS .................................................................................. 3 Scope 3 References 3 Quality Control of Concrete Strength 4

6.2 6.2.1 6.2.2 6.2.3

TRIAL LENGTH ....................................................................................................... 5 General Requirements for Trial Length 5 Assessment of Trial Length 6 Approval and Acceptance of Trial Length 7

6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 6.3.15 6.3.16 6.3.17 6.3.18 6.3.19 6.3.20 6.3.21 6.3.22 6.3.23 6.3.24 6.3.25 6.3.26 6.3.27 6.3.28 6.3.29 6.3.30 6.3.31 6.3.32 6.3.33 6.3.34 6.3.35 6.3.36

REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE .................................. 7 Materials and Mix Designs for Pavement Quality Concrete 7 Workability of Pavement Quality Concrete 7 Trial Mixes 8 Separation Membrane 8 General Requirements for Steel Reinforcement 8 Jointed Reinforced Concrete Slabs 9 Continuously Reinforced Concrete Slabs (CRCP or CRCR) 10 General Requirements for Transverse Joints 10 Transverse Contraction Joints 11 Transverse Expansion Joints 11 Transverse Warping Joints 11 Transverse Construction Joints 11 General Requirements for Longitudinal Joints 12 Longitudinal Construction Joints 13 Dowel Bars 13 Joint Grooves 16 Groove Formers and Bottom Crack Inducers 17 Joint Filler Board 18 Preparation and Sealing of Joint Grooves 18 Sealing with Applied Sealants 19 Sealing with Compression Seals 20 Joint Seals 21 Joints at Manhole and Gully Slabs 21 Inspection of Dowel Bars 22 Side Forms, Rails and Guide Wires 22 Delivery, Storage and Batching of Concreting Materials 23 Mixing Concrete 24 Transport and Delivery 24 General Requirements for Construction by Machine 24 Construction by Fixed Form Paving Machines 25 Construction by Slip-Form Paving Machine 26 Construction by Small Paving Machines or Hand Guided Methods 26 Surface Textures 28 Strength 29 Trial Mixes 29 Trial Length 29

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6

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Surface Finish

30

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.12 6.4.13

REQUIREMENTS FOR CEMENT BOUND MATERIALS ....................................... 30 General Requirements for Cement Bound Materials 30 Batching and Mixing 31 Transporting 31 Laying 31 Compacting 32 Curing 32 Preliminary Trial 33 Cement Bound Material Category 1 (CBM1) 33 Cement Bound Material Category 2 (CBM2) 34 Cement Bound Material Category 3 (CBM3) 34 Cement Bound Material Category 4 (CBM4) 34 Testing of Cement Bound Materials 35 Special Requirements for Cement Bound Materials 35

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6.3.37

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6

CONCRETE ROAD PAVEMENTS

6.1


6.1.1

Scope

1

This part of the specification covers the; materials, mix designs, production and laying of pavement quality concrete, lean mix concrete and cement bound materials.

2

Related Sections and Parts are:

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This Section Part 3 ............... Earthworks Part 4 ............... Unbound Pavement Materials Part 5 ............... Asphalt Works

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Section 5 - Concrete

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Part 16 ............ Miscellaneous - Pavement Quality Concrete References

1

The following standards are referred to in this part of the specification

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6.1.2

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BS 1377: Part 9 ..........Methods of testing soils – in-situ tests BS 1881...................... Methods of testing concrete Hot applied joint sealants for road pavements

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BS 2499 & BS EN 14188

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BS 1924: Part 1 & 2.... Stabilised materials for civil engineering purposes BS 2752...................... Chloroprene rubber compounds

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BS 3900: Part F12 ...... Determination of resistance to neutral salt spray BS 3963...................... Method for testing the performance of concrete mixers

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BS EN ISO 11600 ...... Two part polysulphide sealants

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BS 4449...................... Reinforcing bars BS 4482...................... Cold drawn steel wire for reinforcing concrete

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BS 4483...................... Reinforcing mesh BS 5212: Part 1 & 2.... Cold applied joint sealants for concrete pavements BS EN 206 & BS 8500

Supply of concrete

BS 7542...................... Methods for test of curing compounds for concrete BS 812........................ Testing methods for aggregates

ASTM D3406 .............. Specification for joint sealant - hot applied elastomeric types ASTM 7116 ................ Specification for joint sealant - hot applied elastomeric types (jet fuel resistant) ASTM D2628-91......... Specification for preformed joint seals DTP ............................ Manual of contract documents for highway works -Volume 1 specification for highway works

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6.1.3

Quality Control of Concrete Strength

1

Sampling and testing for, and compliance with the specified characteristics strength of designed mixes shall be in accordance with BS EN 206 & BS 8500, except that it shall be at the following rates of sampling and testing and meet the following requirements: (a)

Concrete cubes of the appropriate size shall be made, cured and tested in accordance with BS 1881 respectively from concrete delivered to the paving plant, each group being from a different delivery of concrete. At least 3 cubes shall be made per group 2 for each 600 m of concrete slab and not less than 6 groups shall be made each day, 2

for each type of mix. For areas less than 600 m , at least 4 cubes shall be made for 2

each 100 m or less. This rate of sampling and testing may be reduced at the Engineer's discretion.

.

2

For areas of 600 m or more, one cube shall be tested in compression at 7 days and

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the other two at 28 days after mixing. Groups of four consecutive results at 28 days shall be used for assessing the strength for compliance with BS EN 206 & BS 8500. 2 For areas less than 600 m , two cubes shall be tested at 7 days and two tested at 28

ta

days and assessed in accordance with BS EN 206 & BS 8500. The ratio R between 7 and 28 day strengths shall be established for the mix to be used in the slab by testing pairs of cubes at each age on at least six batches of the proposed mix or it shall be quoted by the supplier of the concrete. The average strength of the 7 day pair of cubes shall be divided by the average strength of the 28day pair of cubes for each batch and the ratio R shall be the average of these six values. The ratio R shall be expressed to three decimal places.

(d)

If during the construction of the trial length or during normal working, the average value of any 4 consecutive 7 day test results falls below the strengths required then the cement content of the concrete shall be increased by 5 % by mass or by an amount

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(c)

The values in columns 3 and 4 of Table 6.1 may only be used with the permission of the Engineer when sufficient test results on trial mixes for calculating the ratio are not available. Once sufficient results are available from normal working the ratio R shall be calculated from the results available on Site.

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agreed by the Engineer. The increased cement content shall be maintained at least until the four corresponding 28-day tests have been assessed. If the cement content is increased, the concrete mix shall be adjusted to maintain the required workability.

(f)

To assess the time for use of a concrete slab by traffic, the strength development rate may be predetermined by trial mixes. Alternatively pairs of cubes shall be made for 2 each 600 m or less and stored alongside the pavement in containers or in such a way that their sides are well insulated. If thermal insulation is used for accelerated curing the cubes shall be similarly insulated. Pairs of cubes shall be tested at intervals decided by the Engineer. Tests for compliance with the specified strength shall be made in the normal way.

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Table 6.1 7 Day Cube Strength

All Mixes, R available

PC Mixes, R not available

PFA or ggbs mixes, R 2 not available N/mm

C40

43R

35

29

C30

33R

27

22

C20

22R

18

14

C15

17R

13

11

C10

10R

8

7

C7.5

7R

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4.5

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Grade of Concrete

TRIAL LENGTH

6.2.1

General Requirements for Trial Length

1

Except in rapid construction projects, at least one month prior to the construction of the trial length of surface slabs or CRCR (Continuously Reinforced Concrete Road Base) the Contractor shall submit for the Engineer's approval a detailed description of the proposed materials, mix proportions, plant, equipment and construction methods.

2

No trials of new materials, plants, equipment or construction methods; nor any development of them shall be permitted either during the construction of the trial length or in any subsequent paving work, unless they form part of further approved trials.

3

The Contractor shall demonstrate the materials, mix proportions, plant, equipment and method of construction that are proposed for concrete paving, by first constructing a trial length of slab, at least 150m but not more than 300 m, long for mechanised construction, and

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6.2

at least 30m long for hand guided methods, or otherwise as directed by the Engineer. The mix proportions decided by trial mixes may be adjusted during the trial but shall not be changed once the trial length has been approved except with the agreement of the Engineer.

5

The trial length shall be constructed in two parts over a period comprising at least part of two separate working days, with a minimum of half the proposed trial lengths constructed each day. The trial length shall be constructed at a similar rate to that which is proposed for the main construction in the permanent works.

6

At least two transverse joints and one longitudinal joint of each type that are proposed for unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in the permanent works shall be constructed and assessed in the trial length.

7

If in the trial length expansion joints are not demonstrated, the first 2 expansion joints and at least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for hand

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guided method of construction laid in the main construction in the permanent works, shall be considered the trial length for these joints.

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8

One construction joint shall be demonstrated in each trial length of CRCP or CRCR.

6.2.2

Assessment of Trial Length

1

The trial length shall comply with the Specification in all respects, with the following additions and exceptions provided in (a) through (d) below. (a)

Surface Levels and irregularity (i)

in checking for compliance the levels shall be taken at intervals of not more than 2.5 m along any line or lines parallel to the longitudinal centre line of the trial length. The maximum number of permitted irregularities of pavement surfaces shall comply with the requirements for asphalt pavements as per Part 5 for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on values for a 300 m length.

(b)

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(ii)

Joints

At least 3 cores of minimum diameter 100 mm shall be taken from the slab at

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joints to check the lateral and vertical location of joint grooves and bottom crack inducers. After a minimum of 24 hours following construction the removable part of the joint groove former shall be taken out and at least three joints and the sides of the groove shall be inspected for compaction. If there are voids the size and number should be compared with a similar size section of the photograph for 3% excess voidage in BS 1881. If there is excess voidage, additional compaction shall be provided and further joints inspected. The joints so exposed shall be temporarily or permanently sealed

(iii)

Alignment of dowel bars shall be inspected in any two consecutive transverse joints. If the position or alignment of the dowel bars at one of these joints does not comply after the next 3 consecutive joints of the same type have been inspected then the method of placing dowels shall be deemed to be satisfactory.

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(ii)

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(iv)

(c)

Density (i)

(d)

If there are deficiencies in the first expansion joint constructed as a trial, the next expansion joint shall be a trial joint. Should this also be deficient further trial expansion joints shall be made as part of a trial length which shall not form part of the Permanent Works, unless agreed by the Engineer.

Density shall be assessed from at least 3 cores drilled from each part of the trial length.

Position of Reinforcement and Tie Bars (i)

Compliance for the position of steel reinforcement and for the position and alignment of tie bars shall be checked by drilling additional cores from the slab unless they can be determined from cores taken for density assessment.

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Approval and Acceptance of Trial Length

1

Approval of the materials, mix proportions, plant, equipment and construction methods will be given when a trial length complies with the specifications. The Contractor shall not proceed with normal working until the trial length has been approved and any earlier defective trial lengths have been removed, unless they can be remedied to the satisfaction of the Engineer.

2

When approval has been given, the materials, mix proportions, plant, equipment and construction methods shall not thereafter be changed, without the approval of the Engineer except for maintenance of plant. Any changes in materials, mix proportions, plant, equipment, and construction methods shall entitle the Engineer to require the Contractor to lay a further trial length as described in this Clause to demonstrate that these changes will not adversely affect the permanent works.

3

Trial lengths which do not comply with the Specification, with the exception of areas within the pavement surface which can be remedied shall be removed immediately upon notification of deficiencies by the Engineer and the Contractor shall construct a further trial length.

6.3

REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE

6.3.1

Materials and Mix Designs for Pavement Quality Concrete

1

The constituent materials and mix designs for pavement quality control shall be as per Section 5: Part 16.

6.3.2

Workability of Pavement Quality Concrete

1

The workability of the concrete at the point of placing shall enable the concrete to be fully compacted and finished without undue flow. The optimum workability for the mix to suit the paving plant being used shall be determined by the Contractor and approved by the Engineer.

2

The workability shall be determined by the compacting factor test, or the Vebe test or alternatively for concrete grade C20 or below, by the slump test, all in accordance with BS 1881, at the minimum rate of one determination per 300 m2 of slab laid or 6 times per day,

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6.2.3

m

whichever is greater. For areas less than 300 m2 the rate shall be at least one determination to each 20 m length of slab or at least 3 times per day. 3

Alternatively the volumetric method of determining the Compacting Factor in BS 1881 may be used. Tests for workability shall be carried out at the point of placing, in conjunction with tests for strength and any tests for air content. The workability shall be maintained at the optimum within the following tolerances. Compacting Factor (CF) Slump Vebe

4

+0.03 +20mm +3 seconds or as agreed by the Engineer as a results of trial mixes.

Any alteration to the optimum workability necessitated by a change in conditions shall be agreed beforehand by the Engineer.

QCS 2014

5


Page 8

If any determination of workability gives result outside the tolerance, a further test shall be made immediately on the next available load of concrete. The average of the two consecutive results and the difference between them shall be calculated. If the average is not within the tolerance or the difference is greater than 0.06 for CF or 20 mm for slump, or 6 seconds for Vebe or other value agreed with the Engineer, subsequent samples shall be taken from the delivery vehicles, which shall not be allowed to discharge into the Works until compliance with the Specification has been established. Trial Mixes

1

For concrete grades C15 and above the Contractor shall carry out laboratory trials of designed mixes with the materials from all sources to be used in the Works, in accordance with BS EN 206 & BS 8500 unless recent data relating entirely to the proposed mix is approved by the Engineer.

2

The trial mixes shall be repeated if necessary until the proportions of ingredients are determined which will produce a concrete which complies in all respects with the Specification.

3

Apart from minor adjustments to the mix as permitted by BS EN 206 & BS 8500 any changes in sources of materials or mix proportions that are proposed by the Contractor during the course of the Works shall be assessed by making laboratory trial mixes and the construction of a further trial length unless otherwise approval is given by the Engineer.

6.3.4

Separation Membrane

1

A separation membrane shall be used between jointed reinforced concrete surface slabs or unreinforced concrete surface slabs and the sub base.

2

Separation membranes shall be impermeable plastic sheeting 125 microns thick laid flat without creases. Where an overlap of plastic sheets is necessary, this shall be at least 300 mm. There shall be no standing water on or under the membrane when the concrete is

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6.3.3

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placed upon it.

Under CRCP and CRCR a waterproof membrane shall be provided, which shall be a bituminous spray before concreting. Where a bituminous spray has been used to cure cement bound material or wet lean concrete then only those areas which have been damaged shall be resprayed after making good. The waterproof membrane shall be bituminous cutback in accordance with clause 5.12 of this Section.

6.3.5

General Requirements for Steel Reinforcement

1

Reinforcement shall comply with any of the following standards and be in prefabricated sheets or cages, or bars assembled on site and shall be free from oil, dirt, loose rust and scale:

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(a)

(Carbon steel bars for the reinforcement of concrete) BS 4449

(b)

(Cold-reduced steel wire for the reinforcement of concrete) BS 4482

(c)

(Steel fabric for the reinforcement of concrete) BS 4483

QCS 2014

(d)

2


Page 9

When deformed bars are used they shall conform to Type 2 bond classification of BS 4449.

Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in longitudinal bars shall be not less than 35 times bar diameters or 450 mm which ever is greater. In continuously reinforced concrete slabs (CRCP or CRCR) only one third of the laps may be in any one transverse section, except in single bay width construction where half the laps may be in any one transverse section. There shall be a minimum of 1.2 m longitudinally between groups of transverse laps or laps in prefabricated reinforcement sheets. Alternatively the reinforcement may be butt welded by a process approved by the Engineer.

3

Laps in a transverse reinforcement shall be a minimum of 300 mm. Where prefabricated

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reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is required in the transverse bars within the lap of the longitudinal reinforcement. These transverse bars may be cropped or fabricated shorter so that the requirements for cover are met. If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal supports and retained in position at the required depth below the finished surface and distance from the edge of the slab so as to ensure that the required cover is achieved. Reinforcement assembled on site shall be tied, or firmly fixed, by a procedure agreed with the Engineer, at sufficient intersections to provide sufficient rigidity to ensure that the reinforcement remains in the correct position during construction of the slab.

5

Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCR) is constructed in two layers, the reinforcement in the form of prefabricated sheets may be placed on or into the bottom layer which shall be spread and compacted to such a level that it will support the reinforcement without distortion at the required position in the slab. The sheets shall be tied together at overlaps and after the second layer has been spread and compacted, the reinforcement shall have the required cover.

6

When a reinforced concrete slab is constructed at maximum width the transverse reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal

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diameter bars at 600 mm centres. This reinforcement shall be at least 600 mm longer than one third of the width of the slab and be lapped to other transverse reinforcement bars or sheets, or be continuous across the whole width of each slab. 6.3.6

Jointed Reinforced Concrete Slabs

1

The reinforcement shall be so placed that after compaction of the concrete, the cover below the finished surface of the slab is 50 + 10 mm for slabs less than 200 mm thick, 60 + 10 mm for slabs 200 mm or more but less than 270 mm thick and 70+20 mm for slabs 270 mm thick or more.

2

The negative vertical tolerance shall not be permitted beneath road stud recesses.

3

Where traffic signal detector loops are to be installed, the minimum cover to the reinforcement from the surface shall be 100 mm.

QCS 2014


Page 10

4

The vertical cover between any longitudinal joint groove forming strip and any reinforcement or tie bars shall be at a minimum of 30 mm.

5

Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any transverse reinforcement shall terminate at 125+25 mm from the edges of the slab and longitudinal joints, where tie bars are used.

6

No longitudinal bars shall lie within 100 mm of a longitudinal joint. The reinforcement shall terminate 300 mm + 50 mm from any transverse joint, excluding emergency construction joints. Continuously Reinforced Concrete Slabs (CRCP or CRCR)

1

The reinforcement shall be Grade 460 deformed steel bars as detailed on the Contract Drawings.

2

The reinforcement shall consists of bars assembled on site, or of prefabricated sheets.

3

Except where otherwise shown on the Drawings the longitudinal bars shall be parallel to the centre line of the road.

4

The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at the mid depth of the specified thickness of the slab + 25 mm. No longitudinal bar shall lie

In reinforcement assembled on site, longitudinal bars shall be placed immediately above any transverse bars, which shall be at right angles to the longitudinal axis of the carriageway. Any transverse reinforcement shall terminate 125+25 mm from the edges of the slab and

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within 100mm of a longitudinal joint.

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6.3.7

longitudinal joints where tie bars are used. General Requirements for Transverse Joints

1

Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and shall be contraction, expansion or warping joints at the spacing shown on the Drawings such that for unreinforced concrete slabs the length/width ratio shall be not greater than 2.0.

2

Joints in the surface slab and sub-base shall be staggered so that they are not coincident vertically and are at least 1m apart.

3

Transverse joints shall be straight within the following tolerances along the intended line of the joint, which is the straight line transverse to the longitudinal axis of the carriageway at the position proposed by the Contractor and agreed by the Engineer, except at road junctions or roundabouts where the positions shall be as shown on the Drawings:

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6.3.8

(a)

Deviations of the filler board or bottom crack inducer from the intended line of the joint shall be not greater than ± 10 mm.

(b)

The best fit straight line through the joint groove as constructed shall be not more than 25 mm from the intended line of the joint.

(c)

Deviations of the joint groove from the best fit straight line of the joint shall be not greater than 10 mm.

QCS 2014

(d)


Page 11

When top groove formers and bottom crack inducers are used, the joint groove as constructed shall be located vertically above the bottom crack inducer within a horizontal tolerance of ± 25 mm.

Transverse joints on each side of a longitudinal joint shall be in line with each other and of the same type and width. The position of the joints relative to manholes and gullies shall be in accordance with the Drawings.

5

Transverse joints shall have a sealing groove which shall be sealed in compliance with Clause 6.3.20 of the specification.

6.3.9

Transverse Contraction Joints

1

Contraction joints shall consist of: Either a sawn joint groove, or

(b)

a wet formed joint groove and a bottom crack inducer

(c)

dowel bars

(d)

a sealing groove.

1

Expansion joints shall consist of:

(b)

dowel bars

(c)

a sealing groove.

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a joint filler board

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(a)

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Transverse Expansion Joints

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6.3.10

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(a)

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4

The filler board shall be positioned vertically within the prefabricated joint assemblies along the line of the joint and at such depth below the surface as will not impede the passage of the finishing beams on the paving machines.

3

The joint filler board together with the sealing groove shall provide a complete separation of adjacent slabs and any spaces around dowel bars and between the sub-base and the filler board shall be packed with a suitable compressible material after fixing the joint assembly.

6.3.11

Transverse Warping Joints

1

Warping joints shall consist of:

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(a)

Either a sawn joint groove, or

(b)

a wet formed joint groove and a bottom crack inducer

(c)

tie bars

(d)

a sealing groove.

6.3.12

Transverse Construction Joints

1

Construction joints made at the end of a working day in unreinforced concrete slabs and jointed reinforced concrete slabs shall be expansion joints or contraction joints. In the event of mechanical breakdown of the concreting machinery, or at the onset of adverse weather, emergency joints may be formed.

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Page 12

2

Emergency joints in unreinforced concrete slabs shall be either contraction or expansion joints not less than 2.5 m from the preceding or succeeding joint position.

3

Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the preceding or succeeding joint position. The stop end formwork shall be sufficiently rigid to ensure that dowel bars, tie bars or reinforcement will be held in position in compliance with the specification, and placed in such a position that it permits the longitudinal reinforcement to project through the joint for a distance of at least 750 mm.

4

Construction joints in continuously reinforced concrete slabs (CRCP and CRCR) in an emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement

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without the approval of the Engineer. The stop end formwork shall be sufficiently rigid to ensure that the longitudinal reinforcement and the tie bars projecting through the joint are held in the correct position. General Requirements for Longitudinal Joints

1

Longitudinal joints shall be provided in surface slabs between or at the centre of traffic lanes within the allowable positions as shown on the Drawings, so that bay widths are not greater than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with

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6.3.13

limestone aggregate) for reinforced concrete surface slabs with transverse reinforcement.

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Longitudinal joints shall be provided in CRCR between lanes or at the centre of lanes, within a tolerance of +150 mm so that bay widths are not greater than 6 m (or 7.6 m with limestone

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aggregate).

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Joints in the surface slab, road base or sub-base shall be staggered so that they are not coincident vertically and are least 300 mm apart. The positions of all longitudinal joints in any

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slab shall be agreed by the Engineer prior to construction of the slab. Wet-formed longitudinal joints shall consists of wet-formed joint grooves, bottom crack inducer and tie bars except where transverse reinforcement is permitted in lieu.

5

Longitudinal joints shall be constructed in the positions agreed by the Engineer within the following tolerances:

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(a)

Deviations of the bottom crack inducer from the intended line of the joint parallel to the axis of the road shall not be greater than +13 m.

(b)

The joint groove shall be located vertically above the bottom crack inducers within a horizontal tolerances of +25 mm.

(c)

The best fit line along the constructed joint groove, shall be not more than 25 mm from the intended line of the joint.

(d)

Deviations of the joint groove from the best fit line of the joint shall be not greater than 10 mm.

QCS 2014

6


Page 13

Tie bars may be replaced by continuous transverse reinforcement across the joints in continuously reinforced concrete slabs, which are constructed in more than one lane width in one operation, provided that the transverse reinforcement is a minimum of 12 mm diameter bars at 600 mm centres.

6.3.14

Longitudinal Construction Joints

1

Longitudinal construction joints between separate slabs shall have tie bars with a joint groove. Alternatively, if split forms are used, the transverse reinforcement, if 12 mm diameter or more, may be continued across the joint for a minimum of 500 mm or 30 times the diameter of the transverse reinforcement bars, whichever is greater. A joint sealing groove is not required in construction joints in continuously reinforced concrete road bases. Where the edge of the concrete slab is damaged it shall be made good to the approval of the Engineer before the adjacent slab is constructed.

6.3.15

Dowel Bars

1

Dowel bars shall be Grade 250 steel complying with BS 4449 and shall be free from oil, dirt, loose rust and scale. They shall be straight, free of burrs and other irregularities and the sliding ends sawn or, if approved by the Engineer, cropped cleanly with no protrusions outside the normal diameter of the bar. For expansion joints, dowel bars shall be 25mm diameter at 300 mm spacing, 600 mm long for slabs up to 239 mm thick and 32 mm diameter

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for slabs 240 mm thick or more. For contraction joints, dowels shall be 20 mm diameter at

240 mm thick or more.

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300 mm spacing 400 mm long for slabs up to 239 mm thick and 25 mm diameter for slabs

Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to construction of the slab. For contraction joints, as an alternative to prefabricated assemblies, dowel bars may be mechanically inserted with vibration into the concrete by a method which shall ensure full recompaction of the concrete around the dowel bars and the surface finished by a diagonal finishing beam. Or a longitudinal oscillating float travelling across the slab.

3

Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm.

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They shall be aligned parallel to the finished surface of the slab, to the centre line of the carriageway and to each other within the following tolerances: (a)

for bars supported on cradles prior to construction of the slab and for inserted bars in two layers construction prior to placing the top layer: (i)

All bars in a joint shall be within ± 3 mm per 300 mm length of bars.

(ii)

Two thirds of the bars shall be within ± 2 mm per 300 mm length of bar.

(iii)

No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm length of bar in either the horizontal or vertical plane.

(b)

for all bars, after construction of the slab: (i)

Twice the tolerances for alignment as in (i) above.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements (ii)

Page 14

Equally positioned about the intended line of the joint within a tolerance of ± 25 mm.

4

Cradles supporting dowel bars shall not extend across the line of the joint.

5

Dowel bars, supported on cradles in assemblies, when subjected to a load of 110N applied at either end and in either the vertical or horizontal direction (upwards and downwards and both directions horizontally) shall not deflect more than the following limits:

6

Two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm per 300 mm length of bar.

7

The remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm

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length of bar.

The assembly of dowel bars and supporting cradles, including the joint filler board in the case of expansion joints shall have the following degree of rigidity when fixed in position:

9

For expansion joints the deflection of the top edge of the filler board shall be not greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical

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face of the joint filler board and distributed over a length of 600 mm by means of

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a bar or timber packing at mid depth and midway between individual fixings, or 300 mm from either end of any length of filler board, if a continuous fixing is used.

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The residual deflection after removal of the load shall be not more than 3 mm. The joint assembly fixings to the sub-base shall not fail under the 1.3kN load applied for testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.

11

The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail before the load reaches 2.6 kN when applied over a length of 600 mm by means

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of a bar or timber packing placed as near to the level of the line of fixings as practicable. Failure of the fixings shall be deemed to be when there is displacement of the assemblies by more than 3 mm with any form of fixing, under the test load. The displacement shall be measured at the nearest part of the assembly to the centre of the bar or timber packing. 13

Dowel bars shall be covered by a thin plastic sheath over the whole length of the bar. The sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The sheathed bar shall comply with the following pull out test:

QCS 2014

14


Page 15

Four bars shall be taken at random from stock and without any special preparation shall be covered by sheaths. The dowel bars which have been sheathed shall be cast centrally into concrete specimens 150x150x450 mm, made of the same mix proportions to be used in the pavement, but with a maximum nominal aggregate size of 20 mm and cured in accordance with BS 1881.

At 7 days a tensile load shall be applied to achieve a movement

of the bar at least 0.25 mm.

The average bond stress to achieve this movement

shall be not greater than 0.14 N/mm2. 15

For expansion joints a closely fitting cap 100 mm long consisting of waterproofed cardboard

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or an approved synthetic material shall be placed over one end of each dowel bar. An expansion space 10 mm greater than the thickness of the joint filler board shall be formed between the end of the cap and the end of the dowel bar. Tie Bars

17

Tie bars in transverse or longitudinal joints shall be Grade 250 steel or Grade 460 deformed steel bars complying with BS 4449, in accordance with the requirements given below and Table 6.2. Deformed bars shall have Type 2 bond classification. Tie bars shall be free from oil, dirt, loose rust and scale. Tie bars which are to be cranked and later straightened shall be Grade 250.

18

Tie bars projecting across a longitudinal joint shall be protected from corrosion by a flexible polymeric corrosion resistant coating, bonded onto the previously cleaned centre section, leaving between 250 mm and 300 mm of each of the bars uncoated.

19

Where tie bars are cranked for construction joints and later straightened the coating shall be shown to be capable of being straightened through 90 degrees without cracking. The coating shall also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS 3900 : Part F12, without showing any visible cracking, or corrosion of the protected part of the bar. Any damage observed on the coating after straightening shall be made good before the concrete is placed.

20

Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid assemblies with adequate supports and fixings to remain firmly in position during the construction of the slab.

21

Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from above using a method which ensures recompaction of the concrete around the tie bars.

22

At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted into the side of the slab by a method which ensures recompaction of the concrete around the tie bars and adequate bond and which shall be approved by the Engineer.

23

Tie bars shall be positioned and remain within the middle third of the slab depth, approximately parallel to the surface and approximately perpendicular to the line of the joint, with the centre of each bar on the intended line of the joints within a tolerance of ± 50 mm,

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16

and with a minimum cover of 30 mm below any top crack inducer or joint groove for slabs 200 mm thick or more, or 20 mm for slabs up to 200 mm thick.

QCS 2014

24


Page 16

At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m long and of the same grade and size as the longitudinal reinforcement, and shall be fixed at twice the normal spacing midway between the longitudinal reinforcement bars so that 750 mm ± 50 mm extends each side of the joint at the same level as the longitudinal reinforcement and be tied to the transverse reinforcement. Where paving from a construction joint is not resumed within 5 days, and extra longitudinal reinforcement bar at 8 m long shall be lapped and tied to each tie bar. These extra bars may be combined with the tie bars. Where the spacing between longitudinal reinforcement and the extra 8 m long bars is less than 90 mm, the nominal size of aggregate shall be 20 mm for a sufficient number of concrete batches to complete that section of pavement. Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be placed at the same level as the transverse reinforcement and tied to the longitudinal reinforcement.

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25

Length (mm)

Spacing (mm)

460

1500

Twice the spacing of main reinforcement

12

250 or 460 deformed

1000 750

600 600

12

250 or 460 deformed

1000 750

300 600

12

250 or 460 deformed

1000 750

600 600

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As for main reinforcement

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Transverse construction joints in continuously reinforced concrete Emergency construction joints in jointed reinforced concrete slabs other than at contraction or expansion joints

Grade of Steel

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Diameter (mm)

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Joints

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Table 6.2 Tie Bar Details

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Warping joints

Longitudinal. All joints, except where transverse reinforcement is permitted in lieu

Note: The transverse reinforcement may be continued across the joint in reinforced concrete with the approval of the Engineer if the bars are of a minimum nominal diameter of 12 mm and the bars are protected from corrosion and the cover is as required in this Clause. 6.3.16

Joint Grooves

1

Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.

QCS 2014


Page 17

Transverse joint grooves which are initially constructed less than the full width of the slab shall be completed by sawing through to the edge of the slab and across longitudinal joints as soon as any forms have been removed and before an induced crack develops at the joint.

3

Sawn transverse joint grooves shall be undertaken as soon as possible after the concrete has hardened sufficiently to enable a sharp edged groove to be produced without disrupting the concrete and before random cracks develop in the slab. The grooves shall be between 1/4 and 1/3 of the specified depth of the slab and of any convenient width not less than 3mm. The sealing groove may be constructed at the same time to be sawn to the required width later. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall be sawn immediately before sealing.

4

Construction Joint Grooves in Surface Slabs shall be formed by fixing a groove-former, strip or cork seal along the top edge of the slab already constructed, before concreting the adjacent slab. Where the edge of the concrete is damaged it shall be ground or made good to the approval of the Engineer before fixing the groove forming strip.

5

Alternatively the subsequent slab may be placed adjacent to the first and a sealing groove sawn later in the hardened concrete to the minimum depth required in Table 6.3 or to the manufacturer's instructions if greater, and to sufficient width to eliminate minor spalling of the joint arris, up to a maximum of 25mm for longitudinal joints and 40mm for transverse joints. The joints shall be sealed.

6.3.17

Groove Formers and Bottom Crack Inducers

1

Except where joint grooves are sawn, a bottom crack inducer shall be provided at each contraction, warping or longitudinal joint position.

2

The bottom crack inducer shall be an approved triangular or inverted Y-shaped fillet, with a base width not less than the height, made of timber or rigid synthetic material. It shall be firmly fixed to the sub-base so as to remain in position during the whole process of constructing the slab.

3

The combined depth of groove formers and bottom crack inducers shall be between 1/4 and 1/3 of the depth of the slab and the difference between the depth of the groove former and the height of the bottom crack inducer shall not be greater than 20mm.

4

The groove former for wet formed transverse joint grooves shall be made of an approved rigid material of a width not greater than the required width of sealing groove as in Table 6.3. The groove former shall be smooth sides with rounded protrusions no greater than 3mm. Any removable part of the groove former may be tapered with a maximum difference in width of 2mm in 20mm depth.

5

Groove forming sealing strips for wet formed longitudinal joints shall be of firm compressible strips of ethylene vinyl acetate foam of a minimum density of 90kg/m3, or synthetic rubber, or equivalent material subject to approval by the Engineer. They shall have a minimum thickness of 5mm and shall be sufficiently rigid to remain vertical and straight in the concrete without curving or stretching. They shall be inserted continuously along the joint.

6

For CRCP Universal Beam Anchorage Transverse Joints one side of the beam shall be separated from the CRCP slab by an expansion joint filler board against the vertical face and ethylene vinyl acetate foam or similar compressible material, between 5 mm and 10mm thick, stuck under the top flange.

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QCS 2014


Page 18

Joint Filler Board

1

Joint filler board for expansion joints and manhole and gully slab joint shall be 25mm thickness unless otherwise shown in the Drawings, within a tolerance of ± 1.5mm.

2

It shall be self expanding cork seal or a firm compressible material or a bonded combination of compressible and rigid materials of sufficient rigidity to resist deformation during the passage of the concrete paving plant.

3

The depth of the joint filler board for manhole and gully slabs shall be the full depth of the slab minus the depth of the sealing groove. In expansion joints, the filler board shall have a ridged top as shown on the Drawings, except where a sealing groove former is permitted by the Engineer.

4

Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the sheathed dowel bar.

6.3.19

Preparation and Sealing of Joint Grooves

1

All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed using one of the joint seals described. Additionally longitudinal joints which are sawn or widened shall be sealed.

2

Joint grooves shall be prepared in accordance with BS 5212: Part 2 and in compliance with (a) through (g) below:

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that part of the groove former used to form the sealing groove or any temporary seal shall be removed cleanly without damaging the joint arises to a minimum depth of 25 mm where compression seals are used or otherwise to such depth as will provide

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(a)

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6.3.18

if joint grooves are not initially constructed to provide the minimum dimensions for the joint seals as given in Table 6.3, they shall be widened by sawing. Joint grooves formed by tapered formers need not to be widened. The sealing grooves shall be cleaned out immediately after sawing using high pressure water jets, to remove all slurry from the joint, before the slurry hardens. if rough arrises develop when grooves are made they shall be ground to provide a chamfer approximately 5mm wide. If the groove is at an angle up to 10 degrees from the perpendicular to the surface, the overhanging edge of the sealing groove shall be sawn or ground perpendicular. If spalling occurs or the angle of the former is greater than 10 degrees the joint sealing groove shall be sawn wider and perpendicular to the surface to encompass the defects up to a maximum width, including any chamfer, of 40 mm for transverse joints and 25mm for longitudinal joints. If the spalling cannot be

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an applied seal to the dimensions as will provide in Table 6.3.

so eliminated then the arris shall be repaired by an approved thin bonded arris repair using cementitious materials. (d)

for applied sealants the sides of the joint sealing groove shall be scoured by dry abrasive blasting. This shall not be carried out before the characteristics compressive 2 strength of the concrete is expected to reach 15 N/mm . When compression seals are used, the sides of the groove may be ground or wire brushed.

QCS 2014


Page 19

(e)

for hot and cold applied sealants, compressible caulking material, debonding strip or tape or cord compatible with the sealant, of a suitable size to fill the width of the sealing groove shall be firmly packed or stuck in the bottom of the sealing groove to such a depth so as to provide the correct depth of seal as described in Table 6.3 with the top of the seal at the correct depth below the surface of the concrete.

(f)

all grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil free compressed air. The groove shall be clean and dry at the time of priming and sealing.

(g)

for applied sealants the joint grooves shall be primed with the relevant primer for the hot or cold applied sealant in accordance with the manufacturer's recommendations and with BS 5212: Part 2, except that when necessary the joint grooves may be

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primed and sealed earlier than 14 days after construction, as soon as the grooves have been grit-blasted and cleaned. Sealing with Applied Sealants

1

Sealing shall be carried out continuously along the full length of joint in any one rip, except for remedial areas. When hot or cold applied sealants are used the sealant shall be applied within the minimum and maximum drying times of the primer recommended by the manufacturer. Priming and sealing with applied sealants shall not be carried out when the naturally occurring temperature in the joint groove to be sealed is below 10 C except between 8 C and 10 C it may be carried out when the temperature is rising.

2

Hot applied sealants shall be heated in and applied from a thermostatically controlled, indirectly heated dispenser with the recirculating pump. The sealant shall not be heated to a temperature higher than the safe heating temperature nor for a period longer than the safe heating period, both as specified by the manufacturer. The dispenser shall be cleaned out at the end of each day and reheated materials shall not be used.

3

The components of cold-applied sealants shall be thoroughly mixed in the correct proportions in accordance with the manufacturer's instructions using an automatic metering and mixing dispenser approved by the Engineer or, for hand application, using a power operated paddle mixer for sufficient time to produce homogenous mix without entrapped air. As soon as possible after mixing and within the worklife of the sealant, the material shall be dispensed into the joint, or applied using a caulking gun, to the correct level below the concrete surface. The tack-free time shall be achieved within 3 hours, for machine dispensed material, or within 12 hours for hand applied material.

4

Test certificates shall be supplied from an approved testing laboratory stating that the sealant complies with the relevant standard. Site testing of cold applied sealants shall be in accordance with BS 5212: Part 2. Hot-applied sealants shall be sampled at the same rate and checked for dimensions as in BS 5212: Part 2 and by the penetration test of the relevant standard for the material.

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6.3.20

QCS 2014


Page 20

Table 6.3 Dimensions of Applied Joint Seals Hot Applied (mm)

Impregnated Foam Compression Strips (mm)

Depth of Seal Below the Concrete Surface(mm)

13 (Note 2) 20 30 30 10

13 15 20 20 10

15 20 25 25 13

30 30 40 40 30

5+2 5+2 5+2 7+2 5+2

10

10

13

30

20

15

20

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Cold Applied (mm)

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Contraction: 15 and under Over 15 to 20 Over 20 to 25 Expansion All Transverse Warping Longitudinal Joints (if sealed) Gully and Manhole Slabs

Minimum Width (mm)

30

0 to 5

0 to 3

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Type and Spacing of Joints (m)

The depth of seal is that part in contact with the vertical face of the joint groove. The depth of seal below the surface shall be taken at the centre of an applied seal relative to a short straight edge, 150mm long, placed centrally across the joint within 7 days of sealing.

Note: (2)

For cork seals other than in construction joints, grooves shall be 20 mm wide and 50 mm deep.

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Note: (1)

Sealing with Compression Seals

1

When compression seals are used, the widths of the seal shall be selected in relation to the width of the sealing groove, the bay lengths and manufacturer's recommendations so that the estimated maximum width of the joint opening shall be not more than 70% of the original width of the seal, the estimated maximum width being calculated on the basis of a movement of 4mm per 10m run of slab.

2

The maximum calculated width of sealing groove shall be 30mm.

3

The depth of groove shall be such that the contact face of the seal with the side of the groove shall be not less than 20mm and that the top of the seal shall be a minimum of 3mm below the surface of the concrete.

4

Compression seals shall be inserted into the grooves without prior extension or rotation and, where recommended by the manufacturer, with a lubricant adhesive which is compatible with the seal and the concrete. The adhesive shall be applied to both sides of the sealing groove or the seal, or to both. The seal shall be positioned with its axis perpendicular to the concrete surface. Excess adhesive on top of the seal shall be removed to prevent adhesion of the top faces of the seal under compression.

5

Except when compression seals are used in longitudinal joints the transverse joint seal shall be continuous across the slab and the longitudinal joint groove forming strips shall be cut to the required depth after the concrete has hardened for the transverse seal to be inserted.

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6.3.21

QCS 2014


Page 21

If compression seals are used in longitudinal joints where the grooves have been sawn after construction of the slab they shall be continuous across transverse joints, with the transverse seals butted and fixed to the longitudinal seals with adhesive.

6.3.22

Joint Seals

1

Joint seals shall consist of hot or cold applied sealants or compression seals or self expanding cork seals.

2

Hot-applied sealants shall comply with ASTM Standard D3406, or D7116 (for fuel-resistant sealant).

3

For joints between concrete surface slabs and bituminous surfacing, polymer modified bitumen sealing strips shall be used and applied in accordance with the manufacturer's instructions. Hot-applied sealants complying with BS 2499 & BS EN 14188 may be used for such joints and in joints in asphalt kerbs laid on concrete pavements.

4

Cold applied sealants shall be Type N complying with BS 5212: Part 1 except that Type F shall be used for lay-bys and hardstandings.

5

For joints in kerbs and joints other than in pavements, seals may be any of the pavement sealants if they have the suitable characteristics for the application. Also, gunning grade cold applied plasticised bituminous rubber sealant or gunning grades of two part polysulphidbased sealants complying with BS EN ISO 11600 may be used.

6

Alternatively, polyurethane-based sealing compounds may be used provided their performance is not inferior to BS EN ISO 11600 material.

7

Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing strip, or rubber seals made of polychloroprene elastomers complying with BS 2752 and conforming to the requirements of ASTM Standard D2628-91.

8

Compression seals shall be shaped so that they will remain compressed at all times and shall have a minimum of 20mm contact face with the sides of the sealing groove. If lubricant adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant to abrasion, oxidisation, fuels and salt.

9

Self Expanding Cork seals may be used in longitudinal joints, joints for manhole and gully slabs and for transverse joints in short lengths of individual slabs or for replaced slabs.

6.3.23

Joints at Manhole and Gully Slabs

1

Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be contained in separate small slabs, which shall be larger than the exterior of the manhole and gully shafts, including any concrete surround less than 150mm below the underside of the sub-base layer. The joint around the manhole or gully slab shall be vertical and incorporate joint filler board but without dowel bars and tie bars.

2

Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint, extending the gully slab as necessary to a maximum of 2m. Where this is impractical, an extra tied warping joint shall be provided adjacent to or within the gully slab and at least 2m from the next transverse joint. If the edge of an isolator slab is within 1m of any longitudinal joint the isolator slab shall be extended to that joint.

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Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or longitudinal joints. If the manhole is within the middle third of the bay length a warping joint shall be constructed on one side of the manhole slab across the whole width of the bay to the nearest longitudinal joint.

4

Reinforcement as shown on the Drawings shall be placed in the main concrete slabs in the corners between the manhole and gully slab and the transverse or longitudinal joints. Extra reinforcement as described in the Contract shall be placed in reinforced concrete slabs around the manhole or gully slabs.

5

Manhole and gully slabs shall have oblique corners, minimum 200mm long, at approximately 45 degrees to the axis of the pavement at all corners which are not adjacent to a transverse or longitudinal joint in the main slab.

6

Reinforcement as shown on the Drawings shall be placed in the gully or manhole slab and concrete grade C40 shall be placed by hand in the space between the main slab and the manhole frame. The concrete shall be fully compacted and finished.

7

A sealing groove shall be made directly above the joint filler board and sealed.

6.3.24

Inspection of Dowel Bars

1

The position and alignment of dowel bars at contraction and expansion joints shall be checked by measurement relative to the side form or guide wires.

2

When the slab has been constructed, the position and alignment of dowel bars and any filler board shall be measured after carefully exposing them across the whole width of the slab. When the joint is an expansion joint the top of the filler board shall first be exposed sufficiently in the plastic concrete to permit measurement of any lateral or vertical displacement of the board. During the course of normal working these measurements shall be carried out at a rate of one joint per 1500m length of slab or one per 5 working days whichever occurs the sooner. For small areas the rate shall be decided by the Engineer.

3

If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the next two joints shall be inspected. If only one joint of the three is defective, the rate of checking shall be increased to one joint per day until the Engineer is satisfied that compliance is being achieved. In the event of non-compliance in two or more successive joints, the Contractor shall revert to the construction of trial lengths and make any necessary alterations to the concrete mix, paving plant or methods until the dowel bar position and alignment is satisfactory.

4

After the dowel bars have been examined, the remainder of the concrete shall be removed 500mm on each side of the line of the joint, and reinstated to the satisfaction of the Engineer. Alternatively if the dowels are examined in the penultimate joint of a day's work that joint shall be made a construction joint for the next day's work and the remainder of the concrete in the last slab may be discarded.

6.3.25

Side Forms, Rails and Guide Wires

1

All side forms and rails shall be made of steel and be sufficiently robust and rigid to support the weight and pressure caused by the paving equipment. Side forms for use with wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below the top of the forms.

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The forms shall be secured by using not less than three pins for each 3m length having one pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint, free from play or movement in any direction. Forms shall be cleaned and oiled immediately before each use. The rails or running surface shall be kept clean in front of the wheels of any paving machine. The forms shall be straight within a tolerance of 3mm in 3m.

3

The forms shall be bedded on low moisture content cement mortar or concrete grade C7.5 and set to the pavement surface level as shown on the Drawings within a tolerance of +3mm. The bedding shall not extend under the slab. There shall be no vertical step between the end of adjacent forms greater than 3mm. The horizontal alignment for forms shall be to the required alignment of the pavement edge as shown on the Drawings within a tolerance of + 10mm. The mortar or concrete bedding shall be broken out after use.

4

Side forms shall not be removed earlier than 6 hours after the completion of the construction of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie bars during the removal of the forms. If the removal of forms results in any damage to the concrete the period of 6 hours shall be increased to that which is necessary to avoid further damage and the Contractor shall make good the damaged areas.

5

Unless otherwise agreed by the Engineer, a guide wire shall be provided along each side of the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant height above and parallel to the required edges of the slab as shown on the Drawings, within a vertical tolerance of + 3mm. Additionally one of the wires shall be at a constant horizontal distance from the required edge of the pavement as shown in the drawings within a lateral tolerance of + 10mm.

6.3.26

Delivery, Storage and Batching of Concreting Materials

1

Aggregate for roadworks shall be delivered to and stored on the Site in one of the following ways: in separate nominal single sizes of coarse aggregate and fine aggregate.

(b)

as graded coarse aggregate of appropriate size and fine aggregate.

(c)

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as all-in aggregate for grades C20 to below.

If the Contractor proposes to blend aggregate off the site from two separate sources, he shall obtain the Engineer's approval for the blending process, and for the arrangements for inspection during the course of the work.

3

Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Fine aggregate nominally below 5 mm sieve size shall have been deposited at the site for at least 8 hours before use.

4

Batching plant and storage for aggregate shall comply with the following requirements as appropriate to the method of delivery:

m

2

(a)

if separate gradings of aggregate are stockpiled, separate accommodation shall be provided for each nominal size of coarse aggregate or blend of fine aggregate. The base for stockpiles shall be suitably surfaced to prevent contamination of the aggregate. Drainage of the stockpile bases shall be provided.

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(b)

aggregate shall be measured by mass and provision shall be made for batching each nominal size or blend of aggregate separately, to the tolerances specified in BS EN 206 & BS 8500.

(c)

all-in aggregate shall be delivered and stockpiled in such a manner and to a height that avoids segregation.

Mixing Concrete

1

Mixing concrete shall conform to the requirements of Section 5 Part 7 except as amended herein.

2

Concrete shall be mixed on site in a stationary batch type mixer in compliance with BS EN 206 & BS 8500 unless with the approval of the Engineer, ready mixed concrete is supplied from an approved source.

3

The drums or blades of all mixers shall be operated at the speed using for testing, in accordance with BS 3963 for the mix proportions required, within a tolerance of ± 1 revolution per minute. The mixing blades of a pan mixer shall be maintained within the tolerances specified by the manufacturers of the mixer and the blades shall be replaced when it is no longer possible to maintain the tolerances by adjustment. All drums or pans which have been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed in them.

4

The rated output of the batching and mixing plant shall exceed by at least a third the amount of concrete that is required at a constant rate to enable the paving train to move forward continuously, at the planned rate of progress.

6.3.28

Transport and Delivery

1

Transportation, delivery of concrete shall conform to the requirements of Section 5 Part 8.

6.3.29

General Requirements for Construction by Machine

1

The concrete slab shall be constructed in a continuous process by either slip-form or by fixed form paving plant or by small paving machines or hand guided methods.

2

The slab may be constructed in either one or two layers. In two layer construction the thickness of the top layer shall be not less than 50mm or twice the maximum size of the coarse aggregate whichever is greater, and shall be at least 15 mm thick than the depth of the groove former, if used.

3

While the concrete is still plastic its surface shall be brush-textured and the surface and edges shall be cured.

4

The spreading, compacting and finishing of the concrete shall be carried out as rapidly as possible and the paving operation shall be so arranged as to ensure that the time between the mixing of the first batch of concrete in any transverse section of the slab and the application of the sprayed curing membrane to the surface of that section shall not exceed those given in Table 6.4.

5

Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge next to a transverse joint while the concrete is plastic. In continuously reinforced concrete pavement the slab shall be marked with the chainage at intervals not greater than 50m apart.

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6.3.27

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Construction by Fixed Form Paving Machines

1

A fixed form paving train shall consist of separate, powered machines which spread compact and finish the concrete in a continuous operation.

2

Concrete shall be discharged without segregation into a hopper spreader which is equipped with the means of controlling its rate of deposition onto the sub-base or onto the lower layer. The concrete shall be spread in each layer without segregation and to a uniform uncompacted density over the whole area of the slab.

3

The deposited concrete shall be struck off to the necessary level by the underside of the hopper as it is traversed across the spreading machine.

4

The machine shall be capable of being rapidly adjusted for changes in average and differential surcharge necessitated by changes in slab thickness or crossfall. When the slab is constructed in two layers, the spreading of the concrete in the top layer shall follow the completion of the bottom layer within the times given in Table 6.4.

5

Prior to being compacted, the surface level of each loose spread layer shall be adjusted to the correct surcharge by means of rotating strike-off blades or a screw device.

6

The concrete shall be compacted by vibration or by a combination of vibration and mechanical tamping throughout the full depth of the slab. Poker vibrators shall be used in each layer adjacent to the side forms and the edge of a previously constructed slab.

7

The initial regulation and finish to the surface of the slab shall be effected by means of a beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam shall be readily adjustable for both height and tilt.

8

When grooves are wet-formed the concrete shall be recompacted around the former by a hand held vibrating plate compactor drawn along or on each side of the joint, prior to regulation of the surface by the diagonal finishing beam. Or recompacted and finished if the former is inserted after the finishing beam.

9

The regulation and finishing of the surface of the slab shall be carried out by a machine which incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and span the full width of the slab. The leading beam shall be vibrated. The beams shall be supported on a carriage, the level of which shall be controlled by the average level of not less than four points evenly spaced over at least 3.5m of the supporting rail, beam or slab, on each side of the slab that is being constructed. After the final regulation and before texture is applied any excess concrete on top of the groove former shall be removed.

10

When a concrete slab is constructed in more than one width, flanged wheels on the paving machines shall not be run directly on the surface of any completed part of the slab. The second or subsequent slabs shall be constructed either by supporting machines with flanged wheels on flat bottom section rails weighing not less than 15 kg/m laid on the surface of the completed slab, or by replacing the flanged wheels on that side of the machines by smooth flangeless wheel.. Flangeless wheels or rails shall be positioned sufficiently far from the edge of the slab to avoid damage to that edge.

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6.3.30

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Construction by Slip-Form Paving Machine

1

A slip-form paving train shall consist of powered machines which spread, compact and finish the concrete in a continuous operation.

2

The slip-form paving machine shall compact the concrete by internal vibration and shape it between sliding side forms or over fixed side forms by means of either a conforming plate or by vibrating and oscillating finishing beams.

3

The concrete shall be deposited without segregation in front of the slip-form paver across its whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of a strike-off plate or a screw auger device extending across the whole width of the slab. The equipment for striking off the concrete shall be capable of being rapidly adjusted for changes of the average and differential surcharge necessitated by changes in slab thickness or crossfall.

4

The level of the conforming plate and finishing beams shall be controlled automatically from the guide wires by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be controlled automatically from the guide wire by at least one sensor attached to the paver. The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative to the guide wire or to the surface and edge of the slab.

5

Slip-form paving machines shall have a vibration of variable output, with a maximum energy output of not less than 2.5 kW per metre width of slab per 300mm depth of slab for a laying speed of up to 1.5m per minute or pro rata for higher speeds. The machines shall be of sufficient mass to provide adequate reaction on the traction units to maintain forward movements during the placing of concrete in all situations.

6

Where grooves are wet-formed the concrete shall be compacted around the former by a separate vibrating plate compactor with twin plates. The groove former shall be compacted to the correct level by a vibrating pan which may be included with the transverse joint finishing beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the surface along the joint. Alternatively the surface shall be regulated with a longitudinal oscillating float travelling across the slab. Any excess concrete on top of the groove former shall be removed before the surface is textured.

7

Where a concrete surface slab is constructed in more than one width or where the edge needs to be matched for level to another section of surface slab, and the surface levels at the edges are not achieved, paving shall be carried out over separate fixed side forms to support the edge to the required levels.

6.3.32

Construction by Small Paving Machines or Hand Guided Methods

1

As an alternative to fixed form or slip-form paving trains, the concrete slab may be constructed using parts of trains, small paving machines, truss type finishing beams or hand guided methods. Hand tamping beams may only be used for short lengths or infill bays or tapers. Reinforcement, dowel bars and tie bars shall be supported in position, except where two layer construction is used and reinforcement is placed on the bottom layer in a method of construction approved by the Engineer.

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6.3.31

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The concrete shall be spread uniformly without segregation or varying degrees of precompaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a screed or auger so that the average and differential surcharge is sufficient for the surface of the slab to be at the correct levels after compaction of the concrete.

3

The concrete shall be compacted by vibrating finishing beams across the slab and with vibrating pokers adjacent to the side forms or the edge of a previously constructed slab. In addition, internal poker vibration shall be used for slabs thicker than 200mm and may be used for lesser thicknesses. When used, the pokers shall be at points not more than 500mm apart over the whole area of the slab, or drawn continuously across the slab in front of the finishing beams.

4

The finishing beams shall be metal with a contact face at least 50mm wide. They shall be rigid or supported by a frame or truss without sag across the width of slab being paved. The beams shall be supported on rails or forms or an adjacent slab and shall be moved forward at a steady speed of 0.5m to 2m per minute whilst vibrating, to compact the concrete and to produce a smooth surface finished to the correct crossfalls, crowns and levels relative to the top of the forms or adjacent slab.

5

Any irregularities at wet-formed joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further application of a twin vibrating finishing beam. All slabs shall be checked for level using a straight edge at least 4m long. Any excess concrete on top of the groove former shall be removed before the surface is textured.

6

The surface shall be brush textured.

7

The surface shall be cured within the time to completion given in Table 6.4

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Table 6.4 Maximum Working Times

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Temperature of concrete at discharge from the delivery vehicle

Reinforced Concrete Slabs Consumed in Two layers Mixing first layer to finishing concrete

Not more than 25 °C

All other Concrete Slabs

between layers

Mixing first layer to finishing concrete

between layers in 2 layer work

3 hours

1/2 hour

3 hours

1 1/2 hours

Exceeding 25 °C

2 hours

1/2 hour

2 hours

1 hour

Exceeding 30 °C

unacceptable for paving

unacceptable for paving

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Surface Textures

1

After the final regulation of the surface of the slab and before the application of the curing membrane, the surface of concrete slabs to be used as running surfaces shall be brush textured in a direction at right angles to the longitudinal axis of the carriageway.

2

The texture shall be applied evenly across the slab in one direction by a brush not less than 450 mm wide. The texture shall be uniform both along and across the slab.

3

Curing

4

Immediately after the surface treatment, the surface and exposed edges of surface slabs shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter period). This will be by the application of an approved resin based aluminised curing compound, or polythene sheeting or an approved sprayed plastic film which hardens into a peelable plastic sheet. It shall be removed before road marking and opening to traffic.

5

Resin based aluminised curing compound shall contain sufficient flake aluminium in finely divided dispersion to produce a complete coverage of the sprayed surface with a metallic finish. The compound shall become stable and impervious to evaporation of water from the concrete surface within 560 minutes of application and shall have an efficiency index of 90% when tested as described in BS 7542.

6

The curing compound shall not react chemically with the concrete to be cured and shall not crack, peel or disintegrate within three weeks after application.

7

Prior to application, the contents of any containers shall be thoroughly agitated. The curing compound shall be mechanically applied using a fine spray onto the surface at a rate of at least 0.221L/m2. For the sides of slip-formed slabs or when the side forms are removed within 24 hours and for small areas where mechanical application cannot be used, the compound shall be sprayed by hand lance at a rate of at least 0.271/m2. The rate of spread shall be checked during construction of each trial length and subsequently whenever required by the Engineer.

8

The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound in its container during spraying.

9

Continuously reinforced concrete road bases shall also be cured. Wet lean concrete road bases and sub-bases shall also be cured.

10

REQUIREMENTS FOR WET LEAN CONCRETE

11

Materials and Mix Designs

12

The constituent materials and the grades of concrete for wet lean mix shall comply with the requirements of Section 5: Part 16.

13

Placing

14

Wet lean concrete shall be spread uniformly without segregation and without varying degrees of pre-compaction.

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6.3.33

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The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that after compaction the surface is at the required level.

16

Compaction

17

The spread wet lean concrete shall be compacted using internal or external vibration, or combination of both to meet the required density.

18

Compaction and finishing to level shall be completed within the times given in Table 6.4.

19

Joints

20

At transverse and longitudinal construction joints between two separately constructed slabs, the previously laid slab end or edge shall present a vertical face before construction of subsequent slabs.

21

Longitudinal joints in wet lean concrete shall be staggered by at least 300mm from the position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse joints.

6.3.34

Strength

1

From each sample, three cubes of the appropriate size shall be made, cured and tested in compliance with BS 1881.

2

One of each group shall be tested at 7 days and the other two at 28 days. The cubes shall be assessed for compliance on groups of four 28-day test results in accordance with BS EN 206 & BS 8500 for compliance with the grade required.

3

If the average value of any four consecutive results of tests at 7 days falls below the required values the cement content of the mix shall be increased by an amount agreed with the Engineer which shall be maintained until the corresponding 28-day test results have been assessed.

6.3.35

Trial Mixes

1

Trial mixes complying with the requirements for pavement quality concrete shall be required for designed mixes for Grade C15 and above, unless recent data relating to the proposed mix is approved by the Engineer.

6.3.36

Trial Length

1

At least 10 days before the start of the main wet lean concrete works a trial length of at least 400 m2 for mechanised construction and 30m for hand guided methods shall be constructed.

2

The trial length shall be laid to assess the suitability of the proposed material, plant, equipment and construction methods to meet the requirements of the Specification.

3

The main construction in the permanent works shall not start until the trial length has been approved by the Engineer.

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If any trial length does not conform to the Specification another trial length shall be constructed. Trial lengths not complying with the Specification shall be removed unless they can be rectified to comply with the Specification to the satisfaction of the Engineer.

5

After approval has been given, the material plant, equipment and construction methods shall not be changed without the approval of the Engineer.

6

Any proposed changes shall entitle the Engineer to require the Contractor to lay a further trial length to assess the suitability of the proposed changes.

6.3.37

Surface Finish

1

The surface of the wet lean concrete after compaction and finishing and before overlaying shall be free from ridges, loose material, pot holes, ruts or other defects.

2

The surface texture shall comply with the sub-Clause for pavement quality concrete, Section 5: Part 16.

6.4

REQUIREMENTS FOR CEMENT BOUND MATERIALS

6.4.1

General Requirements for Cement Bound Materials

1

Cement bound materials shall be made and constructed as described in the following clauses.

2

Cement bound materials shall be tested in accordance with this specification for the requirements of Table 6.5

3

Cement water and aggregates shall comply with the requirements of the Section 5: Part 16.

4

Cement for use in all cement bound materials and aggregates for use in CBM3 and CBM4 shall be delivered and stored in compliance with the requirements of Section 5: Part 16.

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Table 6.5 Cement Bound Materials Field Requirements

Category

Mixing Plant

Method of Batching

Moisture Content

Minimum Compaction

CBM 1

mix in place or mix in the plant

volume or mass

NOTE 1

NOTE 2

CBM 2


volume or mass

NOTE 1

NOTE 2

CBM 3

mix in the plant

mass

NOTE 1

NOTE 2

CBM 4


volume or mass

NOTE 1

NOTE 2

NOTE 1 NOTE 2

to suit the requirements for strength surface, level regularity and finish 95% of cube strength

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Table 6.6 Cement Bound Materials Specimen Requirements

Category

Curing

Compressive Strength Testing

CBM 1

BS 1924 Part 2 1990

CBM 2

CBM 3

Individual (Note2) (MPa)

BS 1924 Part 2 1990 or BS 1881Part 116

4.5

2.5

BS 1924 Part 2 1990

BS 1924 Part 2 1990 or BS 1881 Part 116

7.0

4.5

BS 1881 Part 111

BS 1881 Part 116

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Average (Note1) (MPa)

BS 1881 Part 116

10.0

6.5

15.0

10.0

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CBM 4

The average strength of 5 cubes shall not be less than the stated figure The strength of any individual cube shall not be less than the stated figure

as

NOTE 1 NOTE 2

Minimum 7 days Cube Strength

Batching and Mixing

1

Batching and mixing shall be carried out in the appropriate manner described in Table 6.5.

2

Where the mix-in plant method is used and materials are batched by mass, the materials shall be batched and mixed in compliance with BS EN 206 & BS 8500. Where continuous mixers are used and materials are batched by mass, the continuous mixers shall comply and tested in accordance with BS 3963.

6.4.3

Transporting

1

Plant-mixed cement bound material shall when mixed be removed at once from the mixer, transported directly to the point where it is to be laid and protected from the weather both during transit from the mixer to the laying site and whilst awaiting tipping.

6.4.4

Laying

1

All cement bound material shall be placed and spread evenly in such manner as to prevent segregation and drying.

2

Spreading shall be undertaken either concurrently with placing or without delay.

3

Road base cement bound material shall be spread using a paving machine or a spreader box approved by the Engineer and operated with a mechanism which levels off the cement bound material to an even depth.

4

Cement bound material shall be spread in one layer so that after compaction the total thickness is as specified.

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6.4.2

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At longitudinal or transverse construction joints, unless vertical forms are used, the edge of compacted cement bound material shall be cut back to a vertical face where the correct thickness of properly compacted cement bound material has been obtained.

6

In the case of cement bound sub bases under a concrete surface slab or continuously reinforced concrete road base, longitudinal construction joints in the sub-base shall be staggered by at least 300mm from the position of the longitudinal joints in the concrete surface slab or continuously reinforced concrete road base, and by 1m for transverse joints.

6.4.5

Compacting

1

Compaction shall be carried out immediately after the cement bound material has been spread and in such a manner as to prevent segregation.

2

Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse construction joints.

3

Compaction shall be carried out in compliance with Table 6.5 and be completed within 2 hours of the addition of the cement. The 2 hours may be varied at the discretion of the

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Engineer if the preliminary trial indicates that this is necessary or appropriate. After compaction has been completed, compacting equipment shall not bear on cement bound material for the duration of the curing period. The surface of any layer of cement bound material shall on completion of compaction and immediately before overlaying, be well closed, free from movement under compaction plant and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated or otherwise defective areas shall be removed to the full thickness of the layer and new cement bound material laid and compacted.

6.4.6

Curing

1

Immediately on completion of compaction, the surface of concrete or wet lean concrete or cement bound road bases and sub-bases shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter period) by one of the following methods:

2

Covering with an impermeable sheeting with joints overlapping at least 300 mm and set to

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prohibit egress of moisture. The sheeting shall be removed at the end of the curing period. 3

Bituminous spraying which shall only be applied when there is no visible water. When the cement bound material is likely to be exposed to high temperatures and solar radiation, the bituminous spray shall be blinded with light coloured material.

4

Spraying with a curing compound.

5

Spraying with an approved plastic film which when hardened shall be removed before applying any other pavement layer.

6

Whichever method is used, immediately prior to overlaying with any bituminous layer in cationic bituminous tack coat shall be applied at a rate between 0.351/m2 to 0.551/m2.

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6.4.7

Preliminary Trial

1

At least 10 days before the start of the main cement bound material works a trial area of at least 400 m2 shall be laid to asses the suitability of the proposed materials, mix proportions, mixing, laying, compaction plant and construction procedures. When applicable the area shall include one longitudinal and one transverse construction joint. The location and area of the trial shall be subject to the approval of the Engineer.

3

The rate of testing for the trial area shall not be less than that required in this section of the specification.

4

The trial area will only be accepted for main construction in the Permanent Works if it complies with the Specification.

5

The main construction in the Permanent Works shall not start until the trial has been approved by the Engineer.

6

After approval has been given, the materials, mix proportions, mixing, laying compaction plant and construction procedures shall not be changed without the approval of the Engineer who may require the Contractor to lay a further trial area to assess the suitability of the proposed changes.

6.4.8

Cement Bound Material Category 1 (CBM1)

1

CBM1 shall be made from material which has a grading finer than the limits of Table 6.7

2

In addition to the requirements of Table 6.6 the average compressive strength determined after immersion in water of five test specimens of CBM1 shall not be less than 80% of the average compressive strength of five control specimens when subjected to the test procedure described in BS 1924: Part 2: 1990, clause 4.3.

3

After the 7 days immersion period the specimens shall not show any signs of cracking or swelling.

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NOTE:

Table 6.7 Material for CBM1 - Limit of Grading

BS Sieve Size (mm)

Percentage by Mass Passing

50

100

37.5

95

20

45

10

35

5

25

0.600

8

0.300

5

0.075

0

The particle size distribution shall be determined by the washing and sieving method of BS812:

QCS 2014


Page 34


1

CMB2 shall be made from gravel sand, a washed or processed granular material, crushed rock, all in aggregate, blastfurnace slag or any combination of these. The material shall fall within the grading limits of Table 6.8.

2

The material shall have 10 % fines value of 50 kN or more when tested in accordance with BS 812 with samples in a soaked condition.

3

In addition to the requirements of Table 6.6 the average compressive strength determined after immersion in water of five test specimens of CBM2 shall not be less than 80% of the average compressive strength of five control specimens when subjected to the test procedure described in BS 1924: Part 2: 1990, clause 4.3. After the 7 days immersion period the specimen shall not show any signs of cracking or swelling.

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Table 6.8 Material For CBM2 - Range Of Grading

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6.4.9

20

100 95-100 45-100 35-100 25-100

2.36

15-90

0.600

8-65

0.300

5-40

0.075

0-10

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BS Sieve Size

The particle size distribution shall be determined by the washing and sieving method of BS 812.

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NOTE: 6.4.10


1

CBM3 shall be made from aggregates as in the sub-Clause 6.5.9.

2

The grading of the aggregate shall be within the limits of Table 6.9.

6.4.11


1

CBM4 shall be made from aggregates as in sub-Clause 6.5.9

2

The grading of the aggregate shall be within the limits of Table 6.9.

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Table 6.9 Material for CBM3 and CBM4 - Range of Grading Percentage by Mass Passing. Nominal Maximum Size

BS Sieve Size (mm)

50

100

-

37.5

95-100

100

20

45-80

95-100

5

25-5-

35-55

0.600

8-30

10-35

0.150

0.8*

0-8*

0.075

0.5

0-5

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20 mm

The particle size distribution shall be determined by the washing and sieving method of BS 812. *0-10 for crushed rock fines

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NOTE:

40 mm

Testing of Cement Bound Materials

1

Samples shall be provided in accordance with BS 1924: Part 1: 1990 Clause 5 from the laid cement bound material before compaction. One group of five samples shall be provided from five locations equally spaced along a diagonal that bisects each 800 mm2 or part thereof laid each day. The number of groups may be increased if required by the Engineer.

2

One 150 mm cube shall be made from each sample taken in accordance with sub-clause 1 of this clause. The cubes shall be made in accordance with BS 1924: Part 2: 1990, clause 4.2.5 without further mixing of the material and within 2 hours of the addition of the cement. Cubes shall be cured and tested in accordance with Table 6.6.

3

To determine the wet density of cubes the mould shall be weighed prior to making the cube and the mass recorded. Immediately after completion of compaction, the cube and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the wet density of the cube.

4

The in-situ wet density of a layer of cement bound material shall be taken as the average of the wet densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part thereof laid each day. The wet density at each location shall be the average of two readings obtained using a nuclear density gauge complying with BS 1377: Part 9. The two readings shall be taken at 180 degrees to each other using the same source rod hole. The source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings shall be taken within two hours of completing final compaction.

6.4.13

Special Requirements for Cement Bound Materials

1

Where specified in the contract documents or on the project drawings cement bound road base in flexible composite construction shall be laid in individual widths with longitudinal construction joints in locations as detailed below:

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6.4.12

(a)

Single All purpose. One longitudinal construction joint at the centre lane line marking.

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(b)

Dual 2 lane All-purpose. One longitudinal construction joint at the lane line marking.

(c)

Dual 3 lane All-purpose. Two longitudinal construction joints, one at each of the lane line markings.

(d)

Dual 2 lane Motorway. Two longitudinal construction joints, one at the lane line marking and one at the edge line marking between hard shoulder and left hand lane.

(e)

Dual 3 lane Motorway. Three longitudinal construction joints, one at each lane line marking and one at the edge line markings between hard shoulder and left hand lane.

(f)

Dual 4 lane Motorway. Four longitudinal construction joints, one at each lane line marking and one at the edge line marking between hard shoulder and left hand lane.

Longitudinal constructions joints shall not be more than 150 mm from the centre of the centre

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Longitudinal construction joints shall not be located within the left hand lane or dual carriageways. At tapers and other changes in section the construction joint layout shall be agreed with the Engineer, and where necessary joints shall also be permitted within 150 mm

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of the mid-point of the traffic lane.

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END OF PART

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line, lane line, or edge line marking, with individual widths not exceeding 4.75 m.

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 1

ASPHALT PLANTS ................................................................................................. 3

7.1

ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE .............................. 3

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

ASPHALT PLANTS PRODUCTION CONTROL ...................................................... 4 Factory Production Control (FPC) 4 Factory Production Control Quality Plan 4 Organizational Structure 5 Internal Audits 5 Management Review 5 Document Control 5

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

PRODUCT REALISATION ...................................................................................... 6 Constituent Materials 6 Customer Supplied Product 6 Process Control 6 Handling, Storage and Delivery 7 Plant Calibration and Maintenance 7 Plant Quality Control Laboratory 8

7.4 7.4.1 7.4.2 7.4.3

INSPECTION AND TESTING .................................................................................. 9 General 9 Incoming constituent materials 9 Finished Asphalt Mixture 9

7.5 7.5.1 7.5.2

NON-CONFORMITY ............................................................................................. 10 General 10 Non-conformity of Material or Asphalt Mixtures 10

7.6

INSPECTION, MEASURING AND TEST EQUIPMENT ......................................... 11

7.7

PLANT GENERALLY ............................................................................................. 11

7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.8.5 7.8.6 7.8.7 7.8.8 7.8.9 7.8.10 7.8.11 7.8.12 7.8.13 7.8.14 7.8.15 7.8.16

ASPHALT PLANT .................................................................................................. 12 General 12 Automatic Operation 12 Cold Bins System 12 Drier 13 Dust Collector 13 Screens 13 Hot Bins 13 Asphalt Binder Storage 14 Thermometric Equipment 14 Control of Mixing Time 14 Pugmill 14 Temporary Storage of Mix 15 Safety Requirements 15 Weigh-Box 15 Scales or Meters 16 Plant Control System 16

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7

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APPENDICES APPENDIX “A” .................................................................................................................... 17 APPENDIX “B” .................................................................................................................... 22

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APPENDIX “C” .................................................................................................................... 25

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7

ASPHALT PLANTS

7.1

ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE

1

Before loading, the bitumen manufacturer shall examine the shipping container and remove all remnants of previous cargos that may contaminate the material to be loaded.

2

The manufacturer shall furnish with each shipment two (2) copies of the delivery ticket containing the following: Consignees’ details.

(b)

Net liters.

(c)

Net weight.

(d)

Type and amount of anti-stripping agent (if any).

(e)

Identification number (truck, car tank, etc.)

(f)

Destination.

(g)

Date.

(h)

Loading temperature, and the recommended delivery temperature range.

(i)

Specific gravity.

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(a)

The bitumen manufacturer shall deliver a signed Certificate of Compliance to cover the quality and quantity of material and the condition of container for each shipment. Test results shall be provided with the shipment.

4

Bituminous materials furnished without a Certificate of Compliance should not be introduced into the work until the Contractor has had sufficient time to sample and test the delivered materials.

5

The delivery tanker shall be insulated with a rock wool or similar material. Burner tubes shall be designed so that the bituminous material is evenly heated with no hot spots within the tanker. Temperature gauges shall be calibrated and positioned such that the maximum temperature in the tanker shall be indicated. The temperature of unmodified and modified bitumen during delivery shall be maintained in accordance with the manufacturer recommendations. Tankers shall be designed to enable the safe sampling of the bitumen from the top of the tanker or from a sampling valve. Sampling shall not take place whilst the tank is under pressure.

6

The Contractor shall obtain acceptance samples of bituminous material according to ASTM D140 at the applicable point of acceptance.

7

For bituminous material used in direct application on the road, samples shall be taken from each shipping container at the time of discharge into distributors or other conveyances on the project.

8

For bituminous material initially discharged into storage tanks on the project, samples shall be taken from the line between the storage tank and the distributor or the asphalt plant after each delivery. Samples shall be taken after a sufficient period of circulation has taken place to ensure samples are representative of the material in the storage tank.

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Page 4

The manufacturer of bituminous materials shall test all materials produced and the test results retained for reference. Each shipment of bituminous material delivered to the asphalt plant shall be sampled. The samples shall be numbered consecutively and identified by project, type and grade of bituminous material, date of delivery and use. Samples testing frequency shall be based on LSA and the Engineer approval.

10

Each bitumen delivery and storage tank and its associated delivery pipe and control valve must be independently and uniquely identified with the tank number.

11

Storage tanks must also display the grade of bitumen held in the tank.

12

Adequate and reliable means of gauging the bitumen tank contents and ullage must be available at the discharge point.

13

Vent pipes must be fitted in bitumen tanks and located where they do not pose a risk to any personnel or delivery vehicles and must be kept clear at all times.

14

It is recommended that bitumen tanks should be fitted with a correctly designed drain valve to enable the safe emptying of the tank for cleaning and maintenance. In the absence of a drain valve, a specific risk assessment must be carried out prior to any uplift of product.

15

Samples must not be taken from the bitumen delivery vehicle or hoses at the delivery site unless equipment is fitted to do so safely.

16

If there is a requirement to take bitumen samples a purpose designed valve should be permanently fitted to the tank (or corresponding pipework).

7.2

ASPHALT PLANTS PRODUCTION CONTROL

7.2.1

Factory Production Control (FPC)

1

The Organization shall establish and operate a permanent factory production control system to ensure delivery of the quality requirements of the project specification whilst maintaining a regime of continuous improvement and ensure the competence and training of staff and operators. The Organization shall document and maintain the FPC system in which procedures, regular inspections and tests and/or assessments and the use of the results to control raw and other incoming materials or components, equipment, the production process and the product.

2

A sample plant inspection checklist, which includes the minimum items to be covered as part of LSA inspection, Engineer inspection and producer internal audit system, is provided in Appendix “C”.

7.2.2

Factory Production Control Quality Plan

1

The Organization shall establish and maintain FPC documentation for each asphalt production site used to supply the works.

2

The FPC documentation shall include a means for identifying and detailing the specific processes that directly affect the quality of the asphalt. This shall particularly address:

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(a)

Producer’s organizational structure relating to conformity and quality.

(b)

Document control.

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Page 5

(c)

Control procedures for constituent materials and purchaser supplied product.

(d)

Process control

(e)

Requirements for the handling and storage of the product.

(f)

Plant calibration and maintenance.

(g)

Quality control laboratory calibration and maintenance.

(h)

Requirements for inspection and testing of processes and products.

(i)

Procedures for handling non-conformity.

Organizational Structure

1

The responsibility, authority and inter-relation of all personnel who manage, perform and verify work affecting conformity and quality shall be defined in the quality plan, particularly for personnel who have authority to:

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7.2.3

Initiate action to prevent the occurrence of product non-conformity.

(b)

Identify and record any product quality problems.

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(a)

The producer shall identify a person with appropriate authority, knowledge and experience to supervise Factory Production Control and to ensure that the requirements of the quality plan are implemented and maintained. The person identified may exercise such supervision over a group of plants.

3

The management structure shall be documented. Names, affiliations, and positions of principal staff shall be listed. The organization chart shall clearly define relationships with other partner organizations where applicable.

7.2.4

Internal Audits

1

The Organization shall carry out internal audits to verify which activities comply with the planned arrangements and to determine the effectiveness of the Factory Production Control system. Audits shall be scheduled on the basis of the status and importance of the activity. The audits and follow up action shall be carried out in accordance with documented procedures. The results of the audits shall be documented and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on the nonconformities found by the audit and shall keep a record of the action taken.

2

The frequency of such audits shall be that each area of process is audited at least annually.

7.2.5

Management Review

1

The system shall be reviewed at least annually by management to ensure its continuing suitability and effectiveness.

7.2.6

Document Control

1

The producer shall establish and maintain documented procedures to control all documents and data that relate to the requirements of these specifications.

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Page 6

The producer shall maintain all documents related to daily production quality records, test methods, practices, procedures, and specifications.

3

Records relating to Factory Production Control shall be maintained and accessible by the Organization and shall be produced if requested by the Engineer or any authorized audit body.

4

Management review, internal audits, 3rd party assessment, and inspection and testing of finished asphalt shall be kept for a minimum of ten years. All other quality records shall be kept until at least five years after the completion of the project, or longer as the Organization requires.

7.3

PRODUCT REALISATION

7.3.1

Constituent Materials

1

Adequate supplies of constituent materials shall be available to ensure that the planned rates of production and delivery can be maintained.

2

The specification and tolerances for incoming constituent materials shall be established and communicated to suppliers by appropriate traceable and confirmable means.

3

The control procedures shall verify that suppliers of incoming materials are capable of providing the required quality of materials.

4

Different material types or grades shall be transported and stored in such a manner as to avoid intermingling, contamination or deterioration which may adversely affect the quality of the product.

5

The general requirements of this clause shall be translated into more detailed plant specific requirements within the FPC and include the following:

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Procedures for the control of aggregates delivered to a depot or plant site.

(b)

Requirements for labelling of storage bays and silos.

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Requirements for heating, temperature control and insulation of binder tanks, pipes and pumps.

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(c)

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(a)

(d)

Requirements for controlling delivery of binders into the correct tanks, including stirrers/agitators and labelling of tanks, and the selection of the correct tanks for use.

(e)

Requirements for the control of additives.

(f)

Requirements for the manufacture of polymer modified binders at site by the Organization or its supplier, where applicable.

7.3.2

Customer Supplied Product

1

Any constituent material supplied by the customer for inclusion in the asphalt shall be handled, stored and maintained free of contamination by the Organization.

7.3.3

Process Control

1

The FPC quality plan shall include the following items of process control:

QCS 2014


Page 7

A description of the flow of materials and the processes carried out on them from receipt at the plant to delivery to the job site. This shall incorporate a flow diagram.

3

A statement of the production control processes necessary to maintain and regulate the quality of material in conformity with the specification. This will include the procedure for the control of batching instructions.

4

A schedule for monitoring the performance of the process, which is shown in Table A-1 in Appendix “A”, resulting in a record of plant performance against stated tolerances.

5

A detailed method statement for the production of polymer modified binder including storage and quality control, and the procedure for the handling of nonconforming product.

7.3.4

Handling, Storage and Delivery

1

The FPC quality plan shall contain procedures to ensure that the asphalt mixture is handled, stored, discharged and delivered at the specified temperature range, minimizing segregation and degradation.

2

The asphalt mixture shall be identifiable and traceable with regard to its production data and can be referenced from information on the delivery ticket from its manufacture to its point of installation. The quality plan shall however make clear the point to which the Organization’s responsibility for handling storage and delivery extends.

3

The quality plan shall describe the characteristics of any hot storage system and define its mode of operation. The Organization shall ensure thorough checks, inspections and records that such systems are used correctly and that bituminous mixtures maintain their suitability for use.

4

Bituminous materials shall not be heated during the process of its manufacture or during construction so as to cause damage to the materials as evidenced by the formation of carbonized particles.

7.3.5

Plant Calibration and Maintenance

1

The FPC quality plan documentation shall identify those items of measuring equipment which require calibration and the frequency of such calibration which shall comply with the requirements of QCS 2014, or its revisions, and the contract specification.

2

Calibration procedures shall be provided, including the permitted tolerances for the equipment to remain in service. The quality plan shall state the required accuracy of all plant calibrations and shall identify any that require traceability to national reference standards (e.g. mass or weight).

3

The plant shall be maintained to ensure that it continues to be capable of producing asphalt to the required specifications and tolerances. Table A-2 gives guidance with regard to schedules for calibration and checks.

4

The FPC quality plan documentation shall identify those items and areas of the plant where constant use and wear will affect the quality of production including, but not limited to, the dryer drum, hot elevator, screen deck and meshes, hot bins, weighing and mixing apparatus, and state the inspection and maintenance schedules for these items in order to maintain them to the condition necessary to ensure the quality of production.

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QCS 2014


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5

A maintenance schedule shall be available and maintenance records shall be kept.

7.3.6

Plant Quality Control Laboratory

1

The asphalt plant shall have a quality control testing laboratory capable of conducting the following tests: Sieve analysis (ASTM C117, C136, and D5444).

(b)

Specific gravity for coarse and fine aggregates (ASTM C127, C128).

(c)

Theoretical maximum specific gravity and density of asphalt mixtures (ASTM D2041).

(d)

Quantitative extraction of asphalt binder from asphalt mixtures (ASTM D2172).

(e)

Bulk specific gravity and density of compacted asphalt mixtures (ASTM D1188, D2726).

(b)

Qualified laboratory manager.

(c)

Qualified technicians.

(d)

Calibrated equipment.

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Efficient quality management system.

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(a)

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The asphalt plant laboratory shall have a database includes but not limited to the following: (a)

Production data.

(b)

Testing data.

(c)

Materials type and materials traceability to source data.

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3

The asphalt plant laboratory shall have the following:

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(a)

The plant laboratory shall keep records of materials and asphalt mixtures properties on a daily basis.

5

The laboratory shall maintain a position description for each technical operational position shown on the laboratory’s organization chart. Position descriptions shall identify the position and include a description of the duties, required skills, and education and experience associated with the position.

6

The laboratory shall maintain technical staff training records, qualifications, work experience, licensure, certifications, and current position for each supervisory technical staff member.

7

The laboratory shall maintain a procedure which describes the methods used for laboratory personnel training to perform tests in accordance with standard procedures. Records of laboratory personnel training shall be maintained.

8

The laboratory shall maintain a procedure describing the method used to evaluate staff competency to ensure that each test covered by the scope of this standard is performed in accordance with standard procedures. This description shall include the frequency of competency evaluations for each technician and indicate what position or employee is responsible for evaluating staff competency and maintaining records. The procedure shall ensure that each technician receives a performance evaluation for each test that technician performs.

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Page 9

The laboratory shall calibrate, standardize, and check all significant equipment associated with tests which the laboratory performs.

10

The laboratory shall have a procedure for the storage, retention, and disposal of test samples.

7.4


7.4.1

General

1

All necessary facilities, equipment and personnel shall be available to carry out the required inspections and tests.

2

Inspection and testing shall be carried out at least as frequently as indicated in Tables A-3 to A-7. Sampling shall be randomised so as not to introduce undue bias in the assessment of compliance. Due care shall be taken to adequately cover both large and small volumes of material.

3

At least 10% of quality control tests related to constituent materials and finished mixtures shall be carried out by an approved thirty party laboratory. Third party testing schedule shall be liaised with the Engineer.

4

The results of all tests carried out on materials shall be recorded. Tests taken specifically for the resolution of problems arising from process control shall be kept separately and need not be used for the purpose of calculating compliance with the technical specifications.

5

All sampling and testing shall be carried out in accordance with the relevant standard procedures required by the specification.

7.4.2

Incoming constituent materials

1

Incoming constituent materials shall be inspected and tested using procedures detailed in the quality plan and to a schedule complying with this clause and the requirements of QCS 2014, or its revisions, and the contract specification.

2

The required inspections of materials in storage shall be maintained to establish that no deterioration has occurred.

3

Detailed requirements shall be as follows:

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(a)

Aggregates: see Table A-3.

(b)

Filler: see Table A-4.

(c)

Additive: see Table A-5.

(d)

Binders: see Table A-6.

(e)

Finished Asphalt Mixture: see Appendix “B”.

7.4.3

Finished Asphalt Mixture

1

The finished asphalt mixture shall be inspected and tested using procedures detailed in the quality management system documentation and to a schedule complying with the requirements of QCS 2014 and the contract specification.

QCS 2014


Page 10

Appropriate statistical records shall be maintained in order to monitor and verify process capability and product characteristics.

3

Individual batch readings shall be recorded as part of the quality records. The plant pyrometer shall be calibrated in accordance with ASTM E2847 and checked daily against a calibrated laboratory thermometer, the record of which shall be maintained in the plant control cabin/office. The temperature of the finished asphalt shall be the average load temperature however no batch or part of the load shall exceed the maximum JSM temperature for the mix. Measurement shall be in accordance with QCS 2014.

4

As a regular audit check on the efficacy of the plant quality control laboratory, 10% of samples analysed for mix composition by the plant control laboratory shall have a duplicate sample analysed in an independent laboratory, which is ISO17025 accredited in related tests. The duplicate sampling may be done simultaneously as part of the Organization’s other testing obligations conducted by an approved independent laboratory. The duplicate results shall be regularly reviewed and any differences falling outside the reproducibility limits published in the test standard applicable to the ASTM test methods employed shall be investigated.

5

The results of all tests carried out on materials shall be recorded. Tests taken specifically for the resolution of problems arising from process control shall be kept separately and need not be used for the purpose of calculating compliance with the technical specifications.

6

All sampling and testing shall be carried out in accordance with the relevant standard procedures required by the specification.

7

Sampling frequencies, operating compliance level (OCL) and test frequencies are provided in Appendix “B”.

7.5

NON-CONFORMITY

7.5.1

General

1

The producer shall establish and maintain documented procedures to ensure that constituent materials or asphalt mixture which when identified by in-process inspection does not conform to specified requirements is prevented from use or installation. This control shall provide for identification, evaluation, separation from conforming product (when practical) and disposal of the nonconforming material or asphalt mixture.

2

The non-conformance process shall include:

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(a)

Constituent materials upon arrival at the plant or storage site.

(b)

Constituent materials in storage.

(c)

The manufacturing process.

(d)

Handling, storage and delivery of the finished product.

7.5.2

Non-conformity of Material or Asphalt Mixtures

1

Where non-conforming constituent materials or finished asphalt mixtures are identified, the cause of the non-conformance shall be investigated and identified to effect appropriate corrective actions to prevent a reoccurrence. Such corrective actions shall be incorporated into the FPC quality plan.

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Page 11

Corrective actions may involve reworking the material, adjusting the process, redirection to another use where it may be acceptable, recycling for further use or rejection and disposal.

3

The FPC quality plan shall identify the action to be taken in process control when nonconforming product is identified from analysis.

4

The FPC quality plan shall state the process under which the installation contractor and the supervising agency will be notified of non-conforming analysis results.

7.6

INSPECTION, MEASURING AND TEST EQUIPMENT

1

The Organization shall control, calibrate and maintain suitable measuring and test equipment as required by this guidance document and QCS 2014.

2

To ensure the testing of incoming constituent materials and finished asphalt conforms to the relevant test method specification, the Organization, or where an independent laboratory is employed by the Organization to conduct its quality control testing, shall ensure within the FPC quality plan that the measuring and test equipment used is maintained in a known state of calibration and maintenance.

3

The equipment control procedures shall demonstrate the following:

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Accuracy and frequency of calibration, which should be in accordance with the relevant test standard.

(b)

Equipment is used in accordance with a documented procedure.

(c)

Equipment is uniquely identified.

(d)

Calibration records to be maintained.

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(a)

PLANT GENERALLY

1

The machinery and tools used in constructing the various items involved in asphalt works shall be in good working condition and free of oil and fuel leaks. The Contractor shall maintain and preserve them for the whole duration of the work. The Engineer shall approve the machinery and tools before works begin and the Contractor shall supply adequate quantities of such machinery in order to execute the work with due speed and precision. Equipment approved for use shall not be removed from the Site without the approval of the Engineer.

2

If required the Contractor shall furnish the Engineer with the manufacturer's catalogues, specifications and other published data for the equipment and machinery he proposes to use.

3

On first erecting an asphalt plant and at least once each three months thereafter, the plant shall be calibrated by a calibration service organisation approved by the LSA. Production shall not be permitted if the weigh batch calibration does not comply with the requirements of ASTM D995-95.

4

The Engineer shall have the right to stop the use of any equipment or plant which he deems to be inferior to the quality required or detrimental to the permanent works and to instruct the removal of such equipment and to have it replaced by suitable equipment.

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The Contractor shall immediately comply with such instructions without being entitled to any indemnities or extensions as a result of such instructions. The Contractor shall not be allowed to use any equipment or plant before obtaining the approval of the Engineer, and the Contractor shall undertake to follow sound technical methods in operation and to engage skilled and trained operators, mechanics and labour to carry out the works. The Engineer shall have the right to expel any operators, mechanics or labour and to instruct suitable replacement thereof at any time he deems such action is necessary.

6

The Contractor shall comply with any special plant requirements published by the concerned authority.

7.8

ASPHALT PLANT

7.8.1

General

1

All plant used by the Contractor for the preparation of asphalt hot mixes shall be batch type plants conforming to the requirements as detailed below.

2

The Engineer may permit the use of continuous drier drum type asphalt plants after a fully detailed technical submission by the Contractor itemising the differences from the specification. In such cases after approval of the technical submission the Contractor shall carry out a full scale laying trial with testing of the hot and laid mix and monitoring of the plant operation by the Engineers staff to assess the suitability of the proposed plant.

3

No laboratory verification or plant trial shall be carried out by the LSA unless an automatic compaction apparatus is available at the producer’s laboratory.

7.8.2

Automatic Operation

1

The plant shall be designed, co-ordinated and operated so as to continually produce an asphalt mix within the job mix tolerances specified.

2

The plant shall be equipped and operated so that the proportioning of the hot aggregate, filler and bitumen, together with the dry and wet mixing cycles are all controlled automatically. Positive interlock shall be provided so that proportioning, mixing and discharge are accomplished by one operation without manual control of the separate phase.

3

The use of manual and semi-automatic plants for the production of asphalt is not permitted unless specific approval is given in writing by the Engineer.

7.8.3

Cold Bins System

1

The plant shall include a sufficient number of cold storage bins so that there is at least one bin for each different stockpile of material being used.

2

Intermixing of material from different stockpiles in one bin or on the ground before putting into the bin is prohibited.

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The cold bins and loading equipment used shall be compatible to prevent overflow between the bins. Baffle plates shall also be used between bins to prevent overflow of one bin into another. Each cold bin shall include an accurate means for continuously feeding the required amount of mineral aggregate so that uniform production is achieved. The settings on the cold bins shall be approved by the Engineer and shall be checked and calibrated as often as he may deem necessary to ensure their continued accuracy. Change of settings shall be made only with the approval of the Engineer.

7.8.4

Drier

1

A drier of satisfactory design shall be provided. The drier shall be capable of uniformly drying and heating the aggregate to the moisture and temperature required without leaving any visible burned oil or carbon residue on the aggregate when discharged from the drier.

7.8.5

Dust Collector

1

The plant shall be provided with a dust collector designed to waste, or to return all or part of the material collected to the asphalt plant.

2

The asphalt plant shall have an efficient fugitive emission collection and control system to control dust or fume emissions from the drying, screening, weighing and mixing operations. The collection system shall be so designed to prevent the emission of dust and fumes into the atmosphere in accordance with the environmental standards of Qatar.

3

The collected dust from the drying process shall pass through a coarse collector which will pass the coarse particles, substantially greater than 0.075mm, back to the hot elevator or to a silo for the controlled return to the asphalt mix. The reclaimed dust substantially less than 0.075mm shall be collected and passed into a storage silo for the controlled return as mineral filler to the asphalt mix through the filler weighbox or sent to waste.

4

The plant shall be equipped with a filler silo for recovered filler. An additional dry storage silo shall be provided for imported mineral filler with a provision of a separate weighing hopper to proportion this filler into the mix.

7.8.6

Screens

1

Plant screens shall be capable of screening all aggregates to the specified sizes and proportions. They shall have capacities equal to or greater than the maximum rated capacity of the plant. They shall have an operating efficiency such that the aggregate deposited in any bins shall not contain more than 10 % oversize or undersize material. This screen tolerance shall not invalidate the job mix tolerances specified.

7.8.7

Hot Bins

1

The plant shall include at least three storage bins for hot aggregate of sufficient size to supply the pugmill when it is operating at full capacity. They shall be arranged to ensure separate and adequate storage of appropriate fractions of the aggregate. Each compartment shall be provided with an overflow pipe that shall be of such size and at such location as to prevent any backing up of material into other bins or against the screens. Bins shall be so constructed that samples can be readily obtained therefrom. The hot bins shall be equipped with continuous level indicators to provide information about the level of each ingredient of the JMF and to avoid shortage or overflow of aggregate from one bin to another.

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Asphalt Binder Storage

1

Tanks for storage of asphalt binders shall be equipped for heating the material using positive and automatic control at all times, to a temperature within the specified range. The heating shall be accomplished by hot thermal oil, electricity or other approved means such that no direct flame shall come in contact with the bitumen or heating tank.

2

The circulating system for the asphalt binder shall be of adequate size to ensure proper and continuous circulation during the entire operating period. Suitable means shall be provided either by double jacketed steam or hot oil or other insulation for maintaining the specified temperature of the bituminous material in the pipeline, meters, weigh buckets, spray bars, and other containers and flow lines.

3

The storage tank capacity shall be sufficient for at least one day's operation. Circulation return lines to the asphalt storage tanks should be submerged to the same elevation in the storage tanks as the feeder line. Two or three vertical slots may be cut in the return line above the high level mark to break vacuum when reversing the pump.

4

The Contractor shall provide a sampling outlet in the asphalt binder feed line connecting the plant storage tanks to the asphalt binder weighing or metering box. The outlets shall consist of valves installed in such a manner that samples may be withdrawn slowly at any time during plant operation. The locations of the sampling outlets shall be readily accessible and free from obstructions. Drainage receptacles shall be provided for flushing the outlets before sampling.

7.8.9

Thermometric Equipment

1

An armoured thermometer reading from 38 C to 204 C shall be fixed in the bituminous feed

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7.8.8

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line at a suitable location near the discharge valve. Similar devices shall be fixed in the heating and storage tanks. The plant shall be further equipped with either an approved dial-scale, mercury-actuated thermometer, an electric pyrometer, or other approved thermometric instruments placed at the discharge chute of the drier and in the hot fines bin so as to register automatically or indicate the temperature of the heated aggregates. For better regulation of the temperature of the aggregates, replacement of any thermometer by an approved temperature recording apparatus may be required by the Engineer and he may further require that daily temperature charts be submitted to him by the Contractor.

7.8.10

Control of Mixing Time

1

The Plant shall be equipped with positive means to govern the time of mixing and to maintain it constant unless changed at the direction of the Engineer.

7.8.11

Pugmill

1

The batch mixer shall be an approved twin pugmill type, capable of producing a uniform mixture within the job-mix tolerances. It shall be so designed as to permit a visual inspection of the mix. The mixer capacity shall be not less than 600 kg per batch and shall be so constructed as to prevent leakage of contents.

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The bitumen system shall deliver an even flow of binder into the mixer to ensure an even distribution of bitumen binder throughout the mix during the wet mixing cycle.

3

The mixer shall be fully enclosed with sufficient air extraction to prevent emissions of dust and fumes. The mixing cycle shall be controlled such that from charging of the mixer until the closing of the mixer door at the completion of the cycle there shall be no leakage of aggregate, filler or bitumen from the weighing hoppers. The system shall permit a dry mixing period, defined as the interval of time between opening of the weigh box gate and the start of application of bitumen, if required by the mixing process.

4

The wet mixing period is defined as the interval between the discharge of the bitumen binder into the mixer and the mixer gate is opened to discharge the mix, and shall be not less than 30 seconds. The wet mix time shall be capable of being incrementally set at intervals of not more than five seconds up to a wet mix time of three minutes. A mechanical batch counter shall register the completely mixed batches.

5

The mixer shall be equipped with a full set of mixer paddles in a suitable arrangement, in accordance with the manufacturer’s specification, to produce a proper and uniformly mixed batch. All paddle arms and tips, and mixer liners shall be in good condition. Mixing shall cease if any mixer arms or tips are missing, and shall not resume until replaced and inspected.

7.8.12

Temporary Storage of Mix

1

Plants may be equipped with skips or elevators for delivering batched mix to hoppers or silos before discharging to hauling units. The skips or elevators shall not be sprayed with diesel or other solvents; where necessary they may be sprayed with a minimum amount of lime water, soap or detergent solution. Hoppers or silos shall be of such design that no segregation or loss in temperature of the mix occurs.

7.8.13

Safety Requirements

1

Adequate and safe stairways to the mixer platform and guarded ladders to other plant units shall be placed at all points required for accessibility to all plant operations. Accessibility to the top of truck bodies shall be provided by means of a platform or other suitable device to enable the Engineer to obtain mixture temperature data. To facilitate handling scale calibration equipment and sampling equipment, a hoist or pulley system shall be provided to raise or lower the equipment from the ground to platform or vice-versa. All gears, pulleys, chains, sprockets and other dangerous moving parts shall be thoroughly guarded and protected. Ample and unobstructed passage shall be maintained at all times in and around the truck loading space. This space shall be kept free from drippings from the mixing platform.

2

Accessibility to the top of loaded truck body shall be provided by means of a platform to enable obtaining asphalt mixture samples and temperature readings and to check truck body condition. All necessary safety measures shall be provided for accessing the top of loaded truck body.

7.8.14

Weigh-Box

1

The plant shall include means for accurately weighing each size of aggregate in a weigh-box or hopper, suspended on scales, ample in size to hold a full batch without hand raking or running over.

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The weigh-box or hopper shall be so constructed that they will not be thrown out of alignment or adjustment. All edges, ends and sides of weighing hoppers shall be free from contact with any supporting rods and columns or other equipment that will in any way affect the proper functioning of the hopper.

3

There shall also be sufficient clearance between hoppers and supporting devices to prevent accumulations of foreign materials. The discharge gate of the weigh-box shall be so hung that the aggregate will not be segregated when dumped into the mixer and shall close tightly when the hopper is empty so that no material is allowed to leak into the batch in the mixer during the process of weighing the next batch.

4

Weighing boxes and hoppers shall be free hanging and placed on high precision load cells or strain gauges.

7.8.15

Scales or Meters

1

Scales or meters used for proportioning aggregates, mineral filler and bitumen shall be accurate to 1 % of the indicated quantity. Scales and meters shall be substantially constructed. Scales and meters that require frequent adjustment shall be replaced. Scales shall be constructed and located so as to prevent vibration in the dial pointer.

2

Weighing sequence of hot aggregates shall progress from coarse to fine.

3

Bituminous material shall be automatically proportioned by either weighing or metering. The minimum gradation shall be not more than 1 litre or 1 kg. Bituminous scales and weigh buckets shall be such that the required amount of bitumen is provided in a single weighing and delivered to the pugmill without loss due to overflow, splashing or spillage.

4

Bituminous weigh buckets shall be satisfactorily insulated to prevent loss of heat in the bitumen or accumulation of bitumen in the bucket. Bituminous metering devices shall be rotating positive displacement pumps and shall be capable of providing the designated quantity of material for each batch.

5

All scales and meters shall be approved by the Engineer and shall be checked and calibrated as detailed in Clause 5.3. Production shall not be permitted if the weight batch calibration does not comply with the requirements of ASTM D955-95.

7.8.16

Plant Control System

1

The asphalt plant operations shall be fully automated and connected to a centralized control system. Preferably, the plant operating software shall be capable to store the detailed production history.

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APPENDIX “A”

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Table A-1: Process control minimum inspection schedule Inspection/Test

Purpose Identify contamination, intermingling, level ground for tipping, stock availability

Aggregate stockpiles

As FPC quality plan

Cold feed bins

As FPC quality plan

Aggregate dryer

As FPC quality plan

Dried heated aggregate

Aggregate temperature

Control for conformance

Aggregate screens

As FPC quality plan

Identify mechanical and physical defects

As FPC quality plan

Identify mechanical and physical defects

Hot bin gradations

Check screening efficacy

Daily

Weekly

Monthly or as FPC quality plan

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Continuously in production Weekly or as FPC quality plan

Weekly

as

Hot aggregate bins

Ensure correct feeding to plant and maintenance of bins Maintenance inspection to ensure effective heating and drying

Minimum frequency

.

Control Area

As FPC quality plan

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Weighing apparatus

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Identify mechanical and physical defect

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Tank temperature

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Bitumen

Binder properties

Check weighing efficacy against truck scale Check storage conformance

Daily

In accordance with storage recommendations

As FPC quality plan or in case of doubt

Temperature monitoring equipment for drying/heating and asphalt mix process

Test of accuracy comparison with calibrated reference thermometer

To ascertain the equipment is functioning correctly

Asphalt mix

Mix temperature

Ensure temperature conformance

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Weekly

Each batch or continuously in production

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Table A-2: Minimum plant calibration and check requirements Inspection/Test

Purpose

Weighing equipment Testing of weighing accuracy - calibration

Organoleptic* inspection Admixture/additive dispensers

Test for accuracy as described in procedures.

To ensure that weighing equipment is Daily functioning correctly 1

To ensure accuracy within quality plan requirements

a) on installation b) every 3 months c) in case of doubt.

To ensure that dispenser is functioning correctly

First batch of the day containing admixture

To ensure accuracy within quality plan requirements


Batching system (on batch plants)

Comparison of actual mass of constituents in the batch with the intended mass using the method prescribed in the quality plan

1


ta

rw

Flow meters

Comparison of the actual To ensure accuracy amount with the metered within quality plan amount by reconciliation requirements

1

.

Visual inspection as described in procedures

Minimum frequency

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To ensure the batching 1 a) on installation accuracy in b) every 3 months accordance with the c) in case of doubt. quality plan

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Comparison of actual mass in a measured Proportioning period of time with the system (cold feed) intended mass using the method prescribed in the quality plan

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Temperature monitoring equipment (infrared pyrometer)

o

Visual as described in procedures Test of accuracy comparison with calibrated reference thermometer Test of accuracy calibration

Temperature monitoring equipment (contact probe or thermocouple for drying heating process)

Visual as described in procedures

Test of accuracy calibration

To ensure the accuracy in accordance with the quality plan To ensure the equipment is functioning correctly To ensure the equipment is functioning correctly

1


Daily

Weekly 1

To ensure correct temperatures are recorded


To ensure the equipment is functioning correctly

Daily

To ensure correct temperatures are recorded


1

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Table A-3: FPC Inspection and test guidance for aggregate stockpiles Inspection/Test

Purpose

Minimum frequency

Tests for aggregate properties

To check suitability for intended use

As required by QCS 2014, or its revisions

Tests for aggregate consistency by sieve analysis

Each size: Weekly To check consignment quality Each consignment: in case of doubt

Inspection of delivery ticket

To check consignment is as ordered and from correct source

Each delivery


Tests for filler consistency

To check consignment or production quality

As required by QCS 2014, or its subsequent revisions

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Tests for filler properties

Minimum frequency

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Purpose

ta

Inspection/Test

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Table A-4: FPC inspection and test guidance for Filler

Gradation: Weekly Plasticity: Weekly

as

Filler: Non plastic

To confirm characteristics of product or check compliance with specification

Each delivery or weekly for reclaimed filler dust


To check consignment is as ordered and from correct source

Each delivery

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Appropriate tests to determine specified properties

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Table A-5: FPC inspection and test guidance for additives Inspection/Test

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Appropriate tests to determine intrinsic properties


Organoleptic* check of consignment

Purpose

Minimum frequency

To confirm characteristics of product or check compliance with specification To check that consignment is as ordered and from the correct source

a) Source approval prior to initial use and b) as stated in the quality plan

For comparison with normal appearance

Each delivery, if practicable; otherwise in accordance with quality plan.

Each delivery

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Table A-6: FPC Inspection and test guidance for bitumen binder Inspection/Test

Purpose

Minimum frequency

Tests for bitumen properties


As required by QCS 2014 and project particular specification


To check consignment is as ordered and from the correct source To check that binder is within specified temperature limits

Each delivery or production batch

Temperature

(a) Each delivery or production batch (b) Each tank recorded daily

To assess compliance with specification

1 per 450 tons of binder delivered in normal production

Grade Properties (PG76- 10)

To assess compliance with specification

1 per 450 tons of binder delivered in normal production

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Grade Properties (60/70)

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Prior to production if stored for more than 3 days without further deliveries or production batches

For comparison with normal perceptible properties

Each delivery or daily survey of tanks

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Organoleptic* Check

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Table A-7: FPC minimum inspection/test frequencies for product quality control Minimum frequency Every load

Suitability of delivery vehicles by visual assessment Cleanliness of delivery vehicles by visual assessment

To check adequacy of insulation

a) Prior to first use b) In case of doubt.

To avoid contamination To control use of release agent

Every load prior to loading

Mixed asphalt temperature

To assess conformity

Grading and binder content


a) As required under Table 1 b) Whenever samples are taken In accordance with QCS 2014

Other characteristics included in technical specifications


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For comparison with normal appearance with regard to grading, evenness of mixing and adequacy of binder coating

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Organoleptic* check on mixed asphalt

Purpose

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Inspection/Test

In accordance with QCS 2014

* Organoleptic check: a broader evaluation made with the senses: sight, touch, smell, hearing etc. rather than a visual inspection.


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APPENDIX “B”

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MINIMUM SAMPLING FREQUENCIES AND TOLERANCES FOR THE FACTORY PRODUCTION QUALITY CONTROL OF FINISHED ASPHALT General This Appendix includes sampling frequencies and tolerances for mixture composition for use in the evaluation of conformity of mixed asphalt during production. It is consistent with QCS 2014 but is specifically intended as guidance for the Organization (Asphalt Producer) to maintain the quality control of the finished asphalt mixture at the point of manufacture and does not impede on the requirements of QCS 2014, or its revisions, or the contract specification. The sampling and frequencies are the minimum that should be considered for control but it is to discretion of the Organization to ensure sufficient samples, tests and assessments are made in order for the asphalt mixture conforms to specification requirements.

2

The properties of asphalt mix characteristics shall conform to the requirements of QCS 2014 and the contract specification. Should these not properties be found not to conform to the Job Mix Formula the design should be assessed.

3

The guidance provides for three levels of minimum frequency. The minimum frequency which shall be carried out for all production circumstances and higher frequencies which are appropriate where it is necessary to give a greater assurance of consistency where the measured level of conformity has decreased.

4

A guide to assessment of production quality control test conformity is given.

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1

Asphalt mixture composition Job Mix Tolerances shall be in accordance with QCS 2014, as indicated in Table B.1:

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Testing tolerances and conformity assessment

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Table B.1: Job Mix Tolerances Base Course

Intermediate Course

Wearing Courses

Aggregate retained on 4.75mm sieve or larger

±5%

±4%

±4%

Aggregate passing 4.75mm sieve and retained on 850m sieve

±4%

±3%

±3%

Aggregate passing 850m sieve and retained on 75m sieve

 3%

 2%

 2%

Aggregate passing 75μm sieve

± 1.5 %

± 1.0 %

± 1.0 %

Binder Content

± 0.3 %

± 0.2 %

± 0.2 %

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Description

Operating Compliance Level 1

The Operating Compliance Level (OCL) shall be applicable to each single plant and shall be determined on an ongoing basis from the number of non-conforming compositional test results within the last 32 analyses of all asphalt mixtures tested. In addition, the OCL shall take into account the consistency of production with assessment of the mean deviation from target as detailed in Table B.2.

QCS 2014

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Page 24

In the event of 5 or more of the previous 32 results being non-conforming, and/or variance of the mean deviation from target from the prescribed tolerances, the plant shall be subject to an immediate and comprehensive review of equipment and procedures.

Mean Deviation from Target For each analysis the deviation from target shall be determined for each of the sieves sizes and binder content indicated in Table B.1. A running mean of the deviations for the last 32 analyses of each asphalt mixture shall be maintained.

2

Should the running mean of the deviations exceed the values stated in Table B.2, this shall be deemed to be non-conforming asphalt mixture in accordance with Clause 25.4.2 and the appropriate corrective quality control action taken. The Operating Compliance Level shall be lowered by one level for as long as the mean deviation stays outside tolerance.

Intermediate Course

±4

±3

-

Aggregate passing 12.5 mm

-

Aggregate passing 9.5 mm

±4

ta

±3

±2

±2

±3

±2

±2

± 1.5

± 1.0

± 1.0

± 0.3

± 0.2

± 0.2

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Test Frequency

±3

±3

Aggregate passing 75 μm sieve Soluble Binder Content

±3

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Aggregate passing 4.75 mm (Superpave) Aggregate passing 2.36 mm (Marshall)

Wearing Course

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Aggregate passing 19 mm

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Base Course

Description

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The frequency for sampling shall be determined weekly and shall be maintained at the operating compliance level minimum frequency indicated in Table B.3.

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Table B.2: Mean deviation from target tolerances

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1

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Table B.3: Determination of Operating Compliance Level and Sampling Frequency

2

Number of nonconforming analyses in last 32

Operating Compliance Level

0-2

A

1 per 250t per mix or part thereof

3-6

B


≥6

C


Minimum Sample Frequency

New plants commencing production, plants restarting after relocating, a major repair or overhaul, or those recommencing commercial production after a period exceeding 3 months cessation shall operate under OCL until 32 results have accumulated after which the frequency shall revert to the OCL achieved.

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APPENDIX “C”

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Table C-1: Sample of plant inspection checklist Aggregate Stockpiles

Yes

1

Are aggregate stockpiles separated by walls or clear space with signed labelling?

2

Are the stockpiles free of significant contamination and segregation? (Plant drain-out aggregate is acceptable if the aggregate size is similar and uncoated.)

6

Aggregate Cold Feed

6 7 8

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3

Is the aggregate collecting conveyor in good condition, with no holes or splits, or evidence of tracking (side movement) and the belt scrapers are in good order?

o

2

Has each aggregate size its own designated and labelled bin/hopper? Are bins/hoppers in good condition with no holes, with bin wall divider plates between each? Is aggregate overflow between hoppers being prevented by divider plates? If meshes (grizzlies) are fitted over the bins/hoppers, are they in reasonable condition and fit for purpose? Are the feeder gates, feeder belts and vibrators in good condition? Are there no-flow paddles/sensors on each feeder and are they working? Date of the last feeder calibrations:

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5

Is the truck tipping area at the stockpile level? (Non-level surfaces can cause trucks to tip over.) Do the aggregate delivery and test records conform to the approved mix designs? Have the aggregates been sampled and tested in accordance with requirements?

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4

Is the aggregate in good condition with no signs of degradation on the stockpile due to vehicle/plant movements?

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3

No

1

2

Is there any significant aggregate spillage under the dryer conveyor, the dryer drum or around the base of the hot elevator? Are the dryer lifters and flights are in good condition without undue bending or deformation and none missing. (when dryer is cold and stopped)

4

Is the drum exit chute temperature pyrometer, thermocouple or probe clean, working and in calibration? Date of last pyrometer, thermocouple or probe calibration:

5

Has the drum exit chute temperature equipment been checked recently with a referenced laboratory probe?

3

Date: Drum chute:

°C

Laboratory probe: °C

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Page 27

Dust Collection 1

Does the pre-skimmer or knockout box return the collected fine sand to the plant hot elevator? a: returned to a silo for re-use?

2

Is the bag house extracted dust:-

b: directly fed back into the asphalt plant?

5

Date of last certified plant stack emission test?

6

Is the plant stack emission is visually clean with no obvious dust or smoke??

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Does the laboratory monitor the gradation of the coarse preskimmer or knockout box fines and bag house filler? Is there a dust emission monitoring system on the plant?

3

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Aggregate Screening Is there any spillage around the screen deck area?

2

Did the last screen inspection indicate any defects?

3

Date of last screen deck inspection:

7

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8

Are there any loose screen meshes that need tightening or support bars that are loose and need welding? Is there evidence of side seal seepage which could contaminate screened aggregate or wear other parts?

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6

Are there any signs of damage or wear, especially adjacent to screen bearings or shafts? Is there any significant dust emission from the screen housing lids, covers or doors? Is there any evidence of holes, splits or tears in the screen meshes and is there any apparent and significant pegging or blockages?

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1

4

3

Is there any indication of hot bin oversize or undersize in hot bin drain-outs? Bin 1 Aggregate size 0 / X mm

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Hot Aggregate Bins 1

Bin 2 Aggregate size X / X

mm

4


mm

5


mm

6


mm

7


mm

8

9

10

.

c: wasted?

Are the individual hot stone bin overflow chutes/pipes blocked or damaged? Are there holes or damaged seams or welds in the hot bin walls, especially in the corners and in the lower half of the bins? Do the hot stone bin doors stick or seize? Is there evidence of holes in or leakage from the doors?

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Page 28

Weighing and Measuring Apparatus

3

Are the calibrations of the aggregate, filler and bitumen weighing apparatus current and in date? Aggregate weighing apparatus calibration date: Bitumen weighing apparatus calibration date:

4

Filler weighing apparatus calibration date:

5

Mixed asphalt pyrometer calibration date:

6

Has the mixed asphalt pyrometer been checked recently with a referenced laboratory probe?

1 2

Date: Pyrometer:

°C

Laboratory probe:

°C

Do the printed batch weights equal the weight indicators and are total load batch weights similar to the truck scale net weight?

2

Does the bitumen bucket/kettle pass the static load test? (Hold a fully weighed batch of bitumen for at least 30 seconds and note any change in weight. Repeat when empty and note any major change in tare)

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5

qa

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Is the bitumen bucket/kettle adequately insulated and heated? Seepage or leakage from the charge and the discharge pipes? Check the butterfly valve underneath for direct gravity discharge systems.

se

4

Does the aggregate and filler weighing apparatus pass the static load test? Is there any bitumen seepage or leakage from the charge and the discharge pipes, and the butterfly valve underneath on direct gravity discharge bitumen bucket/kettle systems?

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Bitumen Storage and Pumping

Where fitted, are breather vents clear on the bitumen weigh bucket/kettle and delivery pipe to the mixer? Are the bitumen tanks and are all tanks clearly labelled according to the grade of binder stored? Are stored binder tank temperatures compliant with specification or supplier recommendations? Where PMB is stored, are the stirrers operational and in good condition? Is there a supplier defined procedure for the storage and use of polymer modified binders? Are all tanks, pipes, pumps and flow meters properly insulated and the surrounds clean and in good order? Is there any evidence of excessive bitumen or oil seepage/leaks from pump(s), valves or manifolds? Are bitumen tank temperatures monitored and recorded daily by the plant staff? Are the bitumen binders tested for foaming when heated to 175°C? Is there a control or procedure for tank/binder grade selection according to asphalt mix recipe to avoid using the incorrect grade?

3 4 5 6 7 8 9 10

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Weighing efficacy:

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Asphalt Mixing

4 5 6 7 8

Is there excessive overflow from the aggregate overflow chutes? Check the required batch weights on the mix card. Are batch deviations within acceptable guide tolerance?

.

3

Are inspection hatches secure and sealed to prevent dust emission? Are electric cables, hydraulic and air lines well maintained and in good order? Are all mixer arms, paddles and tips, liners and door seals present and in good condition? Is the aggregate weighing sequence, coarse size to fine size?

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1

Are the weighing apparatus and mixer external surrounds in clean and good order with no apparent seepage or leakage of aggregate, filler or bitumen?

Batch aggregate component ±1.5% of total batch weight

10

Bitumen deviation ±0.1% of total batch weight

11

Mineral filler deviations ±0.1% of total batch weight

qa

ta

9

sec.

14

What is the delay time after aggregate discharge for filler:

sec.

se

er

On completion of the mixing cycle, does the mixer fully empty?

o

16

What is the total wet mixing time in seconds? (From the complete discharge of the bitumen and filler to the emptying of the finished batch)

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15

as

13

Are the in-flight adjustments being made automatically by the plant control system? What is the delay time after aggregate discharge for bitumen:

12

18 19 20 21

et it

On visually inspecting single batches of asphalt, is the appearance consistent from side to side and front to back, and not segregated? Does each batch conform to the mix temperature specification requirement?

m

17

Does the plant indicated mixed asphalt temperature correspond with a laboratory check? Where used, is the skip hopper acceptably clean? Are the empty hot storage silos acceptably clean without cold asphalt sticking to the sides and corners?

Loading 1 2 3

Are all trucks acceptably clean prior to loading without any evidence of diesel being used as a release agent? Are all trucks equipped with load cover sheets or canvasses? Are the loaded trucks free of significant segregation?

sec.

QCS 2014

4 5

6

7


Page 30

Is the asphalt temperature acceptably consistent and within range tolerance throughout the load front to back? Has the correct delivery ticket been issued to the driver with accurate asphalt description, truck reference or number, site address, driver name, and ticket number? Is the plant sampling technician equipped with all necessary PPE including safety helmet, steel-capped boots, overalls, gloves, hi-visibility jacket, and protective eye glasses? Are the plants sampling procedures being following by the technician to ensure a representative sample? (Ask for and retain a copy of the sampling procedures.) Are plant sample details, including truck delivery details, are recorded on each plant sample?

9

Request plant compliance rate for each product supplied to the project or contract for record purposes.

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8

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END OF PART

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 1

RECYCLED AND STABILISED ROAD MATERIALS ............................................................ 2

8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5

GENERAL SCOPE REFERENCES DEFINITIONS SUBMITTALS QUALITY ASSURANCE

2 2 2 3 4 4

8.2

COLD STABILISED MATERIAL - GENERAL

4

8.3

MATERIALS

5

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 8.4.8

CEMENT TREATED BASE (CTB) PREPARATION AND MIX DESIGN FOR CEMENT TREATED BASE SITE TRIALS FOR CEMENT TREATED BASE AND BITUMEN STABILISED MATERIAL INSITU STABILISATION AND COMPACTION OF CEMENT TREATED BASE EXSITU PRODUCTION OF CEMENT TREATED BASE LAYING AND COMPACTION OF CEMENT TREATED BASE JOINTS IN CEMENT TREATED BASE SAMPLING AND TESTING - CEMENT TREATED BASE EVENNESS AND LEVEL

8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8

BITUMEN STABILISED MATERIAL (BSM) PREPARATION AND MIX DESIGN FOR BITUMEN STABILISED MATERIAL SITE TRIALS FOR BITUMEN STABILISED MATERIAL INSITU STABILISATION AND COMPACTION OF BITUMEN STABILISED MATERIAL EXSITU PRODUCTION OF BITUMEN STABILISED MATERIAL LAYING AND COMPACTION OF BITUMEN STABILISED MATERIAL JOINTS IN BITUMEN STABILISED MATERIAL SAMPLING AND TESTING - BITUMEN STABILISED MATERIAL EVENNESS AND LEVEL

12 12 13 13 14 15 16 16 17

8.6

DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN (EXPANSION RATIO AND HALF LIFE) SCOPE DEFINITIONS APPARATUS METHOD REPORTING SITE QUALITY CONTROL

18 18 18 18 19 19 20

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6 6 7 7 9 9 10 10 12

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8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6

.

8

APPENDIX ............................................................................................................................................ 21 GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)

QCS 2014


Page 2

RECYCLED AND STABILISED ROAD MATERIALS

8.1

GENERAL

8.1.1

Scope

1

This Part includes materials, equipment, mix design guidelines and other requirements for the construction of insitu and exsitu recycled pavement layers.

2

Incorporation of stabilized or cement bound materials in pavement layers shall be based on pavement structural design criteria such as layer(s) strength characteristics, load distribution, layer(s) thickness equivalency, layers strength balance and the target level of pavement performance.

3

Use of recycled and stabilized materials and their associated construction and quality assurance and quality control processes shall be approved by the Engineer.

4

Related Parts are: General Earthworks Asphalt Works

Part 4

Water

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References

AASHTO T180: ..........Standard Method of Test for Moisture-Density Relations of Soils

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ASTM C150: ..............Standard Specification for Portland Cement

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ASTM C977: ..............Standard Specification for Quicklime and Hydrated Lime for Soil Stabilization

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ASTM C1097: ............Standard Specification for Hydrated Lime for Use in Asphalt Cement or Bituminous Pavements

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ASTM D422: ..............Standard Test Method for Particle-Size Analysis of Soils ASTM D946: ..............Standard Specification for Penetration-Graded Asphalt Cement for Use in Pavement Construction

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8.1.2

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Section 5

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Section 6

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ASTM D1556: ............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1632: ............Standard Practice for Making and Curing Soil-Cement Compression and Flexure Test Specimens in the Laboratory ASTM D1633: ............Standard Test Methods for Compressive Strength of Molded SoilCement Cylinders ASTM D2216: ............Standard Test Methods for Laboratory Determination of Water (Moisture) Content of Soil and Rock by Mass ASTM D2922: ............Standard Test Methods for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth) ASTM D4215: ............Standard Specification for Cold-Mixed, Cold-Laid Bituminous Paving Mixtures ASTM D4318: ............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils

QCS 2014


Page 3

ASTM D4944: .............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D4944: ............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D6926: ............Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus ASTM D6931: ............Standard Test Method for Indirect Tensile (IDT) Strength of Bituminous Mixtures ASTM D6938: ............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

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ASTM D7382: ............Standard Test Methods for Determination of Maximum Dry Unit Weight and Water Content Range for Effective Compaction of Granular Soils Using a Vibrating Hammer ASTM E2583: ............Standard Test Method for Measuring Deflections with a Light Weight Deflectometer (LWD) MCHW Specification for Highways Works Series 900, UK

ta

TG2 Technical Guideline: Bitumen Stabilised Materials: Asphalt Academy, South Africa

qa

TRL 611: A Guide to the Use and Specification of Cold Recycled Materials Definitions

1

Stabilisation is the permanent modification of soils and aggregates, including recycling existing pavements, to enhance the engineering properties thereby improving the load bearing capacity and performance of a new pavement structure.

2

Aggregate: Granular material used in construction. Aggregate may be natural, manufactured or recycled.

3

Primary Aggregate: aggregate extracted directly from the ground in quarries or pits, or dredged from rivers or the sea. They can be either hard rock such as gabbro and limestone, or sand and gravel.

4

Secondary Aggregate: materials produced as a by-product of other mining or quarrying activities or as a by-product of other industrial processes, e.g. blast furnace slag, incinerator ash, or the ash from power stations.

5

Recycled Aggregate: materials produced by the recycling of construction and demolition waste. These can be crushed concrete, bricks or glass, asphalt planings (i.e. the asphalt layers of roads removed during roadworks, also known as RAP – Recycled Asphalt Pavement).

6

Cold Stabilised Material (CSM): materials produced for pavement construction structural layers using recycled or secondary aggregates.

7

Bitumen Stabilised Material (BSM): bitumen or bitumen emulsions.

8

Cement Treated Base (CTB): granular aggregate materials bound with cement or hydrated lime hydraulic binder.

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8.1.3

granular aggregate materials bound with foamed

QCS 2014


Page 4

Exsitu Stabilisation: mixing processes that are carried out away from the construction location in a remote mixing plant.

10

Insitu Stabilisation: mixing processes that are carried out at the construction location by specialised stabilisation equipment.

11

Optimum Moisture Content: the moisture content of soil at which a specific degree of compaction will produce the maximum dry density when determined in accordance with the AASHTO T180.

12

Maximum Dry Density: the dry density of soil obtained using a specific degree of compaction at the optimum moisture content when determined in accordance with AASHTO T180.

8.1.4

Submittals

1

The Contractor shall submit recent test results for the proposed sources of materials for all quality requirements of the Contract. The contractor shall submit a test certificate that proves that the raw materials that are purchased/used comply with specifications. The testing may be performed by an approved private laboratory or by the laboratory associated with the plant itself.

2

The contractor shall submit to the Engineer for approval method statements, which includes but not limited to the following:

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9

Quality assurance and quality control plans of all construction activities

(b)

Material, handling, storage, identification and marking, traceability to source of production and testing.

(c)

Equipment suitability to fulfil all construction activities to the required quality

(d)

Personnel capability

(e)

Safety and environment preservation plans

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(a)

The Contractor will be required to produce detailed method statements for the chosen method of recycling rehabilitation and shall include all stages of the process for approval by the Engineer. This shall include the credentials and details of experience of the stabilising contractor, the site investigation report, the stabilised material mix design and the equipment to be used for the entire process. A separate method statement shall be submitted for each of the production and construction activities of each layer.

8.1.5

Quality Assurance

1

If requested the Contractor shall arrange for the Engineer to visit the source of the materials and jointly take samples for testing. The Contractor shall carry out testing as directed by the Engineer.

8.2

COLD STABILISED MATERIAL - GENERAL

1

Cold Stabilised Material (CSM) comprises base and binder courses produced by the process of in-place recycling (insitu) or in a fixed or mobile mixing plant (exsitu) where the aggregate source shall be obtained by cold pulverisation of all, or part, of the existing road structure, blended if necessary with other aggregate and bound with cementitious / hydraulic (CTB) or bituminous binders (BSM), separately or in combination, or by the use of primary aggregates.

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Page 5

Cold Stabilised Material (CSM) shall be designed and produced to form the foundation or main structural layer of the road pavement.

3

For Bitumen Stabilised Material (BSM) the primary active binder (stabilising agent) shall be foamed bitumen, with cement as an adhesion agent as required by the design. For Cement Treated Base (CTB) the primary active binder shall be cement, hydrated lime or a blend of both in accordance with the mix design. The aggregate grading may be adjusted by the addition of inactive mineral filler.

4

Insitu and exsitu methods of stabilisation rehabilitation are permissible with the approval of the Engineer on a site by site basis.

5

Stabilisation design and installation processes shall be in accordance with internationally recognised standards and specifications, and shall meet the necessary pavement structural design according to the appropriate traffic classification.

6

The Cold Stabilised Material shall be designed to achieve the specified level of the appropriate end performance property to the requirements of the total pavement design. The minimum layer thickness shall be as required by the design method used, as approved by the Engineer.

7

The asphalt type and thickness above the CSM shall be as required by the pavement design method and shall also be sufficient to prevent reflective cracking and early life trafficking, to the satisfaction of the Engineer.

8.3

MATERIALS

1

The method statement submitted by Contractor shall contain details of all aggregates to be used in the CSM.

2

Aggregates may include:

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2

Material planed or excavated from a road or other paved area.

(b)

Primary, secondary or recycled aggregate from other sources.

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Mineral filler from primary or secondary sources.

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(c)

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(a)

3

The aggregate including added inactive filler shall not contain deleterious material that adversely affects the performance of the mixture. This includes clay materials, friable materials, organic and metallic materials, or other extraneous or detrimental material.

4

The aggregate gradation for CSM shall follow the requirements stated in the mix design method, as approved by the Engineer, and shall generally follow the recommended gradations in Table 8.1 Recommended Gradations for Cold Stabilised Materials.

5

For BSM, material passing the 0.425mm sieve shall have a maximum liquid limit of 25% and the plasticity index shall not exceed 6.

6

Bitumen specified for use in BSM shall be 60/70 penetration grade in accordance with ASTM D946 and shall only be obtained from approved sources. The temperature of the bitumen prior to foaming shall be greater than 175°C but less than 195°C. Bitumen shall not contain any additives which may suppress foaming.

QCS 2014


Table 8.1 Recommended Gradations for Cold Stabilised Materials Bitumen Stabilised Job Mix Control Cement Treat Base (CTB) Material (BSM) Sieve Tolerances 100

100

100

100

-2

37.5

85

100

87

100

±5

25

72

100

77

100

-

19

60

100

67

99

±8

12.5

50

100

67

90

-

9.5

42

90

48

80

±8

6.3

35

80

40

62

-

4.75

30

72

35

56

± 10

2.36

21

56

25

42

1.18

14

44

18

0.6

9

35

14

0.425

7

31

12

0.3

5

27

10

0.15

2

21

0.075

2.0

18.0

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50

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Sieve Size (mm)

Page 6

-

28

±5

26

-

ta

33

-

7

17

-

4.0

10.0

±3

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as

24

Cement specified for use in BSM and CTB shall be Portland cement in accordance with ASTM C150 and shall only be obtained from approved sources. Sulfate resisting cement shall be used if instructed by the Engineer.

8

Hydrated lime for use in BSM shall be in accordance with ASTM C1097 and for CTB shall be in accordance with ASTM C977, and shall only be obtained from approved sources.

9

Water for use in CSM shall in accordance with Section 5 Part 4.

8.4

CEMENT TREATED BASE (CTB)

8.4.1

Preparation And Mix Design For Cement Treated Base

1

The Contractor shall produce a detailed existing pavement investigation report and the proposed stabilised material mix design which shall be submitted for approval by the Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the commencement of the stabilisation works. The pavement investigation report shall consist of cores and trial pits excavated to the existing subgrade and include tests for, but not limited to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and liquid limit, and other tests required by the selected design method.

2

All equipment and method statements shall be submitted for approval by the Engineer at least 30 days prior to commencement of works.

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Page 7

The mix design method for the CTB mix shall be as approved by the Engineer. Methods may include that stated in this part, MCHW Specification for Highways Works Series 900: UK, or other similar and equivalent recognised international design methods for cement or hydraulic bound materials.

4

The CTB mix shall have a minimum individual 7 day compressive strength > 2.1 MPa with a maximum average 7 day compressive strength of 4.2 MPa when tested in accordance with ASTM D1633.

5

The mix design shall derive the gradation tolerance parameters of the pulverised material, moisture content at the point of compaction and target flow rates for the active filler, binder and added water at the point of mixing, appropriate to the production or stabilisation method used for the approval of the Engineer.

8.4.2

Site Trials For Cement Treated Base And Bitumen Stabilised Material

1

The CTB mix design shall be subjected to full preliminary trials and testing at least 10 days prior to commencement of the full works and shall determine:

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The effectiveness of the production and laying plant for exsitu processes;

(b)

The number of passes of the stabilisation machine necessary to achieve uniform pulverisation and mixing for insitu processes;

(c)

The field moisture content control required to achieve specified compaction requirements;

(d)

The compaction routine and rolling patterns necessary to meet the specified compaction requirements;

(e)

The reference density;

(f)

The effectiveness of the contractor’s inspection and test plan.

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(a)

The length of the trial section shall be at least 150 metres and the full width of the carriageway proposed for stabilisation to ensure joints and full width compaction can be achieved without excessive segregation or other significant defects.

3

The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer.

4

Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior to commencement of the works. No works may proceed until all tests and final method statements have been submitted and approved by the Engineer.

5

Where materials and processes are demonstrably similar, mix designs and trials tests from previous projects may be approved at the discretion of the Engineer, in liaison with Qatar Quality Standards.

8.4.3

Insitu Stabilisation And Compaction Of Cement Treated Base

1

The insitu CTB stabilisation/recycling shall be produced by specialist equipment specifically designed for the purpose of insitu recycling processes.

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Page 8

The material shall be pulverised and stabilised in a single layer if its compacted thickness is 300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be pulverised and stabilised in the minimum number of layers between100 mm and 300 mm thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that the lower layer has achieved adequate stability before proceeding with the overlying layer.

3

Where required by the Engineer the stability of a layer in any area shall be assessed after a curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles). The vertical deformation shall be measured in all wheel-tracks at monitoring points on each of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The mean vertical deformations at the above trafficking increments shall be plotted against the respective number of truck passes and the mean vertical deformation corresponding to 100 standard axles shall be interpolated. The layer shall be deemed acceptable if the mean vertical deformation corresponding to 100 standard axles is less than 10 mm.

4

The active filler (cement/hydrated lime) shall be supplied to the recycler by a specifically designed and calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

5

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the production process.

6

Should either the slurry mixer supply to the mixer fail to operate or deliver the correct proportions to the recycler, all work shall cease until this has been corrected. Prior to resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip exceeding 50 metres to ensure the process is fully operational and under control.

7

The recycler shall proceed in a continuous operation to the full depth of the layer being recycled as required by the pavement design.

8

The CTB moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

9

Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is appropriate with the thickness of the layer being compacted. The vibration mode must be set on high amplitude to achieve maximum penetration of compactive effort.

10

The rolling pattern should first concentrate on the middle section between the rear wheel paths of the recycler, then across the full cut width to achieve uniform density. The travel speed of the roller shall not exceed 3 km/h.

11

When initial compaction is complete, the surface shall be struck off to level by a grader and the surface again checked for level and any defects or damage caused during the operation which shall be corrected prior to final compaction.

12

Where the recycler has a screed finisher which achieves the required level, initial compaction shall follow the recommendations of the recycler supplier.

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Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not excessively over or under bindered, or watered.

14

Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a 2 rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand 2 applied at a rate of 5.5 to 7.0 kg/m .

15

Traffic, including delivery vehicles shall not be permitted on the uncompacted or semicompacted recycled material. The exposed longitudinal joint shall be protected from damage by construction plant and vehicles.

8.4.4

Exsitu Production Of Cement Treated Base

1

The exsitu production of CTB shall be produced by specialist recycling and stabilisation production equipment specifically designed for the purpose of exsitu processes.

2

The active filler (cement/hydrated lime) shall be supplied to the mixer by specifically designed and calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

3

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the production process.

4

CTB shall not segregate significantly during production and all measures shall be taken to avoid this occurrence.

5

CTB shall be conveyed from the mixer to its place in the Works as rapidly as possible in covered vehicles which will prevent segregation or drying out and ensure that the material is of the required workability and moisture content at the point of delivery to the paving equipment.

6

Where CTB is produced on an exsitu production plant, the material shall be laid and fully compacted within 2 hours of production, ensuring that the moisture content is within the required limits at the time of laying. CTB that exceeds 2 hours shall be rejected.

8.4.5

Laying And Compaction Of Cement Treated Base

1

Exsitu produced CTB materials shall be laid with paving machines and compaction plant as detailed in Section 6 Part 5, but may include additional specialist equipment deemed appropriate indicated in the detailed method statement.

2

The CTB moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

3

Material shall be laid to a thickness that would result in layers not more than 150 mm thick after compaction. Where the finished compacted thickness exceeds 150 mm placing shall be executed in composite layers each layer not exceeding 150 mm in compacted thickness as directed by the Engineer.

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Final compaction for CTB shall follow the general requirements Section 6 Part 6 using a combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with the approved method statement.

5

Where the surface of the recycled layer has been graded to level, it may be dampened with a water spray prior to compaction. Care shall be taken not to use excessive watering.

6


7

Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material, the requirements of Section 6 Part 5 shall be followed.

8


9


8.4.6

Joints In Cement Treated Base

1

Transverse joints shall be made by cutting back at least 2 metres to the position of conforming level and compaction, and cleaned to remove any loose material. The joint shall be fully compacted and left level and smooth.

2

Longitudinal joints shall be formed as follows:

3

For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to cross compaction. Joints are deemed to be fresh when the pavement materials on both sides of the joint have been stabilised and are able to be compacted within 1 hour. The 500mm partially compacted strip together with the exposed edge shall be lightly moistened prior to placement of the second strip.

4

For paver laid materials and where the stabilised layer has been laid previously or is deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to remove any loose material prior to paving the new adjacent strip.

5

Longitudinal construction joints in CTB shall always be formed at the lane line marking positions where practically possible.

8.4.7

Sampling And Testing - Cement Treated Base

1

The Contractor shall produce an inspection and test plan for the complete process which shall include daily production control and the finished stabilised pavement for approval by the Engineer.

2

Bulk samples shall be taken from the stabilised material to the full depth of the layer.

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Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and protected from the heat and sun in an ambient temperature of no greater than 20°C.

4

Samples shall be provided from the laid CTB before compaction, as approved by the Engineer. One group of five samples shall be provided from five locations equally spaced along a diagonal that bisects each 800m2 or part thereof laid each day. The number of groups may be increased if required by the Engineer. Each group shall be combined to provide samples for reference density, compressive strength and laboratory determined moisture content.

5

For each group, 3 specimens for reference density and compressive strength testing shall be compacted in accordance with AASHTO T180within 2 hours of the addition of the cement and cured in accordance with ASTM D1632, and tested in accordance with ASTM D1633.

6

To determine the reference density of test specimens the mould shall be weighed prior to making the specimen and the mass recorded. Immediately after completion of compaction, the specimen and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the reference density of the specimen.

7

The in-situ density of a layer of cement bound material shall be taken as the average of the densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part thereof laid each day. The in-situ density at each location shall be the average of two readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings shall be taken within two hours of completing final compaction.

8

Testing for CTB shall be required as Table 8. 2 Sampling and Testing Requirements for Cement Treated Base

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TEST

SPECIFICATION

FREQUENCY

ASTM D422

Pre-Stabilised Pulverised Materials

Design mix gradation

1/1000m

3

ASTM D4318


Less than design mix determination

1/1000m

3

ASTM D4318


Less than design mix determination

1/1000m

3

ASTM D1556/D6938

Compacted Stabilised Material

100% reference density

5/800m

2

ASTM D4944

Pre-compacted Stabilised Material

± 2% OMC

1/800m

2

ASTM E2583


Report Values

5/800m

2

Compressive Strength

ASTM D1633


Individual >2.1 MPa Average of 3 <4.2 MPa

1/800m

2

Reference density

AASHTO T-180


-

1/800m

2

Moisture Content

ASTM D2216

Laid Stabilised Material

± 2% OMC

1/800m

2

Sieve Analysis Liquid Limit

m

Plasticity Index

METHOD

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SAMPLE POINT

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Table 8. 2 Sampling and Testing Requirements for Cement Treated Base

Field Density Field Moisture Content Surface Modulus

1

Note 1 – The surface modulus determined in accordance with ASTM E2583 shall be reported as directed by the Engineer for data collection. It shall not form part of the acceptance or rejection criteria.

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Evenness And Level

1

The transverse regularity of the surface of the CTB shall be tested by means of a 4 metre long straight edge. No irregularity in excess of 10 mm shall be permitted.

2

The longitudinal regularity of the surface of the CTB shall be tested by means of a rolling straight edge. No irregularity in excess of 10 mm shall be permitted.

3

The finished surface shall also be checked by dips or spot levels and shall be constructed to the designated grade levels to within ± 10 mm.

4

Where these requirements are not met, the Contractor shall determine the full extent of the area which is out of tolerance and shall make good the surface of the course by scarifying to a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater, reshaping by adding or removing material as necessary, adding water if necessary and recompacting the layer. The minimum length of rectification shall be 50 metres.

5

Acceptance of the stabilised pavement is subject to completion of all testing and inspection requirements to the satisfaction of the Engineer.

8.5

BITUMEN STABILISED MATERIAL (BSM)

8.5.1

Preparation And Mix Design For Bitumen Stabilised Material

1

The Contractor shall produce a detailed existing pavement investigation report and the proposed stabilised material mix design which shall be submitted for approval by the Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the commencement of the stabilisation works. The pavement investigation report shall consist of cores and trial pits excavated to the existing subgrade and include tests for, but not limited to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and liquid limit, and other tests required by the selected design method.

2

All equipment and method statements shall be submitted for approval by the Engineer at least 30 days prior to commencement of works.

3

The mix design method for the BSM mix shall be as approved by the Engineer. Methods may include that stated in this part, or MCHW Specification for Highways Works Series 900: (UK), or other similar and equivalent recognised international design methods for Bitumen Stabilised Material.

4

The aggregate gradation for BSM shall follow the guideline in Error! Reference source not ound. unless otherwise stated in the approved alternative design method.

5

The Design Mixture for BSM shall have minimum bitumen content of 2.5% with an active filler content no greater than 1%, by mass of total mix.

6

The Binder Expansion Ratio (ER) shall be greater than 10 times and the Binder Half Life (T½) greater than 12 seconds.

7

The Indirect Tensile Strength dry (ITSdry - 100mmØ specimens) shall be greater than 225 kPa and the Indirect Tensile Strength wet (ITSwet - 100mmØ specimens) shall be greater than 100 kPa when tested in accordance with ASTM D6931. The Tensile Strength Ratio (TSR) shall be greater than 80%

8

The Unconfined Compressive Strength of the mixture shall be between 1200 and 3500 kPa when tested in accordance with ASTM D1633.

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8.5.2

Site Trials For Bitumen Stabilised Material

1

The BSM mix design shall be subjected to full preliminary trials and testing at least 10 days prior to commencement of the full works and shall determine: the effectiveness of the production and laying plant for exsitu processes;

(b)

the number of passes of the stabilisation machine necessary to achieve uniform pulverisation and mixing for insitu processes;

(c)

the field moisture content control required to achieve specified compaction requirements;

(d)

the compaction routine and rolling patterns necessary to meet the specified compaction requirements;

(e)

the reference density;

(f)

the effectiveness of the contractor’s inspection and test plan.

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(a)

2

The length of the trial section shall be at least 150 metres and the full width of the carriageway proposed for stabilisation to ensure joints and full width compaction can be achieved without excessive segregation or other significant defects.

3

The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer.

4

Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior to commencement of the works. No works may proceed until all tests and final method statements have been submitted and approved by the Engineer.

5

Where materials and processes are demonstrably similar, mix designs and trials tests from previous projects may be approved at the discretion of the Engineer, in liaison with Qatar Quality Standards.

8.5.3

Insitu Stabilisation And Compaction Of Bitumen Stabilised Material

1

The insitu BSM stabilisation/recycling shall be produced by specialist equipment specifically designed for the purpose of insitu recycling processes.

2

The material shall be pulverised and stabilised in a single layer if its compacted thickness is 300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be pulverised and stabilised in the minimum number of layers between100 mm and 300 mm thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that the lower layer has achieved adequate stability before proceeding with the overlying layer.

3

Where required by the Engineer the stability of a layer in any area shall be assessed after a curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles). The vertical deformation shall be measured in all wheel-tracks at monitoring points on each of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The mean vertical deformations at the above trafficking increments shall be plotted against the respective number of truck passes and the mean vertical deformation corresponding to 100 standard axles shall be interpolated. The layer shall be deemed acceptable if the mean vertical deformation corresponding to 100 standard axles is less than 10 mm.

4

The bitumen tanker shall a consistent flow of binder to the recycler. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

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The active filler (cement) shall be supplied to the recycler by a specifically designed and calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder. The addition shall be monitored with records taken to confirm the correct addition rate according to the mix design.

6

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when bitumen streaks or blotches are observed, or where cement is seen to agglomerate or not fully mix in during the production process.

7

Should either the slurry mixer or the binder supply to the mixer fail to operate or deliver the correct proportions to the recycler, all work shall cease until this has been corrected. Prior to resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip exceeding 50 metres to ensure the process is fully operational and under control.

8

The recycler shall proceed in a continuous operation to the full depth of the layer being recycled as required by the pavement design.

9

The BSM moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

10

Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is appropriate with the thickness of the layer being compacted. The vibration mode must be set on high amplitude to achieve maximum penetration of compactive effort.

11

The rolling pattern should first concentrate on the middle section between the rear wheel paths of the recycler, then across the full cut width to achieve uniform density. The travel speed of the roller shall not exceed 3 km/h.

12

When initial compaction is complete, the surface shall be struck off to level by a grader and the surface again checked for level and any defects or damage caused during the operation which shall be corrected prior to final compaction.

13

Where the recycler has a screed finisher which achieves the required level, initial compaction shall follow the recommendations of the recycler supplier.

14

Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not excessively over or under bindered, or watered.

15

Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand applied at a rate of 5.5 to 7.0 kg/m2.

16

Traffic, including delivery vehicles shall not be permitted on the uncompacted or semicompacted recycled material. The exposed longitudinal joint shall be protected from damage by construction plant and vehicles.

8.5.4

Exsitu Production Of Bitumen Stabilised Material

1

The exsitu production of BSM shall be produced by specialist recycling and stabilisation production equipment specifically designed for the purpose of exsitu processes.

2

The bitumen shall be supplied to the mixer by specifically designed and calibrated metering apparatus to ensure the correct addition of the binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

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The active filler (cement) shall be supplied to the mixer by specifically designed and calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

4

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when bitumen streaks or blotches are observed or where cement is seen to agglomerate or not fully mix in during the production process.

5

BSM shall not segregate significantly during production and all measures shall be taken to avoid this occurrence.

6

BSM shall be conveyed from the mixer to its place in the Works as rapidly as possible in covered vehicles which will prevent segregation or drying out and ensure that the material is of the required workability and moisture content at the point of delivery to the paving equipment.

7

Where BSM is produced on an exsitu production plant, the material shall be laid and fully compacted within 2 hours of production, ensuring that the moisture content is within the required limits at the time of laying. BSM that exceeds 2 hours shall be rejected.

8.5.5

Laying And Compaction Of Bitumen Stabilised Material

1

Exsitu produced BSM materials shall be laid with paving machines and compaction plant as detailed in Section 6 Part 5, but may include additional specialist equipment deemed appropriate indicated in the detailed method statement.

2

The BSM moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

3

Material shall be laid to a thickness that would result in layers not more than 150 mm thick after compaction. Where the finished compacted thickness exceeds 150 mm placing shall be executed in composite layers each layer not exceeding 150 mm in compacted thickness as directed by the Engineer.

4

Final compaction for BSM shall follow the general requirements Section 6 Part 5 using a combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with the approved method statement.

5

Where the surface of the recycled layer has been graded to level, it may be dampened with a water spray prior to compaction. Care shall be taken not to use excessive watering.

6


7

Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material, the requirements of Section 6 Part 5 shall be followed.

8


9


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8.5.6

Joints In Bitumen Stabilised Material

1

Transverse joints shall be made by cutting back at least 2 metres to the position of conforming level and compaction, and cleaned to remove any loose material. The joint shall be fully compacted and left level and smooth.

2

Longitudinal joints shall be formed as follows: For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to cross compaction. Joints are deemed to be fresh when the pavement materials on both sides of the joint have been stabilised and are able to be compacted within 1 hour. The 500mm partially compacted strip together with the exposed edge shall be lightly moistened prior to placement of the second strip.

(b)

For paver laid materials and where the stabilised layer has been laid previously or is deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to remove any loose material prior to paving the new adjacent strip.

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(a)

Longitudinal construction joints in BSM shall always be formed at the lane line marking positions where practically possible.

8.5.7

Sampling And Testing - Bitumen Stabilised Material

1

The Contractor shall produce an inspection and test plan for the complete process which shall include daily production control and the finished stabilised pavement for approval by the Engineer.

2

Bulk samples shall be taken from the stabilised material to the full depth of the layer.

3

Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and protected from the heat and sun in an ambient temperature of no greater than 20°C.

4

Samples shall be provided from the laid BSM before compaction, as approved by the Engineer. One group of five samples shall be provided from five locations equally spaced 2 along a diagonal that bisects each 800m or part thereof laid each day. The number of groups may be increased if required by the Engineer.

5

For each group, 3 specimens for strength based testing shall be compacted within 2 hours of the addition of the bitumen binder. Reference density and UCS shall be compacted and cured in accordance with AASHTO T-180, and tested in accordance with ASTM D1633. ITS testing shall be compacted in accordance with ASTM D6926 and tested in accordance with ASTM D6931.

6

The foamed bitumen expansion ratio and half life shall be determined at the commencement of works each day if required by the Engineer.

7

To determine the reference density of test specimens the mould shall be weighed prior to making the specimen and the mass recorded. Immediately after completion of compaction, the specimen and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the reference density of the specimen.

8

The in-situ density of a layer of cement bound material shall be taken as the average of the 2 densities at five locations equally spaced along a diagonal that bisects each 800 m or part thereof laid each day. The in-situ density at each location shall be the average of two readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings shall be taken within two hours of completing final compaction.

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Testing for BSM shall be required as Table 8.3 Sampling and Testing Requirements for BSM. Table 8.3 Sampling and Testing Requirements for BSM METHOD

SAMPLE POINT

SPECIFICATION LIMIT

FREQUENCY

ASTM D422


Design mix gradation

1/1000m

3

Liquid Limit

ASTM D4318


Maximum 25

1/1000m

3

Plasticity Index

ASTM D4318


Maximum 6

1/1000m

3

Field Density

ASTM D1556/D6938


100% reference density

5/800m

2

Field Moisture Content

ASTM D4944


± 2% OMC

1/800m

2

Surface Modulus

ASTM E2583


Report Test 1 Values

5/800m

2

Binder Expansion Ratio

This Part:‎8.6

Pre-mixing/ stabilisation

>10 times

1/first 500 2 m /day

Binder Half Life (τ½)

This Part:‎8.6

> 12 seconds

1/first 500 2 m /day

Unconfined Compressive Strength

ASTM D1633 (150mmØ)

1200 to 3500 kPa

1/800m

2

Moisture Content

ASTM D2216

Laid Stabilised Material

± 2% OMC

1/800m

2

Indirect Tensile Strength

ASTM D6931 (100mmØ)


ITSdry >225 kPa ITSwet >100 kPa

1/day if 2 >800m


> 80%

1/day if 2 >800m

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Tensile Strength Retained (TSR)

ITSwet / ITSdry

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Pre-mixing/ stabilisation Pre-compacted Stabilised Material

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Sieve Analysis

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TEST

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Note 1 – The surface modulus determined in accordance with ASTM E2583 shall be reported as directed by the Engineer for data collection. It shall not form part of the acceptance or rejection criteria.

8.5.8

Evenness And Level

1

The transverse regularity of the surface of the BSM shall be tested by means of a 4 metre long straight edge. No irregularity in excess of 10 mm shall be permitted.

2

The longitudinal regularity of the surface of the BSM shall be tested by means of a rolling straight edge. No irregularity in excess of 10 mm shall be permitted.

3

The finished surface shall also be checked by dips or spot levels and shall be constructed to the designated grade levels to within ± 10 mm.

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Page 18

Where these requirements are not met, the Contractor shall determine the full extent of the area which is out of tolerance and shall make good the surface of the course by scarifying to a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater, reshaping by adding or removing material as necessary, adding water if necessary and recompacting the layer. The minimum length of rectification shall be 50 metres.

5

Acceptance of the stabilised pavement is subject to completion of all testing and inspection requirements to the satisfaction of the Engineer.

8.6

DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN (EXPANSION RATIO AND HALF LIFE)

8.6.1

Scope

1

The foaming characteristics of bitumen are defined by the Expansion Ratio and Half Life of the bitumen in its expanded state. The expanded state of the bitumen is achieved when a small percentage of water is introduced into hot bitumen. The objective is to determine the percentage of water required that will produce the best foam characteristics for a particular source of bitumen. The aim is to produce foamed bitumen with the largest expansion ratio with the longest half-life possible.

8.6.2

Definitions

1

The expansion ratio is a measure of the viscosity of the foam and provides an indication of how well the binder will disperse in the mix. It is calculated as the ratio of the maximum volume of foam relative to the original volume of bitumen. The half-life is a measure of the stability of the foam and provides an indication of the rate of collapse of the foam during mixing. It is calculated as the time taken in seconds for the foam to collapse to half of its maximum volume.

8.6.3

Apparatus

1

The following equipment shall be required: For mix design only: Foamed Bitumen Laboratory Unit, capable of producing foamed bitumen at a rate of between 50g and 200g per second. The method of production shall closely simulate that of full scale production of foamed bitumen on the recycling machine. The apparatus shall have a thermostatically controlled kettle capable of holding a mass of 10kg of bitumen at a constant temperature between the range of 160ºC and 200ºC, ± 5ºC. The unit shall have an expansion chamber similar to that on the recycling machine in which cold water is injected into hot bitumen. Water injection shall be variable from 0 to 5% (by mass of the bitumen) with an accuracy of 0.25%. The plant shall capable of accurately discharging a predetermined mass of foamed bitumen directly into the mixing bowl of an electrically driven laboratory mixer with a minimum capacity of 10kg.

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(b)

Cylindrical metal container, 250mm diameter and at least 20 litre capacity.

(c)

Calibrated Dip Stick, calibrated for the cylindrical metal container with 500g of bitumen as 1 unit measure. Prongs are attached to the dip stick at every 5 or 6 times the unit volume.

(d)

A stop-watch with 60 second dial.

(e)

Heat resistant gloves.

(f)

An electronic balance to weigh up to 10kg, accurate to 1g.

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8.6.4

Method

1

Preparation (a)

The foamed bitumen laboratory unit discharge rates are checked in accordance with the manufactures specifications. If the unit is being used for the first time then the pump rate and water flow rates need to be calibrated as per the manufactures specifications. Check that 500g of bitumen is being discharged at the predetermined settings.

(b)

Ensure that the cylindrical metal container and dip stick are reasonably clean. Discharge foamed bitumen, at least twice, into cylindrical metal container prior to testing in order to pre-heat the container. Decant excess bitumen from the container into a suitable waste receptacle.

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Heat the bitumen in the kettle of the foamed bitumen laboratory unit with the pump circulating the bitumen through the system until the required temperature is achieved (normally starting with 160 °C). Maintain the required temperature for at least 5 minutes prior to commencing with testing.

(b)

Set the water flow-meter to achieve the required water injection rate (normally starting with 2 % by mass of the bitumen).

(c)

Discharge foamed bitumen into the preheated steel drum for the calculated spray time for 500 g of bitumen. Immediately after the foamed bitumen discharge stops, start a stopwatch.

(d)

Using the calibrated dipstick measure the maximum height the foamed bitumen achieves in the drum. This maximum volume is recorded as the expansion. Continue to measure the time in seconds that the foam takes to dissipate to half of its maximum volume. This is recorded as the foamed bitumen’s half-life.

(e)

Repeat the above procedures three times or until similar readings are achieved.

(f)

The expansion and half-life are determined at different percentages of water. Typically, values of 2 %, 3 % and 4 % by mass of bitumen are used.

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Plot a graph of the expansion ratio versus half-life at the different water injection rates on the same set of axes. The optimum water addition is chosen as an average of the two water contents required to meet the minimum criteria. (Figure 7.1 Determination of Optimum Foaming Water)

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(h)

If the required properties are not met at 160°C, further testing should be carried out with the bitumen at higher temperatures (typically 170°C and 180°C).

8.6.5

Reporting

1

The foamed bitumen characteristics and optimum water content are reported as; Optimum water content (%): Expansion (times): Half-life (sec):

Percentage by mass of bitumen; Ratio of maximum expansion to original volume of bitumen; Time taken from maximum expansion to half this volume.

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Site Quality Control

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The above method may be used to determine the expansion ratio and half-life of foamed bitumen dispensed by the production plant or recycler.

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Figure 7.1 Determination of Optimum Foaming Water

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8.6.6



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APPENDIX

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GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)

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GENERAL PREPARATION OF SAMPLES FOR MIX DESIGN PROCEDURES MIX DESIGN PROCEDURE FOR CEMENT STABILISED MATERIALS MIX DESIGN PROCEDURE FOR BITUMEN STABILISED MATERIALS (BSMS) DETERMINATION OF THE FLUID / DENSITY RELATIONSHIP PREPARATION FOR STABILISING W ITH BITUMEN EMULSION (BSM-EMULSION) PREPARATION FOR STABILISING W ITH FOAMED BITUMEN (BSM-FOAM) MANUFACTURE OF 100MM DIAMETER SPECIMENS DETERMINATION OF THE STRENGTH OF 100MM DIAMETER SPECIMENS MANUFACTURE OF 150MM DIAMETER SPECIMENS DETERMINATION OF THE STRENGTH OF 150MM DIAMETER SPECIMENS STRENGTH TEST PROCEDURES SELECTION OF THE AMOUNT OF BITUMEN TO BE ADDED FOR BSM DETERMINATION OF THE SHEAR PROPERTIES OF BSM DETERMINATION OF TRIAXIAL SHEAR PARAMETERS USING SIMPLE TRIAXIAL TEST USING LABORATORY TEST RESULTS FOR ESTIMATING STRUCTURAL LAYER COEFFICIENTS PROFORMA REPORT SHEET FOR ITS TESTING LABORATORY EQUIPMENT REQUIREMENTS

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8.7 8.7.1 8.7.2 8.7.3 8.7.4 8.7.5 8.7.6 8.7.7 8.7.8 8.7.9 8.7.10 8.7.11 8.7.12 8.7.13 8.7.14 8.7.15 8.7.16 8.7.17


23 23 25 27 28 29 29 32 34 34 36 37 38 40 40 45 46 47

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8.7


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GENERAL The detailed procedures for carrying out stabilisation mix designs in a laboratory are described below. Procedures for both cement (or lime) and bitumen stabilisation are included as well as guidelines for interpreting the test results for bitumen stabilised materials (BSMs). Comprehensive lists of laboratory equipment are provided. In addition, a chart has been included showing how laboratory test results can be utilised to indicate the relevant structural coefficient for a BSM (for use in the AASHTO 1993 pavement design method). Preparation Of Samples For Mix Design Procedures

1

Field Sampling: Bulk samples are obtained from test pits excavated as part of the field investigations. Each layer in the upper pavement (± 300mm) must be sampled separately and at least 150kg of material recovered from each layer that is likely to be included in any mix design procedure. Representative samples shall be obtained and prepared either from the excavation process at source or by laboratory crushing and screening.

2

Standard soil tests: Carry out the following standard tests on the material sampled from each individual layer:

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8.7.1

Sieve analysis to determine the grading (ASTM D 422);

(b)

Atterberg limits to determine the liquid limit and plasticity index (ASTM D 4318); and

(c)

Moisture / density relationship (AASHTO T-180).

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(a)

Sample blending: Where necessary, blend the materials sampled from the different layers to obtain a combined sample representing the material from the full recycling depth. The in-situ density of the various components must be considered when blending materials, as illustrated in

4

Figure 7.1 Determination of Optimum Foaming Water Repeat the standard soil tests described above to determine the grading and plasticity index of the blended sample.

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Existing upper pavement structure

60mm Asphalt 3 (in situ density 2300 kg/m )

200mm Subbase 3 (in situ density 2000 kg/m )

Recycling depth 200mm =

60mm Asphalt + 140mm Gravel

The materials are blended in proportion to layer thickness and insitu density as follows: Per square metre Proportion by mass Per 10kg sample Material (kg) (%) (g) 0.06 x 2300 = Asphalt (60mm at 2300 kg/m3) 138/418 = 0.33 0.33 x 10000 = 3300 138 0.14 x 2000 = Gravel (140mm at 2000 kg/m3) 280/418 = 0.67 0.67 x 10000 = 6700 280 Total

418

1.00

Figure 7.2 Example of Density Proportioning

10000

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Page 24

Representative proportioning: Separate the material in the representative sample into the following four fractions: 

Retained on the 19.0mm sieve;



Passing the 19.0mm sieve, but retained the 12.5 mm sieve;



Passing the 12.5 mm sieve, but retained on the 4.75mm sieve; and



Passing the 4.75mm sieve.

.

Reconstitute representative samples in accordance with the grading up to the portion passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material that passes the 19.0mm sieve, but is retained on the 12.5 mm sieve. The example in Table 8.4 Material Combination explains this procedure:

Sieve analysis

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Quantity of material to be included in a 10kg sample

Percentage passing (from sieve analysis)

19

90.5

12.5

72.3

4.75

53.6

Passing 4.75mm

Passing 12.5mm Retained 4.75mm

(53.6/100 x 10000) = 5360g

((72.3-53.6)/100 x 10000) = 1870g

Passing 19mm Retained 12.5mm

((100-72.3)/100 x 10000) = 2770g

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Sample quantities: The guidelines shown Table 8.5 Test Quantities should be used for the quantity of material required for the respective tests:

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Table 8.5 Test Quantities Test

Sample quantity required

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If there is insufficient material (i.e. passing the 19mm sieve but retained on the 12.5mm sieve) for substituting that retained on the 19mm sieve, then lightly crush the material retained on the 19.0mm sieve to provide more of this fraction.

Moisture / density relationship (AASHTO T180)

5 x 7kg

Unconfined Compressive Strength (150mm Ø specimens)

20kg per stabiliser content

Bitumen stabilisation mix design (100mm Ø specimens)

Minimum 10kg per stabiliser content

Bitumen stabilisation mix design (150mm Ø specimens )

Minimum 20kg per stabiliser content

Determination of moisture content

Approximately 1kg

Hygroscopic moisture content: Two representative air-dried samples, each approximately 1kg, are used to determine the hygroscopic (air dried) moisture content of the material. (Note: Larger sample size should be used for more coarsely-graded materials.) Weigh the air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a temperature of between 105ºC and 110ºC until they achieve constant mass. The hygroscopic moisture content (W air-dry) is the loss of mass expressed as a percentage of the dry mass of the sample. Determine the hygroscopic moisture using equation 1:

QCS 2014


where:

W air-dry

= (Mmoist – Mdry) / Mdry x 100

[Equation 1]

W air-dry

= hygroscopic moisture content

[% by mass]

Mmoist

= mass of moist material

[g]

Mdry

= mass of dry material

[g]

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8.7.2

Mix Design Procedure For Cement Stabilised Materials

1

Determination of the Moisture / Density Relationship: This test is carried out using standard compaction effort to determine the Optimum Moisture Content (OMC) and Maximum Dry Density (MDD) of the cement stabilised material.

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Step 1: Weigh out the required mass of stabilising agent for each of five 7kg samples prepared as described in ‎8.7.1. The amount of stabilising agent required (expressed as a percentage by mass of the dry sample) should be close to the anticipated optimum for the material being treated. In the absence of previous tests, the following can be used as a guideline: Subbase layers:

2% for coarse material (> 50% retained on 4.75mm sieve)

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3% for fine material (< 50% retained on 4.75mm sieve) 4% for coarse material (> 50% retained on 4.75mm sieve)

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Base layers:

6% for fine material (< 50% retained on 4.75mm sieve)

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se

as

Step 2: Add the stabilising agent to the raw material and mix immediately prior to the addition of water. In order to simulate conditions on the road, compaction of the stabilised material is delayed for one hour after mixing the untreated material with stabilising agent and water. The mixed material is placed in an air-tight container to prevent loss of moisture and is thoroughly mixed every fifteen minutes.

et it

o

Manufacture of Specimens for Strength Testing: The procedure described below is for the manufacture specimens that are of 150mm in diameter and 127mm in height. These specimens will be used to determine the Unconfined Compressive Strength (UCS) and Indirect Tensile Strength (ITS) of the material.

m

2

ov

Step 3: Determine the OMC and MDD for the stabilised material in accordance with the modified moisture-density relationship test procedure (AASHTO T-180).

Step 1: Place the 20kg sample, prepared as described in ‎8.7.1, into a suitable mixing container. Step 2: Determine the dry mass of the sample using equation 2:

where:

Msample

= (Mair-dry/ (1 + (W air-dry x 100))

[Equation 2]

Msample

= dry mass of sample

[g]

Mair-dry

= air-dried mass of the sample

[g]

W air-dry = moisture content of air-dried sample [% by mass] Step 3: Determine the required amount of stabilising agent using equation 3:

where:

Mcement

= (Cadd / 100) x Msample

[Equation 3]

Mcement

= mass of lime or cement to be added

[g]

Cadd

= percentage of lime or cement required

[% by mass]

Msample

= dry mass of the sample

[g]

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Page 26

Step 4: Determine the percentage water to be added for optimum mixing purposes using equation 4 and then the mass of water to be added to the sample using equation 5:

where:

W add

= W OMC - W air-dry

[Equation 4]

Mwater

= (W add / 100) x (Msample + Mcement)

[Equation 5]

W add

= water to be added to sample

[% by mass]

W OMC

= optimum moisture content

[% by mass]

W air-dry

= moisture content of air-dried sample

[% by mass]

Mwater

= mass of water to be added

[g]

Msample


[g]

rw .l. l

.

Mcement = mass of lime or cement to be added [g] Step 5: Mix the material, cement and water until uniform. Allow the mixed material to stand for one hour with occasional mixing, as described above, before compacting three 150mm diameter specimens using modified AASHTO (T-180) compaction effort. (Note: Two 150mm diameter specimens are normally manufactured for each test.)

= (Mmoist - Mdry) / Mdry x 100))

W mould

= moulding moisture content

[% by mass]

Mmoist


[g]

as

W mould

se

where:

qa

ta

Step 6: Samples are taken during the compaction process and dried to a constant mass (at 105 to 110°C) to determine the moulding moisture content (W mould). Determine the moulding moisture using equation 6: [Equation 6]

er

Mdry = mass of dry material [g] Steps 7 to 9: Repeat the above steps for at least three different stabiliser contents.

o

ov

Step 10: Remove the specimens from the moulds either by dismantling the split moulds or, if ordinary moulds are used, extruding the specimens carefully with an extrusion jack, avoiding distortion to the compacted specimens.

m

et it

Step 11: Record the mass and volume of each specimen and determine the dry density using equation 7:

where:

DD

= (Mbriq / Vol) x (100 / W mould +100) x 1000

[Equation 7]

DD

= dry density

[kg/m³]

Mbriq

= mass of specimen

[g]

Vol

= volume of specimen

[cm ]

W mould


[%]

3

Note: With certain materials lacking cohesion, it may be necessary to leave the specimens in the moulds for 24 hours to develop strength before extracting. When this is necessary, the specimens in the moulds should be kept in a curing room or covered with damp cloth (hessian).

3

Curing the Specimens: Cure the specimens for seven days at 95% to 100% relative humidity and at a temperature of 20ºC to 25ºC in a suitable curing room. An alternative curing method is to place the specimen in sealed plastic bags and cure in an oven at: 70ºC to 75ºC for 24 hours for cement; or

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Page 27

60ºC to 62 ºC for 45 hours for lime. After the curing period, remove the specimens from the curing room (or plastic bags) and allow to cool to ambient temperature, if necessary. Specimens for unconfined compressive strength (UCS) tests should be submerged in water at 22°C to 25°C for four hours prior to testing. Strength Tests: The Unconfined Compressive Strength (UCS) test and the Indirect Tensile Strength (ITS) test procedures are described under ‎8.7.11.

5

Determination of the Optimum Stabiliser Content: The ITS and UCS strengths achieved are plotted against the percentage stabilising agent added using the average UCS or ITS of the three specimens for each stabiliser content, ignoring any obvious incorrect result that may have been caused by damage to the specimen before testing. The required application rate of stabilising agent is that percentage at which the minimum required criteria are met.

8.7.3

Mix Design Procedure For Bitumen Stabilised Materials (Bsms)

1

Active Filler Requirements: Bitumen stabilisation is normally carried out in combination with a small amount (1% by mass) of active filler (cement or hydrated lime) to enhance the dispersion of the bitumen and/or the breaking time (where bitumen emulsion is used as the stabilisation agent). The PI of the material is used as an initial guideline for the use of hydrated lime or cement in the mix:

as

qa

ta

rw .l. l

.

4

Table 8.6 Guide to Addition of Active Filler

se

Plasticity Index: < 10

ov

er

Carry out Preliminary Level 1 tests (explained below) to determine the need to add cement or hydrated lime.

Plasticity Index: > 10 Pre-treat with hydrated lime (ICL value) (The initial consumption of lime (ICL value) must first be determined using the appropriate pH test.)

2

m

et it

o

Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2 hours prior to the addition of the bitumen emulsion or foamed bitumen. (The treated material must be placed in an air-tight container to retain moisture and the moisture content checked and, if necessary, adjusted prior to adding the bitumen stabilising agent.) Such materials are not subjected to “Preliminary Level 1” tests. Preliminary Level 1 Tests: Where the PI < 10, the need for an active filler and the type of active filler (cement or hydrated lime) that is appropriate for the material must first be determined by carrying out “Level 1” tests on three different mixes. The same amount of bitumen (residual bitumen for bitumen emulsion treatment) is added to all three mixes, determined from the fractions passing the 4.75mm and 0.075mm sieves, as shown in Table 8.7 Suggested bitumen addition relative to key aggregate fractions.

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Table 8.7 Suggested bitumen addition relative to key aggregate fractions Percentage passing sieve size (%) 0.075mm

> 50

2.0

5.0 – 7.5

2.25

7.5 – 10.0

2.5

> 10.0

2.75

< 5.0

2.25

5.0 – 7.5

2.5

7.5 – 10.0

3.0

.

< 50

< 5.0

rw .l. l

4.75mm

Bitumen addition (% of dry aggregate)

> 10.0

3.5

ta

The first mix contains no active filler, 1% cement is added to the second mix and 1% hydrated lime is added to the third mix. 100mm diameter specimens are manufactured, cured and tested to determine the relevant ITSDRY, ITSWET and TSR values as described in ‎8.7.12.

as

qa

Where the TSR value for the mix with no active filler added is in excess of 60%, the mix design should be undertaken with no active filler. (This situation is usually confined to materials consisting of good quality crushed stone, often including a high proportion of reclaimed asphalt pavement (RAP) material.)

er

se

Where the TSR value of the mix with no active filler added is less than 60%, the mix with the type of active filler that produces a significantly higher TSR value (> 5%) indicates whether cement or hydrated lime should be used. If the TSR values for both active fillers are of the same order (difference < 5%) then either type of active filler is suitable.

Determination Of The Fluid / Density Relationship The Optimum Fluid Content (OFC) and the Maximum Dry Density (MDD) of the stabilised material is determined using standard compaction effort.

m

8.7.4

et it

o

ov

Note. Should cement and/or hydrated lime be not readily available and tests indicate the need for an active, the use of 15% (by volume) quarry fine aggregate (5mm to 0mm) or similar material with > 10% passing the 0.075mm sieve may be used as a substitute in the mix designs.

Note: For foamed bitumen stabilisation, the OFC and MDD can be assumed to be the same as the OMC and MDD, as determined for representative samples of the untreated material. The OFC for bitumen emulsion treated material is the percentage by mass of bitumen emulsion plus additional moisture required to achieve the maximum dry density in the treated material. As described below, the OFC is determined by adding a constant percentage of bitumen emulsion whilst varying the amount of water added. Step 1: Measure out the bitumen emulsion as a percentage by mass of the air-dried material for each of five prepared samples following the procedure described in ‎8.7.1. The percentage of bitumen emulsion added is normally between 2 and 3% residual bitumen (e.g. for 3% residual bitumen, add 5% of a 60% bitumen emulsion). Step 2: The bitumen emulsion and water is added to the material and mixed until uniform immediately prior to compaction. Step 3: Determine the OFC and MDD for the stabilised material in accordance with the modified moisture-density relationship test procedure (AASHTO T-180).

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8.7.5


Page 29

Preparation For Stabilising With Bitumen Emulsion (Bsm-Emulsion) Step 1: Place the required quantity of sample into a suitable mixing container (10kg for the manufacture of 100mm diameter specimens, or 20kg for the manufacture of 150mm diameter specimens). Step 2: Determine the dry mass of the sample using equation 1. Step 3: Determine the required percentage of active filler (lime or cement) using equation 3. Step 4: Determine the required percentage (by mass) of bitumen emulsion using equation 8: = (RBreqd / PBE) x Msample

[Equation 8]

Memu

= mass of bitumen emulsion to be added

[g]

RBreqd

= percentage of residual bitumen required

[% by mass]

PBE

= percentage of bitumen in emulsion

[% by mass]

.

where:

Memul

Mwater

= {((W OFC – W air-dry) / 100) x Msample} – Memul

Mwater


[g]

W OFC

= optimum fluid content

[% by mass]

W air-dry


[% by mass]

Memul

= mass of bitumen emulsion to be added

[g]

qa

ta

[Equation 9]

as

where:

rw .l. l

Msample = dry mass of the sample [g] Step 5: Determine the amount of water to be added for optimum compaction purposes using equation 9:

er

se

Msample = dry mass of the sample [g] Step 6: Mix the material, active filler, bitumen emulsion and water together until uniform. Immediately manufacture specimens following the relevant procedure for either 100mm or 150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.

ov

Repeat above steps for at least four mixes with different bitumen emulsion contents.

et it

o

Recommended bitumen addition interval for different specimen sizes Difference in amount of bitumen added (%) to Specimen diameter (mm) each mix 100 (Level 1) 0.25 0.1

m

150 (Level 2)

For 100mm diameter specimens, use Error! Reference source not found. as a guideline or the amount of bitumen addition that the material will require for effective stabilisation. For 150mm diameter specimens, use the results of Level 1 tests from ‎8.7.8 as the maximum addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this value). 8.7.6

Preparation For Stabilising With Foamed Bitumen (Bsm-Foam)

1

Determination of the foaming properties of the bitumen: The foaming properties of each bitumen type is characterised by: Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio of the maximum volume of the foam relative to the original volume of bitumen; and Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in seconds for the foam to collapse to half of its maximum volume.

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The objective is to determine the temperature and percentage of water addition that is required to produce the best foam properties (maximum expansion ratio and half-life) for a particular source of bitumen. This is achieved at three different bitumen temperatures (not exceeding 195°C) with the following procedure: Step 1: Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump circulating the bitumen through the system until the required temperature is achieved (normally starting with160°C). Maintain the required temperature for at least 5 minutes prior to commencing with testing. Step 2: Calibrate the discharge rate of the bitumen and set the timer on the Wirtgen WLB10 S to discharge 500g of bitumen (Qbitumen). Step 3: Set the water flow-meter to achieve the required water injection rate (normally starting with 2% by mass of the bitumen).

rw .l. l

.

Step 4: Discharge foamed bitumen into a preheated (± 75°C) steel drum for a calculated spray time for 500g of bitumen. Immediately after the foam discharge stops, start a stopwatch.

ta

Step 5: Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel drum of 275mm in diameter and 500g of bitumen) measure the maximum height the foamed bitumen achieves in the drum. This is recorded as the maximum volume.

qa

Step 6: Use the stopwatch to measure the time in seconds that the foam takes to dissipate to half of its maximum volume. This is recorded as the foamed bitumen’s half-life. Step 7: Repeat the above procedure three times or until similar readings are achieved.

as

Step 8: Repeat steps 3 to 7 for a range of at least three water injection rates. Typically, values of 2%, 3% and 4% by mass of bitumen are used.

ov

er

se

Step 9: Plot a graph of the expansion ratio versus half-life at the different water injection rates on the same set of axes (see the example in graph below). The optimum water addition is chosen as an average of the two water contents required to meet these minimum criteria. Repeat Step 1 to 9 for two other bitumen temperatures (normally 170°C and 180°C).

et it

o

The temperature and optimum water addition that produces the best foam is then used in the mix design procedure described below. Note: The absolute minimum foaming properties that are acceptable for effective stabilisation (material temperature of 25°C) are: Expansion ratio:

10 times

Half-life:

12 seconds

m

 

2

If the minimum requirements cannot be met, the bitumen should be rejected as unsuitable for use.

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Page 31

Prepare the material for foamed bitumen treatment as follows: Step 1: Place 20 to 25kg of sample prepared as described in ‎8.7.1 into the Wirtgen WLM30 pugmill mixer. Step 2: Determine the dry mass of the sample using equation 2. Step 3: Determine the required percentage of active filler (lime or cement) using equation 3. Step 4: Determine the percentage water to be added for optimum mixing moisture content as calculated using equation 10. The amount of water to be added to the sample is determined using equation 11. [Equation 10]

Mwater

= (W add / 100) x (Msample + Mcement)

[Equation 11]

W add

= water to be added to sample

[% by mass]

W OMC


W air-dry


[% by mass]

Mwater


[g]

Msample


rw .l. l

.

= 0.75W OMC - W air-dry

ta

where:

W add

[% by mass]

[g]

qa

Mcement = mass of lime or cement to be added [g] Step 5: Mix the material, active filler and water in the mixer until uniform.

er

se

as

Note: Inspect the sample after mixing to ensure that the mixed material is not packed against the sides of the mixer. If this situation occurs, mix a new sample at a lower moisture content. Check to see that the material mixes easily and remains in a “fluffed” state. If any dust is observed at the end of the mixing process, add small amounts of water and remix until a "fluffed" state is achieved with no dust.

= (Badd /100) x (Msample + Mcement)

[Equation 12]

Mbitumen

= mass of foamed bitumen to be added

[g]

Badd

= foamed bitumen content

[% by mass]

Msample


[g]

o

Mbitumen

et it

where:

ov

Step 6: Determine the amount of foamed bitumen to be added using equation 12:

Mcement = mass of lime or cement to be added [g] Step 7: Determine the timer setting on the Wirtgen WLB10 S using equation 13:

m

3


where:

T

= Mbitumen / Qbitumen

[Equation 13]

T

= time to be set on WLB10 S timer

[s]

Mbitumen

= mass of foamed bitumen to be added

[g]

Qbitumen = bitumen flow rate for the WLB10 S [g/s] Step 8: Position the mixer adjacent to the foaming unit so that the foamed bitumen can be discharged directly into the mixing chamber. Step 9: Start the mixer and allow it to mix for at least 10 seconds before discharging the required mass of foamed bitumen into the mixing chamber. After the foamed bitumen has discharged into the mixer, continue mixing for a further 30 seconds or until uniformly mixed. Step 10: Determine the amount of water required to bring the sample to the OMC using equation 14.

QCS 2014


where:

Page 32

Mplus

= (W OMC – W sample) / 100 x (Msample + Mcement)

[Equation 14]

Mplus


[g]

W OMC


[% by mass]

W sample

= moisture content of prepared sample

[% by mass]

Msample


[g]

Mcement = mass of lime or cement added [g] Note: This moisture adjustment is to be carried out when 150mm diameter specimens are to be manufactured. Where 100mm diameter specimens are to be manufactured, the moisture content of the material is to be adjusted to 90% of OMC. Step 11: Add the additional water and mix until uniform.

rw .l. l

.

Step 12: Transfer the foamed bitumen treated material into a container and immediately seal the container to retain moisture. To minimise moisture loss from the prepared sample, manufacture the specimens as soon as possible following the relevant procedure for either 100mm or 150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.

ta

Repeat the above steps for at least four mixes with different foamed bitumen contents.

100 (Level 1)

se

150 (Level 2)

Difference in amount of bitumen added (%) to each mix

as

Specimen diameter (mm)

qa

Recommended bitumen addition interval for different specimen sizes

0.25 0.1

er

For 100mm diameter specimens, use Error! Reference source not found. as a guideline or the amount of bitumen addition that the material will require for effective stabilisation.

et it

o

ov

For 150mm diameter specimens, use the results of Level 1 tests in ‎8.7.8 as the maximum addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this value). Manufacture Of 100mm Diameter Specimens

1

For Level 1 mix designs ITS tests are carried out on 100mm diameter specimens. Six specimens are manufactured for each sample at the different bitumen contents. The two primary objectives of undertaking the Level 1 mix design are to determine:

m

8.7.7



the optimum bitumen content for the BSM, and



the need for an active filler.

2

Specimens may be made using either Marshall or vibratory compaction methods.

3

Marshall Compaction shall be carried out as follows: Step 1: Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate and face of the compaction hammer. Note: the compaction equipment must not be heated but kept at ambient temperature. Step 2: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded.

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Step 3: Compact the mixture by applying 75 blows with the compaction hammer. Care must be taken to ensure the continuous free fall of the hammer. Remove the mould and collar from the pedestal, invert the specimen (turn over). Replace it and press down firmly to ensure that it is secure on the base plate. Compact the other face of the specimen with a further 75 blows. Step 4: Take approximately 1kg representative samples after compaction of the second and fifth specimen and dry a constant mass (at 105 to 110°C). Determine the moulding moisture using equation 15:

where:

W mould

= (Mmoist – Mdry) / Mdry x 100

[Equation 15]

W mould


[% by mass]

Mmoist


[g]

rw .l. l

.

Mdry = mass of dry material [g] Step 5: After compaction, remove the mould from the base-plate and extrude the specimen by means of an extrusion jack. Measure the height of the specimen and adjust the amount material if the height is not within the required limits.

qa

Vibratory Compaction shall be carried out as follows:

se

as

Step 1: Fix the mounting head and appropriate tamping foot to the vibratory hammer and fit hammer onto guide rods. Place 5kg surcharge weight onto mounting head (total mass of assembly [Hammer + foot + surcharge] = 25kg) and fasten tightly. Using the pulley system raise the vibratory hammer to an adequate height that will allow operator to work safely beneath the vibratory hammer and lock in position.

ov

er

Step 2: Clean the mould, collar and base plate. Fix the mould to the base of the compaction frame. Note: the compaction equipment must not be heated but kept at ambient temperature.

et it

o

Step 3: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded. Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould. Apply 15 seconds of vibratory compaction to the sample in the mould.

m

4

ta

Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

Step 5: Raise hammer to the safe position, remove mould, invert mould and secure to base. Step 6: Lower vibratory hammer to surface of material in mould and ensure vibratory hammer rests freely on sample and is perpendicular to the base of the mould. Apply further 15 seconds of vibratory compaction to sample in the mould. Step 7: Take approximately1kg representative samples after compaction of the second and fifth specimen and dry to constant mass (at 105 to 110 oC). Determine the moulding moisture using equation 15. Step 8: After compaction, remove the mould from the base-plate and extrude the specimen carefully by means of an extrusion jack. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

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5

Curing procedure: Compacted specimens shall be cured by placing the specimens on a steel mesh and curing in a forced-draft oven until a constant mass is obtained (normally 72 hours at 40°C). Remove from oven after curing and allow to cool to ambient temperature.

6

When specimens have cooled to ambient temperature determine the bulk density for each specimen: Step 1. Determine the mass (Mbriq). Step 2. Measure the height at four evenly-spaced places around the circumference and calculate the average height (h). Step 3. Measure the diameter (d). Step 4. Calculate the bulk density using equation 16: x h) x 1000

BD


Mbriq

= mass of specimen

h

= average height of specimen

[Equation 16]

.

= (4 x Mbriq

[kg/m³]

rw .l. l

where:

2

BD

[g] [cm]

qa

ta

d = diameter of specimen [cm] Note: Exclude from further testing any specimen whose bulk density differs from the mean bulk density of the batch by more than 50 kg/m³. The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water” method for those specimens designated for soaked testing.

8.7.8

Determination Of The Strength Of 100mm Diameter Specimens

1

The 100mm diameter specimens are tested for indirect tensile strength under dry and soaked conditions to determine the ITSDRY and the ITSWET values. To prevent moisture loss, specimens should be tested as soon as they are prepared. The results are used to indicate the optimum bitumen content and the need for active filler. In addition, these test results are used as a guide for the classification of the BSM.

8.7.9

Manufacture Of 150mm Diameter Specimens

1

Level 2 mix designs ITS tests are carried out on specimens that are 150mm diameter and 95mm in height. These specimens are cured to simulate the equilibrium moisture content achieved in the field. This method of curing provides more realistic values for classification of the bitumen stabilised materials.

2

The procedures described allow for the manufacture of four 150mm diameter specimens to a compacted height of 95mm. If additional specimens are required, the sample quantity shall be increased.

3

Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction methods.

4

MODIFIED AASHTO (T-180) compaction shall be carried out as follows:

m

et it

o

ov

er

se

as

7

Step 1: Prepare and treat at least 24kg of sample for each selected bitumen content. Step 2: Where required, add sufficient moisture to bring sample to optimum compaction moisture content and mix until uniform. Immediately after mixing, place material in an airtight container.

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Step 3: Take approximately 1kg representative samples after compaction of the first and third specimen and dry to a constant mass (at 105 to 110°C). Determine the moulding moisture using equation 15. Step 4: Compact at least 4 specimens using a 150mm diameter split-mould, applying modified AASHTO (T-180) compaction effort (4 layers approximately 25mm thick, 56 blows per layer using a 4.536kg hammer with a 457mm drop). Step 5: Carefully trim excess material from specimens, as specified in the AASHTO T180 test method. Step 6: Carefully remove the specimen from the spilt-mould and place on a steel mesh. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

.

Vibratory compaction shall be carried out as follows:

ta

rw .l. l

Step 1: Fix the mounting head and appropriate tamping foot (150mm diameter) to the vibratory hammer and fit hammer onto guide rods. Place 10kg surcharge weight onto mounting head (total mass of assembly [hammer + foot + surcharge] = 30kg) and fasten tightly. Using the pulley system raise the vibratory to an adequate height that will allow operator to work safely beneath the vibratory hammer and lock in position.

qa

Step 2: Clean the 150mm diameter spilt mould, collar and base plate. Fix the mould to the base of the compaction frame.

2

= ( x d x h / 4) x (MDD) /1000

Mmix

= Mass of mixed material

d

[Equation 17] [g]

= diameter of specimen

[cm]

= required height of layer (4.75cm for ITS)

[cm]

o

h

er

Mmix

ov

where:

se

as

Step 3: Weigh sufficient material to achieve a compacted height of 47.5mm ± 1.5mm. An approximation of the quantity required can be calculated using equation 17. Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded.

Apply

et it

MDD = maximum dry density [kg/m³] Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould.

m

5

25 seconds of vibration for bitumen emulsion stabilised materials 35 seconds of vibration for foamed bitumen stabilised materials.

Step 5: Raise hammer to safe position. Step 6: For the second layer, if necessary, adjust for the amount of material to be added such that the final compacted thickness is 95mm. Using a chisel, scarify the entire surface area of the top of the compacted layer to a maximum depth of 10mm. Add the required amount of material and ensure the material is as level as possible. Step 7: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould. Apply

25 seconds of vibration for bitumen emulsion stabilised materials 35 seconds of vibration for foamed bitumen stabilised materials.

Step 8: Raise hammer to safe position. Remove mould from base plate and open the split mould to remove the specimen.

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Page 36

Step 9: Take approximately 1kg representative samples after compaction of the first and third specimens and dry to a constant mass. Determine the moulding moisture using equation 15. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting. Curing procedure: Place the specimens in an oven at 40°C for 24 hours (or until the moisture content has reduced to at least 50% of OMC). Thereafter place each specimen in a sealed plastic bag (at least twice the volume of the specimen) and place in an oven at 40°C for a further 48 hours.

7

Remove specimens from the oven after 48 hours and remove the respective plastic bags, ensuring that any moisture in the bags does not come into contact with the specimen. Allow to cool to ambient temperature.

8

When specimens have cooled to ambient temperature determine the bulk density for each specimen:

rw .l. l

.

6

Step 1: Determine the mass (Mbriq).

qa

ta

Step 2: Measure the height at four evenly-spaced places around the circumference and calculate the average height (h). Step 3: Measure the diameter (d).

as

Step 4: Calculate the bulk density using equation 16:

se

Note: Exclude from further testing any specimen whose bulk density differs from the mean bulk density of the batch by more than 50 kg/m³. The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water” method for those specimens designated for soaked testing.

8.7.10

Determination Of The Strength Of 150mm Diameter Specimens

1

The 150mm diameter specimens are tested for indirect tensile strength under equilibrium moisture content and soaked conditions to determine the ITSEQUIL and the ITSSOAK values. To prevent moisture loss, specimens should be tested as soon as they are prepared. The results are used to refine the optimum bitumen content and amount of active filler that was initially determined from the 100mm diameter specimens. In addition, these test results are used to classify the BSM with additional confidence.

2

Additional ITS tests should be carried out using 150mm diameter specimens to determine the sensitivity of the mix to minor variations in both the amount of added bitumen and active filler.

m

et it

o

ov

er

9

If, for example, Level 2 test results indicated an optimum bitumen addition (OBA) of 2.2% with an active filler addition of 1%, then the following further tests should be undertaken: Step 1: To check the sensitivity of the bitumen addition, follow the Level 2 procedure in ‎8.7.9 to manufacture, cure and test the following mixes:

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials Added bitumen (%) 2.2 (Level 2 OBA) 2.1 2.0 1.9

Page 37

Active filler (%) 1 1 1 1

ITS test results will allow the optimal bitumen addition (OBA) to be refined. Step 2: To check the sensitivity of the amount of active filler added, follow the Level 2 procedure in ‎8.7.9 to manufacture, cure and test the following mixes: Active filler (%) 0.9 0.7 0.5

.

Added bitumen (%) OBA OBA OBA

rw .l. l

ITS test results will indicate the minimum amount of active filler required in the mix. Strength Test Procedures

1

The Unconfined Compressive Strength (UCS) of a cement stabilised material is determined by measuring the ultimate load to failure of a 127mm high and 150mm diameter specimen that is subjected to a constant loading rate of 140kPa/s (153kN/min), as follows:

qa

ta

8.7.11

as

Step 1: Place the specimen on its flat side between the plates of the compression testing machine. Position the specimen such that it is centred on the loading plates.

se

Step 2: Apply the load to the specimen, without shock, at a rate of advance of 140kPa/s until the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.

er

Step 3: Immediately after testing a specimen, break the specimen up and take a sample of approximately 1000g to determine the moisture content (W break). This moisture content is used to determine the dry density of the material using equation 21. = (4 x P) / (  x d ) x 10000

[Equation 18]

o

= unconfined compressive strength

[kPa]

P

= maximum load to failure

[kN]

d

= diameter of specimen

[cm]

UCS UCS

2

2

m

et it

where:

ov

Step 4: Calculate the UCS for each specimen to the nearest 1 kPa according to equation 18.

Indirect Tensile Strength (ITS) of a stabilised material is determined by measuring the ultimate load to failure of a specimen (both 100mm and 150mm diameter specimens) that is subjected to a constant deformation rate of 50.8 mm/minute on its diametrical axis, as follows: Step 1: Place the specimen onto the respective ITS jig for the 100mm and 150mm diameter specimens. Position the sample such that the loading strips are parallel and centred on the vertical diametrical plane. Step 2: Place the load transfer plate on the top bearing strip and position the jig assembly centrally under the loading ram of the compression testing device. Step 3: Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per minute until the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.

QCS 2014


Page 38

Step 4: Immediately after testing a specimen, break it up and take a sample of approximately 1000g to determine the moisture content (W break). This moisture content is used in equation 21 to determine the dry density of the material in the specimen. Step 5: Immediately after testing a specimen, measure the temperature of the broken face using a digital thermometer. Record the temperature, accurate to 0.1°C. Step 6: Calculate the ITS for each specimen to the nearest 1 kPa using equation 19:

where:

ITS

= (2 x P) / ( x h x d) x 10000

[Equation 19]

ITS

= indirect tensile strength

[kPa]

P

= maximum applied load

[kN]

h

= average height of the specimen

[cm]

rw .l. l

.

d = diameter of specimen [cm] Step 7: To determine the soaked ITS, place the specimens under water at 25°C ± 1°C for 24 hours. Remove specimen from water, surface dry and repeat steps 1 to 5. Record the results and determine the following as required:

ITSDRY = average of 3 specimens cured to constant mass ITSWET = average of 3 ITSDRY specimens soaked for 24 hours. 150mm Ø specimens: ITSEQUIL = average of 2 specimens cured at equilibrium moisture ITSSOAK = average of 2 ITSEQUIL specimens soaked for 24 hours Step 8: Determine the Tensile Strength Retained (TSR). The TSR is the relationship between the average soaked and unsoaked ITS values for a specific batch of specimens, expressed as a percentage using equation 20: = Average soaked ITS / Average unsoaked ITS x 100

[Equation 20]

se

TSR

as

qa

ta

100mm Ø specimens:

er

Step 9: Using the moisture content determined in each test described above, calculate the dry density using equation 21:

where:

DD

o

Mbriq

= (Mbriq / Vol) x (100 / (W break + 100) x 1000

ov

DD

et it

Vol

[Equation 21]

= dry density

[kg/m³]

= mass of cured specimen

[g]

= volume of specimen

[cm ]

3

m

W break = moisture content of the specimen [%] Report the results using the template sheet shown in ‎8.7.16 as a guide. 8.7.12

Selection Of The Amount Of Bitumen To Be Added For Bsm

1

Plot the results of the respective soaked and unsoaked ITS test results against the relevant bitumen content that was added. The added bitumen content that best meets the desired BSM classification is selected as the optimum amount of bitumen to be added, as shown in the example below (Figure 7.3 Determination of BSM class and added bitumenFigure 7.3 Determination of BSM class and added)

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Page 39

Interpretation of ITS Tests BSM1

BSM2

BSM3

Purpose

ITSDRY

100 mm

> 225

175 to 225

125 to 175

Indicates the optimum bitumen content

ITSWET

100 mm

> 100

75 to 100

50 to 75

Indicates need for active filler.

TSR

100 mm

N/A

N/A

N/A

Indicates problem material where TSR < 50 and ITSDRY > 400 kPa

ITSEQUIL

150 mm

> 175

135 to 175

95 to 135

Used for classifying the BSM and for optimising the bitumen and active filler content.

ITSSOAK

150 mm

> 150

100 to 150

60 to 100

Check value on ITSWET

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.

Specimen Ø

et it

o

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as

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Test

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Figure 7.3 Determination of BSM class and added bitumen

2

The TSR value is useful for identifying problem materials. If the TSR is less than 50%, it is recommended that active filler is used. If such treatment does not increase the ITSWET value with a maximum application of 1% lime or cement, then the nature of the material being stabilised should be investigated:

3

Where the material is granular, a TSR value below 50% combined with an ITSDRY value in excess of 400 kPa suggests contamination (normally attributed to clay or deleterious materials). In this situation, it is suggested that material is pre-treated with hydrated lime and the Level 1 tests repeated.

4

Where the material is 100% RAP, a TSR value below 50% combined with an ITSDRY value in excess of 500 kPa indicates that the treated material is partly stabilised and partly continuously bound (cold mix). In this situation, the material probably requires blending with crusher dust to ensure that the stabilisation process dominates the mix.

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Page 40

5

Level 2 testing using 150mm diameter specimens should be undertaken to verify the relevant ITS values for BSM classification.

8.7.13

Determination Of The Shear Properties Of Bsm

1

Triaxial testing is carried out to determine the cohesion and angle of internal friction of BSM specimens. Testing is normally carried out at the bitumen content selected from the results of ITS tests carried out on 150mm diameter specimens (see above). Additional tests at different bitumen contents can always be carried out to investigate the sensitivity of the shear properties.

2

Specimens for triaxial testing shall be produced as follows:

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.

Step 1: Prepare and treat 50kg of sample (adequate for manufacture of 4 specimens) with either bitumen emulsion or foamed bitumen at the optimum bitumen content. Include any active filler requirements. Step 2: Where required, add moisture to bring sample to optimum compaction moisture content and mix until uniform. Place the mixed material in an air-tight container.

ta

Step 3: Take approximately1 kg representative samples of each specimen to determine the moulding moisture using equation 15.

as

qa

Step 4: Compact at least four (4) specimens using a 150mm diameter split mould with an effective internal height of 300mm, using equation 17 to calculate the approximate quantity for each layer. Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction methods.

4

Compaction using modified AASHTO (T180) shall be in 12 layers, each approximately 25mm thick, compacted with 56 blows using a 4.536kg hammer with a 457mm drop. Carefully trim any excess material from the specimen.

5

Compaction using vibratory compaction shall be in 5 layers, each approximately 60mm thick, using a hammer assembly of 30kg total mass. Each layer is compacted for: 

25 seconds for BSM-emulsion, or 35 seconds for BSM-foam

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

et it

o

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3

The height of each compacted layer is measured and, if necessary, an adjustment made for the quantity of material used for the next layer to achieve the required height for the respective layers. 6

The specimens shall be cured using the same procedure for 150mm diameter specimens.

8.7.14

Determination Of Triaxial Shear Parameters Using Simple Triaxial Test

1

This method describes the determination of triaxial shear parameters (cohesion and internal angle of friction) of Bitumen Stabilised Materials by measuring the resistance to failure (monotonic) of a cylindrical 150 mm diameter and 300 ± 2 mm height specimen prepared according to Vibratory Hammer Compaction Procedure.

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Page 41

Apparatus: (a)

Triaxial Cell comprising a galvanised steel casing 5 mm thick comprising a ring handle and simple mechanical clamps top and bottom, a base with bottom platen for sitting specimen, top disk and a latex tube at least 320 mm in height.

(b)

Testing System comprising a Material Testing System (MTS) or its equivalent system must at least comprise of an actuator, reaction frame, a control panel and data acquisition system. The system must be capable of providing ramp loads with minimum loading capacity of 100 kN and a minimum stroke of 40 mm. The actuator should be operated by a servo-controlled hydraulic pressure system with a closed loop feedback system that is capable of both displacement and load controlled testing if required.

(c)

Measuring devices should include but not limited to a load cell (100 kN Capacity) for measuring load, an actuator displacement transducer (> 40 mm stroke) for measuring displacement (deformation) and pressure regulator, gauges, and valves for lateral pressure.

(d)

Additionally air compressor, loading ram and silicon oil or grease.

rw .l. l

.

2


The specimen must be prepared and cured according to Vibratory Hammer Compaction Procedure as stated previously.

4

The triaxial testing of the specimens must be planned to take place within 48 – 72 hours after completion of the curing procedure. This delay must be kept as constant as possible. The following steps describe the procedure taken to assemble specimen in the simple triaxial cell and the cell in the loading frame:

se

as

qa

ta

3

Place the specimens, casing with tube, top disk and base plate in a climate chamber and condition them overnight at 25ºC.

(b)

Lightly grease the sides of the top disk and base plate to reduce friction as much as possible.

(c)

Place the specimen in the middle of the base plate.

(d)

Carefully introduce the casing, comprising the tube, around the specimen. Take care not to damage the edges of the specimen during this procedure.

ov

o

et it

Clamp the casing in position on to the base plate using simple mechanical clamps on the casing.

m

(e)

er

(a)

5

(f)

Put the top disk on top of the specimen.

(g)

Place the cell in the hydraulic loading frame; adjust actuator position until visual contact is made with the loading ram.

(h)

Connect the air supply to the cell; open the regulator and valve on the cell pressure port until the cell pressure is stable at the desired level.

(i)

Set monotonic test parameters on the MTS controller including displacement rate of strain (2.1%), full-scale for the loading (10.0V = 98.1 kN) and half-scale for the displacement (10.0V = 40mm), and run the test

Monotonic Triaxial Test: Select four specimens of comparable density, moisture content and conditioned at 25°C. Assemble the specimen in the triaxial cell according to 4 ensuring the tube is air tight.

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Page 42

Operate the testing system in displacement control mode. Ensure that there is sufficient space between the actuator and the reaction frame to accommodate the triaxial cell. Place the triaxial cell in the hydraulic loading frame.

(b)

Adjust the actuator position until visual contact is made with the loading ram. Monitor the load cell reading to prevent loading of the specimen during this process. Connect the air supply to the cell pressure port. Open the valve on the cell pressure port and open the regulator until the cell pressure is stable at the desired level. The cell pressures for a series of monotonic tests are 0 kPa, 50kPa, 100 kPa and 200 kPa.

(c)

Test the first specimen without confinement pressure (0 kPa). Begin the test by compressing the specimen at a constant rate of displacement of 2.1%. Record the load versus displacement during the test with a minimum sampling rate of 10 Hz, as well as the cell pressure, temperature and specimen identifier.

(d)

Stop the test and the recording when the total displacement exceeds 18 mm (6% strain) or when the specimen bulges excessively before the end displacement is reached.

(e)

Repeat this procedure for other three specimens until all specimens have been tested at the four levels of confinement pressures.

ta

rw .l. l

.

(a)

Remove the specimens after completion of test after completion of a test. Hold the actuator to its current position, close the valve on the cell pressure port and release the cell pressure by disconnecting the pressure supply tube to the cell (if possible speed up the pressure release by applying suction). Return the actuator to a position whereby the cell can easily be removed from the loading frame. Remove the top disk. Clean the top disk and wipe off any grease. Unclamp the casing and lift the casing with tube from the cell base. Clean the tube from possible remains of the deformed specimen (it is not necessary to remove the tube from the casing). Remove the tested specimen from the base plate. Place it in the plastic bag and seal. Clean the base plate and wipe off any grease.

7

When all the specimens have been tested, remove the tested specimens one by one from the plastic bags. Break the tested specimens up and sample between 500 and 1000 gr. of material from the middle of the specimen. Use this sample to determine the moisture content of each specimen.

8

Calculations:

m

et it

o

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as

qa

6

(a)

Determine the applied failure load Pa,f for each specimen tested. The applied failure load is defined as the maximum applied load during the test. Calculate the applied failure stress σa,f :

σa,f where:

σa,f

= applied failure stress

[kPa]

Pa,f

= applied failure load

[N]

= end area of a cylindrical specimen at beginning of test

[m ] or mm ??

A

2

2

QCS 2014


Page 43

Calculate the major principle stress at failure σ1,f for each tested specimen:

(b)

where:

σ1,f

= σa,f + σdw

σ1,f

= major principle stress at failure

[kPa]

σa,f

= applied failure stress

[kPa]

σdw

= pressure resulting from dead weight of top disk and loading ram

[kPa]

The relationship between σ1,f and confinement stress (σ3)is determined by:

(c)

σ1,f

= A.σ3+B

A where:

rw .l. l

.

B

Values of A and B can be determined by performing a linear regression analysis on the four combinations of σ1,f and σ3 per mix.

ta

where:

Values of φ [°] and C [kPa] can be calculated as follows: φ

qa

(d)

as

C

Report the following in the table format as illustrated in

10

Table 8. 8 Format Report for Simple Triaxial Test below:

er

se

9

Specimen number or identifier;

(b)

Confinement pressure (σ3);

(c)

Applied stress at failure (σa,f);

(d)

Major principal stress at failure (σ1,f);

o

et it

(e)

ov

(a)

Cohesion, C [kPa]; Angle of internal friction, φ [°]; and

(g)

Coefficient of variance, R

m

(f)

11

2

Plot the Mohr Circles and the Mohr-Coulomb failure envelope as shown in Figure 7.4 Example of Mohr Circle Plot, noting: (a)

The centre of Mohr circle must be on the abscissa and is given by (σ1,f + σ3)/2;

(b)

The radius of such circle is (σ1,f - σ3)/2;

(c)

Angle of internal friction is the angle of the Mohr-Coulomb failure envelope (failure line);

(d)

The failure line intersects with ordinate at the cohesion value.


Page 44

rw .l. l

.

QCS 2014

qa

ta

Figure 7.4 Example of Mohr Circle Plot

m

et it

o

[kPa]

Principle stress at Failure σ1,f

Cohesion

Internal Friction Angle

Correlation Coefficient

[kPa]

[kPa]

[°]

[R ]

se

Applied Stress at Failure σa,f

er

Confining Pressure, σ3

[kPa]

ov

Specimen No.

as

Table 8. 8 Format Report for Simple Triaxial Test

2

QCS 2014

Page 45

et it

Notes:

o

ov

er

se

as

qa

ta

rw .l. l

.

Using Laboratory Test Results For Estimating Structural Layer Coefficients

The minimum Retained Tensile Strength (%) requirement should be 75%. The following minimum compaction requirements are recommended:

m

8.7.15


Material Type

Percentage of Modified AASHTO compaction T180

BSM3

BSM2

BSM1

> 97%

> 100%

> 102%



The material passing the 0.075mm sieve to be >2% for BSM-emulsion and >4% for BSM-foam.



The maximum recommended addition of cement (active filler) is 1% by mass.



Materials with a Plasticity Index > 10 to be pre-treated with hydrated lime to reduce the PI to <6.

QCS 2014

Page 46

Proforma Report Sheet For Its Testing

et it

o

ov

er

se

as

qa

ta

rw .l. l

.

The report sheet shown below may be used for all ITS tests, regardless of whether the tests were carried out for mix design purposes or for testing field samples.

m

8.7.16


QCS 2014


Laboratory Equipment Requirements

1

Laboratory Equipment For Soils Testing

m

et it

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as

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ta

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.

8.7.17

Page 47

QCS 2014

et it

o

ov

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as

qa

ta

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.

Additional Laboratory Equipment for Cement or Lime Stabilisation

m

2


Page 48

QCS 2014

et it

o

ov

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as

qa

ta

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.

Additional Laboratory Equipment for Bitumen Stabilisation

m

3


END OF PART

Page 49

QCS 2014

Section 06: Roadworks Part 09: Recycled Aggregate for Roadworks

Page 1

RECYCLED AGGREGATE FOR ROADWORKS ................................................................... 2

9.1 9.1.1 9.1.2 9.1.3 9.2 9.3 9.4 9.4.1 9.4.2 9.5 9.6

GENERAL ---------------------------------------------------------------------------------------------- 2 Scope 2 References 2 Definitions 3 SOURCE ----------------------------------------------------------------------------------------------- 3 APPLICATIONS -------------------------------------------------------------------------------------- 3 RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS ------------ 4 Requirements of Materials 4 Compaction of Fill Material 5 RECYCLED AGGREGATE FOR SUB-BASE MATERIAL ---------------------------------- 5 RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN VILLAGE AREAS AND TEMPORARY ROADS ----------------------------------------------- 6

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.

9

QCS 2014


Page 2

9

RECYCLED AGGREGATE FOR ROADWORKS

9.1

GENERAL

9.1.1

Scope

1

The conditions of this part cover the requirements of recycled aggregate obtained from demolition and excavation waste for use in roadworks.

2

Related Parts are:

.

General Earthworks Unbound Pavement Materials

9.1.2

References

1

The following standards are referred to in this Part :

rw .l. l

Part 1, Part 3, Part 4,

qa

ta

ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

as

ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine of

particle

size

distribution

-

Sieving

method

se

BS EN 933 Part 1 .......Determination Aggregates

er

ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ov

BS 1377 Part 4 ...........Methods of test for Compaction-related tests, California Bearing Ratio (CBR) of Laboratory-Compacted Soils

et it

o

ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate BS 1377 Part 3 ...........Standard Test Methods for Classification tests, Liquid Limit, Plastic Limit, and Plasticity Index of Soils

m

BS EN 933 Part 3. ......Methods of test for Determination of particle shape - Flakiness index BS EN 933 Part 4. ......Methods of test for Determination of particle shape - Shape index BS EN 933 Part 5 .......Methods of test for Determination of percentage of crushed and broken surfaces in coarse aggregate particles. BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests BS EN 933-11:2009 ...Tests for geometrical properties of aggregates. Classification test for the constituents of coarse recycled aggregate BS EN 1097-2:2010...Tests for mechanical and physical properties of aggregates. Methods for the determination of resistance to fragmentation QS 29 / 2012 ..............The general Conditions For Recycled Aggregate Obtained From Building Demolition

QCS 2014


Page 3

Definitions

1

Demolition Waste: Waste Material obtained from Excavated and/or demolished concrete structures.

2

Concrete Demolition Waste : Waste Produced by demolition of concrete structures in general.

3

Demolition Waste from Hard Concrete : Waste obtained from demolition of hard concrete members such as columns, foundations and other mass concrete blocks.

4

Excavation Waste : Waste obtained from excavated materials.

5

Mixed Demolition Waste : Waste material obtained from both excavated and demolished concrete structures.

6

Mixed Aggregate : Recycled fine and coarse Aggregate combined together.

7

Recycled Aggregate: a materials produced by the reprocessing of reclaimed construction and demolition waste. These include but are not limited to asphalt planings (i.e. the asphalt layers of roads removed during roadworks, also known as RAP – Reclaimed Asphalt Pavement), fill, selected fill, granular subbase and rock from construction excavations.

9.2

SOURCE

1

The debris pieces of blocks collected from road demolitions in various places should be stock piled at suitable location where different types of materials can be separated.

2

The clean, tough, hard, durable, free from organic material and uncoated particles containing no harmful materials in quantities sufficient to adversely affect construction works shall be stock piled separately according to the required nominal sizes. The material free from pieces of steel, plastic and wood.

3

The sources of aggregate should be regularly and thoroughly investigated to ensure the quality of material is satisfactory. The aggregate shall be non-plastic and chemically stable.

9.3

APPLICATIONS

1

Carefully selected recycled aggregate can be used in many applications as shown below.

2

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.

9.1.3

(a)

For Non-structural Concrete (Grade SRC 20) for backing of kerbs, channels, edging and quadrant in road work.

(b)

For manufacture of Hollow & Solid Blocks and Paving blocks for pedestrians.

(c)

For Earth works related to roads.

(d)

For Aggregate of sub-base materials.

(e)

For Minor Roads of village areas and temporary roads.

Recycled materials from construction or a construction process, or from existing pavement layers shall be separated according to type for processing. The separate processed materials shall be stored in stockpiles of no greater than 4000 tons and quarantined for testing and approval by the Engineer prior to use.

QCS 2014


Page 4

3

Samples shall be taken of the recycled aggregate constituents for classification by handsorting the coarse aggregate particles in accordance with BS EN 933-11. The test shall be carried out by a suitably trained laboratory technician who has demonstrated competence in classifying the constituent classes in accordance with the test method.

4

Testing frequency shall be according to parts 3 and 4 of this section unless otherwise stated by the Engineer.

5

Recycled aggregate shall be free from non-aggregate constituents such organics and shall have a minimum amount of deleterious material which may affect its reuse.

6

The Percentage use of recycled aggregate shall not exceed the following: A maximum of 50% of recycled fine, and/or coarse and/or mixed aggregates whether obtained from Concrete or mixed waste can be used for concrete works of less than 20 MPa strength or any other construction works but not for asphalt layers.

(b)

It is not allowed to use recycled Aggregate obtained from concrete or mixed demolition wastes in asphalt mixes. Only Recycled Aggregate from excavated material can be used in asphalt mixes.

(c)

A maximum of 100% of recycled aggregate obtained from excavated material can be used in any of the above mentioned construction works.

qa

ta

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.

(a)

RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS

9.4.1

Requirements of Materials

1

Recycled material shall be tested according to the relevant parts of BS 1377 and shall be within the limits of following table:

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as

9.4

ov

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Table 9.5 Specifications of Recycled Aggregate for use in Earth Works Related to Roads

et it

o

Requirement Grading

m

Particle Size Organic Material (%) Liquid Limit (%) Plasticity Index (%) Material Passing 0.075 mm (%) Water Soluble Salts (%) Acid Soluble Salts (%) Soaked CBR Value Swell (%) Tree and Plant Stumps Perishable Materials Materials Subject to Spontaneous Combustion Material From Sabkha and Marshes

General Fill (Filling on low level areas) Standard

Selected Fill ( Sub-grade) Standard

Less than 75mm 2 max 40 max 11 max 40 max 5 max

Less than 75mm 2 max 35max 10 max 35 max 5 max

10 max Free Free

10 max More than 15 2 max Free Free

Free

Free

Free

Free

QCS 2014


Page 5

Compaction of Fill Material

1

All Fill materials shall be placed in loose layers within the effective range of compaction of the approved plant. The maximum permissible loose layer thickness shall be limited to 200mm.

2

The fill material shall be watered and mixed as necessary to ensure that prior to compaction, the moisture content of the whole layer ±3% of the optimum moisture content obtained at the laboratory compaction test (LCT). The compaction of layer shall continue until a density of at least 95% of the maximum dry density of LCT.

3

No layer shall be covered by the next layer until it has been tested, inspected and approved by the Engineer.

9.5

RECYCLED AGGREGATE FOR SUB-BASE MATERIAL

1

The following table illustrates the material requirements for unbound materials for roadworks.

rw .l. l

.

9.4.2

qa

ta

Table 9.6 Requirements of Recycled Aggregate for Roadworks Unbound Layers Raw Materials

Requirement

Coarse Aggregate

Standard

Standard

Less than 4.75mm

More than 4.75mm

as

Fine Aggregate

se

Grading

er

Particle Size

Less Than 4.0mm

More than 4.0mm

Organic Material (%) Liquid Limit (%) –material passing 0.425 or 0.500mm Plasticity Index (%)–material passing 0.425 or 0.500mm MaterialPassing0.075mm (%)

0.5 max

Free

Water Soluble Chlorides (%)

o

ov

OR

Production

25 max

-

Sub-Base Class C

Free 25 max 6 max -

-

1.0 max

1.0 max

Acid Soluble Chlorides (%)

-

2.0 max

2.0 max

Water Soluble Sulphates (%) Acid Soluble Sulphates SO 3(%) Soaked CBR Value Swell (%) Tree and Plant Stumps Perishable Marshes Materials subject to Spontaneous combustion Material from Sabkha and Marshes Clay Balls Ratio of Passing 0.075mm & 0.425mm (%)

-

1.5 max 3.0 max Free Free

1.5 max 3.0 max 80 min 1.0 max Free Free

-

Free

Free

-

Free

Free

Free

Free

Free

66

-

-

-

35 max

35 max

m

et it

-

Flakiness Index (%)

6 max -

-

Aggregate

QCS 2014


Page 6

Raw Materials

Production

Requirement Coarse Aggregate

Elongation Index (%)

-

40 max

40 max

Los Angeles Abrasion (%)

-

40 max

40 max

Soundness - magnesium sulphates, 5 cycles (%)

-

20 max

20 max

Sand Equivalent Value

-

-

25 min

Sub-Base

Mix Designs The recycled aggregate shall be used in aggregate sub-base and base courses. The fine and course aggregate shall be combined proportionately in order to achieve the following class of grading:

rw .l. l

(a)

.

2

Aggregate

Fine Aggregate

Percentage Passing (by Weight) Class C

er

se

63.0 50.0 37.5 25.0 19 9.5 4.75 2.36 0.425 0.075

100 90-100 50-85 35-65 25-50 15-30 5-15

Screening and Mixing

m

3

et it

o

ov

63.0 40.0 20.0 10.0 4.0 2.0 0.500 0.063

ASTM Sieve (mm)

as

BS EN Sieve (mm)

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Table 9.7 Gradation of Recycled Aggregate for use in Subbase Layers

(a)

Screening is required for recycled materials used in the road base and sub base to ensure that the designated gradation is attained.

(b)

Central Mixing plant is required for the mixing of materials.

9.6

RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN VILLAGE AREAS AND TEMPORARY ROADS

1

Recycled Aggregate for use in Asphalt layers of temporary and minor roads in village areas shall be reclaimed from excavated natural soil which is mechanically and chemically stable and of specifications in the following table:

QCS 2014


Page 7

Table 9.9 Specification of Recycled Aggregate for use in Asphalt Layers for Village and Temporary Roads Recycled Aggregate

Requirement

Standard Less than 2.36 mm

Standard More than 2.36mm

0.5 max

0.5 max

4 max 2.0 max 3.0 max Free -

2.0 max 2.0 max 3.0 max Free Free Free 35 max 40 max 40 max 25 max -

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The different sizes of material shall be separated by screening and re-combined together to produce the all-in Recycled crushed aggregate, which shall achieve the following grading limits :

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Coarse Aggregate

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Grading Particle Size Organic Material - including wood and materials prone to disintegration (%) Water Absorption –Saturated surface dry (%) Liquid Limit Plasticity Index (%) MaterialPassing0.075mm (%) Acid Soluble Chlorides (%) Acid Soluble Sulphates SO 3 (%) Materials subject to Spontaneous combustion Materials from Sabkha and Marshes Clay Balls Flakiness Index (%) Elongation Index (%) Los Angeles Abrasion (%) Crushing Value (%) Soundness - magnesium sulphates, 5 cycles (%) Sand Equivalent Value

Fine Aggregate

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Gradation of Recycled Crushed Aggregate for use in Asphalt Layers for Village and Temporary Roads

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BS EN Sieve (mm) 63.0 40.0 20.0 10.0 4.0 2.0 0.500 0.063

BS Sieve (mm)

Percentage Passing (by weight)

50.0 37.5 19.0 9.5 4.75 2.36 0.600 0.075

100 95-100 60-80 40-60 25-40 15-30 8-22 5-12

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Recycled aggregate for use in Asphalt layers of minor roads in village areas and temporary roads shall be non–plastic.

4

The material shall wet during transporting and spreading in order to avoid segregation. END OF PART

QCS 2014

Section 07: Green Constructions Part 01: Introduction

Page 1

INTRODUCTION ..................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4

GREEN CONSTRUCTION ...................................................................................... 2 Green Construction and Sustainability 2 Reference 2 Green Construction Regulations and Environmental Assessment Tools 2 Green Building Definition 2

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Section 07: Green Constructions Part 01: Introduction

Page 2

INTRODUCTION

1.1

GREEN CONSTRUCTION

1.1.1

Green Construction and Sustainability

1

Buildings, infrastructure and the environment are inextricably linked. Energy, water, materials and land are all consumed in the construction and operation of buildings and infrastructure. These built structures in turn become part of living environment, affecting living conditions, social well-being and health. It is important to explore environmentally and economically sound design and development techniques in order to design buildings and infrastructure that are sustainable, healthy and affordable, and encourage innovation in buildings and infrastructure systems and designs.

2

The concept of sustainability in building and construction has evolved over many years. The initial concept was on how to deal with the issue of limited resources, especially energy, and on how to reduce impacts on the natural environment. Emphasis was placed on technical issues such as materials, building components, construction technologies and energy related design concepts. Recently non-technical issues become appreciated such as economic, social sustainability and cultural heritage aspects of the built environment. Also, there are greater attention to create more green buildings by upgrading the existing buildings through the application of new developments or the invention and use of innovative technologies for energy and material savings.

1.1.2

Reference

1

The following documents are referred to in this section:

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Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for Research and Development, Qatar, formerly known as (QSAS) (Note: QCS reference shall be limited only to this particular version of GSAS and non-other) Green Construction Regulations and Environmental Assessment Tools

1

Many countries have developed their own standards for green building or energy efficiency for buildings and Building Environmental Assessment tools. Now there are many of building rating systems tools and guidelines in the world currently in use. A new sustainability assessment system known as GSAS (GLOBAL Sustainability Assessment System) is referred to herein in this document.

1.1.4

Green Building Definition

1

Green building is the process through which buildings are designed, constructed and operated to reduce natural resources consumption, eliminate environmental degradation and enhance social and economic aspects of humans.

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END OF PART

QCS 2014

Section 07: Green Constructions Part 02: QCS Green Building

Page 1

QCS GREEN BUILDING ......................................................................................... 2

2.1 2.1.1 2.1.2

SCOPE .................................................................................................................... 2 General 2 References 2

2.2 2.2.1 2.2.2 2.2.3

QCS GREEN BUILDING REQUIREMENTS ............................................................ 3 Types of Buildings 3 QCS Green Building Categories & Criteria 3 Submittal Requirements 5

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QCS GREEN BUILDING

2.1

SCOPE

2.1.1

General

1

This section specifies minimum environmental performance requirements that apply to the design, construction and operations of new buildings.

2

The minimum environmental performance requirements apply to 8 building typologies only (Section 2.2.1) and have been specified for eleven environmental performance criteria (Table 1).

3

The environmental performance criteria apply to all new buildings for those building typologies specified and shall apply to:

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Buildings under design but not yet constructed (i.e. pre-construction);

(b)

Buildings under construction; and

(c)

Buildings constructed prior to hand over.

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(a)

For buildings under construction or constructed and not handed over, the minimum environmental performance requirements shall apply as far as is reasonably possible without the need to undertake a major re-design and retrofit. Where building owners, designers or contractors, etc. judge that any re-design or retrofit to meet the environmental performance requirements specified herein is not reasonable, the relevant Qatari authorities / government agencies reserve the right to ask for a justification to explain such a decision.

5

The Engineer shall specify the applicable Green Building Assessment System for the QCS’s Building typologies and to assess compliance with QCS’s Green Building Requirements.

6

The minimum environmental performance requirements specified herein have been derived from the Global Sustainability Assessment System (GSAS) v2.1-2013.

7

The Engineer shall ensure compliance with QCS’s minimum sustainable building requirements or higher specified by the relevant authorities or the Engineer.

8

QCS 2014 encourage the use of any environmental or sustainability performance criteria in addition to those environmental performance criteria specified to help design, construct and operate better buildings.

2.1.2

References

1


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Global Sustainability Assessment System (GSAS) v2.1-2013, Gulf Organisation for Research and Development, Qatar

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QCS GREEN BUILDING REQUIREMENTS

1

The values listed herein for the Commercial, Health Centres, Education, Mosques, and Light Industries Schemes and Typologies shall be considered as the minimum requirements for the applicable criteria (Table 3).

2.2.1

Types of Buildings

1

COMMERCIAL: Types include Spaces that Serves various functions such as offices, 2 conference rooms, foyers, retail spaces, and ancillary areas, with built up area of 10000 m or more.

2

GOVERNMENTAL BUILDINGS: Types include Capitol, Diplomatic Buildings, Statehouses, Courthouses, Municipalities, Post offices, etc.

3

PUBLIC BUIDLINGS: Types include:

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RAIL BUILDINGS: Types include spaces that serve various functions of a railway station such as but not necessarily limited to platform/concourse, offices, station control room, ticketing, retail, food/beverage areas, and ancillary areas.

(b)

SPORTS: Facilities include indoor or outdoor competition areas, fitness suites, locker facilities, retail spaces, offices, restaurants, and common areas

(c)

EDUCATION BUILDINGS: Types include educational facilities for students in th kindergarten through 12 grade as well as college and university facilities. This includes classrooms, libraries, auditoriums, cafeterias, kitchens, offices, and other spaces that are part of academic buildings.

(d)

MOSQUES AND OTHER RELIGIOUS BUILDINGS: Types include the building containing the congregational worship areas.

(e)

HOSPITALS AND HEALTH CENTERS BUILDINGS: Types include specialist hospitals, general hospitals, out-patient hospitals, and primary care health centres.

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LIGHT INDUSTRIES BUILDINGS: Types include both operational and office areas as well as the general building as a whole.

2.2.2

QCS Green Building Categories & Criteria

1

The minimum QCS’s requirements unless other values specified by the relevant authorities.

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Table 1: Green Building Categories & Criteria QCS Category

ENERGY

Criteria Energy Demand Performance

Minimum Requirements *

EPC ≤ 1.0

Energy Delivery Performance

Building Typologies Commercial, Governmental Education, Mosques & other religious buildings, Light Industry, Health Centres, Railways, Sports

WPC ≤ 1.0 WATER

Water Consumption

Commercial, Governmental, Education, Mosques, Light Industries, Health Centres, Railways, Sports


QCS Category

Criteria

Page 4

Minimum Requirements * PMV ≤ 2.0 80 ≤ ADPI Comply with ASHRAE Standards Comply with ASHRAE Standards PMV ≤ 2.0 office spaces

Natural Ventilation Can be Utilized(x) 0 < X ) month of the year(

Commercial, Governmental, Education, Mosques, Light Industry

Comply with ASHRAE Standard Natural Ventilation Can be Utilized(x) 0 < X (month of the year) Comply with ASHRAE Standard no existence of equipment with efficiency less than specified in ASHRAE 90.12010

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VOC_emi_total ≤100%

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Support of National (GCC) Economy

% of Construction Expenditure Benefiting National Economy (x) 20 ≤ X

Cultural Identity & Heritage

To be defined & assessed by Certification Authority

MANAGEMENT & OPERATION

Recycling Management

Recycling Management Plan demonstrates Compliance

MATERIALS

Regional Materials

Performance Indicator (X) X < 30

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Natural Ventilation

Mechanical Ventilation

CULTURAL & ECONOMIC VALUE

Health Centres

worst case heat load ≤ 1.6 Exposed Spectator Seating

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INDOOR ENVIRONMENT

Commercial, Light Industry, Governmental Education, Mosques

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Thermal Comfort

Building Typologies

.

QCS 2014

Health Centres Sports Railways (above ground) Commercial, Education, Mosques, Light Industry Health Centres, Railways Commercial, Governmental Education, Mosques, Light Industry Health Centres, Sports, Railways Commercial, Governmental Education, Mosques, Light Industry Health Centres, Railways, Sports Commercial, Governmental Education, Mosques, Light Industry Health Centres, Railways Commercial, Governmental Education, Mosques, Light Industry Health Centres, Sports, Railways Commercial, Governmental Education, Mosques, Light Industry Health Centres, Railways, Sports

QCS 2014


Page 5

2.2.3

Submittal Requirements

1

Building owners, designers or contractors, etc. shall provide the relevant authorities with a report that shows how the minimum environmental requirements have been met. The report shall include: All raw data used to performance calculations;

(b)

All calculations used to derive results against the environmental criteria specified (and / or copies of relevant GSAS calculator tools where appropriate);

(c)

All specifications where relevant of construction materials, equipment, fixtures and fittings, etc;

(d)

Details of suppliers / service providers with evidence that purchases have been made or services commissioned, etc.

(e)

All other information necessary to demonstrate how the environmental performance requirements have been met.

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END OF PART

QCS 2014

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ENERGY [E] ............................................................................................................ 2 Scope 2 Reference 2 Abbreviations 2 Scope 3 Description 3 Measurement Principle 4 Measurement ( EPCnd) 4 Score ( EPCnd) 4 Scope 4 Description 5 Measurement Principle 5 Measurement (EPCdel) 5 Score (EPCdel) 6

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3 3.1.1 3.1.2 3.1.3 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

Section 07: Green Constructions Part 03: Energy

QCS 2014


Page 2

3

ENERGY [E]

3.1

GENERAL

3.1.1

Scope

1

The Energy category consists of factors associated with energy demand of buildings, the efficiency of energy delivery, and the use of fossil energy sources that result in harmful emissions and pollution. Impacts: Negative impacts resulting from energy use and unsustainable practices include: (i)

Climate Change

(ii)

Fossil Fuel Depletion

(iii)

Air Pollution

(iv)

Human Comfort & Health

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Designing the building to lower its energy demand

(ii)

Selecting efficient building systems

(iii)

Lowering the demand on non-renewable sources of energy thereby reducing harmful emissions and depletion of fossil fuels

(iv)

Minimizing the amount of harmful substances produced by the energy delivery systems and the energy supply network

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(i)

Energy is sub-categorised as follows: (i)

Energy Demand Performance

(ii)

Energy Delivery Performance

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(c)

Mitigate Impact: Factors that could mitigate environmental impacts due to energy use include:

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Reference

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3.1.2

Global Sustainability Assessment System (GSAS) – V2.1 2013, Gulf Organization for Research and Development , Qatar (Note: QCS reference shall be limited only to this particular version of GSAS and non-other). 3.1.3

Abbreviations

1

The following abbreviations are defined for use in this section.     

EPC EPCnd EPCdel EPCp fop

Energy Performance Coefficient Energy Demand Performance Energy Delivery Performancet Primary Energy Performance Operation factor for a particular Building category

QCS 2014


 Edelivery

Page 3

The delivered energy is defined as the supplied energy To the technical building systems through the system boundary, to satisfy 2 the uses of the building in KWh/m /yr. The reference value used in the GSAS scoring method for the 2 Delivered energy for the building type in KWh/m /yr. 2 The total primary energy consumed for the building in KWh/m /yr. the reference value used in the GSASscoring method for primary 2 Energy for the building type in KWh/m /yr. 2 The emitted mass of CO2 in g/m /yr. calculated from the net delivered Energy and emission coefficient. The emission coefficient includes the CO2 emissions associated with the primary energy consumed for the building. the reference value used in the GSASscoring method for CO2 emissions for the building type in g/m2/yr. 2 the building thermal energy demand in kwh/m /yr. which takes into account the energy losses (transmission and ventilation), heat gains (solar, internal and system heat losses), and the dynamic parameter (loss utilization factor). the reference value used in the GSAS Scoring method for energy 2 demand for the building type in kwh/m /yr. 2 The emitted masses of NOX & SOX in gm./m /yr. calculated from the net delivered energy and emission coefficients. the reference values used in the GSAS scoring method for NOX & 2 SOX emissions for the building type in gm./m /yr.

 Eref_del  EP  Eref_p  CO2

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 CO2ref

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 NOXref,SOXref

ENERGY [E.1] ENERGY DEMAND PERFORMANCE

3.2.1

Scope

1

The energy demand performance shall buildings:

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3.2

be measured for the following categories of

Table 1: Building Typologies Commercial Governmental Education Mosques & other religious buildings Light Industry Health Centres Railways Buildings Sports

3.2.2

Description

1

Establish energy demand performance levels for the building in order to reduce environmental and economic impacts associated with excessive energy use.

QCS 2014


Page 4

Measurement Principle

1

The Engineer shall Calculate Building performance in relation to the baseline as specified below. All calculations will adhere to the GSAS Energy Application document.

3.2.4

Measurement ( EPCnd)

1

The Engineer shall calculate the EPCnd value based on building data and cooling energy needs of the project as per the energy performance standard calculation tool (EPSCT).

2

Calculated EPCnd = Qdesign / Qref_nd The Qdesign is calculated according to the GSAS Energy Application document.

3

Commercial & Governmental (with baseline reference) Qref_nd = 125 [kWh/m²/yr].

4

Education: With Baseline reference Qref_nd = 122* fop.education [kWh/m²/yr]. where fop.education is the operation factor for education typologies. The Qdesign and fop,school are calculated according to the GSAS Energy Application document.

5

Mosques & other religious buildings: With Baseline reference Qref_nd = 170 [kWh/m²/yr] . The Qdesign is calculated according to the GSAS Energy Application document.

6

Health Centers: The Qref_nd are area weighted average calculated according to the reference guidelines document.

7

Railways: The Qref_nd are area weighted average calculated according to the refference guidelines document.

8

Sports : the Engineer shall determine energy demand performance in two steps. Step 1, the project will use the Energy Performance Calculator to determine the Energy demand (Q nd.fc,I) for each functional component (FC) of the project. Step 2, the project will enter the Qnd,fc,I for each FC in the composition sheet in the energy calculator to determine the aggregated criterion score for the entire sports facility.

9

Light Industry : With Baseline reference Qref_nd = 475 [kWh/m²/yr.]

3.2.5

Score ( EPCnd)

1

The Recommended minimum requirement * value for EPCnd shall be as per table 2:

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Note : (*) minimum QCS’s requirements unless other values specified by the relevant authority Table 2: EPCnd Values EPCnd Value

0.8 < EPCnd ≤ 1.0

3.3

ENERGY [E.2]: ENERGY DELIVERY PERFORMANCE

3.3.1

Scope

1

The energy delivery performance shall be measured for the following categories of buildings:

QCS 2014


Page 5

Table 3: Building Typologies Commercial Governmental Education Mosques & other religious buildings Light Industry Health Centres Railways Buildings

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Description

1

The Engineer shall establish delivered energy performance levels of the project in order to reduce environmental and economic impacts associated with excessive energy use.

3.3.3


1

The Engineer shall calculate the building performance in relation to the baseline as specified below. All calculations will adhere to the GSAS Energy Application document.

3.3.4

Measurement (EPCdel)

1

The Engineer shall complete the Energy Performance Standard Calculation Tool (EPSCT) to determine the EPCdel value based on building data, HVAC specifications, lighting system, and DHW system and energy generation.

2

Calculated EPCdel =Edel Application document.

3

Commercial & Governmental : with Baseline reference Eref_del = 89 [kWh/m²/yr].

4

Education With Baseline reference Eref_del = 88* fop_education [kWh/m²/yr]. where fop_education is the operation factor forEducation Typologies. The Edelivery and fop,education are calculated according to the GSAS Energy Application document.

5

Mosques & other religious buildings: With Baseline reference Eref_del = 82 [kWh/m²/yr]. The Edelivery is calculated according to the GSAS Energy Application document.

6

Light Industry: With Baseline reference Eref_del = 165 [kWh/m²/yr].

7

Sports Facilities: The Engineer shall determine energy delivery performance in two steps. Step 1, the Engineer shall use the Energy performance calculator to determine the delivered energy (Edel,fc,i) for each functional component (FC) of the project. Step 2, the Engineer shall enter the Edel,fc,I for each FC in the energy score calculator to determine the aggregated criterion score for the entire sports facility.

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3.3.5

Score (EPCdel)

1

The Recommended minimum requirments* EPCdel value shall be categorised as per table 4. Note : (*) minimum QCS’s requirements unless other values specified by the relevant authority Table 4: EPCdel minimum required value 0.8 < EPCdel ≤ 1.0

EPCdel Value

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END OF PART

QCS 2014

Page 1

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WATER [W] .............................................................................................................................. 2 SCOPE 2 REFERENCE 2 SCOPE 2 DESCRIPTION 3 MEASUREMENT PRINCIPLE 3 MEASUREMENT (WPC) 3 * SCORE 4 RAILWAY TEMINALS 5

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Section 07: Green Constructions Part 04: Water

QCS 2014


Page 2

4

WATER [W]

4.1

GENERAL

4.1.1

Scope

1

The Water category consists of factors associated with water consumption and its associated burden on municipal supply and treatment systems. (a)

Impacts: Environmental impacts resulting from water consumption and unsustainable practices include: (i)

Mitigate Impact: Factors that could mitigate environmental impact and lower demand on water include:

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Water depletion

Specifying efficient plumbing fixtures

(ii)

Creating a system for the collection and storage of rainwater

(iii)

On-site treatment of water for later reuse

(iv)

Designing a landscaping plan that minimizes the need for irrigation.

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The recommended criteria is Water Performance Coefficient (WPC) [W.1] Reference

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4.2

WATER CONSUMPTION

4.2.1

Scope

1

The Water consumption will be measured for the following categories of buildings listed in table 1:

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[W]

Table 1: Building Typologies Commercial Governmental Education Mosques & other religious buildings Light Industry Health Centres Railways Buildings Sports

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Page 3

Description

1

Minimize water consumption in order to reduce the burden on municipal supply and treatment systems.

4.2.3


1

The Engineer shall demonstrate conservation in the use of water in relation to the baseline and targets outlined in the Water Consumption Calculator.

4.2.4

Measurement (WPC)

1

The Engineer shall determine cumulative water consumption [Water Performance Coefficient (WPC)] using the Water Consumption Calculator. Cumulative water consumption is determined by several input parameters including:

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The project site area and the number of full time staff, students, or residents and visitors occupying the building

(b)

Specifications for plumbing fixtures

(c)

Landscaping and irrigation plan

(d)

Rain and storm water collection and reuse plan

(e)

Grey and black water treatment and reuse plan

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(a)

Based on input parameters provided by the project, the application conducts multiple calculations to determine the building’s estimated water consumption. Three estimated calculation values, Water Consumption for occupants (WCcal_occupant), Water Consumption for irrigation (WCcal_irrigation), Water Supply from reuse strategies (WScal_reuse) are computed by the calculator. The annual net water demand is calculated by subtracting water supply (WScal_reuse) from the summation of water consumptions (WCcal_occupant + WCcal_irrigation). Then, the net water demand is compared against the summation of the two reference water consumption values (WCref_occupant + WCref_irrigation) to generate the Water Performance Coefficient (WPC).

3

For each building type, the equations to calculate reference values apply to all buildings regardless of operating duration, occupancy density and site area. A different reference value will be calculated for project buildings with varying site and operational characteristics, and the resulting WPC will therefore be applicable across the entire spectrum of each building type.

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(a)

The Referenced Water Consumption for Occupants is: WCref_occupant = A x Operating Hours x Occupants Where: Operating Hours = 8 (hours per day) x 20 (days per month) x 12 (months per year)

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Page 4

Occupants = The total number of full time employees per day + the total number of visitors per day (b)

The Referenced Water Consumption for irrigation is: 2

WCref.,irrigation = B x 365 (days per year) x 24 (hours per day) x Site Area (m ) Reference values A and B can be found for the different typologies in the following table:

B

0.006519

0.000034

Education

0.008423

0.000001

Mosques & other religious buildings

0.003888

0.000002

Light Industry

0.005355

0.000004

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Table 2: Reference values A and B

N/A

N/A

Additional input parameters required:

(b)

Number of staff and students occupying the building

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* Number of worshippers visiting the mosque, both on a daily basis and during times of full occupancy. The Referenced Water Consumption for Occupants is:

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WCref_occupant = A× No. Operating Hours_d × No.Occupants_d) + (No. Operating Hours_f x No. Occupants_f) Notes:

6

(i)

Where ‘No.Occupants_d’ is the number of daily worshippers, ‘No.Occupants_f’ is the number of occupants during full occupancy.

(ii)

‘No.Operating Hours_d’ are normalized as 6 (hours per day) x 30 (days per month) x 12 (months per year)

(iii)

‘No.Operating Hours_f’ are normalized as 2 (hours per day) x 30 (days of Ramadan) + 52 (Friday prayers per year)

Light Industry Additional input parameters required: Number of full time employees and visitors occupying the building

4.2.5

*

Score

The minimum Requirement values by QCS for Water Performance Coefficient shall be:

QCS 2014


Page 5

Note : (*) minimum QCS’s requirements unless other values specified by the relevant authority 1

COMMERCIAL & GOVERNMENTAL Table 3: minimum score for commercial Typology WPC(X) Value

2

0.87 < X ≤ 1.0

EDUCATION Table 4: minimum score for Education Typology WPC(X) MOSQUES

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0.85 < X ≤ 1.0

Table 5: minimum score for Mosques Typology

0.89 < X ≤ 1.0

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Table 6: minimum score for Light Industry Typology

HEALTH CENTRES

0.84 < X ≤ 1.0

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RAILWAY TEMINALS Table 8: minimum score for Railways Typology

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WPC(X)

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WPC(X)

0.84 < X ≤ 1.0

SPORTS FACILITIES Table 9: minimum score for Sports Typology WPC(X)

END OF PART

0.0 ≤ X < 0.5

QCS 2014

Section 07 : Green Constructions Part 05 : Indoor Environment

Page 1

INDOOR ENVIRONMENT [IE] ................................................................................................. 2

5.1 5.1.1 5.1.2

GENERAL ................................................................................................................................ 2 SCOPE 2 REFERENCE 2

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5

INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT ........................................................ 3 SCOPE 3 DESCRIPTION 3 MEASUREMENT PRINCIPLE 3 MEASUREMENT (THERMAL COMFORT) 3 * SCORE 4

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

INDOOR ENVIRONMENT [IE.2] Natural Ventilation ............................................................... 5 SCOPE 5 DESCRIPTION 5 MEASUREMENT PRINCIPLE 5 MEASUREMENT (NATURAL VENTILATION) 6 SCORE* 6

5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5

INDOOR ENVIRONMENT [IE.3] : Mechanical Ventilation ...................................................... 7 SCOPE 7 DESCRIPTION 7 MEASUREMENT PRINCIPLE 7 MEASUREMENT (MECHANICAL VENTILATION) 7 * SCORE (MECHANICAL VENTILATION) 8

5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

INDOOR ENVIRONMENT [IE.4] Low-Emitting Materials ........................................................ 8 SCOPE 8 DESCRIPTION 8 MEASUREMENT PRINCIPLE 8 MEASUREMENT (VOC) 8 SCORE (VOC) 9

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5

INDOOR ENVIRONMENT [IE]

5.1

GENERAL

5.1.1

Scope

1

The Indoor Environment category consists of factors associated with indoor environmental quality such as thermal comfort, air quality, acoustic quality, and light quality..

(ii)


(iii)

Air Pollution

(iv)


rw

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Climate Change

Mitigate Impact: Factors that could improve indoor environmental quality include: Monitoring air temperature and quality and adjusting or calibrating as appropriate

(ii)

Maximizing the time period that the building can utilize natural ventilation

(iii)

Designing an adequate mechanical ventilation system

(iv)

Ensuring adequate illuminance levels for visiual performance and comfort

(v)

Maximizing the use of natural lighting in interior spaces

(vi)

Providing for occupant comfort by minimizing glare

(vii)

Maximizing views to the exterior for all occupants

(viii)

Controlling the amount of noise produced by or transferred from the building interior and exterior

(ix)

Specifying materials with low VOC levels

(x)

Controlling indoor pollutants and sources of airborne contamination

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(i)

The QCS’s requirements for Sub-Indoor Environment criteria Includes:

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(c)

(i)

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(b)

Impacts: Impacts resulting from ineffective control and design of the indoor environment include:

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(a)

(i)

Thermal Comfort

(ii)

Natural Ventilation

(iii)

Mechanical Ventilation

(iv)

Low-Emitting Materials

2

The Public and Government Buildings are to be considered as commercial for the purpose of Indoor Environment calculation as applicable.

5.1.2

Reference

1


QCS 2014


Page 3

Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for Research and Development (GORD), Qatar (Note: QCS reference shall be limited only to this particular version of GSAS and non-other), And American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)

5.2

INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT

5.2.1

Scope

1

The Indoor Environment for Thermal Comfort shall be measured for the following categories of the buildings: Table 1: Building Typology

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Commercial

rw

Governmental Education

ta


Health Centres

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Railways Terminals

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Light Industry

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Sports Facilities Description

1

The Project shall provide a thermaly comfortable environment to ensure the comfort and health of building occupants.

5.2.3


1

The Engineer shall calculate the system capacity and either PMV or ADPI Values for the hottest hour of the year for the worst case for all applicable occupied spaces

2

Sport Facilities.

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5.2.2

The Project shall also Calculate the heat loads for all critical seats for the hottest outdoor conditions for scheduled events. 5.2.4

Measurement (Thermal Comfort)

1

The Project shall complete the Thermal Comfort Calculator (Considering GSAS Assessment System or any other recommended system) in order to compute PMV or ADPI values and demonstrate that system Capacity can meet the peak cooling loads for the worst case for all typical occupied spaces. (a)

System Capacity : The capacity of the system should be properly sized to meet the peak cooling loads of critical spaces. All projects will calculate the peak cooling loads for the hottest hour of the year.

QCS 2014

2


Page 4

(b)

PMV values: The project will evaluate all critical spaces and perform thermal comfort assessment for the hottest hour of the year. Calculate PMV values of different positions in critical spaces such as different positions relative to window and diffuser locations and select the worst PMV value for assessment.

(c)

ADPI values: The project will evaluate the selected worst case for each typical space and perform thermal comfort assessment for the hottest hour of the year in terms of Air Diffusion Performance Index.

The following table outlines the measurement type and typical spaces used in the calculation according to the appropriate typology: Table 2: measurement type and typical spaces

Mosques

ADPI

Light Industry

PMV

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Office , Operational Areas

PMV

Typical Occupied Spaces

PMV or ADPI for the worest case Heat Load

Office spaces (a),Exposed Spectator Seating (b)

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Score

Prayer Halls

*

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5.2.5

Classrooms, Offices, Special Functional Spaces.

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Health Centres Sports

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ADPI

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Education

Office, Reception Areas

ta

PMV

as

Commercial

TYPICAL SPACES

.

MEASUREMENT TYPE

qa

TYPOLOGY

1

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Note: (*) minimum QCS’s requirements unless other values specified by the relevant authority The score values for Commercial, Light Industry Typologies Table 3: Commercial & Light Industry Typologies PMV

2

1.5 < PMV ≤ 2.0 Under the system capacity meeting the peak load

The score values for Education, Mosques Typologies Table 4: Education, Mosques Typologies ADPI

80 ≤ ADPI< 85 Under the system capacity meeting the peak load

QCS 2014

3


Page 5

The score values for Health Centres Typology Table 5: Health Centers The Building will Comply with ASHRAE Standards- Design Manual for Hospital and Clinics

4

The score values for Sports Typology Table 6: Railways Typology a.

for office spaces (a)

for Exposed Spectator Seating (b)

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b.

.

1.5 < PMV ≤ 2.0 Under the system capacity meeting the peak load

PMV

1.185 < b ≤ 1.600 worest case heat load

rw

ADPI

INDOOR ENVIRONMENT [IE.2] NATURAL VENTILATION

5.3.1

Scope

1

The Indoor Environment for Natural Ventilation shall be measured for the following categories of the buildings.

as

qa

ta

5.3

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Table 6: Building Typologies Commercial

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Governmental

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Education


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Light Industry Health Centres Rail Buildings Sports

5.3.2

Description

1

The Project shall encourage effective natural ventilation strategies in conjunction with mechanically ventilated systems.

5.3.3


1

The Engineer shall maximize the number of days that the building can utilize natural ventilation, either through user operable windows or through controlled opening

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5.3.4

Measurement (Natural Ventilation)

1

All projects using operable windows will complete the Natural Ventilation Calculator to determine the number of months that all typical spaces can utilize natural ventilation by verifying minimum fresh air supply to guarantee indoor air quality as recommended in ASHRAE 62.1-2010. All projects using mechanical ventilation systems will demonstrate thorough calculation and/or simulations the number of months a project can utilize natural ventilation. Exclude all circulation areas from this measurement.

2

The following table outlines the typical spaces used in the calculation according to the appropriate typology: Table 7: Typical Spaces for Natural Ventilation

Mosques

Prayer Halls

Light Industry Health Centres

Office areas

qa

as

LIGHT INDUSTRY

Operational Areas associated with the industrial process are not included as part of this criterion.

HEALTH CENTRES

All Projects will undertake a full thermal model analysisto calculate the air flow provided by the natural ventilation to determine if each typical space can gurantee indoor air quality as recommended in ASHRAE 62.1-2010.Circulation areas and Clinical areas can be excluded from this calculation in line with guidance HTM 03-01.

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(i)

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(i) (b)

Staff areas, Library/Seminar rooms, Dining rooms

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(a)

ta

Classrooms, Libraries

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Office, Reception areas

Education

.

Typical Spaces

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Typology

M Commercial

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(ii)

Typical Spaces to be assessed against the ASHRAE Standards include: Satff areas , Office accommodation, Library /Seminar rooms , Dining rooms .Natural ventilation in accordance to ASHRAE must achieve fresh air rates of 5 l/s/person.

5.3.5

SCORE*

1

The recommended minimum Score for the QCS,s Targeted Typologies : (*) minimum QCS’s requirements unless other values specified by the relevant authority Table 8: Commercial,Governmental,Sport, Education , Mosques,Light Industry Typologies Number of Months Natural Ventilation Can be Utilized

0 < months of the year ≤1

Table 9: For Health Centres, Rail Terminals The Building will Comply with ASHRAE 62.1-2010 Standards- Design Manual for Hospital and Clinics

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5.4

INDOOR ENVIRONMENT [IE.3] : MECHANICAL VENTILATION

5.4.1

Scope

1

The Indoor Environment for Mechanical Ventilation shall be measured for the following categories of the buildings Table 10: Building Typologies Commercial Governmental

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Education Mosques

rw

Light Industry Health Centres

qa

ta

Railways Description

1

The Project shall provide effective mechanical ventilation to ensure occupant comfort and health.

5.4.3


1

The Engineer shall ensure that mechanical ventilation in all primary occupancy areas meets the minimum requirements of ASHRAE 62.1-2010 and the system requirements in ASHRAE 90.1-2010.

5.4.4

Measurement (Mechanical Ventilation)

1

The mechanical system shall meet the minimum requirements of ASHRAE 62.1-2010, ASHRAE 90.1-2007. These requirements include, but are not limited to:

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5.4.2

(a)

Mechanical equipment must meet minimum Efficiency standards, and be properly verified and labeled.

(b)

Mechanical systems must have proper control systems, including the use of zoning, proper dead bands, off-hour controls, and automatic shut-offs.

Note: In the Calculation of the required fresh air supply, both EN-ISO and ASHRAE should be used, and the larger of the two standards should be used in the verification of over ventilation. 2

MEASUREMENT (a)

LIGHT INDUSTRY (i)

(b)

Operational Areas associated with the industrial process are not included as part of this criterion.

RAILWAYS

This Criteria applies to both underground or overground stations.

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*

5.4.5

Score (Mechanical Ventilation)

1

The Recommended minimum Requirements by QCS as shown in (Table 11): Note: (*) minimum QCS’s requirements unless other values specified by the relevant authority Table 11: Minimum Value Outdoor Air Volume (X)

≥ 15 % of ASHRAE 62.1-2010 requirement; AND no existence of equipment with efficiency less than specified in ASHRAE 90.1-2010

INDOOR ENVIRONMENT [IE.4] LOW-EMITTING MATERIALS

5.5.1

Scope

1

The Indoor Environment for Low-Emitting Materials shall be measured for the following categories of the buildings.

rw

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5.5

ta

Table 12: Building Typologies

qa

Commercial

Education

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Mosques

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Governmental

Light Industry

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Health Centers

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Railways

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Sports

Description

1

The project shall meet the minimum emissions targets for indoor materials and finishes to ensure the comfort and health of occupants and installers.

5.5.3


1

The Engineer shall choose materials and finishes that minimize Volatile Organic Compounds (VOC) emissions.

5.5.4

Measurement (VOC)

1

The Engineer shall complete the Low-Emitting Materials Calculator to evaluate the measured VOC contents of specified indoor materials.

2

The Engineer shall develop a plan to specify materials with low VOC emission rates as found in the Low-Emitting Materials Calculator.

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5.5.2

Exclude materials used in spaces that are exposed to the exterior. 3

RAILWAYS: This Criteria applies to both underground and overground stations.

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Page 9

5.5.5

Score (VOC)

1

Recommended minimum Requirements by QCS as shown in (table 6) Table 13: VOC score value 85% < X ≤ 100 %

VOCemi,total (X)

(*) minimum QCS’s requirements unless other values specified by the relevant authority

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END OF PART

QCS 2014

Section 07: Green Building Part 06: Cultural & Economic Value

Page 1

Cultural & Economic value [ce] ................................................................................................ 2

6.1 6.1.1 6.1.2


6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL gcc ECONOMY [ce.1] ....... 2 SCOPE 2 DESCRIPTION 3 MEASUREMENT PRINCIPLE 3 MEASUREMENT (SUPPORT OF NATIONAL GCC ECONOMY) 3 SCORE 3

6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5

CULTURAL & ECONOMIC VALUE - Heritage & Cultural Identity [ce.2] ................................ 3 SCOPE 3 DESCRIPTION 4 MEASUREMENT PRINCIPLE 4 MEASUREMENT (HERITAGE AND CULTUAL IDENTITY ) 4 SCORE 4

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6

CULTURAL & ECONOMIC VALUE [CE]

6.1

GENERAL

6.1.1

Scope

1

The Cultural and Econmic Value category consists of factors associated with cultural conservation and support of the local economy. Impacts: Impacts resulting from lack of cultural conservation and economic planning include: (i)

Loss of Cultural Identity

(ii)

Economic stagnancy or decline

Encouraging designs to align with cultural identity and traditions

(ii)

Designing for a seamless integration into the existing cultural fabric

(iii)

Planning for the use of local materials and workforce

The recommended sub-criteria Includes: (i)

Support of National Economy

(ii)

Heritage & Cultural Identity

ta

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(i)

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(c)

Mitigate Impact: Factors that could mitigate impact include:

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(b)

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(a)

Reference

1


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6.1.2

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GSAS (Global Sustainability Assessment System) - v 2.1-2013, Gulf Organization for Research and development, Qatar (Note: QCS reference shall be limited only to this particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of reference]

CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL GCC ECONOMY [CE.1]

6.2.1

Scope

1

The Cultural & Economic Value for Support of National Economy will be measured for the following categories of the buildings.

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6.2

Table 1: Building Typology Commercial & Governmental Education Mosques Light Industry Health Centers Sports Railways

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Page 3

Description

1

The Project shall maximize the percentage of construction expenditures for goods and services originating from the national GCC economy (Gulf Cooperation Council- GCC)

6.2.3


1

The Engineer shall maximize the percentage of construction expenditure benefitting the national GCC economy.

6.2.4

Measurement (Support of National GCC Economy)

1

The Engineer shall complete the Support of National GCC Economy Calculator to determine the amount of construction expenditure benefitting the national economy, as a percentage of total construction costs. Construction expenditures include, but are not limited to, the following:

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6.2.2

Laborers/Contractors

(b)

Building Materials

(c)

Construction Materials

(d)

Construction Tools/Equipment

(e)

Temporary Facilities/Rental Spaces

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(a)

RAILWAYS: This criteria applies to both underground and overground stations

6.2.5

Score

1

The recommended minimum score by QCS for % of Construction Expenditures Benefitting National Economy is as follows (Table 2).

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Table 2: Recomended Minimum Score for QCS Building Typologies Expenditures

Benefitting

X ≥ 30%

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% of Construction National Economy (X)

CULTURAL & ECONOMIC VALUE - HERITAGE & CULTURAL IDENTITY [CE.2]

6.3.1

Scope

1

The Cultural & Economic Value for Heritage and Cultural Identity shall be measured for the following categories of the buildings.

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6.3

Table 3: Building Typologies Commercial Governmental Education Mosques Health Centers Sports Railways

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Page 4

Description

1

The Project shall encourage design expression that will align with and strengthen cultural identity and traditions.

6.3.3


1

The Engineer shall develop a concept brief outlining design strategies. The Qatar Heritage organization and/or an independent expert panel assigned by the Certification Authority will assess the design and determine whether the project meets the goals outlined in the mission statement.

6.3.4

Measurement (Heritage and Cultual Identity )

1

All projects shall develop a concept brief to demonstrate the following through drawings and descriptions of the design strategy:

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6.3.2

Enhancement, strengthening and reflection of cultural identity and traditions

(b)

Harmonization with cultural values of the region

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(a)

qa

ta

The compliance range will be defined by an Expert Heritage Panel assigned by the Certification Authority RAILWAYS: This criteria applies to both underground and overground stations

6.3.5

Score

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2

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Table 4: Recomended Minimum Score for QCS Building Typologies

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To be defined by Certification Authority

END OF PART

QCS 2014

Section 07: Green Constructions Part 07: Management & Operations

Page 1

MANAGEMENT & OPERATION [MO] ..................................................................................... 2

7.1 7.1.1 7.1.2


7.2 7.2.1 7.2.2 7.2.3 7.2.4

MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT .............................. 3 SCOPE 3 DESCRIPTION 3 MEASUREMENT PRINCIPLE 3 SCORE 3

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7

MANAGEMENT & OPERATION [MO]

7.1

GENERAL

7.1.1

Scope

1

The Management and Operations Category consists of factors associated with building design management and operations Impacts: Environmental impacts resulting from ineffective building management and operations include: (i)

Climate Change

(ii)


(iii)

Water Depletion

(iv)

Materials Depletion

(v)

Land use and Contamination

(vi)

Water Pollution

(vii)

Air Pollution

(viii)


rw ta qa

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Mitigate Impact: Factors that could mitigate impact include: Creating a Commissioning plan to meet all the sustainable goals of the project

(ii)

Providing facilities for the collection ,storage ,and proper removal of organic waste

(iii)

Providing facilities for the collection ,storage ,and proper removal of recyclables

(iv)

Providing leak detection systems

(v)

Providing energy and water use sub-metering systems

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(i)

(vi)

Providing an automated building control system to optimize building performance

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(a)

(vii)

Managing hospitality resources to reduce waste and support sustainable food sources

(viii)

Promote and educate users about the sustainable initiatives of the building

(ix)

Providing a beneficial legacy to the community

7.1.2

Reference

1

The following documents are referred to in this section: Global Sustainability Assessment System (GSAS) - v 2.1-2013, Gulf Organization for Research and development, Qatar (Note: QCS reference shall be limited only to this particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of reference]

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7.2

MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT

7.2.1

Scope

1

Recycling Management shall be measured for the following categories of the buildings: Table1: Building Typology Commercial Governmental Education Light Industry Health Centers

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Sports

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Railways Description

1

The Project shall encourage space planning to designate containment facilities for the building’s recyclable waste streams in order to minimize waste taken to landfills or incineration facilities.

7.2.3


1

The Project shall develop and implement a Recycling Mangement Plan for the collection, storage, and removal of recycling.Measurement

2

The Engineer shall demonstrate that a central sorting and storage area is located close to a truck loading area, and that sufficient storage has been provided for the recyclable material produced. The sorting and storage area must be properly isolated and ventilated to reduce negative health impacts for users and visitors on the site. Outline the collection procedures for recyclable materials in the project to demonstrate that recyclable materials will be easily collected and sorted. The Engineer shall also demonstrate how recyclable materials will be handled at an off-site facility.

7.2.4

Score

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7.2.2

Table 2: Recommended minimum Requirement for QCS’s Building Typologyies Recycling Mangement Plan Shall demonstrate Compliance

End of Part

QCS 2014

Page 1

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MATERIALS [M] ....................................................................................................................... 2 SCOPE 2 REFERENCE 2 SCOPE 2 DESCRIPTION 3 MEASUREMENT PRINCIPLE 3 MEASUREMENT 3 SCORE 3

m

8 8.1.1 8.1.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5

Section 07: Green Constructions Part 08: Materials

QCS 2014


Page 2

8

MATERIALS [M]

8.1

GENERAL

8.1.1

Scope

1

The Material category consists of factors associated with material extraction, processing, manufacturing, distribution, use/reuse, and disposal.

1

(ii)

Climate Change

(iii)


(iv)

Air Pollution

rw

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Material depletion

ta

Mitigate Impact: Factors that could mitigate environmental impact due to material use include: Using local Materials to reduce transportation needs

(ii)

Using responsibly sourced materials

(iii)

Using materials with high recycled contents

(iv)

Recycling and Reusing materials, on-and off-site

(v)

Reusing structural elements, on-and off-site

(vi)

Designing for ease of disassembly and reuse/recycling

Reference

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qa

(i)


o

8.1.2

(i)

er

(b)

Impacts: Environmental impacts resulting from material use and unsustainable practices include:

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(a)

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Global Sustainability Assessment System (GSAS) - V2.1 2013, Gulf Organization for Research and Development, Qatar (Note: QCS reference shall be limited only to this particular version of GSAS and non-other),

8.2

MATERIALS [M.1] REGIONAL MATERIALS

8.2.1

Scope

1

The Regional Materials shall be measured for the following categories of the buildings Table 1: Building Typology Commercial Governmental Education Mosques Light Industry Health Centres Sports Railways

QCS 2014


Page 3

Description

1

Encourage the use of regionally manufactured and assembled building elements and materials in order to reduce the carbon footprint of the materials

8.2.3


1

All projects shall use materials that are regionally manufactured and assembled

8.2.4

Measurement

1

All projects shall complete the Regional Materials Calculator to compute a Performance Indicator based on the weight and sourcing distance of all applicable materials. Materials sourcing distance can either be regional (less than or equal to 200 kilometres) or external (over 200 kilometres). All projects will only consider materials permanently installed in the project. Exclude mechanical, electrical, and plumbing assemblies, as well as specialty items and equipment.

8.2.5

Score

ta

rw

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8.2.2

qa

Table 2: Recommended minimum Score for QCS’s Building Typologies

20 ≤ X  30

as

Performance Indicator (X)

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END OF PART

QCS 2014

Section 08: Drainage Works Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8

SUMMARY .............................................................................................................. 2 Scope 2 References 2 Definitions 2 System Description 3 Submittals 3 Quality Assurance 5 Site in Private Lands 5 Inspection and Handover Procedure 5

1.2 1.2.1 1.2.2

TESTING OF MATERIALS ...................................................................................... 5 Materials Generally 5 100 Day Acid Test 6

1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6

IMPLEMENTATION ................................................................................................. 7 Site Information 7 Health and Safety 7 Setting Out of the Works 10 Inspection of Works 10 CCTV Survey 11 Compensation for Damage to Property 12

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GENERAL

1.1

SUMMARY

1.1.1

Scope

1

This Section includes specifications for the construction and rehabilitation of sewerage, surface water drainage and treated sewage effluent pipelines, piping, pipeline appurtenances and sewage treatment plants.

2

This Part includes general requirements basic to this Section and common to its Parts.

3

Related Parts and Sections are as follows: Pipeline Cleaning and Inspection Survey

Section 1,

General

Section 5,

Concrete

Section 6,

Roadworks

Section 9,

Mechanical and Electrical Equipment

Section 10,

Instrumentation, Control and Automation

Section 21,

Electrical Works.

as

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ta

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1

References

1

Documents of the following agencies are referred to in this Section:

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1.1.2

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American National Standards Institute, ANSI American Society for Testing and Materials, ASTM American Water Works Association, AWWA British Standards Institution, BS Euro Norms, EN Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance Section National Joint Health and Safety Committee for the Water Services, UK International Organization for Standardization, ISO Swedish Standards Commission, SS Water Research Centre, WRC, UK 2

The following standards or revised/updated versions and other documents are referred to in this Part: BS 6100 ......................Glossary of building and civil engineering terms BS 8010 ......................Pipelines BS EN 752 ..................Drain and Sewer Systems outside buildings

1.1.3

Definitions

1

The following definitions apply generally to this Section. These and other definitions included in this Section are based, where applicable, on BS 6100, Part 2. (a)

Surface water: Water that flows over, or rests on, the surface of buildings, other structures or the ground; the definition is extended to include groundwater.

QCS 2014


Page 3

(b)

Sewage: Contents of a sewer that does not solely convey surface water.

(c)

Treated sewage effluent (TSE): Effluent from a sewage treatment works following completion of treatment of sewage and disinfection of the treated sewage effluent to attain a water quality standard suitable for reuse for selected purposes.

1.1.4

System Description

1

Unless otherwise specified herein or elsewhere in the Specification, designated in the Project Specification, or directed by the Engineer, the material, equipment and systems to be provided under this Section shall: be capable of providing the required level of service under the climatic conditions in Qatar as stated in Section 1

(ii)

in handling the process fluids and materials of the prevailing and indicated

(iii)

quality and quantity and variations thereof

(iv)

under the prevailing and indicated characteristics and quality of the natural and

(b) 1.1.5

.l. l rw

process environments and process materials

ta

(v)

.

(i)

comply with the provisions of BS EN 752, BS 8010, and BS 8301.

qa

(a)

Submittals

as

General

The Contractor shall submit to the Engineer for approval all drawings and data including samples, calculations, schedules, certificates and other submittals specified in Section 1, this Section, the Project Specification, and required by variations. Submittals shall be in accordance with the procedures specified in Section 1, in this Part and in the other Parts of this Section.

2

The Contractor, shall be responsible for preparing final record drawings relating to the civil, structural and architectural aspects of the Works. Mechanical, Electrical and ICA record drawings shall be provided by the Contractor as required by Section 1 Part 21.

3

During the course of the Works, the Contractor shall maintain a detailed record of all changes in order to facilitate accurate preparation of record drawings and to ensure that these drawings are in all respects a true record of the installation.

4

The Contractor shall provide the Engineer or his nominated representative drawings and a photocopy of each schedule correctly and neatly modified in red ink to truly represent the Works constructed. These shall be submitted to the Engineer or his nominated representative for approval before the contract completion date.

5

If any drawing is not approved, it shall be returned to the Contractor with marked indications of the additional information required.

6

In addition the Contractor shall complete the Drainage Affairs Network Record Sheets in the prescribed format but not necessarily limited to, the following Record Sheets as applicable in both hard copy and electronic copy in a widely used Data Exchange Format (DXF) textual (i.e. .mdb, .xls or similar approved) format. Electronic format record sheets shall be obtained from the Engineer or his nominated representative.

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(2 b)

Pumping Station Hoist Inventory Sheet

c)

Pumping Station Motor Inventory Sheet

d) Valve Inventory

d)

Pumping Station Penstock Inventory Sheet

e) Valve Chamber Survey (3 pages)

e)

Pumping Station Data Sheet

f) TSE Pipeline Record

f)

Pumping Station Pump Inventory Sheet

g) Rising Main Record

g)

Pumping Station Shaft Inventory Sheet

h) TSE Tower Record

h)

Pumping Station Valve Inventory Sheet

i) TSE Distribution Chamber

i)

Pumping Station Ventilation Inventory Sheet

j) Overflow Pipe Record

j)

Pumping Station Fan Inventory Sheet

k) TSE/Rising Main Fittings Record

k)

Pumping Station Generator Sheet

l) House Connection Record

l)

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Record

Pumping Station Control Panel Inventory Sheet 1 m) Pumping Station Control Panel Inventory Sheet 2 n) Pumping Station Control Panel Inventory Sheet 3 o) Pumping Station Actuator Sheet

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b) Discharge Chamber pages) c) Sewer Record

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a)

PUMPING STATIONS Pumping Station Well Inventory Sheet

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p)

Pumping Station Air Conditioner Sheet

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The Contractor shall be deemed to have included all provisions within his Tender should the above list be altered by PWA from time to time.

8

Individual Record Sheets shall be prepared for each length of sewer, TSE pipeline, rising main and overflow pipe, each manhole and house and gully connection, and shall be submitted to the Engineer or his nominated representative for approval after which they shall become the property of the Employer.

9

Record sheets for pipelines (c, f, g, i, j, k, l & n above as appropriate), and record sheets for any other work that is to be covered up, shall be presented for approval prior to covering up the works. Backfilling will not be permitted prior to the record sheets being approved.

10

Record sheets for work of an exposed nature that can be later verified by the Engineer or his nominated representative may be submitted up to 14 days after the work has been carried out.

11

Photocopies of record sheets relating to work carried out since the previous valuation shall be submitted with each interim valuation application.

12

No valuation of sections of work will be considered in the absence of completed record sheets for the work in question.

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A Certificate of Completion will not be issued until a complete set of Record Sheets endorsed by the Engineer’s Site Representative has been presented to the Engineer.

14

Blank hard copy Record Sheets, as detailed in sub-clause 6 above will be supplied by the Engineer.

15

The Contractor shall accurately locate by co-ordinates to the Qatar National Grid, the centre of all covers of manholes and chambers constructed under this project or to which any work whatsoever has been undertaken under this project. The Contractor shall also locate by coordinates the position of buried bends and fittings on pressure mains. Where pipelines are not laid to straight lines between chambers or fittings the co-ordinates of every pipe joint shall be recorded prior to covering up the pipeline. Where flexible pipes are used coordinates shall be at 10m intervals.

16

All Survey works shall be undertaken by Survey Company approved by Engineer.

1.1.6

Quality Assurance

1

Materials and products shall be furnished by approved suppliers as designated in the Contract and Project Specifications.

2

Survey work for obtaining record sheet data and the compilation of the data shall be carried out by approved prequalified surveying companies designated in the Contract or Project Specification.

1.1.7

Site in Private Lands

1

The Employer will serve the necessary notices to permit pipelines to be constructed in private land in accordance with the agreed programme of work. The Contractor shall not enter those lands without the Engineer’s permission. The Contractor shall temporarily fence the Site in private lands to the satisfaction of the Engineer and the Contractor’s operations shall be confined within the fenced area. The Contractor shall use the Site for the purposes of constructing the Works only.

1.1.8

Inspection and Handover Procedure

1

The inspection and handing over of the Works to the Employer shall be in accordance with the procedure specified in Section 1, and, Clauses 1.3.4 and 1.3.5 of this Part.

1.2

TESTING OF MATERIALS

1.2.1

Materials Generally

1

All materials to be used in contact with sewage or its atmosphere must be shown to withstand corrosion. In the absence of satisfactory evidence of equivalent testing results, materials will be required to pass the 100 day acid test as detailed in Clause 1.2.2 of this Part.

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1.2.2


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100 Day Acid Test General Based on the results at 100 days, materials shall be deemed to be unsuitable for use in contact with sewage or sewer atmosphere in the opinion of the Engineer the tested samples fail to satisfy any of the following requirements:

2

All materials to be used in contact with sewage or its atmosphere must be shown to withstand corrosion and in the absence of satisfactory evidence of equivalent testing results will be required to pass successfully the 100 day acid test as detailed in this Specification. The test shall be carried out by an approved laboratory, experienced in undertaking the test.

3

All materials to be used in contact with sewage or its atmosphere must be shown to withstand corrosion. Such materials may be divided into two categories:

4

Category 1 Materials - material which serve a purpose other than protection (e.g. pipes and pipe jointing materials)

5

Category 2 Materials – materials which protect other (usually structural) corrodible materials (e.g. coating to step irons, GRP manhole liners, acid resistant mortar).

6

Sample preparation and testing shall, as far as is possible, simulate the conditions to which the materials will ultimately be subjected.

7

Samples shall be taken and prepared in a manner to be approved by the Engineer. Care shall be taken in preparation of samples of non-homogenous materials to ensure that only the face that will be exposed to the corrosive environment in the sewer is exposed to the acid during the testing.

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Samples in Category I materials shall be cut from pipe/pipe joint samples selected by the Engineer and cut ends adequately protected by a gel coat.

(b)

Samples of Category II materials shall be generally prepared by coating a corrodible material with the protective coating to be tested.

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For each test two samples shall be prepared and indelibly marked with an identifying number.

9

One sample shall be partially immersed in 10% V/V sulphuric acid maintained at a º temperature of 50 C for 100 days. The concentration of acid shall be maintained by preventing evaporation. In addition the strength of the acid shall be regularly checked and the level and strength adjusted as necessary. The second sample shall be kept as a control.

10

The test sample shall be visually inspected at weekly intervals. Interim reports on the condition of the sample shall be submitted to the Engineer by the laboratory following visual inspections of the samples after 25, 50 and 75 days. Such reports shall include reference to any changes in surface condition and colour of the samples, changes in colour of the liquid, and any presence of any particles in the liquid.

11

If the interim report after 75 days is satisfactory the Contractor may request the Engineer’s approval to use of the material prior to completion of the 100 day acid test. Such approval shall be solely at the discretion of the Engineer, and the use of the materials shall be entirely at the Contractor’s risk. Any costs associated with the replacement of such materials, should they subsequently fail the acid test, shall be borne by the Contractor.

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On completion of the test period, the sample tested in sulphuric acid shall be split or the coating removed to determine the internal condition of the sample. The final test report shall give full details of: (a)

The test procedure adopted.

(b)

The surface condition of the samples before, during and after testing, listing the times at which significant changes in appearance were noted.

(c)

The internal condition of the sample.

(d)

Any changes in the solution.

Materials shall be deemed to be unsuitable for use in acid environments if the acid tested samples fail to satisfy any of the following requirements: Category 1 Materials - the surface of the samples shall not be significantly different in texture from the non-immersed control sample.

(b)

Category 2 Materials -the underlying corrodible material shall not show any sign of corrosion.

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The surfaces of the samples shall not be significantly different in texture from the nonimmersed control sample. No change in surface hardness will be permitted, and no splits, cracks, blisters or delamination will be allowed.

1.3

IMPLEMENTATION

1.3.1

Site Information

1

Notwithstanding any relevant information included or referred to in the Project Specification or furnished by the Engineer, the Contractor shall be responsible for obtaining his own information on ground and subsoil conditions at the Site and the locations of all pipelines and services within or near the Site.

2

The Contractor shall complete a services information sheet for each section of the Works and shall submit the completed sheet for the Engineer’s approval at least seven days before work is due to begin on that section. Work shall not begin on that section until the respective services information sheet has been approved by the Engineer.

3

Blank services information sheets will be provided by the Engineer.

1.3.2

Health and Safety

1

The requirements of this Clause are pursuant to or in addition to the health and safety requirements in Section 1 and Section 11. Safety requirements in relation to specific classes of work are specified in other Parts of this Section.

2

The recommendations contained in ”Working with Sewage – The Health Hazards” Pbulished by the Health & Safety Executive – http://www.hse.gov.uk/pubns/indg198.htm shall be adhered to in respect of all work to be carried out in operational sewers, pumping stations and sewage treatment works.

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Page 8

Arrangements shall be made with Drainage Operation and Maintenance Department, Public Works Authority before entering in or working on existing sewers and associated works. A Permit to Work must be obtained from Asset Affairs Drainage Operations and Maintenance Department prior to any works taking place .

4

The Contractor’s attention is drawn to the hazards involved in working in confined spaces including sewers, manholes, inspection chambers, wet wells, pumping stations and ancillary structures. The Contractor shall be responsible for ensuring that adequate precautions are taken to ensure safe working conditions as well as the availability of safe tools and facilities. The Contractor shall issue his risk assessment to the Engineer for his approval prior to applying for a Permit to Work at the site. This risk assessment shall meet but not be limited to the requirements of this Part of this Section.

5

The Contractor shall appoint a Safety Officer who shall be suitably qualified and experienced. The Contractor shall ensure that the Safety Officer is available on Site during the mobilisation period and thereafter to train the Contractor’s personnel in safety operations. The work shall not proceed unless such training has been accomplished to the Engineer’s approval.

6

The Safety Officer’s main responsibilities shall be to

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ensure that all the Contractor’s employees follow the agreed safety procedures

(b)

ensure that all employees are supplied with the appropriate safety/protective equipment and that it is used and maintained as per agreed procedures

(c)

assist in carrying out of refresher safety training courses for working in confined spaces

(d)

investigate all accidents and dangerous occurrences, and where applicable, submit reports recommending actions to be taken to prevent a recurrence.

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(a)

The Contractor shall provide and erect approved safety barriers around all unattended open manholes and trenches. All manholes shall be covered with suitable temporary steel sheets. Advance warning notice road signs shall be erected at least 50 m either side of areas where work is in progress.

8

The need for adequate protection to the general public in the vicinity of the Works is stressed.

9

Care must be exercised when working in or near live sewers, and tests must be made to verify that no hydrogen sulphide or other toxic gases are present, before anyone enters an existing manhole or confined space.

10

Particular attention is drawn to the dangers of poisoning, asphyxiation or explosion while working in, or near, or inspecting pipelines, manholes, chambers, treatment units, pumping stations, or any confined space. In this connection the Contractor must obtain appropriate safety equipment and acquaint all personnel with the dangers involved, and precautions to be taken, and shall regularly discuss with the Engineer's Representative the sufficiency of safety precautions on site.

11

The following minimum precautions must be taken before entry into a manhole, chamber or other confined space:

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(a)

Sufficient numbers of covers of manholes or chambers upstream and downstream of the entry point shall be removed to ensure adequate ventilation.

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Page 9

The manhole or confined space must be thoroughly ventilated by mechanical air blower prior to entry.

(c)

Before entering the confined space the atmosphere shall be checked for the presence of toxic gases, flammable gases, and oxygen level.

(d)

The mechanical air blower must be kept close by the manhole or confined space that has been entered.

(e)

No naked lights, matches or lighters shall be used in a sewer or in close proximity to an open manhole or chamber. All equipment shall be intrinsically safe.

(f)

The hydrogen sulphide level in the manhole or confined space must be continually monitored. If the level rises the manhole or confined space must be evacuated immediately.

(g)

All persons entering a manhole or confined space must wear a safety harness properly rigged to the lifting frame.

(h)

At least two top men must be available to operate the air blower and lifting tackle in the event of an emergency. The top men shall keep in touch with the men in the sewer, manhole, chamber or confined space by calling or signalling to them at frequent intervals. No person shall enter the confined space alone.

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(b)

Before entering any confined space, the atmosphere shall be checked for the presence of toxic gases, flammable gases and oxygen level. The Contractor shall have on site in working order, sufficient calibrated gas monitors to continually monitor the atmosphere in all confined spaces and in all areas adjacent to sewage where men are working.

13

The Contractor will not be permitted to work in manholes, pipelines, or pumping stations if such gas monitors are not in use.

14

The following equipment is to be made available throughout the Contract at each and every entry point to a confined space.

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1 No. 1 No. 1 No. 1 No.

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Safety Harness (not a safety belt) and ropes Lifting frame and tackle for safety harness Gas monitor Mechanical air blower with compressor and generator

Gas monitors shall incorporate the following features: (a)

(a) Continuous monitoring of oxygen level, with visual and audible high and low level alarms.

(b)

(b) Continuous electrochemical monitoring of Hydrogen Sulphide with indication of the gas concentration, and audible and visual alarms under the following conditions:

(c)

(i)

Time weighted average providing 8 hours exposure at the threshold limit value.

(ii)

Time weighted average providing 10 minutes of exposure at short term exposure limit, or ceiling value.

(iii)

Exposures to ten times the threshold limit value.

(c) Continual monitoring for flammable gas at intervals not exceeding 2 minutes.

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1.3.3

Setting Out of the Works

1

The following requirements are pursuant to or in addition to the requirements in Section 1. The Contractor shall locate, by co-ordinates to the Qatar National Grid, the locations of the elements of the Works. Pipelines shall be located by the position of the centre of manholes and chamber covers. Pressure pipelines shall be located by the position of bends and fittings.

2

The execution of surveys, recording of data and preparation of record sheets shall comply with the following requirements: surveys shall be based on Qatar National Grid survey control points

(b)

co-ordinates shall be located to within 0.1 m

(c)

co-ordinates shall be determined by radial (polar) observations using theodolite and electronic distance measuring (EDM) equipment. The co-ordinates shall be checked by independent methods and the error shown to be within acceptable limits

(d)

if required, additional temporary control points may be established as follows:

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observations for additional temporary control points shall consist of at least two

(ii)

rounds of angles (on two faces) with a different zero setting for each round.

(iii)

where applicable, distances shall be determined by trigonometric methods and

(iv)

at least two rounds of vertical angles (on two faces) shall be observed.

(v)

positions of additional temporary control points shall be determined by

(vi)

reference to not less than three Qatar National Grid survey control points and shall be proven to have standard errors of not more than  0.08 m.

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(i)

On completion of work, all observations, computations, sketches and any other documentation used in determining the co-ordinates shall be submitted to the Engineer. A daily log giving the number of additional control stations and manholes surveyed shall be maintained and submitted. A comprehensive report on the work carried out including methods used, problems encountered, solutions used and a full summary of the results shall be submitted.

4

The Engineers approval of the setting out shall be obtained before work on each element commences.

5

The Contractor shall be deemed to have included all provisions within his tender for the ‘topographical survey information which should include: - features (fittings), manhole chamber co-ordinates/levels in a widely used Data Exchange Format (DXF), accurate positional survey drawings (i.e. either.DWG or.DXF) layout files together with equally widely used DXF textural (i.e. xls, .txt or similar approved).

1.3.4

Inspection of Works

1

The Contractor shall provide a safe and convenient means of access to the Works to enable the Engineer’s inspections to be carried out.

2

The Contractor shall submit to the Engineer notice of work requiring inspection on a completed Notice of Inspection Required form not less than 24 hours before requiring inspection of those works. Blank forms will be provided by the Engineer.

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Requests for inspection by the Engineer shall be submitted for the following: setting out

(b)

formation level of excavation

(c)

pipelaying, bedding and testing

(d)

base slabs

(e)

manhole precast chamber rings in place before internal linings and external coatings are applied

(f)

manhole concrete surround

(g)

formwork and reinforcing steel before concreting

(h)

before backfilling of permanent Works

(i)

before reinstatement

(j)

any other constructional operation that the Engineer may require.

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Works covered up or in any way made unavailable for inspection before the submission of the Notice of Inspection Required form or the Engineer’s approval to proceed shall be uncovered at the Contractor’s expense.

5

Prior to inspection, the Contractor shall submit his Quality Control plan (QC plan) / Inspection and Test Plan (ITP) in accordance with Section 1 Clause 7.6.3.

1.3.5

CCTV Survey

1

The Contractor shall on written instruction of the Engineer undertake a CCTV survey on designated lengths of pipelines laid during the execution of the Works, including pipeline cleaning where necessary and submission of a Survey Report, as part of the final inspection of the Works.

2

The Certificate of Completion for the Works or part thereof shall not be issued until the CCTV Survey, including provision of the Survey Report, and any subsequent sewer remedial works have been completed to the satisfaction of the Engineer.

3

Should any length of the surveyed between adjacent manholes, or the manholes indicate failure to comply with the requirements of the Contract, the whole cost of any pipeline cleaning, the CCTV Survey, Survey Report and any subsequent remedial works carried out to the satisfaction of the Engineer shall be borne by the Contractor.

4

The CCTV Survey shall be carried out by an approved specialist subcontractor designated in the Project Specification. The subcontractor shall provide suitable documentation to verify previous experience in undertaking CCTV Surveys to the satisfaction of the Engineer.

5

Pipeline cleaning and CCTV surveys and reporting shall be carried out as specified in Part 10 of this Section.

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1.3.6

Compensation for Damage to Property

1

Before commencing any work on site, the Contractor shall undertake an extensive condition survey of all properties adjacent to the proposed works. A detailed report including sketch plans, schedules of defects and photographs shall be submitted to the Engineer for agreement.

2

The Contractor shall not mark boundary walls to properties in any way whether deliberately for identification purposes or accidentally. All markings, howsoever caused, shall be repaired and repainted. Sufficient area of wall shall be repainted to avoid a patchy appearance.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 10: Pipeline Cleaning and Inspection Survey

Page 1

10

PIPELINE CLEANING AND INSPECTION SURVEY .................................... 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7

Scope References Submittals Specialist Subcontractor Programme of Work Topographic Survey of Sewers Safety Requirements

10.2

SEWER CLEANING ...................................................................................... 6

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7

Scope Cleaning of Sewer Pipelines Jetting Winching Bucketing Balling or Kiting and Pipeline Internal Gauging General Cleanliness of Areas during Sewer Cleaning

10.3

SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING .......... 10

10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7 10.3.8

Scope of Work Survey Requirements Survey Equipment Survey Vehicle Photographs Site Coding Sheets Excavation Survey Reporting

10.4

OVERPUMPING AND FLOW DIVERSION ................................................. 16

10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.4.6 10.4.7 10.4.8 10.4.9

Source of Flow Pipe Stoppers Stopping Off Flow Pumping Plant Sewage Flooding Overpumping of Flow Temporary Diversion of Flow Entrances to Private Properties Odour and Noise Control During Flow Diversion and Overpumping

10.5

CONTRACTOR’S QUALITY CONTROL PROCEDURE .............................. 18

6 7 8 9 9 9 9 10 10 11 13 14 14 15 15

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16 17 17 17 17 18 18 18 18

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PIPELINE CLEANING AND INSPECTION SURVEY

10.1

GENERAL

10.1.1

Scope

1

This Part includes the specification for all work necessary to clean and carry out inspection surveys of sewerage pipelines. The specification applies equally to the cleaning and inspection survey of surface water and ground water pipelines.

2


Section 1,

General.

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This Section Part 1, Part 2, Part 4, Part 11,

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References

1

The following document is referred to in this Part:

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Water Research Centre (WRC) Manual of Sewer Condition Classification Water Research Centre (WRC) Sewer Rehabilitation Manual Submittals

1

The Contractor shall submit complete data and details for pipelines cleaning and inspection survey for the Engineer’s approval as follows:

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programme of work, detailed method statement, and schedule of equipment to be used on the project, general plant and specialist equipment

(b)

proposed methods of flow diversion and overpumping

(c)

specific data for the proposed specialist equipment before beginning any sewer cleaning and inspection as follows:

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original catalogues for all the proposed specialist equipment, which complying with the Specifications. These catalogues shall be considered as an integral part of the Contractor’s method statement. All equipment to be provided for sewer cleaning and closed circuit television (CCTV) survey and sonar scanning shall be reliable and in good working condition

(ii)

typical video recordings preferably on CD ROM of similar work carried out previously by CCTV camera and sonar scanner. Such recordings, if acceptable, will be retained by the Engineer as the standard for appraisal of subsequent recordings

(iii)

video graphic printer

(iv)

still pictures in digital format (Tiff, JPEG) for computer data storage and

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retrieving (d)

specific data to be submitted while carrying out and at the completion of the work: (i)

site coding sheets as designated under Clause 10.3.6 in this Part

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(ii)

the master and a copy of each video recording as designated in Clause 10.3.2 in this Part

(iii)

still colour pictures using video graphic printer of the inside of sewers, manholes, inspection chambers, and grease and oil interceptors, and the interior of pumping stations as required and as specified in Clause 10.3.5 of this Part.

The Contractor shall submit a method statement to the Engineer for approval four weeks in advance of commencing activity on site. The method statement shall comprise but not necessarily be limited to: Equipment set-up and locations of proposed access points

(b)

Anticipated cut off periods for services

(c)

Procedures for notifying affected residences and businesses

(d)

Procedures for verification of active services

(e)

Procedures for complying with traffic control

(f)

Procedures for seeking permits to work.

(g)

Safety procedures in particular working with scaffolding and entering confined spaces.

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Specialist Subcontractor

1

The Contractor shall employ an approved specialist subcontractor designated in the contract document.

2

The Contractor shall provide the following information on sewer cleaning and inspection survey contracts carried out by the proposed subcontractor during the last five years:

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10.1.4

project location

(b)

name and address of client

(c)

start and completion dates

(d)

cost of the works undertaken by the subcontractor

(e)

length, diameter and material of sewers

(f)

reference letter from the client or engineer

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a sample document of the reports produced for at least two projects.

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3

All operators employed by the subcontractor shall be fully skilled in the specified works.

4

The operator for interpreting the video recordings and preparing the site coding sheets shall be fully conversant with picture interpretation, defect coding and classification. A copy of the operator’s current certificate of qualification for sewer surveys and fault classification issued by Water Training International of the U.K. or an equivalent body for the types of sewers to be inspected shall be submitted to the Engineer for approval before beginning the survey. If the Engineer determines that the Operator’s qualifications and experience are not acceptable, the Contractor shall provide an acceptable replacement before beginning the survey.

10.1.5

Programme of Work

1

The sewage pipelines may be frequently surcharged and ready access to them may not be available. The Contractor shall make due allowance for such disruptions in his programming of operations. The Contractor shall cause minimum disruption to the utilisation of the pipelines and the period of overpumping shall be kept to the minimum necessary. Before starting the cleaning and inspection survey in any sewer length, the Contractor shall submit an applications to CED Drainage Division O & M Section for a permit to work in the sewers.

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Page 4

Topographic Survey of Sewers

1

A topographic survey of the pipelines to be cleaned shall be carried out by the Contractor and a schedule provided to the Engineer. Some manhole covers may be buried under landscaping, debris, or the surface of roads, footpaths, or other pavements. These manholes shall be located by the Contractor on the basis of the Employer’s record drawings using appropriate techniques and apparatus. The topographic survey of the sewer system shall include resurveying where affected by any rehabilitation works on completion of the sewer cleaning and inspection surveys as directed by the Engineer.

2

The survey shall include details of manholes, chambers, and oil and grease interceptors including topographic levels of covers and inverts, locations and co-ordinates.

3

The Contractor shall locate accurately and survey all junctions and lateral connections into manholes, or directly into sewers, whether or not the existence or location of such junctions and lateral connections are shown on the Employer’s record drawings.

4

The Contractor shall survey the original ground surface, taking levels at 50 m intervals or as directed by the Engineer along the route of the sewer, determine existing pipe diameters and invert levels, and the details shall be recorded in a schedule to the Engineer’s approval. These details shall, when finally and mutually agreed, be signed by the Contractor and authorized by Engineer as truly representing the configuration of the particular areas.

10.1.7

Safety Requirements

1

The Contractor’s attention is drawn to the hazards involved in working in confined spaces including sewers, sewer manholes, inspection chambers, wet wells, pumping stations and ancillary structures. The Contractor shall be responsible for ensuring that adequate precautions are taken to ensure safe working conditions.

2

The Contractor shall give evidence of having carried out training in avoiding the following risks associated with working in confined spaces in sewerage pipelines: presence of toxic, flammable and explosive gases

(b)

persons falling

(c)

falling objects

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drowning infection.

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10.1.6

Training shall include the following: (a)

definition of confined spaces

(b)

atmospheric hazards

(c)

purpose and practical use of gas monitoring equipment

(d)

practical use and maintenance of safety equipment such as breathing apparatus, safety harnesses, life lines and lifting frames

(e)

personal protective equipment such as hard hats, gloves and safety boots

(f)

health hazards

(g)

hygiene procedures

(h)

basic first aid procedures

(i)

pre-entry procedure

(j)

entry procedure

QCS 2014


(k)

exit procedure

(l)

rescue procedure.

Page 5

All training courses shall involve both class room instruction and hands-on practical training which should include both entry and rescue drills. Safety and Protective Equipment. The Contractor shall safeguard his work force against physical injury caused by falling or being struck by falling objects. Precautions shall include, but are not limited to, the provision of the following equipment for each person working in confined spaces: (a)

safety helmet with chin guard

(b)

safety boots

(c)

safety harness

(d)

PVC gloves/gauntlets

(e)

overalls

(f)

rubber boots

(g)

ear, eye, and face protection, where applicable.

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In addition to the above, each gang working in a confined space shall have with them: four sets of 15 m life lines with spring shackle one end, eye at other

(b)

portable ladder

(c)

lifting frame complete with ropes and shackles for hand operation

(d)

powerful hand lamp, explosion proof (intrinsically safe)

(e)

ventilation blower together with portable generator and flexible ducting

(f)

position pressure respiration face masks with associated portable compressor or air line system supplying air via compressed cylinders

(g)

gas detectors capable of detecting both high and low oxygen, hydrogen sulphide and methane gas explosion proof (intrinsically safe).

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All safety and protection equipment shall be regularly maintained and inspected by a competent person. Gas monitors shall be calibrated in accordance with the manufacturer’s recommendations and a certificate issued with the date of calibration.

7

Each group of workers engaged in working in sewers, manholes, pumping stations and ancillary structures shall be provided with, and shall be familiar with the operation of gas testing equipment suitable for checking hydrogen sulphide, combustible gases, and lack of oxygen. Before entering confined spaces the atmosphere within such spaces shall be tested and certified as safe for entry by the responsible person to ensure that there is no build up of hydrogen sulphide or combustible gases, nor lack of oxygen. When working in sewers where accumulation of sludge or silt exists, the Contractor's attention is drawn to the fact that, when disturbed, sludge may release toxic gases. Adequate ventilation facilities shall be provided and continuous monitoring shall be made while work is in progress in live sewers or structures containing sludge or silt.

8

Should anyone working in a confined space complain of nausea or dizziness, all personnel shall be removed from that location immediately. Work may resume only when it is certified safe to do so, using breathing apparatus if necessary.

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The Contractor shall safeguard his work force against health hazards while working in sewers and inform his work force of the dangers of bacterial infection while working in a sewage contaminated environment, and shall impress upon them the importance of personal hygiene. All members of the work force shall be fit, and everyone who will be expected to work in sewers shall not suffer from: (a)

Any heart defect.

(b)

Any history of fits or blackouts.

(c)

Deafness or loss of balance.

(d)

Claustrophobia.

(e)

Recurrent back ailments.

(f)

Shortage of breath on light exertion.

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All members of the work force shall be vaccinated against tetanus, typhoid, paratyphoid, hepatitis A and B and cholera, and shall each carry an up-to-date medical record on their person. The Contractor shall provide a medical certificate of fitness for all his personnel.

11

The Contractor shall keep personal hygiene and emergency equipment within easy access of each working group. Emergency equipment which shall include but not be limited to:

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Barrier cream.

(b)

Disinfectant.

(c)

First-aid kit with eye bath.

(d)

Stretcher.

(e)

Life lines 15 m long with spring shackle one end, eye at other.

(f)

Lifting harnesses.

(g)

Two sets of breathing apparatus with air bottle.

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(a)

The address and telephone number of the nearest hospital with emergency facilities shall be posted in each working location.

13

The Contractor shall be solely responsible for liability for any claim or legal action arising as a result of an accident and shall not be absolved of any liability under the Contract for his having conformed to the above requirements.

14

The Contractor shall provide and erect approved safety barriers around all unattended open manholes and cover them with suitable temporary steel sheets. Advance warning notice road signs shall be erected at least 50 m in front and behind the area being worked in one day. At the end of each day works all manhole covers shall be replaced.

10.2

SEWER CLEANING

10.2.1

Scope

1

The cleaning of sewer pipelines and appurtenances includes but is not limited to the following elements:

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(a)

location of manholes and chambers using suitable detection techniques and removal of overburden where necessary

(b)

cleaning of manholes and chambers with either or both water jetting or wire brushing or other means approved by the Engineer

(c)

removal of any grit and debris from manhole bases and benching

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(d)

providing cutoff walls and overpumping where necessary

(e)

water jetting including vacuum suction of debris

(f)

bucket and winch dredging, balling, kiting, pipeline internal gauging, or any other cleaning process as approved by the Engineer

(g)

flushing with water

(h)

removal of all sand, grit and debris jetted or dredged from the sewers and disposal of same to a disposal site required by the Engineer

(i)

controlling of odour and nuisance arising out of rehabilitation works, flow diversion or overpumping.

Cleaning of Sewer Pipelines

1

Cleaning of sewers and manholes before inspection surveys shall include one or more of the above operations. The Contractor should note that pipelines, manholes, may have structural defects cracks etc., and may have been completely filled with sand, grit, sediment and other debris and the requirement to accurately measure the vertical inside diameter of the sewer necessitates that the invert of the sewer to be free of all sediment. The Contractor shall allow for the removal of all such material and disposal of same to a disposal site approved by the Engineer. Cleaning of sewers shall progress downstream.

2

Sewer cleaning shall be thorough and shall only be carried out by methods approved by the Engineer to remove all deposits, foreign matter, solid or semi-solid and hard intruding material and all other debris including sand, silt, slime, sludge, sediment, grease, roots, loose flaky or soft pipe wall materials, loose concrete from walls and underside of cover slabs and benching of manholes from within sewers and manholes. The liquid biological element of the sludge may be returned to the sewer system after suitable filtering methods to be agreed with the Engineer.

3

Where cast iron junction pieces have been used, the Contractor shall ream out or grind off the corrosion products to produce a pipe of diameter equal to the adjacent pipes. Care shall be taken to grind off all burrs which may otherwise puncture in-situ lining tubes during subsequent renovation works.

4

Pump station wells shall be cleaned where necessary to permit pipeline cleaning.

5

The designated sewer/manhole sections shall be cleaned using hydraulically propelled, highvelocity jet, or mechanically powered equipment. The equipment and methods selected shall be satisfactory to the Engineer. The equipment shall be capable of removing dirt, grease, rocks, sand, and other materials and obstructions from the sewer lines and manholes. If cleaning of an entire section cannot be successfully performed from one manhole, the equipment shall be set up on the other manhole and cleaning again attempted. If, again, successful cleaning cannot be performed or the equipment fails to traverse the entire manhole section, it will be assumed that a major blockage exists and the cleaning effort shall be temporarily abandoned until further notification by the Engineer.

6

If the Contractor’s cleaning equipment becomes lodged in a sewer it shall be removed by the Contractor at his own expense. This shall include excavation, repair of sewer, backfill and surface restoration.

7

All sludge, dirt, sand, rocks, grease, and other solid or semi-solid material resulting from the cleaning operation shall be removed at the downstream manhole of the section being cleaned. Passing material from manhole section to manhole section, which could cause line stoppages, accumulations of sand in wet wells, or damage pumping equipment, shall not be permitted.

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10.2.2

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Roots shall be removed in the designated sections where root intrusion is a problem. Special attention should be used during the cleaning operation to assure almost complete removal of roots from the joints. Procedures may include the use of mechanical equipment such as rodding machines, bucket machines and winches using root cutters and porcupines, and equipment such as high-velocity jet cleaners.

9

All solids or semi-solids resulting from the cleaning operations shall be removed from the site and disposed of at an approved off-site disposal facility. All materials shall be removed from the site no less often than at the end of each workday. Under no circumstances will the Contractor be allowed to accumulate debris, etc., on the site of work beyond the stated time, except in totally enclosed containers and as approved by the Engineer.

10

Acceptance of sewer line cleaning shall be made upon the successful completion of the television inspection and shall be to the satisfaction of the Engineer. If CCTV inspection shows the cleaning to be unsatisfactory, the Contractor shall be required to reclean and reinspect the sewer line until the cleaning is shown to be satisfactory.

10.2.3

Jetting

1

Jetting shall be carried out using motorised jetting vehicles specially designed for the work involved and complete with an integral water tank. Jetting shall be carried out at an appropriate water pressure such that no damage to pipes occurs. The jetting pump shall have the capability to vary the water pressure at the jetting nozzle and be equipped with a sufficient length of suitable armoured bore hose and jetting heads to accommodate all possible working conditions and pipe size in the sewer system. Jetting pressure to be approved by the Engineer.

2

Brackish water shall not be used for cleaning. Treated sewage effluent may be used subject to the approval of the Engineer.

3

The hose shall be mounted on a power operated drum reel having variable speed and direction controls and a meterage indicator. The hose shall be equipped with a variety of nozzles totalling 15 to 30 including rear jets only, rear plus forward jets, rear plus side jets, and other such configurations necessary to ensure adequate cleaning of the pipeline. Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.

4

During all jetting operations the channel of the downstream sewer manhole shall be provided with a cut off wall and all decumulated grit and debris shall be removed.

5

Hydraulically propelled equipment shall be of a movable dam type and be constructed in such a way that a portion of the dam may be collapsed at any time during the cleaning operation to protect against flooding of the sewer. The movable dam shall be the same diameter as the pipe being cleaned and shall provide a flexible scraper around the outer periphery to ensure removal of grease. Sewer cleaning balls or other equipment which cannot be collapsed shall not be used.

6

Mechanically powered rodding machines shall be either a sectional or continuous rod type capable of holding a minimum of 200 m of rod. The rod shall be specifically heat-treated steel. To ensure safe operation, the machine shall be fully enclosed and have an automatic safety clutch or relief valve. Buckets, scrapers, scooters, porcupines, brushes and other mechanical equipment may also be utilised.

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All equipment and devices shall be operated by experienced personnel so that sewer lines are not damaged in the process of cleaning. When hydraulically propelled tools (which depend upon water pressure to provide their cleaning force), or tools which retard the flow in the sewer line are used, all necessary precautions shall be taken to ensure that the water pressure created does not damage or cause flooding of property being served by the sewer. When possible, the flow of sewage in the sewer shall be utilised to provide the necessary pressure for hydraulic cleaning devices. When additional water from water mains is necessary to avoid delay in normal work procedures, the water shall be conserved and not used unnecessarily.

10.2.4

Winching

1

The jetting machine shall incorporate a power-driven cable drum having not less than 200 m of 13 mm steel cable. The cable drum shall be mounted on an A-frame, fixed to the vehicle or trailer high enough off the ground to allow the bucket to be lifted above ground level. The backpull machine shall incorporate a power-driven cable drum with not less than 200 m of nylon rope or light steel cable. The working machine shall have a swinging arm fixed to the top of the A-frame. The swinging arm shall be capable of lifting the bucket clear of the ground and rotating it away from the manhole for emptying. A chute with rollers and a shaker bar may be used subject to the approval of the Engineer.

10.2.5

Bucketing

1

A range of bucket sizes shall be provided to suit the various pipe diameters. The buckets shall be cylindrical in cross-section with bails at each end having centre eye lugs and shall be of the clam shell type with the bottom made of two hinged halves such that when the bucket is pulled in the reverse direction, bottom first, the jaws open permitting debris to pass through. When the bucket is pulled forward the jaws shall close, thereby retaining any material in the bucket or which subsequently enters. Both ends of the bucket shall be able to dig into and scrape sediments and debris from the sewer invert.

10.2.6

Balling or Kiting and Pipeline Internal Gauging

1

Balls shall be of inflatable rubber or other material approved by the Engineer having an outside spiral thread and a swivel connection. With a hydraulic head differential of approximately 0.6 m, the ball shall rotate rapidly and produce a scouring jet on its periphery.

2

Suitable cable or rope shall be attached to the swivel connection fed from a cable drum mounted on an A-frame complete with braking facilities. A manhole jack and cable guide roller shall be used to feed the cable into the sewer. If the flow in the sewer is insufficient to produce adequate scouring velocity, the Contractor shall provide the additional supply of water to overcome the deficiency.

3

Kites may be used as an alternative to balls for sewers 600 mm diameter and above.

4

Pipeline internal gauges shall not be used unless attached to lines in both upstream and downstream manholes.

5

During all balling, kiting or gauging operations, the channel of the downstream manhole shall be provided with a cut off wall and accumulated debris removed.

6

Sewer cleaning balls or other equipment which cannot be collapsed shall not be used.

10.2.7

General Cleanliness of Areas during Sewer Cleaning

1

The Contractor shall take all necessary precautions to ensure that during the sewer cleaning operations there is no spillage of sewage and debris onto the streets and other areas. When spillage occurs, the Contractor shall immediately remove all spillage and clean all surfaces to their original condition.

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10.3

SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING

10.3.1

Scope of Work

1

CCTV survey and sonar scanning shall be carried out only after satisfactory cleaning of the pipeline as specified in Clause 10.2 of this Part. The CCTV survey and sonar scanning shall include but not be limited to: Production of colour video tape recording on compact disc (CD) and coding.

(b)

Accurate profiling of the cross-section of sewers and measurement of deflections.

(c)

Still colour pictures from a video graphic printer of the inside of sewers and manholes, inspection chambers and grease and oil interceptors, as directed by the Engineer.

(d)

Recording the complete survey on a computer database in accordance with WRC Manual of Sewer Condition Classification.

(e)

Pictures to be printed in a digital format (Tiff) for computer data storage and retrieval.

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(a)

Survey Requirements

1

The rate of travel of the camera shall be such as to enable all details to be extracted from the video tape recording.

2

The axis of the camera shall be arranged to coincide with the centreline of the pipe.

3

The picture transmitted by the CCTV scanning camera (a scanning camera which can view lateral connections to sewers) and sonar scanner shall be free from interference and loss of vertical and horizontal hold. The picture shall be in focus, properly illuminated, of good contrast and without distortion. If vision is obscured at any time by the fouling of the lens, or lighting system, or if travel is impeded by obstructions, the camera shall be withdrawn and the defect rectified immediately.

4

The Contractor shall record the complete survey on a video tape format conforming with the recording equipment manufacturer’s specification. The recording shall provide a continuous display of data on the monitor screen comprising the following information: automatic update of camera meterage

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10.3.2

(d)

gradient of sewer

(e)

nominal diameter of sewer and the actual measured horizontal, vertical and diagonal diameters at close intervals as directed by the Engineer

(f)

manhole/pipe type length reference number

(g)

sewer use

(h)

time of start of survey

(i)

location reference.

date, day, month and year direction of survey - upstream or downstream

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(b)

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The video recording shall be stopped whenever the camera is stationary for more than 5 seconds and shall have manual override capability.

6

The completeness of the video tapes shall be an accurate record of the sewer system which identifies and locates sewer defects, provides information that permits accurate analysis of the cause, extent, nature and severity of sewer deterioration and the measurement of horizontal, vertical and diagonal diameters of sewer and their locations.

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Portions of video tape marred by interference, or otherwise unacceptable shall be erased and the relevant portion of sewer shall be resurveyed and rerecorded. The Engineer’s decision as to the acceptability of any video recording shall be final.

8

Still colour photographs as designated under Clause 10.3.5.

9

The photographic negatives, the master video tapes, and a copy of the video tapes shall be handed over to the Engineer and shall become the property of the Employer.

10

If a self-propelled camera is used, it shall incorporate features to enable it to be winch drawn without affecting the quality of the video recording.

11

The location of any conditions that may result in a limitation of rehabilitation techniques that could be used and/or prevent proper installation of designated rehabilitation materials in the pipelines shall be noted. The Contractor shall propose corrective measures and/or alternative methods of rehabilitation for the approval of the Engineer.

10.3.3

Survey Equipment

1

The CCTV survey and sonar scanning equipment shall be modern and of advanced design and shall be tested and calibrated immediately before beginning work. The equipment shall be tested as designated herein by the manufacturers or an approved independent test laboratory at intervals of not more than 6 months. Original certificates of compliance with the specifications of this Part shall be submitted to the Engineer before beginning work. The equipment shall include but not limited to the following:

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CCTV camera and sonar scanner suitable for mounting on the same trolley as and when required

(b)

colour TV camera with swivel, lift and radial device and able to focus on points of interest

(c)

camera light head assembly with sufficient illumination for the diameter of sewer pipes

(d)

camera wheeled/tracked crawler assembly, self-propelled/flexible-shaft driven and remotely operated with forward, reverse, left, right stop and load indication

(e)

cable reel of minimum 200 m cable length with fully automatic and microprocessor controlled cable handling facility

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(h)

colour TV monitor

(i)

high-resolution scanning device including high speed pipe profiler and software to interpret the signals

(j)

video cassette recording system with audio video information system

(k)

all standard and optional accessories recommended by the manufacturers.

power winch with either lockable or ratcheted drums CCTV/Sonar central control units

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(f)

2

The picture quality of the camera shall be tested using the Marconi Resolution Chart No. 1 or equivalent clearly defined with no tinting to show white, yellow, cyan, green, magenta, red, blue and black.

3

The quality of the CCTV electronics, camera and monitor shall be such that the following criteria are satisfied and if any of the criteria are not met during the survey the lengths of sewer so affected shall be resurveyed at the Contractor’s expense: (a)

Shades of Grey. The grey scale shall show equal changes in brightness ranging from black to white with a minimum of five stages

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(b)

Colour. With the monitor control adjusted for correct saturation, the six colours plus black and white shall be resolved with the primary and complementary colours in order of decreasing luminance. The grey scale shall appear in contrasting shades of grey with no tint

(c)

Linearity. The background grid shall show squares of equal size, without convergence or divergence over the whole picture. The centre circle shall appear round and have the correct height/width ratio within 5 %

(d)

Resolution. The live picture shall be clearly visible with no interference and capable of registering a minimum number of TV lines/picture height lines. The resolution shall be checked with the monitor colour control turned down. For tube type cameras this shall be 350 lines and for CCD type cameras it shall be 250 lines

(e)

Colour Consistency. The colour on the live picture and that on the video picture shall be consistent with that described for the Marconi Resolution Chart No. 1.

The camera shall be capable of taking clear pictures in any direction; i.e., 90  to the left and 90  to the right (total 180  in horizontal axis) and also 360  in the circumference of the pipe without using extra revolving mirror attachment.

5

The camera shall continuously transmit distance at each meter length, electronically matched to the movement of the camera with a maximum tolerance of  0.1 % on the control TV monitor and the resultant video tapes.

6

The camera shall indicate the degree of inclination of the sewer line with tolerance of 0.2 % on the TV monitor with a printout of the slope.

7

The camera crawler assembly shall be adjustable for deployment in sewers of varying diameters. When required, both sonar scanning and CCTV equipment shall be mounted on the same crawler assembly.

8

The video tape recording of the transmission for CCTV and Sonar scanning units shall be provided to accurately record on video tapes, of quality approved by the Engineer. In the central control unit, the operator shall have remote facilities to control the camera, the cable drum and power winch.

9

Each unit shall carry sufficient number of guides and rollers to ensure that, when surveying all bonds are supported away from pipe and manhole structures and all CCTV cables and lines used to measure the camera’s location within the sewer are maintained in a taut manner and set at right angles, where possible, to run through or over the measuring equipment.

10

At the start of each and every working shift, the camera shall be positioned centrally and at right angles to the test card at a distance where the full test card just fills the monitor screen, ensuring that the edges of the test card castellation coincide with the edges of the horizontal and vertical scan (raster). The card shall be illuminated evenly and uniformly without any reflection. The illumination shall be to the same colour temperature as the colour temperature of the lighting that will be used on the CCTV survey equipment in the pipe. The test shall be recorded for subsequent use by the Engineer, the recording time to be at least 30 seconds. The type of camera used is to be identified on the test recording. The recording must show the camera being introduced into the test device and reaching its stop position. Other test devices may be used subject to approval by the Engineer.

11

The Contractor shall note that the Engineer may periodically check both the live and recorded picture colour consistency against the colour bar. Any differences will necessitate re-survey of the lengths affected at the Contractor’s expense.

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The adjustment of focus and iris shall allow optimum picture quality to be achieved and shall be remotely operated. The adjustment of focus and iris shall provide a minimum focal range from 50mm in front of the camera’s lens to infinity. The distance along the pipe in focus from the initial point of observation shall be a minimum of twice the vertical height of the pipe. The illumination must be such as to allow an even distribution of the light around the pipe perimeter without the loss of contrast, flare out of picture or shadowing.

13

Where the CCTV survey equipment is towed by winch and bond through the pipe, all winches shall be stable with either lockable or ratcheted drums. All bonds shall be steel or of an equally non-elastic material to ensure the smooth and steady progress of the CCTV survey equipment. All winches shall be inherently stable under loaded conditions.

10.3.4

Survey Vehicle

1

The CCTV and sonar scanning vehicles shall be equipped with the following three separate compartments:

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driver’s cabin

(b)

operator and viewer’s compartment (seating for minimum three persons)

(c)

Camera and sonar scanner equipment storage compartment.

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(a)

The operator and viewer’s compartment shall be insulated against noise and extremes in temperature and be provided with means of controlling external and internal sources of light in a manner capable of ensuring that the monitor screen display complies with the specified requirements.

3

The equipment storage compartment shall have adequate space for equipment, both operational and stored. Equipment used in sewers shall not be stored in compartment.

4

The vehicle shall be equipped with air-conditioner for the driver’s cabin and the operator’s room. A wireless communication system between the operator inside the vehicle and the helper outside the vehicle shall be provided.

5

The vehicle shall be complete with all equipment and apparatus necessary to carry out a complete sewer inspection survey. Colour monitors, a sonar processor unit, replay and onboard reporting, video recorders, video printers, computers and computer printers to generate survey reports and data base shall be provided. The operator/viewer’s compartment shall be designed for optimum productivity.

6

The vehicle shall be equipped with the following road safety equipment:

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(a)

a minimum of two amber regulation flashing beacons fixed at diagonal corners of the vehicle, which shall operate continuously while the vehicle is stationary on the highway in a working situation

(b)

traffic signs and cones, which shall be displayed in accordance with the recommendations of the Traffic Police Section, with a minimum of:

(c) 7

(i)

four reflective boards: Arrow

(ii)

two reflective boards: Men Working (in English and Arabic)

(iii)

two reflective boards: Road Narrows (in English and Arabic)

(iv)

20 reflective cones

(v)

12 battery operated flashing road lamps.

a sufficient number of bright coloured overalls with fluorescent over-jackets or belts, which shall be worn by all operatives while working on roads.

Relevant safety equipment specified in Clause 10.1.7 shall be made available.

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10.3.5

Photographs

1

After sewer cleaning and in parallel with the CCTV inspection, excellent quality still colour photographs 90 mm x 130 mm with the date and submitted in TIFF format an album with captions providing a detailed description, the precise location and reference numbers as designated shall be taken of: the inside the sewer to show the typical conditions for each length of sewer. A minimum of three photographs per manhole length shall be taken at every junction piece, faulty joint, broken pipe, and other points of interest as directed by the Engineer

(b)

the interior of each manhole, chamber and grease/oil trap. A minimum of three photographs shall be taken of each structure showing the general extent of corrosion to the structure’s walls, bases, benching and the underside of cover slabs as directed by the Engineer

.

(a)

Photographs shall be taken of the internal condition of the pipes at the beginning of a defect, at service connections and such other places as the Engineer shall direct. Where defects exist at adjacent points, photographs should not be taken at intervals of less than 2m unless absolutely necessary to show the second defect. Where photographs are not otherwise required, a general condition photograph shall be taken at every l0m.

3

Photographs must clearly and accurately show what is displayed on the monitor which shall be in proper adjustment.

4

Photographs shall be clearly identified in relation to the location (minimum requirement manhole start and finish numbers or pipe length reference numbers) survey direction, chainage, photograph number, and date when the photograph was taken. The annotation shall be clearly visible and in contrast to its background, shall have a figure size no greater than 5mm, and be type printed. The annotation shall be so positioned as not to interfere with the subject of the photograph.

5

Hard copy of the photographs shall be supplied in suitable A4 sized plastic holders and bound in ring binders or lever arch files. The photographs shall be presented in chronological order and each file shall contain a contents page providing clear cross-referencing to the report. The minimum requirements of the contents page shall be locations (district, street name and road number), photograph numbers and dates when photographs were taken.

10.3.6

Site Coding Sheets

1

Site coding sheets detailing the condition of each pipe length and manhole shall be completed in the format of the WRC Manual of Sewer Condition Classification and as approved by the Engineer. These sheets shall be submitted to the Engineer with the video tape to which they refer. A draft copy of the coding sheets shall be submitted weekly to the Engineer for his approval. When requested by the Engineer, more frequent reports of selected parameters shall be submitted.

2

The site coding sheets shall be standardised to the approval of the Engineer to indicate the following minimum requirements:

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(a)

location reference to sewer length concerned

(b)

nominal diameter of sewer

(c)

actual measured horizontal, vertical and diagonal diameters of sewer and their locations, as a continuous computer printout at close intervals and as directed by the Engineer

(d)

date of survey

(e)

direction of survey

QCS 2014

(f)

time of start of survey

(g)

sewer gradient

(h)

trial hole records

(i)

coded reference to any defects encountered

(j)

location of defects

(k)

location of any junctions or laterals encountered

(l)

location of any still photographs taken.

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In addition to the final report and any interim reports on a section of the pipe as defined above, the Contractor shall provide the Engineer with the following: (a)

One copy of the completed survey report coding forms at the end of each working shift.

(b)

One copy of sheets containing the pipe reference number, distance, orientation and deflection measurements of the pipes surveyed at the end of each working shift.

(c)

One copy of photographs and recordings on a weekly basis as the work progresses or as previously agreed with the Engineer in writing.

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Excavation

1

When directed by the Engineer, the Contractor shall excavate and expose sections of sewer for examination.

2

The Contractor shall carry out such excavations expeditiously and shall break or expose the sewer section upon removal from the trench for detailed physical examination and testing.

3

Excavations shall be carried out in accordance with Part 2 of this Section.

4

When directed by the Engineer, the Contractor shall reinstall the sewer section or replace the sewer section with new pipe of same size and material in a manner to completely conform to the original installation and shall backfill, compact and reinstate the excavation in accordance with Part 4 of this Section.

10.3.8

Survey Reporting

1

The Contractor shall complete the CCTV survey and sonar scanning in appropriate lengths as directed by the Engineer before handing over the records for that line. All records for a particular length shall be handed over at one time unless directed otherwise by the Engineer and all recordings on one tape shall be of the same length. The report shall include the following, all as designated herein:

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10.3.7

(a)

site coding sheets

(b)

correctly labelled video tapes of approximately one hour duration

(c)

pictures on compact discs in a digital format (Tiff)

The report shall be completed using a computer based database with software that shall be fully compatible with the Oracle database used by the Ministry of Municipal Affairs & Agriculture’s ARC INFO GIS system and approved by the Engineer. One copy on a 3.5 inch diskettes of all computer generated data shall be provided with the report. Four copies of draft report shall be submitted for Engineer’s approval followed by final report incorporating appropriate responses to the Engineer’s comments.

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The Contractor shall enter the information obtained from the survey into a computer database in accordance with the WRC manual of sewer classification which shall allow for the storage, retrieval and analysis of this information. Furthermore the database shall link the survey information with an electronic drawing of the pipeline which shall allow the viewing of still images representative of the major problems identified by the survey.

4

The Contractor shall supply 2 copies of each recording in CD format.

5

The condition survey report shall include the following: Pipe condition classification in accordance with the WRC format.

(b)

Manhole/pipe length reference numbers.

(c)

Date of survey.

(d)

Road name/location.

(e)

Direction of survey.

(f)

Time of start of survey.

(g)

Weather conditions.

(h)

Pipe dimensions.

(i)

Materials of construction.

(j)

Depth of flow.

(k)

Profiling of pipe cross sections to give a complete circumferential profile and deflections within the pipe.

(l)

Clock position of all connections including meterage from manhole.

(m)

Whether or not connections are dry and running.

(n)

Location and description of obstructions, structural defects, missing pieces of pipe, open and/or offset joints, ovality, leakage or evidence thereof, corrosion, erosion, break-in connections, protruding connections, mineral deposits, roots, previous repairs, sags and other abnormalities with respect to the pipeline’s condition with counter distance in metres from the start manhole’s centreline.

(o)

Photographs as specified herein.

(p)

Recommendations, including options and alternative methods to extend the service life by a further 50 years by lining, replacement or other refurbishment. Estimated cost and programme for carrying out the recommendations.

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6

If the Engineer requires separate survey reports for any section of the survey or requires some or all of the section to be grouped together in a single survey report he shall notify the Contractor accordingly.

10.4

OVERPUMPING AND FLOW DIVERSION

10.4.1

Source of Flow

1

Manholes and sewers being worked on shall be completely isolated and by-passed such that they do not contain any sewage. This shall be achieved by plugging, pumping and bypassing or diverting the flow.

2

When flow in a sewer line is plugged, pumped and bypassed or diverted sufficient precautions must be taken to protect the sewer lines from damage that might result from sewer surcharging. Further, precautions must be taken to ensure that sewer flow control operations do not cause flooding or damage to public or private property being served by the sewers involved.

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Page 17

The Contractor shall submit his proposed method of overpumping or flow diversion to the Engineer for approval.

4

The Contractor shall co-ordinate and agree all his activities on live facilities with the Drainage Affairs Maintenance Department staff responsible for upkeep of the drainage system. A signed Permit to Work shall be obtained from Maintenance Department prior to the commencing the work.

10.4.2

Pipe Stoppers

1

The flow shall be stopped off using pipe stoppers of a type approved by the Engineer. The stopper shall be of circumferential compressible rubber rings fully inserted inside the pipe before tightening. Inflatable type stoppers for sewers less than 300 mm diameter shall be of a type approved by the Engineer.

2

Stoppers shall be suitable for the sizes and classes of pipe in which they are used and must not cause damage to existing pipes. Stoppers must be able to withstand the maximum possible differential head at each location and shall be fully restrained in accordance with the manufacturer’s recommendations.

3

The Contractor shall be solely responsible for maintaining such stoppers in good working condition and for the consequences of any failure thereof.

4

Where a section of the sewerage system is isolated for work involving man-entry to the isolated area, a minimum of two stoppers shall be used at each boundary location isolating the area from the main sewer and subsidiary sewers. At least one of these stoppers at each location should be of an approved pneumatic type.

10.4.3

Stopping Off Flow

1

For the length of sewer being surveyed, the Contractor shall plug off the outlet of the downstream manhole and the inlet to the upstream manhole. The next upstream manhole shall be used as a pumping sump with the outlet to that manhole also being plugged off.

2

All service connections discharging into the plugged off sewer shall be satisfactorily isolated the overpumping system shall be provided to the approval of the Engineer.

1

Interruption of service will not be permitted.

10.4.4

Pumping Plant

1

Overpumping shall be carried out using suitable mobile pump sets of adequate capacity and head to the approval of the Engineer.

2

The Contractor shall provide sufficient number of standby pumps of adequate capacity. Where required by the Engineer, a temporary sump shall be provided to prevent surcharging of upstream sewers.

3

The pumps shall be controlled by suitable level controls installed to operate at levels to be approved by the Engineer and shall be capable of dealing with the flow in the sewer and any material likely to be transported in it without being blocked.

10.4.5

Sewage Flooding

1

Full-time attendance with mobile phone facilities shall be provided by the Contractor at each pumping location such that in the event of mechanical breakdown, flooding or blockage, immediate assistance will be summoned.

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Page 18

Overpumping of Flow

1

Pumped sewage flows shall be discharged to a manhole downstream of the sewer length being cleaned or surveyed. The open end of the pump delivery pipe shall be laid in order to minimise turbulence of the pumped flow. No sewage shall be dumped onto any surfaces outside the sewer system.

2

The pump delivery pipe shall be of suitable armoured material which in all locations subject to traffic flow shall be suitably protected with preformed steel plates bridging the pipe or by other means approved by the Engineer. Such protection shall be adequate to allow passage of vehicular traffic over the pipe.

10.4.7

Temporary Diversion of Flow

1

Where temporary sewer diversion is required the Contractor shall notify the Engineer accordingly and submit his proposals for implementation of such diversion.

2

The Contractor shall obtain all other permissions and approvals from relevant authorities prior to commencement of such diversion. On completion of temporary diversionary works the temporary pipelines shall be removed or be adequately sealed and inlet and outlet manholes reinstated to their original condition.

10.4.8

Entrances to Private Properties

1

The Contractor shall not cause any obstruction to the access of private properties. If the obstructions are unavoidable, the Contractor shall provide and maintain in good order alternative access to the approval of the Engineer.

10.4.9

Odour and Noise Control During Flow Diversion and Overpumping

1

The Contractor shall take necessary precautions for controlling odour and noise with prescribed limits approved by the Engineer and for preventing nuisance and inconvenience to the local residents and the public during the flow diversion and overpumping operations.

2

The Contractor shall include in his method statement, the measures to be taken for noise and odour control.

3

The Contractor shall provide special measures to prevent the odour release to the approval of the Engineer.

4

The Contractor shall install temporary chemical dosing system to contain the odour release if other measures fail.

5

For odour control, the measurement of hydrogen sulphide shall not be more than 1 ppm measured at a distance of 1m from the point of discharge to the adjacent property.

10.5

CONTRACTOR’S QUALITY CONTROL PROCEDURE

1

The Contractor shall operate a quality control system, to be approved by the Engineer, which will effectively gauge the accuracy and consistency of the CCTV survey report produced by the operator from the monitor picture.

2

The system shall be such that the accuracy of reporting should be a function particularly of:

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10.4.6

(a)

The number of faults not recorded (omissions).

(b)

The correctness of the coding and classification of each fault recorded.

The minimum levels of accuracy to be attained shall be as follows:

QCS 2014


(a)

Header accuracy

95%

(b)

Detail accuracy

85%

(c)

Lowest acceptable tolerance

Page 19

75%

The Engineer shall be entitled in accordance with Section 1 Part 8 and this section to audit periodically the control system and be present when assessments are being computed.

5

When requested by the Engineer, the Contractor shall forward to the Engineer sufficient details and information for this audit assessment.

6

Should any report fail to achieve the specified percentages for a particular pipe length, the Engineer shall require the Contractor to re-code and re-submit the report. If the accuracy check fails, the Contractor shall repeat the full quality control check on 10 surveys, 5 surveys either side of the survey which has failed. If any further failures are found to be outside the tolerances laid down above within these additional checks, the process will be repeated until an acceptable standard is reached. Any reports that have failed will be re-coded by another qualified surveyor and submitted to the Engineer to replace those in his possession.

7

Quality selection is achieved by using two parameters:

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Population - the anticipated number of surveys carried out by one surveyor over a period of time (normally I year).

(b)

Sample size - the number of surveys required to be checked to satisfy the quality control validity.

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(a)

The sample surveys for quality control are to be selected by the use of computer generated random numbers (ERNI) or other such equivalent method and shall be 5% of the total population. Each surveyor shall have a different set of random numbers, which are sorted into chronological order, and are renewed once the population size has been reached. The random numbers shall not be disclosed to the surveyor until they have been used up.

9

On site the surveyor logs certain information on the surveys being carried out and in the order in which they are surveyed.

10

The “in-office” staff then count, through the surveys that have taken place and copy those reports that coincide with the random numbers.

11

Copy of the relevant section of the recording shall also be made available.

12

Information on the recording and its contents are entered on a survey selection log.

13

Header information - All header information shall be checked to ensure that left and right justified entries are correctly entered, alpha or numeric symbols are correctly used and all compulsory boxes filled in. The percentage of accurate entries shall be ascertained and any that fall below the value specified shall be rejected. All decimal percentage points shall be rounded down to the nearest whole number.

14

Detail information - Each error/omission is treated on an equal basis whether or not it is a minor or major error or omission. During the checking each error/omission is highlighted on the report from which the following totals are calculated for each survey report:

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(a)

The number of actual entries that should have been made.

(b)

The number of actual errors/omissions made.

These totals are entered on the right of the survey report being checked. Individual column totals are also calculated and entered on to the survey accuracy log.

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Page 20

16

The accuracy of each survey is arrived at by taking the number of actual errors/omissions away from the number of actual entries that should have been made and dividing the result by the number of actual entries that should have been made and multiplying by 100 to create a percentage.

17

This percentage is entered on the survey detail rating form.

18

The ongoing accuracy of the surveyor (the “confidence level”) is calculated by taking the mean of 5 percentage results (each 5 representing one control unit).

19

Both the individual survey percentages and the mean results are entered onto the surveyor’s accuracy graph which has two boundaries: Specified mean - the level of accuracy expected.

(b)

Specified tolerance - the level to which the accuracy can fall before specific action is taken.

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END OF PART

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Any surveyor whose quality control results fall below the specified mean on more than 2 occasions or the specified tolerance at any time shall be deemed to have failed his quality control criteria and shall be invalidated from acting as a team leader on this Contract until he has attended and passed an approved course for pipe condition classification.

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QCS 2014

Section 08: Drainage Works Part 11: Sewer Rehabilitation

Page 1

11

SEWER REHABILITATION ........................................................................... 3

11.1

GENERAL ...................................................................................................... 3

11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6

Scope References Definitions Submittals Quality Assurance Warranty

11.2


11.2.1 11.2.2 11.2.3 11.2.4 11.2.5

Work Programme Review, Cleaning, Inspection Safety Preparation for Installation of Linings Delivery, Storage and Handling Annulus Grout

11.3

SEALING OF PIPES AND MANHOLES ...................................................... 11

11.3.1 11.3.2 11.3.3 11.3.4

Scope Sealing Compounds Joint Sealing of Pipes Sealing of Manholes

11.4

SLIPLINING OF SEWERS .......................................................................... 15

11 11 12 14

15 15 16

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18 18 19

CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD) ......... 20

11.6.1 Scope 11.6.2 Materials 11.6.3 Installation of Cured-In-Place Liner 11.7

9 9 9 11 11

DEFORMED PIPE LINER INSTALLATION ................................................. 18

11.5.1 Scope 11.5.2 Materials 11.5.3 Installation 11.6

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11.4.1 General 11.4.2 Materials 11.4.3 Installation of Sliplining 11.5

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3 3 5 6 8 9

20 21 22

SPIRAL WOUND PROFILE LINER ............................................................. 23

11.7.1 Scope 11.7.2 Materials 11.7.3 Installation of Spiral Wound Profile Liner

23 23 25

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Page 2

11.8

PIPE CRACKING OR BURSTING ............................................................... 26

11.8.1 11.8.2 11.8.3 11.8.4 11.8.5

Scope General Materials Installation Equipment Installation

11.9

INSPECTION AND TESTING OF PIPE LINES AFTER REHABILITATION ....................................................................................... 29

11.10

MANHOLE REHABILITATION..................................................................... 30

26 26 26 27 27

30 30 30 31 31 31 32

MANHOLE LINING ...................................................................................... 32

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11.11.1 Scope 11.11.2 Materials 11.11.3 Installation of Lining 11.11.4 Inspection and Testing

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11.10.1 Scope 11.10.2 General 11.10.3 Materials 11.10.4 Rehabilitation of Manhole Walls and Bases 11.10.5 Rehabilitation of Manhole Shafts and Slabs 11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or Replacement 11.10.7 Inspection and Testing

32 32 32 33

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Page 3

11

SEWER REHABILITATION

11.1

GENERAL

11.1.1

Scope

1

This Part includes the specifications for all work necessary to rehabilitate sewers, manholes and chambers including, but not limited to:

(b)

manhole rehabilitation

(c)

manhole lining

(d)

sliplining of sewers

(e)

deformed pipe lining

(f)

cured-in-place pipe (inversion method)

(g)

spiral wound profile liner

(h)

pipe cracking or bursting.

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General Earthworks Pipeline Installation Metal Works Miscellaneous GRP Works Painting and Protective Coatings Sewer Cleaning and Inspection Survey

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This Section Part 1 Part 2 Part 4 Part 6 Part 7 Part 8 Part 10

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sealing of sewers and manholes

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(a)

References

1


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11.1.2

ASTM C923 M ............Specification for Resilient Connectors Between Reinforced Concrete Manhole Structures Pipes and Laterals [Metric] ASTM D543 ................Resistance of Plastics to Chemical Reagents ASTM D618 ................Methods of Conditioning Plastics and Electrical Insulating Materials ASTM D638 ................Standard test method for tensile properties of plastics. ASTM D746 ................Standard test method for brittleness temperature of plastics and elastomers by impact. ASTM D790 ................Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials ASTM D883 ................Definition of Terms Relating to Plastics ASTM D991 ................Standard test method for rubber property-volume resistivity of electrically conductive and antistatic products. ASTM D1238 ..............Standard test method for melt flow rates of thermoplastics by extrusion plastometer.

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Page 4

ASTM D1248 ..............Specification for Polyethylene Plastics Moulding and Extrusion Materials ASTM D1505 .............Standard test method for density of plastics by the density gradient technique. ASTM D1525 ..............Standard test method for Vicat softening temperature of plastics. ASTM D1600 ..............Abbreviations of Terms Relating to Plastic Pipes ASTM D1693 ..............Test for Environmental Stress-Cracking of Ethylene Plastics ASTM D1784 ..............Specification for Rigid PVC Compounds and Chlorinated PVC (CPVC) Compounds ASTM D2122 ..............Method for Determining Dimensions of Thermosetting Pipe and Fittings by Acetone Immersion

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ASTM D2152 ..............Test Method for Degree of Fusion of Extruded PVC Pipe and Moulded Fittings by Acetone Immersion

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ASTM D2240 ..............Standard test method for rubber property-Durometer hardness.

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ASTM D2412 ..............Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

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ASTM D2444 ..............Test Method for Impact Resistance of Thermoplastic Pipe and Fittings by means of a Tup (Falling Weight) ASTM D2657 ..............Practice for Heat-Joining Polyolefin Pipe and Fittings

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ASTM D2837 ..............Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials

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ASTM D3035 ..............Specification for Polyethylene (PE) Plastics Pipe (SDR-PR) Based on Controlled Outside Diameter

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ASTM D3350 ..............Specification for Polyethylene Plastics Pipe and Fittings Materials ASTM D3753 ..............Specification for Glass-Fiber-Reinforced Polyester Manholes

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ASTM D4703 ..............Standard practice for compression moulding thermoplastic materials into test specimens, plaques or sheets.

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ASTM F412 ................Definitions of Terms Relating to Plastic Piping Systems ASTM F477 ................Specification for Elastomeric Seals for Joining Plastic Pipe

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ASTM F585 ................Practice for Insertion of Flexible Polyethylene Pipe into Existing Sewers ASTM F714 ................Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Outside Diameter ASTM F1216 ..............Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube ASTM F1248 ..............Standard test method for determination of environmental stress crack resistance (ESCR)of polyethylene pipe. ASTM F1533 ..............Standard specification for polyethylene (PE) pipe ASTM F1606 ..............Standard practice for rehabilitation of existing sewers and conduits with deformed polyethylene (PE) liner. ASTM F1697 ..............Standard specification for poly (vinyl chloride) (PVC) profile strip for machine spiral-wound liner pipe rehabilitation of existing sewers and conduits

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Page 5

ASTM F1698 ..............Installation of Poly (Vinyl Chloride) (PVC) Profile Strip Liner and Cementitious Grout of Rehabilitation of Existing Man-Entry Sewers and Conduits ASTM F1741 ..............Standard practice for installation of machine spiral wound poly (vinyl chloride) (PVC) liner pipe for rehabilitation of existing sewers and conduits. ASTM F794 ................PVC Large Diameter Ribbed Gravity Sewer Pipe and Fittings based on Controlled Inside Diameter BS 2494......................Materials for elastomeric seals for joints in pipework and pipelines BS 4346......................Joints and fittings with unplasticized PVC pressure pipes BS 5556......................Specifications for general requirements for dimensions and pressure ratings for pipes of thermoplastic materials

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BS 5955......................Code of practice for plastic pipe work

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BS 8010......................Pipelines BS EN 752..................Sewerage

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BS EN 1401................Plastic piping systems

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BS EN 13244..............Polyethylene pipes (type 50) in metric diameter for general purposes

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BS EN 1852-1 ............Plastic piping system for non-pressure underground drainage and sewerage polypropylene (PP)

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CP 312, ......................Plastic pipe work

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ISO 161 ......................Thermoplastic Pipes for the Transport of Fluids Nominal Outside Diameters and Nominal Pressures

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ISO 9000 ....................Quality Systems ISO 9967 ....................Method for Determination of Long Term Ring Stiffness

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WRc ...........................Sewer Rehabilitation Manual

Definitions

1

The following terms have the meanings hereby assigned to them except where the Contract clearly renders these meanings inapplicable:

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11.1.3

(a)

Sliplining: insertion of a new liner pipe into an existing pipeline of larger diameter followed by grouting of the annulus.

(b)

Cured-in-place, inversion, in-situ or soft lining: the creation of a new pipe within an existing pipeline by insertion of a resin impregrated polyester felt liner by inversion under pressure lining inversion under pressure, the liner then being cured in-situ.

(c)

Spiral wound profile lining: insertion of helically wound, profile walled thermoplastic sections to form a liner, followed by grouting of the annulus.

(d)

Deformed pipe lining: a continuous deformed pipe which reverts to its predeformed shape after installation.

QCS 2014


Page 6

(e)

Pipe cracking or bursting: replacement of an existing pipeline between manholes or inspection chambers or a combination thereof with a new pipe of equivalent or greater size whereby the new pipe is inserted behind the pipe breaking machine as fragments of the existing pipe are displaced to the sides.

(f)

Length of sewer: length of sewer pipe between two consecutive manholes or inspection chambers.

(g)

Service connection: the connection of the property sewer with the main sewer pipeline.

11.1.4

Submittals

1

The Contractor shall submit complete data and details of sewer rehabilitation for the Engineer’s approval as follows: name and experience of specialist subcontractor

(b)

a programme of work, detailed method statement, and schedule of plant to be used in the Works, detailing the working practices, and specialist equipment.

(c)

proposed method of overpumping or flow diversion as applicable to undertake sewer rehabilitation.

(d)

specific data for proposed materials and equipment for the Engineer’s approval 14 days prior to commencement of any sewer rehabilitation works as follows:

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(a)

test certificates and technical literature to show that the sealants, liners, and lining systems materials proposed meet the requirements stated in the specifications

(ii)

original catalogues specific to the requirement for all proposed equipment. All equipment shall be suitable and made of such materials to withstand the prevailing climatic conditions of Qatar and the corrosive environment.

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Specific data to be submitted while carrying out and at the completion of the work: records of sealing of sewers in each length of sewer, including joint sealing verification results

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(ii)

(f)

CCTV video tapes, pictures in digital format (TIFF) and site coding sheets prepared in accordance with Part 10 of this Section showing the initial condition and the completed work including the restored condition.

The Contractor shall submit to the Engineer following data for 15 sewer rehabilitation projects carried out by the proposed subcontractor during the last five years: (i)

project location

(ii)

name and address of client

(iii)

start and completion dates

(iv)

cost of the works

(v)

length, diameter and material of pre-rehabilitated sewers

(vi)

length, diameter and liner material for each type of rehabilitation system

(vii)

reference letter from the client or the engineer.

QCS 2014

Page 7

The Contractor shall submit the following data to supplement (d) of this sub-clause:

Manufacturers name.

(ii)

Suppliers name.

(iii)

Installers name (Subcontractor)

(iv)

Product name (if applicable).

(v)

Product description.

(vi)

Manufacturers technical data.

(vii)

Test results or certificates.

(viii)

Checked and approved liner pipe thickness design and stiffness calculations.

(ix)

Storage instructions.

(x)

Installation instructions.

(xi)

Installation records in the same project area

(xii)

Proposed grout mixture where applicable.

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(i)

Manhole and joint sealing materials and manhole rehabilitation materials Manufacturers name.

(ii)

Suppliers name.

(iii)

Installer name (Subcontractor)

(iv)

Product name (if applicable).

(v)

Product description.

(vi)

Manufacturers technical data.

(vii)

Test results or certificates.

(viii)

Storage instructions.

(ix)

Application instructions.

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(b)

Sewer Liner

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The Contractor shall submit method statements to the Engineer for approval 4 weeks in advance of commencing the site activity. These shall comprise but not necessarily be limited to: (a)

Sewage bypass pumping and/or diversion plan which shall include an emergency response plan to be followed in the event of a failure of the bypass pumping and/or diversion plan.

(b)

Detailed construction plan including: (i)

Equipment set-up and locations of proposed access points.

(ii)

Anticipated cut off periods for services.

(iii)

Procedures for verification of active service connections.

(iv)

Procedures for notifying affected residences and businesses.

(v)

Procedures for complying with traffic control.

(vi)

Procedures to be adopted to obtain permits to work from the Drainage Affairs.

QCS 2014


Page 8

(vii)

Safety procedures in particular working with scaffolding, entering confined spaces and operations with hot media.

(viii)

Sewer cleaning procedures.

(ix)

Liner installation procedures.

(x)

Procedures for sealing annular space between liner pipe and host pipe where applicable.

(xi)

Methods of sealing any annular space between liner pipe and host pipe at manholes.

(xii)

Procedures for manhole liner-pipe liner joint sealing.

(xiii)

Procedures for manhole rehabilitation.

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Liner insertion locations.

(b)

Sewage bypass pumping and/or diversion locations.

(c)

Liner end sealing at manholes and GRP lamination to manhole wall and benching liners.

(d)

Any required modification to existing manholes.

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(a)

Representative samples, as agreed with the Engineer, must be submitted for at least the following items before work commences.

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5

The Contractor shall submit drawings to the Engineer for approval in advance of commencing the site activity. These shall comprise but not necessarily be limited to:

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(xiv) Procedure for any required modifications (temporary or permanent) to existing manholes (such as widening of access opening, removal of cover slabs, removal of intermediate landings, ladders, removal of manholes benching etc).

Proposed liner system.

(b)

Liner to host pipe sealing materials.

(c)

Manhole rehabilitation materials.

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(a)

Manhole liner to pipe liner sealing materials.

Quality Assurance

1

The system shall be design to comply with the appropriate provisions of BS 2782, BS 3412, BS 5556, BS EN 752 and BS 8010.

2

The Contractor shall employ approved prequalified specialist subcontractors designated in the Project Specification.

3

The specialist subcontractor shall conduct this work in accordance with the quality management procedures conforming to ISO 9000.

4

Key operators employed of the subcontractor shall be competent in the relevant sewer rehabilitation methods and techniques.

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11.1.5

QCS 2014


Page 9

Warranty

1

The Contractor shall provide the Engineer with a seven year unconditional warranty against failure of all GRP manhole linings whether caused by defective materials or workmanship. The warranty shall be valid from the date of completion of the installation and submitted to the Engineer as a precondition to the issuance of the Certificate of Completion.

11.2


11.2.1

Work Programme Review, Cleaning, Inspection

1

When designated in the Project Specification, the Contractor shall allow in his programme of work for the requirement that he shall work at many locations at any one time. However, at least one team shall be fully engaged on each length of sewer, and shall finish all rehabilitation works required on that length of sewer including manholes and chambers before beginning work on a new length of sewer.

2

The Contractor shall provide methods statements for each of the rehabilitation methods and systems he proposes to use for each of the functional requirements designated in the Project Specification.

3

As cleaning and inspection work proceeds, the Contractor shall submit weekly sewer and manhole condition reports to the Engineer. In the reports, the Contractor shall include his confirmation that his proposed method of rehabilitation meets the required performance criteria. Should the originally proposed method not meets the performance requirements for lengths of sewer, or manholes, the Contractor shall submit his proposals to meet the performance requirements for such lengths of sewers or manholes to the Engineer for approval.

4

The Engineer and the Contractor shall agree on the locations and systems to be used for rehabilitation if necessary, and if necessary the Contractor shall review and revise his programme of work and submit to the Engineer for approval. The Engineer’s approval shall not relieve the Contractor of his obligations under the Contract.

5

Sewer cleaning, inspection and overpumping work shall be satisfactorily completed before undertaking sewer rehabilitation.

11.2.2

Safety

1

The Contractor shall carry out all operations in accordance with the safety requirements specified in Section 1 and Part 10 of this Section.

11.2.3

Preparation for Installation of Linings

1

The following installation procedures shall be adhered to unless approved otherwise by the Engineer:

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11.1.6

(a)

before installing lining in sewers the Contractor shall ensure that the sewers are clean of debris in accordance with Part 10 of this Section. Sewers shall also be gauged to ensure that they can accommodate the liners.

QCS 2014


Page 10

the Contractor shall inspect by CCTV the section or sections to be lined and shall record salient features including any obstructions and service connections, in accordance with Part 10 of this Section.

(c)

the Contractor shall overpump the sewage flow around the section or sections of the pipeline that are to be lined. The overpumping shall be carried at in accordance with Part 10 of this Section. Leaks in the pipes due to groundwater infiltration shall be stopped by grouting or other appropriate methods approved by the Engineer.

(d)

the Contractor shall clear the pipeline of obstructions, solids, dropped joints, or tree roots or collapsed pipe that will prevent the insertion of the liner. Where inspection or gauging reveals an obstruction that is not at the location of the entry shaft, the Contractor shall remove the obstruction by means of a cutting machine inserted into the sewer line. Where this is not possible, the Contractor shall make an excavation to expose and remove or repair the obstruction as directed by the Engineer.

(e)

a temporary tie-in shall be made between the relined section and the existing system and the bypass plug removed at the end of each working day.

(f)

Prior to dispatch of any product and/or material from source the Contractor shall notify the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect and test the product and/or material prior to delivery.

(g)

To allow the Engineer to inspect the Works the Contractor shall give the Engineer a minimum of 24 hours notice of carrying out the following activities on site.

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(b)

Sewer cleaning.

(ii)

CCTV survey.

(iii)

Sewage bypass pumping and/or diversion.

(iv)

Liner installation.

(v)

Manhole rehabilitation.

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No lining work shall be permitted until the prepared sewer has been inspected and approved by the Engineer.

(i)

Where it is necessary to carry out any modification to existing manholes to enable manhole and/or sewer cleansing, CCTV survey or sewer rehabilitation, the Contractor shall carry out any such modification to the Engineer’s approval. Following completion of the works in a manhole, the Contractor shall return the manhole to its original or better condition to the approval of the Engineer including reinstatement to surfaces disturbed as a result of manhole modification/sewer rehabilitation. Modification to manhole may include removal of manhole cover slab, intermediate landing slabs, platforms and manhole benching. Removal of intermediate landing slabs/platforms may be considered as permanent (i.e. may not necessarily be reinstated) provided the GRP wall liner is extended to cover the exposed area due to slab removal and welded to the existing liner, and the GRP ladder is adjusted and re-installed as a continuous ladder throughout the manhole height.

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(j)

Unless specifically itemised and listed in the BOQ, modifications to manholes which may be necessary to carry out the sewer rehabilitation and associated works shall be deemed to be included in the sewer rehabilitation rates.

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11.2.4


1

Delivery, storage and handling of products and materials shall be in accordance with the manufacturers’ recommendations and the following provisions. Delivery storage and handling shall at all times be performed in a manner to avoid product damage.

(b)

The liner shall not come in contact with any sharp projections that may cause damage during transportation loading and unloading. Cover liner during transportation.

(c)

Store materials on a flat level area and raised above the ground on timber bearers.

(d)

Store materials under opaque cover and out of direct sunlight at all times. Maintain a free flow of air around materials at all times.

(e)

The Contractor shall visually inspect all products upon delivery to site and report any damage to the Engineer.

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(a)

Any products damaged during delivery, storage and handling shall be marked by the Contractor and set aside.

3

Proposals for repair of any damaged products shall be submitted in writing to the Engineer for approval.

4

Any damaged products deemed unsuitable for repair by the Engineer shall be removed from site and replaced.

11.2.5

Annulus Grout

1

Low strength grout filling the annular space between the host pipe and the liner (where applicable) shall be a cementitious mixture incorporating suitable admixtures as approved by 2 the Engineer and shall have a minimum compressive strength of 12N/mm .

2

Generally, the equipment shall be capable of performing the specified operations in lines where flows do not exceed the maximum line flows for joint testing/sealing.

11.3

SEALING OF PIPES AND MANHOLES

11.3.1

Scope

1

Complete or an initial step of rehabilitation by the remote sealing of sewer pipe joints using a sealing packer. The materials specified herein shall also be applicable in sealing of manaccess sewers and manholes.

11.3.2

Sealing Compounds

1

The sealing material shall comply with BS 2494 and shall perform effectively in the intended application and under expected field conditions.

2

Mixing and handling of sealing materials shall be in accordance with the manufacturer’s recommendations.

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Chemical sealing compounds shall have the following properties and characteristics: while being injected, the chemical sealant shall be able to react/perform in the presence of either, or both, surface water or groundwater, if present

(b)

the cured material shall withstand submergence in either, or any combination of, surface water, groundwater, sea water or sewage without degradation

(c)

the resultant sealant formation shall prevent the passage of water through the sewer pipe joint

(d)

the sealant material, after curing, shall be flexible

(e)

in place, the formed sealant shall be able to withstand wet/dry cycles without adversely affecting the seal

(f)

the formed sealant shall be non-biodegradable

(g)

the cured sealant shall be chemically stable and resistant to the chemical constituents sewage and the sewer environment

(h)

packaging of component materials shall

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be compatible with site storage and handling requirements

(ii)

ensure worker safety

(iii)

cause minimal spillage during handling

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mixing of the component materials shall be compatible with field operations

(j)

cleanup shall be effected without inordinate use of flammable or hazardous chemicals

(k)

residual sealing materials shall be removed from the sewer to prevent any blockage of the sewage flow.

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Chemical resin for sealing pipe joints and manholes shall be a hydrophilic polyurethane compound suitable for injection.

5

The material must be “salt-water” grade, able to react with saline ground water to form a flexible seal.

11.3.3

Joint Sealing of Pipes

1

Joints shall be sealed using the internal joint sealing method. Where bell cracks or chips are evident from pipe section offset, sealing shall be undertaken where the offset is small enough to allow proper seating of the sealing packer on both sides of the joint to be sealed. Longitudinally cracked or broken pipe shall be replaced.

2

The sealing equipment shall comprise a CCTV survey system, chemical sealant containers, pumps, regulators, injection sealing packers, hoses, valves and all other necessary apparatus and tools required for sealing sewers of the various diameters. The packer shall be cylindrical and shall be so sized and have cables attached at each end to enable it to be pulled freely through the pipeline. The packer device shall be constructed in a manner to allow an amount of sewage to flow as designated in the Project Specification.

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Joint shall be sealed by injecting chemical sealing compound into or through faulty joints using a system of pumps, hoses, and sealing packers. Jetting or driving pipes from the surface that could damage the pipelines or impair their structural integrity will not be permitted. Uncovering the pipe by excavation of pavement and soil will not be allowed. The packer shall be positioned over the faulty joint by means of a measuring device and the CCTV camera in the pipeline. The Contractor shall ensure that the packer is accurately positioned over the joint. The packer ends shall be expanded using controlled pressure. The expanded ends shall seal against the inside periphery of the pipe to form a void area at the faulty joint which shall be completely isolated from the remainder of the pipeline. Sealant compound shall be pumped into the isolated area through the hose system at controlled pressures in excess of groundwater pressure, if any.

4

Upon completing sealing of each joint, the packer shall be completely deflated then reinflated and the joint retested. Should the void pressure meter not read zero after deflation, the Contractor shall clean his equipment of residual grout material or make the necessary equipment repairs/adjustments to produce accurate void pressure readings. Joints that fail to meet the specified test criteria shall be resealed and retested until the test criteria can be met.

5

Residual sealing materials protruding into the pipe shall be removed. The sealed joints shall be left flush with the pipe surface. Excessive residual sealing materials which accumulate in the pipeline shall be removed.

6

Records shall be kept of joints sealing performed in each length of sewer to identify the length of sewer in which joints were, the location of each joint sealed, and the joint sealing verification test results.

7

Not more than one month before the expiration of the Period of Maintenance and as a precondition to the Engineer’s issuance of the Maintenance Certificate for the Contract, sewers shall be retested as follows: an initial retest area consisting of specific lengths of sewers will be selected by the Engineer. Length of sewers to be retested shall be randomly selected throughout the project area and shall be representative of the majority of the sealing work originally performed. The initial retest area shall consist of at least 5 %, but not exceed 10 %, of the length contained in the Contract

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(b)

within the initial retest area, the Contractor shall retest all previously sealed joints as specified. Any joints failing the retest shall be resealed at no extra cost to the Employer

(c)

if the failure rate of the joints exceeds 5 % of the retested joints, an additional retest area of equivalent size will be selected by the Engineer and all previously sealed joints shall be retested. The additional testing and sealing, where necessary, shall continue until a failure rate of less than 5 % is achieved

(d)

additional testing or sealing required beyond the initial retest area shall be accomplished at the Contractor’s expense. The Contractor shall provide adequate number of crews at Site so that the retesting will proceed at a rapid rate.

The pumping unit, metering equipment and the packer device shall be designed so that proportions and quantities of materials can be regulated in accordance with the type and size of the leak being sealed.

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Sealing of Manholes

1

During cleaning and inspection work the condition of manholes shall be observed and their structural soundness shall be evaluated by the Contractor and reported in the cleaning and inspection reports. Sealing work shall only be carried out on manholes which the Engineer considers structurally sound and which experience extraneous water leakage.

2

Cracks and openings to be sealed shall be marked out in detail on the concrete elements by the Contractor and agreed with the Engineer before proceeding with sealing operations.

3

Sealing equipment shall consist of chemical sealant containers, pumps, regulators, injection packers, hoses, valves, and all other necessary apparatus and tools. The chemical injection pumps shall be equipped with pressure meters for monitoring pressure during the injection of the chemical sealants. Where necessary, fluid bypass lines equipped with pressureregulated bypass valves shall be incorporated into the pumping system.

4

Structural cracks shall be repaired out as follows:

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11.3.4

holes shall be carefully drilled close to the damaged section from within the manhole and shall extend through the entire manhole wall

(b)

if leakage is occurring through cracks due to high groundwater table, fewer holes shall be drilled provided all leakage is stopped from these holes. A watertight seal between the holes and the injection device shall be provided. Hoses, shall be attached to the injection device from an injection pump. Chemical sealing materials shall then be pumped through the hose until material refusal is recorded on the pressure gauge mounted on the pumping unit or a predetermined quantity of sealant has been injected

(c)

care shall be exercised during the pumping operation to ensure that excessive pressures do not develop and causing damage to the manhole structure

(d)

upon completion of the injection, the packers shall be removed and the remaining holes filled with mortar and trowelled flush with the surface of the manhole walls or other surfaces

(e)

the mortar used shall be of the quick-setting type with non-shrinking characteristics

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any GRP internal lining which has been disturbed shall be repaired in accordance with Part 7 of this Section.

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(a)

5

Not more than one month before the expiration of the Period of Maintenance and as a precondition to the Engineer’s issuance of the Maintenance Certificate for the Contract, manholes shall be visually inspected by the Contractor in the presence of the Engineer. Sealing work that has become defective shall be repaired at no additional cost to the Employer.

6

All manhole sealing shall be done during high groundwater conditions, unless the points of leakage have been previously identified.

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SLIPLINING OF SEWERS

11.4.1

General

1

The scope of work consists of rehabilitating sewers by the insertion of liner pipe into existing sewers. The finished liner shall extend the full distance detailed in the project specific documentation, which may be for localised repair, or extend the full sewer length. In either case the lining shall be completely sealed and watertight.

2

Procedures set out in ASTM F 585 shall be followed, except as otherwise specified in this Part.

3

The Contractor is not constrained on the type of lining method he puts forward, but the Contractor will have to demonstrate, through previous project documentation, that the proposed method has a proven track record and that it is fully applicable to the conditions to be found in the Gulf region.

4

The Contractor shall design the liner to support all combinations of imposed loads including earth, traffic, hydrostatic etc and have a minimum service life of 50 years. For the purpose of calculations, it shall be assumed the ground water table is at ground level. Host pipes shall be considered to be fully deteriorated. The liner shall have a minimum allowable long term 2 stiffness of 2500N/m and be designed to have a factor of safety of 2.

5

The normal requirement will be that the liner shall provide the least possible thickness or decrease in diameter to meet the requirements of this section and consequently it is preferable to be of the close fit type.

6

Liner shall be of a light colour to enhance Closed Circuit Television (CCTV) clarity for inspection purposes.

7

Leak repair shall be carried out when required to create an environment to enable the rehabilitation works to be executed successfully. If the rehabilitation method adopted can be successfully implemented under wet conditions, the Contractor is not obliged to repair the leaks.

8

The finished liner shall be continuous over the entire length of an insertion run between two manholes or access points and shall be free from visual defects.

9

The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to manhole liner using a material that is compatible with the liner.

11.4.2

Materials

1

The sewer liner pipe and fittings shall be manufactured from a polyethylene compound conforming to ASTM D1248 and meeting the requirements for Type II or III, Class B or C, Grades P23 or P34, Category 5. Pipe made from this compound shall have a minimum longterm hydrostatic strength rating of 8.6 MPa in accordance with ASTM D2837. When the environmental stress crack resistance (ESCR) of the compound is measured in accordance with ASTM D1693, Condition C, the compound shall withstand not less than 192h in 100 % solution Igepal CO-630 at 38 C before reaching a 20 % failure point (F20).

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2

The standard dimension ration (SDR), defined as the specified outside diameter (OD) divided by the minimum wall thickness, shall be demonstrated by calculation to be sufficient to support the worst combination of internal and external loads. The wall thickness tolerance shall be within plus 12 %.

3

Liner pipe shall be provided with joints designed so that neither the outside diameter of the pipe is increased nor the internal diameter of the pipe is decreased at the joint.

4

Liner pipes shall be suitable for use in ambient air temperatures up to 55 C and with sewage 0 up to 45 C.

11.4.3

Installation of Sliplining

1

Where excavations for insertion of liner are made, the Contractor shall locate the excavations on the basis of the location of the sewers to be sliplined, pulling distances, and traffic conditions subject to Engineer’s approval. Excavation locations shall be such as to minimise traffic disruption, and the number of excavations reduced by inserting the pipe in both directions from a single opening. Insertion shafts shall be designed to avoid imposing a bending radius of less than 35 times the outside diameter of the liner. Insertion shafts shall be sloped gradually from the ground surface to the soffit of the sewer. The Contractor shall provide sufficient sheeting and bracing to the excavation as required. The soffit of the existing sewer shall be exposed and the crown of the pipe shall be removed as necessary for insertion of the liner. Care shall be taken not to disturb the bottom portion of the existing pipe.

2

Jointing shall be by thermal butt-fusion welding in accordance with the manufacturer’s recommendations. All fusion jointing shall be carried out by trained personnel with equipment designed for butt-fusion welding of thermoplastic pipe.

3

Sections of liner shall be jointed above ground either at the Site or at a remote location.

4

Where the insertion shaft is not at a manhole the jointing shall be accomplished using a stainless steel full-encirclement clamp. If such jointing cannot be achieved, then a new manhole shall be constructed. Recommended minimum lengths of clamps to afford adequate pullout protection are given in Table 11.1.

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Table 11.1 Minimum Length of Clamps

OD of Liner Pipe

Minimum Length of Clamp

(mm)

(mm)

90

190

115

250

135

250

170

380

180

380

220

380

270

500

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Page 17

OD of Liner Pipe

Minimum Length of Clamp

325

500

340

500

405

760

455

760

475

760

560

760

661

760

Alternative pipe jointing methods shall be subject to the approval of the Engineer.

6

The liner shall be inserted with a power winch and steel cable connected to the end of the liner using of an appropriate pulling head. Where necessary a second pulling head may be attached to the other end of the liner for attachment of a tag line to pull the liner back out of the sewer.

7

Pulling shall be continued form start to completion without interruption, and precautions shall be taken during insertion to protect the liner pipe so that any ragged edges of a broken sewer pipe will not score the outside of the liner.

8

The manufacturer’s recommendations regarding relaxation of the liner shall be followed before sealing the annular space between the liner and existing sewer pipe. The annular space between the polyethylene liner and the existing sewer shall be sealed using a method approved by the Engineer.

9

Where an existing manhole is used as an entrance shaft the manhole shall be reinstated to good condition or it shall be replaced with a new manhole in accordance with Part 4 of this Section.

10

Foam sealant shall not protrude into the manhole and the sealant shall be finished over with a quick-setting, non-shrinking type of cement grout. Finishing inside the manhole shall be accomplished using a quick-setting cement type grout to raise the manhole trough to the invert of the liner pipe and reform the manhole benching as required. Exposed cement type grout surfaces shall be protected against corrosion by lining with GRP in accordance with Clause 4.4.1 of this Section.

11

Precautions shall be taken to prevent collapsing of the liner owing to excessive grouting pressure.

12

The liner shall be secured in the upstream manhole. Each existing service connection shall be excavated and reconnected to the new liner pipe using either polyethylene heat fusion saddles or strap-on saddles as conditions require. A neoprene gasket shall be inserted between the liner and the strap-on saddle. Saddles shall be secured to the liner pipe using stainless steel bands. Connections of saddle fittings to existing service connections shall be made using elastomeric boots, full-encirclement clamps, or other methods approved by the Engineer.

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Before backfilling any existing sewers that had been broken to open, the pipe shall be repaired and the annular space between the existing sewer and the new liner sealed using cement or expandable foam to the approval of the Engineer.

14

At locations where the liner pipe has been exposed, the pipe and fittings shall be encased in Grade 20 SRC concrete.

11.5

DEFORMED PIPE LINER INSTALLATION

11.5.1

Scope

1

The scope of the work consists of rehabilitating sewers by the insertion of a deformed thermoplastic pipe into existing sewers. The deformed pipe on the application of pressure and temperature or on release of deforming stress induced by swaging reverts to its predeformed shape to form a tight fit inside the host pipe without the formation of an annulus.

11.5.2

Materials

1

The HDPE liner material shall be designed for use in gravity sewers and shall be in strict conformance with all applicable sections of ASTM F1533.

2

The liner shall be made from High Density Polyethylene resins complying with ASTM D1248, Type III, Grade P34 and Cell Classification PE 345434C, D or E per ASTM D3350. The Contractor shall submit to the Engineer for approval certified test results from the liner pipe manufacturer to verify that the resin material used for extrusions of the liner meets the specified requirements, including the quality control records during the liner extrusion process.

3

At the time of manufacture, each lot of liner shall be inspected for defects with samples being taken in accordance with ASTM D4703 and tested in accordance with ASTM D1693, ASTM D2837 and ASTM F714.

4

For testing purposes a production lot shall consist of all liner having the same marking number. It shall include all items produced during any given work shift and must be identified accordingly to differentiate it from previous or following production.

5

Each deformed liner coil in compliance with ASTM F1533 shall be clearly marked by the manufacturer with the following information:

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(a)

ASTM F1533 designation.

(b)

Nominal outside diameter.

(c)

SDR.

(d)

Approximate coil length.

(e)

Standard material designation code.

(f)

Manufacturer’s name.

(g)

Manufacturer’s production code from which plant location, machine and date of manufacture can be identified.

(h)

The project or contract number.

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6

Liner minimum wall thickness shall be determined by strength and minimum stiffness requirements.

7

The liner shall be fabricated from materials which will be resistant to internal exposure to sewage, sewage gases and reagents listed in Table 1 above, when tested in accordance with the provisions of ASTM D543, to a temperature of 40°C.

8

The HDPE material used in the production of the liner shall meet, or exceed, the physical properties given in Table 11.5 below. Table 11.5 Deformed Pipe Liner Properties Test Method

Value

ASTM D1505

950kg/m

Flow rate

ASTM D1238

Tensile strength @ ultimate

ASTM D638

Tensile strength @yield

ASTM D638

Ultimate elongation

ASTM D638

Flexural modulus

ASTM D790

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8.0g/10min

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stress

crack

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Environmental resistance

ASTM D1693

se

F0, hours condition C

3

.

Density

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Property

30N/mm

2

20N/mm

2

600% 1000N/mm

2

10,000 hrs

ASTM F1248

10,000 hrs

ASTM D746

-117 C

Vicat softening temperature

ASTM D1525

125 C

Hardness, Shore D

ASTM D2240

50

ASTM D991

10 ohm-cm

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Brittleness temperature

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Volume resistivity

0

0

15

0

0.20mm/m/ C

m

Thermal expansion

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Compressed ring ESCR F0

9

At the time of installation the liner shall be homogeneous throughout, uniform in colour, free of cracks, holes, foreign materials, blisters and deleterious faults.

11.5.3

Installation

1

The Contractor’s method statement shall be submitted to the Engineer for approval. In the method statement the Contractor shall describe the means of deforming the liner in-situ and of providing, maintaining, monitoring, and controlling the reforming environment until the liner has reverted to its original circular shape and the temperature returns to the normal sewer ambient temperature.

2

Calculations demonstrating the adequacy of the pulling capacity of the winch shall be prepared and submitted by the Contractor for the Engineer’s approval.

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The liner shall be positioned at the upstream manhole without excavation and shall be winched directly from the coil through the upstream manhole and the host pipe.

4

Due care shall be exercised during winching to avoid damage to manholes and snagging. Guides or rollers shall be used within the manholes to avoid the risk of snagging.

5

The pulling winch shall be equipped with a tension gauge capable of controlled operation at variable speed.

6

The pipe shall be cut flush at manhole inlet and outlet points using a rotary cutter and the joints sealed.

7

The Contractor shall adopt working practices for plastic pipes accordance with BS 5955.

8

The Contractor shall obtain detailed installation instructions and procedures from the manufacturer for the actual installation of the deformed and reformed system. The requirements of ASTM F1606 shall also be satisfied.

9

When the deformed pipe liner is in place it shall be cut and the pipe end closing assembly used for heat and pressure control within the liner shall be attached and secured at both pipe ends. Temperature and pressure measuring instruments shall be attached to both ends of the deformed HDPE liner to provide a continuous monitor of the temperature and pressure being applied to the liner.

10

Through the use of steam and air pressure the deformed pipe shall be reformed to conform to the existing pipe wall.

11

The reformed HDPE liner shall be cooled in accordance with the manufacturer’ recommendations.

12

Temperatures and pressures shall be monitored and recorded throughout the installation process to ensure that each phase of the process is achieved at the manufacturer’s recommended temperature and pressure limits

13

For each length of liner two samples shall be taken at locations determined by the Engineer. The sampling method shall include the use of a former to replicate the host pipe. The samples shall be clearly labelled with date taken and location. The samples shall be tested for average inside diameter, average outside diameter and minimum wall thickness in accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM D2412 and for the properties given in Table 3. The stiffness so measured shall meet, or exceed the stiffness requirements determined by calculation for that section of sewer line or the minimum specified stiffness whichever is greater. Any material may be rejected for failing to meet any of the requirements of this specification.

14

The water tightness of the liner shall be gauged throughout the forming process.

11.6

CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD)

11.6.1

Scope

1

The scope of work consists of rehabilitating sewers by the installation of a resin impregnated flexible felt tube inverted into existing sewers. When cured, the new material shall extend over the length of the inversion as a continuous, tight-fitting, watertight lining.

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Materials

1

The liner material shall be designed for use in gravity sewers and shall be in strict conformance with all applicable sections of ASTM F1216.

2

The felt liner tube shall be a thermoplastic polyester tube consisting of one or more layers of flexible needled felt or an equivalent woven and/or non/woven material capable of carrying resin, and with sufficient needling and crosslapping and strength to withstand the installation pressures and curing temperatures.

3

The felt tube shall be compatible with the resin and catalyst systems to be utilised.

4

The finished liner shall consist of a felt layer (or layers) impregnated with a thermosetting resin and fabricated to fit tight against the host pipe. An allowance shall be made for circumferential stretching during installation where applicable.

5

Each felt liner tube shall be clearly marked by the manufacturer with the following information:

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11.6.2

Manufacturer’s name.

(b)

Manufacturer’s production code from which plant location, machine and date of manufacture can be identified.

(c)


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The lining technique shall comprise using a suitable preliner to prevent loss of resin.

7

The resin used shall be a general purpose, unsaturated, thermosetting, vinylester resin able to cure in the presence or absence of water and a catalyst system compatible with the insertion process that provides physical properties given in Table 11.6.

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Table 11.6 Cured in Place Liner Properties Test Method

Value

m

Property

Flexural strength

ASTM D790

31N/mm

Short term flexural modulus

ASTM D790

1724N/mm

Long term flexural modulus

ASTM D790

862N/mm

Tensile strength

ASTM D638

21N/mm

2

2

2

2

8

The installed and cured liner shall be chemically resistant to exposure to sewage and sewage gases as experienced with the high temperatures in Qatar.

9

At the time of installation the liner shall be free of all visible tears, holes, cuts, foreign materials and other defects.

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10

The liner shall be fabricated to a size that when installed will neatly fit the internal circumference of the sewer being renovated. Allowance shall be made for circumferential stretching during insertion. The minimum length shall be that deemed necessary by the Contractor to effectively span the distance from inlet to outlet of the respective manholes unless otherwise designated in the contract specification. The Contractor shall verify the lengths on Site before impregnation. Individual inversion runs may be made over one or more lengths of sewer as determined on Site by the Contractor and approved by the Engineer.

11.6.3

Installation of Cured-In-Place Liner

1

The following installation procedure shall be adhered to unless otherwise proposed in the Contractor’s method statement and approved by the Engineer: the Contractor shall designate a location or locations where the reconstruction tube will be vacuum impregnated before installation. The Contractor shall allow the Engineer to inspect the materials and wet-out procedure. A catalyst system compatible with the resin and reconstruction tube shall be used

(b)

the Contractor shall provide facilities to control the temperature of the wet-out reconstruction tube to prevent premature setting of the resin

(c)

the wet-out reconstruction tube shall be inserted through an existing manhole or other approved access by means of an inversion process and the application of an inversion medium of sufficient pressure and volume sufficient to fully extend it to the designated or termination point

(d)

the inversion pressure shall be adjusted to be sufficient to cause the impregnated tube to invert from manhole to manhole and hold the tube tight to the pipe wall and to produce dimples at side connections and flared ends at the manholes. Care shall be taken during the elevated curing temperature so as not to overstress the felt fibre

(e)

after inversion is complete, the Contractor shall provide a suitable curing environment. Monitoring and control equipment shall be provided to permit observation and maintenance of the curing environment. Temperature and other factors of the curing environment shall be those recommended by the resin manufacturer

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(a)

(f)

should excessive infiltration into the sewer be present, a preliner shall be inserted into the sewer line to prevent washout of the resin.

2

Initial curing shall be deemed to be completed when inspection of the exposed portions of cured pipe appear to be hard and sound and the remote temperature sensor indicates that the temperature is of a magnitude to realise an exotherm. The curing period shall be that recommended by the resin manufacturer, as modified for the cured-in-place inversion process, during which time the Contractor shall maintain the quality of the curing environment to the levels recommended by the resin manufacturer.

3

The Contractor shall cool the hardened liner to a temperature below 38 C before relieving the pressure. Cooling may be accomplished by the introduction of cool water into the inversion standpipe to replace water being drained from a small hole made in the downstream end. Care shall be taken in the release of the static head so that a vacuum will not be developed that could damage the newly installed liner.

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Where the new liner fails to make a tight seal due to broken or misaligned host pipe at the manhole wall, the Contractor shall apply a seal at that point. The seal shall be of a resin mixture compatible with the liner and the host pipe.

5

After the new liner has been cured in place, the Contractor shall reconnect existing active service connections as directed by the Engineer. Unless otherwise designated in the contract specific documentation, shall be done without excavation. In the case of non -man-entry pipes from the interior of the system by means of CCTV cameras and a cutting devices that re-establish the service connection and seal the joint at the point of entry of the service connection.

6

The Contractor shall obtain detailed installation instructions and procedures from the manufacturer for the actual installation of the cured in place liner system. The requirements of ASTM F1216 shall also be satisfied.

7

The section of pipeline to be lined shall have been cleaned, surveyed and repaired to the requirements of this section of the standard specification prior to liner installation.

8

For each length of liner two samples shall be taken at locations determined by the Engineer. Sampling method shall include the use of a former to replicate the host pipe. The samples shall be clearly labelled with date taken and location. The samples shall be tested for average inside diameter, average outside diameter and minimum wall thickness in accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM D2412 and for the properties given in Table 2. The stiffness so measured shall meet, or exceed the stiffness requirements determined by calculation for that section of sewer line or the minimum specified stiffness whichever is greater. Any material may be rejected for failing to meet any of the requirements of this specification.

9

The watertightness of the pipe shall be gauged while curing and under a positive head.

10

The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to the manhole liner using a material that is compatible with the liner.

11

Wrinkles in the finished pipe which exceed 5% of the pipe diameter are unacceptable and the liner shall be removed and a replacement liner installed to the approval of the Engineer.

11.7

SPIRAL WOUND PROFILE LINER

11.7.1

Scope

1

The scope of work consists of rehabilitation of sewers by the installation of helically wound, profile walled thermoplastic pipe.

11.7.2

Materials

1

The physical properties of the PVC-U material used in the production of the liner shall conform to the cell classifications 12454C or 1236C, as defined by ASTM D1784. Notwithstanding this requirement, the material shall meet or exceed the following physical properties, as given in Table 11.2:

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Table 11.2 Physical Properties of PVC-U Material

Property

2400 MPa

Flexural Modulus (Long Term)

800 MPa

Tensile Strength (Short Term)

45 MPa

Tensile Strength (Long Term)

20 MPa

Heat Distortion Temperature

70 C

Specific Gravity

1.4

Allowable Long-term Strain

2%

Hardness (Shore D)

80

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Flexural Modulus (Short Term)

ta

The base material for the liner shall consist of a profile walled strip, extruded from PVC-U or other thermoplastic material, approved by the Engineer in accordance with ASTM F 1697. All materials shall be resistant to internal exposure to potable water, sea water, sewage, sewer gases, and reagents listed in Table 11.3, when tested in accordance with the provisions of ASTM D543, to a temperature of 35 C:

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Value

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Table 11.3 Resistance of Liner Material Concentration 5%

Phosphoric Acid

10 %

Sulphuric Acid

10 %

Detergent

0.1 %

Soap

0.1 %

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Nitric Acid

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Reagent

Where high liner stiffness is required to resist external loads, the strength of the liner may be enhanced by the provision of plastic-coated stainless steel reinforcement wound into the liner at the time of installation. The steel reinforcement shall consist of stainless steel type 316L and shall be coated with a low density polyethylene coating or other material approved by the Engineer, not less than 1 mm thick. The steel shall meet or exceed the following physical properties given in Table 11.4:

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Table 11.4 Physical Properties of Steel Property

Value

Tensile Strength

250 MPa

Modulus of Elasticity

195 GPa

Coefficient of thermal expansion

9 x 10 / C -6

For each length of liner a sample shall be prepared prior to the winding machine being placed into the manhole. A length of pipe shall be formed from the same batch of material to be used in the installation. The length of sample shall be such that three lengths may be cut and tested in accordance with ASTM D2412 for pipe stiffness at 5% deflection and for the properties given in Table 4. The stiffness so measured shall meet, or exceed the stiffness requirements determined by calculation for that section of sewer line or the minimum specified stiffness whichever is greater. Any material may be rejected for failure to meet any of the requirements of this specification.

5

Each liner shall be clearly marked by the manufacturer with the following information:

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Manufacturer’s name

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Manufacturer’s production code from which plant location, machine and date of manufacture can be identified The project or contract number At the time of installation the liner shall be homogenous throughout, uniform in colour, free of cracks, holes, foreign materials, blisters and deleterious faults.

7

This method may only be used for pipes of 250mm diameter or greater.

11.7.3

Installation of Spiral Wound Profile Liner

1

The installation of spiral wound liner shall follow the recommendations of ASTM F-1698.

2

Spirally wound profile liners shall be installed using a winding machine placed at the bottom of the manhole, with the liner being introduced at a diameter of approximately 25 mm less than the minimum diameter of the pipeline to be rehabilitated. After the liner has been installed, the annular gap shall be filled with a cementitious grout or the liner shall be expanded until it comes into intimate contact with the host pipe.

3

Jointing of the liner shall be accomplished by the use of an adhesive material suitable for use with the liner material. The adhesive shall be fully resistant to the corrosive sewer environment and shall be applied to the strips at temperatures of 35 to 50 C. Alternatively the liner shall be joined using a mechanical locking strip. The strip shall have mechanical and chemical resistance properties that are not less than those of the liner material. The joint shall be continuous and watertight for the full length of the sewer. The interface between the liner and manhole shall be sealed with material specified in Clause 11.10.3.

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Grouting of the annulus shall be carried out using the differential pressure method. The liner shall be filled with water and maintained at a constant pressure that is greater than the grouting pressure. Failure to maintain pressure in the pipeline will indicate that a defect exists. The water pressure shall be monitored via a gauge fitted to the grout plug, whereas the grouting pressure shall be monitored via a gauge fitted at the end of the grout hose. When water direct from a potable supply is used, an anti-siphon device shall be used to prevent contamination. Grouting shall be continued until there is a consistent flow of grout at the upstream manhole. Should grout pressure build up, before a show of grout is observed, the injection shall be stopped immediately to prevent damage to the liner. A sample of the grout shall be taken during grouting and its curing time monitored.

5

Alternative grouting methods that are specific to a particular lining system will be allowed only with the approval of the Engineer.

11.8

PIPE CRACKING OR BURSTING

11.8.1

Scope

1

Rehabilitation of sewers by the replacement of existing pipes with polyethylene (PE) or polypropylene (PP) pipes by breaking the existing pipes, expanding the hole size and inserting the replacement pipes in one operation with a minimum of disturbance to the surrounding ground and no surface disruption.

11.8.2

General

1

The Contractor shall satisfy the Engineer that the pipe bursting procedures will not have detrimental effects on adjacent utilities or structures, particularly from vibration arising from use of pneumatic bursters. The Contractor shall be responsible for such damage and shall bear the cost of rectification.

2

The Contractor shall comply with the requirements of service authorities and shall be deemed to have identified the location of services which may be affected by the Works. Unless otherwise required by the service authorities, where services are known to be located within one meter of the pipe to be burst, the Contractor shall expose the service in advance of pipe bursting. A minimum free space of 500 mm shall be created beneath the service over a length to be agreed between the Contractor and the service authorities.

11.8.3

Materials

1

The materials used for replacement of the existing pipes shall be polyethylene or polypropylene unless otherwise specified in the contract documents.

2

The method of jointing the pipes shall be as the manufacturer’s recommendations for the application. Unless otherwise specified or approved by the Engineer pipe joints shall be designed to be watertight against external water pressure assuming that groundwater extends to the ground surface.

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11.8.4

Installation Equipment

1

Pipe bursting equipment shall be hydraulically or pneumatically powered incorporating an expander at the nose of the machine which will fragment the existing pipe and expand the space uniformly to a diameter sufficient to allow the replacement pipe to be inserted. The annular space between the expander and the replacement pipe shall not exceed 20 mm unless otherwise agreed by the Engineer.

2

The method of inserting the replacement pipe shall be such that stresses transmitted to the replacement pipe shall not damage the pipes or exceed the tensile capacity of the replacement pipe.

3

Pipe bursting equipment shall be capable of

(b)

Dealing with small quantities of unreinforced concrete of maximum 150 mm nominal thickness found surrounding pipes, joints, saddles and service connections and for bursting pipes laid on a concrete cradle without being deflected off line and level.

(c)

Working under a hydrostatic pressure of groundwater.

(d)

Operating at maximum depth of 10.0 m from surface level.

(e)

Operation without jamming of moving parts or other malfunction due to the ingress of groundwater or sand particles.

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Working from existing manholes so that they can be used as launch and reception shafts wherever possible. Provision shall be made for remote starting and stopping.

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Where the Contractor has not previously used the equipment or demonstrated the pipe bursting technique to the satisfaction of the Engineer then he shall demonstrate the suitability of the equipment as follows: construct in open ground at a location approved by the Engineer, a 50m long temporary section of pipe of the same bore and material as the sewer to be rehabilitated at similar depth, complete with unbenched chambers at each end;

(b)

backfill the excavation;

(c)

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demonstrate the pipe bursting procedure. on completion of the pipe installation flood the site to artificially bring the water table to the ground surface and demonstrate that infiltration requirements of Part 4 of this Section are met.

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(a)

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Should difficulties be encountered in completing the trial installation the Contractor shall modify his proposal for approval by the Engineer before recommencing work.

6

Measures shall be taken to ensure that the replacement pipe does not become separated from the pipe expander should the system employ an insertion technique which allows the replacement pipe to slide within the pipe expander.

11.8.5

Installation

1

Shafts for launch and reception shall be existing manholes and excavations made over existing inspection chambers and service connections where the latter are proposed to be reconnected to the pipeline. Service connections to be abandoned or redirected to upstream or downstream chambers or manholes shall not be excavated.

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Unless specifically approved by the Engineer pipe bursting shall not be carried out by constructing shafts adjacent to manholes. Where necessary, the channel, benching and walls of existing manholes shall be altered to receive the pipe bursting equipment. All manhole alterations shall be made good.

3

The Contractor’s attention is drawn to the potential problems arising from the inflow of groundwater and loss of ground from the outside of manholes. His proposed method of working shall take these into consideration and shall be subject to the Engineer’s approval and shall ensure that no inflow of groundwater or loss of ground occurs. Where manholes are located in roads, the Contractor shall obtain permission from the Roads Division prior to carrying out any wellpoint dewatering operations around the manhole. In the event that means of stabilising the ground around the manhole and connecting pipelines are not approved by the Engineer, the Contractor shall not use pipe bursting methods at that location unless any other alternative method is approved by the Engineer.

4

Existing service connections shall be disconnected from the existing pipeline in advance of pipe bursting and reconnected on completion of the installation of the replacement pipe. In the interval, the Contractor shall maintain service by temporarily connecting service connections to the sewerage system downstream of the section, by overpumping, or by such other method the Contractor may propose for the Engineer’s approval.

5

Sewer lengths to be rehabilitated shall be checked for the presence of collapses occurring subsequent to cleaning by gauging between shafts. Where a collapse is detected its position shall be determined and an additional shaft shall be excavated if the debris cannot be removed.

6

Pipe bursting shall not commence unless sufficient lengths of replacement pipes are available on Site to complete the length of pipe to be rehabilitated.

7

Where pipe bursting is delayed for a period exceeding 7 days following cleaning, the pipeline shall be reinspected.

8

Winching shall conform to the following requirements: Details of the proposed winching method shall be submitted to the Engineer for approval at least 7 days before the insertion date

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(b)

Winches shall be of the constant load type fitted with a direct reading load gauge. At the end of each day’s work, the Contractor shall provide the Engineer with a copy of the winching loads recorded at the start of any pull and during the pull at increments of 20 m of winching distance and at any restart following temporary stops

(c)

Winches shall be fitted with an automatic device to disengage when the load exceeds a preset maximum load.

(d)

The Contractor shall supply sufficient cable in one continuous length to ensure the pull is continuous between approved winching points

(e)

Winches, cables and cable drums shall be provided with safety cages and supports

(f)

The Contractor shall provide a system of guide pulleys and bracings at each manhole

(g)

Nose cones fixed to the head of pipe expanders shall be fitted with a swivel attachment to prevent twist transmission between the winch cable and the nose cone

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(h)

Where the Contractor proposes to use a lubricant to ease the pull, the type of lubricant, method of introduction, removal and quantity to be used shall be submitted for the Engineer’s approval before beginning winching

(i)

Trench sidewall support in the insertion trench shall remain completely separate from the pipe support system and shall be designed so as not to be in contact with the pipe or the winch cable.

Replacement pipe shall be inserted in accordance with the following requirements: the maximum force shall be within the stress limit of the pipe

(b)

continuous length pipelines shall not be used. The maximum pipe length for insertion shall be 1.5 m where pipe bursting is undertaken between excavated shafts and either 700 mm or 800 mm where pipe bursting is undertaken from manhole to manhole

(c)

where a device is employed to exert force on the rear of the inserted pipe lengths, the force applied to the inserted pipe shall be evenly distributed around the wall of the pipe

(d)

Where lengths of pipe are joined and a device is employed to exert force to the rear of the inserted pipe lengths, precautions shall be taken to ensure that no buckling, crushing, twisting, or damage to the joint of the pipe takes place. Where, in the opinion of the Engineer, excessive deformation of the pipe has taken place, the pipe shall be replaced at the Contractor’s expense.

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(a)

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Where the lining is to be joined using ‘Snap-Lock’ or similar fittings, the Contractor shall comply with the manufacturer’s recommendations for jointing. Means of verifying the critical dimensions of the joints shall be provided on site by the Contractor. The joint shall be fitted with a suitable sealing ring and shall be designed to be watertight against an excess external water pressure of 20 metres head.

11.9

INSPECTION AND TESTING OF PIPE LINES AFTER REHABILITATION

1

The completed sewer shall meet the leakage requirements of pressure tests or air tests as specified in Part 4 of this Section.

2

After completion of each length of sewer, the Contractor shall flush the pipeline and undertake a CCTV and deflection survey and provide video tapes, pictures on digital format and site coding sheets to the Engineer.

3

Where necessary the Contractor shall remove any debris and carry out any remedial work identified. Upon completion of remedial work and removal of debris the section shall be resurveyed and the Engineer provided with the latest CCTV video tapes. Further additional CCTV surveys resulting from the need to again clean or carry out further remedial work shall be at no additional cost to the Employer.

4

The rehabilitated sewer shall be returned to service only after the written approval of the Engineer.

5

During the guarantee period any defects which will affect the integrity or strength of the pipe shall be repaired at the Contractor’s expense, in a manner mutually agreed by the Engineer and the Contractor.

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11.10


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MANHOLE REHABILITATION

11.10.1 Scope 1

The scope of work consists of the materials and types and methods of repair for the rehabilitation of manholes.

11.10.2 General Manhole rehabilitation shall comprise but not be limited to any combination of the following: Rehabilitation of walls or bases by plugging, patching, and removing, providing or replacing mortars, coatings, sealants and liners, to improve structural condition, prevent infiltration, provide corrosion protection or external tanking protection.

(b)

Repair of shaft and cover slab and reconstruction to the required level

(c)

Reinstallation or replacement of manhole frame and cover

(d)

Installation of manhole sealing plate.

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11.10.3 Materials

Materials used shall be suitable proprietary materials for manhole rehabilitation and the specific application in which they are used. The materials shall be supplied in factory-labelled containers. All materials shall be mixed and applied in accordance with the manufacturer’s instructions.

2

Materials used for plugging holes and stopping infiltration in manholes shall be either:

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Premixed hydraulic cement consisting of Portland cement, graded silica aggregates, special plasticising and accelerating agents with a set time of approximately 50 s and a 10 min compressive strength of approximately 3.5 MPa and free of chlorides, gypsum, plasters, iron particles, or gas-forming agents

(b)

Siliconate-based liquid accelerator mixed with neat Portland cement with a set time of approximately 50 s.

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(a)

Materials used for patching, filling and repairing non-infiltration holes, cracks, and breaks in concrete and masonry manholes shall comprise a premixed Portland cement-based hydraulic cement consisting of Portland cement, graded silica aggregates, special plasticising and accelerating agents with a set time of approximately 3 min or 15 min to suit application and a one-hour compressive strength of approximately 4.2 MPa. It shall not contain chlorides, gypsum, plasters, iron particles, or gas-forming agents.

4

Materials used for waterproofing membrane, corrosion protection, and strengthening of concrete and block work manholes shall be:

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liquid polymer modified water based waterproof coating which shall provide a secure mechanical and chemical bond with a curing time of approximately 1.5 h and a cured compressive strength of approximately 40 MPa. The coating shall be applied with a brush to surfaces without cracks or voids wider than 1.5 mm

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(b)


Page 31

100 % solids, three-component system consisting of a two-component epoxy resin and a special blend of fillers which shall provide a secure mechanical and chemical bond with an initial curing time of approximately 4 h and a cured compressive strength of approximately 76 MPa. The resin with fillers shall be applied with a trowel to a thickness of 3 mm to 12 mm. Epoxy resin (without fillers) used for waterproofing and corrosion protection shall be applied with a brush.

Remove all defective linings together with 100mm of adjoining good lining in existing manholes and other structures, including areas of lining covering leakage points.

6

Break out defective concrete to sound concrete surface.

7

Apply approved epoxy bonding agent and reinstate concrete using an approved concrete repair material.

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11.10.4 Rehabilitation of Manhole Walls and Bases

Surfaces of manhole walls and bases shall be thoroughly cleaned to remove all loose material and surface contaminants. Cleaning shall be accomplished by pressure jetting, sandblasting, or applying a 10 % solution of muriatic acid or hydrochloric acid. Where an acid solution is used the surface shall be thoroughly rinsed and neutralised before the application of mortars and coatings.

2

After surface preparation and before the application of mortars and coatings, infiltration shall be stopped by sealing as specified in Clause 11.3.4.

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11.10.5 Rehabilitation of Manhole Shafts and Slabs The Contractor shall take all necessary precautions to prevent debris from damaging the manholes and the sewer.

2

Shafts and cover slabs shall be repaired and rehabilitated with suitable sound materials approved by the Engineer.

3

Rings shall be provided as appropriate to reconstruct the shaft to the required elevation.

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11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or Replacement 1

The Contractor shall remove covers, frames, and sealing plates. Where the Engineer determines that cover, frames and sealing plates are to be replaced, the Contractor shall dispose of them.

2

The Contractor shall adjust the level and slope of the manhole cover as required. The manhole shall be raised by building precast concrete rings.

3

Covers and frames determined by the Engineer to be in good condition shall be grit blasted and coated on all exposed faces with a zinc primer and coal-tar epoxy paint finish as specified for System C in Part 8 of this Section. Replacement covers, frames and sealing plates shall be as specified in Part 6 of this Section.

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4

The Contractor shall reinstall or replace the manhole cover and frame using either of the following methods in accordance with the Contract Drawings and clause 4.4 of this Section.

5

Sealing plates shall be installed as specified in Part 6 of this Section.

11.10.7 Inspection and Testing 1

Completed rehabilitation works shall be visually inspected in the presence of the Engineer. Work that has become defective shall be redone at no additional cost to the Employer.

11.11

MANHOLE LINING

11.11.1 Scope

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The scope of work comprises structural rehabilitation of manholes by the installation of in-situ glass fibre reinforced manhole liners.

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11.11.2 Materials

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GRP liner materials shall be as specified in Part 7 of this Section. 11.11.3 Installation of Lining

The cover slab and manhole cover shall be removed and disposed of off Site. The manhole cover and frame shall be thoroughly cleaned, treated with two coats of bituminous paint and delivered to CED store and placed into storage.

2

Step irons shall be removed and the walls made good and prepared with 3:1 sand/cement mortar.

3

Concrete surfaces to be lined shall be cleaned and lightly abraded prior to the application of the GRP. The GRP lining shall be built up by applying isophthalic or vinyl ester resin. A layer of ECR glass mat shall then be rolled into the resin using a suitable steel roller to exclude all air and provide complete immersion of the glass fibre in the resin. After a period to allow pregel to a tacky state, a second coat of resin shall be applied followed by a further layer of glass fibre mat. This process shall be repeated until the total thickness of lining is approximately 4 mm. Vinyl ester resin and “C” glass veil shall then be used to complete the lining.

4

Top surfaces of benching shall incorporate silica sand to form a non-slip surface.

5

The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall be raked out 15 mm deep on the inside face and pointed with an approved pitch extended polyurethane sealant.

6

GRP ladders of an approved pattern as specified may be purpose made to suit the depth of each manhole. Fixings for ladders shall be approved stainless steel stud anchors. Fixing holes shall be grouted with epoxy mortar and sealed as above. Rungs or treads shall be ribbed to provide a non-slip surface.

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11.11.4 Inspection and Testing 1

After the manhole lining has been installed, the manhole shall be visually inspected in the presence of the Engineer and subject to the approval of the Engineer.

2

Before the expiration of the Period of Maintenance, the Contractor shall visually inspect the lined manholes in the presence of the Employer or Engineer. Work that has become defective shall be redone at no additional cost to the Employer.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 12: Vacuum Sewerage System

Page 1

12

VACUUM SEWERAGE SYSTEM .................................................................. 2

12.1

GENERAL ...................................................................................................... 2 2 2 2 3 3 4 4 4 5 5

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12.1.1 Scope 12.1.2 References 12.1.3 Definitions 12.1.4 System Description 12.1.5 Submittals 12.1.6 Quality Assurance 12.1.7 Warranty 12.1.8 System Operation 12.1.9 Commissioning 12.1.10 Maintenance

SYSTEM DESIGN AND PERFORMANCE .................................................... 5

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

General Design of the System Design of Vacuum Station Design of Collection Chambers Design of Vacuum Pipelines

12.3

PRINCIPAL SYSTEM COMPONENTS ......................................................... 8

12.4

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12.3.1 General 12.3.2 Vacuum Pipelines 12.3.3 Collection Chamber 12.3.4 Interface valves 12.3.5 Controller 12.3.6 Sensor 12.3.7 Vacuum Vessel 12.3.8 Vacuum Pumps 12.3.9 Forwarding Sewage Pumps 12.3.10 Motor Control Centre 12.3.11 Telemetry Outstation 12.3.12 Discharge Pipelines

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5 5 6 7 7 8 8 9 9 10 10 10 11 11 11 12 12

INSTALLATION OF THE SYSTEM ............................................................. 12

12.4.1 Pipelines 12.4.2 Pipe Joints for Vacuum Pipelines 12.4.3 Pumps, Motors and Instrumentation

12 12 13

12.5

TESTING ..................................................................................................... 13

12.5.1 12.5.2 12.5.3 12.5.4

General Testing of Interface Valves, Controllers and Sensors Testing of Pipelines Testing of Pumps, Motors and Instrumentation

12.6

TRAINING OF EMPLOYER’S PERSONNEL............................................... 14

13 13 13 14

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Page 2

VACUUM SEWERAGE SYSTEM

12.1

GENERAL

12.1.1

Scope

1

This Part includes the specifications for the design and provision of vacuum sewerage systems.

2


12.1.2

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This Section Part 1 General Part 2 Earthworks Part 3 Pipes and Fittings Materials Part 4 Pipe Installation Part 5 Valves, Penstocks and Appurtenances Part 6 Miscellaneous Metalwork Part 8 Protective Coatings and Painting Section 1, General Section 9, Mechanical and Electrical Equipment Section 10, Instrumentation, Control and Automation Section 21, Electrical Works Section 22, Air Conditioning, Refrigeration and Ventilation.

.

12

References

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BS 5500, welded pressure vessels

European Standard CEN/TC 165, Vacuum sewerage system outside buildings. Definitions

1

The following definitions of vacuum sewerage system apply to this Part: Batch Volume: volume discharged from a collection sump during one normal cycle of the interface valve and is equivalent to the volume of the sump within the operating range of the sensor.

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12.1.3

(b)

Collection Chamber: interface between the vacuum sewerage system and the collection sewers consisting of a collection sump and interface valve pit.

(c)

Collection Sump: storage capacity provided to store flows of sewage until sufficient volume has accumulated to activate the interface valve. Storage may also be provided to reduce the risk of flooding if there is a system failure.

(d)

Controller: device which, when activated by the sensor, opens the interface valve and, after the passage of sewage and air, closes the valve.

(e)

Forwarding Pumps: pumps installed at the vacuum station to pump the sewage from the vacuum system to the trunk sewer.

(f)

Interface Valve: valve which admits the flow of sewage and air into the vacuum sewer through the service connection.

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Page 3

Isolation Valve: valve installed to isolate a particular section in the vacuum sewer network.

(h)

Lift: up-grade section between two down-grade sections of a vacuum pipeline. The lift height is the difference in sewer invert levels between two successive down-grade sections. The static lift is the increase in the hydraulic grade line at a lift and is generally the increase in invert level minus the internal diameter.

(i)

Sensor: device which senses the presence of sewage in the collection sump and activates the controller to open the interface valve.

(j)

Service Connection: that part of the vacuum pipeline which connects a single collection chamber to the vacuum sewer.

(k)

Vacuum Generator: equipment installed at the vacuum station to generate a vacuum.

(l)

Vacuum Pipeline: pipeline under negative pressure.

(m)

Vacuum Pump: pump that creates the vacuum in the vacuum pipeline.

(n)

Vacuum Recovery Time: time taken after the operation of an interface valve for the negative pressure at the valve to be restored to its original value.

(o)

Vacuum Sewer: the major part of the vacuum pipeline into which the service connections discharge.

(p)

Vacuum Station: vacuum generators, vacuum vessel (or sewage sump), forwarding pumps and system controls.

(q)

Vacuum Vessel: negative pressure vessel connected to the vacuum pump. The vacuum sewer discharges into the vacuum vessel and the forwarding pumps pump sewage from the vessel. The vacuum pumps maintain a negative pressure in the vessel. When the vacuum generator is an ejector pump, the vacuum vessel is replaced by a sewage sump at atmospheric pressure.

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(g)

System Description

1

The Contractor shall be solely responsible for the design and construction of the system to meet the specified requirements.

2

The design of the system shall conform generally with European Standard CEN/TC 165, except as otherwise specified in this Part.

3

The vacuum sewerage system shall be required to operate under very low flows but it shall provide effective transfer of sewage to the sewers under all conditions and not cause flooding or overflow of sewage from the collection vessels.

4

The maximum noise level at the vacuum station and elsewhere in the system shall not exceed 65 dbA.

12.1.5

Submittals

1

The Contractor shall submit complete data and details of vacuum sewerage systems for the Engineer’s approval as follows:

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12.1.4

(a)

method statement which shall include : (i)

name and experience of specialist

(ii)

detailed procedure for the works

QCS 2014

Section 08: Drainage Works Part 12: Vacuum Sewerage System (iii)

list of all construction plant and tools

(iv)

safety procedures

Page 4

hydraulic, structural, mechanical and electrical calculations used in the preparation of the shop drawings.

(c)

shop drawings for all components and the complete system.

(d)

certificates that all components and equipment to be provided are suitable and made of such materials to withstand the prevailing climatic conditions of Qatar and the corrosive environment. Details of proposed corrosion protection systems shall be provided.

(e)

complete justification for any proposed changes in materials.

(f)

Training program

(g)

operation and maintenance methods manual which shall include:

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(b)

complete information of the system illustrated in detailed drawings

(ii)

detailed procedures for correct operation and maintenance of all system components.

(iii)

reprogramming manual

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(i)

The Contractor shall not procure materials or commence installation of the Works until the Engineer has approved his submittals.

12.1.6

Quality Assurance

1

The vacuum system shall be provided by approved, specialist manufacturers, suppliers and installers designated in the contract Project Specification.

2

All supervisors and technicians employed shall be fully competent in the installation methods.

12.1.7

Warranty

1

The control equipment shall be provided with a satisfactory performance warranty.

2

In addition to the warranty requirements of Part 1 of this Section, the vacuum sewerage system supplier shall warrant that the system and its components will meet the performance for a period of 24 months from the date of startup. The vacuum system supplier shall be solely responsible for the warranty. The warranty shall be in the form of a letter and report which shall be submitted to the Engineer, for review. Within the warranty period, any remedies necessary to bring the vacuum sewerage system into compliance with the specifications shall be the sole responsibility of the vacuum system supplier.

3

The Contractor shall furnish the Employer with manufacturer’s warranty and guarantee certificates for all equipment.

12.1.8

System Operation

1

On satisfactory completion, the Contractor shall operate and run the vacuum system for a period of 400 days during which time he shall be totally responsible for all maintenance including spares.

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12.1.9

Commissioning

1

The Contractor shall submit instruction manuals in draft to the Engineer four weeks prior to the commissioning.

2

The Contractor shall demonstrate to the Engineer that all equipment functions to meet the design criteria and specifications.

12.1.10 Maintenance The Contractor shall provide any special tools and equipment needed to operate and maintain the system and provide spare parts for two years operation and an additional 400 days for the maintenance, all at his expense.

12.2

SYSTEM DESIGN AND PERFORMANCE

12.2.1

General

1

The vacuum system shall be supplied by a manufacturer approved by the Engineer.

2

The general location of the vacuum sewerage system including the locations of collection chambers, vacuum pipelines, vacuum station and pressure pipeline discharging to the trunk sewer which forms part of the gravity sewerage system shall be as shown on the Drawings.

3

The Contractor shall be responsible for carrying out any additional site investigations, for the design, and for provision of a complete system including supply of all materials and equipment, testing, startup and commissioning.

12.2.2

Design of the System

1

The design of the system shall satisfy either of the two conditions:

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outline design of the sewerage system provided by the Engineer

(b)

as an alternative option proposed by the Contractor to avoid deep sewers in the Contract in which case the design will be based on the Contract Drawings

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(a)

The Contractor shall not procure materials, equipment or begin construction of the Works until the Engineer has approved the design and all other submittals.

3

The vacuum sewerage system shall intercept sewage flow and convey the flow to collection chambers. Collection chambers, interface valves and vacuum pipelines shall be located so that they do not interfere with or obstruct existing services and access thereto.

4

Sewage from the collection chambers shall be drawn into the system through interface valves and conveyed by the vacuum pipelines to a collection vessel located in the vacuum station, equipped with vacuum pumps.

5

Sewage from the vacuum station shall be pumped through the pressure pipeline to the gravity sewerage system. All necessary pipework shall be included from the vacuum station to the point of discharge to the gravity sewer.

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Design of Vacuum Station

1

The Contractor’s design shall optimise the number and locations of the vacuum stations. Where more than one station is required, the size of the collection vessels, vacuum pumps and other equipment shall be standardised as far as practicable.

2

Vacuum stations shall comprise all civil works; mechanical and electrical works including pipework, vacuum vessel, vacuum pumps, cooling systems, forwarding pumps, odour control equipment; motor control centre; instrumentation including vacuum data loggers, and valve telemetry display and telemetry outstation and connection to the control centre; lighting and all other work necessary in accordance with Sections 9 and 21 to make the vacuum station complete in all respects.

3

Forwarding pumps shall be controlled by level probes installed in the collection vessel; two sets of probes shall be installed, an upper set to run on normal day operation and a lower set to empty the vessel under extreme low flow conditions. The pump control station shall include automatic timer, indication and alarm in accordance with Sections 9 and 21.

4

The vacuum station shall be of cavity wall construction. The Contractor shall design the station building and submit detailed design drawings for the Engineer’s approval. The station building shall incorporate the following minimum requirements: 2

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minimum internal floor area 12 m

(b)

external cement, sand or concrete blocks

(c)

aluminium doors and window frames

(d)

black PVC-U rainwater drainage connected to surface water drainage conduits if available, otherwise to a gargoyle and soakaway

(e)

sufficient wall area for telemetry outstation

(f)

QGEWC supply meters to be mounted in external box (QGEWC supply)

(g)

a connection point to the incoming vacuum sewer, fitted with an isolation valve, for independently testing vacuum valves

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a separate room housing a single water closet and hand basin with both hot and cold running water

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(i)

water supply to a 200 l GRP header tank above the roof

(j)

external washdown tap with concreted splash area below, draining to the on-site vacuum collection chamber

(k)

activated carbon type exhaust air filter

(l)

a collection chamber shall be constructed at the site which shall receive the flows from the water closet, hand basin, external washdown tap, and coolant water from the liquid ring vacuum pumps.

The vacuum station shall include all pipework necessary for satisfactory performance, operation and maintenance.

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Design of Collection Chambers

1

Collection chambers shall be designed such that in each case the lowest invert of the incoming gravity sewer is above the high operation sewerage level of the interface valve to avoid surcharging the gravity sewers during normal operation.

2

Collection chamber sumps shall be sized to give a 4 h retention capacity at average flow below the level of the incoming sewers. The Contractor shall account for the probability of power failure and its consequences. Provision shall be made in the control panel and cabling for connecting mobile standby power generation.

3

Collection chambers shall be fitted with a level sensing devices and local and remote alarms as designated, and shall be so located and fitted with access openings to enable clearing of sewage using pumping or vacuum tankers. In no case will the provision of facilities for discharge of sewage to the surface water drains be permitted.

4

Collection chambers shall incorporate an intermediate platform within the chamber to facilitate easy access to the vacuum interface valve. The area of the platform must be at least equal to half the plan area of the chamber. Access to the lower part of the chamber below the intermediate platform shall be provided with a minimum 600 mm diameter clear opening. Where the intermediate platform is provided by means of a concrete slab, the access hole into the lower chamber shall be provided with a galvanised open mesh cover as specified in Clause 6.5.7 of this Section permitting viewing of the lower part of the chamber from the top of the chamber.

5

Vacuum interface valves in collection chambers shall incorporate an auxiliary suction pipe such that if the valve fails the chamber can be emptied into the vacuum pipeline. The auxiliary suction pipe shall be positioned within 100 mm below the cover level and shall be operable from ground level outside the chamber.

6

Interface valve assemblies shall incorporate isolating valves such that the interface valves can be easily removed without necessitating loss of vacuum in the vacuum pipeline.

7

Where breathers are used on vacuum interface valves they shall not exceed 5 m in length. Where the breather head is not against a structure to which it can be securely fixed the breather head shall be protected by a 50 mm by 50 mm galvanised steel angle cast in concrete, the head being fixed into the angle with plastic cable ties or similar. Where any double valve collection chambers are used each valve shall have a dedicated breather.

8

The sump shall be vented to allow the intake of air. The sump may be vented by the gravity system provided that the operation of the vacuum system does not unseal the traps on the internal sewerage system and that the internal sewerage system is vented to atmosphere.

12.2.5

Design of Vacuum Pipelines

1

Pipeline profiles shall be as follows:

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12.2.4

(a)

the size of individual lifts shall be kept as small as possible to maximise vacuum transport efficiency and many small lifts shall be provided instead of one large lift. The minimum horizontal distances between profile changes shall be 6 m for vacuum sewers and 1.5 m for service connections

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(b)

except at lifts, vacuum sewers shall have a minimum gradient of 1:500 in the direction of flow. Profile changes shall be made where necessary to ensure that the pipeline depth does not become excessive

(c)

where the ground surface has a gradient of 1:500 or more in the direction of flow, vacuum sewers may be laid parallel to the surface. Stagnation of sewage shall be avoided at locations followed by an uphill section

(d)

lifts shall generally not be more than 1.5 m, but where conditions are such that a lift exceeds 1.5 m special care shall be taken in the design of pipelines by taking into consideration the flow capacity and total lengths of the vacuum pipeline.

Air Flow. The total average air/liquid ratio shall not be less than 1.5:1. The Contractor shall identify in his calculations the average air liquid flows for which the system is designed.

3

Minimum Negative Pressure. The system design shall achieve a minimum negative pressure of 25 kPa (gauge) under no flow conditions at each interface valve.

4

Vacuum Recovery. The system shall be designed so that the vacuum recovery will be fast enough to ensure that temporary surcharging of collection chambers does not occur under normal flow conditions.

5

Length of Vacuum Sewers. Lengths of vacuum sewers shall be such to enable the system to restart automatically and recover vacuum following rectification any breakdown.

6

Service Connections. Service connections shall slope away from the interface valve and shall connect into the top sector of the vacuum sewer contained within the angle of +60  about the vertical axis.

7

Branch Connections. Branch connections to vacuum sewers shall be by junctions connected to the sewer above the horizontal axis, and the angle of the junction shall ensure that the flow towards the vacuum station is generated and backflow is minimised. No connection shall be made within 2 m of a lift.

8

Isolating Measures. Adequate means of isolating lengths of vacuum sewer to permit maintenance shall be provided by isolating valves or appropriate inspecting pipes. Isolating valves shall be suitable for service under vacuum and pressure and shall be capable of sustaining a differential vacuum of 80 kPa.. Buried valves shall be provided with extension spindles and surface boxes.

12.3

PRINCIPAL SYSTEM COMPONENTS

12.3.1

General

1

All materials used in the manufacture of collection chamber, interface valve and controller shall be capable of resisting corrosion from soils, groundwater, sewage and sewage gases.

12.3.2

Vacuum Pipelines

1

Vacuum sewers shall have a minimum diameter of 80 mm and service connections shall have a minimum diameter of 50 mm.

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All vacuum pipes and fittings shall be of MDPE as specified in Part 3 of this Section. The minimum pressure rating for plastic pipes shall be 0.6 MPa but higher ratings shall be employed if the pipe has an initial ovality or if progressive deformation is likely to occur.

3

Pipelines and components shall be designed to withstand the stresses arising from earth cover, traffic and cyclic loads, particularly at connections to structures and the range of negative pressures arising during operation and testing.

12.3.3

Collection Chamber

1

The chamber shall be watertight and shall be protected against floatation in waterlogged areas. The internal surface of the sump shall be smooth and the sump shall be designed to be self-cleansing.

2

Access to the chamber shall be through a manhole cover and frame as specified in Part 4 of this section. The size of chamber shall be similar to inspection chamber on the Contract Drawing.

12.3.4

Interface valves

1

Interface valves shall be all ABS construction and shall be capable of performing sufficient cycles to evacuate 3000 m3 without attention. All materials shall be serviceable at 50 C ambient temperature and 100 % humidity conditions except if the valves are exposed to the sun where the temperature could reach 80oC. The valve mechanism shall be explosion proof.

2

Interface valves shall:

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be minimum of 80 mm diameter and capable of passing solids with a maximum size of 65 mm diameter with a visual flow through area of not less than 60 %

(b)

be complete with controller, sensor pipework, fittings and telemetry connections

(c)

be vacuum-operated in opening and spring-assisted in closing

(d)

be controlled by sump liquid level and by vacuum

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fail safe in the closed position

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prevent backflow to the collection sump

(g)

evacuate the batch volume on each cycle.

3

Batteries shall not be used in valve actuating or control elements.

4

Valve opening initiation level and valve opening times shall both be adjustable.

5

Configurations shall be such that the vacuum ensures positive valve seating.

6

When the valve is open, the flow stream shall not be obstructed by the valve plunger. The valve may be protected from obstruction by the installation of constriction in the suction lift pipework.

7

The internal diameter of the suction pipe shall not be greater than the internal diameter of the interface valve which shall not be greater than the internal diameter of the service connection.

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8

Valves installed in sumps shall be capable of operating when submerged in sewage.

9

Valves shall be designed to allow easy access for maintenance. Fixing arrangements shall enable the valve and control system to be readily replaced.

12.3.5

Controller

1

Controllers shall be explosion proof

(b)

open the interface valve only if there is a minimum vacuum of 15 kPa available

(c)

maintain the valve fully open until the sump has been fully emptied

(d)

be adjustable so that a range of air to sewage volume ratios can be obtained.

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If the introduction of air is allowed after the sewage has been fully emptied, the controller shall maintain the valve in the open position for a further period.

12.3.6

Sensor

1

The interface valve shall be provided with a sensor to determine the level of sewage in the collection sump. The sensor shall be designed to be fouling resistant. Where level sensor pipes are employed they shall not be less than 45 mm diameter.

12.3.7

Vacuum Vessel

1

Flows from vacuum pipelines discharged to vacuum stations shall be collected in a vacuum vessel. The vessel shall be manufactured of steel and be in accordance with the requirements of BS 5500 or other corrosion resistant material such as GRP. The steel shall be corrosion protected in accordance with Clause 8.4.2 of this Section.

2

Vessel capacity shall suit vacuum generator and forwarding pump capacities and the vacuum rate of inflow and storage volume.

3

Vessels shall

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(a)

be fabricated and tested for a working vacuum of 70 kPa and rest vacuum of 90 kPa

(b)

be fitted with the required number of correctly sized sewage inlet and outlet pipes which shall be integral with the vessel. No inlet pipes shall be connected below the system emergency stop level. The inlet and outlet pipes shall be located such that solids do not accumulate in the vessel

(c)

be provided with a suitable flanged manhole access cover to permit entry for internal inspection and maintenance

(d)

be fitted with a level control system which is suitable for operation in vacuum and easily removed for adjustment or replacement

(e)

be fitted with suitable galvanised mild steel cradles for bolting to the concrete floor of vacuum station.

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The pump manufacturer’s advice on the need to install equalising lines connecting the discharge side of the pumps to the vacuum vessel shall be sought. If required by the pump manufacturer, a suitably sized and valved equalising line from each pump to the vessel shall be provided

5

The steel vessel shall be internally and externally protected from corrosion with a suitable protection system in accordance with Part 8 of this Section. Details of the proposed protection method shall be submitted as required by Clause 12.1.5 of this Section. The protection system shall take account of accessibility for inspection and maintenance.

12.3.8

Vacuum Pumps

1

Two vacuum generators such as liquid ring or rotary vane pumps or ejector pumps shall be provided each having sufficient capacity to serve the system.

2

Vacuum pumps shall be capable of continuous operation and shall be designed for a minimum of 12 starts per hour. Pumps of equal capacity shall be installed such that one pump can act as standby.

3

Vacuum pumps shall be operated by pressure switches attached to the vacuum vessel. The pumps shall operate on the liquid ring principle and shall exhaust air from the vacuum vessel. One duty and one standby vacuum pump shall operate in conjunction with a common tank containing the operating liquid, normally water, and associated pipework connecting the pumps to the tank so that the water level is maintained at all times. The service liquid shall be maintained at 30 C by a refrigerated cooling unit, circulating the liquid through the tank. Ambient air temperatures up to 50 C shall not limit the functioning of this equipment or cause the vacuum pumps to trip on high circulating water temperature.

4

Each pump shall be provided with a rotary seal comprising a rubber seal, spring loaded and rotating against a carbon face. Suitable non-return valves shall be provided to prevent the exhausted air from returning into the vacuum system. The pressure switches shall control the operation of the vacuum pumps to maintain the vacuum within the system.

12.3.9

Forwarding Sewage Pumps

1

Forwarding pumps or pressure vessels used to forward the sewage shall have sufficient capacity to serve the system. Forwarding pumps shall be as specified in Section 9 except as modified below.

2

Forwarding pumps shall be unchokeable sewage pumps suitable for operating under negative pressure without cavitations. They shall be suitable for a maximum of 12 starts per hour. The motor speed shall be 1500 rpm.

3

A 25 mm connection of swept flanged tee shall be provided on each pump delivery, with hand hole incorporated in the impeller casing or duckfoot bend under the pump and reversible wear plate fitted under the impeller. Pumps shall be fitted with lip seals to prevent loss of vacuum from the shaft when pumping from the sewage vessel.

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12.3.10 Motor Control Centre 1

The motor control centre for the operation of all pumps shall be as specified in Sections 9 and 21.

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2

The operation of pumps shall be controlled by a programmable logic controller and shall prevent simultaneous starting of the vacuum and sewage pumps to prevent surges.

3

The controls shall permit the manual or programmed selection of duty and standby pumps and shall provide for automatic start of the standby pumps in the event of duty pump failure.

4

The vacuum pumps shall be controlled by monitoring the vacuum in the vacuum vessel with adjustable pressure switches set to the desired operating range. Additional pressure devices shall be provided to indicate and record both high and low vacuum.

5

The level control system shall respond to the following sewage levels in the vacuum vessel or the sewage sump:

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stops vacuum generation forwarding pumps operate starts forwarding pumps stops forwarding pumps.

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Start level Normal stop level (Low Level)

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All power, control and instrumentation cabling shall be provided as required for the complete system.

7

The following alarms with appropriate remote signalling shall be provided:

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low vacuum alarm indicating that system vacuum is below the minimum preset level

(b)

high sewage alarm indicating that sewage level in the vacuum vessel or sewage sump is at the high level mark.

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Telemetry shall be designed and installed in accordance with Section 10.

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12.3.12 Discharge Pipelines

All pipes, fittings and valves on the discharge side of the forwarding pumps shall be as specified in Parts 3 and 5 of this Section.

12.4

INSTALLATION OF THE SYSTEM

12.4.1

Pipelines

1

Vacuum and pressure pipelines shall be installed in accordance with Part 4 of this section and valves shall be installed as specified in Part 5 of this Section, except where modified herein.

2

Vacuum pipelines shall be jointed as specified herein.

12.4.2

Pipe Joints for Vacuum Pipelines

1

Pipeline components shall be connected in such a way that the pipeline is sealed and accommodates static and dynamic stresses.

2

Where mechanical joints are employed they shall comply with the requirements of Part 3 of this Section and be suitable for vacuum service.

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Pipelines shall be securely anchored or bedded to resist thrust arising from internal vacuum. Precautions shall be taken against flotation where necessary.

4

Welded joints shall only be made by suitably trained personnel using approved welding equipment.

12.4.3

Pumps, Motors and Instrumentation

1

Pumps shall be installed as specified in Section 9.

2

Motors shall be installed as specified in Sections 9 and 21.

3

Instrumentation shall be installed as specified in Section 10.

12.5

TESTING

12.5.1

General

1

The Contractor shall prepare and submit his proposed testing program for the approval of the Engineer.

2

The Engineer shall be notified 24 hours in advance of testing.

3

Pipelines and equipment shall be adequately restrained before testing.

4

On satisfactory completion of testing, the Contractor shall submit a report describing the tests undertaken and the test results.

12.5.2

Testing of Interface Valves, Controllers and Sensors

1

Interface valves, controllers and sensors shall be tested to demonstrate that they function correctly to meet specified duties.

2

Where new valves or controllers are introduced or significant changes are made to proven valves, laboratory tests shall be undertaken under simulated working conditions and test certificates provided. The tests, using water and air, shall demonstrate that the complete valve mechanism can comply with the preceding performance requirements.

12.5.3

Testing of Pipelines

1

Pipelines shall be pressure and vacuum tested.

2

Pressure tests shall be carried out in accordance with Clause 4.5.3 of this Section.

3

Before carrying out a vacuum test, the Contractor shall ensure that the test equipment is calibrated, is in working order and correctly fitted to the pipe.

4

The permitted loss of vacuum in pipeline tests shall be corrected to allow for changes in temperature and atmospheric pressure. Pipe temperatures atmospheric pressure shall be recorded at the start of the test and at hourly intervals.

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Regular vacuum testing and final vacuum testing shall be carried out as specified herein. In the event of failure under either test, the leaks shall be located and repaired, and the tests redone.

6

Regular vacuum testing of all service connections and vacuum sewers shall be carried out on the pipelines before backfilling and in sections as approved by the Engineer. The test duration shall be 1 h. Open ends of pipeline shall be capped and a vacuum of 80 kPa applied and allowed to stabilise for 15 min after which time the fall in vacuum shall not exceed 1.0 % over the 1 h test.

7

Final testing of service connections, vacuum sewers and vacuum vessels shall be tested before the installation of the interface valves. The test duration shall be 4 h. A vacuum of 80 kPa shall be applied using the vacuum pumps in the vacuum station. Instrumentation shall be provided to record system vacuum during testing. After the vacuum has stabilised, the fall in vacuum shall not exceed 1.0 %/h for each hour of the test.

12.5.4

Testing of Pumps, Motors and Instrumentation

1

Testing of pumps shall be in accordance with Section 9.

2

Testing of motors shall be in accordance with Sections 9 and 21.

3

Testing of instrumentation shall be in accordance with Section 10.

12.6

TRAINING OF EMPLOYER’S PERSONNEL

1

The Contractor shall prepare and submit a training program and manual for the approval of the Engineer. The training shall cover system installation, operation and maintenance, and record keeping and interpretation.

2

On-site training shall be provided by the system manufacturer specialist staff for a minimum period of 90 days.

3

The Contractor shall provide facilities required for implementation of the training program.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 02: Earthworks

Page 1

2

EARTHWORKS ............................................................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5

Scope References Definitions Trial Holes Services Co-ordination

2.2

EXCAVATIONS ............................................................................................. 3

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12 2.2.13 2.2.14

General Surfaces Materials Excavations to be Kept Dry Access Trench Excavations Appurtenant Structures for Pipelines Excavation in Roads Excavation in Areas Other Than Road Reserves Support of Excavations Slips and Falls and Excess Excavation Trimming and Levelling Excavations Not to be Left Open Dewatering of Excavations

2.3

BACKFILL .................................................................................................... 13

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8

Pipe Bedding Pipe Surround Geotextile Filter Membrane Backfilling Excavation Backfilling Excavations with Cement-Bound Granular Material Backfilling Excavation with Flowable Fill (Foamed Concrete) Backfilling Next to Pipeline Structures No-Fines Concrete as Trench Backfill

2.4

REINSTATEMENT OF SURFACES ............................................................ 22

2.4.1 2.4.2

Reinstatement within the Highway Reinstatement of Surfaces Other Than in the Highway

2.5

EXISTING SERVICES ................................................................................. 23

2.6

BLASTING ................................................................................................... 24

2.7

MISCELLANEOUS ...................................................................................... 26

2.7.1 2.7.2

Service Ducts Formation of Bunds and Embankments

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2 2 2 3 3 3 3 4 5 5 6 8 9 9 10 10 11 11 12 14 16 16 17 19 21 22 22 22 22

26 26

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EARTHWORKS

2.1

GENERAL

2.1.1

Scope

1

This Part includes earthworks for pipelines including, excavation, granular pipe bedding, concrete protection of pipe, backfill and compaction, and service protection ducts to protect existing utilities.

2


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General Pipeline Installation Trenchless Pipeline Construction Sewer Rehabilitation Vacuum Sewerage System General Ground Investigation Concrete Roadworks Earthworks Related to Buildings Landscaping.

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This Section Part 1, Part 3, Part 9, Part 10, Part 12, Section 1, Section 3, Section 5, Section 6, Section 12, Section 28,

.

2

References

1

The following standards and other documents are referred to in this Part

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BS 410........................Test sieves

BS 1924......................Stabilised materials for civil engineering purposes

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BS 6031......................Code of practice for earthworks

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BS EN 12620..............Aggregates for concrete BS EN ISO 10319 ......Geosynthetics

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BS EN ISO 11058 ......Geotextiles and geotextile-related products BS EN ISO 12236 ......Geosynthetics BS EN ISO 12956 ......Geotextiles and geotextile-related products Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance Section, Code of Practice and Specification for Road Openings in the Highway 2.1.3

Definitions

1

Trench excavation means excavation in all materials of whatever nature encountered for trenches into which pipes, ducts or cables are to be laid, or manholes, chambers and appurtenances constructed, and the term pipe shall mean pipe of all kinds and for whatever purposes.

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Trial Holes

1

Trial holes for determining the location of existing services shall be excavated well ahead of the trench excavation to such depths as necessary to determine and confirm the alignment for the trench and the soil condition. The Contractor shall arrange for the refilling and reinstatement of trial holes to be carried out immediately after the required information is obtained. The reinstatement of trial holes shall be carried out to the approval of the Engineer.

2.1.5

Services Co-ordination

1

In addition to the requirements of the relevant Parts of Section 1 and Part 1 of this Section, the following paragraphs shall apply to services co-ordination for pipeline excavations.

2

Notwithstanding any relevant information furnished by the Engineer, the Contractor shall be responsible for ascertaining from his own inspection of the Site and the respective Utilities Service Departments and private landowners the position of all mains, pipes, cables, and other services and facilities whether underground or overhead within or near the Site.

3

Except as otherwise specified, the Contractor shall make arrangements necessary for carrying out the Works with the various Utilities Service Departments and private landowners. The Contractor shall be responsible for any damage caused as a result of his omission in this respect, and for any damage caused by his failure to notify the Engineer’s representative and the agencies concerned immediately any service is encountered in the excavations.

4

Work on existing services is specified in Subparts 2.4, 2.5 and 2.7 of this Part.

2.2

EXCAVATIONS

2.2.1

General

1

The Contractor shall be deemed to have obtained additional site information in accordance with Clause 1.3.1 of this Section.

2.2.2

Surfaces

1

Before the surface of the area to be excavated is disturbed the Contractor shall take and record levels of the area in the presence of the Engineer. At least two days notice shall be provided to the Engineer.

2

The demolition of existing works shall be in accordance with Section 2.

3

Except as otherwise designated in the Project Specification or directed by the Engineer, breaking out and restoration of existing surfaces and works shall be done in accordance with the Code of Practice and Specification for Road Openings in the Highway published by the Highway Maintenance Section, Civil Engineering Department, Ministry of Municipal Affairs and Agriculture.

4

Surface materials shall be carefully stripped or otherwise removed and set aside for reuse, restoration, or replacement as directed by the Engineer.

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2.1.4

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Page 4

Where the trench excavation crosses surface barriers such as fences and walls the Contractor shall (a)

obtain the written approval of the Engineer before breaching the barrier

(b)

minimise the size of the opening, where possible using a short heading

(c)

carefully dismantle the barrier as necessary for reuse, replacement, or reinstatement

(d)

provide temporary fencing for any removed parts of such barriers as directed by the Engineer.

Materials

1

Selected excavated material shall be the most suitable portions of the excavated material free from matter harmful to other materials in the works and which is capable of being compacted to the specified density to form stable fill. The material shall also conform to the requirements mentioned in Clauses 3.3.2, 3.3.3 and 3.3.5 of Section 6.

2

It shall be the responsibility of the Contractor to locate suitable borrowed or imported fill material which may be necessary and to carry out such tests as the Engineer may require to demonstrate the suitability of the fill to be supplied. Imported fill shall be from a source approved by the Engineer. Imported fill shall have the following properties

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2.2.3

maximum stone size of 150 mm except as specified in Clause 2.3.2 of this Part

(b)

liquid limit less than 35 %

(c)

plasticity index of not more than 10.

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(a)

Excavated material unsuitable for use in the Works shall not be stockpiled on the Site.

4

Disposal of excavated material not used in the Works shall be the responsibility of the Contractor and shall be at a location approved by the relevant government agency.

5

Excavated material shall not be stockpiled on road reservations nor at other locations designated in the Project Specification. The Contractor shall confine his operations to the working areas available to him for the construction of the Works particularly where this is located in roads or in other places to which the public has free access.

6

Stockpiling materials on the Site or off the Site, as necessary, shall be the responsibility of the Contractor. The stockpiling of surplus excavated material or other debris on site is not permitted. All surplus excavated material shall be removed from site to approved disposal sites. All dump trucks transporting waste shall be fully covered to prevent discharge of the contents.

7

Any temporary storage alongside the trench excavation shall be to stable slopes and heights and deposited in such a manner that no damage and as little inconvenience as possible is caused. Backfilling materials shall be fenced off and continuously irrigated with water to avoid dust and pollution.

8

Where the nature of the excavated material is suitable, the Contractor’s temporary storage as aforesaid shall include for separate storage as the Engineer may direct of the various grades of materials hereinafter specified for the refilling and surface reinstatement of trench or structure excavation, namely, soft material, coarse material, hard material and topsoil. The Contractor is to agree a screening location with the concerned municipality.

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The screening of trench excavated material will not be permitted on site without the written approval of the Engineer.

10

The Contractor shall post signs indicating proposed use of material stockpiled. Post signs shall be readable from all directions of approach to each stockpile. Signs should be clearly worded and readable by equipment operators from their normal seated position.

11

The Contractor shall not stockpile excavated materials near or over existing facilities, adjacent property, or completed work, if weight of stockpiled material could induce excessive settlement.

12

The Contractor shall obtain all necessary approvals for the sites of borrow pits and quarries. All borrow pits shall be left in a tidy and regular state. The Contractor shall ensure that pits are self-draining at all times and do not constitute a nuisance and danger to the public.

2.2.4

Excavations to be Kept Dry

1

The Contractor shall keep excavations free of water, sewage, and other liquids whether affected by tides, floods, storms, or otherwise so that the Works shall be constructed in dry conditions.

2

The Contractor shall keep the subsoil or accumulated water or sewage at a level lower than the bottom of the permanent work until trench backfilling is complete or for such other period directed by the Engineer.

3

Measures taken by the Contractor for the control of water shall conform with the specifications of this Part.

2.2.5

Access

1

A minimum clear carriageway width of 3 m shall be maintained for vehicular traffic unless otherwise approved by the Engineer.

2

Excavations in roads shall be organised to reduce to a minimum the interval between opening up and backfilling excavations.

3

The Contractor shall supply, post and display at all entrances to all properties a Notice of Excavation before any excavation is undertaken in front of or in the vicinity of the property. The notice shall be in the form of a self- adhesive glossy sticker which shall be easily removable. A typical sample is shown in Section E of the Contract Documents. The Contractor shall remove the label after all the excavation has been backfilled.

4

Should cess-pits of other artificial obstructions be encountered in the excavation either above or below ground level the Contractor shall forthwith advise the Engineer’s Representative thereof and execute at his own cost such work as may be ordered.

5

The Contractor shall allow for laying pipes through any cess pits or septic tanks encountered along the route. Pipes shall be laid such that joints occur either side of the structure or in a manner approved by the Engineer’s Representative.

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Trench Excavations

1

The Contractor shall provide the necessary support of excavations. Details of excavation support systems shall be submitted to the Engineer for review and approval at least sixty (60) days before any excavation work commences.

2

Support of excavations shall be provided in accordance with BS 6031, except as otherwise specified in this Part.

3

The term “necessary support of excavations” covers all normal methods of temporary support including timber, concrete, steel sheet piling, steel trench sheeting or other materials as may be approved by the Engineer. Where excavation is carried out near or under an existing structure or any portion of the Work, the Contractor shall prevent damage due to subsidence with methods approved by the Engineer.

4

The maximum trench width shall be as given in Table 2.1 unless otherwise shown on the drawings. The width of the excavation shall be increased if necessary to provide space for the trench support system; undercutting of the trench sides will not be permitted.

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Table 2.1 – Maximum pipe trench width at 300mm above pipe crown Nominal Bore Maximum Trench Nominal Bore Maximum Trench mm Width mm mm Width mm 550

150

600

200

800

300

900

400

1000

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1350

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1550

1000

2000

1200

2300

1400

2500

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500 1250 1500 2700 If the Contractor exceeds these trench widths he shall provide plain or reinforced concrete cradles and /or reinforced concrete arches to the requirements shown on the drawings and to the approval of the Engineer at no additional cost. When directed by the Engineer, supply and install strong and sufficient shoring to support excavations at no additional cost. No additional payment will be made to the Contractor for working in a confined space or if the position of the Works precludes the use of mechanical excavators or the storage of excavated materials next to the excavations.

6

The Contractor shall submit shop drawings of all temporary works and trench support systems or proprietary manufacturers’ catalogues detailing his proposed methods of construction at least one month prior to starting excavations. The shop drawings shall be complete with all details, design calculations, and description of construction methods. The Engineer’s approval of the Contractor’s submittal shall not relieve the Contractor from obligations under the Contract.

7

Except as otherwise precluded by the Project Specification, the Contractor may propose to excavate with battered side slopes. If required by the Engineer, the Contractor shall provide three copies of a report which shall include relevant calculations and method statement demonstrating the adequacy of the proposals.

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8

In the event of any trench being excavated with battered or stepped sides, that portion of the trench which extends from the formation to a point not less than 300 mm above the crown of the pipe when laid in its correct position shall be formed with vertical sides. Support shall be provided to the vertical trench sides to prevent ground movement. Where temporary trench supports are provided they shall be such that no ground movement occurs on removal.

9

Where battered sides are proposed, no excavation work shall begin until the Engineer’s approval has been obtained. The Engineer’s approval shall not relieve the Contractor from his obligations under the Contract.

10

The line and level of trenches shall be as shown on the Drawings and shall be maintained in accordance with the following procedure: before beginning trench excavations, the route of the pipeline shall be surveyed and set out accurately and the existing ground level shall be agreed with the Engineer

(b)

sight rails shall then be fixed and maintained at each change of gradient, and at as many intermediate points as may be necessary. The centreline and the level to which the excavation is to be carried out shall be marked on the site rails and the rails shall not be more than 20 m apart

(c)

alternate methods to maintain line and level of excavations shall be subject to the approval of the Engineer.

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Trench excavation shall be carried out as follows:

trench excavation shall be carried out by such methods and to such lines, dimensions and depths as shall allow for the proper construction of the Works

(b)

trench widths shall conform with the limits shown on the Drawings, or ,in the case of flexible pipes, to the widths stated in the Contractor’s approved methods statement. Where trench widths do not conform to the limits shown on the Drawings, the Engineer will direct the Contractor as to the measures to be taken to remedy the situation. Such remedial works shall be carried out by the Contractor as an obligation under the Contract at no additional cost to the Employer

(c)

rock encountered in trench excavations shall be so excavated that the clearance between the pipe, when laid, and the rock sides and bottom of the trench is kept to the minimum limits necessary to provide for the specified thickness of bedding and where provided the concrete protection of the pipe

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(a)

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(d)

bell holes and holes and depressions for couplings, valves and the like shall be excavated the same distance below these installations as specified for the pipe.

(e)

When the trench width measured 300mm above the crown of the pipe exceeds the maximum allowable shown on the drawings for granular surround the Contractor shall proceed as Clause 4.3.2 of this Section.

Limitations on the lengths of opened trenches shall be as follows: (a)

no length of trench excavation shall begin until the pipes and fittings to be laid in the length of excavation are available at the Site.

(b)

the Engineer reserves the right to direct the Contractor on the lengths of trench which shall be excavated at any one time

(c)

the Contractor shall not be permitted to excavate trenches in more than one location in any road at a given time without the Engineer’s approval

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in areas accessible by the public, the maximum length of open trench in any one section shall not exceed 100 m. In other areas the trench shall be dug only so far in advance of pipe laying as the Engineer shall permit.

The Contractor shall at his own expense remove from the Site all unsuitable and excess material resulting from excavations beyond that required for the foundation, lining or bedding and shall make good the same with concrete or suitable fill material as may be required by the Engineer.

14

The Engineer will inspect ground condition, or trench formation level and may direct the Contractor to remove additional material and to refill the excavation with concrete or other approved material. Should any acceptable native material at the foundation level subsequently become unsuitable the Contractor shall remove it and replace it with concrete or other suitable material as directed by the Engineer at no additional cost to the Employer.

15

If utility obstructions are encountered during excavation and cannot be diverted, the Contractor shall make the necessary changes to the design drawings and submit to the Engineer for approval. The Contractor shall not make any deviation from the specified lines or grade of the tunnel without written approval from the Engineer.

16

Excavation shall be carried out to the dimensions, depths or levels in such a manner as to avoid excavation of or disturbance of material below grade.

17

Pipes of greater strength or the use of superior pipe bedding may be used in lieu of maintaining the maximum trench widths shown in Table 2.1 or specified for various pipe diameters, subject to the Engineer’s prior written approval.

18

The Contractor shall excavate trenches to the levels that will allow for the pipe wall thickness and bedding thickness.

19

The Contractor shall leave a clear space as approved by the Engineer, between the edge of the excavation and the inner toes of the spoil banks.

20

The Contractor shall grade the trench bottom with hand tools, remove loose and disturbed material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for bedding material if shown on the design drawings or as specified.

21

The Contractor shall remove soft sub-grade that may cause pipe settlement and replace with suitable backfill compacted in layers not exceeding 150 mm.

22

The bottom of excavations for permanent structural works shall be free from mud and water, trimmed clean, protected from the effects of the weather and consolidated to achieve the required bearing capacity prior to the placement of structural work or construction materials within the excavation.

2.2.7

Appurtenant Structures for Pipelines

1

The Contractor shall carry out the necessary excavations to accommodate appurtenant structures such as manholes, chambers and thrust blocks. The requirements for the completion of excavations and handling of excavated material shall be as specified above for trench excavations shall apply.

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Excavation in Roads

1

In addition to the foregoing and the provisions of Section 1, pipeline excavation in roads and highway reserves including the provision of public safety facilities including barriers and enclosures shall be in accordance with the Code of Practice and Specification for Road Openings in the Highway published by the Highway Maintenance Section, Roads Department, Ministry of Municipal Affairs and Agriculture (MMAA).

2

Where trenches are excavated open cut in roads, the asphalt shall be saw cut along the edges of the trench, prior to excavation.

3

In the lanes of the road that remain open to traffic, road drains and channels shall be kept free from construction materials, debris and obstruction at all times.

4

Normally trench excavation along roads shall be located in the service reserves or verges adjacent to the road rather than in the carriageway itself. Trench excavation shall wherever practicable be carried out in such a way that every part of the excavation is at least 1 m clear of the existing edge of the carriageway. The Contractor shall obtain information regarding utilities reservations from the Planning Department of the Ministry of Municipal Affairs & Agriculture and refer to their publication entitled Road Hierarchy: General Guidance for Road Cross-Sections and Utilities Disposition.

5

The Contractor shall take special precautions, which includes the continuous support of the sides of the excavation, from the start of excavation until the refilling and compaction of the trench backfill material is completed.

6

The Engineer may direct the trench excavation to be realigned from that shown on the Drawings to facilitate the flow of traffic.

7

Where trench excavation or any other part of the Works obstructs any footpath or right-ofway, or property access, the Contractor shall provide, at his own cost, a temporary access around the obstruction to the satisfaction of the Engineer. Where applicable, this temporary access shall include stout wooden bridges with hand rails and kick boards or other approved construction across any open trench. Suitable steel road plates shall be provided and maintained where vehicle access is deemed necessary.

8

No excavated material shall be permitted to be deposited or stockpiled in grassed or planted areas. The Contractor shall immediately remove excavated material to a temporary storage area and import selected approved materials for the trench filling operations.

9

Where excavated material has temporarily been deposited on a verge, the verge shall on completion of backfill be restored to its original condition and left free from debris.

2.2.9

Excavation in Areas Other Than Road Reserves

1

Areas other than road reserves shall include but not be limited to cultivated areas, undeveloped areas, footpaths, verges, non-asphalt roads, lanes, alleys, and all private lands.

2

The Contractor shall take measures to prevent access of unauthorised persons, the general public and animals to areas in which there are open excavations, access routes and steep or loose slopes arising from the Contractor’s operations.

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The Contractor shall provide adequate temporary barriers and fencing. When necessary, barriers and fencing shall be illuminated.

4

Temporary barriers and fencing shall not be removed without the Engineer’s written permission, which will not normally be given until the trench excavation has been refilled and reinstated.

2.2.10

Support of Excavations

1

The Engineer reserves the right to direct the Contractor to take measures to augment the Contractor’s proposals for the support of excavated surfaces. If, in the opinion of the Engineer, the support proposed by the Contractor is insufficient, the Contractor shall modify his proposals and provide trench support as directed by the Engineer. The absence of the Engineer’s direction, or action by the Contractor in accordance with the direction of the Engineer shall not relieve the Contractor of his obligations under the Contract.

2

Shoring shall be properly maintained until in the opinion of the Engineer the permanent work is sufficiently advanced to permit the shoring to be removed. The removal of shoring shall be carried out only under the personal supervision of a competent foreman. If the Contractor proposes not to remove the shoring on completion of the permanent work he shall obtain the Engineer’s prior written approval.

3

All temporary works supporting the faces of excavations shall be removed during backfilling with the approval of the Engineer. Where removal is impracticable and with the approval of the Engineer, temporary works shall be left in place. Temporary works left in place shall be at no additional cost to the Employer.

4

When, in the opinion of the Engineer, temporary supports need to be left in excavations to support existing structures or the permanent Works, the Engineer may direct that temporary supports be left in place. Temporary supports left in place shall be at no additional cost to the Employer.

5

Underpinning, supports and other protective measures that are required for buildings, structures and apparatus in or adjoining excavations shall be provided by the Contractor. Such permanent or temporary works shall be of adequate design and construction. When directed by the Engineer, the Contractor shall submit his methods statement for such work for the approval of the Engineer. The Engineer’s approval shall not relieve the Contractor from his obligations under the Contract.

6

Damage to the Works and any consequential damages caused by the removal of shoring are the responsibility of the Contractor. Permission or approval by the Engineer to remove shoring shall not relieve the Contractor from this responsibility.

2.2.11

Slips and Falls and Excess Excavation

1

Slips and falls in trenches shall be prevented as follows:

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(a)

the Contractor shall effectively support the sides of all trench excavation to prevent slips and falls of material in the excavation. Support may include the use of closed sheeting or steel sheet piles, where necessary, to prevent any fall or run from any portion of the ground outside the excavation into the trench and to prevent settlement of or damage to existing services and structures next to the excavation

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(b)

any excavation carried out by the Contractor to prevent slips and fall, or should portions of trench walls slip or fall away, the Contractor shall at his own expense take all necessary remedial measures including the excavation removal and reinstatement of all the ground thereby disturbed

(c)

in all cases where the voids so formed when backfilled would provide support for the permanent Works or adjacent structures and services, such voids shall be filled with Grade 20 SRC concrete at the Contractor’s expense. In all other cases the voids shall be filled with selected excavated material compacted as specified in this Part.

Trimming and Levelling

1

No excavation shall be filled in or covered with concrete until it has been inspected by the Engineer.

2

Where shown on the Drawings or instructed by the Engineer, a layer of blinding concrete shall be placed to the required thickness to protect the formation and provide a clean working surface.

3

The Contractor shall compact the formation before placing the blinding concrete, when in the opinion of the Engineer the formation density can be improved by compaction.

4

When excavating to specified levels for trench excavation for pipelines, or to specified limits for the face of any thrust block or other structure required to abut or to rest upon undisturbed ground, excavations shall be trimmed as follows: the Contractor shall not excavate the last 150 mm until immediately before beginning construction work except where the Engineer permits otherwise. Should the Contractor have excavated to within 150 mm above these specified levels or to within 150 mm of these specified limits before he is ready or able to commence the construction work he shall where required by the Engineer excavate further so as to remove not less than 150 mm of material immediately before commencing the construction work and any such further excavation and additional foundation material ordered by the Engineer shall be at the cost of the Contractor. The last 150 mm shall be hand excavated the bottom of excavations shall be carefully boned in and trimmed true to grade with the aid of a straight-edge.

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2.2.12

2.2.13

Excavations Not to be Left Open

1

Trench excavation shall be carried out expeditiously in the following manner: (a)

the refilling and surface reinstatement of trench excavations shall begin and be completed as soon as reasonably practicable after the pipes have been laid and jointed

(b)

the Contractor shall take precautions to prevent flotation of pipes in locations where open trench excavations become flooded, and these precautions shall include the partial refilling of the trench leaving pipe joints exposed for tests of the joints

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if the Engineer considers that the Contractor is not complying with the foregoing requirements, The Engineer will not permit further trench excavation until he is satisfied with the progress of laying and testing of pipes and refilling of trench excavation.

Dewatering of Excavations

1

For construction dewatering refer to Section 1 Part 24 Construction Dewatering.

2

The Contractor shall submit methods statements including drawings and data showing the intended plan for dewatering operations. Details of locations and capacities of dewatering wells, well points, pumps, sumps, collection and discharge lines, standby units, water disposal methods, monitoring and settlement shall be included. The methods statement shall be submitted to the Engineer for approval not less than 30 days before the start of dewatering operations. The Engineer reserves the right to reject the proposal if he is not satisfied with measures.

3

The Contractor shall satisfy himself on the scope of dewatering necessary for the construction of the Works and shall make the necessary investigations to obtain the required data and information.

4

Where necessary, the Contractor shall divert natural and artificial waterways encountered at the Site until the Works are completed.

5

The Contractor shall perform dewatering as necessary to ensure that

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2.2.14

the Works are installed on dry areas and excavations, including without limitation the construction of all structures and underground piping

(b)

dewatering is carried out only to a depth sufficient for the required excavation

(c)

during construction, no groundwater shall come into contact with any concrete surface or reinforcement

(d)

structures shall be capable of withstanding any hydrostatic pressure to which it may be subjected during construction and until completed.

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(a)

The Contractor’s dewatering operations shall be conducted so as not to endanger the foundations or stability of the Works or any adjacent structures. Damage caused by the Contractor’s operations shall be made good by the Contractor at no additional cost to the Employer.

7

Discharge of groundwater from excavations to the sea, into surface storage ponds or deep well recharge shall require the approval of the Ministry of Environment.

8

Water removed from excavations shall first pass through settlement tanks and on-site treatment prior to discharge.

9

Unless otherwise approved by the Engineer, wellpoint dewatering systems shall be provided on both sides of trenches.

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The static water level shall be drawn down a minimum of 300 mm below the bottom of the excavation so as to maintain the undisturbed state of the foundation soils and allow the placement of any fill or backfill to the required density. The dewatering system shall be installed and operated so that the groundwater level outside the excavation is not reduced to the extent that would damage or endanger adjacent structures or property.

11

The Contractor shall, where extensive dewatering is required, be fully qualified to perform the dewatering operations or shall furnish the services of an experienced, qualified, and equipped dewatering subcontractor to design and operate the dewatering and groundwater recharging system required for the work, all subject to the Engineer’s approval.

12

When directed by the Engineer, the Contractor shall establish a specified number of groundwater level monitoring stations at each site which shall be observed during the work. These shall be located as directed by the Engineer and consist of acceptable open tube piezometers. When directed by the Engineer, the Contractor shall provide settlement gauges to the approval of the Engineer and monitor settlement of new and existing facilities.

13

Dewatering shall not result in the flow of water along the pipe zone material. Full consideration should be given to the use of cut-off walls to reduce the potential for groundwater flow along pipe trenches. The Contractor shall submit for the Engineer’s approval, details of his proposed method of working and temporary works installations to achieve this.

14

If the use of drainage conduits, channels or subdrains is approved by the Engineer and are to be left in place below the level and within the width limits of permanent Works they shall be structural capable of providing support. Ballast filled subdrains to be left in place under concrete shall be covered with a geotextile membrane. Subdrains left in place shall be filled with Grade 20 SRC concrete or an approved cementitious grout.

15

The release of groundwater to its natural static level shall be performed so as to maintain the undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or backfill and prevent floatation or movement of structures, pipelines and sewers.

16

No dewatering system shall be removed until infiltration testing is completed nor without the approval of the Engineer. Monitoring and settlement measurement systems shall be maintained in operation until removal is approved by the Engineer. With the approval of the Engineer, wellpoints and like items may be abandoned in place.

17

Partially completed permanent works shall not be allowed to become flooded and the Contractor shall allow for additional standby pumps and equipment required to ensure this. A pump operator shall be on site 24 hours per day to supervise pumping equipment.

18

In the event of partially completed trenches becoming flooded, the Contractor shall reexcavate to formation level and re-lay the pipes.

19

The Contractor shall provide a silt-trap in any temporary drain which he may construct and prior to discharge into any permanent drain which he may wish to use for the removal of water during the construction period. The Contractor shall keep both temporary and permanent drains clear of silt to the satisfaction of the Engineer until the completion of the Contract. Any silting up of the watercourses arising from the Contractor’s failure to comply with this Clause shall be remedied at his expense whether within the Site or not.

2.3

BACKFILL

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2.3.1

Pipe Bedding

1

Pipe bedding shall be provided as shown on the Drawings or stated in the Contractor’s approved methods statement.

2

Pipe bedding shall be well compacted to a minimum void ratio to provide a high load-bearing capacity and a stable base below the pipe and shall completely fill the whole width of the trench excavated. Compaction requirements equivalent to at least 90 percent of the Standard Proctor Maximum Dry Density shall be achieved. Additional bedding necessary to fill voids created by over excavation shall be provided entirely at the Contractor’s expense.

3

Pipe bedding shall consist of granular material and shall shall conform with the following requirements: shall be free of organic and deleterious matter and shall consist of strong durable crushed un-weathered rock or stones having roughly cubical or pyramidal shaped fragments, graded and tested from a source approved by the Engineer. No reactive carbonate rock or sources with indication of local groundwater contamination shall be used.

(b)

pipe bedding material for rigid pipes shall be according to the following grading limits giving in Table 2.2.

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Table 2.2 – Gradation Requirements for Pipe Bedding, Rigid Pipes

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300 - 800 % by Mass Passing 100 80 - 100 60 - 85 20 - 55 10 - 30 0 - 10

>800 % by Mass Passing 100 90 - 100 50 – 80 40 – 70 25 – 60 10 – 40 0 - 15

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Sieve Size 25mm 20mm 14mm 10mm 5mm 2.36mm 0.300

<300 % by Mass Passing 90 - 100 50 - 85 10 - 40 0 - 10 -

(c)

(d)

The minimum thickness of pipe bedding material below the barrel of the pipe is given in Table 2.3. Table 2.3 – Minimum thickness of bedding material below barrel of pipe Uniform Soil Nominal Bore Rock Hand Finished Machine Dug (mm) Trench Bottom Trench Bottom 100 & 150 100 150 200 200 - 500 150 200 250 600 - 800 175 225 275 1000 & above 200 250 300 Pipe bedding and backfill to French drains shall be in accordance with Section 6, Part 14, Clause 14.9.5.

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(e)

The total loss factor for the granular material used in French drains using the ten minute rotational test shall not exceed 10%.

(f)

Chloride and sulphate levels for bedding materials shall conform to BS EN 10319.

Pipe bedding material for flexible pipes be accoding to the following grading limits given in Table 2.4.

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Table 2.4 – Gradation Requirements for Pipe Bedding, Flexible Pipes Pipe Diameter (mm) <300 ≥300 Sieve Size % by Mass Passing % by Mass Passing 14mm 90 - 100 10mm 50 - 85 50 - 85 5mm 10 - 40 0 - 10 2.36mm 0 - 10 0 - 10

ta

The minimum thickness of granular bedding material around the barrel of the pipes shall be 100mm. Should the Contractor exceed the trench widths given in Table 2.1 he shall precede as Clause 4.3.2 of this Section. The design of GRP and PE pipes and bedding is specified in Parts 3 and 4 of this Section. Granular bedding materials for GRP pipe shall be 10mm nominal size according to the grading limits given in Table 2.4 and also meet the manufacturer’s requirements.

6

After trimming and compaction of the formation, granular bedding material shall be spread in the trench bottom.

7

Cut-off walls shall be formed in granular bedding and surround to pipes to prevent the bedding acting as a subsoil drain. Cut-off walls shall be provided at a maximum spacing of 40 m with one at each manhole and structure and at least one cut-off wall between two adjacent manholes and structures.

8

Cut-off walls shall be made from an impervious fine grained clay mixture, prepared with addition of water where necessary, to suitable trench spoil if available, or imported. Concrete cut-off walls shall be Grade 20 SRC concrete. Cut-off walls shall be installed across the full cross-section of the granular bedding material and shall be at least 300 mm wide along the axis of the pipeline.

9

Concreting to the pipeline shall be either bed or bed and surround or encasement or backfill as shown on the Drawings or directed by the Engineer and shall be of Grade 20 SRC concrete placed as follows:

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(a)

concrete shall not be placed until the joints at each end of the pipe have been completed

(b)

each pipe to be encased shall be supported on at least two purpose made precast concrete blocks, which shall be left in place

(c)

concrete encasement shall be placed to the required depth in one operation and pipes shall be prevented from floating or otherwise moving during concreting

(d)

continuity of concrete backfill or encasement to pipe with flexible joints shall be broken at each joint, unless otherwise approved by the Engineer

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(e)

flexible joints in concrete beds and surrounds to pipes shall be formed as shown on the Drawings with suitable compressible fibrous board or other similar approved material

(f)

compaction shall be carried out with approved mechanical vibrators. The maximum period of time between mixing of the materials and final compaction of any given material shall be kept to a minimum.

Where unstable ground conditions are met which are likely to cause undue settlement in the pipeline, the Contractor shall submit a report including site data and the Contractor’s proposal for remedial works including structural calculations for the approval of the Engineer. The Contractor shall carry out the following remedial works as directed by the Engineer. (a)

improvement of mechanical properties of the soil

(b)

replacement of soil by other soil or blinding concrete

(c)

pile foundations

(d)

reinforced concrete slab foundation.

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Pipe Surround

1

Pipe surround shall be provided as shown on the Drawings or stated in the Contractor’s approved method statements.

2

When concrete cradles are used, all concrete shall have attained adequate strength before backfilling of the excavation commences between the completed structure and sides of excavations.

3

Material for pipe surround and to the first 300mm above the top of the pipe, shall be granular material as specified in Clause 2.3.1. The material shall be free from sharped edged stones or other material which may cause damage to the permanent Works.

4

Material for pipe surround shall be placed in layers of not greater than 150mm compacted thickness and thoroughly rammed with suitably shaped rammers working alternatively on either side of the pipe until the fill has been carried up at least 300mm above the top of the pipe. Care shall be taken to avoid damage to the pipe, coating or sheathing.

5

Compaction requirements equivavlent to at least 90 percent of the Standard Proctor Maximum Dry Density shall be achieved.

2.3.3

Geotextile Filter Membrane

1

Geotextile filter membrane for surround to granular material for ground water drainage shall conform with the requirements of Section 6 Part 15 Clause 15.1 and shall be used in the zone extending downwards from 1.5m above the long term water table. The long term water table is to be determined on the basis of observations made on site of the initially encountered water table in the excavations. The placement of Geotextile is then to be directed by the Engineer. Geotextile membrane for structural support to pipe surround in soft ground shall be wrapped round the granular bedding as shown on the Contract drawings.

2

For both of the above applications the geotextile properties shall be:

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2.3.2

(a)

mean peak strength BS EN ISO 10319

(b)

elongation at peak strength BS EN ISO 10319

(c)

CBR puncture resistance EN ISO 12236

8kN/m 28% 1500N

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(d)

pore size (O90) EN ISO 12956

0.15mm

(e)

permeability (50cm head) EN ISO 11058

2

100l/m .s

3

The fabric shall be woven or non-woven consisting of long chain polymeric filaments or yarns formed into a stable network such that the filaments or yarns retain their relative position to each other.

4

The fabric shall be inert to commonly encountered chemicals and chemical properties of the soil and water. Geotextile fabric shall surround the granular bedding as follows: the surface to receive the fabric shall be formed to a relatively smooth condition free of obstruction, depressions, and debris. The geotextile fabric shall be laid loosely.

(b)

if the proposed area for fabric requires more than one panel width of fabric, the panels shall be overlapped a minimum of 15 percent of the panel width

(c)

to prevent slippage of the overlapping fabric, the areas of overlap shall be stabilised, as approved by the Engineer, with pins, anchor blocks, or piles of aggregate

(d)

fabric damaged or displaced before or during installation or during placement of backfill material shall be repaired or replaced

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(a)

Backfilling Excavation

1

All concrete shall have attained adequate strength before backfilling of the excavation commences between the completed structure and sides of excavations.

2

Selected fill material for trench backfill in open areas, shall be suitable material selected from the excavated material as specified in Clause 2.2 of this Part. Stones larger than 150 mm in size may be allowed, provided in the opinion of the Engineer, the required densities can be achieved.

3

Selected fill material for trench backfill under paved areas, shall be suitable material selected from excavated materials meeting the following requirements: (a)

maximum stone size of 75m

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(d)

the uniformity coefficient shall not be less than 10

(e)

the total water soluble / acid soluble salt content (for sulphate and chloride) shall not exceed 2%

(f)

organic content shall not exceed 2%

(g)

the CBR value shall not be less that 15% at 95% maximum dry density at the formation level. The test procedure shall be as Section 6, Clause 3.10 of the specification.

the material passing the 0.063 sieve shall be less than 15%

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the liquid limit shall not exceed 35% and the plasticity index shall not exceed 6%

4

The trench backfill material shall be placed in layers of not greater depth than 200mm thickness and be thoroughly compacted to 95 percent of the Standard Proctor Maximum Dry Density by approved mechanical compaction equipment. In roads and footpaths, the coarse filling is to be carried up to the level at which surface reinstatement is to begin; elsewhere, to such level as with the surface reinstatement of the whole of the topsoil will leave the finished work sufficient to allow for future settlement to the original ground level.

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The moisture content of the material before compaction shall not vary by more than ±2% of the optimum moisture content (BS 1377 Part 2:1990, Test 3.2). If in the opinion of the Engineer, the fill is too dry, it shall be watered at the expense of the Contractor in an approved manner during refilling as may be directed by the Engineer.

6

Any nuclear density measurement (NDM) tests undertaken shall be performed only by persons or companies holding a valid Authorised User Certificate issued by the Materials Central Laboratory. Each NDM device shall have a valid Calibration Certificate, also issued by the Central Materials Laboratory.

7

The Contractor shall provide the necessary testing apparatus for monitoring soil properties and shall maintain the apparatus in good working order. A daily log of tests carried out shall be provided to the Engineer. Testing of soil properties shall be carried out by an approval laboratory.

8

Tests to determine the optimum dry density of the fill material shall be carried out as directed on site, the frequency depending on consistency of material and test results.

9

Unless directed otherwise, testing for density and moisture content shall be at the rate of:

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one test per backfill layer for each structure such as manholes, chambers, and thrust blocks

(b)

one test per backfill layer for every 30 m of pipeline trench.

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(a)

Should the backfilling material being placed become unacceptable to the Engineer due to exposure to weather

(b)

flooding

(c)

having become puddled, soft, segregated

(d)

otherwise unacceptable during the progress of work

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the Contractor shall at his own expense remove such damaged, softened or segregated material and replace it with fresh approved material. To permit the proper consolidation of backfill into the voids behind trench sheeting and supports, trench sheeting shall be withdrawn gradually as backfill progresses in depth and along the trench.

12

On no account shall any excavated material be dozed back when filling trenches in roads and no filling shall be carried out unless in the opinion of the Engineer, sufficient mechanical compactors are in operation on that portion of the work.

13

Where in the opinion of the Engineer sufficient supplies of the suitable material for trench backfilling cannot reasonably be obtained from excavations the Engineer may order the Contractor to:

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(a)

carry out such work as may be necessary to screen out stones

(b)

borrow excavate material from suitable borrow areas on the Site or off the Site and transport it to the length of trench to be filled to the approval of the Engineer. All costs for borrow material shall be borne by the Contractor.

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14

Trench backfilling shall be carried out expeditiously as soon as practicable after the pipeline has been laid, tested and approved.

15

Trench bottom shall be free of any foreign material or backfill contaminated with foreign material from the trench bottom.

16

Check grade and correct irregularities in bedding material. Loosen top 25-50 mm of compacted bedding material with a rake or by other means to provide a cushion before laying each section of pipe, conduit, direct-buried cable, or duct bank.

17

Place backfill material simultaneously in lifts on both sides of pipe and, if applicable, between pipes, conduit, cables, and duct banks installed in the same trench. Pipes up to and including 250 mm in diameter: First lift of backfill less than or equal to 1/2 pipe diameter.

(b)

Pipe over 250 mm in diameter: Maximum 150 mm lifts.

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Thoroughly tamp each lift, including the area under haunches, with handheld tamping bars supplemented by “walking in” and slicing material under haunches with a shovel to ensure that voids are completely filled before placing each succeeding lift.

19

After the full depth of the pipe zone material has been placed as specified, compact the material by a minimum of three passes with a vibratory plate compactor only over the area between the sides of the pipe and the trench walls.

20

Do not use power-driven impact compactors to compact pipe zone material.

21

Backfill used above pipe zone shall be processed to meet specified gradation requirements. Adjust moisture content as necessary to obtain specified compaction.

22

Do not allow backfill to free fall into the trench or allow heavy, sharp pieces of material to be placed as backfill until after at least 600 mm of backfill has been provided over the top of the pipe.

23

Do not use power driven impact type compactors for compaction until at least 1.2 m of backfill is placed over top of pipe.

2.3.5

Backfilling Excavations with Cement-Bound Granular Material

1

Backfilling excavations with cement-bound granular material shall be used for filling excavations at manholes, access shafts, pipe line structures in roadways, underneath exposed existing pipelines or as approved by the Engineer.

2

Cement-bound granular material shall consist of crushed, hard, clean, durable rock or washed sand or a combination thereof. The material shall be sufficiently well-graded to ensure a well-closed surface finish and have a grading within the range shown in Table 2.4

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Table 2.4 – Grading for cement-bound granular material BS 410 sieve size


50 mm 37.5 mm

100 95 - 100

20 mm

45 - 100

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10 mm 5 mm 600 m 300 m 75 m

35 - 100 25 - 100 8 - 65 5 - 40 0 - 10

The granular material shall be mixed with sufficient cement to provide the crushing strength specified in Paragraph 12 of this Clause. The material shall be mixed in a paddle or pan type mixer which may be batch or continuous type. Where a batch mixer is used, the mixing times shall not be less than one minute unless the Engineer approves a shorter time subject to the results of preliminary trials. Where a continuous mixer is used, the paddles, baffles and rate of feed of materials shall be adjusted to provide a uniformly mixed material. Where a spray is used for distributing water into the mixer, it shall be adjusted to provide a uniform moisture content throughout the mix.

4

The moisture content of the mixed material shall not exceed 2 % above the optimum as determined in accordance with the Vibrating Hammer Test of BS 1924.

5

The Contractor shall carry out preliminary tests on trial mixes to attain the specified crushing strength.

6

Plant-mixed material shall be transported to the site by vehicles which shall have capacities suited to the output of the mixing plant and site conditions, and be capable of clean discharge. Mixed material shall be immediately transported to its required location and shall be suitably protected from the prevailing climatic conditions during transportation and the period before tipping.

7

All mixed material shall be placed and immediately spread evenly in one layer such that after compaction the thickness does not exceed 150 mm.

8

Compaction in trenches shall be carried out immediately after the material has been spread and completed within two hours of the addition of cement.

9

Compaction shall be carried out to achieve a density equivalent to 95 % of the average density of the set of five cubes required for testing in paragraph 12 of this Clause.

10

Any layer of cement-bound granular material not covered within two hours shall, immediately on completion, be cured for a minimum period of 7 day unless otherwise approved by the Engineer or the surface is covered by permanent works. Surface curing shall be achieved by covering with impermeable plastic sheeting until the next permanent layer is laid. The plastic sheeting shall be adequately secured to the surface and joints shall be have a minimum 300 mm overlap, set to prevent egress of moisture.

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Samples of the mixed material shall be taken from the site immediately before compaction of the material. A batch of five random samples shall be taken from each layer or such other area as decided by the Engineer. From each sample a cube test specimen shall be prepared, cured and tested using the procedure in BS 1924. The specimens shall be compacted to be within 95 % of the cube density when compacted by vibratory hammer. The specimens shall then be cured at constant moisture content within the range of curing temperatures stated in BS 1924 for a period of 7 days. The specimen shall then be weighed, the dimensions checked and tested in unconfined compression. A representative portion of the crushed material from each specimen shall then be retained for a moisture content determination in accordance with BS 1924 and the dry density of each specimen determined using mass, dimensions and the moisture content of the material.

12

The average 7 days crushing strength for each batch of five test specimens made and tested in accordance with the method described herein shall be not less than 3.5 MPa for cubes. In addition to complying with the minimum strength requirements, the root mean square of the coefficient of variation of the crushing strength of five successive batches of five test specimens of the cement-bound granular material shall not exceed 25 %. If an area or layer of cement-bound granular material represented by these specimens fails these tests, the defective material shall be removed and replaced with new material at the Contractor’s expense.

13

The cement-bound granular material shall in no case be less than 150 mm thick from the outside barrel of the pipe to the nearest point of the shoring, and the greatest care shall be exercised to ensure complete filling of all voids and thorough consolidation of the concrete. The Contractor shall allow in his prices for the additional concrete used in excess of the net requirement.

14

Cement – Bound Granular Material discharged from truck mounted drum type mixer into trench shall:

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Placed in lifts as necessary to prevent uplift (flotation) of new and existing facilities.

(b)

In travelled areas, fill entire trench section to pavement finish grade for a temporary driving surface, and screed off excess and finish with a float.

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In other areas, fill the trench section as shown on the Contract Drawings.

Backfilling Excavation with Flowable Fill (Foamed Concrete)

1

Backfilling excavations with flowable fill shall be used for filling excavations at manholes, trenches, access shafts, pipeline structures in roadways, underneath exposed existing pipelines or as approved by the Engineer.

2

Flowable fill may be placed by chutes, conveyors, buckets or pumps depending upon the application and accessibility.

3

For trench backfill, flowable fill shall be placed continuously. To contain the flowable fill along long open trenches or open ended structures in stages, the end points shall be adequately bulkheaded to prevent movement.

4

Flowable fill shall be placed in a manner to prevent flotation or displacement of the embedded item.

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The 28-day compressive strength of the flowable fill shall be 5 MPa with a unit density of 3 between 1600 – 2000 kg/m . Accelerators may be used subject to the approval of the Engineer.

2.3.7

Backfilling Next to Pipeline Structures

1

Fill materials adjacent to structures such as manholes and chambers shall be placed in accordance with Clause 2.3.4 above.

2

Fill material next to structures other than pipeline structures shall be carried out as Specified in Section 12.

2.3.8

No-Fines Concrete as Trench Backfill

1

Except where otherwise noted in this Clause, the design, manufacture, use and testing of nofines concrete shall comply with the requirements of Section 5 Part 6.

2

All material shall be placed and spread evenly. The full width of the excavated trench shall be filled; formwork other than that required for temporary constructions joints will not be permitted. The Contractor shall be responsible for the use of any extra material required to fill the trench beyond the maximum trench widths detailed on the drawings. The no-fines concrete shall generally be brought up to a height no higher than the level of undisturbed rock on either side of the trench.

3

Compaction shall be carried out with approved mechanical vibrators. The maximum period of time between mixing of the materials and final compaction of any given material shall be kept to a minimum.

4

Any layer not covered within 2 hours by another layer of no-fines concrete shall, immediately on completion of compaction, be cured for a period which shall not be less than 7 days unless the Engineer agrees otherwise. Curing shall be achieved by covering until the next layer is laid with impermeable plastic sheeting, adequately secured from being blown off the surface and with joints overlapped at least 300mm and set to prohibit egress of moisture.

2.4

REINSTATEMENT OF SURFACES

2.4.1

Reinstatement within the Highway

1

All reinstatement of roadworks to be carried out in the public highway shall be carried out in accordance with the latest “Code of Practice and Specification of Road Openings in the Highways”.

2.4.2

Reinstatement of Surfaces Other Than in the Highway

1

Unless provided in the Project Specification, surfaces shall be restored to a condition conforming to the requirements for the particular surface described in the relevant section of this Specification. Where no specification exists, restoration shall be to the satisfaction of the Engineer.

2

All surfaces, gardens or lawns shall be restored to a condition equal to the original surface to the satisfaction of all Authority requirements, the Engineer and the owners/occupiers.

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Any reinstatement shall be fully maintained by the Contractor until such time that a TakingOver Certificate has been issued for the Works or for the Part of the Works containing the reinstatement.

2.5

EXISTING SERVICES

1

The requirements of this Subpart are in addition to the general requirements specified in Clause 2.1.5 of this Part.

2

The Contractor shall be required to submit in advance to the various Utilities Services Departments and to the relevant Municipality where the Works affect the trees and plants and a weekly programme of the pipelines he intends to lay in order that the various departments can expose or advise on the location of their respective services.

3

Except as otherwise designated in the Project Specification, the Contractor shall be responsible for maintaining all services and utilities including but not limited to waterways, sewers, drains, gas and oil mains, water mains electricity and telecommunication cables and all other services, structures, trees, and plants encountered during the construction of the Works and for any remedial measures necessary to make good any damage caused thereto.

4

Where designated in the Project Specification, work on services shall be carried out by the relevant Utility Service Department. The Contractor shall co-ordinate his work with the work of the Utility Service Department, and carry out his work so as not to interfere with or damage their services.

5

Where work is carried out close to or across the line of existing services, the Contractor shall where necessary provide temporary supports or slings. Where service is interfered with or damaged, the Contractor shall immediately notify the relevant Utilities Service Department and shall not undertake repairs without their authorisation and approval. Unless otherwise authorised and approved, repairs shall be undertaken by the Utilities Service Department and the cost of such work shall be borne by the Contractor, and the Contractor shall reimburse the Utilities Service Department its account for performing such work.

6

Where specified on the Drawings or by the relevant Utility Service Departments split ducts, conforming with the requirements of Clause 2.7.1 of this Part shall be provided for the permanent support and protection of services.

7

The Utility Service Department and the Engineer shall determine whether or not a service requires to be permanently diverted, temporarily diverted or supported.

8

Where existing services have to be permanently or temporarily diverted as the unavoidable result of the construction of the Works, such diversions shall be carried out either by the Contractor or the Utilities Service Department as directed by Engineer.

9

Safety shall always be maintained in all work in the vicinity of existing services in accordance with particular requirements of Utilities Service Department and the requirements of Section 1 and Part 1 of this Section.

10

In addition to the provisions of the above paragraphs, when carrying out pipelaying operations in the vicinity of existing gas or oil pipelines, the following requirements shall apply:

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(a)

the minimum clearance between the bottom of the oil or gas line and the top of the pipeline being constructed is to be 600 mm

(b)

a hand excavated pilot hole shall be dug to determine the gas or oil line invert level and position prior to any trench excavation in gas or oil pipeline reservation

(c)

the excavation for the pipeline under construction must be carried out by hand up to

(d)

2.0 m either side of the existing gas or oil pipeline manually operated jack hammers may be used within 5.0 m of the buried pipeline only after completion of item (c) above

(f)

the use of mechanical or hydraulic rock-breakers shall not be allowed within 5.0 m of the buried pipeline

(g)

before the exposure of live pipeline the Contractor is to erect a suitable substantial barrier to prevent damage to the exposed pipeline.

(h)

on completion of the concrete surround to the pipelines under construction, the existing gas or oil pipeline shall be rebedded with a minimum of 150 mm of naturally occurring soft dune sand bed and surround. The remaining backfill and bund shall be made up of selected desert fill with a particle size not exceeding 150 mm which shall be free from organic matter. The Qatar Petroleum (QP) (onshore) Engineer shall be notified a minimum of 24 h in advance, to witness the backfilling operation

(i)

damage to the external protective wrapping to the gas or oil pipeline shall be reported promptly to the QP who will arrange for the damage to be inspected and repaired in strict accordance with QP (onshore) procedures at the Contractor’s cost

(j)

the Contractor is to provide constant competent supervision whilst work is carried out next to the existing gas or oil pipelines

(k)

when the works reach 15 m from the existing gas or oil pipeline, the Contractor shall contact the QP (onshore) Engineering Superintendent, who will arrange the necessary permit to work. QP (onshore) will require a minimum of 48 h notice before work begins

(l)

a QP (onshore) permit to work does not in any way make QP (onshore) responsible for any of the Contractor’s work, nor does it absolve the Contractor from his responsibilities for complying with the above, but only allows the Works to be carried out in accordance with the agreed working methods and practices. QP (onshore) reserve the right to visit the site regularly to observe that the agreed methods and practices are being adhered to and to stop the work and withdraw the permits to work should they consider there is adequate justification to do so

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the requirements of QP (onshore) may vary from and are not necessarily limited to the foregoing.

2.6

BLASTING

1

The Contractor shall not use any explosives in the construction of the works without the prior written approval of the Engineer and such approval shall be contingent upon the Contractor being authorised by the Civil Defence Department and the Police.

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The Contractor shall inform the Engineer in advance about the types and quantities of explosives needed. Explosives shall be obtained and used in accordance with the regulations and procedures of the relevant Government Department. The Contractor shall be deemed to have copies of relevant documentation and to be knowledgeable of relevant practices. The Contractor shall provide copies of relevant documentation to the Engineer for the Engineer’s inspection.

3

Notwithstanding the requirements of this Clause, the Contractor is responsible for the safe and correct transport, handling and use of explosives.

4

Except as otherwise provided in the relevant regulations and procedures the handling of explosives shall be carried out to conform with the requirements stated in the following paragraphs.

5

Except as otherwise permitted by the Government, all unused explosives, or explosive accessories shall be destroyed at the end of each day’s work.

6

Explosives and detonators shall be carried in separate vehicles during transport. The vehicles must be clean and in a good state of repair and be of sufficient capacity to convey the explosives safely. The Police may refuse to issue explosives if vehicles do not meet those standards. A red flag must be clearly displayed by all vehicles when carrying explosives.

7

The Contractor must appoint in writing at least one shotfirer who is in possession of a Qatar Shotfirer’s Certificate of Competence to carry out all work with explosives on behalf of the Contractor. The Contractor shall present and provide copies of such certification to the Engineer for inspection.

8

The Contractor must establish simple safety rules covering the handling and use of explosives. A copy of these rules will be given to the concerned shotfirer, who will sign a receipt book kept for this purpose by the Contractor.

9

The safety rules shall specify: (a)

the places where explosives are to be used times of blasting

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(c)

measures to be taken to contain the products of blasting

(d)

method of initiation

(e)

posting of warning notices, yellow blasting flags and sentries; and audible warning, if applicable

(f)

actions to be taken in the event of any unusual occurrence or accident

(g)

any other safety aspects relating to the use of explosives

(h)

any special instructions concerning transport

(i)

instructions relating to the limitation of blast vibrations, where appropriate.

The Contractor shall submit a copy of the safety rules to the Engineer.

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Shotfirers shall be responsible to the Contractor for ensuring that all explosives and accessories are safely and carefully handled and used, in accordance with the regulations and procedures of the Government, and his own knowledge of correct shotfiring procedure.

12

Where so directed by the Engineer, the Contractor shall provide and operate suitable instruments to monitor and record the blast vibrations at no additional cost to the Employer.

13

Where blasting vibration could cause nuisance; e.g., in close proximity to buildings, pipelines or other structures, the Contractor shall ensure that careful attention is given to the vibration levels to minimise nuisance.

2.7

MISCELLANEOUS

2.7.1

Service Ducts

1

The Contractor shall furnish and install new protection ducts of split PVC-U pipes, concrete encased, to protect existing utility mains or cables where new pipelines are to cross such utility mains or cables.

2

After the split PVC-U pipe has been placed around the existing utility mains or cables, the pipe shall be wrapped twice with polyethylene film, 150 m thick, to prevent fresh concrete from entering the duct. The protection ducts shall be supported on suitable non-corrosive spacers before placing the concrete encasement.

3

All concrete work shall be in accordance with the requirements of Section 5 and concrete encasement shall be with Grade 20 SRC concrete.

2.7.2

Formation of Bunds and Embankments

1

The material used in the formation of embankments bunds and other areas of fill shall be obtained by the Contractor from sources approved by the Engineer. The material shall equate to selected excavated material or similar.

2

Bund and embankment material at the optimum moisture content shall be built up evenly over the full width and compacted in layers not exceeding 300 mm in compacted depth. The moisture content of material may require adjustment to that required to attain maximum density. Material which contains insufficient moisture to obtain the desired compaction will require the incorporation of additional water by the use of approved sprinklers and mixing.

3

Layers more than 300 mm below road formation levels shall be compacted to 90 % of the maximum dry density. Layers less than 300 mm below road formation level shall be compacted to 95 % of the maximum dry density. Maximum dry density shall be determined in accordance with CML 12-97

4

The Contractor shall ensure that material laid immediately next to a structure, concrete wall or thrust block is well compacted. Hand operated vibrating plate compactors vibro-tampers or power rammers shall be used. In other cases, compaction shall be carried out by vibrating compactors smooth wheel or pneumatic tire rollers of types approved by the Engineer.

5

In forming bunds and embankments, the Contractor shall make allowance for consolidation and shrinkage in attaining the dimensions of bunds and embankments shown on the Drawings.

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6

The Contractor shall make due allowance for consolidation and settlement of embankments and bunds both in width and height. Any subsidence that may occur during the period of maintenance shall be corrected by the Contractor at no additional cost and to the satisfaction of the Engineer.

7

Round tops of cut slopes in soil to not less than a 1.8 m radius, provided such rounding does not extend offsite or outside easements and rights-of-way, or adversely impacts existing facilities, adjacent property, or completed Work.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 03: Pipes and Fittings Materials

Page 1

3

PIPES AND FITTINGS MATERIALS ....................................................................... 3

3.1

GENERAL .................................................................................................................................3

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6

Scope References System Description Submittals Delivery, Handling and Storage Pipe Materials

3.2

VITRIFIED CLAY PIPES AND FITTINGS ..............................................................................10

3.2.1 3.2.2 3.2.3 3.2.4

Standards Manufacture Inspection and Testing Repair Couplings for VC Pipes

3.3

CONCRETE PIPES AND FITTINGS ......................................................................................11

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6

Standards Pipe Materials Manufacture Plastic Lining Epoxy Coating Inspection and Testing

3.4

GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS ..........................................14

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7

Standards Design Pipes and Fittings Manufacture General Buried GRP Exposed GRP Inspection and Testing

3.5

PVC-U PIPES AND FITTINGS ...............................................................................................25

1.1.1 3.5.2 3.5.3 3.5.4 3.5.5

Standards Manufacture Joints Inspection and Testing Inspection and Testing

3.6

ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS ..........................28

3.6.1 3.6.2 3.6.3 3.6.4

Standards Manufacture Joints Inspection and Testing

3.7

DUCTILE IRON PIPES AND FITTINGS .................................................................................28

3.7.1 3.7.2 3.7.3 3.7.4 3.7.5

Standards Exposed Joints Buried Joints Internal Lining External Coating and Wrapping, Use and Materials

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3 3 5 5 6 9 10 10 11 11 11 11 12 13 13 13 14 16 17 17 17 23 24 25 26 27 27 27 28 28 28 28 28 28 29 29 29

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3.7.6 3.7.7 3.7.8

Factory Application of Tape Wrapping Factory Applied Extruded Polyethylene Coating Inspection and Testing

3.8

FLANGE ADAPTERS AND FLEXIBLE COUPLINGS ...........................................................32

3.8.1 3.8.2 3.8.3

General Flange Adapters Flexible Couplings

3.9

PIPES FOR OTHER USE .......................................................................................................33

3.9.1 3.9.2 3.9.3 3.9.4

Copper Tubes and Fittings Hose and Appurtenances Stainless Steel Pipes, Tubes and Fittings Carbon Steel Pipes and Fittings

3.10

MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES .......................................34

3.10.1 3.10.2 3.10.3 3.10.4 3.10.5

Applicable Standards Manufacture Fittings Pipes and Fittings for Gravity Applications Testing of MDPE and HDPE Pressure Pipes and Fittings

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.

33 33 33 34 34 35 37 38 38

qa

o

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General Resin Minimum strength

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3.11.1 3.11.2 3.11.3

32 32 33

POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-PRESSURE DRAINAGE AND SEWERAGE ...............................................................................................41

m

3.11

31 31 31

41 41 41

QCS 2014


Page 3

PIPES AND FITTINGS MATERIALS

3.1

GENERAL

3.1.1

Scope

1

This Part includes the manufacture, factory testing and supply of pipes and appurtenances of different materials for use in pipelines.

2


.l. l

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ta

Concrete Plumbing Works Drainage Works to Buildings.

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Section 5 Section19 Section 20

General Pipeline Installation Valves, Penstocks and Appurtenances Miscellaneous Metal Works Miscellaneous GRP Works Protective Coatings and Painting Sewer Rehabilitation Vacuum Sewerage System

qa

This Section ........................ Part 1 ........................ Part 4 ........................ Part 5 ........................ Part 6 ........................ Part 7 ........................ Part 8 ........................ Part 11 ........................ Part 12

.

3

References

1

The following standards or revised/updated versions are referred to in this Part:

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se

3.1.2

ov

ANSI B16.3.................Malleable Iron Threaded Fittings ANSI B16.5.................Steel Pipe Flanges and Flanged Fittings

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ANSI B16.9.................Factory-Made Wrought Steel Butt Welding Fittings

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ANSI B16.11...............Forged Steel Fittings, Socket Welded and Threaded ANSI B16.28...............Wrought Steel Butt Welding, Short Radius Elbows and Returns

m

ANSI B 36.19..............Stainless Steel Pipe ASTM A53 ..................Standard specifications for Pipe, Steel, Black and Hot-dipped, Zinccoated Welded and Seamless ASTM A105 ................Standard specifications for Forging, Carbon Steel, for Piping Components ASTM A182 ................Standard specifications for Forged or Rolled Alloy-steel Pipe Flanges, Forged Fittings, Valves and Parts for High Temperature Service ASTM A234 ................Standard specifications for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures ASTM A240 ................Standard specifications for Heat-Resisting Chromium and ChromiumNickel Stainless Steel Plated, Sheet and Strip for Pressure Vessels ASTM A312 ................Standard specifications for Seamless and Welded Austenitic Stainless Steel Pipes

QCS 2014


Page 4

ASTM A403 ................Standard specifications for Wrought Austenitic Stainless Steel Piping Fittings ASTM A774 ................Standard specifications for As-Welded, Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperature ASTM A778 ................Standard specifications for Welded Unannealed Austenitic Stainless Steel Tubular Products ASTM D1000 ..............Standard Test Methods for Pressure-Sensitive Adhesive-Coated Tapes Used for Electrical and Electronic Applications ASTM D1004 ..............Standard Test Method for Initial Tear Resistance of Plastic Film and Sheeting

.l. l

.

ASTM D2412 ..............Standard Test Methods for External Loading Characteristics of Plastic Pipe by Parallel Plate Loading

rw

ASTM D2584 ..............Standard Test Method for Ignition Loss of Cured Reinforced Resins

ta

ASTM D3681 ..............Standard Test Method for Chemical Resistance of “Fiberglass” (GlassFiber-Reinforced Thermosetting Resin) Pipe in a Deflected Condition

as

qa

AWWA C209 ..............Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines

se

BS 65:1991.................Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for use solely with surface water pipes and fittings BS 864........................Capillary and compression tube fittings of copper and copper alloy

er

BS 2494......................Elastomeric seals for joints in pipework and pipelines

ov

BS 2782......................Methods of testing plastics BS 3063......................Dimensions of gaskets for pipe flanges

o

BS 3396......................Woven glass fibre fabrics for plastics reinforcement

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BS 3532......................Method of specifying unsaturated polyester resin systems

m

BS 3749......................“E” Glass fibre woven rovings for the reinforcement of polyester and epoxy resin systems BS 4027......................Specification for Sulphate-resisting Portland cement BS 4346......................Joints and fittings for use with unplasticised PVC pressure pipe BS 5391...................... Acrylonitrile butadiene-styrene (ABS) pressure pipe BS 5392...................... Acrylonitrile butadiene-styrene (ABS) fittings for use with ABS pressure pipe. BS 5556......................General requirements for dimensions and pressure ratings for pipe of thermoplastic materials BS 5911......................Concrete pipes and ancillary concrete products BS 5955......................Code of practice for plastic pipework (thermoplastic materials) BS 6076......................Tubular Polyethylene film for use as protective sleeving or buried iron pipes and fittings BS EN 197..................Cement BS EN 295..................Vitrified clay pipes and fittings and pipe joints for drains and sewers

QCS 2014


Page 5

BS EN 545..................Ductile iron pipes, fittings, accessories and their joints for water pipelines - Requirements and test methods BS EN 598 ----------- ...Ductile iron pipes, fittings, accessories and their joints for sewer pipelines - Requirements and test methods BS EN 639..................Common requirements for concrete pressure pipes including joints and fittings BS EN 642..................Prestressed concrete pressure pipes BS EN 1057................Copper and copper alloys BS EN 1092................Flanges and their joints BS EN 1401................Plastic piping systems BS EN 12620..............Aggregates for Concrete

.

BS EN 13244..............Plastic piping systems

.l. l

BS EN 14020..............Reinforcements. Specification for textile glass rovings

rw

BS EN 14118..............Reinforcement. Specifications for textile glass mats

BS EN 14364 & BS EN 1796 ---- Glass-reinforced thermosetting plastics (GRP)

ta

BS EN ISO 1456 ........Metallic and other inorganic coatings

qa

DIN 30674-3 ...............Coating of ductile cast iron pipes; zinc coating with protective covering

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ISO 4179 ....................Ductile Iron Pipes for Pressure and Non-Pressure Pipelines, Centrifugal Cement Mortar Lining, General Requirements

er

se

ISO 4633 ....................Rubber Seals - Joint Rings for Water Supply, Drainage and Sewage Pipelines - Specification for Materials. System Description

1

Pipes and fittings, except for those used in treated sewage effluent pipelines, shall be suitable for carrying sewage at temperatures of up to 45C with hydrogen sulphide concentrations up to 400 mg/l.

2

Treated sewage effluent pipelines shall be suitable for chlorine concentration up to 15 mg/l.

3

Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting the following characteristics unless otherwise specified:

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3.1.3

SO3 Content Cl Content pH Conductivity

: : : :

1.7 g/l 1.07 g/l 8.6 4000 µs/cm

4

The Contractor's attention is drawn to the stringent limits on infiltration detailed in Clause 4.5.2 of this section.

5

The Contractor shall be responsible for providing a jointing system as recommended by the pipe manufacturer that enables the installation and use of the designated pipeline systems.

3.1.4

Submittals

1

The Contractor shall order materials to suit the construction programme and obtain the Engineer’s approval of submittals before placing orders. The Contractor shall submit two copies of the following documents for the approval of the Engineer:

QCS 2014

(a)


Page 6

product data (i)

originals of catalogues and engineering data sheets for manufactured items. Each item and option to be provided shall be clearly marked and each item not to be provided shall be deleted

(ii)

literature to show that products provided meet the requirements for material, construction, operation, and tests

(iii)

information on the following items as a minimum:  pipes  flexible couplings  gaskets

.

 isolating joints

.l. l

 sealant systems

manufacturer’s installation instructions for all items

(v)

certified reports for all tests and inspections designated herein, signed and sealed, showing full compliance with referenced standards

(vi)

maintenance requirements and procedures

(vii)

period of guarantee for products

(viii)

Manufacturer’s test reports for hydrostatic proof testing, sustained pressure testing and burst strength testing.

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as

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shop drawings

Piping material, class, grade and joint type, thickness or schedule, seam or seamless, coating information if applicable.

(ii)

fittings, couplings, and joints

(iii)

for concrete pipes, details of reinforcement, concrete and joints for straight

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(i)

(iv)

pipes, specials and connections

design data

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(c)

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(iv)

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(b)

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 linings and protective coatings

(i)

If glass reinforced plastic (GRP) pipes with a stiffness exceeding designated values by more than 30 percent are proposed, the Contractor shall include in his submittal complete structural design calculations indicating the effect of the proposed variation in pipe stiffness of the deformation modulus of the bedding material or any other related aspect

3.1.5

Delivery, Handling and Storage

1

Each pipe, fitting and special appurtenance shall be marked with permanent identification which shall include but not necessarily limited to the following: (a)

nominal diameter

(b)

name or trade mark of manufacturer

(c)

serial number

(d)

class of pipe, pressure rating in compliance with referenced standards

QCS 2014

Page 7

(e)

date of manufacture

(f)

type of service

(g)

details on fittings such as angle of change and taper

(h)

circular concrete pipes with asymmetrical reinforcement shall have the letter "T" clearly marked on the inside and outside to indicate the top of the pipe when laid.

The acceptability of the pipes and fittings on delivery to the Site will be based on the results of tests carried out by one or more of the following: (a)

the manufacturer at the place of manufacturer

(b)

the Engineer

(c)

a third party on behalf of the Engineer

.

2


The Engineer shall be permitted at all reasonable times to visit places of manufacture to witness tests.

4

The Engineer may require checking of the dimensional accuracy of GRP pipes and fittings at the place of manufacture, the cost of such verification shall be borne by the Contractor.

5

Transport, handling and storage of pipes and fittings shall be carried out as follows:

rw

ta

qa

in accordance with the manufacturer’s recommendations subject to the approval of the Engineer

(b)

effective precautions shall be taken to prevent damage to the pipe and fittings.

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(a)

er

During transport

pipes and fittings shall be well secured and adequately supported along their length

(b)

bolsters and binding of approved type shall be used

(c)

nesting of pipes (placing a smaller pipe inside a larger) may be permitted for pipes of certain materials and size provided that methods statements demonstrate that effective precautions will be taken to protect all pipe surfaces and coatings from damage

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(a)

(d)

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6

.l. l

3

(e)

pipes and fittings of plastic materials shall be covered.

m

no pipe shall overhang the end of a vehicle

7

Handling shall be carried out as follows: (a)

pipes should be lifted singly and not handled as bunches

(b)

pipes shall be handled only by means of (i)

approved hooks, of the type having a plate curved to fit the curvature of the inside of the pipe, on ends of sections

(ii)

fabric slings not less than 250 mm wide

(iii)

other methods approved for the pipe used

(c)

use of wire rope, chains and fork lift trucks will not be permitted

(d)

for strings of pipe longer than the standard length precautions shall be taken to avoid curvature and longitudinal stress in excess of allowable limits

QCS 2014

(e)

Page 8

pipes and fittings of plastic materials (i)

smaller than 300 mm diameter may be handled manually, larger than 300 mm diameter and greater than 4 metres in length shall be lifted using fabric lifting straps or large diameter rope slings positioned at a quarter of the pipe length from each end

(ii)

there should be enough slack in the slings to keep the hook approximately 600 mm over the pipe

(iii)

steel chain or hooks shall not come into contact with the pipe

VC pipes and fittings shall be transported in pallets and handled only with suitable equipment

(g)

pipes and fittings shall not be dropped or bumped

(h)

pipes shall not be dragged over the ground

(i)

if rolled, pipes shall be rolled only over adequate timber bearers to prevent damage

(j)

where necessary, chocks shall be used to prevent lateral movement of pipes.

ta

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.l. l

.

(f)

qa

All pipes, fittings and materials shall be stored in accordance with the manufacturer's recommendations and the following: pipes may be stored in the open on a flat level area and raised above the ground on timber bearers so that the lowest point of any pipe or fitting is not less than 150 mm above the ground

(b)

timber bearers not less than 200 mm wide and 75 mm thick to be provided at 4 m intervals maximum

(c)

if on pallets or crated, on the pallets or in their crates until required

(d)

if not on pallets or not crated, stacked one above the other as follows:

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(a)

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8


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in accordance with the manufacturer’s recommendations but not to a greater number of tiers than the following:

m

........................ pipes  900 mm diameter ........................ < 900 mm  600 mm diameter ........................ < 600 mm diameter (i)

2 tiers 3 tiers 4 tiers

suitable protective packing shall be placed between tiers to the approval of the Engineer

(ii)

9

wrapped pipes shall not be stacked

(e)

if spigot and socket, stacked so that successive pipe layers have sockets protruding at opposite ends of the stack

(f)

with pipes of different sizes and thickness stacked separately

(g)

with maximum height of stacked pipes not exceeding 2 m, or that recommended by the supplier if less than 2 m.

Pipes and fittings of plastic materials including GRP shall be: (a)

stored under cover and out of direct sunlight

(b)

adequately supported along their length

QCS 2014

(c) 10


Page 9

provided with a free flow of air around the pipe.

Storage of jointing materials shall be as follows: (a)

under cover

(b)

rubber ring gaskets shall

(c)

(i)

be stored in their original packing

(ii)

not be exposed to sunlight

(iii)

protected from exposure to greases and oils

gasket lubricants shall be stored so as to prevent damage to the container.

Pipes and fittings shall be protected in storage to the approval of the Engineer by means of an impermeable membrane which shall cover the pipes and fittings and separate them from the ground on which they are supported. The membrane shall be strong and durable in the prevailing climate conditions.

12

Pipes and fittings shall be subject to visual inspections after off-loading at site and before installation.

13

The following procedures shall be followed for dealing with damaged pipes and fittings:

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11

pipes and fittings damaged during transportation handling and storage shall be set aside and the damage brought to the attention of the Engineer

(b)

pipes or fittings that show signs of corrosion or deterioration during storage shall immediately be treated to arrest and prevent the corrosion or deterioration or removed from Site, as the Engineer directs

(c)

proposals for repair shall be submitted in writing for the Engineer’s approval

(d)

no attempt shall be made to repair damage without the Engineer’s approval

(e)

if in the Engineer’s opinion the nature of any damage is such that the condition of a pipe has been impaired and cannot be repaired the pipe concerned shall not be incorporated in the Works all rejected pipes shall be immediately removed from the Site

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(f)

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(a)

(g)

damaged pipe shall be replaced or repaired by the Contractor at his expense and such repairs shall be to the approval of the Engineer

(h)

the Engineer may require that any GRP pipe or fittings found to be damaged to be subjected to a further hydraulic test which shall be carried out by the Contractor, at the Contractor’s expense, in accordance with the requirements of Subpart 4.5 of this Section.

3.1.6

Pipe Materials

1

For the purposes of this specification the following shall apply: (a)

Pipes of steel, glass reinforced plastic (GRP), PVC-U and polyethylene shall be deemed to be flexible pipes.

(b)

Pipes of concrete, vitrified clay and ductile iron shall be deemed to be rigid pipes.

QCS 2014


Page 10

VITRIFIED CLAY PIPES AND FITTINGS

3.2.1

Standards

1

Pipes and fittings for foul sewerage and surface water applications shall be manufactured to BS EN 295.

2

Pipes and fittings for land drainage applications shall be manufactured to BS 65.

3

Sealing rings shall be to BS 2494 or ISO 4633.

3.2.2

Manufacture

1

Pipes and fittings shall comply with the following:

.l. l

.

3.2

pipes shall have spigot and socket type joints.

(b)

pipes shall be glazed both internally and externally.

(c)

all pipes shall be free of cracks, blisters, broken ends and other imperfections.

(d)

vitrified clay pipes shall have the minimum strength requirements shown on Table 3.2

qa

ta

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(a)

Table 3.2 – Minimum Strength Requirements

se

28

28

28

200

40

28

300

60

34

400

64

44

500

80

60

600

96

-

800

96

-

1000

95

-

ov

o et it m

Land Drains (Perforated)

28

150

2

Foul / SW (Non-Perforated)

er

100

as

Min. Crushing Strength (FN) kN/m Nominal Bore (mm)

Joints shall be as follows: (a)

Pipes and fittings shall be supplied with flexible mechanical joints of the spigot and socket type joints.

(b)

Sealing rings shall be of elastomeric material suitable for foul sewerage and surfacewater drainage works, as the case maybe, conforming to BS 2494 or ISO 4633.

(c)

Acceptance of VC pipes on delivery is dependent upon the Contractor demonstrating that the joints are capable of meeting the water test requirement of Clause 4.5.2 of this Section.

(d)

Polypropylene sleeve couplings shall not be used.

QCS 2014


Page 11

Fittings shall be capable of withstanding the same load as the adjacent pipes or shall be provided with concrete surround.

3.2.3

Inspection and Testing

1

Barrel impermeability, straightness, crushing strength and bending moment resistance and chemical resistances tests shall be carried out in accordance with BS EN 295 at the frequency designated for the crushing strength test.

3.2.4

Repair Couplings for VC Pipes

1

Repair couplings shall be obtained from an approved manufacturer and shall consist of a moulded synthetic elastomeric sleeve which is fastened over the pipe ends by stainless steel clamping bands and be complete with a stainless steel shear ring. The repair coupling shall be suitable for use with vitrified clay pipes and shall include a bushing adapter when joining to a pipe of the same nominal bore but of a different outside diameter.

2

Repair couplings shall comply with the joint performance requirements of BS 65 and be capable of withstanding an external water pressure of 60 kPa without leaking.

3

Sleeves and bushes shall comply with the requirements of BS EN 681-1. Clamping bands and shear ring shall be made from 300 series austenitic stainless steel.

3.3

CONCRETE PIPES AND FITTINGS

3.3.1

Standards

1

Except as otherwise designated, concrete pipes and fittings shall conform to the requirements of this Subpart following standard specifications:

ov

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.

3

reinforced and unreinforced, BS 5911

(b)

prestressed non-pressure concrete pipes, BS 5911.

o

(a)

The strength requirement and other features of particular application shall be as specified in this Subpart or designated in the contract specific documentation.

3.3.2

Pipe Materials

1

Cement used for manufacturing pipes and fittings shall be Ordinary Portland cement conforming to BS EN 197-1.

2

Aggregate shall conform to BS 882.

3

Reinforcement shall conform to BS 4449 or BS 4483 as appropriate.

4

Admixture shall be used only with the written permission of the Engineer. The methods of use and the quantities of admixtures used shall be subject to the approval of the Engineer. Admixture containing calcium chloride will not be permitted.

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2

QCS 2014


3.3.3

Manufacture

1

Pipes and Fittings:

Page 12

Storage of concrete materials, mixing, curing and testing of concrete shall be in accordance with the appropriate Clauses in Section 5. Any deviation from these clauses shall be made only with the approval of the Engineer

(b)

unless stated otherwise crushing strengths of pipes shall not be less than those designated in BS 5911 for the designated classes of pipes.

(c)

Reinforced concrete pipes shall have a minimum effective length of 2.5 m except as otherwise designated or required for special purposes such as curves, closures or built in pipes.

(d)

Steel reinforcement shall be accurately placed in the concrete wall. The placement of all steel shall not vary from the designated position in the pipe wall by more than  6 mm from the nominal position. In no case shall the cover to the reinforcement be less than 25 mm.

(e)

The planes of the ends of the pipes shall be perpendicular to their longitudinal axis.

ta qa

Joints

except as specified in other Parts of this Section, pipe joints shall be supplied with flexible mechanical joints of the spigot and socket type in accordance with BS 5911, double collar or sleeve type

(b)

gasket stock shall

se

as

(a)

comply with BS 2494.

(ii)

be a synthetic rubber compound in which the elastomer is exclusively neoprene.

(iii)

solid compound shall contain not less than 50 % by volume of neoprene and

ov

er

(i)

shall not contain reclaimed rubber or deleterious substances.

o

stock shall be extruded or moulded and cured in such a manner that

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(iv)

cross-sections are dense, homogeneous and free from porosity, blisters, pitting and other imperfections.

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2

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.l. l

.

(a)

(v)

stock shall be extruded or moulded with smooth surfaces to the designated size within a tolerance of  6 % measured on joint cross-section dimensions.

(c)

the sealing ring shall be confined in a contained groove on the spigot face of each pipe section to properly position and confine the rubber gaskets in the annular space

(d)

each joint shall contain a neoprene ring gasket as follows: (i)

the gasket shall be the sole element depended upon for watertightness of the joint.

(ii)

the gasket shall be of circular cross-section unless otherwise approved by the Engineer.

(iii)

the length and cross-sectional diameter of the gasket, the annular space

QCS 2014

Section 08: Drainage Works Part 03: Pipes and Fittings Materials (iv)

Page 13

provided for the gasket, and all other joint details shall be such as to produce a watertight joint which shall not leak when pulled 13 mm over and above the initial jointing allowance.

(e)

the initial jointing allowance is the gap between the spigot and the shoulder of the socket measured parallel to the centre of the pipeline and shall not be less than 6 mm or greater than 12 mm.

(f)

Joints shall be capable of maintaining water tightness up to an angular deflection of 2° from true, in any direction.

Plastic Lining

1

Where designated concrete pipes shall be lined with polyvinyl chloride plastic (PVC) liner plate. The PVC liner plate material shall be as specified in Section 5 Part 14.6. The liner plate shall be securely fixed to the formwork before pouring concrete and all in-situ welding of the liner plate shall be carried out by skilled labour using the methods specified by the manufacturer. Purpose made units shall be used where required; e.g., at junctions.

2

The installation of liner plates in concrete pipes or structures, and the sealing and welding of joints, shall be carried out in strict compliance with all applicable specifications, instructions and recommendations of the plastic liner plate manufacturer. All welding of liner plate shall be carried out by properly trained and approved workmen.

3

Once cast into the pipe, the liner shall be permanently and physically attached to the concrete by the locking mechanism and shall not rely on an adhesive bond.

4

The lining shall withstand a 100 kPa hydrostatic back pressure applied to the under surface of the lining without losing anchorage or without rupture.

5

Damaged liner plate shall be repaired in accordance recommendation and to the approval of the Engineer.

3.3.5

Epoxy Coating

1

All exterior surfaces of concrete pipes shall be coated by the pipe manufacturer with a heavy duty, solvent free epoxy suitable for application to fresh concrete as specified in Section 5. A minimum of two coats shall be applied to attain a minimum total dry film thickness of 400 m.

3.3.6


1

Inspection procedures and tests shall be carried out at the place of manufacture. Pipes and joints shall be hydrostatically tested in accordance with BS 5911.

2

The performance of pipes shall be verified by the testing of random sample pipes in accordance with the type of inspection and batch size mentioned. The pipes shall be subject to rejection on account of non-compliance with the following:

with

the

manufacturer’s

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.

3.3.4

(a)

failure to pass hydrostatic test

(b)

failure of the longitudinal concrete surfaces of joints to meet dimensional tolerances

(c)

fractures or cracks (i)

passing through the shell, except that a single end crack that does not exceed the depth of the joint shall not be cause for rejection; however

QCS 2014

Section 08: Drainage Works Part 03: Pipes and Fittings Materials (ii)

Page 14

if a single end crack that does not exceed the depth of the joint exists in more than 10 % of the pipes inspected, the defective pipes shall be rejected

(d)

defects that indicate defective mixing and moulding

(e)

surface defects indicating honeycomb or open texture

(f)

spalls deeper than one half the depth of the joint

(ii)

extending more than 100 mm around the circumference

(iii)

smaller than one half the depth of the joint or less than 100 mm around the circumference exist in more than ten percent of the pipes

insufficient cover to the reinforcement.

.

(g)

(i)

GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS

3.4.1

Standards

1

All activities relating to this section of the particular specification shall comply with the following or approved equal standard. The latest version of the standard indicated shall apply.

qa

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3.4

as

Statutory provisions shall always apply as amended from time to time.

se

Generally applicable standards: BS EN 681 .................Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications.

ov

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BS EN 14364 .............Plastic piping systems for drainage and sewerage with or without pressure. Glass reinforced-thermosetting plastics (GRP) based on unsaturated polyester resin (UP). Specification for pipes, fittings and joints

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BS EN 1796................Plastic piping systems for water supply with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)

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CEN TS 14632 ...........Plastics piping systems for drainage, sewerage and water supply, pressure and non-pressure - Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) - Guidance for the assessment of conformity ISO 25780 ..................Plastic piping systems for pressure and non-pressure water supply, irrigation, drainage or sewerage – Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin – Pipes with flexible joints intended to be installed using jacking techniques ISO 3126 ...................Plastic pipes. Measurement of dimensions wall thickness table. ISO 4633 ...................Joint rings for water supply, drainage and sewerage pipelines: Specification for materials ISO 1172 ....................Textile-glass-reinforced plastics, prepregs, moulding compounds and laminates - Determination of the textile-glass and mineral-filler content - Calcination methods DIN 16 869 - Part 1 ...Centrifugally cast and filled glass fibre reinforced polyester resin pipes - dimensions.

QCS 2014


Page 15

DIN 16 869 - Part 2 ...Glass-fibre reinforced polyester resin pipes (UP-GF) – Centrifugally cast – filled Part 2: General quality requirements, testing. DIN EN ISO 178 ........Plastics – Determination of flexural properties (ISO 178:1993) DIN EN ISO 527-1 .....Plastics – Determination of tensile properties – Part 1: General principles DIN EN ISO 527-2 .....Plastics - Determination of tensile properties - Part 2: Test conditions for moulding and extrusion plastics ISO 15306 ..................Glass-reinforced thermosetting plastics (GRP) pipes — Determination of the resistance to cyclic internal pressure ISO 10952 .................Plastics piping systems — Glass-reinforced thermosetting plastics (GRP) pipes and fittings — Determination of the resistance to chemical attack for the inside of a section in a deflected condition

rw

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ISO 10928 ..................Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes and fittings - Methods for regression analysis and their use DIN 16966 -6 ..............Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; collars, flanges, joint rings, dimensions

ta

DIN-16945 .................Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins

qa

DIN-16946 - Part 1 ....Cured casting Resins - Testing DIN-16946- Part 2 Cured casting Resins - Types

as

DIN EN ISO 75 ..........Plastics – Determination of temperature of deflection under load

se

DIN EN ISO 527-4 .....Plastics – Determination of tensile properties – Part 4: Test conditions for isotropic and orthotropic fibre-reinforced plastic composites

er

DIN EN ISO 10468 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor (ISO/DIS 10468:1999)

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DIN EN ISO 14828 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring relaxation stiffness under wet conditions and calculation of the wet relaxation factor (ISO/DIS 14828:1999)

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DIN EN 681-1 ............Elastomeric seals – Material requirements for pipe joint seals used in water and drainage applications – Part 1: Vulcanized rubber

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DIN EN 1119 .............Plastics piping systems – Joints for glass-reinforced thermosetting plastics (GRP) pipes and fittings – Test methods for leak tightness and resistance to damage of flexible and reduced articulation joints ISO 10466 .................Plastics piping systems — Glass-reinforced thermosetting plastics (GRP) pipes — Test method to prove the resistance to initial ring deflection ISO 7685 .................... Plastics piping systems — Glass-reinforced thermosetting plastics (GRP) pipes — Determination of initial specific ring stiffness ISO 8513 ....................Plastics piping systems — Glass-reinforced thermosetting plastics (GRP) pipes — Determination of longitudinal tensile properties ISO 8521 ....................Plastic piping systems — Glass-reinforced thermosetting plastics (GRP) pipes — Test methods for the determination of the apparent initial circumferential tensile strength DIN EN 1447 .............Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of long-term resistance to internal pressure

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ISO 7509 ....................Plastics piping systems — Glass-reinforced thermosetting plastics (GRP) pipes —Determination of time to failure under sustained internal pressure ASTM D2997 .............Standard Specification for Centrifugally cast “Fiberglass” (Glass-FiberReinforced Thermosetting-Resin) Pipe. EN ISO 2078 ..............Textile glass — Yarns — Designation (ISO 2078) ASTM D 3517-01 .......Standard Specification for “Fiberglass“(Glass-Fiber-Reinforced Thermosetting-Resin) Pressure Pipe Design

1

The design of GRP pipes, fittings and bedding shall be carried out by the pipe manufacturer to enable the pipe to meet the requirements of the Works. The following general requirements shall prevail for pipes and fittings:

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3.4.2

they shall be designed to achieve a minimum working life of 60 years under all applicable standard loadings, environmental and installation conditions

(b)

they shall have a minimum stiffness of 10,000 N/m

(c)

Non-pressure pipes and fittings shall be designed for a nominal pressure rating of PN 01 (1 bar)

(d)

Pressure pipes and fittings shall be designed for a normal operating pressure rating of PN16 (16 bar) to pressure ratings in ISO 25780, EN 14364 or EN 1796.

(e)

they shall convey a liquid with a temperature up to 45C

(f)

they shall be designed to withstand up to 5% long term deflection in their installed conditions.

(g)

all bends shall be long radius bends unless otherwise approved by the Engineer.

(h)

they shall be capable of withstanding a 95% lower confidence strain of 0.85% over 60 years without failure or cracking when tested in accordance with the strain corrosion type test requirements specified herein.

(i)

sewerage and drainage pipelines and fittings shall be designed to carry septic sewage having a maximum hydrogen sulphide concentration of 50mg/l at a temperature of 45C

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(a)

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2

(j)

irrigation pipelines and fittings shall conform to the water supply standards

(k)

The manufacturer shall provide a valid Certificate of Conformity to EN 1796, EN 14364 or ISO 25780 as applicable. The certificate shall be issued by an independent certification body or authority.

(l)

For direct jack GRP pipes, the allowable jacking force shall be based on the minimum wall thickness measured at the bottom of the spigot gasket groove where the wall cross section has been reduced, and the mean longitudinal compressive strength of the pipe. A minimum factor of safety of 3.5 in accordance with ISO 25780 shall be used for the jacking force on a straight alignment. A reduced jacking force shall be used when jacking to a curvature.

(m)

Direct jack GRP pipes can be used for pressure and non-pressure applications.

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Page 17

Pipes and Fittings Manufacture

1

The pipes and fitting shall conform to either EN 14364 or EN 1796 for sewage or water supply pipes. Jacking pipes shall comply with ISO 25780. The referenced test standards therein have to be fulfilled.

3.4.4

General

1

All GRP components shall be designed and fabricated by one manufacturer.

2

GRP pipes and fittings shall be manufactured by an approved process utilising a mandrel or rotating mould incorporating equipment to accurately control the quantities and placement of all resins, glass and aggregates.

3

Use resins, reinforcement and aggregates to produce pipes and fittings, which when combined as a composite structure will satisfy the performance requirements of this section of the specification.

4

Internal and external surfaces shall be free from irregularities, which would impair the ability of the component to conform to the requirements of EN 14364, EN 1796 or ISO 25780.

3.4.5

Buried GRP

1

The pipes and fittings shall be constructed using chopped and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric, and polyester / vinyl ester resin, aggregate and fillers. If applicable, additives necessary to impart specific properties to the resin may be used, subject to the approval of the Engineer.

2

Filament Wound (FW) GRP Pipes and Fittings Resins

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(a)

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3.4.3

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Vinyl ester shall be used in the internal resin rich liner of the pipes and fittings. Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings. Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.

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Resins shall be cured to achieve a minimum of 90% of the manufacturer’s recommended Barcol hardness value.

(b)

Additives The use of additives such as fire retardants, UV inhibitors or coloured pigments or dyes shall only be used for specific project based applications and their use shall be subject to the approval of the Engineer.

(c)

Glass reinforcement The glass used for the manufacture of the reinforcement shall be type “E” (aluminacalcosilicate glass), type “C” (alkali-calcium glass) or type “ECR” (alumina-borosilicate glass). The reinforcement shall be made from continuous drawn filaments of glass and shall have a surface treatment compatible with the resin to be used. It may be used in any form, e.g. as continuous or chopped filaments, strands or rovings, mat or fabric.

(d)

Aggregates Aggregates shall be clean, graded silica sand containing no impurities and a maximum moisture content of 2%. The maximum particles size of the sand aggregate shall not exceed 0.8mm.

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Page 18

The overall sand content of the pressure pipes and fittings shall not exceed 30% by weight. The overall sand content of the non-pressure pipes and fittings shall not exceed 60% by weight. (e)

Fillers Fillers (other than silica sand aggregate) shall only be permitted if required for a particular project application and be subject to the approval of the Engineer following satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000 hours.

(f)

Wall construction Lining Layer The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester layer suitably reinforced with C glass veil with a glass content not exceeding 10% by weight. The remainder of the lining shall consist of layers of vinyl ester resin and powder bound ECR acid resistant glass chopped strand mat or roving, depending on the method of manufacture, with a glass content of between 25% and 35% by weight.

(ii)

Sand aggregate shall not be used in the lining layer.

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(i)

Structural Layer

The structural layer shall comprise Type E or ECR glass reinforcement and a thermosetting isophthalic polyester resin with or without sand aggregate.

(iv)

The layer shall be built up in layers of Type E or ECR acid resistant glass chop roving or continuous roving.

(v)

The manufacturing process shall ensure that no aggregate becomes embedded in the internal resin rich liner layer.

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(iii)

Outer Layer

Pipes shall be provided with a resin rich layer with C glass veil reinforcement.

(vii)

The resin used in the outer layer shall have a Glass Transition temperature of at least 75C.

(viii)

The use of special finishes is permitted when the pipe or fitting is expected to be exposed to extreme climatic, environmental or ground conditions. These may include the provision of a sand layer, pigments or inhibitors for UV protection or fire retardation, subject to the approval of the Engineer.

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(vi)

(g)

Bends and Fittings Bends and fittings shall be equal or superior in quality and performance to the corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which have been hydraulically tested successfully.

3

Centrifugally Cast (CC) GRP Pipes and Fittings (a)

Resins Vinyl ester shall be used in the internal pure resin liner of the pipes and fittings. Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings. Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings. Resins shall be cured to achieve a minimum of 90% of the manufacturer’s recommended Barcol hardness value.

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(b)


Page 19

Additives The use of additives such as fire retardants, UV inhibitors or coloured pigments or dyes shall only be used for specific project based applications and their use shall be subject to the approval of the Engineer.

(c)

Glass reinforcement The glass used for the manufacture of the reinforcement shall be Type E or ECR glass. The reinforcement shall be made from chopped glass filament in long and short fibres and shall have a surface treatment compatible with the resin to be used.

(d)

Aggregates

(e)

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Aggregates shall be clean, graded silica sand containing no impurities and a maximum moisture content of 2%. The maximum particles size of the sand aggregate shall not exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm. Fillers

Wall construction

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(f)

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Fillers (other than silica sand aggregate) shall only be permitted if required for a particular project application and be subject to the approval of the Engineer following satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000 hours.

Lining Layer

The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester resin without glass reinforcement and sand aggregates.

(ii)

The barrier and transition layers between the pure resin lining layer and the structural layer shall be to suit the manufacturing process.

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Structural Layer

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(i)

The structural layer shall comprise glass reinforcement and a thermosetting isophthalic polyester or vinyl ester resin with or without sand aggregate.

(iv)

The layer shall be built up in layers of ECR acid resistant glass chopped fibres.

(v)

The manufacturing process shall ensure that no aggregate becomes embedded in the inner pure resin liner layer.

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(iii)

Outer Layer (vi)

Pipes shall be provided with an outer layer formed of a mortar of resin and sand aggregates with no glass reinforcement.

(vii)


(viii)

An outer protection layer shall be provided which has a minimum of 60% sand for corrosion protection.

(ix)

The use of special finishes is permitted when the pipe or fitting is expected to be exposed to extreme climatic, environmental or ground conditions. These may include the provision of a sand layer, pigments or inhibitors for UV protection or fire retardation, subject to the approval of the Engineer.

(x)

The transition layers between the structural layer and the outer layer shall be to suit the manufacturing process.

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(g)


Page 20

Bends and Fittings Bends and fittings shall be equal or superior in quality and performance to the corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which have been successfully pressure tested.

Direct Jack GRP Pipes (a)

Resins Vinyl ester resin shall be used in the internal pure resin liner of the pipes. Isophthalic or vinyl ester resin shall be used in the structural layer of the pipes. Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes. Resins shall be cured to achieve a minimum of 90% of the manufacturer’s recommended Barcol hardness value.

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Additives

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(b)

Glass reinforcement

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(c)

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The use of additives such as fire retardants, UV inhibitors or coloured pigments or dyes shall only be used for specific project based applications and their use shall be subject to the approval of the Engineer.

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The glass used for the manufacture of the reinforcement shall be Type E or ECR acid resistant glass.

Aggregates

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(d)

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The reinforcement shall be made from chopped glass filament in long and short fibres and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric and shall have a surface treatment compatible with the resin to be used.

Fillers

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(e)

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Aggregates shall be clean, graded silica sand containing no impurities and a maximum moisture content of 2%. The maximum particles size of the sand aggregate shall not exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.

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Fillers (other than silica sand aggregate) shall only be permitted if required for a particular project application and be subject to the approval of the Engineer following satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000 hours.

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(f)

Wall construction Lining Layer (i)

The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester layer suitably reinforced with C glass veil with a glass content not exceeding 10% by weight. The remainder of the lining shall consist of layers of vinyl ester resin and powder bound ECR acid resistant glass chopped strand mat or roving, depending on the method of manufacture, with a glass content of between 25% and 35% by weight, when the filament wound manufacturing process is used.

(ii)

The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester resin without glass reinforcement and sand aggregates when the centrifugal manufacturing process is used.

(iii)

The barrier and transition layers between the pure resin lining layer and the structural layer shall be to suit the manufacturing process.

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Page 21

Structural Layer (iv)

The structural layer shall comprise glass reinforcement and a thermosetting isophthalic polyester or vinyl ester resin with or without sand aggregate.

(v)

The layer shall be built up in layers of Type E or ECR acid resistant glass chopped fibres.

(vi)

The manufacturing process shall ensure that no aggregate becomes embedded in the inner pure resin liner layer.

Outer Layer Pipes shall be provided with an outer layer formed of a mortar of resin and sand aggregates with no glass reinforcement.

(viii)


(ix)

An outer protection layer shall be provided which has a minimum of 60% of sand for corrosion protection.

(x)

The use of special finishes is permitted when the pipe is expected to be exposed to extreme climatic, environmental or ground conditions. These may include the provision of a sand layer, pigments or inhibitors for UV protection or fire retardation, subject to the approval of the Engineer.

(xi)

The transition layers between the structural layer and the outer layer shall be to suit the manufacturing process.

(xii)

The outer surface of the pipes shall be smooth with a resin rich topcoat 0.3mm thick.

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Longitudinal Compressive Strength

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(vii)

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Proof of compression strength shall be supplied by testing all pipe types using the procedure set out in Annex A of ISO 25780.

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The test results of compressive properties obtained from coupon or spool test specimens may be used. As described in ISO 25780, the manufacturer shall show the correlation of the results obtained from coupons or full spools by means of initial type tests. The pipes shall meet the following requirements for the initial longitudinal compression properties:

Table 3.4.1 : Longitudinal compressive strength for direct jack GRP pipes Specimen

Pipe quality

Minimum compressive strength (single value)

Mean compressive strength

Rebated and grooved specimen

with filler

80 MPa

90 MPa

Coupon specimen

with filler

90 MPa

100 MPa

Rebated and grooved specimen

without filler

70 MPa

80 MPa

Coupon specimen

without filler

80 MPa

90 MPa

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(h)


Page 22

Dimensions The manufacturer shall confirm that the outside diameter of the pipe conforms to ISO 25780. The outside diameter of the jacking pipe shall be compatible with the jacking machine. The nominal length of the pipe shall preferably be 1m, 1.5m, 2m, 3m or 6m. Other lengths shall be permitted to suit a particular project requirement. The jacking force shall be transmitted face to face on the pipe joint without the use of packer rings, unless required for a specific project application. The permitted deviation from squareness across the joints external diameter shall be as tabled below:

Manufacturer’s declared outside diameter dOD mm dOD ≤ 300

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0.5

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Deviation of squareness mm

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Table 3.4.2 : Permissible deviation from squareness across a joint’s external diameter

1.0

(i)

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300 < dOD

Marking of jacking pipes

Wall thickness

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Markings shall meet the requirements for the application and conform to ISO 25780. Designations to meet special quality requirements as item 6 below are permissible. The marking of the pipe shall be visible on the external and internal surfaces of the jacking pipe.

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The minimum total wall thickness, including the liner and outer protective layer shall be declared by the manufacturer, which shall be complying with the standard performance criteria.

6

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The wall thickness at any point on the pipe and the spigot shall not be less than the manufacturer’s declared values. Abrasion resistance The pipes shall be resistant to abrasion when tested according to CEN TR 15729 over 100,000 cycles. There shall be no evidence of free glass fibres on the inner surface of the pipe. 7

Markings All pipes including cut lengths and all fittings before dispatch from the pipe manufacturer’s works shall be indelibly marked as follows on the external and internal surfaces. (a)

The manufacturer's name, initials, or identification mark.

(b)

The nominal internal diameter in millimetres.

(c)

The length in metres.

(d)

The classification i.e. pressure rating, stiffness.

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Page 23

(e)

The date of manufacture and batch number.

(f)

A stamp to show that they meet the required inspection requirements and hydraulic tests at the point of manufacturer.

(g)

Identification number stencilled on the inside and outside at each end. The same number shall appear on all record sheets and documents relating to the manufacture delivery and testing of that pipe.

(h)

The manufacturing standard.

(i)


Joints

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Except where otherwise detailed on the Drawings, all buried pipes and fittings shall have nonend-load-bearing flexible joints of spigot type or GRP sleeved couplers with EPDM rubber in full faced elements or rings in accordance with BS / DIN EN 681; manufactured according to the individual manufacturing technique and supplied as an integral part of the pipe or as separate fittings. The elastomeric sealing gaskets shall provide the sole means of maintaining joint watertightness. The sealing gaskets shall be supplied by the pipe manufacturer.

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Joints in direct jack applications (non-pressure application) can also be of stainless steel Grade 316 Ti (EN 1.4571) couplers with approximately the same outside diameter as the pipe so that the joints are essentially flush with the pipe outer surface.

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The manufacturer shall declare the maximum draw for which each flexible joint type is designed.

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The manufacturer shall declare the maximum allowable angular deflection and the maximum draw for which each locked joint type and flexible joint type are designed.

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All joints shall remain watertight for all combinations of angular deflection and draw up to the maximum allowable values. In addition, pipe joints for pipelines laid in open cut trenches shall be capable of withstanding an external pressure differential equivalent to +10m head of water without leakage in the straight, deflected and drawn positions.

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When a pipe is cut or turned down in order to form a joint, the exposed faces shall be fully sealed with a continuous coating of vinyl ester resin with a minimum of 1.5mm thick. Wrapped or cemented joints shall only be used subject to the approval of the Engineer. 3.4.6

Exposed GRP The use of GRP pipes and fittings for exposed service shall be subject to the approval of the Engineer. The exposed pipes and fittings shall be designed to resist all bending stresses, thrust forces, surge pressures, negative pressures, thermal and vibratory forces.

1

Exposed pipe and fittings shall be manufactured in the same manner and with the same materials as buried pipe, along with the following requirements unless otherwise approved by the Engineer.

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(a)

Page 24

An outer protective surface layer shall be provided consisting of a topcoat of UV inhibitor and resin with or without glass reinforcement to form a resin rich layer with a minimum thickness of 0.3mm. The outer protective surface layer shall be designed to resist other project specific extraneous causes (atmospheric conditions, mechanical damage and chemical stress etc.) as described in the project specification.

Exposed pipes and fittings inside treatment plant buildings, process structures, pumping stations, and valve chambers shall use PN 16 flanged joints: Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed with epoxy or vinyl ester resins only.

(b)

All bolts shall be stainless steel grade 316.

(c)

Flanges shall be drilled to BS EN 1092 (metric units) resp. DIN 16966-1 type PN16.

(d)

Flanged pipe joints shall incorporate an annular gasket covering the full face of the flange. Gaskets to be 3mm thick self-energised EPDM or nitrile rubber (NBR) with embedded stainless steel inlay O rings. The gaskets shall have a shore hardness of 60±5.

(e)

When flanged joints are to be made, secure the bolts and the nuts initially to finger tightness. Thereafter the final tightening of the nuts shall be effected by torque spanners in such sequence that diametrically opposite nuts are tightened together to achieve the manufacturers recommended torque.

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(a)

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External exposed pipes and fittings shall use fixed laminated joints with expansion bellows and be supported in accordance with the manufacturer’s requirements.

4

The exposed pipeline shall be protected by bollards, lateral sand bunds etc. where there is a risk of physical impact.

3.4.7


1

A pipe type test group consists of a range or family of products made such that the results of the long-term type tests are applicable to all products in the group. A pipe type test group shall be made of products:

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a) manufactured by the same process;

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b) with the same material specifications; c) with the same pipe wall construction (i.e. the sequence of layers, layer compositions, material properties and design method for using the results of the long-term type tests in determining the pipe wall for all combinations of DN, PN and SN); d) tested with the same loading condition (i.e. uniaxial or biaxial load).

2

The pipe manufacturer shall submit type test results according to EN 14364 or ISO 25780 for each product group.

3

Strain corrosion tests shall be carried for each class and diameter range, where applicable, according to ISO 25780 and ISO 10467, as a type test generally in accordance with ASTM D3262 resp. ISO 10952. The strains shall be at levels at which failure can be predicted from the strain corrosion type test results to occur at 100 hours and 1,000 hours. No failures shall be below the lower 95% confidence limit of the type test regression line.

4

The calculated failure strain at 60 years from the results of the quality control test using the least squares method shall not be less than 0.85%. In the event that a specimen fails the strain corrosion test all pipes in that class and diameter range, where applicable, pertaining to that batch which has been manufactured or installed shall be rejected.

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Page 25

The pipe manufacturer shall carry out the following Inspection Tests. The results of these tests shall be made available to the Engineer who shall also be allowed to witness some or all of the tests. (a) One pipe in every 100 of each type and size of manufactured item shall be tested for loss of ignition in accordance with ASTM D2584 resp. ISO 1172. (b) The liner thickness of pipes, fittings and couplings shall be measured in accordance with Section 6 of ASTM D3567 resp EN 3126. A liner check shall be carried out for one in every 100 of each type and size of manufactured item. A minimum of one item of each type and size shall be tested. The liner thickness shall not be less than 1mm at any pitted point.

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Checks will be carried out by the Engineer at Site. The Contractor shall destroy or indelibly mark as rejected and remove from Site any pipes or fittings found at any time failing to meet dimensional criteria or any of the following quality criteria:

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(c) Data for the above tests shall be submitted to the Engineer. The data shall be traceable to the supplied pipes with a unique number as "Batch no", the test data shall hold all the above mentioned tests samples results under this batch no. The batch no. shall be clearly marked as ID on each length of produced pipes.

(a) scratches shall be no deeper than 0.3 mm and no reinforcing fibres shall be exposed

(c) no delaminations shall be evident

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(b) no cracks shall be present on the inside of pipes. Hair cracks on the outside may be permitted with repair if not longer than 200 mm circumferentially or 6 mm longitudinally. Impact cracks shall not affect more than 3 % of surface area

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(d) no impact or other damage to pipe ends shall be evident. The end surface of pipe or fitting shall be completely covered with resin and free from cracks, porosity, bubbles, voids, exposed reinforcement or extraneous matter (e) no protruding fibres permitted on jointing surfaces

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no other protuberances. Small globules or resin projections permissible if not more than 25 % of area is affected. Jointing surfaces shall be completely free of any such flaws. Ridges formed by resin shall not exceed 1.5 mm in depth

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(g) air voids, blisters, bubbles are not acceptable if greater than 5 mm diameter or 1 mm depth. Subject to the approval of the Engineer, if less than 0.5% of internal areas are affected, such defects may be ground out and repaired

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(h) not more than 5 % of the internal or 10 % of the external surface shall be affected by pitting. No individual pit shall be more than 1 mm diameter or 0.5mm depth (i)

wrinkles and indentations shall not be more than 2mm deep and not more than 3 % of surface area affected. Subject to the approval of the Engineer, if not more than 5 mm deep and 0.5 percent of surface area is affected, such defects may be repaired

(j)

any pipe which when resting freely on the ground and not subjected to any loads other than its own weight exhibits a deflection of more than 2%, measured along the diameter, shall be rejected and removed from the Site.

3.5

PVC-U PIPES AND FITTINGS

1.1.1

Standards

1

Except as otherwise indicated, materials and workmanship described in this section shall conform to the latest editions of the following standards: ASTM D1599 ..............Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and Fittings

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AWWA M23 PVC Pipe - Design and Installation BS 3505/3506 - Polyvinyl Chloride Pressure Pipe BS EN 1401 - Plastic piping for non-pressurised underground drainage & sewerage BS EN 1452................Plastic piping systems for water supply (UPVC) DIN 8061 ....................Unplasticised polyvinyl chloride pipes - general quality requirements & testing DIN 8062: 1988 ..........Unplasticised polyvinyl chloride (PVC-U, PVC-HI) pipes – dimensions

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DIN 8063: 1986 ..........Pipe joint assemblies & fittings for unplasticised polyvinyl chloride (PVC-U) pressure pipelines

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ISO 1452 ....................Pipes and fittings in PVC –U pipes for water supply

The strength requirement and other features of particular application shall be as specified in this Subpart or designated in the contract specific documentation.

3.5.2

Manufacture

1

UPVC pipe shall be provided in standard 6 metre lengths, unless otherwise specified, detailed or required on the approved plans. Shorter lengths, up to 3 metres, will be permitted when authorised by the Engineer. Field cut lengths of pipe used as closures may not be shorter than 0.75 metre in length and must be approved by the Engineer. Solvent welded pipes may be permitted in sizes of 100mm and less.

2

For sewerage service, PVC-U pipes 200 mm in diameter may be supplied in lengths up to 4 m. PVC-U pipes 150 mm in diameter and less shall be supplied 50 percent in lengths not exceeding 2 m and 50 percent in lengths not exceeding 4 m.

3

UPVC Pipes shall be SDR17 as a maximum and shall have be designed to withstand a 0 0 nominal operating pressure of PN16 at 25 C (equivalent to PN10 at 45 C) unless otherwise specified in the Contract Documents.

4

All joints for UPVC Pressure Pipe shall be integrally cast, spigot and socket joints, or plain end with EPDM rubber ring couplings. Joints shall be of the same pressure rating as the pipe. Solvent weld joints are not permitted for TSE Mains. Gaskets and lubricants shall be made from materials that are compatible with the plastic material and with each other when used together. They shall not support the growth of bacteria and shall not adversely affect the potable qualities of the water that is to be transported. One elastomeric gasket shall be furnished with each length of socket-end pipe.

5

Pipe shall have a minimum internal diameter equal to or greater than the pipe size shown on the Drawings and Bills of Quantities. SDR shall be defined as outside diameter divided by wall thickness. Acceptable PVC pipe shall have common profiles for interchangeability between rough barrel dimensions, couplings, ends and elastomeric gaskets so as to facilitate future repairs. When assembled, the pipe shall have only one gasket per socket and spigot end.

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Pipes delivered to site shall be no more than 12 months old. The Engineer reserves the right to reject the pipes older than 12 months old.

3.5.3

Joints

1

Solvent welded joints shall not be permitted for sewerage pipelines and all jointing shall be by socket and spigots with sealing rings which shall conform to BS 2494.

2

Unless otherwise designated, irrigation pipework up to 100 mm in diameter shall be solvent welded in accordance with BS 4346 Part 1.

3.5.4


1

Inspection and testing for sewer pipes shall be in accordance with an approved inspection and test plan.

2

Inspection and testing for irrigation pipes shall be in accordance with an approved inspection and test plan.

3

Test certificates shall be provided by the manufacturer.

4

All pipes may be subject to inspection at the place of manufacture in accordance with the provisions of the referenced standards as supplemented by the requirements herein. The Contractor shall notify the Engineer in writing of the manufacturing starting date not less than 14 calendar days prior to the start of any phase of the pipe manufacture.

5

During the manufacture of the pipe, the Engineer shall be given access to all areas where manufacturing is in process and shall be permitted to make all inspections necessary to confirm compliance with the Specifications.

6

The Contractor shall perform said material tests in accordance with the requirements of the Contract Documents. The Engineer shall have the right to witness all testing conducted by the Contractor, provided that the Contractor’s schedule will not be delayed for the convenience of the Engineer.

7

In addition to those tests specifically required, the Engineer may request additional samples of any material for testing by the Engineer.

8

All expenses incurred in obtaining samples for testing shall be borne by the Contractor at no additional cost to the Contract.

3.5.5


1

All fittings shall be push-on joint with mechanical fittings. Fittings shall be in uPVC material compatible with the above specified pipe and having the same minimum Class and Pressure Rating. The fittings when connected to the main pipe shall provide an integral system capable of withstanding the working and test pressure.

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ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS

3.6.1

Standards

1

Acrylonitrile butadiene-styrene (ABS) pipes and fittings for pressure pipes shall conform to BS 5391 and BS 5392.

3.6.2

Manufacture

1

Unless otherwise designated, ABS pipes and fittings shall be class E and manufactured in accordance with BS 5391 and BS 5392.

3.6.3

Joints

1

ABS pipes shall be provided with socket and spigot joints, sealed with elastomeric sealing rings conforming to BS 2494.

3.6.4


1

Inspection and testing for pipes and fittings shall be in accordance with BS 5391 and BS 5392.

3.7

DUCTILE IRON PIPES AND FITTINGS

3.7.1

Standards

1

Unless otherwise stated in the Contract Documents ductile iron pipes and fittings for pipes shall comply with BS EN 545 and shall be suitable for an allowable operating pressure (PFA) of 16 Bar and an allowable maximum operating pressure (PMA) of 20 bar.

2

Unless otherwise stated in the Contract Documents, flanges on ductile iron pipework and fittings shall comply with BS EN 1092-2 and shall be PN16.

3

All puddle flanges shall be cast integrally with the wall piece.

3.7.2

Exposed Joints

1

Ductile iron flanged pipes shall be furnished with integrally cast flanges or screwed on flanges faced and drilled to class designation. Steel bolts and nuts shall be supplied with two washers per bolt. Bolt length shall be such that after the joints are made up, the bolts shall protrude through the nut, but not more than 12 mm. Bolts shall be stainless steel grade to BS 970 Grade 316 S31.

2

Gaskets shall be compatible with the fluid to be conveyed. For treated sewage effluent pipelines, EPDM gaskets shall be used. Gaskets shall be able to withstand a pressure of PN 16 for a 24 h test period. Thickness of gaskets shall be such that, when jointed in accordance with manufacturer’s instructions, the joint shall provide a positive seal for the range of pressures likely to occur in the pipeline under the maximum joint deflection permitted.

3

Pipes and fittings in chambers and pumping stations shall have flanged joints unless detailed otherwise. Flanges shall comply with BS EN 1092-2 and shall be PN16 unless a higher pressure rating is detailed elsewhere.

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3.6

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3.7.3

Buried Joints

1

Pipes and fittings to be buried shall have flexible joints unless detailed otherwise.

3.7.4

Internal Lining

1

Pipes and fittings shall be lined internally with one of the following linings: (a)

Polyurethane lining minimum thickness 1,000 micron

(b)

Fusion bonded epoxy powder lining minimum thickness 500 microns

(c)

Ceramic epoxy lining minimum thickness 1,000 micron

All coatings shall be factory applied in strict accordance with the lining manufacturer’s specification. Pipes shall be blast cleaned or ground to the equivalent of BS EN ISO 8501-1, BS 7079:A1, SA 2.5 prior to application of the products.

3

All liners shall comply with the following standards:

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.l. l

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2

adhesion to pipe (ASTM D4541) Min 10 MPa

(b)

impact resistance (ASTM2794) Min 10 J

(c)

abrasion resistance (AST D4060, 1kg x 1000cycles) Max 100 mg

(d)

vapour permeability (ASTM D1653, Wet cup method) 1.0g/m2/24hr

(e)

immersion test 20% sulphuric acid (ASTM D-714-87) No effect after 2 years

(f)

salt spray test (ASTM B117 – 1,000 hours) pass

(g)

spark holiday test voltage V = 248T0.5, where T = thickness of lining in microns

(h)

any defect found in the lining shall be repaired at the manufacturers plant before shipment.

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(a)

Internal socket end of pipes shall be protected with a minimum thickness of 300m of epoxy.

5

All pipes shall be clearly marked to indicate the type of lining as follows: PU – Polyurethane

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(b)

FBE – Fusion bonded epoxy

(c)

CE – Ceramic epoxy

3.7.5

External Coating and Wrapping, Use and Materials

1

External coatings for ductile iron pipes shall be factory applied to the approved pipe manufacturer’s standards and conform to one of the following specifications.


Inner coat

External DI Pipe Coating Systems

Middle Coat

Final Coat

150m epoxy

Black fusion or hot melt adhesive bonded polyethylene sleeving of nominal thickness 1000m

200g/m2 zinc

150m epoxy

Black tape self adhesive bituminous resin on PVC backing layer complying with AWWA C2009 Section 24 Type 1. 55% overlap.

Nil

Nil

Polyurethane as Part 3 – 3.7.4 minimum thickness 2000m

BS EN 598, ISO 817, AWWA C2009

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200g/m2 zinc

Applicable Standards BS EN 598, BS 6076 and ISO 8179-1

.

Table 3.2

Page 30

.l. l

QCS 2014

Laminate Tape Properties

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Table 3.3

as

Laminate tape shall have the following characteristics:

Applicable Standard

er

Parameter

ASTM D 1000

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Overall thickness PVC backing thickness

et it

o

PVC backing thickness if fabric reinforcement in bituminous layer Tensile Strength

ASTM D 1000 ASTM D 1000

Pipes 600mm dia

Pipes 600mm dia

1.1mm

1.6mm

0.3mm

0.7mm

0.5mm

0.5mm

BS 2782

7.5N/mm

12.0N/mm

Elongation

BS 2782

200%

200%

Tear Resistance

ASTM D 1004

19N/mm

50N/mm

Adhesion to steel

ASTM D 1000

1.0N/mm

2.0N/mm

Adhesion to self

ASTM D 1000

1.8N/mm

1.8N/mm

Impact resistance (single layer) Dielectric strength

DIN 30672

8.0Nm

10.0Nm

BS 2872

25,000V

30,000V

Insulation resistance

BS 2782

Water vapour permeability

BS 2782

1,000,000 megohms  0.65 2 g/m /day

1,000,000 megohms  0.65 2 g/m /day

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2

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NF A48-851

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Spigot ends of pipes that are tape or polyethylene wrapped shall not be wrapped over the depth of engagement of the spigot with the socket or mechanical coupling but shall be coated with a minimum thickness of 300m of epoxy.

3.7.6

Factory Application of Tape Wrapping

1

Before primer application, all oil and grease shall be removed with an approved solvent. Surfaces to be coated shall be cleaned by mechanical brushing to remove loose corrosion products, welding slag, loose factory applied bituminous paint or any other foreign matter and achieve a surface finish equivalent to mechanical scraping and wire brushing as specified in Clause 8.3.5 of this Section. All surfaces shall be solvent wiped after blast cleaning.

2

Primer shall be applied to all surfaces to be wrapped immediately following completion of surface preparation.

3

Primer shall be allowed to dry before wrapping. Primer application shall be limited to the amount that can be wrapped during the working day.

4

Tape shall be applied spirally to provide a 55 % overlap and with sufficient tension to result in constant adherence without voids or wrinkles. On completion of the wrapping the surface shall be smoothed to ensure completely sealed overlaps and the absence of air pockets under the tape. The width of the tape shall be suitable to conform to the size and shape of the pipeline being wrapped.

5

On completion of the wrapping, all tape wrapping shall be checked for continuity by a “Holiday” detection unit. Any Holidays detected shall be repaired by over-wrapping with tape and the wrapping retested.

6

Bond/adhesion tests shall be carried out on all tape wrappings not more than 24 hours after completion of wrapping.

7

Test certificates shall be provided by the manufacturer.

3.7.7

Factory Applied Extruded Polyethylene Coating

1

Extruded polyethylene coating shall be factory applied to preheated epoxy primed pipes and fittings to provide a minimum finished thickness of 2.0 mm. The coating shall be resistant to peeling, free from imperfections, and shall be tested for continuity using a minimum 10 kV spark tester. The polyethylene coating shall be stabilised to prevent ultraviolet and thermal degradation.

3.7.8


1

Inspection procedures and tests for DI pipes and fittings shall be carried out in accordance with BS 4772.

2

The Contractor shall provide Manufacturer’s type and quality control test certificates to be traced to the pipe cast number, heat number or lot number.

3

Manufacturer’s certificates shall state the relevant British or ISO standards to which the pipes and fittings supplied comply.

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4

The repairs to cement mortar linings, if permitted by the Engineer, shall comply with the requirements of the designated thickness, minimum bore and surface conditions.

5

In addition to the prescribed testing, the pipes and fittings shall be subjected to visual inspection at the place of manufacturer and at Site and will be rejected if the pipes are incorrectly marked or have defects outside the ranges permitted.

3.8

FLANGE ADAPTERS AND FLEXIBLE COUPLINGS

3.8.1

General

1

In addition to the types of joints typically designated for each type of pipe, flange adaptors and flexible couplings may be designated particularly for pressure pipelines.

.l. l

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Flange adaptors and flexible couplings shall: be manufactured from rolled steel or other approved materials

(b)

be capable of withstanding the pressure test of the pipeline in which they are incorporated

(c)

permit minimum angular deflection as shown below:

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(a)

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Table 3.3 – Minimum Angular Deflection

450

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Pipe diameter (mm)

0

5

0

4

750 – 1200

3

1200 -1800

2

>1800

1

0 0 0

et it

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600 – 750

be capable of accommodating a movement of 10 mm between ends of pipes they connect.

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(d)

0

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450 – 600

Deflection

2

Adaptors and couplings shall be joined as recommended by the manufacturer.

3

Where necessary to restrain movement at joints tied flange adaptors shall be used and the deflection criteria shall not apply.

4

All fasteners shall be stainless steel to BS970 Grade 316S31.

3.8.2

Flange Adapters

1

Flange adapters shall be used on PVC-U, GRP, cast and ductile iron, and joints between each of the materials as designated. Flanges shall be PN 16 rating and gaskets shall be to BS 3063.

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Flexible Couplings

1

Flexible couplings shall be used with PVC-U, GRP, cast and ductile iron, and between joints between pipes manufactured from each of the materials.

3.9

PIPES FOR OTHER USE

3.9.1

Copper Tubes and Fittings

1

All tubes shall be clean, round, smooth and free from harmful defects and from deleterious films in the bore. Copper tubing shall conform to BS EN 1057 and shall be half hard, light gauge copper. Tubing shall be supplied in straight lengths by an approved manufacturer whose identification mark shall appear on each tube at about 0.5 m intervals. Approved dielectric isolation fittings or attachments shall be furnished where copper fittings, piping or tubing are connected to ferrous fittings or connections.

2

Copper tubes for internal use shall be in accordance with Table X of BS EN 1057. Chromium plated copper tube shall be of plating quality in accordance with BS 1224, free of defects such as blisters, pits, roughness, cracks or unplated areas. Fittings shall be of the compression type complying with BS 864 Part 2 and shall be resistant to dezincification.

3

Copper tubes for external use shall be in accordance with Table Y of BS 2871 Part 1. Tubing shall have a factory applied green coloured polythene sheath with a minimum thickness of 1.0 mm. Fittings shall be of the compression or capillary type complying with BS 864 Part 2 and shall be resistant to dezincification. Joints shall be adequately protected with tape to the approval of the Engineer.

3.9.2

Hose and Appurtenances

1

Hose and hose reel shall be furnished for designated hose bibbs. Hose shall be 25 mm diameter minimum and provided with an adjustable nozzle. Hose pipes for wash water shall be matched to the operating head of the supply system, be constructed for heavy duty and be 50m long. Hose pipes shall have a certified test pressure of 1.5 times the maximum operating pressure. Hose pipes for fire fighting shall be in accordance with Section 23.

2

Couplings shall be furnished for each size hose, one for each 25 m length of hose provided; they shall be of cast brass quick fix type and shall have standard threads.

3.9.3

Stainless Steel Pipes, Tubes and Fittings

1

All stainless steel for pipes, tubes and fittings shall be Type 316L.

2

Stainless steel pipes and tubes shall conform to ASTM A312 and ASTM A688. Plate shall conform to ASTM A240; diameters and wall thickness to ANSI B36.19.

3

Stainless steel fittings and specials shall be compression type conforming to ASTM A234. Plate shall conform to ASTM A240; diameters, wall thickness and dimensions to ANSI B36.19, ANSI B16.9.

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3.8.3

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Pipe sizes 50 mm and smaller shall be of Schedule 40 and above seamless stainless steel with threaded ends, and shall conform to material specifications ASTM A312 and dimensional specifications ANSI B36.19. Fittings shall be threaded, 2,000 pound forged stainless steel, and shall conform to material specification ASTM A182 and dimensional requirements of ANSI B16.11.

5

Unless otherwise designated, pipe sizes over 50 mm shall be Schedule 10 and above, seamless stainless steel with bevelled ends for welding conforming to material specification ASTM A312 and dimensional specification ANSI B36.19. Unless otherwise designated, fittings shall be Schedule 10, seamless stainless steel with bevelled ends for welding and conform to material specification ASTM A403 and to the dimensional requirements of ANSI B16.9 and ANSI B16.28. Flanges shall be ANSI slip-on or welding neck type, with 150 pounds rating conforming to material specification ASTM A182 and to the dimensional specifications ANSI B16.5.

3.9.4

Carbon Steel Pipes and Fittings

1

Carbon steel pipes shall conform to :

2

ASTM A53, ASTM A106 for pipes, and ASTM A105 for fittings and flanges

3

Carbon steel fittings and flanges shall conform to ASTM A105.

3.10

MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES

3.10.1

Applicable Standards

1

MDPE and HDPE pipes shall conform to the latest editions of the following standards.

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4

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EN ISO 527 ................Plastics -- Determination of tensile properties

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EN ISO 1133-1 ...........Plastics. Determination of the melt mass-flow rate (MFR) and melt volume-flow rate (MVR) of thermoplastics.

et it

EN 1519 .....................Plastic piping systems for soil and waste discharge (low and high temperature) within the building structure – Polyethylene (PE)

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EN ISO 1167 ..............Thermoplastic pipes, fittings and assemblies for the conveyance of fluids – Determination of the resistance to internal pressure EN ISO 1183-2 ...........Plastics – Methods for determining the density of non-cellular plastics – Part 2: Density gradient column method EN ISO 2505 ..............Thermoplastics pipes – Longitudinal reversion – Test method and parameters EN ISO 3126 ..............Plastics piping systems – Plastic components – Determination of dimensions EN ISO 6259 ..............Thermoplastic pipes - Determination of tensile properties EN ISO 9080 ..............Plastic piping and ducting systems – determination of the long term hydrostatic strength of thermoplastics materials in pipe form by extrapolation EN 12099 ...................Plastics piping systems – Polyethylene piping materials and components – Determination of volatile content EN ISO 12162 ............Thermoplastic materials for pipes and fittings for pressure applications - Classification and designation – Overall service (design) coefficient

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EN 12201 ...................Plastic piping systems for water supply and for drainage and sewerage under pressure – Polyethylene (PE) EN 12666 ...................Plastic piping systems for non-pressure underground drainage and sewerage – Polyethylene (PE) EN ISO 13479 ............Polyolefin pipes for the conveyance of fluids. Determination of resistance to crack propagation. EN ISO 15512 ............Plastics – Determination of water content EN ISO 16871 ............Plastics piping and ducting systems – Plastics pipes and fittings – Method for exposure to direct (natural) weathering ISO 18553 ..................Method for the assessment of the degree of pigment or carbon black dispersion in polyolefin pipes, fittings and compounds. ISO 4065 ....................Thermoplastic pipes – Universal wall thickness table

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ISO 4427 ....................Plastics piping systems - Polyethylene (PE) pipes and fittings for water supply

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ISO 6964 ....................Polyolefin pipes and fittings – Determination of carbon black content by calcination and pyrolysis – Test method and basic specification

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ISO 9624 ....................Thermoplastic pipes for fluids under pressure – mating dimensions of flange adaptors and loose backing flanges

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ISO 11357-6 ...............Plastics – Differential scanning calorimetry (DSC) – Part 6: Determination of oxidation induction time (OIT)

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ISO 11922-1 ...............Thermoplastic pipes for the conveyance of fluids – Dimensions and tolerances - Part: 1: Metric series

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ISO 13761 ..................Plastics pipes and fittings – Pressure reduction factors for polyethylene pipeline systems for use at temperatures above 20ºC

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ISO 13953 ..................PE pipes and fittings – Determination of tensile strength and failure mode of test pieces from a butt-fused joint

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ISO 14236 ..................Plastics pipes and fittings – Mechanical joint compression fittings for use with polyethylene pressure pipes in water supply systems

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ASTM D638-10...........Standard test method for tensile properties of plastics

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AWWA C224 ..............Standard for nylon-11 based polyamide coating system for the interior and exterior of steel water pipe, connections, fittings and special sections WIS 4-24-01 ...............Specification for mechanical fittings and joints for polyethylene pipes for nominal sizes 90 to 1000 mm OD WIS 4-52-01 ...............Specification for polymeric anti-corrosion (barrier) coatings WIS 4-52-03 ...............Specification for anti-corrosion coatings on threaded fasteners 3.10.2

Manufacture

1

MDPE and HDPE (PE) pipes and fittings shall be manufactured from virgin materials only. Recycled, re-ground or re-generated materials shall not be used.

2

HDPE pressure pipes and fittings shall be manufactured from material conforming to polymer classification PE100 having a minimum required strength value (MRS) of 10 MPa at 50 years and 20ºC in accordance with ISO 4427. Design stress shall be 8 MPa. The pipe manufacturer shall identify the manufacturer of the resin, the resin type and classification.

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The HDPE pipe material shall be certified as meeting the requirements of the PE100+ Association.

4

HDPE pipes to be installed using trenchless technology applications shall be manufactured from a PE100-RC material. Pipes manufactured from such material shall have undergone the Notched Pipe Test at an independent 3rd party laboratory in accordance with ISO 13479 and the time to failure shall have been a minimum of 8,760 hours (1 year). All other characteristics shall comply with the PE100 requirements of ISO 4427 and this specification.

5

HDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by the Engineer and shall have a pressure rating of 16 bar (PN16) at 20ºC (de-rated to 11.8 bar at 40ºC, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by the Engineer.

6

Pipes and fittings shall be designed to achieve a minimum working life of 50 years under all applicable loads, environmental and installation conditions.

7

MDPE pressure pipes and fittings shall be manufactured from material conforming to polymer classification PE80 having a minimum required strength value (MRS) of 8 MPa at 50 years and 20ºC in accordance with ISO 4427. Design stress shall be 6.4 MPa. The pipe manufacturer shall identify the manufacturer of the resin, the resin type and classification.

8

MDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by the Engineer and shall have a pressure rating of 12.8 bar (PN12.8) at 20ºC (de-rated to 9.5 bar at 40ºC, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by the Engineer.

9

Pipes and fittings shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, voids and other injurious defects.

10

The resin from which the pipes and fittings are manufactured shall comply with the requirements of ISO 4427 Part 1 and be protected from UV attack by the addition of carbon black in accordance with the standard.

11

Straight lengths of PE pipe shall be supplied in standard lengths of 12m (-0/+50 mm) measured at 23°C ± 2°C. Unless otherwise specified, coil length shall not exceed 100m. Coiled pipes shall be coiled such that localised deformation is avoided and the minimum internal diameter of the coil shall not be less than 20 x outside diameter. Prior to jointing the degree of pipe ovality shall not exceed the permissible levels given in Table 1 of ISO 4427, Part 2 and the Contractor shall, if required, use mechanical re-rounding equipment to meet these requirements. Field cut lengths of pipe used as closures may not be shorter than 0.75 metre in length and shall be approved by the Engineer.

12

All pipes shall be indelibly marked at intervals of maximum 1m. The colour of the pipe marking shall always contrast with the colour of the pipe. Markings shall include the following information:

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3

(a)

Manufacturer’s name, trademark

(b)

Material and designation i.e. PE100

(c)

The nominal pressure (PN) of the pipe / fitting

(d)

Dimension of the pipe (nominal outside diameter x nominal wall thickness)

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Page 37

(e)

Standard Dimension Ratio (SDR)

(f)

Production period (date / batch code)

(g)

International Standard to which the pipe / fitting has been produced to

(h)

Designation of the medium for which the pipe is produced for (water, gas, sewage)

(i)

Stencilled in legible letters the pipe identification number on the outside at each end. Ensure that the same number appears on all record sheets and documents relating to the manufacture, delivery and testing of that pipe.

Pipes shall be delivered in wooden frames or similar arrangement to avoid movement between pipes. Pipes shall not be stacked higher than 1m in each frame or packing arrangement.

3.10.3

Fittings

1

Unless otherwise specifically approved by the Engineer, all PE pressure pipe fittings for use with pipes of up to 355 mm OD shall be injection moulded with the same polymer classification, material type and pressure rating as the pipe to which they are to be connected. All joints between PE pipes and fittings shall whenever possible be by thermal butt fusion welding or electro-fusion welding process.

2

Connections of PE pipes and fittings to metallic fittings shall be made with PN16 backing rings with a stainless steel stiffener insert or as recommended by the pipe or fitting manufacturer and approved by the Engineer.

3

Transition fittings used to join the pipe to flanged fittings and pipes made of other materials shall be certified by an independent third party as being fully compliant with the Type 1 or Type 2 requirement of WIS 4-24-01 i.e. they shall prevent the pull out of the pipe at their rated operational and test pressures.

4

Metallic fittings shall be fully coated to provide protection against corrosion. The coating shall be a factory applied fusion bonded epoxy or a nylon 11 based polyamide coating system, have a minimum dry film thickness of 250 microns and comply with the requirements of either AWWA C224 or WIS 4-52-01. Any bolts, studs or nuts shall be of stainless steel (grade 304 or better) or else be protected with a coating that complies with the requirements of WIS 4-53-03. All buried metallic fittings shall be protected by petroleum impregnated primer, paste and tape prior to back filling.

5

Where their use is approved by the Engineer, all compression fittings shall be certified by an independent third party as being fully compliant with the requirements of ISO 14236. They shall be tested and certified as being class 1 end load bearing fittings i.e. they shall prevent the pull out of the pipe at their rated operational pressure. Only materials listed in Tables 1 and 2 of ISO 14236 shall be used in the manufacture of the fitting body.

6

Where the use of fabricated fittings has been specifically approved by the Engineer such fittings shall be designed and manufactured in accordance with the requirements of ISO 4427, Part 3, in particular Annex B. The pressure derating factors to be employed by the fittings fabricator shall be in accordance with annex sections B3 and B5 unless they can demonstrate that higher factors can be applied. The use of any higher factors shall be approved by the Engineer prior to commencement of fitting fabrication.

7

All PE fittings shall, as a minimum, be indelibly marked with the following information:

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(a)

Manufacturer’s name, trademark

(b)

International Standard to which the pipe / fitting has been produced to

(c)

Material and designation i.e. PE100

(d)

The nominal pressure (PN) of the pipe / fitting

(e)

Outside diameter and Standard Dimension Ratio (SDR)

(f)

Production period (date / batch code)

PE Fittings shall be individually packed in bulk, bag or individual protection against contamination. Electrofusion fittings shall always be packed in a sealed bag or container. The packaging shall, as a minimum, be labelled with the manufacturer’s name, quantity, type and dimension.

3.10.4

Pipes and Fittings for Gravity Applications

1

Pipes and fittings for drainage applications shall be suitable for carrying potable water, treated sewage effluent, raw sewage and surface water at temperatures up to 40ºC as dictated by the particular application and they shall comply with the requirements of EN1519 or EN 12666, as appropriate.

3.10.5

Testing of MDPE and HDPE Pressure Pipes and Fittings

1

The raw material and pipe manufacturers shall document and certify all products and shall undertake all testing required by ISO 4427 and this specification.

2

Prior to delivery of any pipes or fittings the pipe manufacturer shall provide the Engineer with a comprehensive Inspection and Testing Plan (ITP) for their approval. The ITP shall detail all the certificates and documents that shall be provided by the pipe manufacturer, together with details of the testing that they shall undertake, its frequency and associated test reports. Where the pipe manufacturer cannot themselves undertake the required testing they shall employ an independent third party laboratory to undertake the testing on their behalf.

3

Definition of material, pipe and fittings batches for the purposes of batch release testing: A raw material batch shall be considered as a batch of material supplied by the resin producer having an individual identification number or code. For the purposes of this specification it shall also be the raw material used to manufacture a particular pipe batch.

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4

(b)

A pipe batch shall be considered as a continuous production run of a particular pipe OD and wall thickness manufactured from one resin type with no change in the manufacturing process.

(c)

A batch of fabricated fittings shall be considered as group of fittings of the same OD and wall thickness.

The pipe manufacturer shall undertake the following minimum batch release testing.

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Table 1 –Release tests to be undertaken on each raw material batch Characteristics

Sampling Frequency

Reference

No. of Tests or Inspections

ISO 4427-1 section 4

Once per raw material batch

1

Oxidation induction time



1

Melt mass-flow rate



1

.l. l

.

Compound Density

Reference

Sampling Frequency


Geometrical


Marking

This specification

Melt mass-flow rate Elongation at break

Continuously


-

Each pipe or coil

1


Once per pipe batch

1


Once per pipe batch

1

ISO 6259 (Tensile strength to be ≥ 19MPa)

Once per pipe batch

1

Tensile strength at yield on a sample cut from MDPE pipe

ISO 6259 (Tensile strength to be ≥ 15MPa)

Once per pipe batch

1

Longitudinal reversion


Once per pipe batch

1

ov

as

Continuously

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-

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Appearance and colour

ta

Characteristics

rw

Table 2 – Release inspections and tests to be undertaken on each batch of pipes

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Tensile strength at yield on a sample cut from HDPE pipe

Pipe wall thickness shall be measured and controlled on a continuous basis using and ultrasonic thickness gauge or similar device that shall be regularly calibrated in accordance with the gauge manufacturer’s recommendations. 5

In accordance with the recommendations of ASTM D 638, the maximum thickness of the tensile strength test samples cut from the pipe wall shall be 14 mm. In the event of the pipe wall being thicker than 14 mm the pipe manufacturer shall machine the test samples in accordance with the Table 3.

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Table 3 – Preparation of samples for tensile testing Pipe Wall Thickness (WT) (mm)

Test Sample Thickness (mm)

No. of samples to be taken from the pipe wall

≤ 14

WT

1

14 < WT ≤ 28

WT/2

2

28 < WT ≤ 42

WT/3

3

42 < WT ≤ 56

WT/4

4

56 < WT ≤ 72

WT/5

5

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All testing shall be undertaken in accordance with ISO 6259 and all HDPE samples shall achieve a minimum tensile strength at yield of 19 MPa in order for the pipe to successfully pass the test. MDPE samples shall have achieved minimum tensile yield strength at yield of 15 MPa. Table 4 – Release inspections and tests to be undertaken on each batch of fabricated fittings Reference

Sampling Frequency


Geometrical


Marking


Continuously

-

Continuously

-

This specification

Each fitting

1

o

ISO 4427-3 Annex B

Once per batch of HDPE fittings

1 piece only

o

ISO 4427-3 Annex B

Once per batch of MDPE fittings

1 piece only

se

ov

Hydrostatic strength at 20 C, 100hrs & 10 MPa x ƒ

er

Hydrostatic strength at 20 C, 100hrs & 12.4MPa x ƒ

as

qa

Appearance and colour

ta

Characteristics

et it

o

The fabricated fitting to be hydrostatically tested shall be a tee or branch provided the batch in question contains this type of fitting, otherwise a bend shall be tested. In the case of injection moulded fittings the manufacturer shall issue a certificate confirming compliance with ISO 4427 and providing details of the type testing undertaken by an independent third party in accordance with sections 7 and 8 of ISO 4427 – Part 3.

7

The pipe manufacturer shall provide the Engineer with a copy of the batch release tests i.e. all those tests listed above, with each batch of pipes or fittings that is delivered to site.

8

Prior to delivery of pipes the pipe manufacturer shall provide the Engineer with copies of all the test results and certification required by ISO 4427, this specification and the ITP, but which are not covered by the above batch testing requirements. These documents shall comprise the Type Test Report.

9

The Type Test Report shall include a copy of the raw material manufacturer's "Certificate of Quality Control Testing" covering each batch of raw material used for manufacturing pipes produced under this specification.

10

The pipe manufacturer shall ensure that all the applicable codes and standards are available at their facility for the Engineer’s reference during any visit or inspection.

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The pipe manufacturer shall provide full assistance and co-operation for any inspection, when required by the Engineer or by an inspector appointed by the Engineer.

12

The Engineer may reject any item that does not successfully pass the required tests or fully comply with the requirements of this specification. When a pipe or fitting is rejected, the items manufactured immediately before or after shall be carefully examined and tested at the direction of the Engineer. If further defects are found, the entire batch shall be rejected.

13

All pipes and fittings shall be visually inspected by the PE Welding Inspector before incorporation in the Works.

14

In addition to those tests specifically required, the Engineer may request additional samples of any material for testing by the Engineer and all expenses incurred in obtaining samples for testing shall be borne by the Contractor at no additional cost to the Contract.

3.11

POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE

3.11.1

General

1


2


3.11.2

Resin

1


2

The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method D648. The resin content shall not be less than 7% of the weight of the sample as determine by test method D2584

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3.11.3 1

Minimum strength The minimum strength classes for different pipe shapes are given below Table 3.11.1 Minimum strength classes for pipes designated PRC-OC or PRC-TC Strength class Sc Nominal size N/mm DN PRC-OC PRC-TC 150 ≤ DN ≤ 500 180 180 600 ≤ DN ≤ 1000 145 160 1200 ≤ DN≤ 3000 120 145

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Page 42

Table 3.11.2 Minimum strength classes for pipes designated PRC-OE or PRC-TE Strength class Sc N/mm


PRC-TE

300/450 ≤ WN/HN ≤ 600/900

180

180

700/1050 ≤ WN/HN ≤ 1000/1500

145

160

1200/1800 ≤ WN/HN ≤ 1400/2100

120

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PRC-OE

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Table 3.11.3 — Minimum strength classes for pipes designated PRC-OK or PRC-TK Strength class Sc N/mm

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Nominal size DN

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PRC-OK 145

160

120

145

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1200 ≤ DN ≤ 1800

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800 ≤ DN ≤ 1000

PRC-TK

END OF PART

QCS 2014

Section 08: Drainage Works Part 04: Pipeline Installation

Page 1

PIPELINE INSTALLATION ............................................................................ 3

4.1

GENERAL ...................................................................................................... 3

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12 4.1.13 4.1.14 4.1.15 4.1.16 4.1.17 4.1.18 4.1.19

Scope of Work References Guidelines Definitions Submittals Quality Assurance Delivery, Storage and Handling Specialists, Inspection and Testing Soil Corrosivity Study Setting Out and Pipeline Alignment Tools for Installation and Testing Inspection During Installation Dewatering Closures and Short Sections Cutting of Pipes Stringing of Pipes Inspection of Trench Formation Overpumping and Flow Diversions Other Services

4.2

DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND GRP PIPELINE JOINTING ............................................................................ 8

4.2.1 4.2.2 4.2.3 4.2.4

Push-fit Joints Mechanical Joints Flanged Joints GRP Joints

4.3

MDPE AND HDPE PIPELINE JOINTING .................................................... 10

4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11

General PE Welding Technicians PE Welding Inspectors PE Welding Equipment Method Statements Electrofusion Jointing Electro-fusion Joint Inspection Butt Fusion Jointing Butt Fusion Joint Inspection Testing of Fusion Joints Anchorage

4.4

PIPE LAYING .............................................................................................. 14

4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

General Laying of Rigid and Semi-Rigid Pipes Laying of Flexible MDPE and HDPE Pipes Laying of GRP Pipes Corrosion Protection of Ferrous Pipelines

3 3 4 4 4 5 5 5 6 6 6 6 7 7 7 7 8 8 8

8 9 9 9

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4

10 10 10 11 11 11 12 12 13 13 13 14 15 16 16 18

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Concrete Protection to Pipe Deflection Criteria for Flexible Pipelines Backfilling Deflection at Joints Wadi Crossings Pipe Supports Building-in Pipes to Structures Cleanliness of Pipelines Marker Tape Pressure Pipeline Marker Posts Valve Chamber Marker Posts Abandonment of Pipelines Abandonment of Structures Corrosion Protection of Flexible Couplings and Ferrous Fittings

4.5

PIPELINE STRUCTURES AND APPURTENANCES .................................. 26

4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7

Manholes for Foul Sewerage Manholes for Surface Water Sewerage Chambers Connections to Existing Pipelines Anchor and Thrust Blocks Property Connections Survey Future House Connections

4.6

TESTING OF PIPELINES ............................................................................ 30

4.6.1 4.6.2 4.6.3 4.6.4 4.6.5

General Gravity Sewer Pipelines Pressure Pipelines Other Pressure Pipelines MDPE and HDPE Pressure Pipelines

4.7

MISCELLANEOUS ITEMS .......................................................................... 38

4.7.1 4.1.2 4.7.2

Manhole Covers and Frames Duct Covers and Frames Hinged Aluminium Access Covers

4.8

FUTURE SEWER CONNECTION ............................................................... 40

4.8.1

General

4.9

INSITU LINING OF EXISTING MANHOLES ............................................... 41

4.9.1

General

19 20 20 21 21 22 22 23 24 24 24 24 25 25 26 28 28 28 29 29 29 30 31 32 33 34

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4.4.6 4.4.7 4.4.8 4.4.9 4.4.10 4.4.11 4.4.12 4.4.13 4.4.14 4.4.15 4.4.16 4.4.17 4.4.18 4.4.19

38 39 40 40 41

QCS 2014


4

PIPELINE INSTALLATION

4.1

GENERAL

4.1.1

Scope of Work

1

This Part includes the installation of pipelines.

2


Page 3

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General Demolition and Alterations Ground Investigation Concrete.

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Section 1, Section 2, Section 3, Section 5,

General Earthworks Pipes and Fittings Materials Valves, Penstocks and Appurtenances Miscellaneous Metal Works Miscellaneous GRP Works Protective Coatings and Painting

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Part 1, Part 2, Part 3, Part 5, Part 6, Part 7, Part 8,

.

This Section

References

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4.1.2

BS EN 12620..............Aggregates from natural sources for concrete

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BS 4872......................Approval testing of welders when welding procedure approval is not required BS 6072......................Tubular polyethylene film for use as a protective sleeving for buried iron pipes and fittings

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BS EN 752..................Drain and sewer systems outside buildings BS EN 1092................Flanges and their joints

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BS EN 12007..............Gas supply systems - Pipelines for maximum operating pressure up to and including 16 bar, Part 2: Specific functional recommendations for PE ISO 12176 ..................Plastics pipes and fittings — Equipment for fusion jointing polyethylene systems, Parts 1 and 2 ISO 21307 ..................Plastics pipes and fittings — Butt fusion jointing procedures for polyethylene (PE) pipes and fittings used in the construction of gas and water distribution systems ISO 13953 ..................Polyethylene (PE) pipes and fittings - Determination of the tensile strength and failure mode of test pieces from a butt fused joint ISO 13954 ..................Plastics pipes and fittings - Peel decohesion test for polyethylene (PE) electrofusion assemblies of nominal outside diameter greater than or equal to 90 mm SFS 3115:E ................Plastics Pipes Water Tightness Test for Pressure Pipelines (English version of Finnish Standard) WIS-4-08-02 ...............Specification for bedding and sidefill materials for buried pipelines

QCS 2014


Page 4

AWWA C200 ..............Steel Water Pipe 150 mm and Larger AWWA C600 ..............Installation of Ductile-Iron Water Mains and Their Appurtenances. 4.1.3

Guidelines

1

The following Guidelines are applicable to the installation and testing of HDPE pipes and fittings: DVGW GW330...........Installation & Welding of High Density Polyethylene (HDPE) Pipes for Gas & Water Applications DVGW GW331...........Supervision of Installation & Welding of High Density Polyethylene (HDPE) Pipes for Gas & Water Applications

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DVS 2202-1 ................Imperfections in thermoplastic welded joints: Features, description, evaluation

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DVS 2203-1 ................Testing of welded joints of thermoplastic sheets and pipes: Test methods – Requirements DVS 2207-1 ................Welding of thermoplastics: Heated tool welding of pipes, pipeline components and sheets made of HDPE

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DVS 2208-1 ................Welding of thermoplastics: Machines and devises for the heated tool welding of pipes, pipe parts and panels Definitions

1

Pipes: circular tubes through which fluid can flow including manufactured lengths of pipes, bends, fittings, junctions and other specials, joints and jointing parts.

2

Valves: manufactured devices for controlling the passage of fluids through pipes including sluice gates, reflux valves, and air valves including associated joints, jointing parts, operating gear and fittings.

3

Installation: material transport and handling, pipelaying including the complete operation of laying jointing and testing pipes in trenches or elsewhere, and the construction of pipeline ancillaries

4

Pipeline: long, continuous line of pipes and fittings including valves and ancillary structures and equipment used for transporting fluids; specifically, sewers and ancillary works for the transport of sewage and surface water and similar pipelines for the transport of treated sewage effluent.

4.1.5

Submittals

1

The Contractor shall submit the documents described in the following paragraphs.

2

Working drawings: Before commencing work the Contractor shall prepare working drawings necessary for the construction and installation of facilities. The drawings shall be prepared to A1 size or a size and scale as directed by the Engineer. The drawings shall be submitted to the Engineer in an orderly manner and at periods which will permit adequate time for review and approval by the Engineer. Five copies of drawings shall be submitted.

3

Detailed work programme with schedule for the delivery of pipes and fittings

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4.1.4

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4


Page 5

Methods statements to supplement the working drawings, as follows: (a)

installation (i)

joints and couplings

(ii)

measures to ensure integrity of interior pipe lining and exterior protective coating at joints and couplings installation and adjustment of pipe bedding and other supports

(iv)

fitting of pipelines to valves.

testing of sewer pipelines and pressure pipelines to the requirements described in Subpart 4.5

(c)

welding procedures and electrodes with drawings and schedules as may be necessary

(d)

safety procedures and protective equipment

(b)

(i)

pipe pressure tests

(ii)

dielectric joint tests

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certified copies of reports of required tests including:

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(a)

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Quality assurance and control documents including

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(b)

copies of certificates relating to welder’s tests shall be made available to the Engineers on request

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(iii)

Quality Assurance

1

A suitably qualified and experienced safety officer shall be employed to ensure that all Contractor’s employees follow safety procedures and are provided with appropriate safety and protective equipment.

2

Welders employed on the fabrication and site welding shall have passed the welder approval tests of BS 4872, Part 1 or other standard approved by the Engineer.

4.1.7


1

Delivery, storage, and handling shall be as specified in Part 3 of this Section.

2

The Contractor shall replace or repair pipe damaged during handling and installation, to the approval of the Engineer.

4.1.8

Specialists, Inspection and Testing

1

The Employer may employ the services of a specialist firm to assist the Engineer as he may require in any matter connected with pipes, and fitting including the inspection of materials and workmanship and the witnessing of tests at any stage during the execution and maintenance of the Works.

2

Such independent tests may be carried out at any stage during the execution and maintenance of the Works, but they shall not relieve the Contractor of his obligations under the Contract.

3

To the extent ordered by the Engineer, the Contractor shall provide labour, plant, tools and materials (but not special testing equipment) for direct assistance to the specialist firm in their inspection and independent testing and for any further work, investigations, and repairs which the Engineer considers necessary as a result of such inspection or testing.

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4.1.6

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Page 6

The provision of labour, plant and materials as aforesaid shall be an obligation of the Contractor where in the Engineer's opinion the inspection test or further investigation shows that materials and workmanship provided by the Contractor do not comply with the designated requirements.

4.1.9

Soil Corrosivity Study

1

Where designated in the Project Specification, the Contractor shall carry out a soil corrosivity study along the route of proposed ferrous pipelines as directed by the Engineer and mark the results on the pipeline layout plans.

2

Soil resistivities shall be undertaken using a low resistance, null-balance earth tester and a four pin array, or any other equipment approved by the Engineer. Readings shall be recorded in ohm-cm and shall be taken at 1.0 m incremental depths to a depth 1 m below the pipeline invert levels. Readings shall be taken at a spacing along the route of the proposed pipelines as required to reflect the changing soil conditions, but in no case shall the spacing exceed 500 m.

3

Soil samples shall be taken as directed by the Engineer along the route of the proposed pipelines at a maximum spacing of 500 m. Soil samples shall be tested for sulphates, sulphides, chlorides, pH, moisture content, and carbonates.

4.1.10

Setting Out and Pipeline Alignment

1

All sewers shall be laid accurately to the lines, and levels gradients shown on the approved drawings so that the pipeline is straight between successive manholes in the vertical and horizontal planes.

2

Pressure pipelines shall be laid accurately to the lines levels and depths shown on the approved drawings. Where changes of direction are required, deflections shall be made in accordance with the manufacturer’s recommendations.

3

Manufactured bends shall only be used where shown on the Drawings or where otherwise permitted by the Engineer’s Representative.

4

Where pipelines of constant gradient are to be laid, the Contractor shall provide, fix and maintain at such points as may be directed by the Engineer’s Representative properly painted sight rails and boning rods of pre-determined measurement for the boning in of individual pipes to correct alignment. The sight rails shall be situated vertically over the line of pipes or immediately adjacent thereto and there shall at no time be less than three sight rails in position on each length of pipeline under construction to any one gradient

5

If the Contractor wishes to propose an alternative method of controlling pipeline alignment, he shall submit his proposed method to the Engineer’s Representative for approval

4.1.11

Tools for Installation and Testing

1

The Contractor shall supply all necessary tools for cutting, chamfering, jointing, testing and for any other requirement for satisfactory installing the pipelines.

4.1.12

Inspection During Installation

1

Pipes and fittings including any sheathing, inside linings and outside coatings, shall be inspected by the Contractor immediately before and after installation, and damage or other imperfection shall be repaired by the Contractor as directed by the Engineer before installation and in accordance with the following:

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Page 7

(a)

Material required for the repair of pipe, sheathing, linings and coatings shall be obtained by the Contractor and shall be used in accordance with the manufacturers recommendations.

(b)

Without relieving the Contractor of any of his obligations, the Engineer may inspect and test the pipe and appurtenances by any appropriate means, and damage discovered by such inspection shall be repaired by the Contractor.

(c)

The Contractor shall remove from Site any pipe or appurtenance which in the opinion of the Engineer is so damaged as to be unfit for incorporation in the Works. The obtaining of replacements for damaged pipes and fittings to the approval of the Engineer shall be an obligation of the Contractor.

Dewatering

1

All pipeline installation work shall be carried out in the dry.

2

Dewatering shall be carried out as specified in Part 2 of this Section.

4.1.14

Closures and Short Sections

1

For the purpose of reducing the angular deflections at pipe joints, and for closure sections, the Contractor will be permitted to install pipe sections of less than standard length. Closing lengths and short sections of pipes of all types shall be fabricated and installed by the Contractor as found necessary at Site. Where closing pieces are required, the Contractor shall make all necessary measurements and shall be responsible for the correctness thereof. The Contractor shall be responsible for taking the measurements required to determine the lengths of cut portions of pipes for insertion as closing lengths in pipelines.

4.1.15

Cutting of Pipes

1

Where pipes are required to be cut on the Site the cutting shall be done by the Contractor in accordance with the manufacturer’s recommendations and in a manner approved by the Engineer.

2

The pipe and methods of jointing shall be such that the locations of fittings and lengths of pipe can be adjusted to suit Site conditions.

3

Cutting of reinforced concrete pipes will not be allowed. Special lengths of pipes shall be manufactured for closures as required. Other pipes such as GRP, ductile iron, vitrified clay, MDPE, HDPE, PVC-U and cast iron pipes shall only be cut if approved by the Engineer.

4

The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes for inserting specials, fittings or closure pieces shall be carried out as follows:

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4.1.13

(a)

Cutting shall be carried out in a neat and workmanlike manner with an approved cutting machine without damage to the pipe and so as to leave a smooth end at right angles to the axis of the pipe.

(b)

Cutting by hacksaw shall not be permitted unless approved by the Engineer.

(c)

Only experienced men shall be employed by the Contractor on this work.

(d)

The Contractor shall take every precaution to ensure that both the measurement tolerances and the cutting of pipes are to the accuracy required. Should any errors occur the Contractor shall correct the defects to the approval of the Engineer.

4.1.16

Stringing of Pipes

1

Pipes shall be distributed to installation site only in such quantities as can be installed in one working day or as allowed by the Engineer.

QCS 2014


Page 8

The Contractor shall take pipes from the storage areas, unload and string along the route of the proposed pipeline. Pipes shall be so strung as to cause the least practicable interference with the use of the land.

3

After a pipe has been strung and immediately before being laid, it shall be cleaned out and inspected for defects. Cast or ductile iron pipes shall be rung with a light hammer while the pipe is suspended clear of the ground to detect cracks. Other pipes shall be visually inspected. Any defective, damaged or unsound pipe shall be rejected. Any damage to the lining or coating of the pipe shall be repaired or the pipe rejected as directed by the Engineer.

4

Plastic pipes shall not be strung along the pipe route but shall be stored in accordance with Part 3 of this Section until required for laying and jointing.

4.1.17

Inspection of Trench Formation

1

After excavations have been completed to the designated levels and, trench formation compacted, the Contractor shall issue a formal notice to the Engineer that the trench formation is ready between designated points for inspection. The Engineer will without unreasonable delay inspect the said trench formation, unless he considers it unnecessary and advises the Contractor accordingly. Any rejection of trench formation will be confirmed in writing by the Engineer.

2

The formation will be re-inspected by the Engineer after replacement of any unsound material with material as specified under Clause 2.2.3 of Part 2 of Section 8.

3

No bedding shall be placed until the Engineer’s Representative has given his approval to the trench formation.

4.1.18

Overpumping and Flow Diversions

1

Flow diversions shall be in accordance with Clause 10.4 of the Section.

4.1.19

Other Services

1

Where the Works requires the seeking, protection, diversion or relocation of existing services the procedures set out in Section 6 Part 11 shall be followed.

4.2

DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND GRP PIPELINE JOINTING

4.2.1

Push-fit Joints

1

Immediately before assembling each joint incorporating a rubber ring seal, the rubber shall be inspected for cracks, every part of the ring being deformed by hand to about 150 mm radius. If under this deformation any cracks are either revealed or initiated then the ring shall be rejected, cut through completely to prevent inadvertent use, and the matter reported forthwith to the Engineer. If more than three successive rings inspected in this way are rejected the Contractor shall on the instruction of the Engineer stop all pipe jointing until the cause of the defect has been proved and remedied to his satisfaction.

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Page 9

The rubber ring shall be placed in the groove on the socket or spigot ring. The groove shall be free of deleterious material; e.g., dirt, moisture, oil, and grease. The inside surface of the socket shall be lubricated with a compound recommended by the manufacturer which will facilitate the telescoping of the joint. The spigot end of the pipe shall then be inserted into the socket of the adjoining pipe using a suitable tool to push the spigot into the socket. The position of the pipe and the gasket in the joint shall then be checked using a feeler gauge to demonstrate proper jointing. When joints are not properly made, pipes shall be adjusted, or removed and rejointed as necessary to ensure proper jointing. Care shall be taken to avoid twisting or cutting the ring when jointing the pipe.

3

For pipes up to and including 700 millimetres nominal bore the joints shall be capable of withstanding a deflection of not less than 1.5 degrees in any direction and for pipes over 700 millimetres nominal bore 0.5 degrees in any direction. All pipe joints shall be capable of withstanding a “draw” of 13 millimetres over and above the initial jointing allowance. The initial jointing allowance is the gap between the spigot and the shoulder of socket measured parallel to the centre line of the pipeline and shall not be less than 6 millimetres or greater than 13 millimetres.

4.2.2

Mechanical Joints

1

Where mechanical joints are approved, installation shall be in accordance with the manufacturer’s recommendations. The Contractor shall render the end of each pipe perfectly smooth so as to allow the joint sleeve to slide freely and where necessary shall coat the pipe ends with two coats of an approved quick drying sealing and protective compound. Buried joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied as clause 4.3.5.

4.2.3

Flanged Joints

1

Flanged joints for ductile iron and cast iron pipes and specials shall be made with rubber joint gaskets and steel bolts and nuts which shall include two washers per bolt. The use of jointing paste or grease shall not be permitted. The gasket may be fastened to the bolts with cotton thread. The bores of abutting pipes or fittings shall be concentric and no jointing material is to be left protruding into the bore.

2

All nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference shall then be alternately and progressively tightened with a spanner so as to ensure even pressure all around the joint.

3

Buried joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied as clause 4.3.5.

4.2.4

GRP Joints

1

Joints shall be of the “O” ring or rolling type, and shall incorporate a soft or flexible control register to help to locate the joint.

2

GRP pipe joints shall be assembled in accordance with manufacturer's instructions for the type of flexible joint provided.

3

Joints shall be capable of withstanding the various tests specified for the appropriate class of pipe. Joints shall withstand, while maintaining the specified test pressure, a deflection of not less than 1.5  in any direction or for pipes up to and including 600 mm nominal bore, and

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2

0.5  in any direction for pipes over 600 mm diameter. 4

Rubber joint rings shall be made of EPDM SBR or nitrile rubber (NBR) and shall comply with the relevant requirements of BS EN 681-1 for Type WG rings.

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Page 10

5

Flanged pipes, if required, shall incorporate an annular gasket and these gaskets shall cover the full face of the flange and shall have holes cut in correspondence to the bolt holes in the flanges. Flanges shall be drilled to BS EN 1092 type PN 16. Alternatively jointing system for flanged pipes, incorporating rubber rings, may be approved by the Engineer. Stainless steel backing rings shall be inserted between the bolt head / nut and the GRP flange to spread the load.

4.3

MDPE AND HDPE PIPELINE JOINTING

4.3.1

General

1

The Contractor shall abide by the following guidelines with regards to jointing MDPE and HDPE (PE) pipes and fittings unless otherwise approved by the Engineer. PE pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever possible.

(b)

PE pipes and fittings of less than 90 mm OD shall be joined together using electrofusion couplings and fittings.

(c)

Electro-fusion fittings may also be used to undertake repairs and install off-takes or connections on existing pipelines. They may also be used for the joining together of pipe strings where it is not practical to use a butt fusion welding machine.

(d)

To join PE pipes to metal pipes and fittings such as valves, restrained mechanical transition fittings and stub flanges shall be used.

(e)

Restrained mechanical fittings may, with the permission of the Engineer, to undertake repairs and install off-takes or connections on existing pipelines.

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(a)

PE Welding Technicians

1

All PE electro and butt fusion jointing, PE jointing to GRP and metallic valves and fittings shall only be undertaken by a certified HDPE Welding Technician holding a valid Welder Licence.

2

The PE Welding Technician shall have attended a comprehensive course on the Installation and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall be 5 days and the Technician shall have sat and passed an exam in accordance with the GW330 standard of the German Technical and Scientific Association for Gas and Water (DVGW) or an equivalent national body approved by the Engineer.

3

The PE Welding Technician shall hold a valid GW330 Welder License or equivalent issued by a national body approved by the Engineer, which shall be subject to annual renewal by attending a re-examination course.

4.3.3

PE Welding Inspectors

1

A specialist PE Welding Inspector shall observe and supervise the handling, welding, jointing to other materials and testing on site of all HDPE pipes and fittings.

2

The PE Welding Inspector shall have attended a comprehensive course on the Installation and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall be 5 days and the Inspector shall have sat and passed an exam in accordance with the GW331 standard of the German Technical and Scientific Association for Gas and Water (DVGW) or an equivalent national body approved by the Engineer.

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4.3.2

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PE Welding Equipment

1

All welding machines and welding equipment shall fulfil the requirements of DVS 2208-1 or the relevant part of ISO 12176. All welding machines shall be of an automatic or semiautomatic design where the welding machine determines and controls the welding parameters based on the pipe and fitting details entered by the operator. They shall also be equipped with a data logging function that measures and records information listed in DVS 2208-1.

2

All machines shall undergo a yearly calibration and function test, carried out by a service centre authorised by the machine manufacturer.

4.3.5

Method Statements

1

A detailed method statement for PE pipe jointing shall be prepared by the Contractor and submitted to the Engineer for approval. The method statement shall include details of which equipment shall be used and how the work will be performed to ensure compliance with the recommendations of the pipe manufacturer and of this specification. It shall include, but not be limited to:

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4.3.4

Details of the equipment to be employed by the Contractor, together with procedures for its operation, maintenance, periodic inspection and testing.

(b)

Details of the experience and certification of the pipe and fitting jointers that shall be employed by the Contractor.

(c)

Procedures for joint preparation, indicating method and degree of cutting, cleaning, drying, scraping, alignment, support, etc. of the pipe ends to be joined.

(d)

Jointing procedures, specifying the equipment and tools to be employed, together with all relevant parameters such as voltage, temperature, pressure, heating time and cooling down time and the means by which jointing operations shall be controlled.

(e)

Inspection and testing procedures together with proposals for the independent and on site inspection and testing on welds on a regular basis.

(f)

QA/QC procedures

(g)

All safety precautions and procedures.

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(a)

Electrofusion Jointing

1

All electrofusion jointing shall be undertaken in accordance with this specification and the guidance given in DVS 2207-1

2

Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying with the requirements of ISO4427, Part 3 shall be used. The electrofusion control unit shall incorporate data input through the use of a bar code reader pen and a data retrieval facility to allow historical fusion data to be read on the unit’s screen and to be exported to an external computer or memory stick.

3

The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion fitting. The power generator shall provide the power requirements of the control box, taking into account the electrical characteristics of the control box.

4

Positioning tools including suitable alignment clamps shall at all times be used to minimise misalignment and prevent movement during the fusion and cooling cycle of the joint. A suitable shelter shall be used in cold, windy, dusty or wet weather conditions.

5

Prior to commencing the welding process the Contractor shall measure and ensure that the ovality of the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.

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All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking the pipe scraping, in order to remove any contamination. Prior to scraping the Contractor shall measure and mark the area of the pipe or spigot end to be scraped in order to remove the oxidized surface to a depth between 0.2 and 0.4 mm. The length of the pipe or spigot end to be scraped shall be equivalent to the insertion depth of the electro-fusion joint plus a distance of between 10 and 20 mm.

7

Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip or ribbon over the insertion length of the coupler or fitting, shall be used.

8

Only after preparation and scraping of the pipe end shall the fitting be removed from its packaging and immediately inserted over the pipe end.

9

Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion socket.

10

Alignment clamps shall not be removed before the appropriate cooling time has elapsed. Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior to commencement of the fusion process.

4.3.7

Electro-fusion Joint Inspection

1

All completed electro-fusion joints shall be inspected in accordance with the requirements of Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the standard then the electro-fusion fitting shall be cut out and replaced.

2

After completion of the fusion process, all fusion indicators shall be checked to ensure that they are in the position indicated in the Manufacturer's instructions. If any fusion indicators are not in the required position the electro-fusion fitting shall be cut out and replaced.

3

The Contractor shall, on a regular basis allow the Engineer to download the historical data relating to the welds made by the unit through the data retrieval facility.

4.3.8

Butt Fusion Jointing

1

All butt fusion jointing shall be undertaken in accordance with this specification, the single low pressure jointing procedure given in ISO 21307 and the guidance given in DVS 2207-1.

2

Assign a unique joint number to each joint and have a data retrieval facility to allow historical fusion parameters to be read on the unit’s screen and to be exported to an external computer or memory stick

3

In the case of large diameter pipes having a high wall thickness in excess of 35 mm the Contractor may propose to instead follow the single high pressure fusion jointing procedure described in ISO 21307. Such a deviation from DVS2207-1 shall only be allowed with the written approval of the Engineer.

4

Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.

5

A dummy joint shall be made at the start of each welding session using pipe off cuts of the same size, material and SDR as the pipe being installed. The normal trimming, bead up and full heat soak cycles will be adhered to.

6

If the pipe size is changed during the day, if the heater plate is allowed to cool below 180°C or if maintenance of the butt fusion equipment is carried out then a new dummy weld shall be performed.

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4.3.9

Butt Fusion Joint Inspection

1

All butt fusion joints shall be inspected in accordance with the requirements of Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the standard then the joint shall be cut out and replaced. The inspection shall include the following points: The gap between the two single beads shall not be below the fusion surface.

(b)

The displacement between the fused pipes must not exceed 10% of the pipe wall thickness.

(c)

The difference between two single bead widths shall not exceed 10% of the double bead width.

(d)

The weld beads shall be free from all contamination and have a smooth even surface with no evidence of distortion, holes or bubbles

(e)

At the direction of the Engineer external beads shall be removed with an approved tool and inspected for contamination and defects. They shall also undergo bend back testing. Beads should be solid and rounded with a broad root as hollow beads with thin root and curled appearance can be indicative of excessive pressure or no heat soak.

(f)

Each removed bead shall be numbered with its corresponding joint number clearly displayed and removed beads shall be retained for inspection by the Engineer.

(g)

The width of each external bead width shall be measured using bead gauges and the width of the bead shall be within the range given by the pipe and / or welding equipment manufacturer.

(h)

No signs of damage (such as scratches or deep impressions caused by clamps) shall be visible on either side of the joint.

(i)

Any joints the do not comply with the above requirements shall be cut out and a new joint made; the failed joint shall be handed over to the Engineer.

(j)

Records of all tests and inspections shall be maintained by the Contractor and made available for review and approval by the Engineer.

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(a)

Testing of Fusion Joints

1

A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under laboratory conditions in accordance with ISO 13953 by an approved testing organisation. The joints to be tested shall be selected by the Engineer immediately upon completion of the welding process, whereupon they shall be cut out and delivered for testing.

2

A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested under laboratory conditions in accordance with ISO 13954 by an approved testing organisation. The fittings to be tested shall be selected by the Engineer immediately upon completion of the welding process, whereupon they shall be cut out and delivered for testing. They shall comprise at least 1 of each type of electro-fusion fitting even if this requires more than 1 % of all electro-fusion fittings to be tested. Note that the minimum test requirement is for one fitting of each type i.e. bend, coupling, tapping saddle, tee etc. not one of each size and type.

3

All costs associated with the testing, together with any consequent rectification of faults and retesting shall be borne by the contractor.

4.3.11

Anchorage

1

Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and tie rods used where there is a possibility of pulling the joint under pressure. Concrete thrust blocks shall be used in lieu of the above where socket and spigot pipe is used below ground. The Contractor shall submit, for the Engineer’s approval, working drawings and information demonstrating the adequacy of anchorage systems other than thrust blocks or other systems shown on the Contract Drawings.

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PIPE LAYING

4.4.1

General

1

Except as otherwise specified in this Clause, pipe bedding shall conform with the requirements specified in Part 2 of this Section.

2

The Contractor shall, after excavating the trench and preparing the proper bedding, furnish all necessary facilities for properly lowering and placing sections of the pipe in the trench without damage and shall properly install the pipe.

3

Each pipe shall be carefully lowered onto its prepared bed by means of appropriate slings and tackle. A recess shall be left in the prepared bed to permit the sling to be withdrawn. If the prepared bed is damaged, the pipe shall be raised and the bed made good before pipe laying is continued.

4

No pipe shall be rolled into place for lowering into the trench except over suitable timber planking free from roughness likely to damage any coatings.

5

The section of pipe shall be fitted together correctly and shall be laid true to line and grade in accordance with the bench marks established by the Contractor. The bench marks shall be approved by the Engineer.

6

The full length of the barrel of the pipe shall have a uniform bearing upon the bedding material and if the pipe has a projecting socket, suitable excavation shall be made to receive the socket which shall not bear on the subgrade.

7

Pipes shall be laid with the class identification marks or the jointing marks shown by the manufacturer in the uppermost position. Pipe sections shall be so laid and fitted together that the pipeline will have a smooth and uniform interior. The pipeline shall be clean and unobstructed at the time of its installation and shall be true to the required line and levels.

8

Spigot and socket pipes shall generally be laid upgrade without break from structure to structure and with the socket end upgrade. Backlaying may be permitted as deemed necessary and approved by the Engineer.

9

Whenever work ceases on any pipeline the unfinished end of the pipeline shall be securely closed with tight fitting plug or cover.

10

Before any pipe is lowered into place, the bedding shall be prepared and well compacted so that each length of pipe shall have a firm and uniform bearing over the entire length of the barrel.

11

Pipes shall be laid in straight lines, both in the horizontal and vertical planes, between manholes or, where directed in the case of pressure pipelines and larger diameter sewers to regular curves. The placement of pipes shall comply with the following requirements:

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4.4

(a)

each pipe shall be plumbed to its correct line and directly and accurately sighted by means of a laser positioning system or boning rods and sight rails fixed to secure posts which shall be set up and maintained at each end of the sewer to be laid and not more than 20 m apart. Sight rails shall be clearly painted in contrasting colours and be not less than 150 mm deep, straight and level

(b)

boning rods shall be of robust construction clearly painted and accurately made to the various lengths required, the lower end being provided with a flat edged shoe of sufficient projection to rest on the invert of the pipes as laid. The boning rod shall be complete with a vertical spirit level

(c)

boning rods and sight rails shall not be removed until the pipeline has been checked and approved by the Engineer

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(d)

alternative methods of locating and levelling pipelines may be allowed subject to the approval of the Engineer

(e)

any pipe which is not in true alignment, both vertically and horizontally, or shows any undue settlement after laying, shall be taken up and relaid correctly by the Contractor

(f)

all adjustments in line and grade shall be made by scraping away or filling and tamping in under the barrel of the pipe and not by wedging or blocking

(g)

the trench shall be kept completely dry

(h)

in no case shall pipes be jointed before being lowered into position

(i)

the gasket should be positioned and lubricated.

Pipelines shall be tested in accordance with Subpart 4.5.

4.4.2

Laying of Rigid and Semi-Rigid Pipes

1

Each pipe immediately before being laid shall be carefully brushed out and inspected for defects. In trench pipes with flexible joints except where concrete bed, bed and surround or protection is required shall be laid on a well compacted bed of granular material extending for the full width of the trench and with sufficient material at the sides to permit the pipes to be worked into the granular material and firmly supported to true line and level. Sufficient space should be left to enable the joints to be made tested and inspected but the Contractor shall ensure that at least three quarters of the pipe length is fully supported. After the pipeline has been tested and approved by the Engineer the trench shall be carefully filled to 300 mm above the crown of the pipe with granular material in accordance with the bedding requirements specified in Part 2 of this Section and as shown on the Drawings.

2

Vitrified clay pipes shall be installed in trenches which shall not exceed the maximum trench width at 300mm above crown of pipe as shown in Table 2.1 of Part 3 of this Section.

3

Should the Contractor exceed the trench widths given in Table 2.1 he shall provide calculations to show the loading on the pipe and bedding requirements and where required he shall provide plain or reinforced concrete cradle or surround, to the approval of the Engineer, at no additional cost. The same type of pipe bedding/surround shall be used for the full sewer length between adjacent manholes.

4

Unless otherwise specified, pipe bedding shall be as shown on the Contract Drawings. Notwithstanding the above, for Vitrified Clay pipe the special pipe bedding requirements as Table 4.2 are to be provided in all cases whether or not shown on the drawings or indicated in the bills of quantity.

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Table 4.2 - Special Bedding Requirements for VC Pipes Nominal bore mm

Depth to Invert (D) m

Bedding Type*

700-800

D>9.0

4.1.1.1.1 Plain concrete cradle

>900

4.0
4.1.1.1.2 Plain concrete cradle

>900

5.0
>900

D>9.0

Reinforced concrete cradle with minimum 0.4% transverse steel Reinforced concrete surround with minimum of 1% transverse steel. (* as shown on drawings)

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Laying of Flexible MDPE and HDPE Pipes

1

This clause does not apply to GRP pipes for which laying requirements are given in Clause 4.3.4 of this Section.

2

All operations involving the laying, bedding, jointing, backfilling etc. of pipes of plastic materials shall be strictly in accordance with the manufacturer’s recommendations subject to the approval of the Engineer.

3

The pipeline shall be laid on a well compacted sand or granular material that shall extend across the full width of the trench bottom. The pipe bed shall have a minimum thickness of 100 mm and be compacted to a minimum modified Proctor (AASHTO) density of 90% prior to the laying of the pipeline.

4

After laying of the pipeline the Contractor shall place pipe surround material on both sides of the pipe, ensuring that no cavities are left between the underside of the pipe and the trench bottom or pipe bed. The pipe surround material shall be placed in layers of no more than 150 mm thick and compacted with hand tools across the width of the trench to achieve a minimum Modified Proctor (AASHTO) density of 90%. The pipe surround shall extend to a minimum of 200 mm above the crown of the pipe.

5

Where pipes are laid in good quality ground conditions such as those native soils comprising granular, sandy or rocky materials, the pipe bed and surround shall comprise clean dry sand free from silty and foreign materials and particles of larger than 10 mm diameter.

6

The maximum particle size of the granular material shall also not exceed 10% of the pipe outside diameter.

7

Should the excavated native soil fail to meet the above requirements it shall be graded on site in order to do so or be replaced with an imported sand or granular material complying with the requirements of the UK WIS 4-08-02 or this specification.

8

Where pipes are laid in poor quality ground conditions such as those native soils comprising soft or silty materials, the pipe bed and surround shall comprise an imported granular material complying with one of the grades given in the UK WIS 4-08-02 or this specification.

9

Single sized aggregate shall not be used for the pipe bed and surround in conditions where the native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile filter fabric to prevent migration of fine material from the surrounding soil in to the bed and surround

10

When the grade at which the pipeline laid exceeds 10 trench breakers or clay dams shall be installed to prevent the migration of bed and surround material due to the flow of water along the trench.

4.4.4

Laying of GRP Pipes

1

During the mobilisation period the Contractor shall submit for the Engineer’s approval the pipe manufacturer’s complete and detailed specification for the handling and installation of pipe and fittings in open trench and such other methods of construction of pipeline specified or proposed by the Contractor. This specification shall be submitted during the mobilisation period irrespective of whether the data was submitted with the Tender.

2

The Contractor shall transport, store, handle and lay pipes in accordance with the approved manufacturer’s handling and installation specification as approved by the Engineer.

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The manufacturer’s handling and installation specification shall include details of the manufacturer’s technical expert to be assigned to the Contract. The technical expert shall have extensive experience of handling and installation of GRP and shall be fully familiar with the manufacturer’s handling and installation specification.

4

The manufacturer’s technical expert shall provide comprehensive technical assistance to the Contractor throughout the Contract and shall regularly monitor the Contractor’s handling and installation operations.

5

Any instructions or advice given by the manufacturer’s technical expert to the Contract shall be copied to the Engineer. In the event that the Contractor deviates from the approved handling and installation specification, the manufacturer’s technical expert shall immediately inform the Contractor and the Engineer.

6

All costs associated with the provision of a technical expert by the manufacturer shall be borne by the Contractor.

7

GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding material. The space below the barrel of the pipes shall be filled with special bedding material to the full width of the trench in layers not exceeding 150 mm in thickness. After pipe laying, further special bedding shall be placed and thoroughly compacted to fill the entire space between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater thickness of special bedding below, around and over the pipes than those specified they shall be deemed to have been allowed for in the rates for bedding.

8

Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first 100 mm of pipe at entry to the structure shall be surrounded by an approved flexible material. Flexible joints shall be incorporated adjacent to structures, in accordance with Clause 4.2.4.

9

Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed with two layers of resin, the second layer being paraffin wax filled to ensure full cure.

10

Where GRP pipes are required to be surrounded with concrete, all necessary precautions shall be taken to ensure that maximum allowable deflections are not exceeded. Adequate precautions are to be taken to ensure that the pipe does not float during placing of the concrete surround.

11

At all times, backfilling shall be carefully carried out to ensure no voids or pockets of unconsolidated material are present. The Contractor shall monitor the vertical deflection of the pipes throughout the backfilling operation. No pipe shall exhibit more than 1.5% deflection after placing and compaction of the granular bed and surround. In addition, after completion of the trench backfilling, the average deflection of a length of pipe shall not exceed 1.5%, and every pipe shall be demonstrated to exhibit no more than the manufacture’s calculated allowable ‘Initial Deflection’, or 3.5% deflection, whichever is smaller. If any of these values are exceeded, the affected pipes shall be exhumed and re-laid.

12

The deflection shall also be checked on each length between manholes or chambers before commissioning to determine whether longer term deflections are within permissible limits. The average deflection of a length of pipe shall not exceed 3%, and every pipe shall be shown to exhibit a deflection no greater than 5%, or the calculated allowable deflection consistent with the achievement of a long term deflection not exceeding 5%, whichever is smaller, at any point. Pipes exhibiting greater deflections shall be exhumed and re-laid.

13

Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated allowable long term deflection, shall be exhumed, indelibly marked ‘REJECTED’, removed from the site and not reused.

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Corrosion Protection of Ferrous Pipelines

1

Where tape wrapping is wrapped at site it shall be applied by machine under factory controlled conditions in accordance with Clause 3.7.6 of this Part.

2

Pipe joints shall be protected by continuing the tape wrapping, or by heat shrink polyethylene tubes coated internally with thermoplastic adhesive. The profile of the pipe joint shall be smoothed using bituminous mastic or preformed plastic foam sections taped in position. Heat shrink sleeves shall be on pipes with extruded polythene coatings, and in all cases shall be applied in accordance with the sleeve manufacturer’s and pipe coating manufacturer’s instructions.

3

Joints within in-situ concrete chambers do not require heat shrinkable sleeve protection.

4

Damaged areas of protective coating or wrapping shall be repaired in a manner to be approved by the Engineer’s Representative.

5

Ferrous pipelines shall be supplied with one of the following corrosion protection systems:

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Cold applied self-adhesive laminate tape wrapping

(b)

Extruded polyethylene coating

(c)

Loose polyethylene coating

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Extruded polyethylene coating shall be as Clause 3.7.7. Heat shrink sleeves shall be used over joints in polyethylene coated buried pipes.

7

Spigot ends of pipes coated in either of the approved manners shall not be coated over the depth of engagement within the socket or flexible coupling, but shall be coated with epoxy, polyethylene or polyurethane for pipes internally lined with these materials.

8

Where ductile iron buried pipe is designated to be encased in loose polythene sleeving, installation shall be in accordance with BS 6076.

9

The pipe shall be supported by a central sling and a length of sleeving pulled over the spigot end and bunched up to the sling.

10

The pipe shall then be rested on blocks placed at its extremities and the sleeving pulled up to the socket and folded and taped or tied in position. The sling shall then be replaced to enable jointing to be carried out. A wide sling shall be used to distribute the weight and thus obviate intense pressure on the sleeving. Care shall be taken to avoid damage when removing the sling from the trench.

11

The sleeve shall not be drawn up over the pipe joints until the completion of the hydrostatic testing. Immediately after making the pipe joint, the pipe trench shall be backfilled as described hereinbefore in readiness for the hydraulic testing and to prevent damage to the sleeving.

12

After completion of the hydraulic testing, the sleeving shall be drawn up over and fixed around the pipe joints. A pad of sleeving shall first be placed around the joint to prevent damage to the joint sleeve by the edges of the socket or by bolts. A length of sleeving shall then be drawn over joint overlapping itself either side of the joint for a minimum of 300 mm and this shall be tied or taped tightly in position.

13

Any pipe sleeving perforated during fitting shall be repaired by overlaying with a short sleeve folded and secured with tape. Torn or damaged sleeving which is considered by the Engineer as not repairable by this method shall be replaced by the Contractor.

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Immediately after fitting the pipe sleeving the pipe trench shall be partly backfilled to prevent damage to the sleeving.

4.4.6

Concrete Protection to Pipe

1

Where concrete protection to pipelines is specified or ordered by the Engineer’s Representative a 75 mm thick Grade 20 concrete layer shall be laid over the full width of the trench and never less than 150mm wider on each side than the barrel of the pipe and with its top surface positioned as shown on the drawings.

2

This concrete shall be allowed to set and be thoroughly washed down before pipe laying is started.

3

The length of pipeline laid in any one operation before concreting the pipeline shall be that which in the opinion of the Engineer’s Representative permits accurate laying of the pipeline and proper compaction of the fill.

4

Pipes up to 1200mm diameter shall be firmly supported on precast concrete blocks and separated from them by 25mm thick saturated softwood packing.

5

Pipes greater than 1200mm diameter shall be firmly supported on precast concrete blocks and separated from them by saturated softwood packing 38mm thick.

6

Alternatively for pipes up to 300mm diameter a layer of concrete Grade 20 of minimum water content can be laid on the 75mm concrete layer and the pipes worked into this concrete to true line and level before it sets. Sufficient space shall be left to enable joints to be made, tested and inspected but the Contractor shall ensure that the barrel of the pipe is fully supported for at least two thirds of the pipe length.

7

After the pipeline has been tested, and approved by the Engineer’s Representative, the concrete shall be thoroughly washed down and additional concrete Grade 20 shall be carefully placed and compacted thereon to avoid disturbing the pipes or joints until the appropriate profile for the type of protection required has been reached.

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Minimum thickness of surround mm

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Nominal bore of pipe mm

Up to and including 500

150

500 – 900

250

1000 – 1100

300

1200 - 1400

350

>1400

400

8

Concrete protection to the pipelines shall be concrete cradle or concrete surround as detailed on the Drawings and shall be of concrete Grade 20. The thickness of the concrete surround below, to the sides and above pipes shall be as follows:

9

When support of excavation is provided building paper shall be placed against that support before concreting to facilitate withdrawal of support.

10

In the case of spigot and socket pipes with flexible joints the concrete protection at each joint shall be interrupted in a vertical plane at the edge of the socket by a strip of fibreboard or other material approved by the Engineer’s Representative and of the following thickness: Up to 300mm nominal bore

-

13mm

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Over 300 and up to 600mm nominal bore

-

25mm

Over 600 and up to 1200mm nominal bore

-

38mm

Over1200 and up to 2000mm nominal bore

-

50mm

The protection and filling of headings shall be of mass concrete Grade 20 and may be carried out in one operation.

4.4.7

Deflection Criteria for Flexible Pipelines

1

All flexible pipelines will be subjected to deflection measurements at Site. Sections of pipe failing to meet the specified deflection criteria shall be removed from the trench and relaid, provided the pipe is not damaged. This procedure shall be repeated until the pipeline is found to be satisfactory. Removal from the trench and relaying shall be an obligation of the Contractor. If the permanent set or deflection, after removal, exceeds the limits set out below, the pipes shall be deemed to be damaged and will therefore be condemned. Pipes so condemned shall be indelibly marked, removed from the Site, and replaced by the Contractor.

2

At all times, backfilling shall be carefully carried out to ensure that no voids or pockets of unconsolidated material are present. The Contractor shall monitor the vertical deflection of the pipes throughout the backfilling operation. No pipe shall exhibit more than 3.0 % deflection after placing and compaction of the granular bed and surround. In addition, after completion of trench backfilling, the average deflection of a length of pipes shall not exceed 3.0 %, and every pipe shall be demonstrated to exhibit no more than the manufacturer’s calculated allowable initial deflection, or 5.0 % deflection, whichever is the smaller. If any of these values is exceeded, the affected pipes shall be dismantled and relaid.

3

MDPE and HDPE (PE) pipes may be bent or curved on site down to a minimum radius as recommended by the manufacturer. In the event of the manufacturer providing no recommendation, the minimum bend radius shall not be less than 25 times the pipe OD, Where there are space restrictions the bend radius may be reduced down to 20 times the pipe OD, but only with the written permission of the Engineer.

4

No electro-fusion or mechanical joints should be incorporated in the sections of PE pipework which are to be bent. Instead a formed bend or elbow should be welded in the pipeline in order to prevent excessive stress.

5

The deflection shall also be checked on each length between manholes before commissioning to determine whether longer-term deflections are within the specified limits. The average deflection of a length of pipes shall not exceed 3 %, and every pipe shall be shown to exhibit a deflection no greater than 5 %, whichever is the smaller, at any point. Pipes exhibiting greater deflections shall be exhumed and relaid.

6

Pipes exhibiting a deflection greater than 8 % or 1.6 times the calculated allowable long term deflection, shall be exhumed, indelibly marked “REJECTED”, removed from site and not reused.

4.4.8

Backfilling

1

The requirements of Part 2 of this Section shall apply, except as otherwise specified in this Clause.

2

After the pipeline has been tested and approved by the Engineer, the trench shall be carefully backfilled to 300 mm above the crown of the pipe for rigid pipes with granular material. Backfilling of the pipe trench should be carried out as designated, or shown on the Contract Drawings.

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Where concrete bedding or surround is required, the backfill shall not be placed before the compressive strength of the site concrete has reached 15 MPa.

4

Where concreting to pipeline is specified, a blinding layer of Grade 20 SRC concrete shall be placed over the full width of the trench or heading.

5

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete setting blocks, the top face of each block being covered with a separation layer.

6

Concreting to the pipeline shall be either bed or bed and surround as shown on the Drawings and shall be of Grade 20 SRC concrete along such lengths as are shown on the Drawings or ordered by the Engineer.

7

The pipe shall be prevented from moving during concreting.

8

Where concrete bed and surround is used with GRP and PVC-U pipes the maximum spacing between pipe joints shall be 3 m. For other pipe materials the maximum spacing shall be as directed by the Engineer.

9

When support of excavations is provided, building paper shall be placed against that support before concreting to facilitate withdrawal of the support. Building paper shall comply with BS 1521 Class ‘A2’.

10

In the case of pipes with flexible joints, the concrete at each joint shall be interrupted in a vertical plane at the edge of the socket by a strip of fibreboard or other material approved by the Engineer and of the following thicknesses:

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3

-

13 mm

Over 300 mm and up to 600 mm nominal bore

-

25 mm


-

38 mm

-

50 mm

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Up to 300 mm nominal bore

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The protection and filling of headings shall be of Grade 20 SRC concrete.

12

Where concrete slab protection to GRP and PVC-U pipelines is required such protection shall extend a minimum of 200 mm either side of the pipe trench. The slab shall be of reinforced concrete as shown on the Drawings.

4.4.9

Deflection at Joints

1

Where the Engineer orders or allows a change of direction to deflect pressure pipelines from a straight line, either in the vertical or horizontal planes to avoid obstruction or where long radius curves are permitted, the amount of deflection allowed shall not exceed that required for satisfactory connection of the joint and shall be approved by the Engineer. Where a change of direction cannot be made by deflection at the joints of ordinary straight pipes, bends shall be used. The locations of such bends and other specials are shown on the Contract Drawings and their exact positions will be determined by the Engineer on the Site.

4.4.10

Wadi Crossings

1

Work at any crossing of a wadi or other waterway shall be carried out as expeditiously as possible to the satisfaction of the Engineer and any responsible Government agency or other authority, with minimum interference to the free flow of water. Details of any temporary works which may affect the flow of the wadi shall be submitted to the Engineer at least 14 days before starting work.

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Where pipelines passes underneath a wadi, ditch, open surface water channel, or other waterway, the pipelines shall be encased in concrete. The minimum thickness of encasement shall be 150 mm. Unless otherwise designated, the depth of cover shall not be less than 600 mm from the bed of the water coarse to the top of the concrete.

3

The Contractor shall fill the trench in both banks with rock fill or concrete up to the designated levels. The extent of this work may be varied to suit each individual crossing. Unless otherwise ordered, the concrete encasement of the pipe shall extend at least to a section vertically below the tops of the banks. Protection against erosion to the banks shall be provided by means of stone pitching or riprap.

4.4.11

Pipe Supports

1

Pipe hangers and saddle supports shall be of standard manufacture as shown on the Drawings and in compliance with the following general requirements:

.

2

piping shall be supported independently from appurtenances to which it is affixed.

(b)

all weight of piping and contained fluids shall be transferred to a structures or foundation system through stools, brackets, pipe saddle supports, or overhead hanger systems.

(c)

a support shall be provided for each pipe at or near the point where it is connected to machinery or valves. A support shall be provided for each valve and special fitting.

(d)

flexible joints shall be required at either ends of the support system.

(e)

where necessary, expansion joints shall also be provided.

(f)

pipe hangers and supports shall generally be fabricated in Mild Steel. These shall be galvanised and painted with coal tar epoxy.

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(a)

For pipelines to be fixed in culverts, the Contractor shall prepare proposals for thrust and anchor support and submit them to the Engineer for approval. Such approval shall not relieve the Contractor from his responsibility for the adequacy of his proposal. Additional requirements for both location and details of supports may be shown on the Drawings or directed by the Engineer as the work proceeds to suit the actual conditions encountered.

4.4.12

Building-in Pipes to Structures

1

Pipes constructed into a concrete wall or structure shall be protected with a concrete surround integral with the external face of the structure as shown on the Drawings.

2

All internal and external protection membranes to the concrete shall be sealed around the pipe openings as recommended by the membrane manufacturer. When the pipe is later fixed, the remaining hole shall be re-formed and filled with non-shrink grout.

3

Any over-excavation adjacent to a structure or beneath the formation level of a pipeline, either to be constructed under the Contract or in a future contract, shall be backfilled with Grade 20 SRC concrete.

4

Pipes and pipe specials through concrete walls and floors shall as far as possible be positioned and built in during construction. They shall be located exactly in the positions shown in the Contract Drawings and shall be true to line and level. The Contractor shall take particular care to ensure that fully compacted concrete is in contact with the pipe at all points.

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Where it is impracticable to cast pipes and specials in the concrete, boxouts shall be provided in the formwork. The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger in size than will give adequate clearance for the subsequent positioning and grouting in of the pipe. The sides of the boxout shall be provided with a tapered central annular recess to provide a positive key. The boxout shall be provided with a grout hole and, at the top of the central annular recess a vent hole. The boxhole shall be stripped with the main formwork and the concrete surface thoroughly cleaned and roughened.

6

Unless otherwise shown on the Contract Drawings, where pipes pass through a concrete wall or structure they shall be protected with a surround of Grade 20 SRC concrete integral with the external face of the structure. For pipes of less than 500 mm diameter, the surround shall extend from the wall or structure by 300 mm and the width and depth of the surround beyond the outside face of the pipe at its horizontal and vertical diameters shall be a minimum of 300 mm or as otherwise indicated on the Drawings. For pipes of 500 mm diameter or greater the surround shall extend from the wall or structure by 500 mm and the width and depth of the surround beyond the outside face of the pipe at its horizontal and vertical diameters shall be 500 mm or as otherwise indicated on the Drawings.

7

On socket and spigot pipelines except those of GRP or other plastic materials the socket end of the pipe passing through the wall shall be flush with the outside face of the concrete surround. On socket of spigot pipelines of GRP or other plastic materials the socket end of the pipe passing through the wall shall protrude 300 mm from the concrete surround. A protective synthetic rubber strip 6 mm thick and 150 mm wide shall be provided around the pipe at the limit of the concrete surround as shown on the Contract Drawings.

8

On all other flexibly jointed pipes the plain end of the pipe shall protrude from the concrete surround by a maximum of 300 mm or that distance required to properly make the joint.

9

The first pipe that is clear of concrete surround beyond the external face of a concrete wall or structure shall be a short length of either spigot and socket or double spigot to suit the flow direction and pipe material. The effective length of this pipe shall be 1.5 times the nominal bore or 600 mm whichever is the greater.

10

For mechanically jointed pipes the plain end shall protrude from the surround by a maximum of 300 mm or that distance required to make a proper joint.

11

Where the structure is tanked, Grade 20 OPC concrete shall be used and the tanking shall extend to the concrete surround.

4.4.13

Cleanliness of Pipelines

1

Pipelines and manholes shall at all times be kept free of all silt, mortar, debris and other obstructions. When work is not in progress the open ends of the pipeline shall be securely plugged with an approved watertight plug or stopper firmly fixed to resist unauthorised removal. Claw type plugs or any type liable to damage the pipe shall not be used. All such stoppers, plugs or caps shall be provided with a vent incorporating a valve for the purpose of testing whether the pipeline is under pressure or vacuum and to enable pressures to be equalised before its removal.

2

The Contractor shall clear the inside of each fitting and pipe length immediately before jointing and shall swab all fittings and pipe lengths to remove all dirt, sand or other matter that may clog the pipeline or contaminate the fluid to be transported in the pipeline. After jointing, the interior of the pipes shall be freed from any dirt, stones or other matter that may have entered them. For this purpose, a rubber disc, brush, or other suitable implement that will not harm the internal lining of the pipe shall be pulled through the pipe after jointing.

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Pressure pipelines and treated sewage effluent pipelines shall be flushed and a swab passed through. Large diameter pipelines shall be visually inspected internally to the approval of Engineer.

4.4.14

Marker Tape

1

All trenches for pressure pipelines, shall be marked with a high quality acid and alkaliresistant red non bio-degradable plastic tape with a minimum width of 150 mm placed during backfilling 300 mm below finished surface or as directed by the Engineer. These tapes shall 2 2 have a minimum strength of 125 kg/cm in the longitudinal direction and 105 kg/cm transversely with an elongation factor in the longitudinal direction of 350 percent. The text on the tape shall be permanent black ink bonded to resist prolonged chemical attack by corrosive acids and alkaline with message repeated at a maximum interval of two metres. Tapes over non-ferrous pipes shall be detectable by electro-magnetic means using low output generator equipment.

2

The tape wording and colour shall be as follows:

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COLOUR

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WORDING

RED

CAUTION TREATED SEWAGE EFFLUENT

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SURFACE WATER

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DANGER : FOUL SEWAGE

WATER MAIN

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DANGER : FUEL PIPELINE

GREEN GREY BLUE BROWN

The tape shall be laid continuous over pipelines and at joints there shall be a minimum of one metre overlapping. Tape shall be terminated inside valve boxes to allow clipping of detector equipment to the tape.

4.4.15

Pressure Pipeline Marker Posts

1

Pipeline marker posts shall be provided at all points where the pipeline crosses boundaries or changes direction and elsewhere at maximum intervals of 100m. Each marker post shall be set over the centreline of the pipelines with concrete Grade 20 SRC concrete base surround in accordance with the Contract Drawings. Marker posts shall incorporate a description of the pipeline and its service in Arabic and English to the approval of the Engineer. Offset marker posts may also be used in areas where the post could not be installed over the centreline of the pipelines.

2

Coloured marker plates shall be made from multi-layered plastic, green for TSE and orange for foul sewage.

4.4.16

Valve Chamber Marker Posts

1

Valve chamber marker posts shall be installed at all chambers, indicating the type of chamber, its reference number and distance from the marker post in Arabic and English to the approval of the Engineer.

2

Where the pipeline is in a footpath or verge, the marker post shall be installed against the wall or property boundary and facing the chamber cover, with Grade 20 SRC concrete base surround.

4.4.17

Abandonment of Pipelines

1

Pipelines and service connections to be abandoned shall first be emptied completely.

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Pipelines and service connections to be abandoned shall be filled completely with a cement slurry or concrete using a grout pan or an alternative method approved by the Engineer such that the discharge slurry or concrete can be forced into the pipeline under pressure.

3

The Contractor shall ensure that all existing connections to the sewer to be abandoned have been plugged or disconnected before beginning filling.

4

The Contractor shall inform the Engineer of his intention to begin this operation and shall obtain the Engineer’s approval in writing for the abandonment of each particular length before beginning filling.

5

Upon completion of the above procedure, the Contractor shall undertake abandonment of manholes inspection chambers and other structures. Where a pipeline or service connection to be abandoned connects into a manhole or chamber to be retained, the connection shall be plugged at the chamber wall and the associated channel in the benching of the manhole or chamber shall be cleaned and filled with concrete Grade 20 SRC. The benching shall then be covered with the appropriate protective lining to match the existing manhole lining.

6

Unless otherwise designated, existing pressure pipelines to be abandoned shall be emptied and sealed at each end of the pipeline with a removable expanding stopper to the Engineer’s approval. The stopper shall include a valve for the purpose of venting and for the equalising internal and external pressures removal. Any chambers located along the pipeline to be abandoned shall be demolished and the pipeline ends sealed as specified.

4.4.18

Abandonment of Structures

1

Where manholes, septic tanks, cesspits, soakpits and other structures are to be abandoned, they shall be emptied of their contents to the approval of the Engineer. The contents including sludge from these structures, whether undiluted or mixed with sand, shall be disposed of off the Site by the Contractor to a location approved by the Engineer. The Contractor shall submit in writing his proposals for emptying the contents and disposal. No work shall begin on demolition until the structure has been completely emptied.

2

After desludging, the roof slabs and tops of walls of the structure shall be demolished to an elevation not less than 500 mm below existing ground level. The fragments of demolished structures may be used to partially fill the void. Voids shall be filled up with sand, watered and well compacted up to the elevation of the underside of the cover slab. The frames and covers of manholes and chambers shall be removed by the Contractor and delivered to the designated Employers’ stores and placed into storage.

3

If an existing service is found within a structure to be abandoned, the Contractor shall inform the Engineer and carry out the Engineer’s instructions for ensuring that the service pipeline is retained or restored. If a sleeve is to be provided, the sleeve shall extend for 100 mm on either side of the structure. When backfilling or working around an existing service or sleeve, the Contractor shall take all precautions to ensure that no damage occurs and that there is no interruption of service.

4.4.19

Corrosion Protection of Flexible Couplings and Ferrous Fittings

1

Buried flexible couplings, including flange adaptors shall be protected as follows:

2

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(a)

Mastic paste filling (Denso paste or similar)

(b)

Mastic tape wrapping (Denso tape or similar)

(c)

and finished with cold applied self-adhesive laminate tape wrapping (or heat shrink sleeving) in accordance with Clause 8.4.3.5

Couplings, including all associated nuts and bolts, within chambers or pumping stations shall be polyamide powder coated (“Rilsan” or similar).

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PIPELINE STRUCTURES AND APPURTENANCES

4.5.1

Manholes for Foul Sewerage

1

The Contractor shall prepare a standard record sheet for every manhole and structure and shall submit to the Engineer for information only.

2

Manholes shall be constructed as shown on the Contract Drawings and at the locations indicated thereon or at other locations directed by the Engineer.

3

The blinding concrete shall be mass concrete Grade 25 SRC concrete and the manhole base slab, benching and insitu concrete walls shall be Grade C40 SRC concrete.

4

Precast concrete manhole rings shall be manufactured using Grade C50 SRC concrete. The joint surfaces and outer face of the precast concrete rings shall have factory applied epoxy coating in accordance with Part 8 Clause 8.3.15. The inner face of the precast manhole ring shall be a prefabricated GRP liner at least 6mm thick bonded by lugs to the concrete. The completed joints between precast concrete rings shall have an insitu applied sealing strip at least 6mm thick overlapping the GRP liner by a minimum of 150mm each side. The sealing strip shall be capable of withstanding the full hydrostatic head of external ground water to ground level and the maximum internal hydrostatic head, whichever is the greater.

5

The underside of the base and the external faces of insitu concrete bases and walls shall be protected with a membrane tanking system. The necessary period for setting, as recommended by the manufacturer, shall be allowed before beginning other works to complete the construction of the manhole.

6

The cover slab shall be surmounted by ductile-iron manhole cover and frame of the quality specified. The covers in road and paved areas shall be accurately set on precast concrete segments to the level and slopes of the roads or pavements.

7

In the case of shallow manholes, the cover and frame may be cast directly monolithic with the reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract Drawings.

8

The interior face of manholes and access shafts shall be prefabricated GRP liners at least 6 mm thick permanent lining.

9

Prefabricated GRP benchings and channels shall be preformed, inverted and filled with Grade C40 SRC concrete. Alternatively, the GRP lining may be applied to the in-situ concrete benching after constructing the benching.

10

GRP lining to walls shall incorporate lugs moulded onto the outside face at 500 mm centres to allow bonding to the concrete surround. The lining shall have adequate strength to withstand handling, and shall not buckle or distort during pouring of the concrete surround. Internal bracing may be used during pouring of the concrete surround. Internal bracing may be used during pouring to maintain circularity and verticality.

11

Cover slabs shall be precast using Grade C50 SRC concrete and shall incorporate a preformed flat sheet of GRP on the soffit, bonded to a GRP tube to form the access opening. Both linings shall incorporate lugs moulded onto the surface to allow bonding to the concrete. The overall size of the lining to the soffit of the slab shall be 150mm greater than the internal diameter of the manhole onto which the slab is to be placed.

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In all cases, the outer surface of the GRP, exposed to the sewage atmosphere, shall consist of a chemically resistant layer comprising vinyl ester resin suitably reinforced with a ‘C’ glass or synthetic tissue veil. This layer shall be no less than 2mm thick, and shall have a resin content by weight of approximately 90% at the exposed surface, reducing to 65% - 75% at the inner surface. The remainder of the liner shall consist of vinyl ester or isophthalic resins and “E” or “ECR” glass chopped strand mat. Fillers, such as silica sand and calcium carbonate shall not be used. Loss of Ignition Test to BS 2782 (method 1002) shall be conducted on random samples of GRP manhole liner to detect percentage of glass and the presence of any silica sand filler.

13

Joints in the lining tubes of insitu concrete manholes shall not normally be permitted.

14

Joints between preformed GRP benchings and lining tubes shall be made using an external sleeve 200 mm long bonded onto both units, and then bandaged using suitable resin and chopped strand mat prior to casting the insitu concrete walls. Such bandaging shall extend 75 mm either side of the edge of the sleeve. On the inside face of the manhole, the joint between the benching and liner tube shall be filled with vinyl ester paste to produce a smooth finish.

15

If GRP linings to benchings are to be formed in situ the surface of the wall lining tube shall be lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius shall then be formed of vinyl ester paste at the junction of benching and wall. The GRP lining to the channels and benchings shall then be built up by applying isophthalic or vinyl ester resin to the whole of the benching, fillet and abraded wall lining. A layer of “E” or “ECR” mat shall than be rolled into the resin using a suitable steel roller to exclude all air and provide complete immersion of the glass fibre in the resin. After a period to allow pre-gel to a tacky state a second coat of resin shall be applied followed by a further layer of glass fibre mat. This process shall be repeated until the total thickness of lining is approximately 4 mm. Vinyl ester resin and “C” glass or synthetic tissue veil shall then be used to complete the lining.

16

Top surfaces of benchings shall incorporate silica sand to form a non-slip surface.

17

The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall be raked out 15 mm deep on the inside face and pointed with an approved pitch extended polyurethane sealant.

18

Ladders in structures where shown on the drawings shall be fabricated in stainless steel Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be stainless steel.

19

Intermediate the Contractor shall provide the Engineer with a 10 year unconditional guarantee against failure of all GRP linings whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed to the Engineer before the issue of the Final Completion Certificate.

20

All manholes shall be watertight on completion and where leakage is discovered the Contractor shall perform such work and provide all materials as are necessary to render such faulty work watertight. The Contractor is warned that he should expect rubbish and debris to be deposited in the manholes during the course of construction and he should take the necessary measures to ensure that the manholes clean.

21

Backfilling around manholes in roads shall be carried out using granular material as approved by the Engineer.

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Manholes for Surface Water Sewerage

1

Bases and mass concrete manholes shall be cast using Grade 40 SRC concrete. Where reinforced concrete manholes are specified they shall be constructed in accordance with the drawings and have a GRP liner complying to Clause 4.4.1. The GRP liner shall extend to 300mm above the soffit of the outlet pipe of the manhole. The inner surface above the GRP liner shall have an epoxy protective coating.

2

The benching and channels shall be GRP lined as Clause 4.4.1.

3

The underside of the base and the sides of insitu concrete bases and walls shall be protected with a membrane tanking system as Clause 4.4.1.

4

Precast Grade C50 SRC concrete manhole rings may be used above the level of the GRP inner liner. The precast rings shall have a factory applied epoxy protective coating to all surfaces.

5

Cover slabs shall be precast using Grade 50 SRC concrete and shall have a factory applied epoxy coating to all surfaces.

6

The Contractor shall provide the Engineer with a 10 year unconditional guarantee against failure of all GRP linings whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed over to the Engineer before the issue of the Final Completion Certificate.

7

Ladders in structures where shown on the drawings shall be fabricated in stainless steel Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be stainless steel.

4.5.3

Chambers

1

The Contractor shall prepare a standard record sheet for every chamber for valves, meters, inspection, washouts and other similar purposes for the approval of the Engineer.

2

Chambers shall be constructed in accordance with the Contract Drawings and at the locations or at other locations directed by the Engineer.

3

The Contractor shall ensure that there is a minimum clearance of 300mm around all flanges and parts of valves built into chambers, including the handwheel.

4.5.4

Connections to Existing Pipelines

1

At locations shown on the Contract Drawings or as instructed by the Engineer, the Contractor shall connect the new pipelines to the existing pipelines or structures but not until the said pipelines have passed the final tests.

2

The Contractor shall co-ordinate with Drainage Affairs, Maintenance Department staff to make connections onto existing foul sewers and other drainage pipelines.

3

The Contractor shall be responsible for dealing with all flows while making connections to existing sewers or drainage pipework by over-pumping the entire flow between manholes or other approved bypassing methods. The Contractor shall retain a standby pump and fulltime operator on site during pumping operations.

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4.5.2

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Anchor and Thrust Blocks

1

The Contractor shall construct anchor and thrust blocks at every bend and junction on pressure pipelines and where otherwise shown on the Contract Drawings or instructed by the Engineer. Each thrust block shall to have a sufficient bearing area and shall be placed to safely transmit thrust to the surrounding original ground. If soft, spongy, unstable or similar material is encountered upon which the thrust block is to bear this unsuitable material shall be removed and replaced with Grade 20 SRC mass concrete as directed by the Engineer.

2

The excavation for the thrust block shall be carried out prior to laying the pipes except that a trimming margin of not less than 150mm shall be left to be removed by hand excavation in order to obtain a firm thrust face against undisturbed ground. This trimming margin shall only be removed after laying and jointing of the pipes and the concrete for the thrust block shall be placed on the same day as the removal of the trimming margin.

3

No pressure shall be applied to thrust blocks until the concrete has matured for at least seven days.

4

"Rocker" pipes shall be installed adjacent to all concrete thrust blocks.

4.5.6

Property Connections Survey

1

The Contractor shall complete and submit to the Engineer for approval a standard record sheet of every property connection. The information shall be recorded on forms provided by the Engineer.

2

The Contractor shall survey and prepare individual plans for each property at a scale of 1:500 (or such other scale as may be agreed by the Engineer’s Representative). These shall show existing plot boundaries, location of all buildings, location of all visible services and location and level of all drainage services, including septic tanks. The plans shall indicate the nature of each building, clearly identifying kitchen, mess areas, toilets, washrooms and the drains serving these areas and gullies elsewhere. The plans shall identify the drains serving. The plan shall be submitted on paper and AutoCAD compatible .dwg file. As a separate layer on the dwg file the Contractor shall mark his proposals for the property connection, including a cross-section and this shall be submitted to the Engineer’s Representative for approval. No property connection work shall commence before approval to the proposed layout has been received in writing from the Engineer’s Representative.

3

In special cases only, an inspection chamber may serve more than one service connection. Locations of inspection chambers and the layout of service connections shall be as approved by the Engineer.

4

Service connections shall be laid at sufficient depths to allow for adequate gradient being continued throughout the properly drainage system without the pipelines becoming too shallow for adequate cover to be provided over the pipe.

4.5.7

Future House Connections

1

During the course of the Contract the Engineer’s Representative and the Contractor shall agree on a programme regarding the positions and other details of the junctions to be left for future house connections. Such branches and junctions shall in all cases terminate in an approved stopper obtained from the pipe manufacturer.

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4.5.5

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The Contractor shall survey and prepare individual plans for each plot at a scale of 1:500 (or such other scale as may be agreed by the Engineer’s Representative). These shall show existing boundary walls or fences and ground level at each corner of the plot. The plan shall be submitted on paper and AutoCAD compatible dwg file. As a separate layer on the dwg file the Contractor shall mark his proposals for the property connection and this shall be submitted to the Engineer’s Representative for approval. No property connection work shall commence before approval to the proposed layout has been received in writing from the Engineer’s Representative.

3

The Contractor shall produce accurate records of the exact location of all service connections and shall include for these in his rates.

4.6

TESTING OF PIPELINES

4.6.1

General

1

The Contractor shall submit for the Engineer's approval details of his proposed methods and programme for testing (including details of test equipment) and shall arrange for all test to be witnessed by the Engineer or other person appointed by the Engineer. Test equipment shall be approved by the Engineer and calibration certificates when requested by the Engineer shall be submitted. The Contractor shall provide all equipment necessary for carrying out testing and cleaning including pumps, gauges, piped connections, stop ends, and all other temporary works. All water required for testing and cleaning the pipelines shall be from a source approved by the Engineer.

2

Pipelines shall be adequately restrained before being put under test except as hereinafter detailed. No testing will be permitted until seven days after thrust blocks and other holding down works have been completed. Trenches may not be left open at joints before testing pipelines except as permitted by the Engineer who may lay down certain restricting conditions. In addition to any tests of individual joints or other interim tests which may be designated elsewhere, the Contractor shall submit all parts of the pipelines to a final test.

3

This and the following Clauses on testing pipelines do not apply to GRP pipes for which testing requirements are given in the Project Specification where appropriate.

4

Pipelines shall be tested in lengths between manholes or valve pits with lengths not exceeding 400 metres except by agreement with the Engineer’s Representative. Testing shall not be against closed valves, and pipes of different diameters shall not be tested together in the same test. The arrangements for testing a pipeline shall include provision for purging the air from the pipeline during the test.

5

In all pipelines which are constructed with mechanical joints or with joints which permit axial movement, the joints shall be left open so that they may be inspected during hydraulic testing. In such cases only the barrels of the pipes shall be backfilled prior to hydraulic testing taking great care to avoid the joints and leaving sufficient space all round the joints to permit inspection and to undertake remedial measures should the joint be found to leak under hydraulic testing. After the successful completion of hydraulic testing, the joints shall, if specified, be wrapped, coated or sleeved as appropriate, and then backfilled in the manner specified elsewhere in this specification.

6

The final test shall be applied in the presence of the Engineer’s Representative.

7

The Contractor shall keep a record of all tests in a book which shall be available for inspection and handed over to the Engineer’s Representative on demand. The Contractor shall complete standard test record sheets as provided by the Engineer.

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The section under test shall be properly sealed off with blank flanges or special stop end caps held securely in position by adequate temporary anchorages, and filled with water. All peak points of the pipeline shall be adequately vented during the filling operation using temporary bleed valves. All air valves shall be removed and all other valves shall be set in the open position.

9

Pipe joints, valves and fittings shall be checked carefully for loose bolts or connections which might cause leakage and delay the execution of the tests.

10

Should any section fail to pass the tests, the Contractor shall determine the cause of the failure and shall locate, excavate and repair any damage or leakage sustained by the pipeline before or during the tests and retest the section. The cost of such repair work, additional backfilling and reinstatement and abortive tests shall be borne by the Contractor.

11

Water for the test shall be disposed of in a manner to be approved by the Engineer. Pumping water onto the site shall not be permitted.

12

The Contractor shall be responsible for ensuring that all test methods and procedures comply with his Health and Safety Plan.

13

The Contractor shall provide detailed method statements for his methods of testing access shafts, manholes and pipelines.

4.6.2

Gravity Sewer Pipelines

1

Each pipeline 600 mm or less in diameter shall be tested by air test. Should any pipe fail the air test, the Engineer may order a water test to be carried out. Acceptance of the pipeline will then be based on the results of the water test. All pipelines up to and including 1200 mm shall be tested by air test in accordance with the requirements of BS EN 752.

2

The Contractor shall, at his own expense, furnish all equipment and materials for making the tests. Each pipeline shall be tested before backfilling and also after backfilling before carrying out road reinstatement or laying new road surfacing. Where the pipeline is located under a new road alignment, the pipeline will be tested after sub-base compaction in complete. All pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be clean and empty at the time of testing. Tests shall be performed in the presence of the Engineer. (a)

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Air Test:

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(i)

(b)

the Contractor shall plug all pipe outlets with suitable plugs, and brace each plug securely where needed

(ii)

air shall be pumped in slowly to the pipe until a pressure of 100 mm water gauge is indicated on a manometer connected to the system. After the internal pressure of 100 mm water gauge is obtained, 5 min shall be allowed for the air temperature to stabilise within the pipe.

(iii)

Air may be added to restore the pressure to 100 mm water gauge. During a further period of 5 min, the pressure shall not fall below 75 mm water gauge without further pumping.

Water Test (i)

all the joints of the pipeline shall be able to withstand a pressure of a minimum 5m head of water, above the crown of pipe at the highest point of pipeline without leakage. A layer of embedding soil equal to the diameter of pipe shall be laid over the pipe to prevent the lifting of pipe while applying test pressure. However, all the joints shall be left open for the purpose of inspection for leakage if any. All branches and open ends shall be closed with stoppers, secured with longitudinal braces/thrust block, before testing begins

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(ii)

water shall be filled from the lowest point and air allowed to escape through an air vent fixed for the purpose at the high points of the pipeline section under test. The diameter of air vent shall be about one and half times the diameter of water inlet pipe to allow easy escape of air. No entrapped air shall remain in the pipeline while testing

(iii)

a pressure of 5 m head of water shall be maintained for one hour to allow initial absorption of water. After that the test pressure shall be maintained for 15 min and water added shall be measured. If water consumption in 15 min does not exceed 0.1 l/m2 of wetted inner pipe surface and if there are no visible leakage through joints, the pipeline shall be treated as passed.

Infiltration Test (i)

the upper ends of the sewer and service connections shall be closed sufficiently to prevent the entry of water and pumping of groundwater shall be discontinued until the groundwater surface reaches its natural level before beginning the infiltration test the dewatering system shall be stopped, but not be removed until the infiltration test has been successfully completed or as otherwise permitted by the Engineer the infiltration shall not exceed 6 litres per millimetre diameter per kilometre per day of the portion of sewer being tested, including the length of service connection entering that section.

(ii)

the total length tested in one section shall not exceed 400 m in length. This length is dependent upon the type of deflection measuring equipment proposed by the Contractor if flexible pipes are used.

(iii)

no gravity pipeline will be accepted if the total infiltration exceeds the above mentioned limit and joints will not be accepted if during an internal inspection, any infiltration is visible.

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(c)


Prior to issue of a Certificate of Completion a CCTV survey shall, on the instruction of the Engineer’s Representative, be carried out on a representative sample of no more than 12% of the length of constructed pipelines. Should this survey indicate sections of pipeline which fail to meet the specification requirements, the Contractor will be required to carry out remedial works and undertake additional CCTV surveys at his expense.

4.6.3

Pressure Pipelines

1

The pipeline shall be tested between valve chambers or into sections not exceeding 400 m in length unless approved otherwise by the Engineer. The section tests shall be carried out as follows:

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(a)

each pipeline or section thereof shall be filled with water and all air removed as far as possible

(b)

the pressure shall then be raised by pumping in water until the test pressure is reached and shall be maintained at this level by further pumping until it is steady

(c)

pumping shall then be stopped and the time taken for the observed pressure to fall by 1.0 m shall be recorded

(d)

pumping shall then be resumed and the quantity of water pumped in order to restore the test pressure shall be recorded

(e)

if after three hours the test pressure has not fallen by 1.0 m, pumping shall be resumed at that stage, the time being recorded as three hours

(f)

the rates of loss shall then be calculated as the recorded quantity divided by the recorded time

(g)

the test pump and gauge shall be connected to the pipeline at a location other than the highest point in the pipeline to facilitate release of air from the highest point

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(h)

the test pressure shall be such that the entire pipeline or section being tested is subjected to 1.5 times the working pressure, 1.25 times the maximum surge pressure or 800 kPa, whichever is the greatest

(i)

the loss shall not exceed 0.02 litres per mm diameter per kilometre per 24 hours for each 0.1 MPa of head applied

(j)

if the pipeline fails to pass the test, the faults shall be located and repaired and the pipeline retested until it passes the pressure test. All exposed pipe, fittings, valves and joints shall be visually inspected during the tests.

When all sections have been joined together after completion of section testing, unless otherwise directed by the Engineer, the entire pipeline shall than be subjected to final test as follows: all joints between individual test sections shall be left uncovered during this final test

(b)

the final test shall be carried out using the same procedure as the section test

(c)

in all cases of water tests, where the measured leakage rate exceeds the allowable, the Contractor shall, at his own expense, make all necessary repairs and carryout additional testing until a satisfactory result is obtained

(d)

before pressure testing is started the Contractor shall recheck pipes and valves for cleanliness and shall recheck the operation of all valves. The "open" ends of the pipeline or sections thereof) shall normally be stopped off by blank flanges or cap ends additionally secured where necessary by temporary struts and wedges. All anchor and thrust blocks shall have been completed and all pipe straps and other devices intended to prevent the movement of pipes shall have been securely fastened

(e)

since valves cannot be guaranteed to be perfectly drop-tight, testing against closed valves which are connected to an existing system shall be prohibited; testing against other closed valves (including air valves) not so connected, may be attempted if desired, provided the valves are suitably anchored against thrust. No claims whatsoever will be entertained on account of leaking valves, or any other difficulties in closing off lengths of pipework for testing, which shall be entirely an obligation of the Contractor

(f)

on successful completion of the final test, the exposed joints shall be covered and the trench backfilled as specified in the appropriate Clause 2.3 of this Section.

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The pipeline shall be tested for a period of at least 24 hours after which the test pressure shall be restored by pumping and the quantity of water lost during the test measured.

4

Plastic irrigation drip pipe work shall be completely filled with water and visually inspected for leakage. No section showing signs of leakage will be accepted. In addition, any length of pipe which in the opinion of the Engineer or his designated representative is showing signs of degradation through contact with sunlight shall be cut out and replaced.

4.6.4

Other Pressure Pipelines

1

Water Pipelines and Other Pressure Piping Carrying Liquids

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(a)

water pipelines and other pressure piping carrying surface water ground water and treated sewage effluent excluding raw sewage pressure pipelines having socket and spigot gasket joints shall be given a pressure and leakage test. Ductile iron or PVC-U pipe shall be tested to AWWA C066 ; steel pipe to AWWA C066

(b)

PVC-U treated sewage effluent pipework shall completely filled with water and visually inspected for leakage. No section showing signs of leakage shall be accepted.

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Pressure Pipe, Flanged or Welded Joints (a)

PVC-U, steel, cast iron, ductile iron or other pipe material, with solvent welded, welded, threaded, flanged, grooved end or flexible couplings and joints shall be pressure tested. No leakage shall be permitted.

Pressure Air and Gas Piping: (a)

All piping carrying air or other gasses under pressure shall be given a pressure test. No leakage is permitted. Low pressure air piping shall be tested pneumatically. Air pressure of 140 kPa shall be applied to piping and fittings. High pressure air piping shall be tested to 1400 kPa. There shall be no drop in pressure in a 24-hour period

(b)

Leaks shall be located and repaired to the satisfaction of the Engineer. Pressure drops due to thermal contraction are acceptable if the pressure returns to the original test pressure after 24 hours.

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All piping, including valves, shall be field tested at the specified pressure with duration of two hours minimum, for each pressure test. Piping conveying liquids between process tankage, not subject to pumping, shall be tested to the maximum possible pressure that can be obtained under static conditions. Air piping shall be tested using air or nitrogen.

5

All exposed pipe, fittings, valves, hydrants, and joints shall be carefully inspected before either being cast in concrete or during the open trench tests, or both. All defects discovered shall be corrected by removal and replacement, as approved by the Engineer, and the work then retested to demonstrate satisfactory performance.

6

Where practical, no concrete encasement or backfilling of pipe joints will be permitted before the satisfactory completion of the tests in any given section.

4.6.5

MDPE and HDPE Pressure Pipelines

1

Upon substantial completion of the pipeline or major sections, the line shall be cleaned and hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior to commissioning. Testing shall be performed in accordance with the Finnish Standard SFS 3115:E and the procedure described below. The Contractor shall supply all necessary fittings, equipment and facilities required to undertake the testing.

2

The Contractor shall prepare a detailed Method Statement for the pressure test that shall follow the outline test procedure described below and be subject to the approval of the Engineer.

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(a)

Seal the pipeline. Fix all blank flanges. Remove air valves. Remove all on line equipment that may be damaged by high pressure.

(b)

Only test against blank flanges, do not attempt to test against closed valves.

(c)

Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints exposed where practical.

(d)

If backfilling is not practicable schedule the tests for early morning or evening.

(e)

Fill the pipeline from the lowest point. Bleed the air from all high points and flange points where it is possible and tighten once water begins to spill.

(f)

When the line is full, close off the filling valve and check all flanges and the small diameter test pipework for leaks.

(g)

Phase1 Commence raising the pressure at the filling point to the operating pressure or a pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and add water whenever the pressure drops by 0.2 bar in order to maintain a steady pressure.

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Visually inspect the pipe length for leakage.

(i)

Phase2 After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar, whichever is higher, as quickly as is practical. Again maintain this pressure for two hours by adding water whenever the pressure drops by 0.2 bar.

(j)

Visually inspect the pipe length for leakage.

(k)

Phase3 At the end of the second two hours release the pressure back down to the phase I level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes and as quickly as is practical, in a controlled manner.

(l)

Phase3–Case1 If after one hour the pressure in the pipelines remains at or above the operational pressure, the test is considered to be completed with the pipeline passing the hydrostatic test.

(m)

Phase3–Case2 If after one hour the pressure in the pipeline has fallen below the operational pressure, water shall be added to raise the pressure back to the operating pressure level, having first noted the low pressure before adding any water.

(n)

Phase3–Case2 Measure the added water by draining it off into a measuring cylinder. (i.e. reduce pressure to the previously recorded low value and save the water bled off). The measured quantity is then compared against the allowable quantity to determine if the pipeline passes the hydrostatic pressure test.

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(h)

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Graphical Representation of the Hydrostatic Test Process Case 1 – Pipeline passes test without adding any make up water

Figure 2

Graphical Representation of the Hydrostatic Test Process Case 2 – Water to be added to determine if the pipeline passes or fails

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Figure 1

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3

If during Phase 3 the pressure within the pipeline remains at or above the operational pressure of the pipeline for a period of at least one hour, the pipeline is considered to have passed the hydrostatic test.

4

If water needs to be added the pipeline is considered to have passed the hydrostatic test if the quantity of water added in terms of litres of water per km of pipeline length per hour of the phase 3 period is less than that given in the following expression and in Figure 3. Q ≤ Di/50 – 1 (litres / km/ hour) Q = added water in litres. Di = internal diameter for the pipeline in mm.

Hydrostatic Test Pass

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Figure 3. Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water

The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be connected to the feed pipework.

6

The small diameter test pipework shall include a bleed valve at upper end of the pipeline and at all high points together with feed pipework and valve at the lower end of the pipeline. The feed pipework shall include a means of draining off the water in to a measuring cylinder that shall have a capacity of at least 2 litres capacity, graduated to 100 mls.

7

The Contractor shall also have a thermometer for air and water temperature measurement.

8

Care should be taken not to over pressure the lower end of the system during testing. Gauges should always be placed at the lower end of the length under test. As far as possible the difference between the lower and upper end should be kept to one bar. It is recognized that this may not always be possible when longer lengths are being tested, or where the slope of the pipeline makes it impractical.

9

Where the phase II pressure is within the pressure rating of the pipe and test temperatures O are 30 C or less no adjustment of test pressure is necessary.

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When ambient temperatures at the time of test are over 30ºC and test pressures are over the pressure rating of the pipe then it may be necessary to modify the test pressure according to the table below or as agreed with the pipe manufacturer. Test Temp. O ( C)

32

38

43

49

54

60

Multiplier

0.9

0.8

0.75

0.65

0.6

0.5

When undertaking the testing the Contractor shall also take in to account the following points. (a)

Care should be taken that any mechanical elements on the system are protected from elevated pressure or completely removed from the pipeline.

(b)

Do not subject the line to prolonged over-pressure. procedure within one working day.

(c)

During the summer make sure that the pipe is not subject to direct sunlight during testing.

(d)

During pressure testing pay full attention to the HSE aspects of the procedure. In particular keep the general public away from high pressure test areas.

(e)

The test equipment must be capable of pressurizing the test length within a reasonable time. If the procedure becomes protracted (beyond one working day) the test length may be modified or reviewed. Extremely long test lengths may be subject to special procedures.

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Always aim to complete the

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MISCELLANEOUS ITEMS

4.7.1

Manhole Covers and Frames

1

Manhole covers shall be made from ductile iron and comply with BS EN 124 which shall include:

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Documentation confirming EN 29002 certification; or

(b)

Documentation identified under Annex A to BS EN 124, concerning Independent Third Party Inspection.

(c)

Independent random sample testing at an approved testing facility to demonstrate full compliance with all aspects of the code i.e. load testing and dimensional tolerances.

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Production facilities shall be quality assessed in accordance with ISO 9000 or EN 29002 (BS 5750).

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2

Where manholes are located in road carriageway, the covers shall be non-rock double triangular Class D400 unless otherwise designated. The double triangular cover shall be loosely coupled with stainless steel bolts. The frames for sewer and surface / ground water manholes shall provide a minimum access opening of 750mm square. The frames for TSE chambers shall provide a minimum access opening of 675mm square.

3

Manhole covers in paved areas, car parks, verges, roads within property boundaries, and other areas accessible to pedestrians and light vehicles, shall be non-rock double triangular Class B125 unless otherwise designated. The double triangular covers shall be loosely coupled with stainless steel bolts plate. The frames for sewer and surface / ground water manholes shall provide a minimum access opening of 750mm square. The frames for TSE chambers shall provide a minimum access opening of 675mm square.

4

All castings shall be grit blasted and coated on all exposed faces with a zinc primer and coaltar epoxy paint finish in accordance with Part 8 of this Section which shall result in a smooth coating, tough and tenacious when cold, and neither tacky nor brittle.

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5

The covers and frames on foul sewers shall incorporate a removable self-sealing GRP or similar corrosion resistant plate meeting the requirements of Part 7 of this Section. The plate shall fit between the cover and the frame such that no surface area of the frame shall be exposed to the atmosphere within the manhole. This shall be achieved by the inclusion of a neoprene sealing ring or by a similar approved method. The plate shall be complete with a lifting handle on the upper surface. The design of the frame and cover and plate shall be subject to the approval of the Engineer. A heavy grease seal is to be formed in all cases between the cover and frame to prevent the ingress of sand.

6

Manhole covers for sewerage, surface water and treated sewage effluent systems shall have the following words embossed in both English and Arabic, respectively: (a)

Sewerage:

Drainage Foul Sewer

Surface water:

Drainage

.

(b)

Treated sewage effluent:

Drainage

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Surface Water

Treated Sewage Effluent. The size of lettering shall be approved by the Engineer.

8

The Contractor shall supply one pair of manhole keys or prying and lifting bar, as appropriate with each 30 covers provided with a minimum of one tool for each type cover. Keys and prying and lifting bars shall be of approved appropriate design to match the different cover configurations. Keyways in manhole covers shall be of the closed type.

9

Any manhole covers and frames on sewer or surface / ground water manholes that are damaged or otherwise disturbed during the execution of the Works shall be replaced with covers and frames with a minimum clear opening of 750mm square and incorporate a GRP sealing plate. If the opening through the concrete cover slab is less than 750mm square, then the concrete slab shall also be replaced.

10

Manhole covers for foul sewerage, surface water and treated sewerage effluent shall be provided with inscriptions both in Arabic and English cast into the top surface of the cover. The lettering shall conform to the details given elsewhere in these documents or to the current details available from Drainage Affairs.

4.1.2

Duct Covers and Frames

11

Duct covers and frames shall be of cast iron, galvanised mild steel or aluminium as shown on the Drawings, and shall be waterproof, non-rocking and recessed for filling with concrete.

12

Cast iron duct covers and frames shall be obtained from an approved experienced manufacturer, shall have machined seating faces and sloping mating faces to facilitate sliding out of covers. The covers shall be capable of withstanding a 5 tonne wheel load when the recesses are filled with Grade SRC 25 concrete, or such other load as may be shown elsewhere in the Contract Document.

13

Galvanised steel covers and frames shall be obtained from an approved experienced manufacturer. Covers shall have solid bases fitted with reinforcing rods and where detailed on the drawings shall incorporate locking bolts. Covers shall be capable of withstanding a 5 tonne wheel load when filled with Grade SCR 25 concrete, or such other load as may be shown elsewhere in the Contract Document. Covers shall generally be filled with concrete, but finished with tiling to match the surrounding floor finish.

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Aluminium duct covers and frames shall be fabricated from aluminium alloy Grade 6063-T6 or other such chemically resistant alloy which the manufacturer can demonstrate will withstand aggressive atmospheres likely to be encountered. Covers shall have solid bases, and shall incorporate reinforcing bars held in place in plastic clips. Those faces of the frame which will come into contract with cement mortar or concrete shall be painted with two coats of bituminous paint before installation of the frame.

15

All covers shall be installed strictly in accordance with the manufacturer’s instructions.

16

Two complete sets of lifting keys including any necessary spanners shall be provided in each room in which ducts covers are installed.

17

A heavy grease seal is to be formed between the cover and frame to prevent the ingress of sand.

18

Multiple covers shall have removable intermediate beams.

4.7.2

Hinged Aluminium Access Covers

1

Hinged aluminium access covers shall be fabricated from chequer or ribbed plate. The 2 covers shall be designed to carry a uniformly distributed load of 7.5 kN/m , and deflection under this loading shall not exceed one percent of the span.

2

The frame shall be made from aluminium alloy complying with BS 1474 Grades 6063-T6 or 6082-T6.

3

Where a cover is to be located within tiled areas, the frame shall be made from channel sections. The outer vertical arm of the channel frame shall be set flush with the top of the adjacent floor finishes. The inner vertical arm shall be shorter to allow the chequer plate to sit the inner arm, while allowing the chequer plate cover to be flush with adjacent floor finishes. The edges of the chequer plate cover shall be turned down into the channel section. Hinges shall not stand proud of the cover and sealed lifting eyes shall be provided complete with two lifting keys for each cover.

4

Where a cover is to be located on concrete upstands or flat concrete surfaces, the frame shall be made from angle sections. The edges of the chequer plate cover shall be turned down over the angle frame to provide a weatherproof cover. A lifting handle shall be provided on the edge opposite the hinges and a hasp provided for locking the cover with a padlock. The frame shall be bolted down to the concrete below using a minimum of four 10 mm diameter stainless steel acrylic resin anchors.

5

Fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy from other material.

4.8

FUTURE SEWER CONNECTION

4.8.1

General

1

All stub pipes and pipes built into manholes for future connections are to be sealed with an approved stopper, obtained from the same manufacturer as the pipe.

2

Marker posts shall be provided at the ends of all pipes left for future connection except where a single stub pipe is built into a manhole and are to be located as directed by the Engineer’s Representative.

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INSITU LINING OF EXISTING MANHOLES

4.9.1

General

1

Where directed by the Engineer, the Contractor shall apply a GRP lining to all internal surfaces of an existing manhole. The lining shall generally comply with the requirements of Specification Clause 4.4.1.

2

The cover slab and manhole cover shall be removed. The slab shall be disposed to an approved tip. The manhole cover and frame shall be thoroughly cleaned, treated with two coats of bituminous paint and submitted to Drainage Affairs Store.

3

All surfaces to be lined shall be clean and dry, step irons and any unsound materials shall be removed to the satisfaction of the Engineer prior to the commencement of any lining or sealing work.

4

For walls a preformed liner sized to fit in the existing manhole may be used. The joint between the base of the liners and existing benching shall be sealed into a chase cut into the existing benching by a heavy duty epoxy resin based sealant approved by the Engineer, which must be applied strictly in accordance with the manufacturer's instructions. The space between the existing internal concrete wall of the manhole and the liner shall be filled using an approved non-shrink cementitious grout.

5

Alternatively an in situ wall lining may be used. The walls shall first be made good with 3:1 sand cement mortar and the surfaces to be lined shall be lightly abraded. An in-situ lining 6mm deep in compliance with Specification Clause 4.4.1.9 shall then be formed.

6

On completion of the lining a new GRP ladder shall be installed in accordance with Specification Clause 4.4.1.15, if shown on the Contract Drawings.

7

A new cover slab and manhole cover shall be provided. The cover slab shall comply with Specification Clause 4.4.1.9. The manhole cover and frame shall comply with Specification Clause 4.6.1.

8

The Contractor shall provide the Employer with a 7-year unconditional guarantee against failure of all GRP linings whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed to the Engineer before the issue of the Certificate of Completion.

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4.9

END OF PART

QCS 2014

Section 08: Drainage Works Part 05: Valves, Penstocks and Appurtenances

Page 1

5

VALVES, PENSTOCKS AND APPURTENANCES ....................................... 3

5.1

GENERAL ...................................................................................................... 3

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

Scope References Submittals Quality Assurance Delivery, Storage and Handling

5.2

MATERIALS .................................................................................................. 6

5.3

SLUICE VALVES ........................................................................................... 7

5.4

BUTTERFLY VALVES ................................................................................... 8

5.5

REFLUX VALVES .......................................................................................... 9

5.6

PLUG VALVES ............................................................................................ 10

5.7

SURFACE BOXES ...................................................................................... 10

5.8

VALVE OPERATING TEE KEYS................................................................. 11

5.9

AIR VALVES ................................................................................................ 11

5.10

PRESSURE CONTROL AND RELIEF VALVES.......................................... 11

5.10.1 5.10.2 5.10.3 5.10.4

General Pressure Reducing Valves Pressure Relief Valves Pressure Regulating and Sustaining Valves

5.11

PENSTOCKS ............................................................................................... 12

5.11.1 5.11.2 5.11.3 5.11.4 5.11.5

General Cast Iron Penstocks Stainless Steel Penstock Plastic Penstocks Stoplogs

5.12

OPERATING DEVICES ............................................................................... 15

5.12.1 5.12.2 5.12.3 5.12.4 5.12.5 5.12.6

Lifts Liftnut Gear Lift Handwheel Stem Covers Actuators

5.13

FLAP VALVES ............................................................................................. 17

12 12 12 12

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3 3 4 6 6

5.13.1 Flap Valves (General Purpose) 5.13.2 Flap Valves for Sea Water Applications

12 12 14 14 15 15 16 16 16 16 16 17 17

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5.14

MISCELLANEOUS VALVES AND APPURTENANCES .............................. 17

5.14.1 5.14.2 5.14.3 5.14.4

Ball Float Valves Globe Valves Quick Coupling Valves Emitters

5.15

FITTINGS .................................................................................................... 18

17 18 18 18

5.15.2 Flanges, Gaskets, and Bolts 5.16

18

MECHANICAL COUPLINGS ....................................................................... 18

5.16.1 Grooved End Couplings 5.16.2 Flexible Couplings

.

FLOW CONTROL ........................................................................................ 19

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19 19

5.17.1 Vortex Flow Control Devices

INSTALLATION AND TESTING .................................................................. 20

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5.18

19

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5.18.1 Installation 5.18.2 Testing

20 20

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5

VALVES, PENSTOCKS AND APPURTENANCES

5.1

GENERAL

5.1.1

Scope

1

This part includes the specification for the manufacture, testing and supply and installation of valves, penstocks and appurtenances complete with frames, supports, anchor bolts, stems, stem guides and other appurtenances.

2

Related Sections and Parts are as follows: General Pipes and Fittings Materials Pipe Installation Miscellaneous Metal Works Protective Coatings and Painting

Section 1, Section 9, Section 10,

General Mechanical and Electrical Equipment Instrumentation Control and Automation.

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This Section Part 1, Part 3, Part 4, Part 6, Part 8,

All valves are to be fixed to the pipelines with adaptor flanges for easy removal or installation.

5.1.2

References

1


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ANSI B18.2.1..............Square and Hex Bolts and Screws

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ANSI B18.2.2..............Square and Hex Nuts

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ASTM B62 ..................Composition Bronze or Ounce Metal Castings

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ASTM D256 ................Test Methods for Impact Resistance of Plastics and Electrical Insulating Materials ASTM D570 ................Test Method for Water Absorption of Plastics ASTM D638 ................Test for Tensile Properties of Plastics ASTM D648 ................Test Method for Deflection Temperature of Plastics Under Flexural Load ASTM D695 ................Test Method for Compressive Properties of Rigid Plastics ASTM D696 ................Test Method for Coefficient Linear Thermal Expansion of Plastics ASTM D790 ................Standard Test Methods For Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials ASTM D1784 ..............Specification for Rigid Polyvinylchloride) (PVC) Compounds and Chlorinated Polyvinylchloride (CPVC) Compounds ASTM D2000 ..............Classification System for Rubber Products in Automotive Applications AWWA C500 ..............Metal-Seated Gate Valves

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Page 4

AWWA C501 ..............Cast-Iron Sluice Gates AWWA C507 ..............Ball Valves 150 mm Through 1200 mm AWWA C510 ..............Double Check Valve Backflow-Prevention Assembly. BS 4772......................Ductile iron pipes and fittings BS 5163......................Predominantly key-operated cast iron gate valves for water works purposes BS 970 Part 1 .............General inspection and testing procedures and specific requirements for carbon, carbon manganese alloy and stainless steel BS 2872......................Copper and copper alloy forging stock and forgings BS 2874......................Copper and copper alloy rods and sections (other than forging stock)

.

BS 3416......................Specification for bitumen based coatings for cold application

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BS 4164......................Specification for coal-tar-based hot-applied coating materials BS EN 593..................Butterfly valves

BS EN 1171................Cast iron gate valves

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BS EN 1092................Flanges and their joints

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BS EN 598 ------- Face-to-face valve dimensions

BS EN 1561................Flake graphite cast iron

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BS EN 1563................Founding. Spheroidal graphite cast iron

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BS EN 1982................Copper alloy ingots and copper alloy and high conductivity copper castings

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BS EN 3196................Nuts, hexagonal, self-locking in heat resisting steel

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BS EN 12334..............Cast iron check valves for general purposes

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ISO 9000 ....................Quality Systems Submittals

1

The Contractor shall obtain Engineer’s approval of submittals before placing order for the following items.

2

Valves. Complete data for the supply and installation of all valves and appurtenances shall be submitted as follows:

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5.1.3

(a)

Product data: (i)

for each type and model of valve, provide

(ii)

 assembly instructions,  preventative/corrective maintenance instructions for each actuator, provide

(iii)

 currents at the specified voltage corresponding to locked rotor,  maximum seating torque,  average running load, and speed and full information concerning actuator dimensions and weights shall be provided identification of valves and accessories by tag numbers, where applicable.

QCS 2014

(b)

3


Page 5

The following detailed written procedures shall be submitted to supplement the above data: (i)

installation procedures for fixing, supporting, and anchoring valves

(ii)

test procedures for adjusting and testing valve assemblies.

Penstocks: (a)

Complete fabrication, assembly, foundation, and installation drawings, together with detailed specifications and information covering performance and materials of construction, power drive assembly, devices, and other accessories shall be submitted as follows: (i)

Shop drawings, data and specifications for the equipment shall include, but not limited to:

(ii)

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 anchor bolt placement in the concrete structure including projections from concrete or other surfaces  gate size, model numbers, opening sizes, elevations, locations, and materials of construction  stem sizes including details of connections, thread directions, and stops, and calculations for stem diameter and operators  stem guide details and locations  gear box types, model numbers, and ratios, including connections furnished for each type  wall thimbles  motor data, including the motor manufacturer; minimum guaranteed efficiency and power factor at full load, 3/4 load, and 1/2 load; locked rotor current in amps; full load current in amps; motor speed in rpm; and mounting details Factory Test Reports:

Operations and Maintenance Manuals:

o

The Contractor shall submit five copies of complete operation and maintenance manuals for penstocks and valves written in English in accordance with Part 1 of this Section. Required operation and maintenance data shall include, but not limited to

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(i)

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 Before shipment of any material specified herein, the Contractor shall submit the results of all test reports for the approval of the Engineer.

complete, detailed written operating instructions for each product or piece of equipment. Manuals must be specific to the products supplied herein and the application and operating conditions in Qatar. General manuals will not be accepted

(ii)

complete, detailed preventative maintenance instructions

(iii)

a complete inventory of all parts and components

(iv)

recommended spare parts lists and sources of supply for the parts

(v)

all safety instructions relating to operation and maintenance procedures

(vi)

name, address and phone number of manufacturer, manufacturer's authorised service representative

(vii)

troubleshooting instructions.

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Page 6

Quality Assurance

1

Valves, penstocks and appurtenances shall be supplied by approved manufacturers as designated in the Project Specification. Production facilities shall be quality assessed in accordance with ISO 9000 or equivalent.

5.1.5


1

Packaged items shall be stored in their original packing and wrappers until ready for inspection by the Engineer. After inspection, all packaged items shall be repacked and rewrapped such that the items are sealed to the satisfaction of the Engineer, and stored until ready for use or installation.

2

Valves and appurtenances shall be stored off the ground, protected from dirt and moisture, and protected from foreign material entering the ends.

3

All equipment shall be stored and handled in such a manner to protect equipment, finishes, and coatings, both internal and external.

4

During storage, gates for penstocks shall be placed in a position to support and prevent warping of gates and stems.

5.2

MATERIALS

1

Cast iron shall conform to BS EN 1561 minimum Grade 250 unless otherwise specified.

2

Ductile iron shall conform to BS EN 1563 unless otherwise specified.

3

Aluminium bronze shall conform to BS 2872 Grade CA 104

4

Bronze shall conform to ASTM B62 Grade 1, except that the maximum zinc allowance shall be seven percent and the maximum aluminium allowance be two percent, unless otherwise specified.

5

Gun metal shall conform to BS EN 1982 Grade LG2

6

Stainless steel shall conform to BS 970 Grade 316 S 31 unless otherwise specified.

7

Duplex stainless steel shall conform to BS EN 1.4507 unless otherwise specified.

8

Manganese steel shall conform to BS 970 Pt 1 Grade ISO M19.

9

Anchor bolts, assembly bolts, screws, nuts, and washers, including anchor bolts used in the installation and assembly of each unit shall be stainless steel unless otherwise specified, and of ample size and strength to safely withstand forces created by operation of the unit while subject to the hydrostatic heads described herein. The quantity and size of fasteners shall be as recommended by manufacturer, and as approved by Engineer. All bolt heads and nuts shall be hexagonal. Anchor bolts shall be furnished with two nuts each to facilitate installation and alignment.

10

All hand wheels, headstocks, foot brackets, guide brackets and thrust tubes shall be cast iron. All other materials for valves, penstocks and appurtenances shall be as specified for each item.

11

Unless otherwise stated Cast iron valves, penstocks and appurtenances shall be prepared and painted in accordance with part 8 of this Section.

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5.1.4

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Page 7

5.3

SLUICE VALVES

1

These specifications are applicable to all sizes of sluice valves larger than 80 mm diameter. Sluice valves shall be of the following types. (a)

Potable and treated sewage effluent - 80mm diameter up to and including 300mm diameter, to BS 5163 with resilient seating.

(b)

All other uses other than (a) above, 80mm diameter up to and including 1,000mm diameter to BS EN 1171metal seated.

Valves shall be of the double flanged cast iron wedge-gate type unless otherwise stated. Valves shall be cast iron body with renewable gun metal faces on body and wedge and bolton cast iron bonnet. All exposed valves shall be of the rising stem type unless otherwise specified or shown on the Contract Drawing. Rising stem valves shall also incorporate a combined yoke. Valves shall close clockwise.

3

Valves pressure ratings shall equal the class of pipe unless otherwise indicated on the Drawings.

4

Valve stems shall be of stainless steel SS316 S31, machined all over, with a machine cut robust trapezoidal or square form thread, operating in gunmetal.

5

Stem seals on valves of 350mm diameter and above shall be of the stuffing box and gland form arranged for easy replacement of packing and seal and shall be accessible for maintenance without removal of the valve from service. Stem seals on valves below 350mm diameter may be stuffing box and gland or 'O' ring. If 'O' ring seals are provided they shall be arranged such that they can be replaced without removal of the valve from service. If 'O' ring stem seals are provided, the Contractor shall provide with the valve, two replacement sets of rings labelled with the project number, manufacturer, valve model reference and size of valve.

6

Valves shall be provided with suitable handwheels as follows: diameter shall be adequate for the duty required

(b)

gearing shall be supplied where necessary to ensure that the required operating force applied by hand to the rim of the wheel does not exceed 250N (25Kgf)

(c)

Handwheels shall have smooth rims and the direction of closing, which shall be clockwise, shall be cast on them.

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(a)

The following shall apply to spindles :

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(a)

where possible and providing the valve is not subject to submergence, spindles shall be of the non-rising type and a cast iron bridle piece, or similar, shall be incorporated on valves of the rising spindle type for this purpose.

(b)

for valves of 300mm bore and above, and for all motorised/actuated valves spindles shall be of the rising type. Thrust tubes shall be provided between the valve and headstock in order to absorb the thrust in both direction of operation. Thrust tubes shall incorporate all necessary fixings brackets and spindle guide plates. Headstocks shall incorporate a valve position indicator.

(c)

where rising stem valves are subject to submergence the extension spindle shall also be of the rising type with the threaded portion positioned above top water level.

(d)

extended spindle installations shall include all necessary brackets, intermediate supports etc.

(e)

where extended spindles require to be operated at open flooring level, spindle guides or guide brackets shall be provided close to flooring level.

QCS 2014

(f)


Page 8

all spindles shall be of stainless steel Grade 316S31 and shall be compliant with the requirements for valve stems.

Extension spindle couplings shall be of the muff type and shall be drilled with a nut and bolt for securing the spindle to the valve stem, which will likewise be drilled to accept the bolt.

9

Vandal and weatherproof clear polycarbonate tube covers shall be securely fitted to protect the threads of rising stems and spindles. Tubes shall be clearly and permanently engraved to indicate the position of the valve.

10

Where valves are required to be operated by tee keys, spindle caps shall be fitted. The caps shall be drilled and each provided with nut and bolt for securing to the spindle which shall likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied complete with operating tee key. The extended spindle shall be such that the tee key will be operated at 0.9 to 1.2 m above floor level.

11

Where sluice valves above 350 mm bore are mounted with the spindle in the horizontal plane, valve bodies shall be fitted with renewable gunmetal machined gate slides and the gates with renewable hard bronze shoes accurately machined to reduce sliding fraction.

12

All sluice valves above 500 mm bore (300 mm if power actuated) shall be provided with jacking screws. Valves above 350 mm bore where mounted in a horizontal pipeline shall be provided with feet.

5.4

BUTTERFLY VALVES

1

Butterfly valves shall comply with BS EN 593 and be of the double flanged, non-wafer, double eccentric (Offset) type. The valves shall be designed such that the body and disc seat rings can be easily replaced.

2

Valves shall be suitably designed to protect the disc edge from the effects of corrosion and erosion.

3

The valve body ends shall be double flanged and the flange dimensions shall comply with the relevant requirements of BS EN 1092. The body shall be manufactured from close grained cast iron lined with rubber unless otherwise specified. The body parts shall be circular and the diameter not less than that of the nominal pipe bore. The valve body shall be provided with suitable lifting lugs.

4

The disc shall be designed to withstand the maximum pressure differential across the valve in either direction of flow. The disc shall be contoured to ensure the lowest possible resistance to flow and shall be suitable for throttling operation. Disc material shall be duplex stainless steel.

5

The shaft shall be designed to withstand the maximum torque that will be imposed by the operator. It may be in one piece or attached as two stub ends on opposite sides of the disc. The stub end shall be of polygon profile type conforming to P3G or P4C. The means of attachment of the shaft to the disc shall be by using fixings in a homogeneous corrosionresistant material of a pattern which precludes the assembly becoming loose in operational service. Grub screws, pins (parallel or taper) or clamps shall not be acceptable. The shaft material shall be stainless steel SS316 S31. Self-lubricating PTFE faced bearings with ‘O’ ring seals shall be provided.

6

The body seat shall be stainless steel SS316 S31 and the disc seat shall be one piece moulded nitrile rubber. They shall be designed to be drop tight in either direction at maximum differential pressure.

7

Valves shall be provided with suitable stops to prevent movement of the shaft beyond the limits corresponding to fully open and fully closed position of the disc.

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Page 9

A suitable external locking device shall be provided on the non-drive shaft end, to enable the geared unit to be removed with the valve remaining in service in the open or closed position.

9

Fasteners like nuts, bolts and washers of stainless steel shall be provided.

10

Unless otherwise specified each valve shall be provided with a suitable handwheel of adequate diameter for the duty required and gearing shall be supplied where necessary to ensure that the required operating force applied by hand to the rim of the wheel does not exceed 25 kgf.

11

Extension spindles, headstocks and foot brackets shall be provided where specified. Headstocks shall incorporate a valve position indicator.

12

The valve shall be closed by clockwise movement of an actuator or handwheel. Direction arrows clearly indicating 'open' and 'closed' positions shall be provided on the actuator or cast on the handwheel.

13

Valves shall be provided with a position indicator to show the positions of the disc, mounted on the driven shaft end.

14

All Valves above 350 mm diameter shall be provided with lifting lugs or eye-bolts

5.5

REFLUX VALVES

1

Unless otherwise specified Reflux valves shall be swing type, double flanged cast iron conforming to BS EN 12334. Flange dimensions shall comply with the relevant requirements on BS EN 1092 PN16. Reflux valve shall have face-to-face dimensions in accordance with BS EN 558.

2

The valves shall be of the quick acting single door type designed to minimise slam on closure by means of heavy gunmetal-faced doors weighted as necessary. The valves shall be fitted with renewable gunmetal door sealing faces which shall be positively fixed. The door hinge pin/shaft shall extend through a sealing gland on the side of the body and be fitted with an external lever to permit back flushing.

3

Glands shall be of the stuffing-box type with the exception that for valves below 450 mm bore they shall be of the ‘O’ ring type.

4

The valve door shall be weighted to suit the application and the lever shall be of the heavy duty type designed for the additional of external weights should these be required at some future date.

5

Where there is a likelihood of surge pressures being generated reflux valves shall be of the low loss non-slam wafer type. They shall feature a spring action giving drip tight shut-off. The movement of the sealing plate shall not lead to scuffing of the seat material.

6

All reflux valves shall be suitable for operating in the horizontal plane unless otherwise specified.

7

Cover plates shall be of sufficient size to allow easy hand access for cleaning and service and shall be supplied complete with tapped bosses fitted with air release cocks.

8

Valves above 350 mm bore shall be provided with feet.

9

The design of the valve body shall be such that there is adequate clearance around and at the back of the door to minimise jamming by rags and debris. Stops shall be provided to limit the back lift of the door and shall be positioned to prevent fouling.

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Page 10

The hinge pin/shaft shall be stainless steel SS316 S31 and preferably square in section to ensure positive location of the door. If circular shafts are utilised the back flushing lever shall be located on a squared section, the diagonal dimensions of which shall be equivalent to the full diameter of the shaft. Both door and lever shall be positively and securely fixed to the hinge pin/shaft. Grub screws, pins (parallel to taper) or clamps will not be acceptable. All internal fixing devices shall be of stainless steel SS316 S31.

11

Reflux valves fitted to the delivery side of pumps shall be fitted with balance weights to minimise slam. If specified, they shall be provided with a totally enclosed proximity switch operated by an external cam fitted to the extended spindle. The proximity switch shall be of the metal clad type with sealed actuator and cable entry. Cam operated micro-switches will not be acceptable.

5.6

PLUG VALVES

1

Plug valves shall be eccentric and equipped with resilient faced plugs and be of nonlubricated type capable of handling abrasive and raw sewage. The plug valves shall have PN 16 flanged ends. Valves shall be furnished with manual operators as a unit. Each valve plug shall rotate 90 degrees from the fully open to the tightly shut position and shall seat at an angle of 90 degrees from the pipe axis in which the valve is installed.

2

Valves shall be satisfactory for applications involving throttling service and for frequent operation after long periods of inactivity. Valves with operators shall be suitable for operation with flow in either direction.

3

Valves shall be non-lubricated, with non-shock pressure differential acting in either direction; at 175 kPa differential across the valve, the valve will provide drip-tight shut-off. Valves 75 mm diameter and above shall have bolted bonnet design. Bodies shall be of high carbon cast iron or nickel iron having 1 % to 1.5 % nickel content. Valves shall have raised seats and all surfaces in contact with the plug face shall have 90 % pure nickel or coating. Valves shall have an average tensile strength of 240 MPa. Port areas of valves sizes greater than 100 mm shall be at least 75 % of full pipe area. Flanged valves shall be faced and drilled minimum PN 16 standard and shall have face-to-face dimensions of standard sluice valves. Valves shall have balanced plugs to assure low torque and drip-tight shut-off.

4

Valves shall be equipped with resilient plug facing to provide drip-tight shut-off without use of sealing lubricants. Even if small solids are trapped between the plug and seat, the resilient facing shall provide tight shut-off and prevent seat damage. Resilient plug facings shall be neoprene, ethylene propylene terpolymer, or other suitable materials capable of handling abrasives and raw sewage.

5

Valves shall have heavy-duty upper and lower guide bearings capable of resisting corrosion and lubricated by the liquid being handled.

6

Valves shall be actuated by means of lever for valves under 80 mm in size and by enclosed gear and handwheel operator for valves 100 mm and longer. All valves shall be supplied with operators which required less than 10 N/m torque for operation. Chain wheels with guides shall be furnished on all valves located 2 m or more above floor levels with stainless steel.

7

Valves operating devices shall be as specified in Clause 5.12 herein.

5.7

SURFACE BOXES

1

Surface boxes and covers shall be adjustable cast iron of the slip type and fitted to the sizes and depths of valves as shown on the Drawings. Covers and frames shall be heavy duty and be suitable for wheel loads up to 11.43 tonnes.

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Page 11

Surface boxes shall be coated by dipping or other equivalent means using a hot applied coal tar based material complying with BS 4164 or cold applied bitumen material complying with BS 3416. No coating shall be applied to any casting until its surfaces are clean dry and free from rust oil and deleterious material.

5.8

VALVE OPERATING TEE KEYS

1

Valve operating keys shall have a 50mm square socket. The length of the key shall enable the valve to be operated with hands at waist height. Unless otherwise stated in the Contract Documents one tee key per ten valves that are to be tee key operated, shall be provided for each site.

5.9

AIR VALVES

1

Air and gas relief valves shall be of the double orifice pattern with grey or ductile cast iron bodies. The inlet flange shall be faced and drilled in accordance with BS EN 1092 PN16. Air valves for TSE or potable water shall be of the water type. Air valves for all other waste water work shall be of the sewage type.

2

The valve shall be adequately sized for the release of gas from the pipeline (or other container) without restriction of rate of filling or flow due to back pressure and also to allow admission of air during pipeline emptying at a rate sufficient to prevent excessive depression of pressure in the pipe.

3

Valves shall be designed to prevent the operating elements being in contact with the pipeline liquid by approved means such as the provision of an auxiliary float and chamber sufficiently large to isolate the orifice valves and seats throughout the rated operational range.

4

In applications where the pipeline characteristics may lead to liquid column separation with consequent possibility of surge a vented non-return valve shall be provided which allows air to enter freely on separation but controls explosion of air/gas as the liquid column re-joins.

5

In applications where the hydraulic conditions are such that pressures fall below atmospheric pressure during normal operation and where air inflow at that time could induce surge conditions, an air inflow check valve shall be incorporated.

6

All air and gas relief valves and associated isolating valves shall be works tested and capable of withstanding the same test pressures as the pipeline or vessel on which they operate.

7

Air valves and operating linkages that are not made stainless steel shall be pure epoxy resin coated in accordance with Part 8 of this Section.

8

Air valves shall be vented wherever possible directly into the wet well. In cases where this is not possible the Contractor shall provide suitable odour removal for the air expelled from the valve.

9

Where air may be drawn into the valve that contains dust, sand etc. means shall be provided for trapping/filtering this.

10

Air valves shall be installed in such a manner that routine maintenance can be carried out.

11

Air valves shall be fitted with an isolating sluice valves and gearing shall be provided where necessary to facilitate operation.

5.10

PRESSURE CONTROL AND RELIEF VALVES

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Page 12

General

1

The valve body shall be of cast iron conforming to BS EN 1561 with flanges conforming to BS EN 1092 PN16 or BS 10. The valve shall be extra heavy construction throughout. The valve interior trim shall be bronze as well as the main valve operation. All working parts shall be easily removed from the valve body for ease of maintenance. All controls and piping shall be of non-corrosive construction.

5.10.2

Pressure Reducing Valves

1

Pressure reducing valves shall maintain any desired downstream-delivery pressure for which the reducing pilot valve is adjusted provided the upstream head does not drop below a determined head. During low flow conditions, a resilient rubber valve seat shall ensure drop tight sealing. The valve shall be completely piped ready for installation.

5.10.3

Pressure Relief Valves

1

Pressure relief valves shall maintain constant upstream pressure by bypassing or relieving excess pressure, and shall maintain close pressure limits without causing surges. The main valve shall be a hydraulically operated, diaphragm-actuated, globe or angle pattern valve. It shall contain a resilient, synthetic rubber disc. The downstream pressure setting shall be adjusted by compression of the spring via the adjusted screw.

5.10.4

Pressure Regulating and Sustaining Valves

1

Pressure sustaining valves shall open and close in modulating action as required to maintain constant system pressure. On pressure reversal valve shall close tightly. Operation shall be completely automatic with only one adjustment required to change the pressure setting. Adjustable pressure range from 1.0 bar to 8.5 bar. The valve shall be "Y" pattern globe diaphragm actuated with pilot control. The diaphragm shall be made of reinforced neoprene and the pilot shall be bronze and all tubing copper.

5.11

PENSTOCKS

5.11.1

General

1

Each item of equipment shall be furnished and installed complete with all supports, anchor bolts, stems, stem guides, and appurtenances ready for operation. All mechanisms and parts shall be amply proportioned for the stresses which may occur during operation or for any other stresses which may occur during fabrication and erection. Individual parts furnished which are alike in all units shall be alike in workmanship, design, and materials and shall be interchangeable. Penstock in sewage pumping stations shall be stainless steel/cast iron with gun metal seating suitable for corrosive environment.

5.11.2

Cast Iron Penstocks

1

Penstocks shall be suitable for their application, and shall be installed and positioned in such a manner as to allow ease of operation and maintenance.

2

Penstocks shall carry identification marks and brass name plates in accordance with BS EN 12334, which identify the penstock number and function.

3

Penstocks shall be clockwise closing.

4

Penstocks shall be watertight under the conditions stated for head and direction of flow.

5

All materials used in manufacture of the penstocks shall conform to the following minimum standards unless otherwise specified:

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5.10.1

QCS 2014


Cast Iron Gunmetal Aluminium Bronze Stainless Steel High Tensile Brass (Manganese Bronze) Manganese Steel Phosphor Bronze

BS EN 1561 BS 1400 BS 2872 BS 970 Pt. 1 BS 2874

Grade 250 Grade LG2 Grade CA104 Grade 316 S31 Grade CZ114

BS 970 Pt. 1 BS 2574

Grade ISOM19 Grade P13

Page 13

6

Fixing nuts and bolts supplied by the manufacturer shall be of stainless steel.

7

Each penstock shall be provided with a suitable handwheel of adequate diameter for the duty required. Gearing shall be supplied where necessary: to ensure that the required operating force applied by hand to the rim of the wheel does not exceed 250N (25Kgf)

(b)

if the handwheel cannot be readily accessed, extension spindles, headstocks and foot brackets shall be provided where specified

(c)

where possible, the extension spindle shall be of the rising type with the threaded portion position above top water level

(d)

headstocks for non-rising spindle installations shall incorporate a position indicator.

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(a)

Handwheels shall have smooth rims and the direction of closing which shall be clockwise shall be cast on them. Vandal and weather proof clear polycarbonate tube covers shall be securely fitted to protect the threads of rising stems and spindles. Tubes shall be clearly and permanently engraved to indicate the position of the valve.

9

The frames and doors of cast iron penstocks shall be made from close grained grey iron. The penstocks shall be designed so as to ensure tight closure while maintaining freedom of door movement during operation and minimising sliding wear of the sealing faces. They shall incorporate adjustable wedges or swivelling cams and actuating pegs manufactured from a non-corrodible material.

10

Headstocks and foot brackets shall be provided for non-rising spindle penstocks where the latter are specifically called for. Guide brackets shall however be provided where necessary. Non-rising spindles shall be fitted with thrust collars and arranged so as to transmit the thrust arising due to the operation of the penstock directly to the penstock frame. Where headstocks are required on non-rising spindle installations they shall incorporate a penstock position indicator.

11

Penstock spindles shall be of forged stainless steel SS316 S31 , machined all over, with a machine cut robust trapezoidal or square form thread, operating in a gunmetal nut.

12

Extension spindles shall be of stainless steel SS316 S31and shall be compliant with the requirements for penstock spindles. Extension spindle couplings shall be of the muff type and shall be drilled and provided with a nut and bolt for securing the spindle to the penstock spindle, which shall likewise be drilled to accept the bolt.

13

Extended spindle installations of the rising type shall be provided for valves of 300 mm bore and above, and for all motorised/actuated penstocks. These shall be of stainless or manganese steel or manganese bronze. Thrust tubes shall be provided between the penstock from and headstock in order to absorb the thrust in both directions of operation. Thrust tubes shall incorporate all necessary fixing brackets and spindle guide plates. All handwheels, headstocks, foot brackets and guide brackets shall be of cast iron.

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Page 14

Where penstocks are required to be operated by tee keys, spindle caps shall be fitted. The caps shall be drilled and each provided with nut and bolt for securing to the spindle which shall likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied complete with operating tee key. The extended spindle shall be such that the tee key will be operated at 0.9-1.2 metres above floor level.

15

Where penstocks are provided with greasing nipples, these shall be fitted with extension tubes to facilitate lubrication from a nearby walkway or other readily accessible location.

16

Non-ferrous metal sealing faces shall comprise accurately machined gunmetal or bronze strips bedded and fixed to machined recesses in the frame and door. The strips shall be secured by non-corrodible countersunk screws. The faces of the strips shall then be brought together in the operation position and hand scraped to a watertight finish.

17

Handwheels, headstocks, foot brackets and thrust tubes shall be of cast iron.

18

Cast iron penstocks and headstocks shall be coal tar epoxy coated in accordance with Part 8 of this Section.

5.11.3

Stainless Steel Penstock

1

Where indicated on the drawings or elsewhere in the Contract Documents, penstocks for use in aggressive environments shall be manufactured from corrosion resistant materials as follows:

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Metal parts exposed to the atmosphere shall be manufactured from stainless steel to BS 970 Part 1, Grade 316 S31.

(b)

The frame shall be fixed to the wall using nuts and bolts Grade 316 S31 stainless steel.

(c)

The door of the penstock shall be manufactured from corrosion resistant plastic or stainless steel (Grade 316 S31). Plastic shall also be totally resistant to ultra-violet light. Asbestos shall not be used in any filling materials within plastic gates.

(d)

The seals used on corrosion resistant penstocks shall be suitable for the medium in which the penstock is immersed. Flexible rubber seals shall not be used on penstocks immersed in raw sewage for example, where sharp objects and grit may destroy the seal at the high velocities experienced when opening and closing the doors.

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All other requirements shall be as specified in Clause 5.11.2 herein.

5.11.4

Plastic Penstocks

1

Plastic penstocks shall be of the flush invert type and the underside sealing face shall consist of high resilient material securely bonded into a channel or similar section forming the invert of the frame into which the bottom of the door shall effect a watertight seal.

2

The door of plastic penstocks shall be made from sheets of approved rigid cellular polymer sandwiched between sheets of approved rigid compressed composite plastics. The linear PVC or GRP materials shall be used. The doors thus formed shall have sufficient strength to withstand the required working pressure without deflection or distortion that would affect the operation of water-tightness of the penstock. Totally enclosed steel matrix shall be incorporated in the door construction to ensure adequate rigidity.

3

The sealing faces and side guides shall be EPDM having a high resistance to sliding wear and shall be to the approval of the Engineer. The sealing strips shall be securely fixed to the inner faces of the frames and adjusting devices or other means of ensuring freedom of movement without loss of seal shall be provided. The adjusting devices and fasteners shall be of stainless steel conforming to BS 970 Part 1 Grade SS 316 S31.

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Page 15

Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra-high molecular weight polyethylene material. The operating nuts for the spindle retaining blocks shall be fixed in a visible position inside a separate gate lifting bracket bolted on to the top of the door with stainless steel fasteners. The operating nut or spindle retaining block shall not be contained within the door.

5

All plastic materials shall be non-toxic ultraviolet stabilised and shall have fire resistance as specified in BS 475 and be to Class P and Class I of Part 5 and 7 thereof respectively.

6

All other requirements shall be as specified in Clause 5.1.3 Clause 5.11.2 herein.

7

Plastic penstocks shall only be used when indicated in the Contract Documents and approved by the Engineer.

5.11.5

Stoplogs

1

Stoplogs shall be fabricated from reinforced composite plastic material which is non-toxic and stabilised against ultraviolet light. Asbestos shall not be used in the manufacture of the stoplogs.

2

Plastic logs of 300 mm and 400 mm depths shall be furnished to provide closure of stoplog openings. Full depth gates shall not be acceptable.

3

Each log shall be provided with a stainless steel eye bolt at each end which fits into a recess in the under surface of the next log. Two lifting poles fitted with hooked ends for engaging the eye bolts shall be furnished for each facility and shall be mounted locally on a handrail supported pole rack. Poles and racks shall be constructed of aluminium and bolts of stainless steel.

4

Stoplogs shall provide a high degree of sealing with a leakage rate of less than 0.04 l/sqm of seating perimeter. Stoplog frame shall be for insertion in a wall and invert recess.

5

Anchor bolts shall be stainless steel.

6

Frames shall be manufactured from stainless steel BS 970 or BS 1449 Grade 316. All frames shall be suitably reinforced and include corner gussets where necessary. All fasteners shall be stainless steel.

7

Frames shall be fitted with seals which are molecularly incompatible with the closure material. Where necessary, the seals shall be fixed with corrosion resistant retaining strips and stainless steel fasteners.

5.12

OPERATING DEVICES

5.12.1

Lifts

1

Lifts shall be designed to operate the gate of the specified head with a maximum of 25 kg force applied to the device. The lift shall be a liftnut for tee key operation or gear/handwheel lift as designated.

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Page 16

Liftnut

1

The liftnut shall be hexagonal, gunmetal and internally threaded to fit the stem. The housing shall be cast iron and suitable for mounting in the head angle, gate frame extension or wall mounted bracket. The liftnut shall be flanged to maintain position in the housing and to accommodate the thrust developed during gate operation. Each lift shall be furnished with a bronze stop nut. The nut lift shall accept a T-bar operator or handwheel. Suitable T-bar operators shall be furnished.

5.12.3

Gear Lift

1

The gear lift mechanism if required shall be of the crank operated type with either a single or double gear ratio, depending on the lift load. Each type shall have a cast bronze liftnut threaded to fit the operating stem. Ball thrust bearings shall be provided above and below the flange on the liftnut to take the load developed in opening and closing the gate. Gears shall be of cast iron or steel, accurately machined with cut teeth, and smooth running with suitable shafts running in gunmetal sleeve bearings or roller bearings of ample size. All geared lifts shall be suitable for auxiliary motor operation. All gears and bearings shall be enclosed in a cast iron housing. Fittings shall be provided so that all gears and bearings can be periodically lubricated. The removable cast iron crank shall be fitted with a rotating handle. The lift mechanism shall be supplied with a cast iron pedestal, machined and drilled to receive the gear housing and suitable for bolting to the thrust tubes, operating floor or wall bracket. The maximum crank radius shall be 400 mm. The direction of rotation to open the gate shall be indicated on the lift mechanism. A cast iron stop nut shall be provided for each lift. All exposed cast iron shall be coated according to Part 8 of this section.

5.12.4

Handwheel

1

The housing shall be cast iron and shall be suitable for mounting on the head angle or pipe frame extension. The lift nut shall be flanged to maintain position in the housing and to accommodate maximum thrust developed during gate or valve operation. The lift nut shall be bronze and internally threaded to mate the stem. Each lift shall be furnished with a bronze stop nut. The steel or cast iron handwheel shall have a solid rim and shall be smooth and free of sharp edges and an arrow and the work "OPEN" shall be cast in the rim or attached to the handwheel. Handwheels generally shall be positioned on a headstock 750 mm above operating level.

5.12.5

Stem Covers

1

Stem covers shall be provided on all valves or gates with rising stems. Stem covers shall be clear butyrate with Mylar decals indicating open and close gate position and of sufficient length to totally enclose the stem when the gate is fully open. The top shall be closed and the bottom shall screw into a cast iron housing mounted on top of the gate operator. The inside of this housing shall be bored to the exact diameter of the stem cover to assure accurate alignment of the cover.

5.12.6

Actuators

1

Actuators are specified in Section 21.

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5.12.2

QCS 2014


Page 17

FLAP VALVES

5.13.1

Flap Valves (General Purpose)

1

The seat shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with a raised section around the perimeter of the waterway opening to provide the seat. The raised section shall provide a seating plane diverging, top to bottom, from the plane of the mounting flange to assist in positive closure of the cover. The seat shall be shaped to provide two bosses extending above the top of the waterway opening for mounting the top pivot lugs. Pivot lug bosses shall be drilled and tapped for mounting studs. The flap shall be designed to be either butted to the face of a wall or to the outlet flange of a discharge pipe. The flaps shall be operable at a head of 10 m.

2

The cover shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with necessary reinforcing ribs, with a lifting eye for manual operation, and with bosses to provide a pivot point connection with the links. Bosses shall be designed to place the hinge bolts in double shear when gate is assembled.

3

Each pivot lug shall be one-piece cast iron. Lugs shall have double bosses to place the top hinge bolts in double shear when they are assembled through the links. The lugs shall be adjustable in the horizontal plane without removal of the cover from the gate links. The adjustment shall allow the top pivots to be moved toward the gate seat for reduced sensitivity of the cover, or moved away from the gate seat to provide opening with a minimum differential head. Two studs shall be used to connect each pivot to the gate seat.

4

The links connecting the cover and pivot lugs shall be one-piece heavy duty cast iron. Each link shall be provided with bronze bushings at each pivot point. The bottom of the links shall be provided with an adjusting screw to properly align seating faces on the cover with respect to the seat. The links shall be designed to limit the double hinge action, preventing the cover from rotating sufficiently to become wedged in the open position.

5

Cast iron work shall be coated before delivery with a bituminous compound as specified in Clause 8.5.16.2 of QCS.

5.13.2

Flap Valves for Sea Water Applications

1

Flap valves frames including fixings for sea water and other aggressive applications shall be of stainless steel conforming to BS 970 Part 1. Sealing faces shall be phosphor bronze conforming to BS 2874.

2

Flap valves manufactured from corrosion resistant materials will also be acceptable for general purpose applications.

3

Flap valves above 1500 mm square shall be of the double door type.

4

Doors shall be of reinforced natural rubber compound of sufficient flexibility to maintain an efficient seal under minimal seating head conditions.

5

Door hinges shall be continuous across the full width of the door and manufactured from homogeneous polypropylenes, polyurethane or similar non-ageing material.

5.14

MISCELLANEOUS VALVES AND APPURTENANCES

5.14.1

Ball Float Valves

1

Ball float valves shall comply with BS 1212. Flanges shall conform to BS EN 1092.

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5.13

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PVC ball valves 50 mm and smaller shall be of the true union socket weld type, and valves 75 mm and larger shall be of the flanged type. Valves shall be rated at 1000 kPa at 50 °C unless otherwise specified.

3

Metal ball valves 60 mm and larger shall have brass balls with carbon steel bodies, and valves 50 mm and smaller shall have brass bodies. Valves shall have a Teflon seal and seat. Valves shall be rated at 1000 kPa at 100 °C unless otherwise specified.

4

Stainless steel ball valves shall be flanged with stainless steel body, ball and stem. Valves shall be rated at 1000 kPa at 100 °C unless otherwise specified.

5.14.2

Globe Valves

1

Globe valves shall be low-zinc bronze body type with tapered discs permitting close regulation of flow. Valves 75 mm and larger shall be flanged, Class 125 conforming to ANSI B16.1 in drilling and dimensions. Valves 60 mm and smaller shall be 1,000 kPa, and shall have screwed joints.

5.14.3

Quick Coupling Valves

1

Quick coupling valves shall be of robust construction consisting of a cast bronze body and dust cap with machined bronze valve cage and seat. The valve washer shall be neoprene rubber with stainless steel packing washer and fixing screw. The stem seal ring shall be neoprene rubber.

2

Double lug keys with swivel hose ells and standard 20 mm diameter hose connectors of the same manufacturer shall be supplied to the Employer’s stores at the rate of one key for every five hose points. Each part shall be cast or machined bronze with neoprene rubber seals. The cost of supplying these keys complete shall be included in the rates for valves.

5.14.4

Emitters

1

Bubble emitters shall be brass with 12 mm BSP thread designed for adjustable flows.

5.15

FITTINGS

1

All flanges, fittings, coupling, valves, and appurtenances shall be rated for the pipeline pressure, except as noted on the Drawings.

5.15.2

Flanges, Gaskets, and Bolts

1

Flanges shall be PN 16 rating or as otherwise designated. Flange gaskets shall be ring type. Thickness shall be 1.5 mm for pipes 250 mm and smaller, and 3 mm for larger pipes. Flange assembly bolts shall be standard hexagon head machine bolts with heavy hot pressed, hexagon nuts and shall conform to BS EN 1092. Bolt length shall be such that after the joints are made up, the bolts shall protrude through the nut, but not more than 12 mm. All anchor bolts shall be stainless steel.

5.16

MECHANICAL COUPLINGS

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Grooved End Couplings

1

Couplings shall engage and lock the grooved or shouldered pipe ends allowing some degree of contraction, expansion, and angular deflections. Coupling housing shall be of ductile iron or malleable iron and shall consist of two or more segments held securely together by at least two steel bolts. Sealing gasket shall be of such design that internal pressure in the pipe increases the tightness of the seal and shall be of materials suitable for the intended service. The coupling shall have a rated working pressure not less than the pressure rating of the pipe.

2

Corrosion protection shall be applied in accordance with the requirements specified in Clause 5.16.2 herein.

5.16.2

Flexible Couplings

1

Flexible (sleeve) couplings of the full sleeve type, split sleeve type, or flanged adapter type shall provide the requisite pipe flexibility without jeopardising pipe joint integrity due to hydraulic thrust, and shall have the same pressure rating as the pipe. Couplings shall have all metal bearing surfaces and shall be provided with galvanised steel bolts and nuts. Flexible couplings shall be restrained unless the Engineer has given his approval to omit this feature for specific cases. Specific requirements for each type are as follows:

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5.16.1

full sleeve type couplings shall be properly gasketed and shall be of a diameter to fit the pipe. Each coupling shall consist of a steel middle ring, two steel followers, two gaskets, and the necessary steel bolts and nuts to compress the gaskets. Stepped couplings of this general type shall be used when stepping from one pipe material to another of the same nominal diameter

(b)

split sleeve type couplings shall consist of one gasket, two housing clamps, and two bolts and nuts to obtain the flexibility for connecting the piping. Steel shoulders shall be provided and welded to the pipe ends to accommodate the couplings

(c)

flexible flanged coupling adapters shall be of the sleeve type, consisting of steel middle ring, steel followers, gaskets, and steel bolts and nuts to compress the gaskets. The couplings shall contain anchor studs of strength adequate to hold the pipes together under a pull equal to the longitudinal strength of the pipes.

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Couplings to be installed underground shall, in addition to any factory applied paint coating, site have one of the following corrosion protection systems: hot pour moulding with enamel complying with BS 4164 type IV Grade 105/8, to give a minimum of 20 mm thickness around all parts of the fittings

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(b)

laminate tape coating after priming and profiling with mastic

(c)

paint coating with high build coal tar mastic to give a minimum dry film thickness of 500 m in at least three coats.

3

Step couplings used in force mains with flexible pipes shall be provided with a restraint system where necessary to prevent longitudinal movement between the flexible pipe and the coupling. The restraint system shall be as shown on the Drawings or approved by the Engineer.

4

No joints shall be coated until hydrostatic testing of the joints is successfully completed.

5.17

FLOW CONTROL

5.17.1

Vortex Flow Control Devices

1

Where indicated on the drawings or elsewhere in the Contract Documents, Vortex Flow Control Devices shall be manufactured from corrosion resistant materials as follows:

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(a)

stainless steel to BS 970 Part 1, Grade 316 S31.

(b)

the device shall be fixed using nuts and bolts of Grade 316 S31 stainless steel.

INSTALLATION AND TESTING

5.18.1

Installation

1

The Contractor shall obtain the necessary installation drawings from the manufacturer and shall store, transport, handle and install the valves, penstocks, stoplogs, and appurtenances in strict accord with the manufacturer’s drawings and recommendations. Care shall be taken during mounting of gates and logs to avoid warping the frames and to maintain clearance between seating faces.

2

All ferrous surfaces shall be finish coated in accordance with Part 8 of this Section.

5.18.2

Testing

1

Factory Testing. Penstocks shall be factory-tested for a seat clearance check in accordance with the applicable provisions of AWWA C501. Penstocks that do not conform with the testing requirements of AWWA C501 shall be made satisfactory or rejected and replaced. Before shipment of the gates, the Contractor shall submit certified copies of test reports to the Engineer for review.

2

Site Testing. Following completion of the installation of the penstock, the Contractor shall furnish the services of the authorised representative of the manufacturer to adjust and operate the gates of directed by the Engineer. Adjustment shall be made so that the gates operate smoothly, seat properly, and are installed to the tolerances recommended by the manufacturer. After the equipment has been tested and adjusted, the Contractor shall perform a field leakage test on each gate in the presence of the Engineer in accordance with the applicable provisions of AWWA C501. Both seating and unseating heads shall be tested as applicable. If any of the equipment fails to meet the above test, it shall be modified as required and retested to conform with specifications, until the maximum allowable leakage, per AWWA C501, is not exceeded. Modifications or adjustments required to meet the test shall not impair the smooth operation of the equipment.

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5.18

END OF PART

QCS 2014

Section 08: Drainage works Part 06: Miscellaneous Metal Works

Page 1

6

MISCELLANEOUS METAL WORKS ............................................................. 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5

Scope Reference Submittals Quality Assurance Delivery, Storage and Handling

6.2

MATERIALS .................................................................................................. 4

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7

Steel Stainless Steel Aluminium Iron Welded Anchor Studs U Channel Concrete Inserts Concrete Anchors

6.3

COATINGS .................................................................................................... 5

6.3.1 6.3.2 6.3.3

Galvanising Anodising Factory Painting

6.4

FABRICATION AND ERECTION ................................................................... 7

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7

General Staircases Ladders Step Irons Handrails and Railings Chequer Plate Gratings and Open Mesh Flooring

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2 2 2 3 3 4 4 4 4 4 4 5 5 6 6 7 8 9 10 10 11 12

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MISCELLANEOUS METAL WORKS

6.1

GENERAL

6.1.1

Scope

1

This part includes the specifications for the design, fabrication and erection of ladders, staircase assemblies, open mesh flooring, chequer plate, gratings, handrailing, step irons, supports, anchors, and other appurtenances.

2

Related Sections and Parts are as follows

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This Section Part 1, General Part 3, Pipes and Fittings Materials Part 7, Miscellaneous GRP Works Part 8, Protective Coatings and Painting Section 1, General Section 16, Structural Metalwork Section 17, Metalwork.

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Reference

1


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BS 970........... Wrought steels for mechanical and allied engineering purposes BS 1470......... Wrought aluminium and aluminium alloys for general engineering purposes; plate, sheet and strips BS 1471......... Wrought aluminium and aluminium alloys for general engineering purposes; Drawn Tube BS 1472......... Wrought aluminium and aluminium alloys for general engineering purposes; forging stock BS 1474......... Wrought aluminium and aluminium alloys for general engineering purposes bars, extruded round tube and sections BS 4211......... Specifications for permanent fixed ladders BS 4592......... Industrial type metal flooring, walkways and stair treads. BS 5395......... Stairs, ladders and walkways BS 5493......... Code of practice for protective coating of iron and steel structures against corrosion BS EN 1561... Founding Gray Cast Iron BS EN 1563... Found spheroidal graphite cast iron BS EN 1993... EURO code 3, Design of steel structures BS EN 13101. Manhole steps BS EN ISO 2560 Welding consumables - Covered electrodes for manual metal arc welding of non-alloy and fine grained steels EN 124 .......... Gully tops and manhole tops for vehicular and pedestrian areas – Design requirements, type testing, marking, quality control ISO 9000 ....... Quality System 6.1.3

Submittals

1

The Contractor shall submit complete data as described below.

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2

Page 3

Product Data: (a)

the Contractor shall provide manufacturers’ specifications, load tables, dimension diagrams, anchor details and installation instructions for products to be used in the manufacture of metal fabrications.

Design Calculations and Shop Drawings: (a)

the Contractor shall provide design calculations and shop drawings for the fabrication and erection of all assemblies of metal fabrication work which are not completely shown by manufacturers’ data sheets, including anchorage and accessory items. Plans and elevations at metric scales not less than 1:10 scale, and details of sections and connections at not less than 1:5 scale shall be included

(b)

detailed drawings shall show material type, thickness grade/class dimensions, and construction scheme. The submittal shall include catalogue pages, erection description, manufacturers’ data/instructions and templates.

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Where structural steelwork is to be provided the Contractor shall submit duplicate copies of dimensioned shop drawings for approval by the Engineer’s Representative. If drawings are not approved, one copy shall be returned to the Contractor marked up indicating the alterations required. Upon final approval one copy of the drawing, stamped ‘Approved’ by the Engineer’s Representative, shall be returned to the Contractor. Four further copies of the approved drawings shall then be submitted to the Engineer’s Representative. No shop fabrication may commence before receipt of the relevant shop drawings.

5

The shop drawings shall become record drawings on the completion of steelwork erection and the original drawing and one ISO size A2 (495 & 420) negative of each shall be supplied to the Engineer. If there were any changes to the steelwork during erection these should be supplied together with the original and the size A2 signed negative.

6

WPS and PQR

6.1.4

Quality Assurance

1

Fabricated metal products and materials shall be provided by experienced and approved manufacturers and fabricators as designated in the Contract document to the written approval of the Engineer.

2

Where welding/brazing is required the Contractor shall:

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(a)

submit for approval welding procedure specification (WPS) and procedure qualification record (PQR) in conformance with AWS D1.1(steel structures), ASME IX (piping and pressure vessels) and BS EN 288 part 4 (Aluminium) and BS EN ISO 1101-8 (Iron) as appropriate;

(b)

submit for approval welder qualifications which shall be in conformance with the above codes and or BS EN ISO 9606-2 (aluminium alloys),

(c)

assign a CSWIP 3.1 or AWS QC qualified welding inspector, who shall be subject to the Engineer’s approval, to witness all welding.

6.1.5


1

Metal works shall be stored off the ground, protected from moisture, until ready for use or installation.

2

Metal works shall be stored and handled in such a manner to protect finishes.

3

Metal works shall be stored and handled to prevent bending under its own weight and superimposed loads.

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6.2

MATERIALS

6.2.1

Steel

1

Steel rolled shapes, plates and bars shall conform to the requirements of Section 16 unless otherwise specified in this Part.

2

Bolts and nuts shall be of standard commercial quality steel conforming to Section 16, and shall be galvanised when used with galvanised work. AWS D 1.1 - Steel Structure Welding Code ASME VIII Div. 1 - Pressure Vessel welding ASME IX - Boiler & Pressure Vessel Code - Section IX Welding & Brazing ASME B31.3 - Process Pipe Stainless Steel

1

Stainless steel shall conform to BS 970 and shall be Grade 316 S31 unless otherwise designated.

2

Stainless steel bolts, hexagonal cap screws, and studs shall be BS 970 Grade 316 S31 unless otherwise designated.

3

All stainless steel to be welded shall be BS 970 Grade 316L.

6.2.3

Aluminium

1

All aluminium plate, pipe and structural shapes shall conform to BS EN 12020, and BS 1472 with BS EN 485 Grades 6036-T6 or 6082-T6 or such other chemically resistant alloy that the manufacturer can demonstrate to be suitable for use in aggressive atmospheres likely to be encountered in sewage pumping stations. All aluminium items embedded in concrete shall have two coats of bituminous paint. Where aluminium surfaces are in contact with concrete surfaces or with dissimilar metals, PVC-U gaskets shall be used to isolate the aluminium.

6.2.4

Iron

1

Ductile Iron. Ductile iron shall be in accordance with BS EN 1563.

2

Grey Cast Iron. Cast iron shall be in accordance with BS EN 1561.

3

Malleable Iron. Malleable iron shall be in accordance with BS EN 13101.

6.2.5

Welded Anchor Studs

1

Headed anchor studs (HAS) or threaded anchor studs (TAS), as indicated on the Contract Drawings:

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6.2.2

(a)

Carbon Steel: BS EN ISO 898, either semi-killed or killed aluminium or silicon dioxidation, unless indicated otherwise.

(b)

Stainless Steel: BS EN ISO 3506, Grade SS 316, Condition CW, where indicated.

6.2.6

U Channel Concrete Inserts

1

Rolled: BS EN ISO 9445 Type 316 stainless steel, 2.7 mm thickness, 40 mm width by 35 millimetres depth, with stainless steel anchors at 250 mm maximum spacing, Styrofoam fillers, and end cap.

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Page 5

Nut and Bolt Hardware: Type 316 stainless steel, 16 mm minimum diameter, unless indicated otherwise. Manufacturer’s standard to match insert.

6.2.7

Concrete Anchors

1

For concrete anchor spacing less than 12 anchor diameters and edge distances less than six anchor diameters, make reduction in allowable pullout and shear values.

2

Allow for thermal movement resulting from the maximum range in ambient temperature in design, fabrication, and installation of handrails to prevent buckling, opening up of joints, over stressing of components, connections and other detrimental effects. Base design calculation on actual surface temperatures of materials due to both solar heat gain and night time sky heat loss. Temperature change is difference between high or low temperature and installation temperature.

3

Use approved service load allowable values for size, length, embedment, spacing, and edge distance to match required loads shown in calculations.

6.3

COATINGS

6.3.1

Galvanising

1

Galvanising shall be executed after all fabrication has been completed and shall be carried out in accordance with BS 5493:1977. The articles shall be pickled in dilute sulphuric or hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They shall be thoroughly washed, stoved and dipped in molten zinc and brushed so that the whole of the metal shall be evenly covered and the coating thickness after dipping shall not be less than the BS 5493 System Reference Number recommended for the particular conditions and in any case not less than 85 microns.

2

Unless otherwise specified, all ferrous metals shall be galvanised in conformance with reference standards according to the nature of the work. Factory fabrication shall be complete before galvanising. Galvanised coatings that have been marred or damaged during erection or fabrication shall be repaired using designated touch-up material.

3

Surfaces of exterior units which have been galvanised after fabrication and are intended for bolted or screwed field connections shall not be welded, cut or abraded.

4

Galvanised coatings marred or damaged during erection or fabrication shall be repaired conforming to BS 5493 and in accordance with the coating manufacturer's instructions.

5

Unpainted galvanized surfaces shall not be used in an immersed condition within three months of hot dip galvanizing and/or before an adequate protective patina has formed.

6

All mild steel parts unless otherwise stated, are to be heavily galvanised by the "hot dip" process, or other methods as agreed by the Engineer, after fabrication. Where large units are concerned, an approved metal spraying process to BS specifications may be used subject to the approval of the Engineer. With the exception of the metal flooring to be supplied unpainted, the whole of the galvanised mild steel parts and metal sprayed parts are to be treated with a zinc phosphate primer before leaving the place of manufacture. (No lead oxide or iron may be used in priming the galvanised parts.) Painting shall be in accordance with the Schedule A [Work Requirements], Part 5 [Warranted Project Data], 5.1 [Drawings] or as selected by the Engineer.

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All steel and ironwork of whatever kind to be galvanised shall be thoroughly de-scaled by shot blasting to clear metal to BS 4232 second quality, to clean the surfaces of all dirt, weld spelter, grease, slag, oil-paint or other deleterious materials, and immediately after is to be galvanised by a hot dip process, followed by quenching in water. The molten zinc in the galvanising bath shall contain not less than 98.5 percent of zinc by weight. All articles are to be immersed in the bath only for a time sufficient for them to attain the temperature of the bath and they are to be withdrawn at such a speed that a coating of 90 microns thickness is achieved, or such other practicable maximum thickness for the article defined in BS 729, Part "Hot dip galvanised coating on iron and steel." The galvanising is to be done in all cases after machine work, chipping, trimming, filling, fitting, drilling or bending is completed. Every article is to be covered evenly on all sides.

8

The zinc coating shall consist of a uniform layer of zinc free from abrasions, creeks, blisters, chemical spots or other imperfections, and so applied that it will adhere firmly to the surface of the steel.

9

The galvanising shall be applied in such a manner that the spelter will not peel off. The coating of the finished product shall be even, smooth and uniform throughout. Machine work, dye work, cutting, punching, bending, welding, drilling, thread cutting and other fabrication shall all be done, as far as practicable, before galvanising.

10

The galvanising shall have no adverse effect on the mechanical properties of the articles so treated. Variations in dimensional properties shall be kept to a minimum.

11

The work of surface preparation and galvanising shall be carried out, for any one article, on the same working day.

12

Galvanising on steelwork where required is to be carried out after fabrication and assembly.

13

Light gauge metal work is to be galvanised by the hot dip process as specified in BS 3083 or BS 2989.

14

Contact between galvanised steel members and aluminium surface is to be prevented by means of a layer of "Densochrome" or similar approved tape.

15

All necessary care and precautions are to be taken in shipping and transporting the galvanised or metal sprayed units to avoid damage to the coating. Where damage proves to be extensive in the opinion of the Engineer, the whole unit shall be recoated.

16

Where galvanised parts are to be bolted or riveted together, the joint shall be made with an approved barium or zinc chromate paste.

17

Where the metal parts are too big to be hot dip galvanised, approval of the Engineer shall be sought for the steel parts to be shot blasted to BS 4232 second quality and then immediately zinc sprayed to a minimum thickness of 0.1 mm in accordance with BS 2569 Part 1.

6.3.2

Anodising

1

All aluminium members shall be anodised after fabrication in accordance with Sections 16 and 17.

2

All aluminium and aluminium alloy materials shall be anodised after fabrication to a thickness of grade AA 20 and subsequently sealed against corrosion. After anodising, the aluminium surfaces shall not be painted but left self-finish. Anodising of aluminium shall comply with the requirements of BS 1615.

6.3.3

Factory Painting

1

All protective coatings and painting shall be carried out as specified in Part 8 of this Section.

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2

Before leaving the factory, ferrous metals not designated to be galvanised shall be given one coat of primer as specified in Clause 8.2 of Part 8. Portions to be embedded in concrete or masonry shall not be painted.

6.4

FABRICATION AND ERECTION

6.4.1

General

1

Stairs, ladders and walkways provided shall conform to BS 4211 and BS 5395.

2

Fabrication and erection shall be performed by approved specialist subcontractors experienced in work of equivalent magnitude. Shop drawings shall be prepared by the Contractor based on the details shown on the Drawings. The Contractor shall verify all measurements and shall take all site measurements necessary before fabrication

(b)

be responsible for correctness of detailing, fabrication, and for the correct fitting of structural members

(c)

not substitute sections

(d)

not modify connections.

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Members and connections, for any part of the structure, not shown on the Drawings shall be the Contractor’s responsibility. The Contractor shall use materials of the size and thickness shown on the Drawings, or if not shown, of the required size and thickness to produce adequate strength and durability in the finished product for the intended use.

4

All work at the factory shall be preassembled to the greatest extent possible to minimise field splicing and assembly of units at the Site. Units shall be disassembled only to the extent necessary to comply with transportation limitations and shall be clearly marked for reassembly and proper installation. Ladders shall be supplied as preassembled units.

5

For the manufacture of metal fabrications which will be exposed to view, only materials which are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled trade names and roughness shall be used. Any such blemishes shall be removed by grinding, or by welding and grinding, before cleaning, treating and application of finishes including anodising and galvanising. Smoothness shall be required all round for handrails and ladders.

6

Exposed work shall be formed true to line and level with accurate angles and surfaces and straight sharp edges. Exposed edges shall be rounded to a radius of approximately 1 mm unless otherwise designated.

7

Exposed connections with hairline joints which are flush and smooth shall be formed using concealed fasteners wherever possible. Exposed fasteners shall be flat-head (countersunk) screws or bolts. Bolt and screw holes shall be predrilled for attachment of metal fabrication work and for the attachment of adjacent materials.

8

Welding shall be carried out by experienced tradesmen, and made with designated electrodes or submerged arc conforming to BS EN ISO 2560. The following procedures shall be carried out:

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(a)

before fabrication, all steel shall be thoroughly wire brushed, clean of all scale and rust, and thoroughly straightened by approved methods that will not injure the materials being worked on

QCS 2014


Page 8

welding shall be continuous along the entire line of contact except where tack or intermittent welding is permitted

(c)

where exposed, welds shall be cleaned of slag and ground smooth.

(d)

All stainless steel welding shall be gas tungsten arc welding (GTAW)or shield metal arc welding (SMAW) processes using stainless steel type 316L consumables conforming to the requirements of the under-mentioned codes / AWS A5.9 (GTAW) or AWS A5.4 (SMAW).

(e)

All aluminium welding shall be undertaken using GTAW process using consumables under 5356 classification of AWS A5.10.

(f)

Welding to be undertaken in accordance with the applicable code as follows: General guidance for arc welding BS EN ISO 1101 –1 Arc welding of ferritic steels BS EN ISO 1101 – 2 Arc welding of stainless steels BS EN ISO 1101 –3 Arc welding of aluminium BS EN ISO 1101-4 Welding of cast iron BS EN ISO 1101 -8 Steel Structures AWS D1.1 Pressure vessels ASME VIII Div 1 Piping ASME B31.3

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Fixing shall be carried out as follows:

the Contractor shall fabricate and install anchoring devices with spacing as required to provide adequate support for the intended use of the work

(b)

fastenings to wooden plugs will not be permitted

(c)

All nuts and bolts shall be threaded in accordance with BS 3643 “Isometric series threads” part 2 “Limits and tolerances for coarse pitch threads” and fitted with 3mm thick washers beneath bolt and nut.

(d)

Regardless of the materials being fixed all bolts, nuts, washers and anchor plates shall be of stainless steel Grade 316 S31 to BS 970 and shall remain unpainted. PTFE washers shall be fitted beneath stainless steel washers for both bolthead and nut.

(e)

Drilled anchor fixings for use on concrete structure shall be of a type approved by the Engineer’s Representative. The positions of all drilled anchors shall be approved by the Engineer’s Representative and any Contractor proposing to use such fixings shall be deemed to have undertaken to supply, mark off, drill and fit.

as

(a)

All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be such that when fitted with a nut and tightened down, the threaded portion shall fill the nut and not protrude from the face thereof by more then half the diameter of the bolt.

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(b)

(g)

All jointing material shall be provided by the Contractor.

10

Dissimilar materials shall be separated by gaskets.

6.4.2

Staircases

1

Metal staircases shall be constructed to the overall dimensions detailed on the Drawings and shall be prefabricated in marine quality mill finished aluminium alloy or galvanised steel. Staircases shall be designed to span longitudinally from wall to wall and shall be designed to carry a live load of 5 kPa. Stringers shall be of adequate size to support dead and live loads.

2

Treads shall be of non-slip surface and shall have adequate stiffness to carry a point load of 1.8 kN at the centre.

3

Landings shall not exceed 3 m.

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4

Kicker plates shall extend to a minimum of 100 mm above flooring and open sides. The risers shall not exceed 200 mm.

5

Chequer plates shall be as specified in Clause 6.4.6 wherein.

6

Unless otherwise shown on the Contract Drawings, furnish flush type abrasive nosing on stairs.

7

Nosing Components: Homogeneous epoxy abrasive, with minimum 50 percent aluminium oxide content, formed and cured upon an extruded aluminium base.

(b)

Epoxy abrasive shall extend over and form curved front edge of nosing.

(c)

Base of Nosing: Extruded aluminium alloy, 6063-T5, heat-treated complying with BS EN 12020.

(d)

Anchoring System: Double-set anchors consisting of two rows of integrally extruded anchors.

(e)

Size: 75 mm wide by 6 mm to 10 mm thick by length as shown.

(f)

Colour: Selected by Engineer from manufacturer’s standard colour range.

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(a)

Ladders

1

Galvanised steel ladders shall be to the form and dimensions shown on the Drawings, and as specified below:

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6.4.3

ladders shall comply with BS 5395, Part 3.

(b)

ladders greater than 6000 m shall be provided with an intermediate platform

(c)

stringers shall be solid flat sections of minimum size 65 mm by 13 mm where extended stringers are provided they shall be radiused over the top for walk-through access and shall be not less than 600mm apart.

(d)

fixing brackets shall be at maximum 2500 mm centres

(e)

rungs shall be

solid sections of minimum 20 mm diameter

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(i)

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(a)

at 300 mm centres

(iii)

minimum 380 mm wide between stringers

(iv)

minimum 200 mm from adjacent walls

(v)

capable of withstanding a point load of 5000 N applied at the centre of the rung

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(ii)

and close to one end (f)

when supported horizontally over a span of 1.0 m with the climbing face uppermost and with a load of 1000 N applied at the centre of the span, the ladder shall not deflect more than 15 mm at the point of application of the load and shall show no permanent deflection after removal of the load. Each ladder fixing shall be capable of withstanding shear and pull-out loads of 5000 N

(g)

safety cages shall be provided where indicated and where the distance between landings exceeds 3500 mm. These shall be constructed of three vertical flat sections, minimum size 50 mm by 8 mm supported by flat hoops with a diameter of 750 mm. The hoops shall be at a maximum of 900 mm centres and the first hoop shall be 2400 mm above lowest platform level. No single hoop shall be used

QCS 2014

(h)


Page 10

all welds shall be ground flush and smoothed and ladders hot-dip galvanised after fabrication. Connections to concrete or masonry walls shall be secure with accurately positioned stainless steel anchor bolts. Ladders shall be mounted to produce a finished appearance that is plumb, straight and true to dimensions.

2

Stainless steel ladders shall generally be of dimensions as designated for galvanised steel ladders except that all materials shall be of stainless steel.

3

Aluminium ladders shall be to the form and specified dimensions shown on the Drawings, and as specified below: the spacing of stringers, rungs and safety hoops shall be as galvanised steel ladders.

(b)

material shall be aluminium alloy to BS EN 573 grade EN AW-6082.

(c)

ladders shall be of all welded construction. Stringers shall be drilled to receive rungs which shall be welded into position from the outside of the stringers. Welds shall not be proud of the outside of the stringers

(d)

rungs shall be of substantial section serrated tube to enable sure hand and foot holds

(e)

fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy from other materials

(f)

all other requirements shall be as specified for galvanised steel ladders

(g)

ladders shall be obtained from approved suppliers.

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(a)

Step Irons

1

Step ironing rising main valve chambers shall be galvanised malleable cast iron, shall conform to BS EN 13101, and shall be of general purpose type. The tail length shall be 230 mm unless the well into which the tail is to be cast is less than 290 mm thick.

2

Step irons in house connection chambers shall comply with BS EN 13101 and be the general-purpose type manufactured of galvanised malleable cast iron. The tail length shall be 115mm. The step irons shall be epoxy coated with a material compatible with a galvanised surface and finished with a two part, acrylic polyurethane topcoat as detailed below and applied in accordance with the manufacturer’s instructions.

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50 DFT

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Two Part Acrylic Finish

Handrails and Railings

1

Handrailing shall be obtained from an approved experienced manufacturer and shall be GRP, circular hollow section, marine quality mill finished aluminium alloy (BS EN 573 grade EN AW-6082) in pre-fabricated lengths complete with fixings or shall be stainless steel circular hollow section (BS970 Grade316S31). Site welding will not be accepted. All welded parts to be completed during manufacturing fabrication with approved WPS by Engineer in accordance with Clause 6.1.4 of this Part. Handrails and railings fabricated from mild steel, stainless steel, or aluminium as shown on the Drawings and meet the following requirements:

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(a)

brackets, bolts and complete installation

fastening

devices

shall

be

provided

as

required

for

(b)

handrailing and railings shall be provided with smooth bends and welded joints ground smooth and flush

(c)

installed railings and supports shall withstand a 1100 N load applied at any point, downward or horizontally or 740 N/m along the top rail, whichever is greater

(d)

the deflection of both rails and standards shall to exceed 2 % of the span/height under a horizontal load of 360 N/m on the top rail.

QCS 2014

2


Page 11

Galvanised steel handrailing shall be provided in accordance with the following requirements: (a)

stanchions shall have a nominal bore of 40 mm and a minimum wall thickness of 3.25 mm

(b)

stanchions on steel stringers shall have base plates or angles welded to bottom of pipe and bolted to stringer

(c)

rails shall have a nominal bore of 32 mm and minimum wall thickness of 4 mm

(d)

horizontal handrails shall be 1,100 mm high with an intermediate rail 550 mm high

(e)

railings shall be (i)

mounted so as to produce a finished appearance that is plumb, straight, and true to dimension, free from kinks, twists, and abrasions curves, where indicated on the Drawings or necessary, shall be bent to a radius

.

(ii)

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of not less than 100 mm. Where shown on the Drawings, or directed by the Engineer, removable sections shall be provided toe plates shall be provided where railings are not mounted on stanchions

(g)

welds shall be ground flush and smooth and handrailing hot-dip galvanised after fabrication

(h)

sleeves shall be provided for setting by other trades where embedded

(i)

connections to concrete or masonry wall surfaces shall be secure with accurately positioned stainless steel anchor bolts, or with cinch anchors and bolts

(j)

where expanding anchor bolts are used on concrete surfaces, the bases shall be bedded on a mastic sealant as approved by the Engineer to prevent ingress of water

(k)

at ladders and other openings, 12 mm minimum galvanised steel safety chains with eyebolt and harness type snap attachments shall be installed.

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(f)

Stainless steel handrailing shall generally be as designated for galvanised steel handrailing except that all materials shall be of stainless steel Grade 316 S 31, including stainless steel safety chains and attachments.

4

Aluminium handrailing shall generally be as designated for galvanised steel handrailing except as modified below: handrailing shall comprise double line handrails made from minimum 43 mm outside diameter 9 SWG tube to BS 1474 Grades 6036-T6, 6082-T6 unless otherwise designated

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(b)

fixings shall be of stainless steel

(c)

at ladders and other openings, two stainless chains shall be installed which shall be fixed to hand rail standards or ladder stringers using suitable aluminium alloy hooks.

5

All joints shall be made within standards and shall consist of a dowel to provide rigidity fixed within the handrailing using countersunk stainless steel grub screws. Where removable lengths of handrails are detailed half lap joints shall be used.

6

Make provisions for handrails in the exterior and interior installations subject to high humidity to drain water from railing system.

7

Posts mounted handrails in concrete, bends and elbows occurring at low points, drill weep holes of 6 mm diameter at lowest possible elevations, one hole per post or rail. Drill hole in the plane of the rail.

6.4.6

Chequer Plate

QCS 2014

1


Page 12

General 2

(a)

all chequer plate shall be designed to support uniformly distributed loads of 7.5 kN/m . The loading shall be considered a minimum requirement. Where an item of equipment demands larger loading, the loading shall be increased accordingly.

(b)

maximum deflection shall be 0.2 % of the span under maximum loading conditions for steel flooring and one per cent for Aluminium

(c)

plate sections shall (i)

have a minimum thickness of 6 mm, excluding the raised pattern

(ii)

Plates shall be reinforced with angle sections of the same material to meet the above loading and deflection requirements.

(iii)

be of diamond shaped pattern at the top and have an angled and opposed

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pattern which shall be non-slip type

joints shall be provided at the centre of all openings unless otherwise shown on the Drawings

(e)

joints and openings shall be reinforced with additional stiffeners where necessary to provide the required load carrying capacity and deflection criterion.

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(d)

Galvanised steel chequer plate and frames shall be hot dip galvanised after fabrication, and all fasteners shall be stainless steel. Where specified on the drawings galvanised chequer plate flooring shall in addition be epoxy coated.

3

Aluminium chequer plate and frames shall be fabricated from aluminium alloy to BS EN 7559, Grade 6082-T6, and all fasteners shall be stainless steel A4. Gaskets shall be provided to isolate aluminium alloy from other materials.

4

Flooring shall be provided in sizes suitable for removal by one man and with the appropriate cutouts to permit its removal without disturbing or dismantling spindles, supporting brackets or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which shall be deemed to be included in the cost of the flooring.

5

Chequer plate flooring covering openings in concrete or brickwork shall be set flush in frames of the same material fixed as shown on the drawings.

6.4.7

Gratings and Open Mesh Flooring

1

General

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2

(a)

all flooring and walkways shall be designed to support uniformly distributed loads of 7.5 2 kN/m

(b)

gratings and open mesh flooring shall be welded, rectangular opening type, bar gratings with seat angles, anchors and supports of the same material

(c)

grating up to and including 1.0 m shall be furnished in pieces approximately 1.0 m in width and all gratings for pans greater than 1 m shall be furnished in pieces 0.8 m in width

(d)

openings required in gratings shall be banded where openings are provided and shall be strengthened as necessary

(e)

installed units shall be true to plane and free of warps and irregularities

(f)

units shall be divided for ease of installation and removal

(g)

bearing bars shall be serrated and have a minimum size of 45 mm deep by 5 mm thick

QCS 2014


Page 13

the edges of all flooring and platforms shall be finished with approved kerbs, which shall be provided by the flooring supplier and shall be fitted with fish tail lugs for building into the concrete work

(i)

the pattern, design thickness and finish shall be approved by the Engineer. The pattern of open type flooring shall be rectangular and shall match between adjacent panels

(j)

flooring and walkway supports shall be independent of bearing supports to prevent the setting up of oscillations and noisy vibrations

(k)

all clips and bolts shall be stainless steel

(l)

all supporting metal work shall be provided on large area openings to provide support for the flooring

(m)

the faces of flooring which come into contact with cement mortar concrete shall have two coats of bituminous paint before installation of the frame.

.

(h)

Galvanised steel gratings and open mesh flooring shall be hot dipped galvanised after fabrication.

3

Aluminium gratings and open mesh flooring shall be manufactured in approved structural aluminium BS 1471, BS 1472 or BS 1474, Grade 6063-T6 or 6082-T6 unless otherwise designated and all fastens shall be stainless steel. Gaskets shall be provided to isolate aluminium alloy from other materials.

4

Stainless steel gratings and open mesh flooring shall be manufactured of Grade 316S31 to BS 970.

5

Flooring shall be removable and set flush in frames of the same material. Frames shall be fixed as shown on the drawings.

6

The deflection under maximum load shall not exceed 0.2 per cent of the span for steel flooring and one per cent for aluminium.

7

Flooring shall be provided in sizes suitable for removal by one man and with the appropriate cut-outs to permit its removal without disturbing or dismantling spindles, supporting brackets or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which shall be deemed to be included in the cost of the flooring.

8

Steel angle support frames to be embedded in concrete shall be stainless steel, BS EN 10272:2000 Type 316, unless indicated otherwise.

9

Welded anchors for stainless steel support frames shall also be stainless steel.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 07: Glass Reinforced Plastics

Page 1

7

GLASS REINFORCED PLASTICS ................................................................ 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6

Scope Related Sections and Parts References Submittals Quality Assurance Warranty

7.2

MATERIALS .................................................................................................. 3

7.2.1

GRP

7.3

FABRICATION AND ERECTION ................................................................... 3

7.3.1 7.3.2 7.3.3 7.3.4

GRP Ladder GRP Handrails and Balustrades GRP Gratings and Open-Mesh Flooring GRP Lining for Pump Station Wet Wells

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3 4 4 4

QCS 2014


Page 2

7

GLASS REINFORCED PLASTICS

7.1

GENERAL

7.1.1

Scope

1

This part includes the specifications for all work in connection with glass reinforced plastics (GRP) ladders, safety cages, handrails, balustrades, gratings, open-mesh flooring, and linings for pump station wet wells.

7.1.2


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Section 1 - General This Section Part 1 General Part 3 Pipes and Fittings Materials Part 4 Pipe Installation Part 6 Metal Works References

1


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7.1.3

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ASTM E84 ..................Test Method for Surface Burning Characteristics of Building Materials BS 3532......................Method for specifying unsaturated polyester resin systems

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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester and epoxy resin systems.

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BS EN 14118..............Reinforcement. Specifications for textile glass mats

Submittals

1

Manufacturers’ Literature:

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7.1.4

(a)

2

the Contractor shall provide manufacturers’ specifications, load tables, dimension diagrams, anchor details and installation instructions for products to be used in GRP works.

Design Calculations and Shop Drawings: (a)

the Contractor shall provide design calculations and shop drawings for the fabrication and erection of all assemblies of GRP which are not completely shown in manufacturers’ data sheets, including anchorage and accessory items

(b)

plans and elevations in metric dimensions not less than 1:20 scale, and details of sections and connections at not less than 1:10 scale shall be included. Detailed drawings shall show material type, thickness grade/class dimensions, and construction scheme

(c)

the submittal shall include catalogue pages, erection description, manufacturers’ data and instructions and templates where appropriate.

QCS 2014


Page 3

Quality Assurance

1

Fabricated GRP products and materials shall be provided by experienced approved manufacturers and fabricators as designated in the contract specific documents and manufactured to approved patterns.

7.1.6

Warranty

1

The Contractor shall provide the Employer with a 7-year unconditional guarantee against failure of all GRP products whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed to the Engineer before the issue of the Certificate of Completion.

7.2

MATERIALS

7.2.1

GRP

1

GRP material for ladders, safety cages, handrails, balustrades, grating and open-mesh flooring shall be fabricated from structural quality fibreglass shapes with chemical and ultraviolet resistance. Resin shall be all vinyl ester. Glass shall be all ECR and GRP thickness shall be a minimum 5 mm. The top surface shall be provided with a non-slip silica sand finish. The structural components shall have Class I fire retardance, with an ASTM E84 flame spread rating of 25 maximum. Fibreglass components shall have an ultimate tensile strength of 207 MPa, an ultimate compressive strength of 207 MPa, a modulus of elasticity of 20.7 GPa, and a Barcol hardness of 50.

2

All cut or trimmed edges of the GRP ladder and braces shall be flow coated with an approved vinyl ester resin. Glass fibres shall not be exposed.

7.3

FABRICATION AND ERECTION

7.3.1

GRP Ladder

1

GRP ladders shall be obtained from an approved experienced manufacturer and shall be purpose made to suit the depth of each installation as shown on the drawings. The ladders shall be drilled for wall fixing at both ends and additional intermediate fixing connections shall be provided at centres not greater than 1.5 metres. Rungs shall be at 300mm centres and at a distance of not less than 200mm from the wall. Rungs if tubular shall be no less than 30mm outer diameter, and stringers shall be of a rectangular or channel section no less than 70mm x 25mm in size.

2

The wall thickness of the laminate shall be not less than 5 mm at any point and there shall be no sharp edges. The support fixing brackets shall be GRP continuously moulded with the main lamination and they shall be not more than 500 mm apart (every 2 steps/rungs). The rungs shall be 250 mm apart with the upper face finished with a non-slip surface.

3

The support fixing brackets shall be put through the liner wall, and be designed to be totally encapsulated by concrete. The ladder brackets shall be laminated to the outside of the liner.

4

Each rung shall be able to withstand a point load of 5000 N.

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7.1.5

QCS 2014


Page 4

When supported horizontally over a span of 1.0 m with the climbing face uppermost and with a load of 1000 N applied at the centre of the span the ladder shall not deflect more than 15 mm at the point of application of the load and shall show no permanent deflection after removal of the load. Each ladder fixing shall be capable of withstanding shear and pull-out loads of 5000 N.

7.3.2

GRP Handrails and Balustrades

1

GRP handrails and balustrades shall be white (or near white) in colour and shall be obtained from an approved experienced manufacturer.

2

The resin, glass and synthetic fibres used in the manufacture of handrails shall be chosen to produce a chemically resistant product with a resin-rich surface layer suitable for use in aggressive atmospheres likely to be encountered in sewers and sewage pumping stations.

3

Standards shall be no smaller than 45 mm square, and shall be 1100 mm high. Base fixing shall be as shown on the drawings. Where installed on concrete surfaces using expanding anchor bolts, the bases shall be bedded on an approved mastic sealant to prevent ingress of water to the bolt holes.

4

Handrails shall be no smaller than 50 mm square, and shall be located 550 and 1100 mm above finished floor level on standards spaced no more than 1500 mm apart. Deflection under vertical loads shall be no greater than deflection under the same horizontal load.

5

The complete installation shall be capable of withstanding a horizontal force at top rail level of 740 N/m. The deflection of both rails and standards shall not exceed 2 % of the span/height under a horizontal load of 360 N/m on the top rail.

6

At ladders and other openings, two removable stainless steel chains, shall be installed which shall be fixed to handrail standards or ladder stringers using stainless steel (316 S31) hook bolts.

7.3.3

GRP Gratings and Open-Mesh Flooring

1

GRP grating and open-mesh flooring shall have the same overall dimensions and design criteria as designated for steel grating and open-mesh flooring in Part 6 of this Section except as modified below.

2

The grating shall be of one piece compression moulded continuous fibreglass strand bar type grating and other requirements shall be as designated for GRP ladders. The colour and pattern of the grating and open-mesh flooring will be selected from the available manufacturer’s standards and to the approval of the Engineer.

7.3.4

GRP Lining for Pump Station Wet Wells

1

GRP linings to pumping station shall consist of a chemically resistant layer comprising vinyl ester resin suitably reinforced with a “C” glass or synthetic tissue veil. This layer shall be no less than 6 mm thick, and shall have a resin content by weight of approximately 90 % at the exposed surface, reducing to 65 % - 75 % at the inner surface. The remainder of the liner shall consist of vinyl ester or isophthalic resins “ECR” glass chopped strand mat. The lining shall be at least 6 mm thick and shall be white (or near white) in colour.

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QCS 2014


Page 5

2

All linings shall consist of preformed sheets and tubes with moulded on lugs to allow bonding to concrete. Joints between sheets shall be bandaged on the hidden face, with the bandaging extending 150 mm either side of the joint. On the inside (exposed) face the joint shall be filled with vinyl ester paste to produce a smooth finish. Where joints form angles, a 50 mm radius fillet shall be formed using vinyl ester paste prior to bandaging.

3

Where the Engineer permits the use of GRP lining to upper surfaces, and other areas where casting in of preformed sheets in inappropriate, lapping of in-situ work onto preformed work, and application of in-situ lining shall be carried out as follows: at the junction between preformed linings and in-situ linings, the preformed lining shall be lightly abraded to a distance of 150 mm from the junction

(b)

a vinylester paste fillet of 50 mm radius shall be formed at internal angles which are to receive an in-situ lining

(c)

the in-situ lining shall be built up by applying isophthalic or vinyl ester resin to the whole of the surface to be lined, the fillet and the abraded strip of the preformed lining

(d)

a layer of “E” or “ECR” mat shall be rolled into the resin using a suitable steel roller to exclude all air and provide complete immersion of glass fibre in the resin

(e)

after a period to allow pre-gel to a tacky state a second coat of resin shall be applied followed by a further layer of glass fibre mat. This process shall be repeated until the total thickness of the lining is approximately 4 mm

(f)

vinylester resin and “ECR” glass or synthetic tissue veil shall than be applied in layers to complete the lining

(g)

where linings are applied to inverts of channels subject to high fluid velocities of 5 m/s, the GRP lining shall be mechanically fixed to the substrate using stainless steel screws and washers. After building up approximately 60 % of the required thickness of lining, stainless steel round headed screws 50 mm long and stainless steel washers 25 mm diameter shall be used at 500 mm centres (by drilling and plugging) to fix the lining to the concrete. Particular attention shall be paid to edges of sheets where the flow of sewage will tend to lift the lining. The remaining layers of GRP shall then be built up over the screw heads and washers.

The top surface of benchings and platforms shall incorporate silica sand to form a non-slip surface.

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(a)

END OF PART

QCS 2014

Section 08: Drainage Works Part 08: Painting and Protective Coatings

Page 1

8

PAINTING AND PROTECTIVE COATINGS .................................................. 2

8.1

GENERAL ...................................................................................................... 2

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 8.1.9

Scope References Definitions System Description Submittals Quality Assurance Delivery, Storage and Handling Warranty Safety

8.2

MATERIALS .................................................................................................. 6

8.2.1 8.2.2 8.2.3

Coating and Painting Materials Coating and Painting Systems Abrasive Blasting Materials

8.3

WORKMANSHIP ......................................................................................... 13

8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 8.3.13 8.3.14 8.3.15 8.3.16 8.3.17

General Manufacturer’s Recommendations Mixing and Thinning Items Not to be Painted During Coating and Painting Operations Surface Preparation Application of Protective Coatings and Paint Maintenance of Prepared Surfaces Environmental Conditions Spray Application Brush Application Shop Coatings Site Painting of Manufactured Items Site Application Epoxy Coating Work Epoxy Coatings for Concrete and Rendered Surfaces Galvanising and Other Finishes of Metals Inspection and Testing

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2 2 3 3 4 4 5 5 6 6 7 13 13 14 14 14 14 18 19 19 20 20 20 20 21 21 22 22 23

QCS 2014


Page 2

8

PAINTING AND PROTECTIVE COATINGS

8.1

GENERAL

8.1.1

Scope

1

This part includes the specification for the Provision of protective coatings and painting to protect the surfaces of structures, materials and equipment in interior, exterior, process, operating, and maintenance service environments as classified in this Part.

2

Related Parts and Sections are as follows: General Pipes and Fittings Materials Valves, Penstocks and Appurtenances Miscellaneous Metal Work

Section 1, Section 5, Section 6, Section 9, Section 10, Section 16, Section 17, Section 21, Section 26,

General Concrete Road works Mechanical and Electrical Equipment Instrumentation, Control and Automation Structural Metalwork Metalwork Electrical Works Painting and Decorating.

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References

1


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ASTM C97 ..................Standard Test Methods for Absorption and Bulk Specific Gravity of Dimension Stone

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BS 245........................Mineral solvents (white spirit and related hydrocarbon solvents) for paints and other purposes BS 1336......................Knotting BS 1710......................Identification of pipelines and services BS 4232......................Surface finish of blast-cleaned steel for painting BS 4652......................Zinc-rich priming paint (organic media) BS 4756......................Ready mixed aluminium priming paints for woodwork BS 4800......................Paint colours for building purposes BS 5493......................Code of practice for protective coating of iron and steel structures against corrosion BS 6150......................Code of practice for painting of buildings BS 7079......................Preparation of steel substrates before application of paints and related products BS 7956......................Specification for primers for woodwork

QCS 2014


Page 3

BS EN 10300..............Bitumen-based hot-applied coating material for protecting iron and steel, including suitable primers where required BS EN ISO 1461 ........Hot dipped galvanised coatings on iron and steel articles SIS 055900.................Rust grades for steel surfaces and preparation grades prior to protective coating Definitions

1

Paints, protective coatings, and coatings: paints, enamels, stains, varnishes, lacquers, sealers, fillers and other types of coatings whether used as primers, intermediate or finish coats.

8.1.4

System Description

1

For purposes of identifying protective coating and painting systems to be applied as specified in this Part, service environments are classified in Table 8.2.

2

The classification of areas and surfaces to be coated or painted shall be as designated in the Project Specification.

3

Painting in unclassified areas shall be carried out as specified in Section 26.

4

Surfaces to be Coated or Painted. In general, the following surfaces are to be coated or painted:

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8.1.3

all exposed piping and other metal surfaces, interior and exterior

(b)

all submerged metal surfaces

(c)

all structural and miscellaneous steel work, including tanks

(d)

interior of tanks, chambers and wet wells that are not protected with GRP or PVC liners

(e)

exterior above ground concrete as Table 8.5 unless otherwise designated in the Project Specification

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exterior above ground brick masonry as designated in the Project Specification interior of structures as designated in the Project Specification.

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(h) 5

equipment furnished with and without shop finished surfaces, except as specified in Clause 8.1.8

Surfaces Not to be Painted or Coated. The following surfaces in general shall not be coated or painted unless otherwise designated: (a)

plastic surfaces

(b)

non-ferrous metal (Galvanised metal shall not be considered a non-ferrous metal)

(c)

mechanical equipment with approved, designated shop finish

(d)

electrical equipment with shop finishes designated in the contract specific documentation

(e)

piping to be galvanised as designated in the Project Specification

(f)

chain link fencing.

QCS 2014


Page 4

In no case shall any concrete, wood, metal, or any other surface requiring protection be left unpainted unless otherwise directed by the Engineer or designated in the Project Specification.

8.1.5

Submittals

1

Manufacturer’s Data. The manufacturer’s specifications and application instructions for paint materials and systems, including certifications, verification of specified thickness and other data to show compliance with these specifications shall be submitted to the Engineer.

2

Painting Programme. A detailed painting programme including method statements shall be submitted for the Engineer’s approval. This programme shall be prepared on the basis of service environments, surfaces, surface preparation, types of paint materials, types of primers and sealers, and number of coats. The brand name of the product of the manufacturer for each use shall be listed.

3

Samples. When required by the Engineer, samples for colour and texture as hereinafter listed shall be submitted for the Engineer’s approval. The Contractor shall be responsible for compliance with all other requirements.

4

Letter of guarantee required under Clause 8.1.8 of this Part.

8.1.6

Quality Assurance

1

Protective painting shall be carried out only by approved prequalified subcontractors as designated in the Project Specification. Protective coating shall be carried out by specialist subcontractor as designated in the Project Specification.

2

Applicator Qualifications: The Contractor shall provide information demonstrating that applicators have successfully completed coating system applications similar in material and extent to those included in the Works. Only applicators for which such information has been provided shall be employed.

3

Single-Source Responsibility: The Contractor shall provide primers and undercoat material produce by the same manufacturer as the finish coats for each type of coating. Only thinners recommended by the manufacturer shall be used, and only within the manufacturer’s recommended limits.

et it

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6

Field Samples: Where required by the Engineer field samples shall be provided as follows: Sample Boards. The Engineer’s colour chips on 300 mm by 300 mm hardboard shall be matched with colour, texture and sheen duplicated to simulate actual conditions. Sample boards shall be resubmitted as necessary for selection by the Engineer.

m

(a)

(b)

4

Sample Areas. Where required by the Engineer, partial areas shall be prepared and finished as directed by the Engineer, using selected 300 mm by 300 mm sample boards as a guide for final approval of colour, texture and sheen. After approval, the sample areas shall serve as the standard for workmanship, appearance and materials for similar areas throughout the project.

All epoxy coating work shall be carried out by a specialist firm or contractor approved by the Engineer. The specialist firm shall be required to submit a letter of guarantee that the product it proposes to supply when applied in accordance with this specification and any additional specifications which shall be quoted by the firm will withstand the environmental service conditions to be encountered. The Contractor shall provide a guarantee of at least three years in relation to this coating from the time of application of the coating.

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1

Except as otherwise specified in this Part, delivery storage and handling of coating and paint material shall be carried out as specified for paint material in Section 26.

2

Coating and painting materials and apparatus shall be stored in areas approved by the Engineer. When not in use, storage areas shall be kept locked and inaccessible to those not employed in protective coatings and painting work. Each storage space shall be provided with fire extinguishers.

3

Coating and paint containers shall be opened only when required for use. Unless otherwise specified in this Part, no materials shall be reduced, changed, or used except in accordance with the manufacturer’s label or tag on container.

4

All coating materials and thinners shall be furnished by the Contractor in original, unopened containers bearing the manufacturers label and instructions. For materials having a limited shelf life, the date of manufacture and the length of life shall be shown. The oldest paint of each kind shall be used first.

5

All coating materials shall be stirred in a container with a power mixer before use to thoroughly remix the pigments and vehicles. Only thinners specified by the manufacturer shall be used. Mixing and thinning directions as furnished by the manufacturer shall be followed unless modified by the Engineer’s Representative.

6

Mixing in open containers shall be done in a well ventilated area. When use of thinner is permitted, thinner shall be added during the mixing process.

7

If a coating material requires the addition of a curing agent, the pot life under application conditions stated on the container label shall not be exceeded. When the pot life limit is reached, the spray equipment shall be emptied, remaining material discarded, the equipment cleaned and the new material prepared.

8

For paints and thinners, records shall be kept of:

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.l. l

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8.1.7

Date of manufacture.

(b)

Shelf life.

(c)

Date of use.

et it

(d)

o

(a)

Daily usage of thinners.

Preparation of the paint for application shall be as BS 5493 and the Manufacturers recommendations.

10

Coating materials, other than thixotropic materials, which have livered, gelled or otherwise deteriorated shall not be used.

11

No paint shall be used on expiry of the manufactures recommended shelf life nor when the paint solids cannot be dispersed by mixing after a maximum of 5% thinners has been added.

8.1.8

Warranty

1

Before beginning coating and specialist paint work, the Contractor shall provide the Engineer with a letter of guarantee from the specialist subcontractor that the products proposed for use when applied in accordance with the specifications of this Part and the manufacturer’s instructions will withstand the environmental service conditions to be encountered for a period of 10 years.

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Page 6

Safety

1

The implementation of manufacturer’s recommendations concerning health and safety aspects of paints approved by the Engineer for use on the works shall be mandatory.

2

Respirators shall be worn by all persons engaged in, and assisting in, spray painting. In addition, workers engaged in or near the work during sandblasting shall wear eye and face protection devices meeting the Engineer’s approval for sandblasting operations and approved air-purifying, half-mask or mouthpiece respirator with appropriate filter.

3

Where ventilation is used to control potential exposure to workers, ventilation shall be adequate to reduce the concentration of the air contaminant to such safe limits that a hazard to the worker does not exist. Methods of ventilation shall meet with the approval of the Engineer.

4

Cloths and cotton waste that may constitute a fire hazard shall be placed in closed metal containers or destroyed at the end of each work day.

8.2

MATERIALS

8.2.1

Coating and Painting Materials

1

Epoxy coating and painting materials shall be as follows: Primer solvent-free low viscosity

(ii)

(ii two or three pack

(iii)

compatible with and have complete intercoat adhesion with the first coat of high

ov

Protective coats

high build straight aromatic amine cured epoxy

(ii)

two or three pack

(iii)

solvent free type

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(i)

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(b)

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build epoxy paint

as

(i)

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(a)

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rw

.l. l

.

8.1.9

(iv)

completely resistant to the corrosion conditions to be encountered.

m

Certain types of coal tar epoxy may also be approved by the Engineer for this purpose in which case the Contractor shall state the type of coal tar and the curing agent to be used and the percentage content of coal tar.

2

Stone Paint. Stone paint to be used on exposed external concrete surfaces shall be single component silane siloxane based water repellent system with not more than 1% water absorption when tested in accordance with ASTM C97.

3

Fungus and Mould Resistant Finishes. Where a fungus and mould resistant surface is designated, the surface shall be treated with a fungicide paint in accordance with the manufacturer’s instructions.

4

Varnish: Varnish shall comply with the relevant provisions of BS EN ISO 150.

5

Where a surface is to receive more than one type of coating or painting material, each different material used on that particular surface shall have a different colour in order to facilitate inspection. Colour schedules for coating and painting materials shall be prepared by the Contractor and submitted to the Engineer for approval.

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Page 7

The list of manufacturers of all paints/coatings/corrosion control systems shall be submitted for approval by the Engineer.

7

All materials for lining/multiple coat work, e.g., priming, undercoat and finishing coat shall be obtained from the same manufacturer and shall be suitable for using together and for the surface concerned.

8

All materials shall be used strictly in accordance with manufacturer’s instructions.

9

Manufacturer's samples of all paints, varnishes, etc., shall be submitted, free of cost, in sealed containers to the Engineer for approval before bulk deliveries are made and before any paintwork is started.

8.2.2

Coating and Painting Systems

1

The materials, application and use of coating and painting systems are specified in Tables 8.1 to 8.5. Surfaces in Location A shall receive a total paint thickness of not less than 200 micron and the surfaces in Location B, C and D shall receive a total paint thickness of not less than 300 micron. The first coat of paint to be applied not more than 4 hours after substrate preparation. Subsequent coats of paint to be applied within 48 hours of previous coat. Approval to factory application of this final coat to be sought from the Engineer where delay in application is liable to cause adhesion problems.

2

Formulate paints with colorants free of lead, lead compounds, or other materials that might be affected by presence of hydrogen sulfide or other gas likely to be present at Site.

3

Identification of pipelines shall be generally in accordance with the Contract Drawings or Specification or as selected by the Engineer.

4

Pipelines shall be identified by the colours in Table 8.6. These shall be applied as follows:

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6

Painting the basic identification colour on the pipe or duct over the whole length and super-imposing the colour code identifications at intervals; or

(b)

Painting the pipe or duct in bands.

ov

er

(a)

Where banding is adopted, the decorative or protective colour along the rest of the pipe or duct shall not be any of the basic identification colours.

6

The basic identification colours shall be placed at all junctions at both sides of valves, service appliances, bulkheads, wall penetrations and any other place where identification is necessary.

7

Any information regarding the fluid such as pressure, temperature, etc., shall be placed on the basic identification colour or next to the basic identification colour band. The names, abbreviations or chemicals symbols shall be either in black or white in order to contrast clearly with the colour of the pipe or with the basic identification colour. The direction of flow of the fluid shall be indicated by an arrow situated in the proximity of the basic identification colour and painted black or white in order to contrast clearly with basic identification colour.

8

For closed circuits, the flow and return pipes shall be indicated by the use of the word "Flow" on the one pipe and the word "Return" on the other.

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Table 8.1 Schedule of Paints and Film Thickness per Coat (DFT) Ref.

DFT microns

Description

P2

Zinc phosphate epoxy corrosion resistant primer Two pack polyamide cured. Zinc Chromate ditto

P3

Zinc phosphate epoxy prefabrication primer. Two pack

50

P4

50

U2

Zinc chromate ditto T-wash pretreatment for galvanised surfaces as described in BS 5493 Epoxy micaceous iron oxide. Two pack. Polyamide cured. Pure epoxy resin. Two pack. Amine adduct cured.

U3

Coal tar epoxy. Two pack. Polyamide cured

U4

Epoxy tie coat

F1

Silicone alkyd enamel

F2

Urethane. Two pack.

X

Hot dip bitumen solution to BS 4147, Type 1 Grade D*

Y

Aluminium sealer. Single pack

50

.l. l

.

125

rw

U1

50

ta

T

50

qa

P1

125 125 25 -

se

as

Table 8.2 Key to Preparation and Painting Schedule Item

er

B

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et it

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C

Item GB Z G

Surfaces above process liquid level and not liable to splashing. Non-aggressive atmospheres. Surfaces in contact with untreated or treated water for potable use. Surfaces below process liquid level or liable to splashing. Non aggressive solutions and/or atmospheres. Surfaces in contact with aggressive solutions and/or atmospheres.

ov

A

D

Locations

Table 8.3 Preparation Standards for substrates Preparation Standards for substrates Grit blast to Swedish Standards Sa 2 1/2 Clean and degrease Pickle and hot dip galvanise to BS 729 (applied to items which may be pieced sufficiently small and excludes stainless steel).

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Page 9

Table 8.4 Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes) Item

Item

Item

Factory Operations

Location

Assembly

Prep.

Coatings 1st

2nd

GB

P1 (a) or P2 (a)

U1 (b)

or G

-

-

Site

GB

P3 (a) or P4 (a)

-

Factory

GB

P1 (a)

U2 (b)

or G

-

-

Site

GB

P3 (a)

-

Factory

GB

P1 (a) or P2 (a)

U3 (b)

-

-

GB

P3 (a) or P4 (a)

-

G

T and P1

-

GB

P1 (a) or P2 (a)

U1 (b)

GB

P1 (a)

U2 (b)

GB

P1 (a) or P2 (a)

U3 (b)

Z

P1 (a) or P2 (a)

U1 (b)

Z

P1 (a)

U2 (b)

Z

P1 (a) or P2 (a)

U3 (b)

G

-

-

A/C/D

Z

-

X

B

GB

P1 (a)

U2 (b)

A/C/D

Z

-

X

B

GB

P1 (a)

U2 (b)

A/B/C/D

G

-

-

GB

P1 (a)

U1 (b)

A

Factory

B

C

rw

or G

Site

A

including headstocks

B

qa

Cast iron and cast steel

ta

D

A

copper)

B

se

Non-ferrous metal (except

as

C

er

C

A/B/C/D

ov

Steel pipes

o

Iron and steel

et it

Penstocks and valves of cast iron

.l. l

Steel and Ferrous metal parts

.

Completed at

m

Steel stairways and supporting Structures

Bridge rail and pin rack rail Water Towers (Exterior)

D

Site

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Page 10

Table 8.4 (Cont’d) Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes)

Item

1st

2nd

3rd

4th

F1

F1

-

-

-

-

-

-

Site

P1 (f) or P2 (f)

U1 (b)

F1

F1

Factory

U2 (c)

-

-

-

-

-

-

-

Site

P1 (f)

U2 (b)

U2 (b)

-

Factory

U3 (c)

-

-

-

rw

Steel and Ferrous metal parts

Assembly

-

-

-

P1 (f) or P2 (f)

U3

U3 (b)

-

P1 (f)

U3

U3 (b)

-

F1

F1

-

-

U2 (c)

-

-

-

U3 (c)

-

-

-

F1

F1

-

-

U2 (c)

-

-

-

U3 (c)

-

-

-

er

Location

Site Operations and Coatings

Item

Item

-

-

-

-

A/C/D

Y

Y

F1

F1

B

U2 (b)

-

-

-

A/C/D

X

-

-

-

B

U2 (c)

-

-

-

A/B/C/D

-

-

-

-

U4

F2

-

-

Completed at

A

Factory

C

-

Site

A

including Headstocks

B

qa

Cast iron and cast steel

ta

D

A

copper)

B C

A/B/C/D

ov

Steel pipes

se

Non-ferrous metal (except

as

C

o

Iron and steel

et it

Penstocks and valves of cast iron

.l. l

.

B

Structures

m

Steel stairways and supporting

Bridge rail and pin rack rail Water Towers (Exterior)

D

Site

Qualifying Notes: (a) To be applied not more than 4 hours after substrate preparation. (b)

To be applied within 48 hours of previous coat.

(c)

Approval to factory application of this final coat to be sought from the Engineer’s Representative where delay in application is liable to cause adhesion problems.

(d)

Refer to Clause 8.3.5.35

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Table 8.5 Preparation and Painting Schedules for Surfaces Other Than Metal Surface

Location

Finish

Particular

Primer

Final Treatment

Preparation Hard Wood and

Interior

Gloss

Soft Wood

Sand down

Q.D. Acrylic

Alkyd undercoat

Treat Knots

Wood primer

Alkyd topcoat

Sand down

Lead free

Alkyd undercoat

Treat Knots

Wood primer

Alkyd topcoat (2 coats)

Degrease

Emulsion thinned to

High opacity acrylic

Sand down

manufacturer's

emulsion (2 coats)

Exterior Gloss

Plaster

Interior

Flat

(including Plasterboard)

instructions Gloss

Ditto

Alkali resistant primer

Multi-

Ditto

Primer

ta

Interior

Interior

Flat

-

Concrete -

Alkyd undercoat Alkyd topcoat Multi-colour wall finish

Emulsion thinned to


manufacturer's

emulsion (2 coats)

as

Rendering,

qa

colour Cement

rw

Interior

.l. l

unprimed)

.

(primed or

instructions

Interior

Gloss

-

se

(fair-faced),

Alkyd undercoat

primer

Alkyd topcoat

er

Brickwork

Alkali resistant

ov

Immersed & splash zone

(Refer to the clause entitled Epoxy Coatings for Concrete and Rendered Surfaces)

o

Aggressive atmospheres

et it

Exterior Masonry Stiff brush

Stabilising primer

m

paint

Hardboard

Interior

Flat

Textured emulsion masonry paint (2 coats)

Zinc chromate High opacity acrylic


spot primer to

emulsion

emulsion (2 coats)

Stabilising primer

Alkyd undercoat

screw and nail heads Interior

Gloss

Ditto

Alkyd topcoat

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Table 8.6 Standard Colours The following colours to BS 4800 shall be used for mechanical and electrical equipment. For equipment not listed the colour shall be agreed with the Engineer. Colour

(a)

External machinery

18

E

53

Green-Yellow

(b)

Motors and Pumps

14

E

53

Green – Yellow

(c)

Panels

14

E

53

Green – Yellow

(d)

GRP Covers

08

B

15

Yellow-Red

(e)

Sewage Pipework

00

E

53

Black

(f)

Airlines

20

E

51

.

Properties

(g)

Sewage valves

00

E

53

Black

(h)

Airline Valves

20

E

51

Light Blue

(j)

Water Pipework

12

D

45

Green

(k)

Water Valves

12

D

45

Green

(l)

Potable Water/Pipes/Valves

qa

Material / Equipment

12

D

45

Green/18 E 53 Auxiliary Blue

.l. l

rw

ta

as se

Surge Vessels

(n)

Fire Extinguishing Systems

(o)

Bulk Storage Tanks

(p)

Electrical Services

E

51

Yellow

04

E

53

Red

o

ov

08

Aluminium E

51

Yellow-Red

Cranes

08

E

53

Yellow

Control Panels, relay panels, Instrumentation enclosures, fuse switches, distribution boards, marshalling cubicles etc.

14

E

53

Green-Yellow

m

(r)

(colour code)

06

et it

(q)

er

(m)

Light Blue

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Page 13

Abrasive Blasting Materials

1

The abrasive employed in blasting shall be grades steel grit, ball shot, silica safe sand or similar and shall be such that it will provide a surface roughness complying with the one specified by the manufacturer for the primer concerned. The abrasive shall be dry, clean and free from soluble contaminants and shall be selected as specified in BS 4232.

2

The type and size of abrasive used for blast cleaning shall comply with the requirements of BS 4323 Table 2. When directed by the Engineer, the Contractor shall carry out a series of tests using various sizes of abrasives smaller than the maximum defined in BS 4232 Table 2 to determine which gives the best profile. This size of abrasive shall be used for all subsequent blast cleaning. The grading of abrasives for equipment which uses abrasives more than once shall be checked at regular intervals and fresh abrasives added to ensure that the correct grading is maintained.

3

The roughness of blast cleaned surfaces measured at the amplitude by any of the methods defined in BS 4232 shall not exceed 75 microns.

4

The pH value shall not be less than 4 or greater than 10 when mixed in neutral water. The material shall not contain soluble chloride.

5

The level of trace toxic contaminants shall meet Government regulations.

6

Dune sand shall not be used.

8.3

WORKMANSHIP

8.3.1

General

1

Unless otherwise specified in this Part, the preparation coating and painting of surfaces shall be carried out as specified in Part 26 and in accordance with the recommendations of BS 6150 subject to the approval of the Engineer.

2

All coatings and paint shall be applied in a workmanlike manner to produce a uniform film of the specified thickness. Edges, corners, crevices, and joints shall receive special attention to ensure that they have been thoroughly cleaned and that they receive an adequate thickness of paint. The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush marks, and variations in colour, texture, and finish.

3

Before beginning coating and painting work, the Contractor shall take precautions to protect the Works and existing facilities from damage or disfigurement. Where necessary, the Contractor shall protect equipment by providing clean cover sheets. If in the opinion of the Engineer the precautions are inadequate, the Contractor shall at his own expense make such improvements as the Engineer directs.

4

The specified film thickness shall be attained. Particular attention shall be paid to the attainment of specified film thickness on edges. In hot weather, additional precautions shall be taken as necessary to ensure the attainment of specified film thickness. Film thickness shall be checked with a paint inspection gauge furnished by the Contractor. The Contractor shall calibrate the gauge for the thickness range to be checked at least twice a day. When measured film thickness is less than specified, additional coats shall be applied as necessary to attain compliance.

5

Manual grit blasting equipment shall be approved by the Engineer before use. Air 3 compressors shall be capable of supplying a continuous air volume of at least 6 m /min at a maximum pressure of 7 MPa to each blasting nozzle. The compressed air supply shall be free of water and oil. Adequate separators and traps shall be provided. Accumulations of oil and water shall be removed from air receivers by regular purging.

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8.2.3

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Page 14

On completion of the works, which may have become spotted or touched with paint shall be cleaned down and all left clean to the satisfaction of the Engineer.

8.3.2

Manufacturer’s Recommendations

1

Unless otherwise specified, the coating and paint manufacturer’s written recommendations and instructions for storage, thinning, mixing, handling, surface preparation, protection of other surfaces, application and protection of coated and painted surfaces and for all other procedures for providing protective coatings and painting shall be strictly observed. No substitution or other deviation will be permitted without the written permission of the Engineer.

8.3.3

Mixing and Thinning

1

Coating materials and paint shall be mixed only in designated rooms or spaces in the presence of the Engineer.

2

Paint and coating materials shall be protected from exposure to extreme weather, and shall be thoroughly stirred or agitated, strained, and kept at a uniform smooth consistency during application. Materials shall be prepared and handled in a manner to prevent deterioration and inclusion of foreign matter.

3

Paint and coating materials of different manufacturers shall not be mixed together.

4

Packaged paint and coating materials may be thinned immediately before application in accordance with the manufacturer’s directions. Only thinners recommended by the paint and coating manufacturer shall be used.

8.3.4

Items Not to be Painted During Coating and Painting Operations

1

Hardware, hardware accessories, name plates, data tags, machined surfaces and similar items in contact with coated surfaces shall not be coated and shall be removed or masked before surface preparation and painting operations. Following completion of coating of each piece, removed items shall be reinstalled. Such removal and reinstallation shall be done by workmen skilled in the trades involved.

2

That portion of steel to be embedded in concrete or masonry shall not be painted and shall be cleaned as designated for steel surfaces before fixing.

8.3.5

Surface Preparation

1

General

m

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o

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as

qa

ta

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.l. l

.

6

(a)

The specified standard of surface preparation shall be attained. Surface preparation shall have no detrimental effect on the material being protected and shall not be prejudicial to subsequent coating and painting operations.

(b)

In addition to complying with the specifications of this Clause and the manufacturer’s instructions the Contractor shall take such other measures needed to ensure that all surfaces are clean, and free of deleterious material including but not limited to dirt, grease, and oil, before the application of primer and between coats.

(c)

All surfaces prepared for coating and painting shall be prepared to the specified standard and approved by the Engineer before coating and painting work begins.

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Page 15

Cleaning and painting shall be so arranged that dust or spray from the cleaning process will not fall on wet, newly painted surfaces. The sharp edges of steel surfaces shall be dulled, rough welds made smooth and weld splatter removed. Hardware, electrical fixtures and similar accessories shall be removed or suitably masked during preparation and painting, or shall be suitably protected. Equipment adjacent to walls shall be disconnected and moved to permit cleaning and painting of wall surfaces, and shall be replaced and reconnected after the painting has been completed. Notwithstanding anything in this Section, all surfaces shall be prepared in strict accordance with the approved paint manufacturer's recommendations.

(e)

Do not apply paint in temperatures or moisture conditions outside of manufacturer’s recommended maximum or minimum allowable.

(f)

Overcoating intervals recommended by the paint manufacturer must be strictly adhered to. The manufacturer must be consulted if and when there is a necessity for a change in overcoating intervals.

(g)

Where a high quality finish is required, the surfaces shall be filled with an approved filler 24 hours after the final priming coat has been applied. When the surface is hard the whole shall be rubbed down with wet and dry abrasive paper to a uniform flat surface and left clean and free of abrasions and powdered filler.

(h)

All surfaces are to be completely dry and above a temperature of 4 degrees C. No painting shall be carried out during damp or inclement weather.

(i)

When required by equipment specifications, such equipment shall be primed and finish coated in shop by manufacturer and touched up in field with identical material after installation.

(j)

Where manufacturer’s standard coating is not suitable for intended service condition, Engineer may approve use of a tie-coat to be used between manufacturer’s standard coating and specified field finish. In such cases, tie-coat shall be surface tolerant epoxy as recommended by manufacturer of specified field finish coat. Coordinate details of equipment manufacturer’s standard coating with field coating manufacturer.

ov

Metal

Except as otherwise specified in this Clause, preparation of metal surfaces shall be in accordance with the relevant provisions of BS 4232, BS 5493, BS 7079, and SIS 055900.

(b)

Steel to be embedded in concrete, other than reinforcing steel, shall be cleaned to SIS 055900 St. 2 and shall not be primed.

et it

(c)

o

(a)

Surfaces shall be clean and dry before application of coatings and paint. If coating or painting takes place over a zinc rich shop primer which has been exposed for an extended period, the entire coated surface shall be sweep blasted to remove “white rust” and other contaminants before application of the first coat.

m

2

er

se

as

qa

ta

rw

.l. l

.

(d)

(d)

After the surface has been prepared as specified, the surface shall be further cleaned by vacuum, clean and dry compressed air, or by clean brush to remove accumulated grit, shot and dust leaving the surface clean, dry and free of scale, rust and other forms of contamination.

(e)

In the event that rusting occurs after the completion of the surface preparation, the surface shall again be prepared to the specified standard.

(f)

When items are to be shop primed or shop primed and finish coated in the shop, surface preparation shall be as specified herein. The Engineer shall have the right to witness, inspect, and reject any sandblasting or other surface preparation done in the shop.

(g)

Blast Cleaning. Blast cleaning shall not be carried out (i)

on surfaces that are wet or damp surfaces, or may become wet or damp before the application of primer,

QCS 2014


Page 16

(ii)

when metal surface temperatures are less than 3 C above the dew point

(iii)

or the relative humidity exceeds 80 percent.

(iv)

In close proximity to subsequent coating operations or near other surfaces susceptible to dust or particle contamination.

In the event of shot or grit blasting not being possible due to interference, the steel surface may, with the prior written approval of the Engineer, be thoroughly cleaned by mechanical means in accordance with BS EN ISO 8504-3 to remove all loose rust and mill scales and primed with one coat of an alkyd type zinc phosphate primer to 60 microns dry film thickness.

(i)

Where blast cleaning is to be carried out outdoors at an exposed (not under cover) location, preliminary blast cleaning may be done at night with the prior approval of the Engineer, provided that all surfaces so treated shall be reblasted during daylight hours to the specified standard before coating or painting materials are applied. This paragraph does not apply where automatic centrifugal or manual grit blasting is carried out under adequate cover, provided the specified preparation standard is attained.

(j)

Oil or grease contamination shall be removed by solvent wash before blast cleaning. If necessary, contaminated areas shall be rewashed and reblasted until contamination is removed.

(k)

When sandblasting is carried out on Site, care shall be taken to prevent damage to structures and equipment. Pumps, motors, and other equipment shall be shielded, covered, or otherwise protected to prevent the entrance of sand and dust. No sandblasting shall commence before the Engineer inspects and approves the protective measures.

(l)

After sandblasting, dust and spent sand shall be removed from the surfaces by brushing or vacuum cleaning.

(m)

Blast cleaned surfaces that are later to be joined by welding and where shop primer is to be applied shall not be primed to a distance of 100 mm from the area to be welded. After welding, the area shall be reblasted and primed as specified.

(n)

Areas that are blast cleaned and shop primed before fabrication and are later welded on Site shall be reblasted to remove all weld slag and splatter and any other foreign elements and reprimed as specified.

(o)

Fabricated metal work shall not be blast cleaned in the shop until machining and fabrication has been completed, including continuous welds, with all exposed surfaces accessible for subsequent treatment. All slag and spatter shall be removed from the area of the welds by chipping hammer before blast cleaning.

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(h)

Concrete and Rendered Surfaces for Epoxy Coatings (a)

Concrete and rendered surfaces shall be thoroughly cured, thoroughly dry and free from moisture before the application of epoxy filler, primer or paint.

(b)

Areas of concrete contaminated with substances deleterious to the application of epoxy coatings including machine oil or grease for example shall be cut out as necessary to remove all traces of such substances. The voids so created shall be filled with an approved epoxy mortar. Areas contaminated with form release agent shall be scrubbed with suitable emulsion cleaners. Mould growth shall be treated using a water soluble fungicide. All surfaces so treated and any other water soluble substances on the surface, such as salt, shall be rinsed with potable water until clean.

(c)

Where membranes have been used for the curing of concrete these must be removed and the surfaces thoroughly cleaned before the application of painting and protective coatings.

(d)

All concrete and rendered surfaces to be coated shall be lightly blast cleaned to remove the cement rich surface layer. Grit and detritus shall be removed by vacuum immediately prior to priming.

QCS 2014

(e)

Page 17

Blow holes and honeycombed areas in the concrete which in the opinion of the Engineer are not capable of being levelled at the primer stage shall be filled with epoxy mortar supplied by the coating manufacturer to obtain a smooth uniform surface. Such mortar shall be knifed into the surface to level the area and leave no excess.

Preparation of Plaster, Brickwork and Concrete Surfaces for Coatings and Paint other than Epoxy (a)

Efflorescence present on the surface of plaster, brickwork and concrete shall be removed by scraping and brushing before any paint is applied. When efflorescence has been removed surfaces shall be left for at least three days before priming. Priming shall be deferred repeatedly, if necessary, until three days after any further efflorescence which has appeared is removed.

(b)

Plaster surfaces to be painted shall be cleaned down smooth as necessary and all cracks filled in with stopping for plaster. Filling shall be carried out for the entire surface before paint is applied to the surface.

(c)

Brickwork, blockwork and concrete surfaces shall be cleaned of contaminating matter before being primed. Subject to the approval of the Engineer, large holes which would cause a break in the paint film shall be filled with mortar and the surface rubbed down to match the surrounding areas.

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Wood surfaces shall not be painted when the moisture content of the wood measured with an electric moisture meter exceeds 12 % for interior surfaces and 18 % for exterior surfaces.

(b)

Hardwoods or softwoods shall be rubbed down with abrasive paper to give a smooth surface free of contaminating substances, scratches and other imperfections.

(c)

Surfaces which are to be painted shall be rubbed down to remove all contaminating substances and imperfections which would be visible in the finished paint film. The surfaces of knots and resinous streaks shall be painted with two coats of knotting, the first being allowed to dry before the second is applied. Knotting shall conform with BS 1336.

(d)

The surfaces of timber treated with waterborne preservative by an impregnation process shall be rubbed down and dry-brushed to remove all traces of efflorescence before the primer is applied.

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Where surfaces are suspected of being infected with mould, they shall be treated with a fungicide.

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Galvanised Surfaces (a)

Dirt and other adhering contaminating material shall be removed by wire brushing, brushing with bristle brushes, or by other methods approved by the Engineer. Cleaning shall not damage the galvanising. Zinc corrosion products remaining shall be removed by washing with potable water and scrubbing with hard bristle brushes.

(b)

After being cleaned and degreased, galvanised surfaces shall be etched with T-wash as described in BS 5493. If any surface fails to turn black, the cleaning, degreasing, etching, and T-wash processes shall be repeated as often as necessary.

Damaged Surfaces (a)

Factory prepared surfaces, other than galvanised surfaces, during handling, site fabrication or erection shall be treated as follows: (i)

all slag and spatter shall be removed from areas of welds by chipping hammer

(ii)

all areas of damaged primer or other coat shall be thoroughly mechanically wire brushed and given one priming coat as detailed in Table 8.3

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Page 18

(iii)

the priming coat shall be applied by brush taking care to completely cover uneven surfaces particularly those of welds

(iv)

subsequent coats shall be applied as specified in this Part.

Application of Protective Coatings and Paint

1

All paint and coating materials shall be applied in accordance with the manufacturer’s printed specifications or instructions; where these differ from the specification of this Part, the more stringent requirements shall apply. The Contractor shall issue copies of appropriate data sheets and of the relevant parts of this specification shall be issued to all supervisory personnel. Where such instructions conflict with this specification a ruling shall be sought from the Engineer’s Representative.

2

Unless in conflict with the manufacturer’s printed instructions or otherwise specified, the Contractor may use brush, roller or air spray. Application by spray painting shall be with the prior approval of the Engineer. Rollers for applying enamel shall have a short nap. Areas inaccessible to spray coating or rolling shall be coated by brushing or other suitable means.

3

The Contractor shall ensure that edges, corners, crevices, welds, bolts, and other areas, as determined by the Engineer, receive a film thickness equivalent to that of adjacent coated surfaces and not less than the specified thickness.

4

On beams and irregular surfaces, edges shall be stripe coated first and an extra pass made later.

5

Application of paint and condition of work shall be in accordance with manufacturer's recommendations and with BS 6150 and BS EN ISO 12944.

6

The designated dry film thickness (DFT) shall be attained for each coat.

7

Each coat shall be applied evenly, at the proper consistency, and be free of brush marks, sags, runs, and other evidence of poor workmanship. When these occur, they shall be brushed out immediately or the materials shall be removed and the surface recoated. Finished coated surfaces shall be free from defects or blemishes.

8

Care shall be exercised to avoid lapping paint on glass or hardware. Coatings shall be sharply cut to lines. Whenever two coats of a dark coloured paint are designated, the first coat shall contain sufficient powdered aluminium to act as an indicator of proper coverage, or the two coatings shall be of a contrasting colour.

9

All coatings shall be cleaned as specified by the manufacturer before the next coat is applied.

10

Manufacturer’s recommended time between coats shall be strictly complied with. Sufficient time shall be allowed to elapse between successive coats to permit satisfactory application of subsequent coats. Once begun, the entire coating operation shall be completed without delay. Without specific permission of the Engineer, no additional coating of any structure, equipment, or other item designated to be painted shall be undertaken until the previous coating has been completed for the entire item. Piping shall not be finish coated until it has been pressure tested and approved. Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted except in the case of work delivered to the Site in a primed condition and suitably protected.

11

Final coats shall not be applied until after other trades whose operations would be detrimental to finish painting have finished their work in the area to be painted, and the areas have been released for final painting.

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All parts such as pipe supports, seatings and cleats, and back-to-back sections which will become inaccessible after fabrication shall be treated on both surfaces with the full paint system before final assembly.

13

Touch-up of all surfaces shall be performed after installation, and all surfaces shall be clean and dry at the time of application.

14

All paints shall be prepared and applied in strict accordance with the manufacture instructions. Copies of appropriate data sheets and of the relevant parts of this specification shall be issued to all the supervisors and foremen concerned with surface preparation and coating. Where such instructions conflict with this specification a ruling shall be sought from the Engineer’s Representative.

15

Except where otherwise specified or approved by the Engineer’s Representative all priming paints shall be applied by brush. Airless spray application only shall be used for painting pipe lining and is the preferred method for the application of epoxy resin based paint.

16

The dried films shall be free from bloom, shrinkage, sheeriness, wrinkling, sagging, curtaining, discolouration and extraneous matter.

17

Any primer coat exposed to freezing, excess humidity, rain, dust etc. before drying, shall be permitted to dry and the damaged area of primer shall be removed and surface again prepared and primed.

18

Bolted site connections other than facing surfaces of Grip Bolts shall be brought together wet.

8.3.7

Maintenance of Prepared Surfaces

1

Primer or other initial coat shall be applied to all prepared surfaces before deterioration or oxidation of the surface. In the case of metals, primer or other initial coat shall be applied within one hour or such shorter period of time which may be recommended by the manufacturer, but always before the metal temperature drops to less than 3 C above the dewpoint and before any rusting occurs. Unless otherwise approved by the Engineer for surfaces other than metal, primer or other initial coat shall be applied within 4h of completion of surface preparation. No prepared surfaces shall be allowed to remain uncoated overnight.

8.3.8

Environmental Conditions

1

Coatings and paint shall be applied in a dry and dust-free environment. Coatings and paint shall not be applied to wet or damp surfaces or when, in the opinion of the Engineer, application or drying of paint is likely to be adversely affected.

2

No exterior or exposed paint work shall be carried out under adverse weather conditions; i.e., during rain, mist, windstorms, sandstorms, or when the relative humidity exceeds 80 %. Paint and coatings shall not be applied when it is expected that the relative humidity will exceed 80 % within 18 hours after the application of the coating or paint. Dew or moisture condensation should be anticipated and if such conditions are prevalent, application of paint and coatings shall be delayed to be certain that the surfaces are dry. The paint or coating shall be completed well in advance of the probable time of day when condensation is expected to occur.

3

During application, painting shall insofar as practicable be shaded from direct sunlight to prevent wrinkling and blistering. Exterior painting shall be carried out in shade during the day.

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Spray Application

1

All equipment for spray application shall be inspected and approved by the Engineer before application begins. Spray guns hoses and pumps shall be clean before new material is added. Adequate moisture and oil traps shall be installed between the air supply and each application unit.

2

Suitable pressure regulators and gauges shall be provided for the air supply to the application units. Spray equipment and operating pressures shall comply with the manufacturer’s recommendations.

3

Heavy pigments which are likely to settle shall be kept in suspension during application by the use of power driven, continuous agitator.

4

The spray gun shall be held at right angles to the surface. Each pass shall overlap the previous one by approximately 50 %.

8.3.10

Brush Application

1

When coatings are applied by brush, brushes shall be pure hair bristles and shall be of a style and quality that will permit proper application of the material. Flat brushes shall not be more that 100 mm wide. Brushes shall be approved by the Engineer. Extending handles shall not be used.

2

Brushing shall be affected so that a smooth coat, as nearly uniform in thickness is obtained. There shall be no deep or detrimental brush marks.

3

Paint shall be worked into all corners and crevices. When applying solvent type coating, care shall be taken to prevent lifting of previous coats.

8.3.11

Shop Coatings

1

Electrical and mechanical equipment shall be coated and painted as specified in this Part and in Section 9. The location of coating and painting; i.e., in the shop or on Site, shall be as specified in Section 9.

8.3.12

Site Painting of Manufactured Items

1

Steel pipework or fabrication shall be works cleaned and painted in accordance with Tables 8.1 through 8.4. Total dry film thickness shall be in accordance with the location of surfaces of painted as specified in Table 8.2

2

Steel, cast or ductile iron encased in concrete (chamber walls and anchor blocks) shall be prepared and coated as specified under Tables 8.1 through 8.4.

3

Non-ferrous parts shall be protected using the same finishing system as that specified in Tables 8.1 through 8.4 for the adjacent ferrous metal structure.

4

When any coating which has been applied at a manufacturer’s works is considered by the Engineer to be unsound or incompatible with the specified system, it shall be rejected. The surfaces shall be recoated to a finish satisfactory to the Engineer.

5

When the Engineer’s Representative does not require the removal of the manufacturer’s coating the equipment shall be solvent cleaned.

6

Hard baked finishes shall be abraded or softened by application of a strong solvent.

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8.3.9

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Page 21

All polished and bright parts shall be coated with an approved rust preventative before despatch and during erection, and this coating shall be cleaned off and the parts polished before being handed over.

8

Manufactured items such as pumps motors, compressors, air vessels, conduits, etc. shall be coated at works to the specification laid down for the environment in which they are to operate. If this is impractical they may be paint coated to the manufacturer’s standard but when on site the Contractor shall apply a sealing paint and top coats specified in Table 8.1 to Table 8.4. Final site painting shall be in accordance with Table 8.1 to Table 8.4. The site coating shall be 150 microns minimum dry film thickness (DFT).

9

Pre-treatment and primers shall be suitable for the metal concerned and to BS 5493. Dry film thickness shall be a minimum of 200 microns for all conditions.

8.3.13

Site Application

1

Protective coverings shall be used to protect surfaces, fixtures, and equipment. Care shall be exercised to prevent paint from being spattered onto surfaces from which such paint cannot be removed satisfactorily. Surfaces from which paint cannot be removed satisfactorily shall be painted or repainted as required to produce a finish satisfactory to the Engineer.

2

Upon completion of the work, staging, scaffolding and containers shall be removed from the site in an approved manner. Paint spots, oil or stains upon adjacent surfaces shall be removed to the satisfaction of the Engineer. No paint, solvents, rags or other materials used by the Contractor shall be disposed of in any manner or location except as approved by the Engineer. The Contractor is specifically cautioned to prevent paint of solvents to be in contact with plants or liquid streams.

8.3.14

Epoxy Coating Work

1

In addition to the general requirements of this specification the following shall apply to epoxy coating works:

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illumination at work site the satisfaction of the Engineer’s Representative

(b)

forced draught ventilation to the approval of the Engineer shall be used wherever required for the needs of personnel or for drying out surfaces

(c)

operatives shall work in pairs.

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The Contractor shall demonstrate his methods equipment and materials before any work commences. Samples areas of substrate shall be prepared and coated as required by the Engineer and for his approval.

3

There shall be strict control of surface cleanliness between primer and epoxy coating and between coats of the same type. Vacuum removal of dust and sand shall be employed and contamination shall be removed as specified in appropriate surface preparation clauses herein. Dirt or dust trapped in the painted surface shall be removed with suitable abrasive paper. The surface being painted shall be completely dry and free of visible moisture throughout the operations.

4

The paint shall be applied only to clean dry primed or previously coated surfaces. Any thick runs or collections of paint shall be removed before they harden.

5

Not less than two coats shall be applied over the primer by airless spray; not less than three by brush.

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Each coat shall be distinctly different in colour from the primer or previous coat. The colour of the final coat shall be as required by the Engineer. Each coat shall be seen to have completely covered the preceding coat without “misses” or pinholes or any areas visibly low in thickness. A high voltage pinhole detector shall also be used to determine the integrity of the coats.

7

The manufacturer of the coating shall stipulate primer and epoxy recoat intervals for all curing temperatures likely to be encountered and these shall be adopted with a maximum tolerance of +4 h. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to remove gloss and provide a key.

8

Wet thickness gauges shall be used by the coating operators continually to check that sufficient paint is being applied to achieve the desired dry film thickness.

8.3.15

Epoxy Coatings for Concrete and Rendered Surfaces

1

No priming shall commence until the moisture content of the cementitious surface is less than 5 % measured by instruments approved by the Engineer.

2

Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 % on the concrete scale of the instrument when the probe tips are held against such painted surfaces just prior to recoating.

3

The primer shall be applied by suitable nylon bristle brush or spray over the whole area to be coated at such thickness that it may then be squeezed into the pores of the concrete. Excess shall be removed by the most suitable means before application of the high build epoxy.

4

The Engineer may approve an alternative application method where the Contractor can demonstrate a suitable technique.

5

The total dry film thickness of the paint layer shall have a minimum value of 0.75 mm.

6

Whenever the Paint Inspection Gauge has been used and wherever the coating has been otherwise damaged for 50 mm around such damage the surface shall be abraded and the area touched in with not less than two thick applications to restore the coating integrity and thickness to that specified.

7

Adhesion tests will be carried out on the cured coating surface using the test equipment supplied under the Contract in accordance with the best practice. The resulting test specimens shall show no indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness.

8

Where required in the Project Specification or on a written request by the Engineer, the following instruments shall be provided for the Engineer sole use for the duration of the Contract:

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(a)

one adhesion tester (0-35 kg/cm )

(b)

one DC high voltage Holiday detector No. 105

(c)

one paint inspection gauge

(d)

one moisture meter.

8.3.16

Galvanising and Other Finishes of Metals

1

Galvanising and other finishes of metals shall be carried out as specified in Parts 3 and 6 of Section 8.

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8.3.17


1

The Contractor shall conduct dry film thickness (DFT) measurements and other inspections of all painted work, on completion of which the Engineer will make his own measurements, examinations and inspections. If painted works are found unsatisfactory, the contractor shall carryout remedial works as necessary at his expense and the works shall be retested by the Engineer until such time the works are found satisfactory.

2

The Contractor shall provide and maintain two sets of the following inspection devices in good working condition until final acceptance of painting and coating. One set shall be for the Contractor’s use and the other for the sole use of the Engineer. On final acceptance of painting and coating, the inspection devices will be handed back to the Contractor. Svensk Photographic Standard in accordance with SIS 055900

(b)

non-destructive magnetic-type DFT gauge

(c)

wet fill thickness combs

(d)

surface profile meter

(e)

non-destructive type electrical holiday detector

(f)

low-voltage detector of the wet-sponge type and a non-sudsing type wetting agent, for testing discontinuities and voids in epoxy and thin film coatings

(g)

high-voltage, low-current, spark type detector for electrical inspection of coal-tar enamel only

(h)

maximum and minimum thermometer

(i)

hygrometer

(j)

flow cup type B No. 4 and timer.

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END OF PART

QCS 2014

Section 08: Drainage Works Part 09: Trenchless Pipeline Construction

Page 1

9

TRENCHLESS PIPELINE CONSTRUCTION ................................................ 3

9.1

GENERAL ...................................................................................................... 3

9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 9.1.8 9.1.9

Scope Related Sections and Parts References Definitions System Description Submittals Specialist Subcontractor Quality Assurance Site Conditions

9.2

TRENCHLESS PIPELINE CONSTRUCTION GENERALLY ......................... 5

9.2.1 9.2.2 9.2.3 9.2.4 9.2.5

Scope Surveys and Setting Out Monitoring Lines and Levels Temporary Site Facilities Safety Requirements

9.3

MATERIALS .................................................................................................. 7

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5

Pipes Joint Packing Lubricant Joint Sealant Grout

9.4

THRUST AND RECEPTION SHAFTS ......................................................... 11

9.5

PIPEJACKING ............................................................................................. 12

9.5.1 9.5.2

General Tunnelling Shields for Pipejacking

9.6

MICROTUNNELLING .................................................................................. 12

9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15

General Contractor Responsibilities Safety and Environment Performance Requirements Micro-tunnel Design Elements Design Checking Finite Element (FE) and Finite Difference (FD) Models Verification of Results Design Parameters for the Calculations Design Loadings Design Submissions Certification Procedure Contractor’s Documents Construction Responsibilities Quality Assurance/Control

5 5 6 7 7 7 10 10 10 10

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3 3 3 3 3 3 5 5 5

12 12 12 13 13 14 15 17 17 18 18 18 19 20 20 21 21

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Page 2

Materials Temporary Works Construction Preparation Pipeline Installation Construction Execution Working in Compressed Air Ground Pre-treatment Drainage During Construction Disposal of Tunnel Seepage and Waste Water Testing Grouting Surface and Building Settlement Monitoring Contractor’s Obligations Microtunnelling Machine

9.7

THRUST SYSTEM ...................................................................................... 28

9.8

LUBRICATION HOLES................................................................................ 29

9.9

RECORDS ................................................................................................... 29

9.10

TESTING ..................................................................................................... 29

22 22 22 23 24 24 25 25 26 26 26 27 28 28

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9.6.16 9.6.17 9.6.18 9.6.19 9.6.20 9.6.21 9.6.22 9.6.23 9.6.24 9.6.25 9.6.26 9.6.27 9.6.28 9.6.29

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9.10.1 General 9.10.2 Watertightness

29 30

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Page 3

TRENCHLESS PIPELINE CONSTRUCTION

9.1

GENERAL

9.1.1

Scope

1

This part includes the specification for the construction of pipelines by microtunnelling, pipejacking or other trenchless methods approved by the Engineer.

9.1.2


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General Concrete Ground Investigation.

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General Earthworks Pipes and Fittings Materials Pipe Installation

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References

1


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9.1.3

BS 2494,.....................Materials for elastomeric seals for joints in pipework and pipelines

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BS 5228,.....................Code of practice for noise control on construction and demolition sites

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BS 6164,.....................Code of practice for safety in tunnelling in the construction industry. Definitions

1

Pipejacking: technique for constructing pipeline by thrusting pipes or other permanent lining of preformed units progressively into the ground by means of jacks or similar equipment while excavation proceeds at the leading end.

2

Microtunnelling: small diameter tunnelling technique employing mechanical excavation methods usually within a non-man entry guided tunnel boring machine with primary lining inserted behind by jacking.

3

Shaft: excavated thrust and reception pits used for tunnelling operations.

9.1.5

System Description

1

The Contractor shall be responsible for the design of the pipes including joints to meet the requirements of the method of construction.

9.1.6

Submittals

1

The Contractor shall submit complete data and details for the trenchless pipeline construction for the Engineer's approvals follows:

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9.1.4

(a)

Structural design calculations for the trenchless pipeline and temporary works: (i)

the description and specification of pipes and design calculations.

(ii)

details of the permitted angular deflection and draw for the proposed pipes.

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Page 4

(iii)

the Contractor shall submit full details of the pipes together with details of previous works undertaken using similar pipes.

(iv)

details of proposed manufacturer of pipes with relevant literature and details of manufacturer's Quality Control system.

(v)

anticipated jacking loads.

(vi)

structural design of thrust walls.

(b)

Shop drawings.

(c)

Materials Specifications.

(d)

Method statements which shall include: details of the specialist sub-contractor's qualifications and experience in microtunnelling together with project references including previous employers' names and current contact details and a curriculum vitae of the proposed tunnelling machine operator including details of relevant experience in Qatar and the Middle East.

(ii)

detailed procedure for the Works.

(iii)

a description of tunnelling equipment with relevant literature and a statement from the tunnelling machine manufacturer detailing a delivery schedule for spare parts and consumables for the proposed tunnelling machines.

(iv)

preconstruction activities (geotechnical investigations including test pits).

(v)

safety procedures.

(vi)

handling and fixing of the inner pipe in the case of pipe jacking with larger diameter pipes.

(vii)

programme of work, including proposed production rates.

(viii)

bentonite injection system details.

(ix)

detailed method statements for all other aspects of micro-tunnelling work.

(x)

where appropriate for the size of machine proposed, details of man access into the tunnel and tunnel boring machine.

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(i)

Designs of thrust and reception shafts and detailed drawings.

(f)

Dewatering arrangements and disposal of groundwater. Methods for dealing with different ground conditions. Equipment layout at the thrust and reception shafts.

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(i)

Details of sleeving system.

(j)

Ventilation.

(k)

Lighting and communications.

(l)

Disposal of surplus excavated material: (i)

details of the spoil separation process to produce clean slurry for recirculation to the tunnel boring machine.

(ii)

details of the containment of the excavated material to prevent water and slurry draining from the Contractor's designated working area or wagons. Lagoons for storage and settlement of slurry from the micro-tunnelling process will not be permitted.

(iii)

details of the purpose made tanks for settlement of slurry shall be provided.

(iv)

details of the solid waste disposal procedure to an approved tip in a manner which does not cause spillage of slurry, mud or any other solid or liquid waste on the carriageway.

QCS 2014

Section 08: Drainage Works Part 09: Trenchless Pipeline Construction (v)

Page 5

disposal of surplus water, once all solids have been removed, to an approved surface/ground water outfall, if locally available, or removed by tanker to an approved point of disposal.

(m)

Pilot bore.

(n)

Plan at 1:50 scale showing working plant positions, spoil removal faculties, materials storage facilities, launch and reception shafts, fencing, offices, discharge lines, ground water removal facilities, etc.

The Contractor shall not procure materials or begin construction of the Works until the Engineer has approved all submittals. The Engineer’s approval shall not relieve the Contractor of his obligations under the Contract.

9.1.7

Specialist Subcontractor

1

The Contractor shall employ an approved specialist subcontractor experienced in trenchless methods for the pipeline construction.

9.1.8

Quality Assurance

1

The Contractor shall employ an approved prequalified specialist subcontractor as designated in the contract specific documentation. All personnel in the employment of the subcontractor shall be experienced and competent in their respective tasks and shall work only under the control of a qualified supervisor.

9.1.9

Site Conditions

1

The Contractor shall carry out additional geotechnical site investigations which he considers necessary. The results of such investigations and laboratory testing together with the factual and interpretive reports shall be submitted to the Engineer for approval. The Engineer’s approval shall not relieve the Contractor of his obligations under the Contract.

9.2

TRENCHLESS PIPELINE CONSTRUCTION GENERALLY

9.2.1

Scope

1

Where a pipeline is designated in the Contract documents to be constructed by a trenchless method, the Contractor shall not be permitted to adopt open trench methods and shall confine his surface operations to working shafts and the area immediately adjacent to such shafts. In locations where construction of pipelines is not indicated to be by trenchless method, the Contractor may elect to construct additional lengths of pipelines by a trenchless method in accordance with this specification, subject to the Engineer’s approval.

9.2.2

Surveys and Setting Out

1

Before commencing the excavation of any shafts for pipejacking or microtunnelling, the Contractor shall

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(a)

establish at least four adequately protected bench marks comprising steel pins embedded in a block of concrete adjacent to the shaft to facilitate the setting out of the underground works

(b)

record the initial levels for pipelines beneath or across roads and submit a copy of these to the Engineer

(c)

record and report with supporting photographs of the condition of structures, roads, footpaths and other paved areas that are located over and beside all jacking or microtunnelling routes.

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Page 6

2

During construction of a drive between any two working shafts, the Contractor shall observe levels on predetermined cross-section points at regular intervals to determine if there is any subsidence. Temporary benchmarks shall be set up along the centre of the pipe at 15 metre intervals between the shafts and at 5 and 10 metres offsets. Levels shall be taken along the centre of the pipeline and at offsets of 5 metres and 10 metres each side of the pipeline at 15 metre intervals between shafts. Levels shall be taken and recorded on all of the above points at daily intervals during micro-tunnelling works, again one week before issue of a Completion Certificate, and finally at the end of the 400 day period of maintenance.

3

Immediately following completion of the drive between any two working shafts, the Contractor shall repeat the level survey of the ground surface along the centreline of the drive as described above

(b)

record and report to the Engineer with supporting photographs any changes to the condition of roads, footpaths and other paved areas.

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(a)

Before the completion of the whole of the Works and again before the expiry of Period of Maintenance, the Contractor shall repeat the surveys and inspections as described above for all of the trenchless pipeline construction.

5

The Contractor shall determine the location of all working shafts having due regard to existing services, minimising disruption to traffic and pedestrian movements and achieving the required system layouts, as approved by the Engineer. The Contractor shall prepare suitably scaled working drawings for the setting out of the Works, including the location of existing services and all other relevant details and submit these for the Engineer’s approval.

6

As-built surveys of each micro-tunnel drive shall be undertaken. For all micro-tunnel drives of internal diameter 800 mm or more, including any permitted sleeves of this size, the Contractor shall employ an approved independent survey company to undertake an as-built survey of the drive. Coordinates and levels shall be provided for every pipe joint. For steel sleeves, coordinates and levels shall be provided at 5 metre intervals. Each completed drive shall be surveyed immediately after completion of the drive. No further micro-tunnel drives may be commenced until the survey results have been submitted to and approved by the Engineer. No pipes may be installed within sleeves until the survey results have been submitted to and approved by the Engineer.

9.2.3

Monitoring Lines and Levels

1

A laser guidance system shall be used for the control of the pipe alignment. The shield/tunnel machine shall be fitted with a calibrated laser target, robustly constructed and rigidly secured to the shield/tunnel machine.

2

The setting of the laser and target and the alignment of the tunnel relative to the laser beam shall be checked frequently at intervals as directed by the Engineer. In addition, the Contractor shall verify the accuracy of the laser guidance system by conventional theodolite and level control methods to the approval of the Engineer.

3

The invert level of the finished pipeline at the drive shaft shall be within ±10mm of the required level shown on, or interpolated from, the Contract drawings.

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The invert level and line of the pipeline shall at no point deviate from the design by more than the following:

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Pipe Bore

Vertical

Horizontal

D mm

mm

mm

D < 600

± 20

± 25

600 ≤ D ≤ 1000

± 25

± 40

1000 < D ≤ 1400

± 30

± 100

D > 1400

± 50

± 200

The pipe manufacturer’s stated permitted draw or angular deflection shall not be exceeded at any individual joint.

5

If the line and levels of any section of pipeline deviates from the design alignment within the tolerances the shield/tunnel machine shall be steered in a manner that ensures a gradual return to the correct alignment.

6

If the deviation in the lines and levels exceeds the tolerance specified above, the Contractor shall stop work and immediately inform the Engineer. The Contractor shall submit proposals to rectify the deviation. Work shall be resumed only on the written instruction of the Engineer.

7

Where micro-tunnelled sewers are required to connect into existing pipelines or pipelines previously completed under this project, due allowance for the tolerance shall be made prior to commencing the drive to ensure that the finished pipeline profile does not require the pipe contents to flow uphill.

9.2.4

Temporary Site Facilities

1

In addition to the provisions of Section 1, the Contractor shall provide the following at each thrust shaft as a minimum: air-conditioned mobile office

(b)

telecommunication between the mobile office and the work crews

(c)

adequate ventilation approved gas detectors and oxygen meters

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(e)

first aid kit.

9.2.5

Safety Requirements

1

The Contractor shall adopt safe working practices for tunnelling in accordance with BS 6164. Only authorised personnel shall be allowed access to the Site.

2

The Contractor shall ensure that a suitably qualified safety officer is present during tunnelling operations.

9.3

MATERIALS

9.3.1

Pipes

1

Pipe material and the lining and coating shall be as designated in the Project Specification. If the use of other pipe material or lining and coating is proposed, technical details and justification shall be submitted for the Engineer’s approval.

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Page 8

Pipes shall be designed to withstand the maximum axial thrust with a factor of safety of four based on the full effective area of the pipe and the ultimate compressive strength of the pipe material. For reinforced concrete pipes the full effective area at the joint shall be used. The pipe design shall take into account both permanent service loads and temporary loads encountered during installation.

3

Where GRP or similar material pipes with concrete surround are proposed the concrete shall be regarded as sacrificial. The concrete surround shall be designed to withstand the maximum jacking force. The design shall also ensure that the GRP or similar material pipe is not subjected to forces during installation. Vitrified clay pipes shall be in accordance with Clause 3.2 of this Section.

4

The Contractor’s submittals shall describe the measures to be taken to avoid the development and transfer of grout shrinkage and expansion stresses to the pipe and to avoid any adverse chemical reaction between the pipe and the concrete, grout or other materials comprising the pipeline. The pipe manufacturer shall guarantee that the crushing and beam strength of the pipe are sufficient for their intended use.

5

Joints in pipes shall be designed to avoid projections which could obstruct the travel of the pipe. Joints shall be watertight under axial loading and at the permissible deflection of the pipes. Quality control tests at the factory shall include subjecting the pipe joints, at maximum permissible deflection, to a hydrostatic pressure of 0.2 MPa.

6

Standard pipes shall generally be of 2.0 m in length. Where required, pipes shall incorporate lubricant injection holes spaced equally around the circumference. Concrete pipes with a liner shall only be permitted to have lubricant injection holes in the concrete. Lubrication holes shall be clear of joints and shall be plugged on completion of the work. Pipes may incorporate lifting holes and fixing holes for securing temporary apparatus; all such holes shall be threaded to enable plugs to be screwed into the sockets to withstand external water pressures.

7

Joints which shall be used in conjunction with a resilient packing and shall be capable of accepting repeated angular deflections as recommended by the pipe manufacturer without

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damage to pipe or loss of structural integrity

(b)

the ingress or egress of water or lubricant under the maximum test pressures

(c)

the ingress of either or both soil or groundwater onto the bearing surfaces.

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(a)

Unless otherwise directed by the Engineer the joint design for concrete pipes shall be such that areas available for transmitting the maximum permitted thrust force will be sufficient to ensure that with an angular deflection of 1  and with resilient packing material in place, the maximum pressure applied to the joint bearing surface will not exceed 23.5 MPa for drives up to 100 m in length and 21.0 MPa for drives in excess of 100 m in length.

9

Unless Authenticated independent test results acceptable to the Engineer are available, two consecutive axial load tests incorporating a 1  angular deflection with the application of double the maximum permissible thrust force (or, if greater, of the greatest thrust force that the proposed thrust equipment can apply) shall have been successfully conducted without visible crushing, cracking or spalling of the pipe being evident, before pipes will be accepted for use. The tests shall be extended to record the loading at which visible signs of failure become evident, and shall be carried out in an approved manner to simulate actual working conditions. Pipes which have been submitted to the proof load test will not be permitted in the Works.

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Where the Contractor elects to construct certain sections within larger diameter pipes and grout the annular space, the external pipe may be of steel. The difference between the external face of the inner pipe and the internal face of the outer pipe shall not be less than 150 mm. The steel pipe and the grout shall be regarded as sacrificial and the inner pipe shall be designed as a stand alone pipe, capable of withstanding installation forces and soil, traffic and groundwater loads.

11

Where the Contractor elects to construct certain sections not within larger diameter pipes, pipe installation by trenchless methods shall continue until at least one additional length of pipe beyond the limit of trenchless construction is exposed. The condition of the exposed pipe and its exterior coating will be inspected by the Engineer. Where in the opinion of the Engineer the pipe or coating has been excessively damaged during installation, the Contractor shall submit a proposal for review by the Engineer, for demonstrating the adequacy of the pipeline installed by trenchless methods and for rectifying defects. The proposal shall also include jacking out of defective pipes.

12

Concrete jacking pipes shall comply with the provisions of BS EN 1916 and BS 5911-1.

13

Collars shall be manufactured from weldable stainless steel plate Grade 316 Ti (EN 1.4571). They shall be provided with suitable stainless steel lugs or anchors to enable them to be cast into the body of the pipe, if applicable.

14

Joints in concrete jacking pipes shall be in-wall flexible joints of the fixed collar type. They shall be designed to include one or more joint seals. All joint surfaces which will transmit load during installation shall be plane and free from irregularities that could cause high local concentrations of stress.

15

The nominal internal bore of the micro-tunnelling pipes shall be as indicated on the Drawings or as specified by the Engineer. The Contractor shall select an appropriate external diameter for the pipe which shall be submitted to the Engineer for approval.

16

The design of the jacking pipes and determination of acceptable pipe fabrication tolerances shall be the responsibility of the Contractor. Maximum compressive stresses applied to the pipe shall not exceed 33% of the design compressive strength of the pipe and shall not exceed the pipe manufacturer’s recommended allowable stresses.

17

Pipes for installation by micro-tunnelling shall be fit for purpose and shall be one of the following: Concrete designed specifically for jacking to BS EN 1916:2002 and BS 59111:2002+A2:2010 with a GRP pipe lining in accordance with Section 8 Part 3 Clause 3.4. . The GRP lining pipe shall incorporate watertight joints between adjacent pipes and shall accept no longitudinal load during jacking. The joint between adjacent pipes shall be designed to ensure concentricity of adjacent pipes and shall prevent application of any lateral forces to the GRP pipe. The coarse aggregate used in the manufacture of the pipes shall be crushed Gabbro rock. The external surface of the pipe shall be coated with at least 300 DFT abrasion resistant epoxy. Pipes shall be factory manufactured by an approved experienced manufacturer. Pipes shall not be manufactured on-site.

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(b)

Concrete designed specifically for jacking to BS EN 1916:2002 and BS 59111:2002+A2:2010 with a polymer lining as described in Section 5 Part 14 Clause 14.6. The coarse aggregate used in the manufacture of the pipes shall be crushed Gabbro rock. The external surface of the pipe shall be coated with at least 300 DFT abrasion resistant epoxy. Pipes shall be factory manufactured by an approved experienced manufacturer. Pipes shall not be manufactured on-site.

(c)

Direct jack GRP pipes to BS ISO 25780:2011 shall be in accordance with Clause 3.4 of this Section.

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(d)


Page 10

The joint between adjacent jacking pipes shall be designed to ensure concentric alignment of adjacent pipes and uniform transfer of jacking forces from one pipe to the next. The pipe joint shall consist of a substantial external stainless steel guide ring to achieve this requirement. The joint shall also incorporate one or more EPDM or other approved elastomeric sealing gaskets.

Joint Packing

1

Packers shall be incorporated into each joint in concrete jacking pipes in order to distribute the jacking pressure and avoid point loads and to prevent damage to the ends of the pipes during the jacking process. The packers shall not extend over the full joint width, a gap to the inside surface should be left to prevent localised spalling, in accordance with the manufacturers recommendations.

2

The material used for packing shall withstand all imposed loadings applied during the installation of pipes for each completed length without showing signs of deterioration or distress. The initial thickness of the packing shall be such that the final joint gaps achieved upon completion of the pipeline are a normal width of 8 mm.

3

The material proposed for the joint packing and its mechanical properties shall form part of the pipe design submission from the Contractor.

9.3.3

Lubricant

1

Lubricant shall always be used. Lubricant shall be polymer or bentonite-based slurry approved by the Engineer. It shall be stored and mixed in a manner recommended by the supplier and tested before use. Sufficient quantity of the lubricant material shall be kept available at Site.

9.3.4

Joint Sealant

1

The joint sealant for the jacking pipe shall be of the elastomeric ring type complying with BS 2494. Joint sealants shall be stored in a manner recommended by the supplier.

9.3.5

Grout

1

Grout used for slurry replacement shall consist of either ordinary or sulphate-resisting cement and water as determined by geotechnical data and directed by the Engineer

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9.3.2

(b)

have nominal strength at least equivalent to the requirement for Grade 20 concrete.

(c)

have admixtures only if tests have shown to the satisfaction of the Engineer that their use improves the properties of the grout, such as by increasing workability or slightly expanding the grout.

Full details of the proposed grout mix including admixtures shall be submitted to the Engineer for approval. 2

Grout used for annular space filling shall (a)

be a low-strength foam concrete placed at low pressures.

(b)

have a mix density in the range 900-1200 kg/m

(c)

have free water/cement ratio not greater than 0.6.

3

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The internal pipe shall be filled with water to avoid floatation forces, hydration temperatures and to resist forces during grouting. A 5 m high free vented standpipe shall be used. A free venting standpipe of not less than 100 mm diameter shall be installed on the grout injection feed to restrict grouting pressures to a maximum of 0.1 MPa. GRP carrier pipe and joints shall be protected from the possible adverse physical or chemical effect of grout, and compressible material shall be wrapped around the pipe.

THRUST AND RECEPTION SHAFTS

1

The dimensions of thrust and reception shafts shall be the minimum necessary to construct the Works.

2

Excavations shall comply with the requirements in Part 2 of this Section. Dewatering, if necessary, shall be conducted at a rate which will minimise the inducement of settlements at the ground surface. The shafts shall be kept dry at all times.

3

The thrust wall of the thrust shaft shall be normal to the proposed line of thrust. The thrust wall shall be sufficient to accept repeatedly the maximum permitted thrust force without movement. The Contractor shall not thrust directly from permanent parts of any shaft, or walls of other structures. The thrust wall shall not be joined to the jacking rig base concrete.

4

Shaft base slabs shall be capable of withstanding external uplift pressure from groundwater, if any, in addition to other imposed loads.

5

Any tail tunnel which has been used as a reaction surface shall pass the designated watertightness test at a time not less than 14 days after the load has been removed.

6

The design of the thrust wall and any other associated temporary works shall be such as to prevent damage to any part of the permanent works.

7

Any void between the soil face used to provide a reaction to the thrust force and the thrust wall shall be grouted up.

8

Where the excavation is in water-bearing ground, the Contractor shall provide means of checking whether any solids are being removed with the water from excavation. Regular checks shall be made to compare the volume of solids removed with the calculated volume as a safeguard against excessive loosening or loss of material beyond the shaft dimensions.

9

The Contractor shall select the location of the drive and reception shafts. These locations shall be submitted to the Engineer for approval. These shafts may be incorporated as part of the permanent works. All modifications to the shafts converting them into access manholes shall be completed at the Contractor's own expense. Details of the modifications shall be submitted to the Engineer for approval and shall conform to those shown on the Contract drawings.

10

Prior to commencing work at a shaft, the Contractor shall provide details of the shaft support system, working plant position, spoil facilities, material storage facilities, dewatering arrangements, etc. The details shall include a sketch of all the working facilities at the head of the shaft.

11

Access down into the shaft for personnel and equipment shall be approved by the Engineer. Hand railing set at a height of 1 100 mm above ground level together with toe boards and protective netting to prevent equipment falling into the shaft shall be provided at each shaft. Fencing shall be erected around each shaft site establishment to prevent the entry of unauthorised persons.

12

The dimensions of shafts shall be the minimum necessary to safely construct the Works.

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Backfilling of shafts shall be undertaken in accordance with Section 8 Part 2 Sub-Clause 2.3.3.

9.5

PIPEJACKING

9.5.1

General

1

The maximum lipping between edges of adjacent jacked pipes shall not exceed the maximum tolerance given in Clause 9.2.3 of this Part.

2

The horizontal drive rate shall be maintained equal to the excavation rate throughout the operation.

3

Where dewatering is required it shall incorporate standby facilities and shall have been in operation sufficiently in advance to attain stable groundwater levels before beginning tunnelling. If, during the course of the work, the shaft face becomes unstable through water ingress, it shall be immediately sealed and made safe.

4

Damaged pipes shall be replaced either by pushing through to the end of the line or broken out and replaced by pushing up adjacent pipes.

5

The Contractor shall ensure that oil and lubricant spillage is minimised. Any spillage of oil or lubricant shall be cleared as soon as is practicable and the inside of the pipes shall be cleaned on completion of the pipejacking.

9.5.2

Tunnelling Shields for Pipejacking

1

Where considered necessary, the Contractor shall provide and maintain a shield suitable for excavating in the ground conditions as envisaged by him and in accordance with his chosen method of excavation. In determining the type of shield and method of excavation to be used, the Contractor shall take account of the need to ensure that the face of the excavation is adequately secured at all times such that ground loss is kept to a minimum and is controlled to prevent excessive ground loss. The shield shall be removed on completion of the tunnelling operation.

2

Rotating excavating heads fitted to shields shall be capable of rotating clockwise and counter-clockwise.

3

The shield shall be equipped with steering jacks and such beads, ploughs and copy cutters as may be required for adjusting the alignment of the pipes.

4

Multiple lubricant injection points shall be provided within the shield in order to provide immediate ground support when necessary.

9.6

MICROTUNNELLING

9.6.1

General

1

Micro-tunnelling shall be defined as a method of installing pipe or casing by jacking the pipe or casing behind a remotely controlled, laser guided, steerable, guided tunnel boring machine which fully supports the excavated face with fluid and/or earth pressure balance at all times.

2

Micro-tunnelling pipe is defined as pipe or casing capable of withstanding installation jacking and any other construction loads in addition to permanent live and dead loads.

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3

The method to be employed for micro-tunnelling shall be selected by the Contractor to suit ground conditions and ground water pressure. The Contractor shall submit a detailed method statement which shall be approved by the Engineer prior to commencing microtunnelling.

9.6.2

Contractor Responsibilities

1

The Contractor shall carry out, and be responsible for, the detailed design of: (a)

The micro-tunnel;

(b)

All associated works (including shafts, connections, etc.).

The design shall be prepared by qualified design engineers or other professionals who comply with the criteria stated in the Specifications. The Contractor warrants that he, his designers and design sub-contractors have the experience and capability necessary for the design. The Contractor undertakes to ensure that the designers shall be available to attend discussions with the Engineer at all reasonable times.

3

The Contractor shall satisfy himself that he has sufficient geotechnical details before commencing the detailed design. If available, a copy of existing geotechnical investigation reports shall be provided to the Contractor. These reports are provided for information only and the Contractor is advised to corroborate the details provided and commission any additional site investigation works he deems to be necessary.

4

The Contractor shall be responsible for ensuring that he avails himself of all necessary utilities information, existing and proposed, prior to commencement. Where available, a copy of existing utilities information shall be provided by the Engineer. These reports are provided for information only and the Contractor shall be responsible for ensuring that the information collected is the most recent and factual record of existing and proposed services in the project area. The Contractor shall utilise appropriate equipment and methods to aid him in the determination of the line and level of existing utilities apparatus. This may be undertaken either by the Contractor’s own staff or by specialist sub-contractors.

5

The Contractor shall be responsible for obtaining all approvals/consents required for the disposal of excavated material/spoil that is surplus or unsuitable for incorporation in the permanent works. The Contractor may propose, subject to the approval of the Engineer, remedial measures to be taken for the improvement of earthwork arisings, which are not suitable in the as-dug condition, for use in the permanent works.

6

The Contractor shall allow the Engineer full access to real time micro-tunnelling data any time during construction.

9.6.3

Safety and Environment

1

The Contractor shall carry out all works to the requirements outlined in all current appropriate Regulations, Codes of Practice. The following recognised documents shall form the basis for guidance and development of the safety plan and site procedures:

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(a)

UK Health and Safety at Work Act including the provisions of BS 5228, Parts 1 and 2;

(b)

BS 6164: Safety in Tunnelling (Code of Practice);

(c)

Guide to Best Practice for the Installation of Pipe-jacks and Micro tunnels.

2

The Contractor shall develop a safety plan to encompass all aspects of safety and environmental requirements prior to commencement of the work. This plan shall be a working document and be subject to continuous review throughout the period of the contract.

3

All machinery, including hoists shall be suitable for quiet and efficient operation and shall be installed and maintained to an acceptable safety standard.

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A site safety culture shall be instigated on-site prior to work commencing and be developed throughout the course of construction. The culture will comprise of the use of key management tools by the site management (and outlined in the site safety plan) in educating the site operatives in all aspects of best safety practice and awareness in their work. An induction session shall be given to all operatives and staff irrespective of their discipline and experience. This should, in particular outline all local requirements relating to the contract, actions to be taken in event of emergencies, and an overview of the Site and its personnel. The content of the induction may be varied to suit the recipients. Each operative shall receive training, together with any appropriate examination or documentation, to ensure he is completely aware of the requirements of each aspect of his job and the hazards which are inherent in its execution.

5

The Contractor shall produce a risk/hazard analysis of the key elements of the pipe-jacking operation and utilise the results of the analysis in reducing such risks that remain to a minimum. Such hazards shall be communicated to workers through induction, tool box talks and the like.

6

The Contractor shall develop and implement a plan for immediate underground evacuation in the event that the presence of toxic/inflammable gas is identified in the excavation. In such case the Contractor shall identify and take appropriate action to rectify such hazard prior to allowing work to recommence.

7

Appropriate training and certification shall be given to all operators of plant. This shall be carried out only by engineering staff competent in the use and hazards associated with the particular item of plant concerned.

9.6.4

Performance Requirements

1

The micro-tunnelling system shall be selected by the Contractor to suit local ground and groundwater conditions. The Contractor shall submit a detailed method statement for approval by the Engineer prior to starting micro-tunnelling work.

2

Micro-tunnelling operations shall be carried out in a manner that minimizes ground movement in front of and surrounding the pipeline. Settlement of the ground surface shall be minimized. Damage to structures and utilities above and in the vicinity of the underground operations shall be prevented.

3

The ground shall be continuously supported in a manner that prevents loss of ground and maintains the stability of the tunnel face and perimeter at all times.

4

A full work force shall be maintained on a continuous basis (24 hours per day) during any emergency or work stoppage that could endanger the tunnel excavation, sub-surface infrastructure and surface facilities.

5

Dust, noxious gasses or other atmospheric impurities shall be actively controlled in accordance with the relevant Qatar occupational health and safety legislation. Approved instrumentation for monitoring air quality in work areas and pipelines accessed by personnel shall be provided. This environmental control and associated procedures to be followed in monitoring shall be fully documented in the Contractor’s Safety Plan.

6

All micro-tunnelling and underground construction work shall be performed in accordance with the relevant Qatar occupational health and safety legislation and the approved Contractor’s Safety Plan. This Plan shall include safe procedures to mitigate risks associated with the work, including identification and logging of any and all visitors into and out of the underground works and prevention of unauthorized entry. Safe procedures shall also be established for personnel entering the tunnel to carry out maintenance or for other purposes.

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9.6.5

Micro-tunnel Design Elements

1

Tunnel Pipe Design

Page 15

The watertight lining pipe shall be installed by single pass pipe jacking using a remote controlled tunnelling operation to the alignments and grades shown on the drawings. Remote controlled tunnelling operations apply to trenchless pipe installation by microtunnelling where the carrier pipe is installed directly behind the tunnelling machine and the machine provides support to the excavation face at all times.

(b)

All jacking pipes, including special designs, shall be sufficiently reinforced with steel to withstand all stresses induced by handling, jacking, earth and water pressures and all working loads at the depths at which they are to be used without cracking, spalling or distortion. A load factor of not less than 1.5 shall be used in the calculations to determine the strength of the pipes required. The clear cover to any steel reinforcement shall not be less than nominal 50 mm. The pipes are designed and calculated in according ATV 161 (Technical Standard of pipe jacking).

(c)

The strength of the pipes shall be tested by a three edge bearing test. When subjected to the design load in such a test, the maximum crack developed on the pipe shall not exceed 0.25 mm. If this test not possible an equivalent quality control and security system has to be developed.

(d)

All pipes shall be manufactured by a supplier approved by the Engineer. The process of manufacture may be by centrifugal or vertical casting subject to submission and approval by the Engineer. All pipes shall be cast with a minimum of 3 grout holes equally spaced around the pipe wall. A steel threaded insert (¾ to 1 BSP minimum dimension) shall be cast in each hole. All pipes shall be of spigot and socket design with an integral steel collar cast on the socket or trailing end. The collar shall be suitably and securely fixed to the reinforcing cage of the pipe prior to the pipe being cast. Each pipe shall have a 75 mm dia lifting hole or lifting anchor cast in the top centre to facilitate a lifting device. All pipes shall have their date of manufacture clearly and indelibly marked on them. All pipes shall be fully cured and have reached the designed concrete strength prior to delivery.

(e)

The Contractor shall submit full details of his proposals for the pipes, giving detailed drawings showing sizes, reinforcement and jointing arrangements, all cast in items and concrete design including specifications for all component materials. A full set of design calculations including the parameters adopted for the design shall also be submitted. The name of the manufacturer, place of manufacture and manufacturing process shall be identified at an early stage and provision made for inspection of such facilities by the Engineer for his approval.

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(g)

The jacking equipment including any required intermediate jacking stations shall have a capacity of not less than 20 per cent greater than the calculated theoretical maximum jacking load.

(h)

The design of the tunnel shall take into account the required life span, the proposed use, the ground conditions, the sequence and timing of construction and the local existence of adjacent structures. Relaxation of stresses in front of boring machine and excavation, installation and water-tightness of lining pipe should be considered. The required life span is 100 years. 100-year durability design shall meet the requirements of BS 8110.

(i)

Numerical methods shall be used to evaluate the loading on the lining pipe. Results of the numerical calculations shall be used to assess surface settlements. The Contractor shall specify, justify and explain the model he intends to use. The Contractor shall also submit two licensed English versions of the software including all manuals, to the Engineer.

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(j)

Page 16

The Contractor shall be solely responsible for the accuracy of the numerical model and the assumptions necessary to fully simulate the anticipated ground and the tunnel excavation within it, the installation of any support measures and the construction of the permanent tunnel lining system. The Contractor shall provide in his Design Submission numerical simulations which are applicable to and reflect the work and construction stages proposed by him. State of the art modelling techniques, material properties, simulation procedures and material definition, shall be applied. In addition the Contractor shall at least consider the requirements as outlined below for the modelling process:

Tunnel Access Shaft The positions of the micro-tunnel shafts and tunnel are shown on the Contract Drawings. The Contractor may suggest alternative positions to suit his equipment and works programme. The final depth and position of the shafts and tunnel however shall be subject to the approval of the Engineer.

(b)

The working shaft shall be designed to withstand the force applied by the main jacking station and of adequate dimensions to fully cater for the underground installation of all necessary pipe-jacking equipment. This will include the jacking frame and thrust ring assembly, slurry pumping equipment, electrical isolation box and guidance system. Consideration must also be given to safe access and working space for the pit bottom crew. The design of the shaft base shall incorporate the requirements of a thrust block for the jacking frame to bear upon and a tunnel launching eye and sealing ring through which the TBM is launched. The design of these structures will depend on the type of ground and jacking pressures envisaged. They are normally considered to be temporary structures, being removed on completion of the drive, but consideration may be given to incorporating them in the permanent works wherever possible.

(c)

Requirements for launching the TBM assembly, which may comprise multiple units of varying length, shall also be taken into consideration when deciding upon the overall size of the shaft base.

(d)

Micro-tunnel shafts shall be placed at main road intersections to take drainage from the surrounding areas.

(e)

Micro-tunnel shafts shall be built to Employer’s standards and requirements. The Contractor may propose alternative designs subject to the approval of the Engineer.

(f)

Shaft openings shall be located within the central reservation or footway areas. No openings shall be accepted within the highway carriageway.

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The design of the tunnel shafts shall take due account of the following: (i)

Need to provide a structurally sound and stable reinforced concrete shaft wall and superstructure that shall comply with all relevant BSI standards. Design calculations and materials shall be submitted for approval to the Engineer prior to any construction work being undertaken.

(ii)

All shafts shall be watertight.

(iii)

All shafts for sewerage applications shall be full lined internally with GRP in accordance with Part 4, Clause 4.4.1.

(iv)

All shafts for surface water / ground water applications shall have a combination of GRP lining and epoxy protective coating internally in accordance with Part 4, Clause 4.4.2. .

(v)

Where practical, the underside of the base slab and external faces of the walls shall be protected by a membrane tanking system. Where this is not possible, the Contractor shall propose a protection system for approval by the Engineer.

(vi)

All ladders, platforms and handrails, where shown on the Contract Drawings, shall be to QCS Section 8, Part 6, Clauses 6.4.1 to 6.4.7. Platforms shall be provided at maximum distances of 6 metres and shall be positioned to allow

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maintenance equipment to be lowered unhindered to the base of the shaft. Ladders shall terminate at platforms and be staggered between platforms. (vii)

Down-pipes shall be secured by stainless steel brackets to the inside of walls.

9.6.6

Design Checking

1

All drawings and calculations intended for incorporation into the design package shall be checked by an approved Independent Checker. Evidence of the extent and scope of checking carried out on each set or subset of calculations shall be provided either in the form of parallel calculations or by marking up the calculation sheets or by providing a summary on the cover sheet.

2

All drawings shall be checked with due consideration for the following: completeness;

(b)

compliance with the relevant requirements of the Contract Documents;

(c)

consistency between calculations, schedules, reports, drawings, specifications;

(d)

compliance with standards, codes, regulations and statutory requirements;

(e)

dimensional accuracy and presentation.

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With his approval the Independent Checker confirms that the relevant documents are in compliance with the Employer’s requirements, relevant local and international standards and designed correctly.

9.6.7

Finite Element (FE) and Finite Difference (FD) Models

1

A numerical analysis shall be carried out and fulfil the following geometrical requirements:

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Notwithstanding the requirements as listed below the mesh layout shall be such that numerical accuracy is guaranteed. If required, the Contractor shall perform sensitivity studies with different levels of mesh refinement.

(b)

Width of mesh shall extend at least two tunnel diameters beyond the limits of the tunnel lining.

(c)

The model used for the design at the ground sections of the tunnel shall be capable of considering the joint system and joint properties of the ground strata, by either explicitly modelling joint systems or applying suitable models with equivalent properties.

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Element size around excavation contours shall not be larger than those elements that correspond to an angle of 10 degrees along the arch. Infinite elements shall be used along the border of the mesh or a suitably large mesh shall be proposed so that the influence of boundary of mesh is negligible for FE models: The practical limit of the aspect ratio of zones should be kept to approximately 1:4 or less in order to achieve reasonable solution accuracy. The practical limit for FD models of the aspect ratio of zones should be kept to approximately 1:1 or less in order to achieve reasonable solution accuracy.

3

Each computation shall be accompanied by a report that shall at least include a description and interpretation of: (a)

definition of the mesh;

(b)

selection of design sections;

(c)

definition of geological strata;

(d)

selected input parameters;

(e)

material models used;

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(f)

results including surface settlements and expected deformations in the tunnel;

(g)

dimensioning of the tunnel lining.

Verification of Results

1

Numerical calculations for the design of the lining shall be verified using different analytical methods.

9.6.9

Design Parameters for the Calculations

1

Parameters required for the design and not defined in this document shall be established by the Contractor. All details on these parameters shall be provided by the Contractor in his Design Basis Report subject to the consent of the Engineer.

2

The results of site investigations carried out are to be summarised in the Data Reports and the Contractor shall conduct supplementary site investigations within the project area as designated and/or where considered appropriate. The interpretation of all site investigation data, including the interpretation of the Data Reports and of the bore logs shall be the responsibility of the Contractor. The Contractor shall justify and explain the derivation of all his geotechnical parameters in his geotechnical interpretative report. The geotechnical parameters used for the design require the consent of the Engineer. The worst credible ground parameters as identified in the site investigation data shall be used to check the micro-tunnel lining (at the ultimate limit state).

9.6.10

Design Loadings

1

The Contractor shall include for the following loads in his calculation of the stresses and strains induced in the installed pipeline:

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9.6.8

Ground/Rock Loads;

(b)

Water Loads: Groundwater levels with sufficient safety margins for the design shall be determined from groundwater observations. The design calculations shall be carried out both for an upper bound and a lower bound of the ground water level subject to the consent of the Engineer;

(c)

Live Loads: For underground structures under a roadway, a live load as defined in BS 5400, Part 2 for highway bridges considering type HA loading combined with 45 units HB loading shall be allowed for in the design; Surcharge Loads: For all underground structures and in locations where live loads as specified above do not apply, a surcharge load of 22.5 kN/m² applied at ground level shall be allowed for in the design;

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(e)

All other loads.

2

The Contractor shall take into account any other loading criteria which may be applicable to achieve the full performance of the micro-tunnel, including water pressures under operational conditions within the lined tunnel.

3

In addition to the design sections as defined above the Contractor shall carry out case studies of all relevant and possible combinations of geological, hydrogeological and geometrical conditions as necessary for his design and construction. The Contractor shall also provide calculations in accordance with the soil /rock classification proposed by the Contractor and based on the Contractor’s geotechnical interpretation. The Contractor’s calculations shall cover all possible geotechnical conditions anticipated over the entire tunnel length. Notwithstanding the calculations as requested above, the Contractor shall consider within his design submissions one numerical simulation of the tunnel construction of at least every 400 m of the bored tunnel section. Within the Preliminary Design Submission the Contractor shall propose these calculation sections which shall be subject to the consent of the Engineer.

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9.6.11

Design Submissions

1

The Contractor shall submit his proposed detailed design report to the Engineer for approval, not less than four weeks prior to his intended construction start date for this element of work, or as specified by the Engineer. The submission should include, but not be limited to, the following : Summary of all subjects addressed in the design stages;

(b)

Summary of the design criteria adopted in the design stages;

(c)

Final hydraulic model for overall drainage system including all input and output data;

(d)

Final hydraulic design and calculations for overall drainage system including connections;

(e)

Final hydraulic design and calculations for the temporary pumping station if required.

4 no. complete sets of detail drawings-paper prints (A1) to include:

The modified positive surface water drainage system and micro-tunnel plans at 1:1000 scale based on survey sheets and incorporating coordinate grid, proposed sewers connections, access and maintenance shafts, invert, cover and ground levels. Key plan of the proposed system plans including coordinate grid, contract area, sewer connections, main building and road/street names, and layout plan of the temporary pumping station sites at 1:100 or 1:50 scale if required.

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For the purpose of obtaining all necessary approvals on completion of the detail design stage, the Contractor shall submit to the Engineer the following:

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Sections of micro-tunnel and the modified positive surface water drainage system at 1:1000 horizontal and 1:100 vertical scales. Sections are to be related to each the system plan and include chainages, access and maintenance shafts number, invert, cover and ground level, tunnel diameter, gradient, terrain crossed, major service crossings and any connecting branch sewer details.

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Standard drawings for the modified positive surface water drainage system, microtunnel cross section, access and maintenance shafts and miscellaneous details to appropriate scales based on Employer’s standards. 4 no. complete sets of the detailed construction specification; 4 no. Bills of Quantities, containing the principal items;

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(d)

The submittal of the detail design for approval shall also be accompanied by 4 copies of a comprehensive “Engineering Report” including the design calculations, which will detail revisions and amendments to the design subsequent to the approvals given for design. The report shall include copies of the comments made on the design and corresponding actions taken;

(e)

Drawings, designs, documents and reports submitted for approval will not be accepted if there is no evidence of internal, qualified, checking; or if the quality of the contents of the Drawings and documents clearly indicate that they have not been checked thoroughly;

(f)

Partial submittals will not be accepted.

If significant changes are required to the above original document submissions, the Contractor shall re-submit to the Engineer.

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Certification Procedure

1

The entire design of the Bored and any Cut and Cover Tunnels (layout design, structural design and geotechnical design) shall be checked by the Accredited Checker. On completion of the design and check the respective certificates shall be submitted to the Engineer in accordance with the UK DMRB BD 2/02.

2

The Contractor shall provide a certificate of assurance from a reputable TBM manufacturer or refurbisher to warranty that the proposed TBM is fit for purpose to carry out the intended works.

3

At least four weeks before the commencement of any tunnel excavation works, the Contractor shall submit to the Engineer test certificates concerning all material properties and characteristics as defined in the relevant sections herein and/or used for tunnel design purposes from an independent and acknowledged source.

9.6.13

Contractor’s Documents

1

The Contractor’s Documents shall comprise, but not be limited to the following:

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Safety Procedure Manual (Project Specific Safety Plan);

(b)

Risk mitigation plan;

(c)

Contingency plan;

(d)

Pre-construction inspection reports of adjacent properties and utilities;

(e)

List of drilling team (Names, qualifications, experience, training, etc.) and management control.

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Full details of the micro-tunnelling system shall be supplied with the above submittals, including: Type(s), number(s) and model reference of proposed micro-tunnelling system. If not from single source, detail main elements of the system.

(b)

Written confirmation from manufacturer (with company seal) that the machine configuration is suitable for the external diameter of pipe proposed.

(c)

Cutter face details, including tooling and face port opening dimensions.

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System of alignment control and steering control and activation. Full details and justification for excavation and spoil disposal method(s).

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(f)

Hydraulic jacking system maximum capacity and method of limiting to maximum jacking pipe capacity.

(g)

Details of any intermediate jacking stations.

(h)

Electrical system and on-site power supply.

(i)

Proposed communication system between the MTBM (Micro-Tunnel Boring Machine) and operating personnel on the surface.

Full and comprehensive details of the procedures and resources that will be used to perform the work shall be provided, including; (a)

Machine launch and reception;

(b)

Pipe handling and connections;

(c)

Supplementary alignment surveying;

(d)

Excavation and spoil disposal;

(e)

Closure of any intermediate jacking stations;

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(f)

Emergency procedures;

(g)

Ventilation of tunnel, including gas monitoring.

(h)

All materials, including slurry, lubricants;

(i)

Location of approved spoil disposal facility;

(j)

Drawings showing layout, temporary equipment locations and complete jacking set-up in typical jacking shaft.

Daily logs shall be used to record the micro-tunnelling work and any associated delays. The log shall be submitted to the Engineer for record purposes on a weekly basis. The basis of the log shall be the electronic data recorder that operates with the micro-tunnelling system. The log shall include: MTBM alignment deviation data and applied jacking load shall be recorded at intervals;

(b)

Alignment deviation shall not exceed 0.3 m in 5 minutes;

(c)

The commencement and completion of jacking of each pipe section;

(d)

The operating pressure if pressure balanced system is used;

(e)

Quantities of lubricant injected;

(f)

Air quality monitoring results;

(g)

Unusual events.

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Construction Responsibilities

1

During construction, the Contractor shall be responsible for:

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9.6.14

Providing a temporary and secured drainage system for the Works (N.B. restricted access, safe and dry working environment, etc.);

(b)

Taking all necessary precautions to protect the tunnel and/or adjacent properties from flooding (e.g. groundwater may be problematic in the area);

(c)

Provision of a temporary wall, if required, to enable the executed tunnel section to serve as temporary storage.

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The Contractor shall provide temporary pumping facilities to the extent required to avoid delays to the construction programme and quality of the work. The Contractor shall also indicate any EFA sites (Emergency Flood Area) if required for flood alleviation works during the construction works and confirm the availability of the land. The Contractor shall be responsible for the fencing, safety and security of any temporary EFA areas. Any fuel and/or power sources shall be provided as appropriate. All facilities/connections in this respect shall comply with standard regulations regarding their storage and/or use.

3

The Contractor however shall be responsible at his cost for providing temporary submersible pumps to evacuate any flooded tunnel sections and discharge to an acceptable outfall point.

9.6.15

Quality Assurance/Control

1

All pipes delivered to site shall be the subject of inspection and approval by the Engineer before they can be incorporated in the Works. Any and all rejected pipes shall be immediately removed from site and replaced with pipes acceptable to the Engineer. Pipes and pipe gaskets shall be stored or stacked on-site in accordance with the manufacturer’s recommendations.

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Every jacking shift shall be supervised by at least one person with previous experience of micro-tunnelling work. Operators of the micro-tunnelling system shall have prior knowledge and ability in its proper operation and shall run test the system after set-up and before starting the drive. The Contractor shall follow manufacturers’ instructions when operating the complete system and operational manuals shall be available to site operational personnel at all times.

3

The installed pipeline shall be subject to visual inspection. Visible leaks (flowing or dripping water) in pipes, pipe joints, manholes and structures shall be repaired even if leakage test requirements are satisfied.

9.6.16

Materials

1

Pipe repair materials shall be supplied by the pipe manufacturer as suitable for the intended purpose and applied strictly in accordance with the pipe manufacturer’s instructions. Water used for lubricant or grout shall be of neutral pH and shall be clean, fresh and free from oil, organic or other deleterious matter. Polymers shall be non-toxic and grout for filling voids outside the installed micro-tunnel pipeline shall be designed by the Contractor and submitted for approval. The pipe material shall be reinforced concrete (RC) or GRP subject to the approval of the Engineer.

2

The Contractor shall also submit a sample of the pipe wall section, joint band and gasket seal. This wall section shall be completely fitted with the proposed grout bush and flush fitting plug to be watertight.

3

The Contractor shall obtain the pipe manufacturer’s warranty that the pipe conforms to the specifications and shall be free from defects in materials and workmanship.

9.6.17

Temporary Works

1

The Contractor shall develop his temporary works design taking into account all site constraints identified elsewhere in the Contract Documents. The Contractor shall provide clear method statements detailing all stages of the temporary works including supporting calculations for the temporary works. These method statements shall be issued to the Engineer before works can commence. Calculations shall be included where relevant, e.g. as part of settlement checks on adjacent structures. A “Detailed Safety Plan” identifying hazards and mitigating measures shall also be included in the Temporary Works Method Statements.

9.6.18

Construction Preparation

1

The Contractor shall be responsible for:

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(a)

the means and methods of micro-tunnelling and pipe jacking operations and shall be solely responsible for and shall ensure the safety of the work, his site personnel, the public and adjacent property (public and private);

(b)

maintenance of clean working conditions at all locations at all times;

(c)

control and implementation of safety precautions for personnel entering pipeline;

(d)

organizing equipment in all areas to ensure safe operation at all times;

(e)

providing safeguards to prevent leakage of fuel or lubrication oils from micro-tunnelling system equipment. Hydraulic oils used by the Contractor’s plant shall be biodegradable and non-flammable.

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Pipeline Installation

1

The pipeline shall be placed within 50 mm of the vertical and 200 mm of the horizontal alignment shown on the Drawings. Steering corrections shall be made to the pipeline so that the joint to joint angle of any two adjacent pipes does not exceed 0.5 degrees. The Contractor shall submit daily records of deviations.

2

Each section of pipe shall be jacked forward as the excavation progresses in such a manner that complete and adequate ground support is provided at all times and such that joints maintain their integrity and the pipe train continuity is maintained.

3

The Contractor shall ensure that jacking loads do not exceed the manufacturer’s safe jacking capacity by effective management of the pipe jacking alignment and pipe lubrication controls (intermediate jacking stations).

4

No damaged pipes shall be permitted to be used in the permanent works. Pipes damaged in the casting and handling process in the factory shall not be permitted on-site. Repairs to cast pipes, either in the factory or on-site shall be confined to minor cosmetic repairs only. All repairs shall be subject to the approval of the Engineer and carried out to an approved procedure. Any pipes identified as being unfit for use in the tunnel shall either be removed from site and destroyed or clearly marked and quarantined for later inspection and possible repair.

5

A proprietary seal of rubber or EPDM shall be incorporated in each pipe joint, including joints between pipes and inter-jacks / TBM. The design of the seal shall be commensurate with the detailing of the pipe joint. Seals may be fitted either at the place of manufacture or on-site prior to placing of the pipe below ground. In either case the seals shall be fitted in accordance with the manufacturer’s instructions. Seals shall be inspected for damage by the surface crew immediately prior to pipe use and any damaged seals replaced. Pipe seals shall be suitably lubricated with a soap solution or other such compound in the pit bottom immediately prior to closing the joint with the jacking frame.

6

A minimum of 30 mm thick Medium Density Fibreboard (MDF) packer shall be fitted to the socket face of each pipe prior to the pipe being used in the tunnel. The packer, comprising several segments to form the 360% annulus, shall be firmly glued to the socket end and in such manner as to be 25 mm inset from the intrados of the pipe. These packers may be fitted on either at the factory or on-site, however it should be noted that in wet weather conditions suitable protection may be required in cases of lengthy exposures.

7

Pipes shall only be lifted on-site using the cast in lifting hole or lifting anchor and a purpose made lifting device. Such device shall be fully tested and carry relevant certification. Pipes shall be stored in an orderly fashion in a designated area, not more than two pipes high and on purpose made timber supports.

8

Pipes shall be power lowered by crane or gantry down the working shaft and set on a purpose made cradle comprising the base of the jacking frame assembly. The cradle shall have been set true to line and level prior to commencement of the jacking and secured to the shaft bottom. The thrust wall assembly behind the jacking frame shall also be set at right angles to the line of drive to ensure that no misalignment occurs at the pipe joint on closure. The lifting device shall be removed from the pipe prior to the joint being closed and jacking of the pipeline recommenced. The lifting hole shall be sealed with a precast concrete plug and rapid setting mortar prior to the hole location passing through the eye seal. Jacking of the pipeline shall be carried out in such manner as to limit any deflection at a joint to the manufacturer's recommended maximum. Pipe loadings shall normally be limited to 50% of the design load (or similar as agreed) whereupon an inter-jack assembly shall be installed.

9

On completion of a drive the line shall be fully inspected for damage or leaking joints. The Contractor shall propose remedial works in such cases. Holes used for injection of lubricants shall be filled with an approved mortar to a smooth finish at the intrados of the pipe.

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9.6.19

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Construction Execution

1

All excavation works shall be properly set out to the line, level, curve or slope required within accepted tolerances. Survey stations, centre lines, bench marks and grade lines shall be clearly marked in paint on the tunnel walls. Chainages at 10 metre intervals shall also be clearly marked by appropriate permanent means.

2

Internal tunnel marking shall be done prior to jacking any “lining” pipes. This method can be used to mark the exact location of any problem areas during the jacking operation.

3

The Contractor shall establish and maintain reference control lines and grades for the Works, which shall be used to exactly locate the pipeline and structures. The primary control for the micro-tunnelling system shall be checked at least once per week or not more than 60 metre intervals of constructed pipeline.

9.6.21

Working in Compressed Air

1

Provisions shall be made on the tunnelling machine to facilitate entry into the face of the machine under compressed air for inspections and maintenance. These provisions shall comply in all respects with all relevant statutory regulations governing work in compressed air. The airlocks and other equipment fitted to the machine shall comply with the requirements of CENprEN12110.

2

All equipment and personnel necessary to perform such interventions for inspection or maintenance shall be available throughout the pipe-jacking operations.

3

The Contractor shall submit details of the compressed air installation for the Engineer’s approval, along with details of the qualification and previous experience of lock attendants, medical lock attendants, compressor attendants and supervisory staff.

4

In highly permeable ground where air losses might be excessive, arrangements shall be made to inject thick bentonite slurry into the face prior to an intervention to form a cake on the exposed face in order to limit air loss.

5

Air compressors shall have a standby capacity of at least 50% and be powered by an independent power source.

6

All essential parts of the compressed air system, including pipelines carrying compressed air to the face, shall be duplicated. All pipework, valves, gauges, etc. must be protected from impact damage. Where flexible hoses are used to carry the compressed air through the pit bottom jacking arrangement they shall also be protected from entrapment. In the event of failure of one part of the system it should be possible to isolate that part without interrupting the air supply.

7

A safety valve shall be fitted to free air side of the pressure bulkhead of the tunnelling machine. This safety valve shall be set to relieve at marginally above the working pressure and shall be of adequate size to match the installed capacity of the air compressors. Prior to any work in compressed air the system should be tested to working pressure.

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9.6.20

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Any airlock fitted to the tunnelling machine shall be at least 1.5 meters diameter. The air lock should be designed as a pressure vessel, subjected to a hydraulic test and issued with an appropriate test certificate. Air lock doors should be at least 500 millimetres by 400 millimetres. Doors should normally be kept closed by the air pressure but the door opening to the front of the tunnelling machine should also be able to be locked shut whilst persons are being decompressed in the lock. The airlock should be comprised of two chambers to allow access into the working chamber in case of emergency. For use at pressures above one bar the lock should be fitted with seating for the persons being decompressed. Where the working pressure is above 0.7 bar a medical lock shall be provided which shall be manned by a medical lock attendant whenever work in compressed air is in progress and for twenty four hours afterwards. If necessary the quality of the compressed air supplied to the working chamber shall be improved by coolers and filters to ensure compliance with the specified requirements. The supply of compressed air to the working chamber shall be sufficient to ensure that the level of any contaminant shall not exceed 10% of the short term exposure level when measured at atmospheric pressure. Air quality should be monitored at least once per day.

9

The Contractor shall appoint a registered medical practitioner experienced in compressed air work to advise on decompression methods to be adopted and on all other aspects of health relating to the work in compressed air. All employees will be medically examined prior to working in compressed air. Records will kept of all medical examinations and details of each compressed air exposure including working pressure, working time, decompression procedures, etc. No person shall be allowed to work in compressed air if the Contractor has reason to suspect that person is under the influence of drink or drugs such that his capacity is impaired. No one shall be allowed to enter the compressed air working chamber alone.

10

An experienced lock attendant shall be on duty at the free air side of the air lock at all times when there are persons in the compressed air working chamber. All valves gauges and controls at the lock attendant’s station shall be clearly marked with their function and method of operation.

11

Smoking shall be banned in compressed air and no person shall take smoking materials into compressed air. As far as is practicable no combustible material shall be taken into the air locks and or the working chamber. The use of burning or welding equipment should be strictly limited and shall be subject to a permit to work system. Fire extinguishers shall be provided in the air locks and the working chamber whenever work in compressed air is in progress.

9.6.22

Ground Pre-treatment

1

Pre-treatment of the ground, where applicable, shall be applied in advance of the tunnel excavation to provide sufficient stability of the excavated area. Execution of such works shall not commence before consent has been given to the design of such works by the Engineer. The surface settlement monitoring shall be installed, initialised and baselined prior to any ground modification work.

9.6.23

Drainage During Construction

1

The Contractor shall supply, install, operate and maintain sufficient pumps and pipe work to control and remove water from any part of the underground works. Standing water shall not be allowed. The capacity of pumps installed where required, including at launch/reception pits, shall always be at least twice the normal volume of the inflow of water plus the volume of flushing water if drilling equipment is used. The minimum capacity of the pumps shall be 20 l/s.

2

The Contractor shall store or immediately have available standby pumps in good working conditions of the same capacity. This equipment shall be maintained properly and tested frequently.

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The Contractor shall provide settlement tanks or other decontamination facilities before the water is discharged. The Contractor shall submit his design for these facilities as part of his method statement. The Contractor shall remove all accumulated slurry, silt or other debris from the Works on an ongoing basis.

9.6.24

Disposal of Tunnel Seepage and Waste Water

1

Tunnel seepage and wastewater arising from the Works shall be collected and discharged via a settlement tank. Seepage and wastewater shall not be discharged into the public drainage system unless it meets the standards listed below. Where necessary, the water shall be treated to achieve these standards.

2

The Contractor shall comply with BS 6031:1981 Code of Practice for Earthworks or equivalent, regarding the general control of site drainage and the requirements of the Relevant Authority. The Contractor shall ensure that water which may have come into contact with contaminated material shall be disposed of in an appropriate manner. The Contractor shall have to apply for consents and approvals as follows:

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obtain and complete standard “permit application form” for proposed discharge into a PWA system.

(b)

before any discharges can be permitted into a PWA pipeline, written approval shall be obtained from the relevant department of the PWA. Failure to obtain the permit can result in immediate closure of the Works.

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The Contractor shall make provisions that all hazardous substances including oil drums or containers on-site are controlled in accordance with the relevant legislation and are properly stored so that no oil or their contaminants are allowed to reach watercourses or groundwater.

9.6.25

Testing

1

The Contractor shall provide all apparatus, assistance, documents and other information, electricity, equipment, fuel, consumable, instruments, labour, materials, and suitably qualified and experienced staff, as are necessary to carry out the specified tests efficiently. The Contractor shall agree, with the Engineer, the time and place for the specified testing of any plant, materials and other parts of the Works.

2

The Engineer may vary the locations of details of specified tests, or instruct the Contractor to carry out additional tests. If these varied or additional tests show that the tested Materials or workmanship is not in accordance with the Contract, the cost of carrying out this Variation shall be borne by the Contractor, notwithstanding other provisions of the Contract.

3

The Contractor shall promptly forward to the Engineer duly certified reports of the tests. When the specified tests have been passed, the Engineer shall endorse the Contractor’s test certificate, or issue a certificate to him to that effect.

9.6.26

Grouting

1

As soon as each section of pipeline has been installed, its periphery shall be grouted using a cement based grout with a minimum 48 hour compressive strength of 345 kPa (50psi) and minimum 28 days compressive strength of 1380 kPa (200psi). Every effort shall be made by the Contractor to place the grout even when it is known that the periphery contains polymer or other lubricant and shall demonstrate that grout is not being taken before the grouting operation is terminated.

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The grouting pressure shall be sufficient to move the grout to fill the annulus along the pipe but shall not be greater at the injection nozzle than the pressure limit set by the pipe manufacturer. The injection points shall be placed at not more than 6 metre intervals along the pipeline. Grouting shall be carried out around pipelines at launch and reception shafts as soon as the pipeline is placed at these locations to prevent water and soil from entering the shafts. Additional grouting shall be carried out at the Contractor’s expense, if required to ensure that the joints are watertight.

3

The micro-tunnel shall be adequately lit and ventilated for safe access, egress and for working. If open flames are to be used where combustible gasses may enter the air, tests for combustible gas shall be conducted continuously during the work. The tunnel workers shall carry a gas meter that automatically records the level of combustible gas. Particular care shall be taken that pipe repairs are carried out in accordance with approved ventilation and safety procedures.

4

Infiltration Acceptance Test of the installed pipe, which shall be witnessed by the Engineer, shall be in accordance with ASTM C969. The internal inspection of the completed pipeline shall be the subject of approval by the Engineer.

9.6.27

Surface and Building Settlement Monitoring

1

The Contractor shall submit, for the consent of the Engineer, the detailed proposal for positioning of ground and building monitoring points and other instruments and the frequency of the measurements. Excavation works shall not start until the consent of the Engineer to that submission has been obtained. During construction the Contractor shall review monitoring frequencies depending on settlement trends, the extent of construction activity in an area and the behaviour of the structures.

2

The monitoring data shall be copied to the Engineer on the same day that the readings are taken, followed by hard copies with analysis within 24 hours. In addition to carrying out all the normal surveying requirements for carrying out a pipe-jack the Contractor shall set-up surface settlement monitoring points at suitable intervals along the projected pipeline. The spacing of such points may be as close as 10 metres in sensitive areas however may vary according to the depth and location of the jack.

3

In addition to monitoring over the centre line of the drive readings shall be taken at suitable lateral distances to the centreline at each monitoring chainage. In roads these cross sections shall extend the full width of the road corridor.

4

Settlement monitoring points shall also be installed at the corner of each building or structure within a recognised distance from the tunnel centreline. The distance shall normally be equivalent to the depth to invert of the proposed pipeline with a minimum of 20 metres.

5

A full record of existing ground and structure levels shall be taken and agreed prior to commencement of pipe-jacking operations.

6

A photographic record of existing damage and faults to all adjacent surface structures shall be made by the Contractor and agreed prior to commencement of pipe-jacking operations.

7

During the jacking operation between any two shafts the Contractor shall survey the levels of the appropriate monitoring points on a daily basis.

8

Monitoring shall be carried out on any particular section of points when the tunnel face is within 20-50 metres of that section dependent on the tunnel depth and ground conditions. Monitoring shall continue at each section until the tunnel drive has been completed or in the case of excessive settlement until the settlement has ceased or the rate of settlement becomes acceptable.

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9

If during jacking operations the actual movement of the ground reaches 90% of the predicted value the Contractor shall immediately review his predictions and if appropriate revise his operational procedures accordingly. Where such movement occurs suddenly and adjacent to the tunnel face the Contractor shall not proceed with the jacking operation until a revised method has been agreed with the Engineer.

9.6.28

Contractor’s Obligations

1

The Contractor shall carry out the Tests on Completion in accordance with this Clause after providing the “As-Built” documents for the part to be tested.

2

Unless otherwise stated in the Particular Conditions, the Tests on Completion shall be carried out in the following sequence: Pre-commissioning tests per stage, which shall include the appropriate inspections and pressure tests to demonstrate that each item of the stage is acceptable and that the Works can safely proceed to the next stage

(b)

Commissioning tests, which shall include the specified operational tests to demonstrate that the Works or Section can be operated safely and as specified, under all available operating conditions.

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(a)

For all tests described in sub-paragraph (a) and (b) the pipe and joints shall be considered watertight if water infiltration is so low that it can only be detected as damp patches without flowing or dripping water. Likewise, the tests described in sub-paragraph (a) and (b) shall be used to confirm that the pipeline remains equally watertight throughout the leak testing.

4

As soon as the Works, or a Section, have passed each of the Tests on Completion described in sub-paragraph (a) and/or (b), the Contractor shall submit a certified report of the results of these tests to the Engineer.

9.6.29

Microtunnelling Machine

1

A remote control tunnelling machine shall be used and it shall include a closed circuit television (CCTV) camera which transmits a picture of the laser beam on the target together with other machine information (such as jacking force, face pressure, length, roll, pitch, steering attitude, temperature valves open or closed) to a microprocessor console on the surface from where the system is operated.

2

The tunnelling machine shall be steerable, incorporating hydraulic rams to move the articulated cutting head. The line and level control shall be achieved by a laser beam transmitted from the jacking shaft to a target mounted in the tunnelling machine

3

The design of the tunnelling machine shall ensure no rotation or rolling during installation.

4

The tunnelling machine shall be capable of operating under groundwater conditions where encountered. The hydrostatic balance shall be not less than 3 m head of water.

9.7

THRUST SYSTEM

1

The thrust system shall distribute the force to the pipes through a thrust ring and packing. The jacks shall be capable of applying the thrust symmetrically to the thrust ring. Intermediate jacking stations may be used at the discretion of the Contractor where frictional resistance or obstructions result in unacceptable thrust forces.

2

A purpose made compressible packer of hard board or other approved material shall be included between the thrusting surfaces. Pushing blocks shall not be in direct contact with the pipe or preformed unit, which shall be protected by means of a steel ring, template or other approved method. Damaged pushing blocks shall not be used.

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Spacer blocks, if used, shall be true and free of distortion.

4

Thrust rings shall be free from distortions and sufficiently stiff so as to transfer the load from the jacks uniformly to the packing.

5

Except at the shield, each group of jacks shall be interconnected hydraulically to ensure that the load is evenly distributed to the thrust ring. Each jack shall incorporate a load cell.

6

At the rig and at intermediate station, automatic thrust recording equipment monitoring load cells incorporated in each jack shall be provided together with a pressure metering device. Other continuous records, including cutter torque, rate of progress, slurry pressure, slurry flow, pitch, roll, and earth face pressure shall be provided. Copies of these records shall be submitted daily to the Engineer.

7

The thrusting force shall not exceed the maximum permissible force stated in the method statement. Thrust pressure shall be monitored and controlled to ensure that the pipe joint deflection does not exceed the maximum permitted angular deflection of 1 .

9.8

LUBRICATION HOLES

1

Lubrication holes shall be threaded to enable plugs to be screwed into the socket and to withstand external pressure. A non-return valve shall be fitted where opening a lubrication hole would permit ground loss. Upon completion of grouting, the plugs shall be covered with material similar to that of the pipes. The pressure of the lubricant shall be maintained until it is replaced by grout.

9.9

RECORDS

1

The Contractor shall maintain and submit to the Engineer after each day a log which records the following information: location of drive, between manholes

(b)

strata encountered

(c)

position and orientation of the pipes

(d)

thrusting pressure used on both main and interjack rams during driving of each pipe

(e)

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line and levels of pipeline constructed including details of angular deflection at joints roll of pipejacking shield

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(f)

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(g)

average length of pipeline constructed per shift

(h)

thrust from ground on face of machine

(i)

readings of oxygen, methane and hydrogen sulphide gas at the excavating face

(j)

volume of excavated materials removed

(k)

volume of grout used, the points of injection and pressure at the points of injection

(l)

Contractor’s operating personnel.

9.10

TESTING

9.10.1

General

1

Upon completion of the permanent construction of the pipeline, it shall be tested for watertightness, alignment, condition and soundness, and all other designated requirements.

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2

In the event of the Works failing a test, the Contractor shall take such remedial action as is necessary, subject to the Engineer’s approval of the methods proposed. The Works shall then be retested until such time as the Works pass the test.

9.10.2

Watertightness

1

Leakage tests shall be carried out in accordance with Clause 4.5.4 of this Section.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 01: General

Page 1

GENERAL ...................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.12 1.2.13 1.2.14 1.2.15 1.2.16 1.2.17 1.2.18

Scope Related Works References Submittals Quality Standards Manufacturer‟s Experience Factory Inspection Factory Tests and Test Certificates Shipment, Storage and Handling Adaptation of Equipment Guarantee Job Conditions Approved Manufacturers and Subcontractors Hydraulic Sump Model Testing Sewage Characteristics Materials Workmanship Tropicalisation De-rating Due to Climate Conditions Steel Equipment Bases and Bedplates Anchors and Sleeves Safety Guards Drive Units Bearings Lubrication Electric Motors Pressure Gauges Nameplates and Data Plates Painting and Protective Coatings Noise Levels and Vibration Metal Plating MV Factory Built Assemblies (FBA‟s)

1.1

INSTALLATION AND COMMISSIONING .................................................... 20

1.2.19 1.2.20 1.2.21 1.2.22 1.2.23 1.2.24 1.2.25 1.2.26 1.2.27

Co-ordination Inspection During Installation Preparation of Installation Areas Manufacturers‟ Installation Supervision Installation Testing and Commissioning Instruction and Training of the Employer‟s Personnel In-Service Checks Specialised Training Programme for Employer‟s Personnel

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2 2 2 3 10 11 11 11 11 12 12 12 12 13 13 14 15 15 15 15 16 16 16 16 17 17 18 18 18 19 19 19 20 20 20 20 20 21 21 23 23 24

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GENERAL

1.1

GENERAL MECHANICAL AND ELECTRICAL REQUIREMENTS

1.1.1

Scope

1

This Part specifies the General Mechanical and Electrical Equipment Requirements, which apply to all mechanical, and electrical systems and equipment and are a part of each and all of the separate Sections of the Specification. The Contractor shall direct the attention of all manufacturers and suppliers of mechanical and electrical equipment and related appurtenances for the works to the provisions in the Contract Documents and this Section and also to the extreme climatic conditions.

1.1.2

Related Works

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General Sewerage Instrumentation, Control and Automation Structural Metal work Metal work Electrical Works

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Section 1, Section 8, Section 10, Section 16 Section 17 Section 21,

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1

References

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BS 88,.........................Cartridge fuses for voltages up to and including 1000 Va.c. and 1500 Vd.c

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BS 89,.........................(IEC 51) Direct acting indicating analogue electrical measuring instruments and their accessories BS 142,.......................Electrical protection relays

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BS 159,.......................High voltage busbars and connections

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BS 162,.......................Electrical power switchgear and associated apparatus BS 381C, ....................Colours for identification, coding and special purposes

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BS 449,.......................The use of structural steel in building BS 729, ......................(ISO 1459,1460,1461) Hot dip galvanised coatings BS 970, ......................(ISO 683) Wrought steels for mechanical and allied engineering purposes BS EN 1561, .............(ISO 185) Flake graphite cast iron BS 1780,.....................Bourdon tube pressure and vacuum gauges BS 2048,.....................Dimensions of fractional horse power motors BS EN 1563, .............(ISO 1083) Spheroidal graphite or nodular graphite cast iron BS 3100,.....................Steel castings for general engineering purposes BS 3643,.....................

ISO metric screw threads. Principles and basic data

BS 3790, ....................(ISO 155, 254, 1813, 4183, 4184, 5292) Endless wedge belt drives and endless V-belt drives

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Page 3

BS 4142, ....................(ISO 1996/2/3) Method of rating industrial noise affecting mixed residential and industrial areas BS 4196, ....................(ISO 3740-3745) Sound power levels of noise sources BS 4794, ....................Pt. 2 (IEC 337-2), Control switches BS 4800, ....................Paint colours for building purposes BS 4884,.....................Technical manuals BS 4921,.....................Sheradised coatings on iron and steel BS 4999,.....................

General requirements for rotating machines

BS 5000,.....................Rotating electrical machines of particular types or for particular applications

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BS 5304,.....................Code of practice for the safety of machinery

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BS 5685,.....................(IEC 521), Electricity meters BS 5950,.....................Structural use of steel work in building BS 6231,.....................PVC insulated cables for switchgear

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BS 7626,.....................(IEC 185), Current transformers

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BS 7671,.....................Requirements for electrical installations

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BS 8233,.....................Sound insulation and noise reduction for buildings BS EN ISO 9000, ......Quality management and quality assurance standards

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BS EN 60439, ............Low voltage switchgear and control gear assemblies

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BS EN 60947, ............Low voltage switchgear and control gear BS EN 10084, ............Case hardening steels. Technical delivery conditions

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BS ISO 10816, Part 1,

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Part 3 and Part 7, ......Mechanical vibration in rotating and reciprocating machinery.

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AWS D1.1, ................Steel structure welding code

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List of „Approved Suppliers‟ prepared by the Public Works Authority 1.1.4

Submittals

1

General (a)

in addition to the requirements of Sections 1, 8, 10 and 21 the Contractor shall submit the following information as described in the below paragraphs

(b)

the Contractor shall note that submittals will not be approved unless submitted in order. All submittals shall be clearly marked with the name of the manufacturers, subcontractors and Contractor‟s contract number such that they can be clearly identified and are unique to the Contract

(c)

all drawings shall be on ISO standard sized paper A1 unless specified otherwise. Each drawing shall be marked with the Contractor‟s and manufacturers names and references, project title drawing number, drawing title, scale, the date of completion and a full description and date of all amendments. A clear space 100m x 160 mm shall be left at the bottom right hand corner of each drawing for the Engineer‟s approval and disclaim stamps

QCS 2014

(d)

Page 4

any work commenced or materials ordered before receipt of the Engineer‟s approval shall be entirely at the Contractor‟s risk. Modifications required to comply with approved submittals shall be at the Contractor‟s expense.

Submittal Schedule general. The Contractor shall submit a programme for all the submittals, with dates, for the Engineer‟s approval. Adequate time shall be left in this programme for approval

(b)

submittal times. Table 1.1 shows a Table of times for submittals and approvals. These times may be varied in the Project Specification depending on the scope and complexity of the Works. The Contractor should also note that the times for approval are dependent on the above, and drawings being submitted in an orderly fashion. Submittals of many drawings and information at any one time will delay the approval process. If the Engineer has to extend the approval time he will notify the Contractor within 7 calendar days of receipt of the submittal of the date on which he will grant approval or otherwise.

(c)

copies: numbers of submittals are as required in Table 1.1 below. In addition to the requirements of Table 1.1 the Contractor shall submit all record drawings, photographic records, test records and operation and maintenance manuals in electronic format on the latest form of digital record such as a CD.

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(a)

Programme

(4)

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(4)

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Manufacturing programme (4) Shipping and delivery schedules (4) Materials and product data (4) Fabrication and assembly drawings (4)

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Material and products data

Shop drawings

Records

Testing and commissioning

Time to be submitted (calendar days)

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Submittal stage

Submittal type Number of copies in brackets

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Table 1.1 Submittals and Approvals

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Working drawings (4) Co-ordination drawings (4) Record drawings (4) Photographic records (3) Plan and procedures (4) Test records (4)

Time for comments/approva l (calendar days)

14 days after Contract start 60 days after Contract start 30 days before start of manufacture

21 days

30 days before shipping

21 days

60 days after Contract start

21 days

90 days after Contract start

21 days

30 days after approval of materials and product submittals 30 days after approval of working drawings 14 days after notification of change 7 days after date of photograph 30 days before commencement of testing 7 days after tests

7 days

21 days

21 days 21 days 21 days 14 days 14 days 21 days

QCS 2014


Submittal stage

Operation and maintenance

*

Submittal type Number of copies in brackets

Time to be submitted (calendar days)

Time for comments/approva l (calendar days)

Operation and maintenance manuals and instructions (5)

60 days before * commencement of testing

30 days

As-built drawings (5)

As erection progresses, but all drawings within 90 days of Practical Completion Certificate

40 days

Draft only. Final version to be submitted before issue of Practical Completion Certificate (PCC) or similar.

Design Data

justification for the overall design, sizing of process units, levels and layout

(ii)

to show compliance with standards used. This may include quality manuals and procedures

(iii)

as required in the particular and general project specification

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(i)

design data shall be derived from standard methods of calculations. Computer generated data will only be accepted if it is produced by software with a proven record of use in the field in which it is supplied

(c)

any calculations which do not follow recognised standards or norms shall have full supporting justifications, with technical references.

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Material and Product Data

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(b)

programme. When required by the Engineer a critical path type programme shall be submitted showing all the manufacturing activities with the critical path clearly identified.

(b)

shipping and delivery schedules. These shall include the following:

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(a)

date of shipping, arrival at port and on site

(ii)

details of packing methods. Any unique packing, shipping, handling and unloading requirements shall be stated.

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this shall include data and supporting calculations which is required for the following:

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(c)

materials and product data (i)

approval of materials and equipment shall be based on latest manufacturer‟s published data

(ii)

complete and detailed information of all materials and equipment to be incorporated in the Works shall be submitted. Detailed descriptions and specifications, catalogue cut outs, installation data, diagrams, dimensions, controls, and any other data required to demonstrate compliance with the Project Specification shall be submitted. Each item submitted shall be referenced to the applicable paragraph in the specification.

(iii)

materials of construction of materials, equipment or components shall be stated. At the request of the Engineer, a sample of these shall be submitted for further study before approval. Where samples are required by the Engineer, the period required to obtain the sample will be taken into account when scheduling approvals.

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Page 6

materials and product specification data forms shall be submitted for each item of equipment. These shall summarise the specification features as called for in these specifications, and including such other necessary data, as would provide a complete and adequate specification, for reordering an exact duplicate of the original item from the manufacturer at some future date. The assigned tag numbers and manufacturer‟s part numbers shall be included, but will not be considered as a substitute for any of the required statement of specifications. More than one tag numbered item may be included on a sheet.

(e)

fabrication and assembly drawings. These shall be supplied for any fabrication or assembly of equipment which is to be carried out in the factory or on site. Sectional drawings shall be provided for equipment such as pumps, clearly showing the materials and individual components.

(f)

test certificates. Manufacturer‟s test certificates, type test certificates, third party test certificates and quality control test certificates shall be submitted as required in the general and particular Project Specification. Certificates shall be originals or certificated copies.

Shop Drawings

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These shall include the following: (a) working drawings. These shall include layout drawings. They are drawings, diagrams, illustrations and schedules specifically prepared by the Contractor for each part or area of the works. They shall include general arrangements of the equipment and appurtenances in relation to the buildings and structures. Standard or specialised procedures for installation work recommended by the manufacturer‟s of materials or equipment and method statements for installation work shall be submitted. They shall include drawings of any templates required for the installation work. co-ordination drawings. These shall be prepared by the Contractor to show how multiple system and interdisciplinary work will be co-ordinated. The location, size and details of fixings, box-outs, apertures, ducts, holes, cable routes, access doors/covers and plinths shall be shown on detailed layout drawings which are coordinated with the building and civil structural drawings. Drawings shall illustrate clearances for lifting equipment, maintenance, access requirements and loadings due to equipment heights.

(c)

electrical drawings. These shall include single line diagrams, load schedules, cable schedules, cable schedules, loop diagrams, piping and instrumentation diagrams, panel layouts and circuit diagrams

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(a)

record drawings. These shall be prepared as work proceeds. They shall provide a record of any modifications to materials and equipment, and to the layout, arrangement and installation of the works.

(b)

photographic records shall also be made, as specified in Section 8, and as required in the Project Specification.

Testing and Commissioning Submittals (a)

test procedures plan. At least 30 days before testing and commissioning is to be performed, a detailed and comprehensive procedure plan shall be submitted for the performance of each separate test. Each procedure plan shall describe and itemise the involved system including associated electrical equipment, and shall include evidence of an organised step-by-step procedure, properly co-ordinating the efforts of the various trades and manufacturers‟ representatives involved, and of the operations of the facilities. Procedures shall include an estimated duration and date for each procedure and the personnel and equipment required.

(b)

procedure plan information. Each procedure plan shall include the following information, as applicable:

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Page 7

(i)

description of temporary procedure facilities, including drawings and sketches as required to fully illustrate the facilities

(ii)

list of test materials and estimated quantities

(iii)

list of instruments, measuring and recording devices, and other test equipment, whether a part of the equipment or furnished separately for temporary use. Copies of calibration certificates shall be submitted for any test equipment.

(iv)

names of supervising and inspecting manufacturers, where applicable

(v)

complete listing of all functional parameters to be served and recorded

(vi)

recording intervals.

record materials. Samples shall be submitted of the forms, charts, and other materials to be used in recording demonstration and validation test results. Wherever possible, standard forms shall be used.

(d)

test recording. Neat and comprehensive records of each test shall be maintained by the Contractor. Each portion of the test procedure shall be described with all components itemised. Records shall be prepared on forms in a step-by-step fashion paralleling the approved procedure plans. Forms shall list for each test or check the following:

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check/list taken

(ii)

result anticipated

(iii)

result obtained

(iv)

if incorrect, corrective action taken

(v)

re-test/check result

(vi)

step (iv) and (v) shall be repeated until all systems operate as required.

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Instruments, gauges, and other sensors and display devices forming a part of the various systems shall be employed for data acquisition where applicable. The Contractor shall furnish all other instruments, gauges, recorders, and test devices as required, types conforming to the approved procedure plans. All applicable data such as, but not limited to, water and other liquid levels, flows, pressures, head differentials, duration of runs, instrument readings, voltage settings, drive speeds, motor running currents, torque, voltages and related information, as applicable, and in accordance with approved test procedures shall be recorded at the start and finish of each operational demonstration and at 30 minute intervals during system validation tests, unless other intervals are specified or agreed with the Engineer.

(e)

8

when a repeat of the same demonstration or validation test is required to verify the results, the repeat procedure shall be indicated on the recorded data by numerical indication, data and time.

Operation and Maintenance Manuals and Instructions - General (a)

the Contractor shall provide fully detailed manuals covering all mechanical, electrical and electronic equipment. The manuals shall be in English

(b)

two copies of the draft manuals shall be submitted to the Engineer for review and approval, before the programmed commencement of commissioning works

(c)

the remaining three copies of the manuals shall be provided to the Engineer, before the commencement of the maintenance period. They shall include all revisions and comments made by the Engineer and any revisions or corrections necessitated by changes made during installation and testing

(d)

manuals shall be contract specific, and be fully indexed and sectioned, for allocation and distribution to the specialist staff involved on the particular plant and equipment

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Page 8

(e)

where several sub-contractors and manufacturers have supplied equipment the Contractor shall, if required by the Engineer provide a complete integrated manual which clearly demonstrates the inter-relation of the equipment

(f)

manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring binders. Lever arch binders are not acceptable. The full project title shall appear on the cover and spine

(g)

the manuals shall enable the client to safely operate, maintain, dismantle, reassemble and adjust all parts of the works

(h)

Original copies of leaflets and instructions provided by the specialist manufacturers shall be provided. Superfluous information shall be clearly deleted and relevant information referred to separately in the text

(i)

all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and in accordance with other recognised guidelines on technical manual writing.

Operation and Maintenance Instructions and Manuals shall confirm to Section 1, Clause 7.12.2.

10

Operation and Maintenance Instructions and Manuals‟ Contents shall also confirm to the following listed items or otherwise agreed with the Engineer.

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these shall comprise a number of volumes, dependent on the amount and technical content of the equipment installed. The operating instructions shall always form a separate volume. Manuals shall include sections containing information as described in the following paragraphs

(b)

introduction. The names, addresses, telephone and fax numbers of the Site, Employer, Consultant, Contractor, sub-contractors, manufacturers and agents. The date the Contract commenced, and the date of the Practical Completion Certificate. This item is to be completed when the date is established. A brief description of the equipment provided and the contractual scope of the work, with descriptions of any work subcontracted

(c)

general equipment description

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(a)

general process description. This shall provide a general description of the treatment processes based on process P&I drawings included with the manual

(ii)

process design parameters. This shall provide information on the performance of the process systems

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(iii)

(iv)

(d)

general description of the mechanical equipment. This shall provide a brief description of all mechanical equipment provided general description of the electrical equipment. This shall provide a brief description of the equipment provided, listing individual control panel compartments and the remote controls

detailed equipment description (i) mechanical equipment. This shall provide details of all the mechanical equipment including type, rating, duties, characteristic curves and manufacturers, and full component schedules, with serial numbers (ii) electrical equipment. This shall provide details of all electrical equipment and cables including detailed information on the control panel(s), listing the display and controls available for each compartment and stating the rating, manufacturer and supplier of main components, and full component schedules with serial numbers. This section shall include a schedule of input and output signals, detailing number, signal type, polarity, digital open or closed state and analogue range, and detailed calibration routine

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Page 9

(e)

operating instructions. These shall provide details of how each component of equipment is controlled and operated in both automatic and hand modes, including the control philosophy and its interrelationship with other interdependent equipment. Details of equipment operation under non-routine conditions and details of start-up and shut-down procedures with any associated safety checks shall be provided. (see note below)

(f)

inspection and maintenance instructions. This shall provide schedules and time intervals for routine inspection, maintenance and lubrication tasks, referring to individual manufacturer‟s instruction manuals for full details. They shall describe briefly to more complex tasks that will be needed from time to time (see note below)

(g)

fault finding and correction. This shall provide a guide to first line checks that can be undertaken in the event of equipment failure, without the need for reference to the detailed instructions. A detailed guide of more complex checks shall be provided as below

more complex tasks, involved with plant shut-downs, fault rectification to component level, fault diagnostics, overhauls, etc.

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Note: section (f), (g) and (h) should, in addition to the routine operating and maintenance tasks, identify the following:

highlight any particular complex or critical tasks over the above normal requirements

(iii)

measurements and guidance on limits of acceptable wear for all items subject to wear.

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spare parts (i)

The Contractor shall assess and recommend the consumable and strategic spares requirements of all equipment supplied under the Contract. They shall be listed in the manuals. These and any other recommended spares shall also be identified in sufficient detail for the Employer to select and purchase spares, and shall be provided with drawings or annotated diagrams showing the spare parts

(ii)

consumable spares are for those components which are scheduled for routine replacement during annual or more frequent service

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specific hazards associated with operating and maintaining the equipment, e.g. auto starting, high voltage, noise levels

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(iii)

strategic spares are for those components or items of equipment (e.g. gear box) not duplicated by standby equipment, which are expected to operate for not less than 5 years under normal operating conditions, but whose premature failure would cause the process to fail

(iv)

the Contractor shall indicate which spares are available ex-stock.

(v)

the Contractor shall provide all the above necessary spares during the maintenance period and in addition shall provide sufficient spares for 2 years of operation on issue of the PCC.

(i)

special tools. A list of the special tools supplied for the maintenance of all equipment included in the Contract shall be provided

(j)

test certificates. Certificates and documents of equipment tests shall be provided (e.g. pressure vessels, lifting equipment, etc.). Performance test certificates and characteristic details shall be provided. Set points for timers, overloads, pressure switches, relief valves, etc. shall be provided

(k)

inventory of as-fitted equipment. A schedule of this shall be provided

(l)

drawings list. A list of the as-built drawings shall be provided

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Page 10

As built drawings after erection has been completed, the Contractor shall submit to the Engineer copies of the following “As-built” drawings for approval, including:piping and instrumentation diagrams

(ii)

site layouts showing main works operational features

(iii)

equipment layout

(iv)

general arrangement drawings

(v)

mechanical details

(vi)

electrical power circuit diagrams

(vii)

control schematic diagrams

(viii)

HV and LV distribution single line diagrams

(ix)

HV and LV cable routes

(x)

PLC or computer programs

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one master copy of the proprietary software package shall be provided to the Engineer within one week of the issue of the PCC. All software licences and/or registration requirements must be forwarded promptly to the Engineer for subsequent registration with the manufacturer. Sole rights to all software developed and written on all schemes financed by Employer will be retained by the Employer assembly drawings shall clearly show the construction details and be in sufficient detail to facilitate dismantling and re-assembly

(xii)

parts lists shall be included for identification of replacement items

(xiii)

cable schedules shall include cable reference numbers and core reference numbers relating to power circuit diagrams

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(xi)

the above are to be supplied to the approval of the Engineer. The Contractor shall provide the Employer prints of each on thick paper and one ISO size A1 (594 x 420) negative of each. All drawings shall be prepared on a CAD system and printed on ISO standard sized paper A3 unless specifically requested otherwise. One set of drawings shall also be submitted in Windows based AutoCAD System, software version and storage media shall be as approved by the Engineer. Each drawing shall be marked with the Employer‟s, Consultant‟s, Contractor‟s and manufacturer‟s names and references, drawing number, title, scales, date of completion and a full description and date of all amendments, and shall be certified „as-built‟. The project title shall be included in a box at the bottom right hand corner of each drawing.

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(xiv) diagrams where necessary shall be in colour to identify different components, networks, systems etc.

1.1.5

Quality Standards

1

All equipment furnished shall be new, and where feasible, shall be a standard product of an approved or experienced manufacturer, and assembled from standard components readily available.

2

Equipment shall conform to the requirements of the Project Specifications and reference standards.

3

Manufacturers shall operate an ISO 9000 approved quality system, or equivalent in-house quality system. If requested, details of the quality system shall be submitted to the Engineer.

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Manufacturer’s Experience

1

Manufacturer‟s shall be from the approved list in the Project Specification and shall have furnished equipment of the type and equal or larger size than specified, which has been installed, and demonstrated successful operation for at least 5 years and at least 5 installations in the Gulf countries, or in countries with similar weather conditions. User certificates will be required to be submitted.

1.1.7

Factory Inspection

1

The Engineer or his representative may inspect the equipment at the factory. The Contractor shall notify the Engineer of the manufacturing schedule 30 days before commencement in order that the factory inspection can be arranged. Factory inspections will be made at any reasonable time during manufacturing, testing or after the completion of testing and prior to shipment. Approval of equipment at the factory only allows the manufacturer to ship the equipment to the Site and does not constitute final acceptance. Where specified, the Contractor shall include in the Contract Price for all the costs of the Engineer or his representative.

1.1.8

Factory Tests and Test Certificates

1

Factory tests shall be carried out as specified in the Project Specification, and as required by international standards and industry norms.

2

The Contractor shall ensure that the manufacturer provides all labour, materials, electricity, fuel, stores, apparatus and all instruments as are requisite and as may reasonably be required to carry out the test efficiently. The Engineer or his representative may witness the tests. Where specified the Contractor shall include in the Contract Price for all the costs of the Engineer or his representative.

3

The Contractor shall submit from the equipment manufacturer, or his authorised representative, a certified written test certificate in accordance with the requirements of the relevant test procedure.

4

If after examining or testing any equipment the Engineer, or his representative, shall decide that such equipment or any part thereof is defective or, not in accordance with the specification, he may reject the said equipment or part thereof. He shall notify the Contractor in writing within 7 calendar days of the rejection, stating the grounds on which the rejection is based.

5

Wherever possible Site conditions shall be simulated, or the tests shall be extended to allow for Site conditions.

1.1.9

Shipment, Storage and Handling

1

All equipment shall be boxed, crated or otherwise enclosed and protected for shipment, handling, and storage. Electrical materials shall be delivered in manufacturer‟s original cartons or containers with seals intact as applicable. Large multicomponent assemblies shall be delivered in sections that facilitate site handling and installation.

2

All equipment shall be kept dry, off the ground and covered from exposure to weather prior to installation. Pumps, motors, electrical equipment and equipment having anti-friction or sleeve bearings shall be stored in weather proof storage facilities. Where possible, heaters provided in equipment shall be connected and operated until the equipment is placed in operation. The Contractor shall prevent corrosion, contamination or deterioration of stored equipment. Storage shall be covered and the temperature and humidity maintained according to the manufacturer‟s requirements.

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1.1.6

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Equipment and materials shall be handled in accordance with manufacturer‟s recommendations. Large or heavy items shall only be lifted by the designated points. Padded slings and hooks shall be used for lifting to prevent damage.

4

All equipment shall be fully protected until final acceptance and all factory surfaces shall be protected from impact, abrasion, discoloration and other damage. All damaged equipment shall be repaired or replaced before final acceptance.

1.1.10

Adaptation of Equipment

1

Any alteration of the structure or building shown on the Contract Drawings to accommodate substitute equipment shall be the responsibility of the Contractor. Equipment which requires alteration of the structures or buildings will be considered only if the Contractor assumes all responsibility for making and co-ordinating all necessary alterations, at no additional cost to the Employer. All modifications to structures, mechanical, electrical, or other work made necessary by such substitution shall require the approval of the Engineer. The cost of this work shall be made at the Contractor‟s expense.

2

Following approval of the mechanical and electrical drawings the Contractor shall prepare and submit to the Engineer the revised drawings showing any necessary modifications to the proposed buildings and civil structures. The location, size and details of box-outs and fixings for mechanical and electrical and other equipment shall be shown on the revised Drawings and the Contractor shall be responsible for providing in the civil structures the correct location and size of the box-outs and fixings shown on the approved mechanical and electrical drawings. The Contractor shall prepare at his own cost the necessary revised civil drawings and detailed structural and other design calculations and submit them to the Engineer for approval. The Contractor shall not be entitled to an extension of time for completion for any delays from the preparation of such revised drawings.

1.1.11

Guarantee

1

The Contractor shall provide a guarantee during the maintenance period for all the equipment in accordance with the General Conditions of Contract. In addition to the general guarantee requirements, equipment warranty shall cover:

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faulty or inadequate design

(b)

improper assembly or erection

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(c)

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(a)

defective workmanship or materials

Job Conditions

1

The Contract Drawings indicate the general arrangement, layout and locations of equipment, valves, inserts, anchors, motors, panels, pull boxes, cables, conduits, stub-ups, lighting fixtures, power and convenience outlets, and exterior lighting units, and may not be exact. The Contractor shall conform to the Drawings as closely as possible, exercising care to secure approved headroom and clearances, to overcome structural interference and to verify scaled dimensions, field dimensions and conditions at the place of work.

1.1.13

Approved Manufacturers and Subcontractors

1

The Contractor shall ensure that all equipment shall be supplied, installed, tested and commissioned by subcontractors recommended by the equipment manufacturer and approved by Engineer. Large complex units, shall be installed, tested and commissioned by the manufacturers representatives as specified. Installation procedures shall be supplied and authorised by the equipment manufacturer.

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1.1.12

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1.1.14

Hydraulic Sump Model Testing

1

Unless otherwise specified in the Project Specification hydraulic sump model tests shall be performed by the pump manufacturer or an approved specialist hydraulic testing laboratory.

2

Physical hydraulic model tests shall be carried out to study the hydraulic performance of the sump and behaviour of flows in the wet well for all possible combinations of pump operation.

3

Models shall be designed and constructed to a scale approved by the Engineer as necessary to properly assess the wet well performance.

4

The model tests shall investigate the effects of the pump performance on sump operation and provide information on the following as a minimum:

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(b) (c) (d) (e)

hydraulic conditions in the pumping station inlet and wet wells under varying flows and pump combinations formation of air entraining vortices in the sumps formation of swirl at the suction pipework of the pumps velocity distribution in the suction pipework of each pump hydraulic surge effects in the pumping station inlet and wet wells caused by starting or stopping of one or more pumps start/stop levels for the pumps grit and solids deposition in the wet well. videos and coloured photographs with time and date stamping shall be produced to show the model test and important features. Commentaries shall be added to videos to describe the events recorded.

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(a)

The model tests and study shall make recommendations on any modifications to the pumping station inlet and wet wells considered necessary to overcome adverse hydraulic conditions, and the provision of any flow splitters, diverters and benching required to improve the hydraulic conditions.

6

Model Requirements:

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the model shall be constructed to an approved scale based on an appropriate Froude number and the pumping station general arrangement drawings

(b)

the walls of the wet well and inlet arrangement shall be constructed from transparent material to allow the flows to be viewed. The top of the model shall be open to allow viewing of the flows. A viewing platform above the model shall be provided for inspection and measurement

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the method of construction shall be such that the dimensions of the wet well may be adjusted to vary the hydraulic distribution and identify the optimum shape

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(d)

the Contractor shall submit four copies of drawings showing the general arrangement and details of the models for approval by the Engineer. The drawings shall also show details of all ancillary equipment forming part of the testing

(e)

after completion of the testing the Contractor shall submit to the Engineer 4 copies of the Model Test report, including all documentation, photographs and videos.

1.1.15

Sewage Characteristics

1

Sewage characteristics are typical of an arid climate municipal area with a sewerage system comprising gravity sewers and rising mains. Hydrogen Sulphide is present in varying levels throughout the sewerage system and the levels given in the Project Specification must be used for materials selection.

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Page 14

Unless otherwise specified in the Contract documents, typical Qatar sewage characteristic shall be taken as: (a)

Temp °C

25 - 45

(b)

PH

(c)

BOD mg/l

200 - 220

(d)

SS mg/l

150 - 200

(e)

Alkalinity (caco3)

225 - 245

(f)

Chloride mg/l

400 - 500

(g)

Sulphide mg/l

10 – 16

(h)

TDS

1500 - 2000

7.0 - 7.5

PRODUCTS

1.2.1

Materials

1

All materials used in the manufacture of equipment shall be new, and guaranteed free from defects, and shall be capable of resisting corrosion from sewage. The Contractor shall ensure that the manufacturer ascertains the conditions and service under which materials and equipment are to operate and warrants that operation under those conditions shall be successful. Equipment and materials provided shall be suitable for the service conditions and for meeting the specifications. All structural members shall be considered as subject to shock or vibratory loads.

2

All equipment and materials shall be designed to sustain all stresses that are likely to occur during fabrication, handling, transportation, erection, and intermittent or continuous operation.

3

Iron castings shall be tough, close-grained grey iron free from blow-holes, flaws, or excessive shrinkage and shall conform to BS EN 1561 Grade 250 and to BS EN 1563 Grade 250 for ductile iron unless otherwise specified.

4

Structural steel shall be as specified in Section 8, 16 and 17.

5

Stainless steel shall be BS 970 Grade 316 S31 unless otherwise specified. All references to BS 970 Grade 316 shall include the statement „(partially replaced by BS EN 10084) after „Grade 316‟.

6

Bolts, nuts, washers and anchor plates, shall be of stainless steel Grade 316 S31, to BS 9701, and shall remain unpainted. At lest two washers shall be provided with each nut and bolt set. PTFE or nylon washers and spacers shall be fitted beneath stainless steel washers for both bolt head and nut when used to fix dissimilar metals.

7

All nuts and bolts shall be threaded in accordance with BS 3643 "ISO metric screw threads" Part 2 "Specification for selected limits of size" and fitted with 3mm thick washers beneath bolt and nut.

8

All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be such that when fitted with a nut and washers and tightened down, the threaded portion shall fill the nut and not protrude from the face thereof by more than half the diameter of the bolt. However, two complete threads must be visible as a minimum.

9

Safety guards shall be of stainless steel of Grade 316S31 to BS 970-1.

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Workmanship

1

All equipment shall be designed, fabricated, and assembled in accordance with the best modern engineering practice. Individual parts shall be manufactured to standard sizes and gauges so that repair parts, are readily available and where practicable can be replaced on site. Corresponding parts of duplicate units shall be interchangeable.

1.2.3

Tropicalisation

1

The equipment shall be suitable for installation in tropical areas. Tropical grade materials shall be used wherever practicable. Some relaxation of these provisions may be permitted where equipment is hermetically sealed.

2

Iron and steel are to be painted or galvanised unless specified otherwise. Indoor parts may alternatively be chromium or copper-nickel plated or other approved protective finish. Small iron and steel parts (other than stainless steel) of all instruments and electrical equipment, the cores of electro-magnets, and the metal parts of relays and mechanisms shall be treated in an approved manner to prevent rusting. Cores which are built up of laminations or cannot be anti-rust treated shall have all exposed parts thoroughly cleaned and heavily enamelled, lacquered or compounded.

3

Iron and steel shall not be used in instruments and relays. Where used, steel screws shall be zinc, cadmium or chrome plated or, where plating is not possible due to tolerance limitations, shall be dull nickel plated brass or be of other approved finish. Instrument screws except those forming part of a magnetic circuit shall be brass or bronze. Springs shall be of non-rusting material. Pivots and other parts for which non-ferrous material is unsuitable shall be of an approved stainless steel.

4

Fabrics, corks, paper and similar materials, which are not subsequently to be treated by impregnation, shall be adequately treated with an approved fungicide. Sleeving and fabrics treated with linseed oil varnishes shall not be used.

5

Wood shall not be used in equipment unless absolutely necessary. Where used, woodwork shall be of thoroughly seasoned teak or other approved wood which is resistant to fungal decay and free from shakes and warp, sap and wane, knots, faults and other blemishes. All woodwork shall be suitably treated to protect it from the ingress of moisture and the growth of fungus and termite attack. All joints in woodwork shall be dove-tailed or tongued and pinned. Where used, metal fittings shall be of non-ferrous material.

6

Adhesives shall be impervious to moisture, resistant to mould growth and not subject to the ravages of insects. For jointing woodwork only synthetic resin cement shall be used.

1.2.4

De-rating Due to Climate Conditions

1

The De-rating requirements for the climate conditions for all materials and equipments shall be in accordance with Section 21 unless otherwise agreed with the Engineer.

1.2.5

Steel

1

Fabrication of structural steel shall conform to BS 449 and BS 5950 AWS D1.1 unless otherwise indicated or specified. All fabrications shall be designed for dynamic and vibratory loadings. Welding shall conform to Sections 16 and 17. All steelworks shall be galvanised after fabrication unless otherwise specified. Galvanised bolts and fasteners shall be used with galvanised assemblies.

2

If practicable, steel plate and members shall have a minimum nominal thickness of 6 mm

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1.2.2

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Wrought steels shall be selected from the appropriate steel grade of BS 970 and shall be free from blemishes, shot or hammer marks. The steel grade used shall be subject to the Engineer‟s approval.

4

Cast molybdenum steel shall be to BS 3100 Grade B unless otherwise specified.

1.2.6

Equipment Bases and Bedplates

1

Equipment assemblies shall be mounted on a single heavy cast iron or welded steel bedplate unless otherwise shown or specified. Bases and bedplates shall be provided with machined support pads, tapered dowels for alignment or mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits. Seams and contact edges between steel plates and shapes shall be continuously welded, and welds ground smooth. Machinery or piping shall not be supported on bedplates other than that which is factory installed. Jacking screws shall be provided in equipment bases and bedplates to aid in levelling prior to grouting. Plates of minimum thickness of 6 mm shall be provided. Pump bedplates shall include a drip lip and provisions for directing gland leakage to a single disposal point.

1.2.7

Anchors and Sleeves

1

Each equipment manufacturer shall supply the required anchor bolts, nuts, washers, and sleeves of adequate design for securing the bases and bedplates to concrete plinths. They shall be stainless steel or, hot-dip galvanised as specified. Sleeves shall be at least 1.5 times anchor bolt diameter. Anchor bolts shall be provided of sufficient length to allow for maximum of 40 mm of grout under baseplates and adequate anchorage into structural concrete.

2

All anchors used in wet areas or areas containing sewage or sewage gases shall be resin anchors of BS 970 grade 316 S31 approved stainless steel. Fixing anchors shall be sealed with material appropriate to and recommended by the manufacturers of the concrete protection material.

3

Steel work shall normally be bolted to the concrete, with grout added as necessary. G.R.P. lamination or other lining material shall be terminated on the equipment secured. Consideration shall be given to subsequent removal of equipment, using additional brackets or bolts which can be demounted without affecting the lining material.

1.2.8

Safety Guards

1

Belt or chain drives, fan blades, couplings, exposed shafts and other moving or rotating parts shall be covered on all sides with safety guards to BS 5304. Safety guards shall be free of all sharp edges and corners. Safety guards shall be fabricated from a minimum of either 2 mm thick, galvanised or aluminium-clad steel, or 12 mm mesh galvanised expanded metal. Guards shall also be of sufficient strength to contain rotating parts in the event of a catastrophic failure. Guards shall be designed for easy installation and removal. Necessary supports, accessories, and fasteners shall be provided, of hot-dip galvanised steel or stainless steel. Guards in outdoor locations shall be designed to prevent entrance of sand. Hinged access doors shall be provided for routine maintenance. Microswitches shall be provided on guards to prevent the main drive from starting, if specified.

1.2.9

Drive Units

1

The requirements for the design, manufacture, construction installation, testing and commissioning of drive units shall be in accordance with Section 21 unless otherwise agreed with the Engineer.

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Bearings

1

The Contractor shall select the most appropriate type of bearing for the equipment being supplied.

2

Equipment with vertical shafts shall have thrust and guide bearings.

3

Sealed for life units are to subject the Engineer‟s approval and shall have a minimum design life of 50,000 hours operation at maximum loading.

4

Bearings fitted to gearboxes shall have a minimum design life of 100,000 hours at maximum loading.

5

Plant which may be subject to vibration whilst stationary shall be provided with bearings designed to withstand damage from such a cause.

6

Single journal plain bearings shall have phosphor bronze or synthetic lubrication impregnated bushes with carbon or stainless steel journals respectively. Synthetic bearings shall only be used where bearing conditions can readily be inspected.

7

Plain type bearings shall be self-lubricating by either grease, forced oil or impregnation.

8

Ball and Roller type bearings shall be adequately lubricated by oil or grease and sealed to prevent leakage of lubricant along the shaft or the ingress of dust and water.

9

Bearings not integral with a casting shall be mounted in substantial Plummer blocks.

10

Bearings shall be sized and rated for the temperatures encountered in service conditions. Additional cooling shall be provided if necessary.

1.2.11

Lubrication

1

Suitable lubrication shall be provided to ensure smooth operation, heat removal and freedom from undue wear. Plant selected shall require minimum lubrication attendance and down time for lubricant change.

2

The Contractor shall supply the first fill of oil and grease from approved lubricant suppliers prior to completion, testing, and final acceptance. In addition sufficient approved lubricants for two years normal operation shall be provided.

3

All grease nipples, oil cups and dip sticks shall be readily accessible, being piped to a point as near as practicable to the lubrication point.

4

Gearboxes and oil baths shall be provided with adequately sized filling and draining plugs and suitable means of oil level indication.

5

Roller chain drives shall have a constant feed of lubricant, when in operation (viz oil bath or autolube system).

6

Drain points shall be located or piped to a position such that an adequately sized container can be placed beneath them. Where a large quantity of oil is involved or drainage to a container difficult, a drain valve and plug shall be provided at the point of discharge.

7

Bearings equipped with forced fed oil lubrication shall be automatically charged prior to machinery starting up, and pressure monitored during operation, with automatic shutdown of machinery and alarm on low oil pressure.

8

Access, without the use of portable ladders, to lubrication systems shall be such as to permit maintenance, draining and re-filling, without contamination of the charged lubricant.

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The design of breathers shall take into account the humidity and atmospheric contamination at the vent point and measures shall be incorporated to prevent contamination of the lubricant.

10

Grease application shall be by steel lubrication nipples manufactured in accordance with B.S. 1486, Part 1 and 4.

11

Anti friction bearings requiring infrequent charging shall be fitted with hydraulic type nipples.

12

Plain bearings requiring frequent charging shall be fitted with button head pattern nipples.

13

A separate nipple shall be provided to serve each lubrication point. Where a number of nipples supply remote lubricating points they shall be grouped together on a conveniently placed battery plate, with spacing in accordance with the recommendations of B.S. 1486, Part I, Table 9 and 10.

14

The type, grade and amount of lubricant shall be clearly marked on a label adjacent to the equipment.

15

Lubricants shall be suitable for the temperatures encountered in service conditions. Additional cooling of lubricant shall be provided if necessary.

16

Lubrication of equipment shall ensure constant presence of lubricant on all wearing surfaces. Lubricant fill and drain openings shall be readily accessible. Easy means for checking the lubricant level shall be provided. Prior to testing and/or operation, the equipment shall receive the prescribed amount and type of lubricant as required by the equipment manufacturer. Equipment lubrication systems shall require no more than weekly attention during continuous operation, shall not require attention during start-up or shut down, and shall not waste lubricants.

1.2.12

Electric Motors

1

The requirements for the design, manufacture, construction installation, testing and commissioning of motors shall be in accordance with Section 21 unless otherwise agreed with the Engineer.

1.2.13

Pressure Gauges

1

Gauges shall be connected to the suction (where applicable) and discharge pipework of each pump, compressor and blower. The gauges shall be 150 mm diameter and in accordance with BS 1780 and Section 10 and shall include a petcock between the pump/blower and the gauge. A non-corrosive diaphragm gauge isolator shall be provided for solids-bearing or corrosive fluids. Suction gauges shall be of the compound type and shall have a range of + 1 bar. Discharge gauge ranges shall be a standard commercially available range with the maximum reading 1.2 times greater than the pump‟s rated shut-off pressure. Discharge gauges shall also read to –1.0 bar. All gauge mountings shall be free of vibration.

2

The pressure readings shall be recorded on the MCC/SCADA system using pressure transmitters.

3

Pressure gauges shall be always kept calibrated as QCS Section 10 requirements.

1.2.14

Nameplates and Data Plates

1

Nameplates and data plates shall be stainless steel of ample size with embossed, stamped or etched lettering in English, fastened to the equipment in a prominent place with corrosionresisting pins. The manufacturer, serial number, date of manufacture, model number and essential operating characteristics shall be displayed on nameplates, which shall be to the approval of the Engineer. Data plates shall be inscribed with specific or directed information.

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Painting and Protective Coatings

1

Protection of Finish. The Contractor shall provide adequate means for fully protecting all finished parts of the materials and equipment against damage, from whatever cause, during the progress of the work, and until final completion. All materials and equipment in storage and during erection shall be protected in such a manner that no finished surfaces shall be damaged or marred, and all moving parts shall be kept perfectly clean and dry. Painting and protective coatings shall conform to applicable requirements of colours. They shall be to the approval of the Engineer, and the following requirements, unless modified or otherwise specified elsewhere. Painting systems shall be as specified in Section 8 Part 8.

2

Factory Painting. On mechanical equipment, drives, starters, control panels and other similar self-contained or enclosed components, a factory primer and high-quality oil-resistant baked industrial enamel finish shall be applied. Surfaces that are inaccessible after assembly shall be painted or otherwise protected by a method which provides protection for the life of the equipment.

3

Shop Priming. Two shop coats of metal primer shall be applied on surfaces to be finish painted at the site, the coating thickness to protect surfaces until finished. Primers specified for the required field applied paint systems as in Section 8 shall be used. The Contractor shall submit for approval the coating systems intended for use. Shop primers for affected items of equipment shall consist of only those approved for the intended protective coating system. Working drawings indicating compliance with this requirement shall be submitted.

4

Rust Prevention. Machined, polished, other ferrous surfaces, and non-ferrous surfaces which are not to be painted shall be coated with an approved rust preventive compound, and, in the case of aluminium be anodised. Structural galvanised steel and stainless steel need not be coated.

1.2.16

Noise Levels and Vibration

1

Noise levels: With the envisaged maximum number of items of equipment operating „on load‟ (including existing equipment), the sound level outside an envelope of 1 metre radius from any items of equipment, shall not exceed 85 dB (A). The Contractor shall include for suitable sound attenuation to achieve this level, generally in accordance with BS 8233. This will apply in the audible frequency range 20 Hz - 20k Hz. Above 20k Hz, the Contractor must state whether any fundamental frequencies are generated in the ultrasonic region. Noise levels shall be assessed in accordance with BS 4196, taking into account the actual or proposed site conditions. Noise levels shall be limited to the values specified for designated equipment.

2

Vibration Levels : The Contractor shall ensure that the stiffness of the floors/buildings and supporting structures must be meet the requirements of vibration and resonance respect to frequencies. Vibration levels shall be within the limits and comply with BS ISO 10816, Part 1, 3 and 7.

1.2.17

Metal Plating

1

Chromium plating shall be to BS 1224.

2

Sheradising shall only be used in internal air conditioned environments, and shall be to BS 4921.

3

Galvanising shall be hot-dip, to BS 729. environment shall be galvanised.

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1.2.15

Whenever possible steel in a wet or external

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MV Factory Built Assemblies (FBA’s)

1

The requirements for the design, manufacture, construction, installation testing and commissioning of all labour, materials and accessories for the MV Cubicle Switchboards, Main Switchboards, Submain Switchboards, Motor Control Centres, MCCB panel boards, distribution boards etc shall be in accordance with Section 21 unless otherwise agreed with the Engineer.

1.1

INSTALLATION AND COMMISSIONING

1.2.19

Co-ordination

1

The Contract Drawings show in a general arrangement form the arrangements desired for the principal equipment, piping, and similar appurtenances, and shall be followed as closely as possible. Proper judgement shall be exercised in carrying out the work to secure the best possible headroom and space conditions throughout, to secure neat arrangement of all equipment, and accessories, and to overcome local difficulties and interference of structural conditions wherever encountered.

2

The Contractor shall take all measurements for his work at the installation sites, verify all dimensions and conditions at the place of installation, verify the Sub-contractor‟s drawings and be responsible for the proper installation, within the available space of the equipment specified and shown on the Drawings. Written details and reasons for proposed deviations from Drawing and Specifications shall be submitted. The Engineer‟s approval for any variations shall be obtained before making any changes.

1.2.20

Inspection During Installation

1

For the tests on the Site the Contractor shall provide at his own expense unless specified otherwise, such labour, materials, electricity, fuel, stores and apparatus and instruments as may be requisite and as may be reasonably demanded to carry out such tests efficiently.

2

If after inspecting, examining, or testing any equipment the Engineer shall decide that such equipment or any part thereof is defective, or not in accordance with the Contract, he may reject the said equipment or part thereof, by giving the Contractor written notice within 7 calendar days of such rejection, stating therein the grounds upon which the decision is based.

1.2.21

Preparation of Installation Areas

1

Prior to installing the equipment, the Contractor shall ensure that installation areas are clean, free of dust intrusion and that concrete or masonry operations are completed. The installation areas shall be maintained in broom-clean condition during installation operations. All buildings where permanent doors and windows have not been installed shall be provided with temporary protection to prevent dust ingress and any other damage to equipment, all to the approval of the Engineer.

1.2.22

Manufacturers’ Installation Supervision

1

Where specified in the Project Specification, the Contractor shall ensure that each equipment manufacturer furnishes the services of an authorised representative especially trained and experienced in the installation of his equipment to:

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1.2.18

(a)

supervise the equipment installation in accordance with the approved instruction manual

(b)

be present when the equipment is first put into operation

(c)

inspect, check and adjust until all trouble or defects are corrected and the equipment installation and operation are acceptable

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Page 21

(d)

witness and supervise operational demonstrations and system validation tests to the extent specified.

(e)

prepare and submit certified test report.

All costs for manufacturers‟ representatives services shall be included in the Contract Price.

1.2.23

Installation

1

General. Prior to installation the equipment shall be cleaned, conditioned, and serviced in accordance with the approved instruction manuals.

2

Equipment. Equipment shall be installed in accordance with approved instruction manuals by an approved specialist sub-contractor. The Contractor shall employ skilled craftsmen experienced in installation of the types of equipment specified, and shall use specialised tools and equipment, such as precision machinist levels, dial indicators, gauges, and micrometers, as applicable.

3

Anchor Bolts. The Contractor shall provide bolts with templates or setting drawings and verify that bolts are correctly located before structural concrete is placed.

4

Base and Bedplate Grouting. Grouting shall not be carried out until initial fitting and alignment of connected piping is completed and approved by the Engineer. The Contractor shall level and align equipment on concrete foundations using suitable steel and brass shimming, then entirely fill the space under base or bedplates with non shrink grout. Exposed grout shall be bevelled at a 45  angle, except that exposed grout at horizontal surfaces shall be rounded for drainage. Exposed grout shall be trowelled or pointed to a smooth dense finish and damp cured with burlap for three days. After the grout has fully hardened, the Contractor shall remove jacking screws and tighten nuts on anchor bolts. The Contractor shall check the installation for alignment and level, and perform approved corrective work as required to conform to the tolerances given in the instruction manual.

1.2.24

Testing and Commissioning

1

General

operational demonstrations and system validation tests are required for all mechanical and electrical equipment, and systems specified including all associated and related electrical systems and control devices specified in this Section, Sections 10 and 21, and the Project Specification all costs for these shall be included in the Contract Price

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(c)

materials, potable water, chemicals and electrical power for testing and commissioning and validation shall be supplied by the Contractor. Temporary facilities, storage, and similar facilities necessary for these shall be supplied by the Contractor. Testing and commissioning shall be performed under continuous inspection by the Engineer. The Contractor shall provide sufficient experienced skilled staff to carry out the testing and commissioning. Various equipment manufacturers shall be present, if specified.

(d)

all defects and malfunctions found by testing and commissioning shall be corrected immediately, using approved methods and new materials for repairs as required. Interruption time necessary for corrective work may, at the Engineer‟s discretion, be added to the specified testing and commissioning periods

(e)

satisfactory completion and approval of required commissioning and testing is one of the conditions precedent to the Engineer‟s acceptance of the work, but does not constitute final acceptance

(f)

testing and commissioning shall be in accordance with the Project Specification, the QCS, the relevant International Standards, QGEWC requirements, industry norms and to the Engineer‟s approval.

QCS 2014

Test Procedures (a)

(i)

primary tests and checks

(ii)

unit testing

(iii)

system validation tests

(iv)

commissioning and setting to work

(b)

the Contractor shall not proceed from one stage to the next without the Engineer‟s written approval

(c)

consolidation of demonstration, testing, and instruction requirements. Unit and system validation testing, commissioning and instruction of the Employer‟s personnel may be performed simultaneously.

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Primary Checks and Tests

all component units and complete systems shall conform to the Specifications, Drawings and the approved working drawings, samples, construction manuals, material lists, and other approved submittals

(b)

all specified components and complete systems shall have been installed satisfactorily and are operable

(c)

all installations shall be safe to use. permitted if approved by the Engineer

(d)

all cleaning work shall be completed

(e)

equipment shall be free from physical damage due to mechanical force, exposure to the elements, incorrect connection, etc.

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Temporary access, covers etc. will only be

Unit Testing (a)

unit testing is defined as tests on individual equipment such as pumps, compressors, blowers, fans conveyors and all similar equipment item. Tests may be performed simultaneously on groups of identical equipment, items, and groups of items supplied by one manufacturer, if practicable

(b)

potable water shall be used to fill tanks, wells piping and systems that contain water, sewage, or sludge in normal operation. Where necessary specified chemicals shall be used for chemical systems but shall not exceed in-service concentrations

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tests shall show that all component units operate with the quantities, efficiency, repeatability, and accuracy specified

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testing shall be carried out in stages as follows:-

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(d) 5

tests shall be carried out continuously for a minimum period of 8 hours, unless other periods are specified.

System validation tests (a)

system validation tests shall not commence until unit tests have been satisfactorily completed

(b)

this is defined as testing of complete systems that perform a discrete process function such as pumping systems, emergency power systems and similar systems. Each system shall include associated structures, tanks, piping, utilities, instrumentation and controls, and like related items. Two or more separate systems shall be validation tested simultaneously when necessary to validate an entire specific function

(c)

potable water shall be used for system validation tests if it is possible to carry them out satisfactorily with this medium. If the tests require use of the medium used in service, then this shall be used

QCS 2014

(d)

Page 23

each system validation tests shall be carried out for minimum of 24 hours, unless longer is needed to prove the performance of the system.

Commissioning and Setting to Work commissioning is defined as testing all the equipment and systems together under actual operating conditions using all the mediums used in actual operating conditions. Setting to work follows consecutively from this. Once the equipment and systems are operating satisfactory they are left to work

(b)

each system shall be tested, including standby equipment, by continuous operation under the “in-service” condition for not less than 7 consecutive days unless required otherwise by the Engineer, with no interruptions except for normal maintenance or corrective work. Where the in-service condition is an automatically controlled repeat cycle with on/off intervals, it shall be so operated

(c)

systems shall be operated continuously under constant inspection of trained operators. System operation shall be cycled from full load to light load and back to full load each 24 h. Variable speed equipment shall cycle through the applicable speed range at a steady rate of change. Simulated alarm and failure operating conditions shall be induced. Test controls and protective devices shall be tested for correct operation in adjusting system functions or causing system shutdown

(d)

failure of an item of equipment or a system during the stated periods will result in termination of the test. The test will only recommence when the Engineer is satisfied with the remedial work. The test shall then recommence for a further 24 hours

(e)

subject to Contractor‟s request and Engineer‟s approval in each specific case, the Contractor may be permitted to simulate certain operating conditions relating to flow rates, water levels, and malfunctions. Permission for simulations will be granted only where it is unwise or impossible to obtain the conditions covered by the capability of ranges or equipment. The simulation methods shall reflect reasonable anticipated operating conditions.

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Instruction and Training of the Employer’s Personnel

1

After the equipment has been installed, tested, adjusted and placed in satisfactory operation the Contractor shall provide the services of qualified staff approved by the Engineer, or if specified in the Project Specification, of the manufacturer‟s representatives, to instruct and train the Employer‟s operating personnel in the use and maintenance of the key items of equipment as specified. An instruction and training programme shall be conducted for up to six operators designated by the Employer. The Contractor shall give the Employer at least one month‟s written notice of the proposed instruction and training programme. Instruction and training covering basic system operation theory, routine maintenance and repair, and “hands on” operation of equipment shall be included. The duration of the programme shall be based on the complexity of equipment involved, and the Engineer‟s approval of instruction adequacy obtained before terminating the programme. Instruction and training periods shall be acceptable to the Engineer and Employer.

1.2.26

In-Service Checks

1

General. In-service checks of all systems and equipment shall be carried out by the Contractor twice during the Contract maintenance period by the Contractor with qualified technical representatives of the various system manufacturers, including manufacturers of equipment components within systems, if specified. Checks shall be detailed and complete and shall be performed under the observation and to the satisfaction of the Employer. All costs for in-service checks shall be included in the Contract Price.

2

Notification. The Employer shall be notified in writing at least 10 days before carrying out of in-service checks and the Employer‟s approval shall be obtained prior to commencing work.

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Page 24

Consultation. During the in-service checks, the manufacturer‟s technical representatives shall consult with the Employer to review the instruction manuals and the pertinent operational and maintenance problems encountered, and shall furnish technical advice and recommendations to the Employer.

4

Programme. Initial in-service checks shall be performed approximately 6 months after final acceptance. The last in-service checks shall be performed 30 days prior to the end of the Contract maintenance period.

5

Reports. A written report on each in-service check, signed by the appropriate manufacturer or his representative, shall be delivered to the Employer within 10 days following the checks. The report shall describe the checking procedures in detail, and shall state all advice and recommendations given to the Employer.

6

Operation and Maintenance Manuals. These shall be altered to take into account any modifications to equipment, drawings or operating procedures. Replacement drawings and pages, marked as revisions, shall be supplied with sufficient copies to allow all the operation and maintenance manuals to be updated.

1.2.27

Specialised Training Programme for Employer’s Personnel

1

Where designated in the Project Specification the Contractor shall provide a specialised training programme and manual for the Employer‟s key personnel in the equipment, electrical systems and instrumentation systems, to be conducted by the supplier/manufacturer and held at locations outside Qatar. The training programme and manual shall be submitted to the Employer for approval and shall be designed to: provide in depth information and familiarisation of the equipment installed in the Project

(b)

receive specialised training in the design, proper operation, maintenance and replacement of the equipment and components

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The Contractor shall provide whatever assistance is requested by the Employer to develop meaningful itineraries for the training programme. The Contractor shall provide hotel accommodation, travelling expenses by air, land transport and per diem allowance as per the Ministry of Education guidelines.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 10: Odour Control Equipment - Scrubber Type

Page 1

10

ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE ................................. 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

Scope References System Description Submittals Warranty

10.2

PRODUCTS ................................................................................................... 4

10.3

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10.2.1 General 10.2.2 Scrubbers 10.2.3 Fans 10.2.4 Recirculation Pumps 10.2.5 Chemical Feed Pumps 10.2.6 Chemical Storage Tanks 10.2.7 Rotameters 10.2.8 WYE Strainer 10.2.9 Sump Overflow Trap 10.2.10 Acid Supply Connection 10.2.11 Pressure And Vacuum Gauges 10.2.12 Pressure Switches 10.2.13 Drench Showers 10.2.14 Water Softener 10.2.15 Control Panel 10.2.16 Factory Inspection and Testing 10.2.17 Spare Parts and Tools

.

2 2 2 3 4 4 5 7 8 9 10 11 11 11 12 12 12 12 12 13 13 13


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10.3.1 Installation 10.3.2 Site Inspection and Testing

14 14

QCS 2014


Page 2

ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the requirements for the design, manufacture, construction, installation testing and commissioning of odour scrubber systems and related auxiliary equipment.

2



Drainage Works Instrumentation Control and Automation Electrical Works

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10

References

1

The following standards or revised/updated versions and other documents are referred to in this Part:

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10.1.2

BS 848,.......................Fans for general purposes

BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes

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BS 1646 (ISO 3511) ...Symbolic representation for process measurement control functions and instrumentation BS 2782 (ISO 181, 174, 307, 8618) Methods of testing plastics

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BS 3496 (ISO 1888) E glass fibre chopped strand mat for the reinforcement of polyester and epoxy resin systems

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BS 3532......................Method of specifying unsaturated polyester resin systems

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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester and epoxy resin systems

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BS EN 1092...............Circular flanges for pipes valves and fittings BS 4994......................Design and construction of tanks and vessels in reinforced plastics

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BS 5000 (IEC 34,72) Rotating electrical machines of particular types or for particular applications BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of electrical apparatus for use in potentially explosive atmosphere BS 5512 (ISO 281) .....Methods of calculating dynamic load ratings and rating life of rolling bearings BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans BS 7671......................Requirements for electrical installations 10.1.3

System Description

1

Performance requirements: concentration of hydrogen sulphide (unless specified otherwise) other contaminants:

: 500 ppm

QCS 2014


Page 3

Mercapatans Amines (mono (di/tri) Ammonia Sulphide concentration in solution Number of air changes per hour in ventilated volume

: : : :

trace only 10ppm 50ppm 50 mgl

:

Removal of hydrosulphide gas and ammonia Removal of amines Removal of mercapatans

: : :

4 minimum. More if Contractor deems necessary. 99.8% 95% No requirement

The above criteria are for domestic sewage of a quality normally encountered in Qatar. Highly septic sewage or sewage from industrial sources will need special analysis and the possible addition of a sulphuric acid stage or a separate sodium hydroxide stage. The scrubber shall be the counterflow, packed bed tower type.

3

Sodium hydroxide 20 % w/w (NaOH) and sodium hypochlorite 12 % w/w (NaOCl) are to be used as the scrubbing reagents for removing hydrogen sulphide from the odour source. For some installations with ammonia levels above 30 ppm or other industrial chemicals, addition of a sulphuric acid 20 % w/w (H2SO4) stage will be necessary. Operation of the scrubber shall be automatically controlled (with manual override capability) as follows. A single speed fan activated by a manual start/stop push-button switch, draws odorous air through the packed beds of the scrubber. The selected recirculation pump (a standby is to be provided), also activated by a manual start/stop pushbutton switch, circulates scrubber liquors through the packed beds. Sulphuric acid (if used), Sodium hydroxide and sodium hypochlorite are added to the scrubber liquor via metering pumps. Sulphuric acid must be added separately in another stage. These pumps are controlled through set points on analysers for pH for H2SO4 and NaOH and Redox (oxidation reduction potential) for NaOCl. Chemical is added until the highest set point on the analyser is reached. The recirculation pumps shall be interlocked with the metering pumps so that in automatic mode, recirculation pump failure will cause shut down of metering pumps. Pressure switches shall initiate change over to the standby Flow switches (rotameters) shall initiate change over to standby on low flow fan.

4

The final control involved in the scrubber is water makeup to replace both “bleed” scrubber liquor and evaporative losses. This is to be achieved with a capacitance type liquid level element and a solenoid valve on the supply line fed from the water softener.

5

Scrubber liquid is bled off continuously so that the potable water added is sufficient to maintain the salts in solution.

6

The odour scrubber system shall be designed for indoor or outdoor installation as shown on the drawings and specified.

7

The chemical storage and feed system shall be designed for outdoor installation.

8

A duplex ion exchange water softener shall be fitted on the potable water supply line, with booster pumps if necessary.

10.1.4

Submittals

1

In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and information as described in the following paragraphs.

2

Design Data providing the following information:

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(a)

calculations to justify the sizing of the fans, packed bed, pumps and chemical storage tanks

QCS 2014

(b)

calculations as required by BS 4994 category III pertaining to the construction of the scrubber and chemical storage tanks

(c)

structural calculations for foundations and guy wires or any other external means of support, taking into account wind loadings

(d)

user certificates.

Shop Drawings providing the following information: (a)

fibreglass resin and plastic liner manufacturer’s technical data on composition. Characteristics of resin and liner including hydrostatic and burn test

(ii)

manufacturer’s technical data on other equipment used

dimensional layout of stack and all equipment used

(c)

fan test data as BS 848 Parts 1 and 2.

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(b)

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Instrumentation:

complete layout and wiring diagrams of unit control panels.

(b)

complete process and instrumentation diagrams drawn in accordance with BS 1646

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(a)

Samples (a)

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(i)

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product data

vessel and duct GRP and liner, packed media.

Operation and maintenance and instruction manuals including:

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(a)

odour reduction field test report(s) as specified in Part 10.3

(b)

the documentation in Clauses 2, 3 and 4 above in Part 10.1.4.

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Warranty

1

In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall ensure that the odour control scrubber equipment manufacturer be responsible for the proper performance and warranty of the odour control system. The system shall be designed and guaranteed to meet the odour removal requirement as outlined in this specification.

2

Warranties and guarantees by the suppliers of various components in lieu of single-source responsibility by the scrubber manufacturer will not be accepted. The Contractor shall ensure that the scrubber manufacturer is solely responsible for the warranty.

3

The scrubber manufacturer must state in his proposal the guaranteed removal efficiency of the scrubber, based on the gas inlet concentration.

10.2

PRODUCTS

10.2.1

General

1

Those items of the scrubbers and fans specified to be constructed of fibre glass reinforced polyester resin shall have approximately 25 % glass reinforcement with a 75 % resin content and conform to the following:

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10.1.5

(a)

the polyester resin shall be ortho and isophtalic polyester vinylester resin to BS 3532

(b)

reinforcing material shall be a commercial grade of glass fibre water resistant type ‘E’ chopped strand mat or woven glass fabric to BS 3496 and BS 3749

QCS 2014


Page 5

(c)

surface finish shall be a gelcoat flow coat isophtalic resin to BS 3532. All drilled, cut or otherwise exposed edges shall be sealed with polyester resin

(d)

all materials, fabrication procedures, manufacturing tolerances, workmanship, tests, and product quality shall conform to BS 4994

(e)

the scrubbing towers and chemical storage tanks shall include conductive resin strips behind weld lines, and nozzle fitting joints, to enable a full spark test to be carried out, both in the factory and subsequently on site

(f)

Each scrubbing tower and chemical storage tank shall have a corrosion resistant welded thermoplastic liner of either PVC-u or polypropylene. If PVC-u is used it shall be annealed after fabrication and welding.

Scrubbers

1

The scrubber shall be single or dual stage vertical, counter-current design, packed tower type.

2

The scrubber shall contain in the main packed bed a minimum depth of 3 m of nominal 50 mm size filamentous toroidal helix shaped or spherical type packing, having a free volume 2 3 of 95 %, with 28 m of surface area per m of packing. Packing is to be randomly dumped into the scrubber; structured type packing is not acceptable. Material of construction is to be polypropylene. Pressure drop per metre of packing shall not exceed 15 mm water column.

3

The scrubber shall include an entrainment separator/demister, internal spray piping or liquid distribution as recommended by the specialist scrubber packing manufacturer, packing, packing supports, lifting and hold down lugs.

4

All liquid handling nozzles, external to the vessel, shall be flanged to NP16. Gas handling nozzles shall be of the dimensions as outlined in BS 6339. Couplings shall be fully flanged, NP16. Minimum projection of nozzles shall be 150 mm.

5

Scrubber nozzles and appurtenances shall include: make-up water inlet

(b)

hydrochloric acid supply connection

(c)

overflow

(d)

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sump drain

scrubber liquor recirculation inlet (to spray header)

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10.2.2

(f)

scrubber liquor recirculation outlet (to pump suction)

(g)

pH probe mounting

(h)

Redox probe mounting

(i)

level sensor mounting connections with stilling well

(j)

a minimum of three manholes with neoprene gaskets (for servicing spray nozzles, packed bed, and scrubber sump)

(k)

four GRP tie down lugs or base flange

(l)

mounting brackets for scrubber recirculation piping

(m)

stainless steel guy wires as necessary

(n)

gas sampling points on inlet and outlet to the scrubber. If necessary, both shall be piped using 12 mm piping to a convenient point for use of a hand held hydrogen sulphide monitor.

QCS 2014


Page 6

The scrubber tower shall be capable of operating at the design flow rate with a maximum static pressure loss of 75 mm water column. The packing depth, recirculation rate, and recirculation solution shall be designed to meet the required efficiency.

7

The scrubber housing and internal structural members shall be fabricated of GRP, and shall be not less than 5 mm thickness. External reinforcing ribs, if required for pressure or vacuum conditions or wind load, shall be suitably designed and installed not more than 1 m apart. Colour shall be white.

8

An internal moisture entrainment separator section shall be furnished with each unit which is to consist of 300 mm deep packed bed. The demister shall be capable of removing not less than 99 % of the entrained moisture of the air exiting the scrubber, consisting of droplets 10 m and larger.

9

Packing support plates for the main bed shall be manufactured from polypropylene having 40 mm by 40 mm square openings and being 40 mm deep. Packing support plates for the entrainment separator section shall be manufactured from polypropylene, having a minimum 84 percent open area , or same as above. Any internal supports required shall be of the same material as the shell. Support plates are not required for chevron blades.

10

The scrubbing liquid distribution system shall be the spray type of manufacturer’s standard design, sized for the flowrates required and taking into varying air delivery rates of +10 %. No liquid distributors shall be permitted. Spray headers shall be placed at the manufacturer’s recommended distance above the packing. Material of construction shall be chlorinated polyvinyl chloride (PVC-C), NP16. Spray nozzles shall be spiral design, full cone type, constructed of PVC

11

The scrubber shall be designed with a minimum of 600 mm of shell height between the gas inlet and bottom to act as an integral sump. The sump shall hold a minimum of two minutes supply of scrubbing liquid. The sump shall be furnished with a level sensor as specified herein.

12

No internal wetted metal bolts, or components are permitted. All external bolts and fasteners including anchor bolts and flanged bolts shall be BS 970 316 stainless steel. Stainless steel anchor bolts guy wires and clips shall be provided by the manufacturer.

13

The scrubber shall be supplied with integral mounting lugs and pipe supports for the (PVC-C) scrubber liquor recirculation piping. Mountings shall be designed with consideration for pipe inlet and outlet connections. Pipe supports shall be non-metallic channels and straps.

14

The scrubber shall be equipped with a differential pressure gauge on the inlet and outlet ductwork which shall be installed so that abnormalities that may occur in the scrubber can be visually detected. The scrubber shall have pressure taps located below the main packed bed and above the entrainment separator, and the gauge shall be mounted on a scrubber shell. The differential pressure gauge shall include instrument traps, and valve manifolds to permit testing and zero setting of the gauge. Plastic tubing equipment with PVC condensate traps shall connect the high and low pressure taps. The gauge shall have a 100 mm round face.

15

Redox and pH probes for analysing the contents shall be located in the scrubber sumps. The probes and analysers shall provide the chemical feed control as described herein. The probes shall meet the following specifications:

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(a)

range : pH probe

(b)

stability :

 01.% per 24 hours, non-cumulative

(c)

wetted materials sensor

Liquid crystal polymer body

(d)

accuracy/ sensitivity

(e)

temp. limits

:

0-14 pH : Redox probe; 0-1000 mV

 0.1 pH unit : Redox probe : ± 1 mV 0

65 C

QCS 2014


Page 7

(f)

pressure rating

0-350 kPa

(g)

interconnect cable

(h)

each probe shall be supplied with a two wire transmitter and analyser

(i)

the analyser shall be microprocessor based with a 4 digit display, with dual programmable high/low set points, contacts. Alarm conditions shall be indicated on the instrument by front panel LED’s with auxiliary alarm contacts. Automatic or manual temperature compensation shall be selectable, with the option to display the process temperature. A data logging system for high/low signals shall be incorporated. Set-up, alarm and control functions shall be accessible on the front panel

(j)

each probe shall be provided with a protector or well as recommended by the manufacturer

(k)

the manufacturer shall supply all necessary hardware and wiring for installation of probe and analyser.

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manufacturer’s standard

The sump liquid level sensor shall be a capacitance type liquid level probe with a Teflon coated probe element and integrally mounted cast iron or epoxy coated enclosure. The probe shall be a dual-point sensor, for high and low liquid levels. On low liquid level, an electrically operated solenoid valve shall open and allow scrubber make-up water to flow into sump. The valve shall close when high set point is reached. Low-low level shall simultaneously sound an alarm in the control panel and shut off the recirculation pumps. Probe shall be inserted in type 316 stainless steel stilling wells mounted externally of the scrubber.

17

All instrumentation mounted inside the scrubber tower or tanks shall be intrinsically safe.

10.2.3

Fans

1

Duty/standby fans shall be provided for each scrubber unit. Each fan shall have a single speed motor with the capacity and power to deliver the required volume of air against the total pressure losses in the air intake, duct collection systems, packed bed, mist eliminator and ductwork to the fan and exiting out of the stack.

2

The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibre glass reinforced plastic or stainless steel, with vibration free mountings. The fan shall be capable of the performance specifications as shown below:

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(c)

operating temperature : 0 -70 C

(d)

Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55; 1500 rpm power as required, rated for zone 2 use with methane gas (BS 5345), to BS 5000, 1500 rpm.

unit capacity

:

static pressure :

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(a)

as required 3000 Pa, or as required 0

3

Exhaust fans shall be suitable for continuous 24-hour operation and shall be nonoverloading. Each fan shall operate such that no point on the fan curve requires more than the rated motor power.

4

The fan housing, flanges and backward curved impellers shall be constructed of flame retardant GRP laminate or stainless steel, capable of resisting continuous fume temperature 0 of 70 C. The manufacturer shall state the type of resin used and confirm that it will perform satisfactorily under the operating conditions. All interior surfaces exposed to the corrosive air stream shall be resin rich.

5

Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of 0.5 m displacement prior to assembly and every fan test run prior to shipment.

QCS 2014

Fans shall comply with BS 848 and be provided with the following standard features: (a)

drive assembly: belts shall be oil, heat and static resistant type, sized for continuous duty. Shafts shall be constructed of heavy duty steel turned, ground and polished, keyed at both ends

(b)

bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings

(c)

shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft leaves the housing, along with a viton shaft slinger between the seal and wheel on belt drive units

(d)

bases: heavy gauge hot rolled steel, epoxy coated

(e)

the fan shall be provided with the following accessories: flanged and drilled inlet and outlet to BS 6339

(ii)

drain

(iii)

access door

(iv)

vibration isolation system

(v)

belt and shaft guard as Part 1

(vi)

earthing as QGEWC requirements and BS 7671

(b)

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flexible connectors:

flexible connectors shall be installed on the fan inlet and outlet to dampen axial, lateral, and vibrational duct movement. Flexible connectors shall be installed at each fan inlet and outlet

(ii)

the flexible connector shall be resistant to the corrosive gases being processed and shall be able to withstand  3750 Pa. The flexible connector shall be minimum 30 mm long.

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Dampers:

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suitable sized dampers shall be provided as follows: (i)

balancing damper between the fan outlet and the scrubber inlet

(ii)

isolation dampers at each fan inlet and outlet

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the dampers shall be provided in accordance with the following specifications:

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(i)

the damper shall be flanged and drilled to withstand 3000 Pa

(ii)

the blade thickness shall be as required by the damper manufacturer

(iii)

the bearings shall be moulded plastic material

(iv)

fibreglass axles shall extend full length of blade and 150 mm beyond frame

(v)

the unit shall be equipped with a full circumference blade seal to limit leakage 3 2 to less than 1 m /m min at 3000 Pa.

10.2.4

Recirculation Pumps

1

Pumps shall be of the direct coupled, single stage, end suction, horizontal, back pullout corrosion resistant, centrifugal type.

2

Impellers with integral shaft sleeves shall be balanced semi-open fibre glass reinforced resin polyester or PVC-C.

3

The pump casing shall be a resin injected hot press moulded fibre glass reinforced polyester or PVC-C. The casing shall be free standing supported by heavy duty non-metallic feet. Suction and discharge nozzles shall be NP16 flanges.

QCS 2014


Page 9

The shaft shall be constructed of 316 stainless steel of sufficient diameter to assure rigid support of the impeller to prevent excessive vibration.

5

The bearing housing shall be constructed of cast iron, machined with precision pins of tongue-and-groove construction to ensure permanent alignment.

6

Bearings shall be of the anti-friction, oil lubricated, ball type and enclosed in a cast iron, oiltight bearing frame. Bearings shall have a minimum L-10 rating of 20,000 hours under full load continuous 24-hour duty. Bearings shall be oil lubricated. The pump shall be equipped with constant level oiler.

7

The shaft seal shall be mechanical, EPDM/carbon/ceramic. Seal water shall be provided if necessary.

8

Pumps and motors shall be bolted to a common GRP baseplate. Pumps shall be grouted in place with epoxy grout.

9

Pumps shall be directly coupled to the motor with a suitable spacer type coupling and guard.

10

Duty/standby change over shall be by means of a low flow switch mounted in the liquor feed.

11

Motor:

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each pump shall be provided with a horizontal squirrel cage induction, totally enclosed fan cooled motor, of sufficient power such that no point on the pump curve requires more than the rated power of the motor furnished

(b)

each motor shall be suitable for 415 V, 3 phase, 50 Hz continuous 24-hour operation and shall conform to the requirements of Part 1 of this Section and Section 21.

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(a)

Chemical Feed Pumps

1

The pumps shall be of the hydraulically balanced double diaphragm type, wherein a measuring piston reciprocates within a cylinder and causes hydraulic oil to deflect a flat diaphragm. The diaphragm shall be supported throughout the entire pumping stroke. The hydraulic oil system shall include a means to automatically relieve excess hydraulic pressure, makeup oil and bleed-off vapours. Mechanically operated devices are not acceptable. The chemical metering head shall include a diaphragm cavity moulded into the head material, or have other intrinsic design features to prevent diaphragm damage during restricted inlet conditions. The pump shall have a flow-through liquid path from bottom to top. The diaphragm shall be capable of sealing under full head bolt torque limits without stressing the diaphragm. Pump heads shall be polyproylene and diaphragms PTFE.

2

The metered liquid shall enter the metering head at the bottom and exit at the top through alumina-ceramic disk or ball type check valves. These may be gravity seating or spring loaded to meet service conditions. Valve assemblies shall be replaceable without threading. Valve seats, shall be of Viton, gaskets shall be PTFE.

3

The pump mechanism shall have flooded lubrication using a common oil with the hydraulic system. It shall not contain auxiliary lubricator mechanisms. The pump mechanism shall be sealed from direct contact with the outside atmosphere and shall be suitable for operation in ambient conditions of 55 C without the use of heating or cooling devices. Manual capacity adjustments between 0 and 100 % shall be accomplished while the pump is idle, or operating, by simply changing the piston stroke length. A minimum of 400 adjustment increments shall be available. Stroke adjustments shall provide positive, repeatable settings within ± 0.25 % over the entire pumping range. Pump delivery shall be repeatable within ± 1 % accuracy over a 10 to 1 range.

4

Pump bearings shall be heavy duty ball or tapered roller type designed for an L10 life of at least 50,000 hours in accordance with BS 5512.

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10.2.5

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Page 10

Each pump shall have an integral pressure relief valve to prevent damage to the pump or piping in the event of a downstream pipe blockage.

6

Pumps shall be capable of operating continuously with liquids at 40° C.

7

Each pump specified herein shall be driven by a squirrel cage induction motor suitable for operation on a 240 V, single phase, 50 Hz power supply, and meeting the requirements for electrical motors as specified in Part 1 of this Section and Section 21. Motors shall be direct coupled to the pumps, with flexible couplings.

8

Each pump discharge shall include a back pressure valve designed to create a constant back pressure without chatter or cycling. Parts in contact with the pumped liquid shall be suitable for use with H2SO4, NaOH and NaOCl as specified herein. A PTFE diaphragm shall seal the spring and bonnet from the product. The diaphragm shall seal on a replaceable seat and shall ensure tight shutoff at zero flow.

10.2.6

Chemical Storage Tanks

1

The storage tanks shall be of lined laminated construction, designed and fabricated in accordance with BS 4994 category III, and shall provide safe, sound, and leak-proof storage at atmospheric pressure for the specified liquids. Lamination thickness specified in the standards shall be considered minimum thicknesses.

2

Tanks shall be constructed of a welded PVDF, PVC-u or polypropylene liner and contactmoulded translucent reinforced plastic resin. As a minimum, tank construction shall consist of a 50 m resin-rich exterior mat, a middle layer mat to develop the necessary strength, and a 250 to 300 m resin-rich nexus veil interior and a minimum 3 mm thick plastic liner.

3

Tanks, anchors, and supports shall be designed for exterior installation that shall withstand a horizontal wind load without movement or damage. Tanks shall also be designed for a concentrated dead load at the top of the tank of 500 kg. Tanks shall include hold-down anchors. Anchors shall be designed to hold the tank against an uplift pressure of 2 m of water column. Tanks shall be designed for pneumatic tanker loading.

4

Factory-applied insulation shall be provided for all storage tanks. Insulation shall be 50 mm thick and shall provide a maximum coefficient of thermal conductivity (K Value) of 0.4 2 kg.cal/h/m /C. Insulation shall be protected by an additional fibreglass laminate built up to a minimum thickness of 0.4 mm. This protective laminate shall include expansion joints spaced to preclude damage due to thermal expansion. A lip shall be provided at each joint to prevent moisture from entering. The exterior laminate shall also include a pigmented protective gel coat in a colour to be selected by the Engineer. Loose insulation shall be packed into the gusset around the pipe neck at each tank nozzle, and shall be taped to provide a weatherproof seal.

5

A permanently attached encapsulated paper or stainless steel tag shall be affixed to the outside laminate covering the insulation. This label shall contain the following information:

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(a)

manufacturer

(b)

corrosion-resistant liner

(c)

type of liner reinforcement

(d)

chemical to be stored

(e)

(i)

concentration

(ii)

maximum specific gravity

(iii)

maximum temperature

exterior resin

QCS 2014

(f)

tank capacity

(g)

date of manufacture.

Page 11

The tanks shall include the fittings and appurtenances shown on the drawings and described herein: (a)

hinged, top-mounted access manway (800 mm diameter) with non-slip walkway and 316 stainless steel ladder cage, and handrailing

(b)

conical gusseted, flanged connections for fill, inlet, outlet, drain, vent and overflow. All shall be minimum 75 mm diameter. The overflow shall be piped into the tank bund to prevent splashing. Connections shall be located as shown on the Drawings. Flange face and bolting shall be in accordance with NP 16

(c)

low level probes shall be fitted in each tank to stop the dosing pumps in the event of low level being detected. Suitable gasketed covers shall be provided for these probes

(d)

screened vent. The vent shall be sized for release of air during tanker offloading

(e)

anchor and lifting lugs

(f)

A visual cat and mouse type liquid level gauge shall be provided on each tank, or alternatively a hand operated pneumatic bubbler.

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Tanks shall be segregated in bunds. Bunds shall have individual capacities equal to 1.1 times the tank full volume. Alternatively tanks of a proprietary design with integral bunds may be provided.

10.2.7

Rotameters

1

General. Rotameters shall be provided as shown on the drawings and specified herein. Rotameters shall include a plastic housing or frame. Rotameters shall include a flow indicator suitable for indoor installations. All wetted parts and fittings shall be 316 stainless steel, except O-rings. Meters shall have a minimum rangeability of 10:1.

2

Make-up Water. Rotameters shall include a dial flow indicator, 316L or plastic, suitable for high pressure, high temperature flow indication. The metering float shall be magnetically coupled to an indicator housed in a fully gasketed, reinforced fibreglass case. Accuracy shall be plus or minus 5 % of full scale. A stainless steel control valve shall be provided for precise regulation of liquid flow rate.

3

Seal Water (if used) and recirculation pump rotameters shall be armoured purge meter type with magnetically coupled indicator used for low flow, high pressure, and high temperature. Accuracy shall be plus or minus 10 % of measuring flow rate. Rotameter shall include a 12 mm stainless steel needle valve.

10.2.8

WYE Strainer

1

Wye strainer shall be installed on the potable water, recirculation and dosing pump feeds,. Strainers shall have a PVC body with type 316 stainless or PVC strainers with 0.8 mm perforations.

10.2.9

Sump Overflow Trap

1

A trap shall be provided on the scrubber sump overflow line to prevent air inflow through the scrubber.

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10.2.10 Acid Supply Connection 1

The scrubber shall be equipped with a nozzle for addition of a dilute acid solution to the sump. A 50 mm PVC ball valve and 50 by 100 mm funnel shall be installed for this.

10.2.11 Pressure And Vacuum Gauges General. Pressure gauges shall be of the stem-mounting type.

2

Construction. Gauges shall be of the bourdon tube or bellows type with 270  clockwise pointer travel. Dials shall be white with black numerals. Dial size shall be 100 mm. Panel mounted gauges shall have round bezels for flush mounting and rear connection, others shall have a stem-mounting bottom connection. Connections for all gauges shall be male 12 mm threaded with square wrench flats. Wetted parts shall be compatible with the process fluid. Cases shall be impact resistant plastic. Accuracy shall be ±0.5 % of span.

3

Chemical Seal. The gauge shall be furnished with a diaphragm seal. The diaphragm seal shall have a 316 stainless steel (minimum) top and bottom housing and a 316 stainless steel diaphragm welded to the top housing. When the process fluid is not compatible with 316 stainless steel, the manufacturer shall provide a diaphragm seal compatible with the process fluid. The process connection shall be a 20 mm threaded connection with a flushing connection. The fill fluid shall be silicone.

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10.2.12 Pressure Switches

Pressure switches shall be operated by a brass bourdon tube actuating a switch. Switches shall be single pole double throw, rated at 4 A, 240 V a.c., 50 Hz, and have deadband adjustable up to 100 % of switch range. The adjustable operating range shall be 1 mPa, with calibrated dials and two pointers indicating set and reset points. Enclosures shall be IP 65.

2

Pressure switches shall be fitted in the dosing and potable water booster pump lines to effect changeover from duty to standby pumps.

3

A pressure drop transmitter shall be fitted in the ducting to effect changeover from duty to standby fans.

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10.2.13 Drench Showers

One or more drench showers shall be provided by the chemical storage tanks, as specified.

2

Showers shall be operated by a walk-on platform with stainless steel operating linkages and a stainless steel stay open valve which locks open.

3

The shower deluge shall be provided by gravity from a tank mounted above the shower with an in-line or tank mounted thermostatically operated heater, fitted with 30 mA RCD protection.

4

The shower shall incorporate an emergency eye/face wash fountain with a flexible hose

5

The shower shall be complete with a light and emergency shower/eye wash signs.

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10.2.14 Water Softener 1

These shall be dual cylinder water softeners, rated for continuous output with an integral meter initiated water power regeneration. The softener shall use a fine bead resin bed in conjunction with a brine solution. The softener shall be rated for 28 days use without the salt storage being replenished.

QCS 2014

2


Page 13

A water storage break tank shall be provided to feed the softeners via duty/standby water booster pumps.

10.2.15 Control Panel 1

A prewired, preassembled electrical control panel shall be provided for the odour control system, as specified in the particular Project Specification

2

The panel shall be supplied complete with all equipment and accessories, including the following: motor control switches and indicating lights for the fans, recirculating pumps chemical metering pumps, pH and Redox analyser/controllers

(b)

interlocks between recirculating pumps, chemical metering pumps, and sump level control. Interlocks between pH and Redox analyser/controllers, chemical metering pumps, and the make-up water solenoid valve and level controls

(c)

selector switches for manual or automatic operation

(d)

an annunciator with volt-free contacts for remote signalling, as required in the Project Specification.

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Additionally the panel construction and components shall meet the requirements of Part 1 of this Section, Section 21 and shall be suitable for connection to 415V 3 phase 50Hz.

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(a)

10.2.16 Factory Inspection and Testing

The Contractor shall secure from the equipment manufacturers certification that the following factory tests have been carried out, and submit to the Engineer prior to shipment.

2

Fibreglass vessels shall be tested as follows:

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hydrostatically tested prior to shipment, with water to the top of the vessel for a minimum of 24 hours

(b)

the water must be contained with no leaks or excessive wall deflection.

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Fans shall be tested as required by BS 848, Parts 1 and 2

4

One pump of each size supplied shall be factory tested. Where multiple units are provided, only one of each size and type shall be tested. Dosing pumps shall be tested in accordance with BS 5316 Part 2, recirculation pumps to BS 5316 Part 1.

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10.2.17 Spare Parts and Tools 1

The Contractor shall provide from the equipment manufacturers all the spare parts and tools required during the commissioning and maintenance periods as specified in Part 1, including those below:

2

In addition, sufficient chemicals shall be provided for the complete operation of the odour removal system for 2 years of operation.

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Page 14

(1) (2) (2) (2) (if fitted)

Scrubber main packing spray nozzles moisture separator packing

(100 %) (for 1 bed) (1) (set) (5%) (of total)

Dosing pumps diaphragms Disk check valves and sets Pump gaskets and ‘O ‘ rings Pumps and motors

(8) (8) (8) (complete sets) (2)

Recirculation Pumps Impeller Seals Pump and motor

(2) (8) (1)

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Fan Complete Centrifugal Fan Sets of V- belts Sets of bearing Shaft seals

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Item

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The following spare parts shall be furnished as a minimum requirement, in addition to any additional spare parts required for two years of operation.

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10.3.1

Installation

1

The Contractor shall ensure the supplier of the odour control system furnishes the services on site of a factory trained service technician or engineer. He shall inspect the equipment installation, advise and assist with commissioning, and train the Employer’s operations and maintenance personnel.

2

The odour control system shall be installed in accordance with manufacturer’s written instructions, by suitably qualified and experienced personnel.

10.3.2

Site Inspection and Testing

1

Vessel and tank tests. The above water tests shall be repeated on site after installation.

2

Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with BS 848 Part 5.

3

Odour System Test: The Contractor shall test as follows:

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10.3

(a)

the odour control system to certify that it meets requirements after completion of the installation

(b)

all odour shall be testing conducted by the Contractor in the presence of the Engineer

(c)

the odour control system test shall be conducted after all the air systems are tested and balanced. Separate H2S tests shall be conducted on each odour control system

(d)

the H2S tests shall be repeated at the end of the maintenance period with the plant in full operation during the time of year determined by the Employer to have greatest odour problems, using the actual gas levels generated by the pumping stations

QCS 2014

(e)

Page 15

the hydrogen sulphide test shall comprise as follows: (i)

hydrogen sulphide (H2S) concentrations shall be measured using a calibrated portable H2S analyser

(ii)

if instructed by the Engineer, bottled H2S gas shall be used to determine if the specified H2S performance requirements are met

(iii)

each test: three sets of samples shall be taken over an 8 h period:

 each test shall consist of an inlet and outlet H2S test  the supplier shall be responsible for supplying the H2S for the bottled H2S testing  the three H2S levels to be tested shall be selected by the Engineer. if the odour control system fails to meet the performance criteria, it shall be the Contractor’s responsibility to make all the modifications necessary to improve performance at no cost to the Employer. The Contractor shall pay for all additional testing required to verify that performance criteria are being met

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(f)


final acceptance of the system will only be possible after successful completion of this testing

(h)

documentation for all the testing shall be submitted to the Engineer.

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END OF PART

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QCS 2014

Section 09: Mechanical and Electrical Equipment Part 11: Screening Equipment

Page 1

11

SCREENING EQUIPMENT ........................................................................... 2

11.1

GENERAL ...................................................................................................... 2


2 2 2

PRODUCTS ................................................................................................... 2

11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.2.7 11.2.8

General Brush Screen Band / Escalator Screen Rotary Raked Bar Screen Semi Rotary Raked Bar Screen 11.2.6 Step Screen Straight Bar Screen Covered Skip Containers

11.3

SCREENINGS TRANSFER SYSTEMS ......................................................... 6

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11.3.1 Screening Trough 11.3.2 Conveyor Belt

2 3 3 4 4 5 5 6 6 6

SCREENING WASHER/COMPACTORS ...................................................... 7

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11.4.1 Screening Washer/Compactor 11.4.2 Washer/Dewaterer

7 7

GEAR REDUCER .......................................................................................... 8

11.6

MOTORS ....................................................................................................... 8

11.7

CONTROLS ................................................................................................... 8

11.8

INSTALLATION AND COMMISSIONING ...................................................... 8

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11.8.1 Installation and Commissioning 11.8.2 Testing

8 8

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Page 2

SCREENING EQUIPMENT

11.1

GENERAL

11.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, installation, testing and commissioning of screening equipment.

2


11.1.2

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General Sewerage Instrumentation, Control and Automation Building Electrical Works Electrical Works

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References

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BS EN 10084, ...........Case hardening steels

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List of ‘Approved Suppliers’ prepared by the Public Works Authority Submittals

1

In addition to the requirements of Part 1 of this Section, the Contractor shall reconfirm the information provided in the Technical Submission Schedules submitted with his Tender.

11.2

PRODUCTS

11.2.1

General

1

Screens shall be complete with all the necessary ancillary equipment and with screenings washing and compacting facilities.

2

The screens shall be fitted with an automatic cleaning mechanism, which shall remove the screenings adequately and positively into a screenings transfer system to the screenings washing equipment without risk of spillage. The transfer system shall be totally enclosed and be fitted with bolted removable access cover sections.

3

Unless otherwise stated in the Contract Documents the Contractor shall make his own assessment of the amount of screenings that will be produced by his equipment and the design of the screenings handling system shall be sized accordingly.

4

In all cases the screens shall be protected by a torque limiting device in addition to the motor overload protection. Rake parking switches shall also be provided and in each case the electrical circuit information for each device shall be provided with drawings for approval. The screening equipment shall not immediately restart on removal of the obstruction but shall be manually reset at the control panel.

5

The screen aperture shall be as stated in the Contract Documents.

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Page 3

All moving parts of the screen shall have oil impregnated, sintered bronze or grease lubricated bearings. In the case of the latter, individual stainless steel feed pipes and flexible polyurethane tubes to the bearings shall be fed from a manifold that shall be located in a convenient position outside any guards on the screen. A manual grease feed pumping system shall be incorporated.

7

The screen framework and components shall be designed to resist both hydraulic and drive mechanism loads during normal running and all modes of failure. Screen rake mechanism shall be arranged such that the minimum number of moving parts will remain immersed when the screen is in the parked position.

8

The complete headgear shall be enclosed within a removable glass reinforced plastic splash hood and a hinged door shall be provided to give visual inspection of the screens. The hood shall incorporate air admittance valves.

9

The plant shall be controlled by PLC suitable for SCADA and telemetry connection and shall incorporate a Human Machine Interface (HMI) within a dedicated Motor Control Centre (MCC).

10

The screen shall be manufactured from stainless steel Grade 316 S31 to BS 970-1(partially replaced by BS EN 10084), unless otherwise stated.

11

Limit of position indication shall be incorporated into the drive mechanism by means of proximity switches protected to IP68.

11.2.2

Brush Screen

1

The screen shall comprise perforated stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), or moulded polyurethane panels with 6mm apertures. .

2

The rotating brush shall incorporate adjustment arrangements to optimise brush effectiveness and reduce brush wear. Brush adjusters shall be fitted with either locknuts, stiff nuts or stop retainers to prevent disengagement of the brush resulting in consequent damage of the screen plates.

3

The screening panels shall be bolted to the framework using stainless countersunk bolts. Edge clearances shall not be capable of trapping screenings and in any event shall not exceed 5mm.

4

The screen shall be provided with a brush wiper mechanism to ensure the complete removal of screenings from the brush.

11.2.3

Band / Escalator Screen

1

Travelling Band / Escalator Screens shall not be permanently secured to the screen chamber walls. Location fixings shall be positioned at coping level for ease of access.

2

Screens to be housed in enclosed structures shall be manufactured in sections to facilitate removal from the chamber making due allowance for the maximum height available.

3

Where the size of the screen permits, the screen may be hinged such that it can be tilted out of the chamber for maintenance purposes.

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Page 4

The screen shall consist of a moving band of screening panels supported above coping level on two cast iron sprockets mounted on a horizontal headshaft supported in self aligning roller bearings. The headshaft shall be mounted on machined guides to allow for adjustment to compensate for chain wear. Tension screws shall be provided and shall be manufactured from stainless steel.

5

The main chain shall comprise links, bushes, pins and rollers and shall be self-lubricating by immersion in the flow. The links shall carry the mesh panel support frame and shall be fixed with stainless steel set screws. The chain shall run in curved guides at the bottom of the channel. Sprockets shall not be used to return the chain at the bottom of the channel.

6

The mesh panels shall be constructed of perforated stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), or moulded polyurethane, and provided with elevators to raise the screened material to the cleaning point. Woven panels shall not be used for screening sewage. The panels shall be designed to withstand full differential head across a fully blinded panel.

7

A sealing plate shall be provided between the outer edge of the mesh panels and a sealing angle bolted to the walls of the screening chamber. The plate shall enclose the chain guide on the upstream side of the screen to prevent debris fouling the chain. Sealing strips shall be provided between adjacent mesh panels to maintain the screening aperture when panels articulate around the bottom curve of the chain guide.

8

Spray jets shall be provided within the head section to remove the screenings from the mesh into a debris collecting trough. The spray pipe feeding the jets shall be provided with a washout valve fitted with a hose connection to facilitate flushing of the system. A rotating brush shall be provided immediately after the spray jets to remove fibrous material that has interwoven between the mesh apertures. The brush shall be easily renewable and fixed by stainless steel set screws.

9

The spray jet water shall be applied at the correct quality and pressure to efficiently remove all screenings during one pass of the panels.

10

Chain driven screens shall be provided with chain tensioners and have provision for manual adjustment in the event of chain stretching.

11

Tracked carriages shall also be provided with wheel adjustment so that engagement in the channels of the track can be optimised.

11.2.4

Rotary Raked Bar Screen

1

Rotary curved bar screens shall be raked by a shaft mounted rake mechanism revolving continuously through 360o. The rotation of the cleaning rake shall clean the radius of the stationary bar rack and elevate screenings to a discharge point at the top of the rack. At this point a wiper mechanism shall ensure that the rake is cleared of all screenings before continuing its cycle.

11.2.5

Semi Rotary Raked Bar Screen

1

Semi rotary curved raked bar screens shall comprise a single cleaning rake which by means of a pivoting linkage describes a rotary path along the stationary curved rack, disengages at the top of the screen rake and re-engages at the bottom of the rack.

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Page 5

2

At the top of the rack a wiper mechanism shall ensure that the rake is positively cleared of all screenings before continuing its cycle.

3

This type of screen may also be hydraulically operated.

11.2.6

11.2.6

1

Step screens shall not be permanently secured to the screen chamber walls. fixings shall be positioned at coping level for ease of access.

2

Screens to be housed in enclosed structures shall be manufactured in sections to facilitate removal from the chamber making due allowance for the maximum height available.

3

Where the size of the screen permits, the screen may be hinged such that it can be tilted out of the chamber for maintenance purposes.

4

The screen shall consist of a series of self cleaning screening bars in a staircase configuration. Every other bar shall be fixed in a rigid structure and the remaining bars shall form a robust moveable framework that shall revolve in a reciprocating motion to lift the screenings step by step to the top for discharge.

5

A sealing plate shall be provided between the outer edge of the screen and the walls of the screening chamber. The plate shall enclose the drive mechanism on the upstream side of the screen to prevent fouling by debris. Chain drives, if used, shall incorporate means of adjustment to compensate for chain wear. Tension screws shall be provided and shall be manufactured from stainless steel.

6

The screen shall be designed to prevent blockage at the base by grit or stones and shall be constructed of stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084).

11.2.7

Straight Bar Screen

1

The straight bar screen may be vertical or inclined and shall comprise a stationary bar rack or grid which is automatically cleaned by one or more power operated rakes.

2

The screen bars shall be at the centres as specified in the Contract and fabricated from stainless steel to BS 970, Grade 316 S31 (partially replaced by BS EN 10084).

3

The screen may be front or back raked. In the case of reciprocating rake machines, the rakes shall clear the bars on the down stroke and engage positively with screen bars prior to the upward stroke. A wiper mechanism shall ensure that the rake is cleared of all screenings before continuing its cycle.

4

The cleaning rake shall be jam proof type, chain driven, suitable for either front or back cleaning, and shall be formed of stainless steel with teeth of adequate length and section bolted on for easy replacement.

5

Chain driven screens shall be provided with chain tensioners and have provision for manual adjustment in the event of chain stretching.

6

Tracked rake carriages shall also be provided with wheel adjustment so that engagement in the channels of the track can be optimised.

Step Screen

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Location

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Page 6

Covered Skip Containers

1

Covered skips shall be suitably sized and fabricated from steel sheets of sufficient thickness to withstand full volume of screenings or grit loading and the stresses of movement and dumping of the screenings and grit.

2

The shape and dimensions of the skip containers shall be compatible with the configuration of the screenings and grit dewaterers so that discharge to the skip containers occurs without spillage. The skips shall have a nominal length of 3.6m, nominal width of 1.8m and nominal liquids capacity of 3.6m3 and shall be suitable for use with Government of Qatar standard skip transporting vehicles.

3

Skip containers shall have rubberised castor wheels, with a minimum wheel diameter 150mm.

4

Skip containers shall be epoxy coated in accordance with Section 8, with a minimum of at least 3 epoxy coats.

5

Covered skips shall be interchangeable between the screens and grit removal applications.

6

Skips shall be subject to a 5 year replacement guarantee under regular use by the Client, provided that the skips are not subjected to misuse.

11.3

SCREENINGS TRANSFER SYSTEMS

11.3.1

Screening Trough

1

Screenings shall be discharged from the screens into a screening trough for water borne transfer to the washer/compactors. The trough shall be made of minimum 6 mm thickness stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) plate with bolted removable access cover sections.

2

Water for flushing the screenings from the screen discharge collection point to the washer/compactor shall be 6mm screened sewage, treated sewage effluent or potable water as specified in the Contract. Screened sewage shall only be used with the approval of the Engineer and the Contractor shall take all necessary measures to eliminate odour release and to treat any odours that are released.

3

The trough shall be supplied with two inspection ports having dimensions of approximately 100 mm by 500mm. A 25 mm pipe flushing connections shall be provided at each end of the drainage collecting trough to allow washing/cleaning of the trough.

11.3.2

Conveyor Belt

1

Conveyor belts shall be of 3-ply standard endless conveyor belting (joints to be vulcanised), reinforced with fabric between plies of width 800mm and a thickness of 20mm (upper plycontact surface 7mm, middle ply 8mm and bottom ply 5mm thickness). This conveyor shall be incorporated with SS side plates, doctor blades, troughing and stainless steel return idlers, adjustable tail pulley and a motorized head pulley permitting rotation in both directions. The conveyor shall be mounted on stainless steel frame work.

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Page 7

SCREENING WASHER/COMPACTORS

11.4.1

Screening Washer/Compactor

1

Screenings compactors shall consist of an inlet hopper, high energy washing zone, screw compactor, electric motors and reduction gear drive unit, discharge pipe, drain connections and water spray system. The whole unit shall be factory assembled and tested prior to shipment. The unit shall be designed to wash faecal and organic matter from the screenings before compaction and discharge through a chute suitable for use with a standard skip.

2

The washing impeller and its drive unit shall be hinged from the tank for ease of maintenance.

3

A drain shall be installed at the lowest point of the wash tank, be fitted with a knife valve and shall be piped, together with the wash water overflow, to a local drain point.

4

The dewatering compartment shall be a screw compactor operating in a trough with maximum 6mm diameter perforations for drainage. The compactor screw shall be fitted with a hard wearing brush on the periphery of the screw blades to ensure free drainage is maintained. The brush shall be arranged to allow adjustment for wear.

5

The compactor will have a minimum capacity as required by the volume of screenings expected to be produced by the contractors proposed screens and will be designed to provide compacted screenings with a maximum moisture content of 50% and a maximum faecal content of 5%.

6

The compactor screw shall be constructed of stainless steel flights welded to a stainless steel solid shaft. The screw shall extend a minimum of 600mm beyond the end of the dewatering zone. The pressing zone shall be a cylindrical stainless steel pipe rising towards the discharge chute. Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084).

7

The discharge pipe shall be made of stainless steel and shall use long-radius fittings designed to avoid any jamming of the partially dewatered/compacted screenings. The discharge pipe shall be easily disassembled to clear blockages and shall terminate in a position or manner such that a standard skip can be easily removed from below it.

11.4.2

Washer/Dewaterer

1

Washer/dewaterers shall be of the two stage brush and perforated plate type and fabricated from stainless steel with removable GRP access covers.

2

The first stage, (washing stage) shall contain the rotating brush assembly fitted with four polypropylene brushes, and the second stage, (dewatering stage) shall contain a rotating rubber roller assembly fitted with four tensioned rollers.

3

The screening panels shall be manufactured from stainless steel with 3mm perforations.

4

The machine shall be complete with integral inspection walkway, access ladder and handrailing, the walkway width being 900mm minimum. Where duty and standby machines are specified a common walkway may be sited between the machines, however the machines must be of sufficient height to allow discharge of the screenings into a common skip.

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Page 8

The filtrate shall collect in the bottom of the machine and discharge through a NP16 flanged outlet of 100mm n.b. A 100mm n.b. overflow outlet, flanged to NP16 shall also be provided above the centre line of the machine. Pipework shall be of stainless steel.

11.5

GEAR REDUCER

1

The screens and washer/compactors shall be powered by an electric motor and gear reducer.

2

The gear reducer shall include anti-friction bearings with high overhung load properties and oil-seal, double-lip, high temperature synthetic riding on precision ground shaft, to minimise leakage possibilities. The speed reducer shall be enclosed in a cast iron weatherproof casing. Gears shall be made of hardened and heat treated forged steel. The gear reducer shall not be overloaded under any normal operating conditions and shall be designed for heavy-duty service. The gearing shall be oil lubricated.

11.6

MOTORS

1

Motors shall have Class F insulation and be rated for continuous duty operation. They shall conform to the requirements of Section 21 of the specification and the recommendations of the manufacturer.

2

Motors shall be sized so that under maximum continuous loading the motor rated power is a minimum of 50 % greater than the driven load.

11.7

CONTROLS

1

All necessary controls shall be incorporated in an FBA as described in Section 21.

2

The controls shall include all the necessary relays, starters, timers, indicators, breakers, switches and fuses and all other electrical accessories required to make the system complete and perfect in every way.

11.8


11.8.1

Installation and Commissioning

1

The equipment delivered to Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict accordance with Part 1 of this Section 9.

11.8.2

Testing

1

Test Procedures shall be in accordance with Part 1 of this Section 9 and the particulars of the Contract.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 12: Grit Removal Equipment

Page 1

12

GRIT REMOVAL EQUIPMENT...................................................................... 2

12.1

GENERAL ...................................................................................................... 2


2 2 2

PRODUCTS ................................................................................................... 2

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5 12.2.6

General Hydro Dynamic Separator Vortex Grit Separator Cross Flow Grit Removal Screw Grit Classifier Reciprocating Rake Grit Classifier

12.3


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Page 2

GRIT REMOVAL EQUIPMENT

12.1

GENERAL

12.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, installation, testing and commissioning of grit removal equipment.

2


12.1.2

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General Drainage Works Instrumentation, Control and Automation Building Electrical Works Electrical Works

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12

References

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BS EN 10084 .............Case hardening Steels

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BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes.

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1


12.2

PRODUCTS

12.2.1

General

1

Grit removal equipment shall comprise vortex grit separators, sized to achieve the specified operating criteria and each shall operate in conjunction with a grit classifier.

2

The Contractor shall make his own assessment of the amount of grit which will be produced by his equipment and the design of the grit handling systems shall be sized accordingly.

3

Grit separators shall be complete with all necessary ancillary equipment and controls.

4

The plant shall be controlled by PLC suitable for SCADA and telemetry connection and shall incorporate a Human Machine Interface (HMI) within a dedicated Motor Control Centre (MCC).

5

An interlock shall be provided between the grit removal device and the grit classifier.

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Page 3

Hydro Dynamic Separator

1

The grit separator shall be designed to efficiently remove grit from waste water inflows to protect downstream components of the Treatment Plant. They shall utilise the special characteristics of controlled hydro dynamic flow, to separate settleable solids and operate at high hydraulic loadings to minimise facility space requirements.

2

The separator shall have no moving parts and require no maintenance. Grit separation shall be accomplished entirely by the unit geometry and hydraulic flow regime. The tangential inlet and overflow design shall ensure that vortex flow develops and that no short circuiting through the unit can take place.

3

The flow shall enter through the tangential bottom inlet pipe, spiral and rise through the separator, flows through the annular opening created by the conical section and the overflow floor, over the overflow weir and out through the de-gritted overflow pipe or channel.

4

Grit and other settleable solids shall drop to the sloped bottom and be concentrated into the unit sump. The concentrated grit shall be removed from the sump using a grit pump or airlift pump.

5

A tangential inlet shall induce a vortex flow pattern within the separator hence creating ideal conditions for the potential currents of a vortex funnel. The resulting flow patterns shall be well defined and low in turbulence leading to favourable conditions for grit settling.

6

A conical section extending into the interior of the vessel shall be used to stabilise the secondary currents and increased the boundary surfaces to induce further grit settling.

7

The collected and concentrated grit in the sump shall be pumped to a screw classifier which shall be used to wash and classify the grit in order to minimise organic solids concentrations in the grit discharge.

8

All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084).

12.2.3

Vortex Grit Separator

1

The circular tank grit trap shall be supplied complete with geared motor, gearhead assembly, impeller drive tube, impeller, air blower and airwash/airlift assemblies.

2

The grit trap shall be designed such that the headloss is less than 7mm. The design shall be capable of removing grit from screened sewage and depositing grit into the grit classifier.

3

The grit removal chamber shall have inlet and outlet separated by greater than 270o of the tank periphery. There shall be a sloping floor connecting the upper and lower sections.

4

The grit removal device shall be fitted with a rotating impeller. The impeller shall be manufactured in two halves and shall be clamped to the drive tube when fully assembled. The stub shaft should not have any supporting bearings under the water and should be hanging from the gear head assembly.

5

The impeller shall be fitted with four fixed blades set at an angle of 30o and provide sufficient washing action to prevent lighter solids entering the classification gap between impeller and grit hopper whilst allowing settled grits through for collection.

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12.2.2

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Page 4

The impeller blades shall create a slight upward flow in the central zone of the upper chamber whilst leaving the outer annulus of the upper chamber quiescent to allow grit settlement.

7

The impeller shall be driven by a helical geared motor with a service factor of 2.0 or greater. The geared motor shall be fully weatherproofed and shall be oil lubricated and the drive shall incorporate a slewing ring bearing and helical spur gearing transmission. Torque limiter to be provided for protecting the drive unit.

8

An airwash/airlift assembly shall be provided to facilitate grit washing and removal. The assembly shall consist of an airlift pump discharge pipe, minimum 100mm diameter, with airwash and airlift headers. Separate air supply lines consisting of minimum 38mm diameter pipe shall connect to the airwash and airlift header. The airwash header shall discharge an adequate quantity of air for air washing of the collected grit. Each air delivery line shall terminate above the drive gear head and connected to a three way ball valve, minimum 38mm diameter, with automatic operation.

9

The Contractor shall supply a displacement blower and pipework to provide air for the airwash/airlift operation. The blower shall have the capacity to provide sufficient quantities of air at the required pressure to ensure efficient operation of the airwash/airlift system.

10

All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084).

12.2.4

Cross Flow Grit Removal

1

Cross Flow Grit Removal Equipment shall be designed to achieve an optimum sewage velocity to enable the complete satisfactory settlement of the specified fine grit particles.

2

Each arm assembly shall be equipped with a sufficient number of scraper flights such that they will be capable of removing up to 50 mm of grit from the floor of the grit settlement tank into a grit sump.

3

The Contractor shall supply and install all the equipment necessary for its operation inclusive of bridge, scraper arms, drive assembly, inlet guide vanes, tubes, pipes, grit pump and fixings etc.

4

The plant shall be designed for installation in a circular flat-bottomed tank.

5

The approach velocity into the detritor shall be 1.2m/s with a maximum horizontal velocity across the tank not exceeding 0.3m/s unless stated otherwise in the Contract Documents.

6

The inlet shall span the diameter of the tank and be equipped with inlet deflectors which shall evenly distribute the flow across the whole width of the tank. The deflector support channels, spindles and sleeves complete with concrete guide vanes shall be supplied and installed by the Contractor.

7

The bridge structure shall be constructed from stainless steel section braced together. The beams shall be designed to withstand the total loadings imposed by the bridge and its associated equipment plus a super-imposed load of 250kg/m2 (equivalent to two men) without exceeding a total deflection of 1/360 of the bridge span.

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Page 5

The access walkway shall comprise stainless steel non-slip floor plates fixed to the bridge structure and supporting double row handrailing which shall comply with Section 8 Part 6.

9

The centre bearing assembly shall be designed to withstand the total loading of the rotating scraper arms and other forces associated with the plant in operation.

10

The scrapers shall be driven by a motor/gearbox unit, directly or via a chain drive. In both cases a torque limiting device shall be supplied to initiate safe plant shut down should a blockage occur.

11

The peripheral speed of the scraper arm shall not exceed 5m/min.

12

The scraper arms, blades and shaft shall be fabricated from stainless steel and shall incorporate a scoop at the extreme end to assist in the sweeping of the deposited grit into a grit sump, or into the classifier hopper, depending on the system design.

13

Duty and standby grit pumps shall lift the grit into the classifier hopper.

12.2.5

Screw Grit Classifier

1

Each grit separator shall have an individual grit classifier. However, the grit delivery pipework shall be arranged such that if one classifier is out of operation, e.g. for maintenance, its associated separator can be connected to another classifier.

2

The grit classifiers shall be capable of handling the water and grit removed from the grit separators at the rate discharged by the grit air lift or grit pump.

3

The grit classifiers shall be a free standing units of the helical screw type which shall efficiently deposit dry organic free grit to a skip positioned beneath the discharge chute.

4

A wash water supply shall be connected into the classifier to assist with washing the grit. The units shall be provided with a valved washout drain at the lowest point which shall be piped, together with the wash water overflow, to a local drain point.

5

The screw drive unit shall be mounted at the upper end of the screw trough. The whole of the unit shall be guarded over its whole length.

6

The screw conveyor shall use a shaft-less screw resting on wearing surfaces. The screw device shall not have a submerged end bearing.

7

The screw shall be formed in stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) plate of 8mm minimum thickness and the trough of a similar metal in 6mm plate.

8

The wearing surfaces in the screw trough shall be easily replaceable and formed of high density polyethylene (HDPE).

9

The screw shall be fitted on one bearing placed in the drive unit. The bearing shall be a combined thrust and radial type sufficient to accommodate the total axial and thrust loading.

10

The screw conveyor shall have adequate accessibility for maintenance.

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Page 6

Reciprocating Rake Grit Classifier

1

Reciprocating rake grit classifiers and cleaning mechanisms shall comprise a multiple-rake reciprocating mechanism mounted within the cleaning channel constructed parallel to the direction of flow and integral with one side of the cross flow grit settlement tank. The mechanism shall be inclined and deposit clean grit into the collecting skip positioned below the grit discharge. The discharge point shall be above Top Water Level. The grit shall be separated from the organic matter by the washing action of the reciprocating rake and suitable means of returning organic matter to the collecting tank shall be provided, together with the necessary built in pipework, screen and washwater pump.

2

The rake and blades shall be fabricated from stainless steel section and shall be suspended from the drive unit by connecting rods and bell cranks.

3

The classifier shall be driven by a motor/gearbox unit with torque unit switch via a crank mounted on the output shaft; balance weight arms, secondary output shaft; bellcrank and rake hangers.

4

The entire reciprocating mechanism shall be totally enclosed to prevent accidental contact and release of odours.

12.3


12.3.1


1


12.3.2

Testing

1


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12.2.6

END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 13: Aeration Equipment

Page 1

13

AERATION EQUIPMENT .............................................................................. 2

13.1

GENERAL ...................................................................................................... 2

13.1.1 Scope 13.1.2 References 13.1.3 Submittals 13.2

2 2 2

PRODUCTS ................................................................................................... 2

13.2.1 General

2

SHAFT ROTOR AERATORS ........................................................................ 3

13.3.1 13.3.2 13.3.3 13.3.4

Rotor Aerators Aeration Tank Baffle Vertical Shaft Surface Aerators Floating Aeration Devices

13.4

SUBMERSIBLE AERATION DEVICES ......................................................... 5

13.5

AIR BLOWERS OR COMPRESSORS .......................................................... 5

3 4 4 4

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13.5.1 General

5

AIR PIPEWORK............................................................................................. 5

13.6.1 13.6.2 13.6.3 13.6.4 13.6.5 13.6.6

Intake Ducting Discharge Pipework Blower Manifold Air Supply Main Distribution Pipework Flow Control and Isolation

13.7

AIR DIFFUSERS............................................................................................ 8

13.7.1 13.7.2 13.7.3 13.7.4 13.7.5

General Fine Bubble Air Diffusers Tubular Membrane Diffusers Plate Membrane Diffusers Coarse Bubble Air Diffusers

13.8


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Page 2

AERATION EQUIPMENT

13.1

GENERAL

13.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, installation, testing and commissioning of equipment to dissolve oxygen into liquids using air.

2


References

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13.1.2

General Sewerage Instrumentation, Control and Automation Building Electrical Works Electrical Works

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BS EN 10084 .............Case hardening steels

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BS 3170 .....................Specification for flexible couplings for power transmission BS EN 779 .................Particulate air filters for general ventilation

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List of „Approved Suppliers‟ prepared by the Public Works Authority Submittals

1


13.2

PRODUCTS

13.2.1

General

1

The works shall be complete with the appropriate number of air blowers, pipework, fittings, valves, diffusers, control equipment and all the necessary ancillaries to make the plant complete.

2

The aeration devices selected by the Contractor shall be based on achieving maximum oxygen transfer efficiency for the design liquid depth. The minimum oxygenation rate in clean water shall be 2.0 kgO2/kW.h at 20ºC

3

Upon selection of a particular aeration device the Contractor shall provide sufficient test data demonstrating the oxygen transfer efficiency of the aeration device at the design liquid depth. Tests shall have been carried out in accordance with the requirements of the American Civil Association standard “Measurement of Oxygen Transfer in Clean Water” test. If the contractor is unable to provide evidence that their equipment has been tested in this way the Contractor shall undertake an oxygen transfer test in clean water in accordance with the American Civil Association standard at an approved testing laboratory.

4

The sizing and number of aeration devices shall be dependent upon the oxygenation requirements of the process.

5

The Contractor shall supply the Engineer with all supporting design calculations and criteria used to determine the type and size/no. of aeration devices selected for approval.

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Page 3

The plant shall be controlled by PLC suitable for SCADA and telemetry connection and shall incorporate a Human Machine Interface (HMI) within a dedicated Motor Control Centre (FBA).

7

The Contractor shall design, supply and install the optimum number and configuration of air blowers to give the best whole life cost and maintain the integrity of the process.

8

The Contractor shall provide standby facility at all control valves and shall, insofar as is possible, design and select the valves to be identical to rationalise maintenance.

9

Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) unless otherwise stated.

13.3

SHAFT ROTOR AERATORS

13.3.1

Rotor Aerators

1

The rotor shall be suitably sized for the process requirements up to a maximum of 9 metres in length. The rotor shall be suitable for immersion at depths of 0-300mm

2

The rotor shaft shall be of stainless steel sealed at both ends and suitably strengthened along its length to minimise the effects of torsion.

3

The shaft shall be supported at the drive end and non-drive end by cylindrical roller bearings.

4

Stainless steel aeration blade elements shall be equi-spaced around the circumference and along the length of the drive shaft.

5

In order to minimise the effects of clogging of the aerator, the aeration blades shall be fixed by bolting to the drive shaft only.

6

The aeration blades should be positioned such that pulsating torque transferred to the drive shaft, caused by the action of their immersion in the process liquid, is prevented.

7

The drive unit shall comprise a helical geared reduction gearbox. Design of the rotor/drive unit shall prevent contamination of the drive unit from sludge thrown by the rotor.

8

Splash type lubrication of the gears shall be facilitated by means of an oil bath.

9

Shaft bearings shall be protected against water ingress by the provision of rubber lip seals.

10

Bearings shall be roller or angular contact type, designed for a B10 life expectancy in excess of 100,000 hours.

11

Steel foundation plates shall be provided beneath the drive mechanism suitable for fixing by anchor bolts.

12

Power transmission from the reduction gearbox to the rotor shall be via a flexible coupling. The coupling shall be designed to minimise the transmission of vibration from the rotor to the drive unit. The flexible coupling shall be in accordance with B.S.3170.

13

The end of the rotor shaft shall be fitted with a split pattern self aligning bearing assembly.

14

The bearing unit shall consist of a cast iron housing and grease lubricated heavy duty double row roller bearing with lip seals. Locking collars shall be provided.

15

The rotor unit shall be fitted with GRP splash guards which shall be positioned along the full length of the rotor between the top of the rotor and the underside of the walkway.

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Page 4

GRP covers shall be provided for the drive unit, bearings and end bearing assembly.

13.3.2

Aeration Tank Baffle

1

An aeration tank baffle shall be provided to direct surface velocities downwards thus maintaining the necessary flow velocities for the depth of tank specified in the contract.

2

The baffle shall cover the full width of the tank and be fabricated from stainless steel.

3

The baffle shall be provided complete with all necessary fixing bolts and brackets.

13.3.3

Vertical Shaft Surface Aerators

1

The aerator shall comprise a central deflector/cone complete with profiled blades. The aerator shall be of all-welded construction. Alternatively the impeller shall be the centrifugal screw type comprising a central shaft to which a spiral vane is fully welded along its length

2

The aerator impeller shall be fabricated from stainless steel.

3

Cross baffles for use with the aerator impeller shall be fabricated from stainless steel and shall be of all-welded construction suitable for bolting to the aeration tank floor.

4

In order to promote mixing of the process liquid and to avoid short circuiting, up-draught tubes shall be fitted below the aerator impeller.

5

Up-draught tubes shall be manufactured from stainless steel or GRP and be suitable for bolting to the tank floor via adjustable mounting brackets.

6

Stainless steel tie rods suitable for bolting to the tank structure shall be provided complete with adjustable turn buckles for alignment of the up draught tube.

7

The drive shaft shall be fully welded construction manufactured from steel tube and plate.

8

The drive shaft shall be connected to the reduction gearbox via a fixed coupling.

9

The drive unit shall comprise a helical geared reduction gearbox.

10

The drive unit shall be fitted with a 3 phase high efficiency motor complying with the requirements of Section 21.

11

Where specified by the contract the drive motors shall be suitable for variable speeds via frequency invertors.

13.3.4

Floating Aeration Devices

1

Where specified vertical shaft type aerators shall be mounted on a floating raft.

2

The raft shall be manufactured from stainless steel box section. The structure shall be suitably braced for rigidity and interconnections between cross members shall be demountable

3

The raft shall be supported in the process media by use of suitably sized Polyethelene drum buoyancy aids, or equal approved by the Engineer, which shall be bolted to the raft framework.

4

The raft assembly shall be restrained within the tank structure by means of a minimum of three stainless steel guy ropes complete with turnbuckles.

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13.4

SUBMERSIBLE AERATION DEVICES

1

The aerator shall comprise the following: (a)

Submersible Motor

(b)

Impeller

(c)

Venturi and / or Diffuser

(d)

Air Inlet pipe

(e)

Base Support

Page 5

The submersible motor shall be in accordance with Section 21 of this specification.

3

The impeller shall be a turbine type manufactured from stainless steel and suitably profiled to promote agitation of the media.

4

Where specified by the Contract agitation of the process media shall be by use of a submersible centrifugal pump which shall be in accordance with Part 3 of this Section 9.

5

The diffuser assembly shall be manufactured from corrosion resistant materials and be rigidly secured to the drive assembly frame.

6

The diffuser profile shall ensure uniform distribution of the aerated liquid.

13.5

AIR BLOWERS OR COMPRESSORS

13.5.1

General

1

Air blowers or compressors shall comply with Section 14 of this Part 9.

13.6

AIR PIPEWORK

13.6.1

Intake Ducting

1

The air supply to the blowers will be provided from the air inside the blower room. Individual air intake ducting shall be supplied for each blower for this purpose.

2

The ducting shall be of stainless steel Grade 316 S31 to BS 970-1 (Partially replaced by BS EN 10084) supported from the blower room floor and shall include two filters (1 No.coarse and 1No.fine), silencer and air intake.

3

The combined efficiency for particle removal by the two filters shall suit the requirements of the blowers and the aeration diffusers selected, but shall not be less than EU4. The filters shall be of the pad or dry pocket type. The filter enclosures shall be fabricated from stainless steel and shall be designed for ease of access to the filter elements for inspection/replacement without dismantling the ductwork.

4

The silencer shall ensure that the noise level described for the blowers shall not exceed 75dBA at one metre. It can be a separately mounted unit or mounted on the common baseplate with the blower assembly. The casing shall be fabricated from stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), and shall be approved by the Engineer. Only reflective or reactive type silencers are to be used. Absorptive or dissipative silencers shall not be used.

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Page 6

The blower room air intakes shall be mounted directly to the wall and shall comprise a fixed blade weather and sand trap louvre complete with bird screen. The louvre shall be designed to exclude rain and sand from entering the building. The intake shall be fabricated from stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), or a suitable non-corroding material as approved by the Engineer.

6

Filters shall be tested in accordance with BS EN 779 at the manufacturer's works.

13.6.2

Discharge Pipework

1

Each blower shall be provided with individual discharge pipework, which shall be connected to a common manifold. The discharge pipes shall be supported from the blower plant room floor.

2

Discharge pipework shall be stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084). The supports shall be of steel galvanised after fabrication.

3

Each discharge pipe shall be provided with a suitably sized blow-off valve, non-return valve and isolation valve.

4

The blow-off valve shall be an actuated butterfly valve and shall be fitted with an exhaust silencer. The discharge from the silencer shall be at least 2 metres above floor level and shall be directed vertically upward or mounted in the horizontal plane. The silencer shall ensure that the noise level of the exhaust does not exceed the level described for the blowers.

5

The non-return valve shall be of the wafer check type.

6

Butterfly valves shall be provided for isolation of the individual pipelines. They shall be gearbox driven to suitably limit the rate at which the operator can shut off the valve. The valves shall be capable of being operated with the operator standing at floor level.

13.6.3

Blower Manifold

1

The blower discharge pipework shall tee into the manifold. The manifold shall be installed in the blower plant room and shall be supported from the floor. The manifold shall be sized for the duty blowers operating simultaneously delivering air at their maximum output.

2

A valved tapping shall be provided for the fitting of a pressure transducer for monitoring the pressure within the manifold.

3

If necessary, a silencer shall be installed within the manifold to ensure that the noise level outside the building, transmitted via the pipework, does not exceed 75dB(A). This shall be based on the duty blowers delivering at their normal rated output.

4

The manifold shall be fabricated from stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084). The supports shall be of steel, galvanised after fabrication.

5

Automatic condensate drain traps shall be installed at any location where water can collect in the discharge pipework/manifold assemblies.

6

The blower manifold and any other above ground air pipework that exceeds 60 C surface temperature shall be insulated.

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Air Supply Main

1

A supply main shall be provided and shall connect the blower house manifold to the distribution pipework. The main shall extend from the blower house to the treatment process units.

2

The supply main shall be sized for the duty blowers operating simultaneously delivering air at their maximum output and the velocity shall not exceed 20 m/s.

3

A dirt pocket with an automatic condensate drain trap shall be installed to collect and drain water at the lowest position on the main. A chamber for access to this condensate drain trap shall be provided.

4

The main shall be laid to an even grade sloping back to the condensate trap.

13.6.5

Distribution Pipework

1

Distribution pipework shall be made from stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084).

2

Additionally, the gauge of the pipes to which the diffusers are to be fitted shall be sufficient to allow the use of screw fit aeration disc base plates and to withstand local forces generated at the joints by the flow of effluent over the discs.

3

The pipework grid shall be broken down into sections, which shall be indicated on the Contractor's drawings.

4

Coupling seals shall be manufactured from a rubber compound suitable for long-term immersion in aerated effluent. If push-fit connections are used they shall be of a design that inhibits the removal of the spigot piece once inserted into the socket.

5

Pipework shall be fixed to the concrete floor of the process units by means of stainless steel pipe supports fixed by means of stainless steel anchor bolts. Pipe supports shall provide a means of fine adjustment of the level of the aeration grid.

6

Pipework supports shall be sufficiently numerous to support the grids without sagging and to allow the pipework to resist mechanical, hydrodynamic and hydrostatic loads without generating excessive loading in the pipework.

7

The maximum air velocity in any portion of the air distribution pipework shall not exceed 20 m/s. When selecting connections, consideration shall be given to heat, internal and external corrosion, expansion and contraction and resistance to all normal and abnormal forces.

8

Each diffuser array shall be provided with condensate drains and purge pipes which shall be taken above TWL and be accessible from walkways. Protection against siphoning of effluent into the air main shall be provided. Self-sealing diffusers shall not be considered to meet this specific requirement.

13.6.6

Flow Control and Isolation

1

Each aeration zone shall be provided with a flow modulation valve to control the flow of air into each zone as required by the process. The valves shall be of an eccentric plug or iris type with a linear characteristic across their design flow range.

2

Each aeration zone shall be provided with an isolation valve. Valves shall be of a gate or butterfly type.

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13.6.4

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Page 8

Each aeration zone shall be aerated by a series of arrays of diffusers via a dropper. Each dropper shall have provision for measuring and adjusting the air flow rate to balance the air flows in the correct proportions over the area of the pocket to maintain adequate mixing.

4

The provisions for measuring and adjusting the air flow rate on each dropper shall be linked to the SCADA system to achieve remote monitoring and adjustment of each individual dropper.

13.7

AIR DIFFUSERS

13.7.1

General

1

The size and number of diffusers selected shall provide the necessary oxygen required by the process.

2

Particular attention should be paid to the number of diffusers selected in order to avoid "dead" areas within the aeration zone.

3

The diffusers shall be evenly spaced along the floor of each tank and shall provide an air 3 2 flow rate of not less than 2.2 m /hr per m of tank surface area

4

Manufacturers test certificates shall be provided clearly stating the required air flow rate necessary to achieve even flow distribution through the diffuser.

13.7.2

Fine Bubble Air Diffusers

1

Diffusers shall be installed on the distribution pipework. Diffuser holders shall be manufactured from materials compatible with the distribution pipework. The diffusers shall be selected for long service with a minimum replacement period of 10 years. Diffusers that can be cleaned in situ will be preferred.

2

The materials of the diffuser shall be non-biological and resistant to sewage and its byproducts and the membrane shall be manufactured from EPDM. The membrane perforations shall be formed such that tearing of the material is minimised. The diffusers shall be fitted with either integral non-return valves, or similar system, which are capable of automatically sealing and preventing water ingress into the air piping if the air pressure falls.

3

The maximum air flow rate through each diffuser shall not exceed the rated design flow for 3 2 the diffuser or 175m /hr of air at standard conditions per m of effective membrane area, whichever is the lower.

13.7.3

Tubular Membrane Diffusers

1

The aerator shall consist of the following:

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(a)

Membrane holder complete with air distribution holes.

(b)

Membrane

(c)

Clamping rings

2

The membrane holder shall be manufactured from stainless steel.

3

The membrane properties shall be as 13.7.2.2 above.

4

The membrane holder shall incorporate an integral check valve to prevent backflow of process media into the diffuser grid pipework.

QCS 2014


Page 9

5

The membrane holder shall be fixed to the distribution pipework via a threaded nipple or via threaded pipe adaptors and stainless steel tie rods complete with stainless steel nuts bolts and washers.

6

The membrane shall be retained to the holder via stainless steel clamping rings.

7

The diffuser shall be suitable for operating at flow rates of 1.0 to 15.0 m /hr.

13.7.4

Plate Membrane Diffusers

1

The size and number of aeration devices selected shall provide the necessary oxygen required by the process.

2

The aerator shall consist of the following:

3

Diffuser trough

(b)

Membrane

(c)

Stiffening plate

(d)

Seal

(e)

Retaining Clamps

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(a)

The diffuser trough shall be fabricated from stainless steel plate. The trough shall comprise suitable brackets for bolting the diffuser assembly to the delivery pipework.

4

The membrane properties shall be as 13.7.2.2 above.

5

The membrane shall be supported by means of a stainless steel stiffening plate which shall contain air distribution holes to uniformly distribute the air across the area of the membrane.

6

The distribution holes shall be positioned relative to the membrane perforations such that backflow of the process media during loss of air supply is inhibited.

7

The membrane assembly shall be sealed into the diffuser trough by means of a profiled rubber gasket.

8

The membrane assembly shall be retained in the diffuser trough by means of stainless steel clamps. The number of clamps shall be dependent upon the length of the diffuser. The clamps shall be equi-spaced along the length of the diffuser.

9

The diffuser shall be suitable for operating at flow rates from 1.0 to 25.0m /hr.

13.7.5

Coarse Bubble Air Diffusers

1

The air diffuser consists of two simple parts, the diffuser body assembly and the flexible check diaphragm. Both parts are molded together so no separation can occur. During aeration, the diaphragm rises allowing the air to exit through the orifice of the disk body. When the air stops, the diaphragm is instantly seated against the diffuser body by the pressure of the liquid, preventing backflow and clogging. The formation of the air check diaphragm will allow double shear of the discharged air from the orifice, along with assisting in reducing the requirements of maintaining each diffuser level for proper air distribution. The air diffuser material shall be adequate to prevent plugging and resist brittleness or growing of the diaphragm through absorption of chemical components in the liquids.

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QCS 2014


Page 10


13.8.1


1


13.8.2

Testing

1


2

Where specified in the Contract the aeration system shall be tested as follows:

3

The aeration tank shall be cleaned of any contaminants which may inhibit successful testing. The use of synthetic detergents for this purpose is not permitted.

4

The aeration tank shall be filled with the required test volume of potable water/final effluent.

5

The dissolved oxygen monitoring equipment shall be calibrated: at zero D.O. using water deaerated with sodium sulphite solution; at saturation, with aerated water after prolonged and vigorous aeration; and at 50 % saturation, achieved by vigorously aerating water with a gas containing 10.5% oxygen in nitrogen.

6

Calibration results should show a linear relation between D.O. meter and concentration of D.O. Deviations shall require recalibration, checking of the probe including necessary refurbishment, checking of any temperature compensation. Calibration shall be undertaken under the same temperature conditions as those envisaged within the tank.

7

Multiple probes shall be utilised and distributed evenly throughout the tank.

8

Once the necessary equipment is positioned and the required volume of potable water/final effluent is added to the tank the air saturation equilibrium concentration of D.O. shall be checked. The water temperature shall also be measured.

9

A strong solution of sodium sulphite shall be made in warm water, if possible. The required quantity shall be sufficient to provide 20% excess over the stoichiometric amount required for deoxygenation. The mass of anhydrous sodium sulphite in Kg is therefore: -

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13.8

Volume of tank x D.O concentration in mg/l (prior to addition of sulphite) x 7.88 x 1.5 1000 Note: excessive sodium sulphite addition will result in a longer oxygen uptake. 10

A strong solution of cobalt chloride, to act as a catalyst, should be added to the tank sufficient to give a concentration of 0.5mg/l. The mass required is therefore: Mass CoCl2 (g) = 2 x tank volume

11

The chemical solutions shall be distributed evenly through the aeration tank. Rapid addition at a single point is not permitted.

12

At the start and end of each test the temperature of the water shall be measured to the nearest o 0.1 C and the barometric pressure to the nearest mm of mercury.

QCS 2014


Page 11

The aeration equipment shall be activated and the airflow rate, temperature and pressure shall be closely monitored. In the case of mechanical aeration equipment the power drawn shall be monitored.

14

The dissolved oxygen probes shall be connected to a multi channel potentiometer recorder. The increase in dissolved oxygen levels shall be monitored until the air saturation is reached (after approx 6/kLa hours). At 90% saturation a sample of liquid shall be taken to examine the quantity of residual cobalt.

15

When the test liquid has reached air saturation level a sample shall be taken and the concentration of dissolved oxygen shall be determined using the modified Winkler method.

16

The recorded concentrations of D.O. and calculated or measured values of saturation concentrations results shall be plotted as graphs of loge of D.O. deficit against time for D.O. values from 20 to 80% of the saturation value for each probe. The slopes of these graphs shall be used to calculate separate values of KLa as described by the equation: -

Cs - Ct =-KLa t(min 1) Cs - Co

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13

The average of the KLa values plotted shall be used to determine the KLa of the aeration system.

18

Cs shall be calculated using the following equation:

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Cs =

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17

Following the determination of KLa and by applying the correction factor the oxygenation capacity of the system shall be calculated using Oc = KLa.V.Cs

20

The aerator shall be + or - 10 % of the contractors stated values for oxygenation capacity. If this tolerance is exceeded the Contractor shall provide rectification at his own expense.

21

Where the aeration equipment is a mechanical device the Contractor shall also demonstrate that the minimum velocity across the aeration tank floor of 60mm/s is achieved. If this velocity is not achieved the Contractor shall provide rectification at his own expense

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END OF PART

QCS 201

Section 09: Mechanical and Electrical Equipment Part 14: Air Blowers & Compressors

Page 1

14

AIR BLOWERS AND COMPRESSORS ........................................................ 2

14.1

GENERAL ...................................................................................................... 2


2 2 2

14.2

PRODUCTS ................................................................................................... 2

14.3

AIR BLOWERS .............................................................................................. 3

14.3.1 Centrifugal Blowers 14.3.2 Positive Displacement Blowers

3 4

AIR COMPRESSORS.................................................................................... 5

14.4.1 14.4.2 14.4.3 14.4.4 14.4.5 14.4.6 14.4.7

General Reciprocating Compressors Rotary Compressors After Cooler Air Receivers Fabrication Requirements Booster Compressor

14.5


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14.4

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QCS 201


Page 2

AIR BLOWERS AND COMPRESSORS

14.1

GENERAL

14.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, installation, testing and commissioning of air blowers and compressors.

2

Related Sections and Parts are as follows: General Drainage Works Instrumentation, Control and Automation Building Electrical Works Electrical Works

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References

1

The following standards or revised/updated versions are referred to in this part:

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14.1.2

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BS ISO 10816 ...........Part 1 and Part 3, Mechanical vibration in rotating and reciprocating machinery

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BS 1123 ....................Safety valves, gauges and fusible plugs for compressed air or inert gas installation BS 5169 ....................Specification for fusion welded steel air receivers

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BS 5493 .....................Code of Practice for protective coating of iron and steel structures against corrosion

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BS EN ISO .................Paints and varnishes. Corrosion protection of steel structures by protective paint systems

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BS ISO 1217 ..............Displacement compressors. Acceptance tests

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BS1042 ......................Measurement of fluid in closed conduits

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ISO 10474 .................Steel & Steel Products Inspection Documents PD 5500 .....................Specification for unfired fusion welded pressure vessels British Compressed Air Society's Code of Practice and the Pressure Systems and Transportable Gas Containers Regulations 1989 List of ‘Approved Suppliers’ prepared by the Public Works Authority 14.1.3

Submittals

1


14.2

PRODUCTS

1

The Contractor shall assess which type and configuration of blowers or compressors that will offer the best whole life cost benefit for use on the plant to supply the process air requirements.

QCS 201


Page 3

The number of blower/compressor sets provided shall be sufficient to ensure the full range of process air requirements can be met and that a minimum of one standby unit for each application is available at maximum process airflow. Blower/compressor sets shall be the same model with the same rated capacity for each separate application.

3

The motor rating shall be rated at least 10% greater than the maximum power required under all climatic and operating conditions.

4

Each blower/compressor set shall be provided with an acoustic enclosure and a surge protection system. The acoustic enclosure shall limit the noise level to not more than 75Db(A) when measured at 1 metre distance from any point at the enclosure surface at any time. The enclosure ventilation shall be designed to ensure that adequate cooling of the blower set is maintained. Consideration should be given to ducting the enclosure exhaust direct to atmosphere to limit the temperature rise within the blower house to a maximum of 5°C above ambient. The enclosure shall be designed to allow for ease of access to the blower set, without the necessity to lift the complete enclosure, to allow for routine inspection and maintenance procedures.

5

The level of vibration in each blower / compressor shall be within the limits and comply with BS ISO 10816, Part 1 and Part 3.

6

The blower/compressor sets shall be of a proven design with at least five years operational experience in similar applications. Where multiple units are required to meet the duty in addition to single duty applications, the design shall be proven in applications where two or more units are automatically controlled to meet the varying air demand.

14.3

AIR BLOWERS

14.3.1

Centrifugal Blowers

1

Blower sets shall comprise of single stage centrifugal air blowers with modulating powered inlet and outlet guide vanes, gearbox, lubrication system, electric drive motor, and suction and discharge flexible stainless steel connection compensators, all mounted on a common baseplate. The sets shall be installed on flexible machine mounts.

2

The volume flow rate from the blowers shall be modulated control on the inlet and outlet guide vanes which shall be capable of varying the delivery rate down to 45% of the rated output without causing the blower to go into surge when operating either singly or in parallel. A high operating efficiency shall be maintained throughout the flow range.

3

Materials and equipments of construction shall give a design running life of at least 100,000 hours before major maintenance is necessary.

4

The impeller shall be statically balanced and the whole rotor shall be dynamically balanced. The first responsive critical speed of the rotating assembly shall be at least 10% above the maximum operating speed.

5

The gearboxes shall be of the parallel shaft high speed helical type. The gears shall have a minimum AGMA service factor of 1.5. A labyrinth oil seal shall be fitted to each shaft to prevent oil seepage from the casing under operating and static conditions. The seals shall be designed to ensure there is no contamination of the process air.

6

Each gearbox shall be fitted with an oil level sight glass and a drain plug which shall be readily accessible in operation.

7

The baseplate shall be provided with lifting points to allow the complete set to be handled using chain slings.

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QCS 201


Page 4

Instrumentation for the safety monitoring of air blowers shall include oil temperature, oil level, air temperature at inlet and outlet from the blower, outlet air pressure, surge conditions, bearing temperature and vibration and motor running current. The instruments shall provide signals for the shutting down of air blowers if unsafe conditions arise and for visual indication of the fault. Additionally, the contractor shall provide all necessary instrumentation for measuring the airflow from each blower.

9

Each blower shall be equipped with an inlet air filter, automatic unloading device, pressure relief valve, pressure switch and under load (no flow) detection device to trip the blower in case of drive/flow failure.

10

Each blower shall be performance tested at the manufacturer’s works, using the control motors, to BS ISO 1217:1996. Air flow measurement for these tests shall be carried out in accordance with BS 1042. Blower casings shall be works hydro-statically tested to 1.5 times the maximum working pressure.

14.3.2

Positive Displacement Blowers

1

The blowers shall be complete with all ancillary equipment which may be required to enable the units to operate correctly.

2

Blowers shall be air-cooled and of the double rotor positive displacement rotary type with cast iron casings delivering oil-free air.

3

Each blower shall be complete with an automatic unloading device, dead-weight pressure relief valve, spring type pressure relief valve, pressure gauge, pressure switch and non return valve of the wafer or nozzle ring check pattern.

4

The blower speed shall not exceed 70% of the maximum designed speed or 2300 rpm whichever is the lower.

5

Each blower shall have an under load detection relay or other similar device to trip the blower in the event of a drive or flow failure.

6

The blower casing shall be high-grade cast iron adequately ribbed to assist cooling and avoid distortion. The rotors shall be spheroidal graphite iron with integral shafting. Timing gears shall be of nickel cast iron positively keyed to the rotor shafts, they shall be accurately ground with close clearances to prevent interference between rotors.

7

The blower shall be fitted with an oil lubrication system for the bearings and timing gears. The blower shall be fitted with mechanical seals to prevent the ingress of oil into the rotor chamber.

8

The lubrication system shall include filling and drain plugs and oil level indicators visible from outside the acoustic cover.

9

The drive between the blower and motor shall be of the vee belt or flat toothed belt type and of approved design.

10

The complete blower assembly shall be mounted on steel section frame which shall incorporate a blower mounting plate, motor adjustment slides and guard support brackets, the frame is to be supported on anti vibration mounts.

11

An inlet silencer complete with replaceable filter element shall be fitted to each blower, the silencer shall be fitted with a visual indicator to warn of filter blockage.

12

Outlet silencer shall be fitted to maintain noise levels as low as possible. A flexible coupling shall be fitted to prevent vibration transmission to the air supply system.

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QCS 201


Page 5

Silencers are to be of the reactive type, absorptive type silencers will not be permitted.

14

Components likely to wear in the course of normal operation shall be capable of replacement with readily available replacement components.

14.4

AIR COMPRESSORS

14.4.1

General

1

The design and installation of the compressed air system shall be in accordance with the requirements of the British Compressed Air Society's Code of Practice and the Pressure Systems and Transportable Gas Containers Regulations 1989.

2

Compressors shall be rated to achieve the duty at optimum efficiency and may be selected from one of the following types unless otherwise specified in the particular specifications:-

(b)

(b) Reciprocating Multi Stage

(c)

(c) Rotary Screw

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Reciprocating Compressors

1

Reciprocating Single Stage Compressors shall be of inherently oil free design. The compressor shall be of cast iron construction with aluminium cylinder heads and shall be air cooled. The unit, complete with electric motor, shall be mounted on a rigid bedplate incorporating anti vibration mountings. The drive arrangement shall be belt or shaft driven and shall be fully guarded. A suitable means of achieving alignment shall be provided and where appropriate flexible couplings shall be used.

2

Reciprocating Multi-Stage Compressors shall be as above but incorporate interstage cooling and be of the short stroke design for low piston speeds.

3

Both single and multistage units shall be provided with the following:-

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14.4.2

Low oil level cut out switch.

(b)

Crank case oil sight glass. Air inlet filter.

Silencer complete with pressure gauge and low pressure cut out (filter blockage protection).

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(e)

Pressure gauge tappings after each stage for compressors up to 15kW, and gauges and safety valves on compressors over 15kW.

(f)

Oil pressure indicator on compressors over 100kW.

(g)

Final air temperature indicator on compressors over 100kW.

(h)

Unloader valve unit.

(i)

Air dryer system (Dehumidifier) where dry air is required.

14.4.3

Rotary Compressors

1

Rotary Screw Compressors shall be of the inherently oil free design and shall be either the single stage or multi-stage type depending on the duty.

2

The separate stages shall be enclosed in individual housings, the male rotor being gearbox driven whilst the female rotor is driven via a timing gear.

QCS 201


Page 6

The rotor shafts shall be supported by precision made ball and roller bearings

4

Lubrication to the driving gear, bearings and timing gear shall be via an oil pump driven by the main shaft. The lubrication system shall be complete with oil filter and cooler, pressure gauge and fail-safe pressure switch.

5

On multi stage units air cooling shall be undertaken by an intercooler.

6

The compressor shall be motor driven via a flexible coupling and gearbox common to both stages. A suitable means of alignment shall be provided.

7

The complete compressor set ie. compressor, motor, gearbox and associated cooling equipment shall be supplied on a rigid bed plate suitable for floor mounting via anti vibration mountings.

14.4.4

After Cooler

1

All types of compressor shall be fitted with an aftercooler. These shall be of the air cooled type comprising an air to air heat exchanger. The aftercooler shall cool the process air to a o temperature of 10 C above ambient. The aftercooler shall be fitted with an automatic condensation drain which shall be provided with a manual bypass.

2

Delivery lines from the Compressor Sets shall be fitted with the following equipment:-

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3

Oil trap/filter prior to entry into the air receiver. The filter shall be fitted with an auto drain and manual by pass.

(b)

Adjustable safety valve (lockable).

(c)

A solenoid valve for unloading (dependant upon compressor size) for applications where the compressor is directly coupled to a surge vessel.

(d)

A non return valve.

(e)

A high efficiency coalescing oil filter (0.001 micron filtration).

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(a)

Air Receivers

1

Unless otherwise stated, one air receiver shall be provided, normally being online, but with the capacity to be isolated from the system.

2

These shall be manufactured from fusion welded steel and shall comply with BS 5169 or equivalent for the appropriate pressure class.

3

Air receivers greater than 1000 litres capacity shall be designed and manufactured in accordance with PD 5500 or equivalent.

4

Each integral air receiver shall have sufficient capacity to damp out air pulses from the compressor and to prevent pressure drops on process valve actuations.

5

The air receivers shall be connected such that the duty compressor delivers into either or, if two air receivers are specified, both of the air receivers. Diaphragm isolation valves shall be provided for isolating either of the receivers from the system.

6

The air receivers shall be suitable for floor mounting and shall be supplied with two inspection ports. The inspection ports shall be of the elliptical type and pressure sealed.

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QCS 201


Page 7

Fabrication Requirements

1

The air compressors shall be air-cooled. The cooling air shall be drawn directly from the ambient air, routed through the enclosure and exhausted upward through the enclosure box. The cooling air for the motor shall be drawn directly from the ambient air.

2

The drive motors shall be directly coupled to the air end by flexible coupling.

3

The compressors shall be suitable for indoor installation.

4

Each air compressor shall have an efficient filter for cleaning intake air and micro filter after the discharge. Each compressor shall be fitted with a silencer, which shall be sized to prevent excessive pressure drop.

5

All instrument tappings shall be via suitable bosses welded to the tank structure. The vessel shall be supplied with:

(b)

Pressure relief valve.

(c)

Drain valve.

(d)

Lifting lugs.

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Pressure gauge.

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(a)

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14.4.6

The vessel shall be corrosion protected to give maintenance free service for a period of 20 years minimum, as defined in BS 5493 (partially replaced by BS EN ISO 12944) or equivalent and as specified in Section 8 part 8

7

Full certification in triplicate shall be supplied with the air vessel. The vessel shall also feature a stainless steel nameplate containing the following details. The manufacturers’ name.

(b)

The date of manufacture.

(c)

The standard to which the vessel was built.

(d)

The maximum design pressure.

(e)

The minimum design pressure where it is other than atmospheric.

(f)

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The design temperature The test pressure

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14.4.7

Booster Compressor

1

In case discharge pressure in excess of 15 bar is required, then booster compressors will be required. Alternatively multistage piston type air compressor can also be proposed. The booster compressor package shall comprise the following items: (a)

Booster compressor and motor mounted on common base plate.

(b)

V-belt drive with guard.

(c)

Oil/water separator or after cooler with automatic drainage and associated unloaded start.

(d)

Solenoid valve to close the inlet at standstill.

(e)

Safety valve on the oil/water separator or after cooler.

(f)

Anti vibration floor mounts.

(g)

Suitably sized air receiver.

QCS 201


Page 8

14.5


14.5.1


1

1 The equipment delivered to Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict accordance with Part 1 of this Section 9.

14.5.2

Testing

1


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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 15: Settlement Tank Equipment

Page 1

15

SETTLEMENT TANK EQUIPMENT .............................................................. 2

15.1

GENERAL ...................................................................................................... 2


2 2 2

MATERIALS .................................................................................................. 2

15.3

BRIDGES AND SCRAPERS .......................................................................... 3

15.3.1 15.3.2 15.3.3 15.3.4 15.3.5

Scrapers Bridges Walkways Bearings Drive Units

15.4

ELECTRICAL EQUIPMENT ........................................................................... 5

15.4.1 15.4.2 15.4.3 15.4.4 15.4.5 15.4.6

General Slip-Ring Current Collectors Emergency Isolator Limit Switch Motor Decontactor Plug and Socket Parking Switch Cabling

15.5

ANCILLARY EQUIPMENT ............................................................................. 6

15.5.1 15.5.2 15.5.3 15.5.4 15.5.5

Diffusion Drum Weir plates and scum boards Scum Skimmer Scum Collection Effluent Channel Cleaning

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15.2

3 3 4 4 4 5 5 5 5 6 6 6 6 7 7 7

QCS 2014


Page 2

SETTLEMENT TANK EQUIPMENT

15.1

GENERAL

15.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, testing and commissioning of equipment for primary and secondary settlement tanks.

2


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15

References

1


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BS 4 Part 1 .................Structural steel sections

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15.1.2

BS 449 Part 2 .............Specification for the use of structural steel in building

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BS 970 ......................Wrought steels for mechanical and allied engineering purposes

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BS 7671 .....................Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition

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BS EN 10029 .............Specification for tolerances on dimensions, shape and mass for hot rolled steel plates 3 mm thick or above

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BS EN 10084 .............Case Hardening Steels BS EN 10113 .............Hot-rolled products in weldable fine grain structural steels BS EN 10155 .............Structural steels with improved atmospheric corrosion resistance

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BS EN 10210 .............Hot finished structural hollow sections of non-alloy and fine grain structural steels BS EN 12020 .............Aluminium and aluminium alloys

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BS EN 60947-1 ..........Specification for low-voltage switchgear and controlgear 15.1.3

Submittals

1


15.2

MATERIALS

1

All reference to stainless steel shall mean stainless steel to BS970 Grade 316 S31 (partially replaced by BS EN 10084) unless otherwise stated.

2

All reference to aluminium shall mean marine grade aluminium milled finished 6063TF alloy to BS EN 12020.

3

All materials shall be protected against corrosion in accordance with Section 8 Part 8.

QCS 2014


Page 3

BRIDGES AND SCRAPERS

15.3.1

Scrapers

1

The tank scrapers shall be of the half-bridge rotating type or fixed bridge type as specified in the Contract Documents.

2

Non retractable tubular steel arms shall connect the scraper blades to the drive. The stainless steel scraper blades shall be fitted with removable heavy duty neoprene rubber or synthetic material hard wearing strips having a minimum shore hardness of 70. They shall be not less than 20mm thick and shall be fastened to the mechanism in such a way that the blades may be reversed. The minimum blade life shall be 2 years. Blades shall be arranged to form a continuous spiral across the floor and vertically up the side wall of the tank. Either the arms or blades shall be hinged to compensate for minor variations in the tank floor and side wall. Slotted holes shall be provided on the scraper rubber blades for adjustment against wear.

3

The two arms of fixed bridge scrapers with any appendages shall be equally balanced statically and be supported for rigidity using stay rods and turn buckles.

4

The scraper and its driving mechanisms shall be designed to allow for longitudinal and vertical movements of the bridge.

15.3.2

Bridges

1

The bridge shall be fabricated from structural steelwork to BS4 Part 1: BS449 Part 2: BS EN10029: BS EN10113: BS EN10155 and BS EN10210.

2

Primary tanks bridges shall be fabricated from stainless steel or from marine grade aluminium. Secondary bridges may be fabricated from mild steel, galvanised and painted in accordance with Section 8.

3

Fixed bridges shall span the full width of the tank.

4

Rotating half bridges shall be supported at the centre of the tank using a tripod manufactured from the same material of the bridge. The structure shall be designed to withstand the total loadings induced by the bridge and other forces associated with the bridge and scraper when in operation. The top plate of the support structure shall accommodate the centre bearing assembly and diffuser drum supports.

5

The bridge shall be designed to take a uniform distribution load of 250 kg/m2 in addition to the weight of the scraper assembly and shall be capable of satisfactory operation under wind loads, acting horizontally and normal to the total area of exposed surfaces.

6

The maximum permissible deflection with this superimposed load shall not be greater than 1/360 of the bridge span. On removal of the load the bridge deflection shall fully recover and return to its original mid span position on either side of the bridge.

7

The bridge design shall include provisions to adequately cope with all torsional moments that it may reasonably be expected to encounter, with a safety factor of 2.0.

8

Fixed bridges shall be constructed with equal mass on both sides of the centre of the tank. At each end provision shall be made in the design of the supports to allow for expansion and contraction resulting from temperature differentials of not less than 10C beyond the recorded maximum and minimum ambient temperatures in the region.

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15.3

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Page 4

Walkways

1

The bridge structure shall have suitably rated open stainless steel or aluminium walkway the full length of the structure and the width shall be 850mm, between handrailing.

2

Handrailing shall be manufactured from stainless steel to BS970 Grade 316 S31 (partially replaced by BS EN 10084) or marine grade aluminium tubes with standards 1100mm above the walkway, top rail and an intermediate rail 550mm above the walkway.

3

Toeboards 150mm high shall be fitted along both sides of the walkway.

4

Insulation shall be provided as necessary to prevent electrolytic action between dissimilar metals.

15.3.4

Bearings

1

Fixed Bridges:

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15.3.3

Rotating Bridges:

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Where the feed pipe rises from the centre of the hopper the scrapers shall be supported from the bridge on a frame around the pipe and shall have at least one steady bearing of phosphor bronze or stainless steel at the base of the scraper frame. The inner ring of this bearing shall be bolted to the feed pipe and the outer ring bolted to the scraper frame. All shafts on the drive system shall have at least two bearings whatever the configuration and as many guides as are necessary to retain stability.

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The centre bearing assembly shall be designed to permit both horizontal rotation and vertical undulation of the bridge structure. The slewing and trunnion arrangement shall be designed to withstand the total loading of the bridge and other forces associated with the bridge and scraper in operation. Lubrication for the pivot pins, trunnions, etc. shall be provided from a readily accessible grease nipple battery plate. Drive Units

1

For fixed bridges a motor, flange mounted to a reduction gearbox, shall provide the drive. The motor speed shall not exceed 1500rpm. The motor and gearbox shall be easily accessible for maintenance.

2

Rotating bridges shall be driven by a double-wheeled drive unit mounted on the end carriage. The end carriage shall be fabricated from mild steel and incorporate the trailing rear-driven wheel and the leading driving wheel and shall incorporate guards covering all wheels to protect from the possibility of wheel nip. The driving wheel shall be driven by a motor and gearbox unit. Both wheels shall be polyurethane tyred.

3

Gearboxes and motors shall have an ingress protection rating conforming to BS EN 609471: IP55 classification. Gearboxes shall have a life of 100,000 hours and be selected in accordance with the AGMA recommendations for power calculation and service factor application, shall incorporate filler cap/breather, dipstick or level plug and drain plug, and have a noise level of not greater than 65 dB(A) at 1 metre distant in any direction.

4

For fixed bridge drive units the following shall apply:

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15.3.5

(a)

A drip tray, with gunmetal drain tap, shall be located under the motor and gearbox reduction unit(s). The drip tray shall be manufactured from stainless steel not less than 2mm thickness.

(b)

Any drive required between the reduction gearbox and the scraper shaft shall be by pinions and spur wheels or geared slewing rings as appropriate.

QCS 2014


Page 5

(c)

The gearbox may be oil or grease lubricated whilst all other bearings shall be grease lubricated. All grease lubrication pipes shall be manufactured from stainless steel tube and be terminated at a common location on the bridge at a point which affords operational access to enable convenient, safe lubrication and be suitably labelled.

(d)

The speed of the scraper assemblies measured at the tank periphery shall be. as follows: Primary tanks 0.75 – 1.0m/min Final tanks 0.3 – 2.5m/min fully variable. The drive system shall incorporate a loss of rotation monitor and an overload protection device comprising a torque limiting coupling set at the appropriate cut out torque. The device shall incorporate a switch and alarm indication system drawing attention to the fact that the torque limiting device has operated.

(e)

The gearbox output mechanism shall be restrained by a torque arm fitted with a weatherproof, strain gauge type torque indicator and electro mechanical overload contacts.

(g)

Guards shall be provided fully enclosing the scraper drive mechanisms.

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(f)

ELECTRICAL EQUIPMENT

15.4.1

General

1

Electrical equipment and installation shall comply with Section 21 together with the following supplementary clauses.

15.4.2

Slip-Ring Current Collectors

1

All power supply, controls and signals to rotating bridges shall be fed to/from the bridge via an underfeed slip ring collector assembly fixed to the stationary centre bearing base plate.

2

The unit shall comprise phosphor bronze sliprings fitted with spring loaded brush-holders complete with copper graphite brushes, housed in an overall enclosure with an IP55 rating.

3

Current rating shall be adequate for starting and running the size of bridge drive motor chosen by the bridge manufacturer. The assembly shall also be suitable for the transmission of control signals.

4

The minimum voltage shall be 24v current capability, twelve circuits shall be provided as a minimum.

5

Cable boxes shall be suitable for accepting cable from below via 25mm cable entry and exit points.

15.4.3

Emergency Isolator Limit Switch

1

Each rotating bridge shall have an emergency isolator switch mounted on the leading edge of the drive carriage.

2

The switch shall have an enclosure rating of IP55 and shall be operated by a touch bar located on the leading edge of the drive carriage. The switch/touchbar assembly will constitute an emergency stop.

15.4.4

Motor Decontactor Plug and Socket

1

The supply cable to the drive motor shall incorporate a suitably rated weatherproof decontactor plug and socket.

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Page 6

The male section of the unit shall be connected directly to the drive motor using suitably rated flexible cable. The female socket shall be securely supported in a position to ensure that the latch button is readily accessible from the bridge.

15.4.5

Parking Switch

1

Each rotating bridge shall be provided with a magnetic proximity switch protected to at least IP55 standard arranged to ensure that the bridge is parked at a fixed location on the tank.

2

On installations with bridge mounted starters, a parking selector switch must be provided which is accessible from off the bridge.

15.4.6

Cabling

1

The Contractor shall supply and install all on-bridge cabling from the slipring collector. Cabling shall be stranded copper 600/1000 volts grade and suitable for the application in accordance with BS 7671 and specification Section 21.

2

The main cable from the collector shall be a single multi-core which is to be terminated at the motor end of the bridge with an IP55 junction box. From the terminal box individual three or two core cables shall be run to the various items of equipment included in the bridge contract.

3

All cables shall be suitably supported along their length with approved cleats. The spacing centres for the cleats shall not exceed that given in BS 7671. Cleats to be of rigid PVC secured to the bridge structure using stainless steel nuts and bolts. The bridge structure must be pre-drilled prior to galvanising to accept the saddle fixings. Crimped terminals shall be used for all connections.

15.5

ANCILLARY EQUIPMENT

15.5.1

Diffusion Drum

1

Diffuser drums shall be constructed in glass reinforced plastic suitably strengthened and supported from the bridge so as to be positioned in the centre of the tank.

2

The drum shall be sized to be 10% of the total area of the tank and 2m deep. The top of the diffusion drum shall project 150mm above TWL.

3

The drum skin and flange thicknesses shall be not less than 4mm and 6mm respectively.

4

Two 180 opposed square cut outs with internal baffles above TWL shall be installed in each drum to enable the removal of grease and sludge.

15.5.2

Weir plates and scum boards

1

'V' notch weir plates shall be supplied for bolting to the tank walls. The weir plate shall have 90o notches equi-spaced around the periphery of the tank and slotted adjustment holes. The spacing and size of "V" notches should be determined by calculation. The maximum discharge per notch should be 30-40m3/day to enable uniform outlet conditions.

2

The weir plate shall be 300mm deep and be fabricated from composite plastic or GRP. The weir plate shall be pre-curved and of minimum thickness 6mm. Sealing strips shall be provided for installation between the weir plates and the tank wall to allow for discrepancies in the structure.

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Page 7

Scum boards and fixing brackets shall be provided on all tanks. The brackets shall be stainless steel with stainless steel bolts and be so designed that no fixing is required to the tank wall within 250mm of the weir level.

4

The brackets shall hold the scum board securely 500mm from the inside face of the weir wall. The scum boards shall be manufactured from GRP, 305mm deep by 6mm thick precurved and shall be positioned so that 100mm of the scum board is above water level.

15.5.3

Scum Skimmer

1

A scum skimming arm (trailing scum board) shall be attached to the bridge (for rotary bridge) or to the scraper arm (for fixed bridge) which must maintain contact with the scum board in all positions. The scum arm shall sweep the scum to a trumpet at the periphery of the tank which shall automatically discharge the scum via pipework to a scum/grease trap. The blade shall be fabricated from GRP or stainless steel and shall protrude 100mm above top water level.

15.5.4

Scum Collection

1

Scum shall be collected in a scum box attached to the tank wall. The scum box shall be fabricated from stainless steel and terminate with a flanged connection. Scum box flush shall be provided suitable for operation from either the bridge or tank periphery. Not less than two scum collection boxes shall be provided at final settlement tanks associated with Activated Sludge Plants.

15.5.5

Effluent Channel Cleaning

1

Where called for in the Contract Documents a spray jet system shall be mounted on the travelling bridge (or on an extension to the scraping mechanism in the case of fixed bridges), to clean the outlet channel. The jets shall be fitted with hooded cover plates to prevent aerosols being forced upwards. A submersible sewage pump, fitted to the bridge or scraper extension shall supply tank effluent to the nozzles. A strainer shall be fitted to the pump. To allow cleaning of the filter, the pump discharge shall be a flexible hose, to allow lifting of the pump from the bridge without dismantling the pipework.

2

Spring loaded polypropylene bristle brushes shall be supplied and arranged to assist in cleaning of the effluent channel and weir walls without restricting effluent flow. The assembly shall be fabricated from 316L stainless steel. Springs shall be of stainless steel.

3

Effluent channel cleaning systems shall not be installed in primary tanks unless they are fully covered and odour controlled.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 16: Tertiary Treatment Granular Filters

Page 1

16

TERTIARY TREATMENT GRANULAR FILTERS .......................................... 2

16.1

GENERAL ...................................................................................................... 2


2 2 2

16.2

PRODUCTS ................................................................................................... 2

16.2.1 16.2.2 16.2.3 16.2.4

General Filtration Rates Nozzle Plates Pressure Filters

16.3


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2 3 4 4

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TERTIARY TREATMENT GRANULAR FILTERS

16.1

GENERAL

16.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, installation, testing and commissioning of tertiary treatment granular filters.

2


16.1.2

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References

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BS 970 ......................Wrought steels for mechanical and allied engineering purposes

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BS 1780 .....................Specification for bourdon tube pressure and vacuum gauges BS 4870 .....................Specification for approval testing of welding procedures

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BS 4871 .....................Specification for approval testing of welders working to approved welding procedures

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PD 5500 .....................Unfired fusion welded pressure vessels

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16.2

PRODUCTS

16.2.1

General

1

Filters shall be of the downward flow sand type and shall include a minimum of two batteries operating in parallel. Access to valves and pipework etc shall be constructed such that operation and maintenance can be carried out safely and without obstruction. The contractor shall be responsible for providing all access walkways and ladders.

2

Unless otherwise specified in the Contract Documents the filter material shall have an effective size of 1.8mm and a uniformity coefficient of 1.5.

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Page 3

Valving, penstocks and associated pipework shall be provided on each filter for raw water inlet, filtered water outlet, washwater inlet, washwater outlet, air scour, filter slow drain and air after back wash. All valves shall be butterfly type and with the exception of the slow drain valve shall be controlled automatically and shall include provision for manual operation. Valves shall be in accordance with the valves section of this specification. Actuators shall be electrically operated, quarter turn type. Valves and penstocks shall be positioned to allow for manual operation from adjacent walkways. The backwash delivery manifold and air scour delivery manifold shall be fitted with a pressure gauge to BS 1780 or equivalent.

4

Pipework shall be stainless steel, uPVC, HDPE or GRP and in accordance with Section 8 of this Specification.

5

Filters shall be automatically backwashed using air scour blowers and washwater pumps.

6

The washwater pumps shall draw filtered water from a backwash tank, which shall automatically be replenished following a wash cycle. The working volume of the tank shall be equivalent to the volume of backwash water required for two complete wash cycles.

7

The backwash pumps shall be controlled to give a gradual increase in wash cycle. Control will either be by speed control of the pump motor or by a controlled slow opening valve on the washwater pipe. A non-return valve shall be included in the delivery pipework.

8

The air scour pipework shall incorporate a non-return valve, which shall rise to a height above the filter top water level, before dropping down to the filter and d an automatic drain valve at the lowest point to relieve the system of leakage water through the valve, to prevent process water passing from the filter to the blower.

9

The backwash delivery manifold and air scour delivery manifold shall be fitted with a pressure gauge

10

Pressure filters shall be provided with a pressure gauge mounted on the front of the vessel visible from the walkway.

11

Loss of media from the filters is not acceptable. The raw water inlet/washwater outlet shall be designed to prevent the passage of media during the backwash cycle. The level of the fluidised bed shall be well below the washwater outlet to prevent sand loss.

12

Flow measuring and recording equipment shall be provided to indicate the flow through each filter, washwater flow and air scour flow.

13

Rapid gravity filters shall be provided with loss of head measuring instrumentation.

14

Sample taps shall be provided on the raw water inlet / washwater outlet and the filtered water outlet pipework of each filter. The taps shall be accessible from walkways.

16.2.2

Filtration Rates

1

Filtration rates shall not exceed 7.5 m/hour for single media filtration and 12m/hour for multimedia filtration. Sufficient capacity shall be provided to ensure that these flowrates are not exceeded with one unit out of service and one unit backwashing.

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Page 4

The maximum allowable solid loading shall be 1.2 kg/m2 between backwashes unless otherwise specified in the Contract Documents. Depending on the type of media selected, a variation to the solid loading of 1.2kg/m2 may be permitted provided that reasons substantiating the variation are clearly stated in the tender as an alternative option.

3

The maximum acceptable number of backwashes shall be ONE per filter per day during "AVERAGE - CONDITIONS".

16.2.3

Nozzle Plates

1

Where a nozzle plate is incorporated into the design of the filter then the plate shall be stiffened to withstand sand, surge and backwash pressure loading. Nozzle fixing access shall be from below. Access through the nozzle plate is not permitted.

2

Where the design of the filter incorporates a nozzle plate, the underfloor section shall be vented to prevent air pocket accumulation and subsequent major sand disturbance during the back wash cycle.

3

Laterals and headers shall be uPVC with nozzles for water and air distribution. Support brackets shall be Grade 316S31 Stainless Steel.

16.2.4

Pressure Filters

1

Pressure filters shall be all steel, designed, manufactured, inspected, tested in accordance with PD 5500 or equivalent.

2

Longitudinal seam welds shall not cross at any intersection with circumferential welds but shall be offset a minimum length corresponding to 90o of shell circumference.

3

Allowance for a vessel life expectancy of 25 years shall be made and the corrosion allowance shall be not less than 2.0mm.

4

Pressure filters shall be fabricated from Carbon Manganese steel, and full fabrication details shall be submitted for approval by the Contractor. The vessel shall comprise two domed ends with an intermediate cylindrical section. Not less than two lifting lugs shall be provided for lifting of the complete vessel. Vessels may be vertically or horizontally mounted.

5

The inlet and outlet pipework shall be designed to the same criteria as the pressure filter terminating in flanged connections. A drain line shall be provided complete with isolating globe valve and flanged hose connection suitable for a flexible hose of 50mm diameter.

6

Pressure filters shall be supplied complete with associated fittings internal manhole access, sand door, pressure gauges and air valves.

7

The sand door shall be located at the lower end of the centre cylindrical section of the filter shell. The underfloor inspection hatch shall be located on the lower domed end of the vessel.

8

The filter shell shall be mounted on fabricated feet for mounting on pre cast concrete plinths on the filter room floor at a height to enable man entry into the lower inspection access hatch.

9

Pressure filters shall be provided with a double acting large orifice air valves.

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Page 5

A 150 mm nominal diameter pressure gauge shall be surface mounted on the vessel using a purpose made mild steel bracket welded to the vessel.

11

The man access shall be of the "T-bolt" closure type of not less than 600 mm internal diameter with the hinge running parallel to the filter diameter and be provided in the cylindrical section of the vessel to permit access and located such that internal launders and bellmouths can be visually inspected without entry into the filter.

12

Both the sand door and under floor inspection hatch shall be of the flanged type and be provided with a lifting swing davit which shall incorporate a lifting screw, so that the whole flange cover may be lifted up and then swung out from the entry port. The davit shall be fabricated onto the cylindrical wall of the vessel.

13

A safety/hand rail shall be located adjacent to the man-way with a fixing for a safety rope. Each man-way access shall incorporate a traffolite warning notice permanently fixed to the cover in view of an operative intending to access the vessel. The notice shall state "WARNING Ensure full isolation and permit to work and depressurisation before entry”.

14

Welding shall only be carried out by Contractors' staff who are qualified and experienced to undertake this work in accordance by PD 5500 or equivalent by reference to the following:-

(b)

BS 4871 or equivalent.

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BS 4870 or equivalent.

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The Contractor shall mark clearly with their respective safe working pressure in lettering not less than 80mm in height in gloss paint.

16

A brass plate shall also be fixed to the vessels which will state:Name of manufacturer with address.

(b)

Identification number.

(c)

Client's Order number. Shell Thickness.

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(e)

Corrosion Allowance.

(f)

Shell Diameter.

(g)

Head Diameter.

(h)

Head Thickness.

(i)

Head Corrosion Allowance.

(j)

Degree of X Ray Inspection.

(k)

Tan Length.

(l)

Design Pressure.

(m)

Hydraulic Test Pressure.

(n)

Weight.

(o)

Length.

QCS 2014


(p)

Inspection Date.

(q)

Inspectors Initials.

(r)

S.W.P.

Page 6

The Contractor shall allow for 100% category 1 radiographic testing.

18

The Contractor shall employ an independent testing authority to oversee the design, fabrication and testing of pressure vessels as defined in BS5500. The independent testing authority shall report direct to the Engineer.

19

The Contractor shall make provision for all the necessary work associated with carrying out the Inspecting Authority's recommendations resulting through the use of PD 5500 or equivalent in assessing design, manufacturing procedure, documentation and testing of the vessel.

16.3


16.3.1


1

The equipment delivered to Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant Parts of this Section 9 for ancillary equipment installed and the manufacturer’s instructions.

16.3.2

Testing

1

Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those listed below.

2

Unless otherwise stated in the Contract Document the performance of the filter shall be assessed by samples taken from the following points within the works. (a)

Raw water - prior to any treatment.

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Final water into storage reservoir

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(c)

Individual filters outlet.

3

Samples are to be collected using automatic composite samplers over a period of 7 days. Each sample shall comprise 24 No discreet hourly samples. Spot samples may also be taken for the performance assessment by the Engineer.

4

The performance of the works will be judged to be acceptable if samples, collected during the Tests before Completion meet all of the criteria for all the determinants listed in the Contract Document.

5

Sample collection and analysis shall be undertaken by an approved independent laboratory at the Contractor’s cost.

END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 17: Sludge Thickening & Dewatering Equipment

Page 1

17

SLUDGE THICKENING AND DEWATERING EQUIPMENT ......................... 2

17.1

GENERAL ...................................................................................................... 2


2 2 2

THICKENING AND DEWATERING ............................................................... 2

17.2.1 General

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17.3.1 General 17.3.2 Polyelectrolyte Mixing System 17.3.3 Conditioning Tank 17.3.4 Drainage Section: 17.3.5 Machine Rollers 17.3.6 Drive Unit 17.3.7 Sludge Scraper and Lift Blades 17.3.8 Washwater System 17.3.9 Hydraulic Power Pack 17.3.10 Machinery Construction and Materials 17.3.11 Ventilation

.

GRAVITY BELT THICKENER ........................................................................ 3

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17.3

2 3 3 3 4 4 4 4 5 5 5 5

CENTRIFUGE................................................................................................ 6

17.4.1 17.4.2 17.4.3 17.4.4 17.4.5

General Sludge Feed Pumps Sludge Discharge Arrangements Ventilation Washwater System

17.5


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Page 2

SLUDGE THICKENING AND DEWATERING EQUIPMENT

17.1

GENERAL

17.1.1

Scope

1

This part specifies the requirement for the design, manufacture, construction, testing and commissioning of sludge thickening and dewatering equipment.

2


References

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BS 970 ......................Wrought steels for mechanical and allied engineering purposes.

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17.2

THICKENING AND DEWATERING

17.2.1

General

1

The approved methods of mechanical thickening of surplus sludge are:

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Centrifuge Gravity belt thickener

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17.1.3

The approved method of mechanical dewatering of sludge is by centrifuge.

3

Sludge feed systems shall comprise feed pumps complete with electro-magnetic flowmeters, interconnecting pipework and fittings. The number of feed pump sets shall be in accordance with the Contract documentation but as a minimum one duty and one standby pump shall be installed.

4

The feed pumps shall be of the progressive cavity type and shall be fitted with a mechanical speed variator. Speed shall be automatically and manually adjustable to regulate the flow into the thickener according to its performance and variations in the incoming sludge quality. The pumps shall comply with the requirements of this Section 9.

5

Thickened sludge shall discharge to a thickened sludge pump and be pumped to the digestion system unless otherwise specified. A minimum of one duty and one standby pump shall be provided. All necessary pipework and valves shall be provided.

6

Thickened sludge pumps shall be of the progressive cavity type fitted with motors rated IP65. The pumps shall be in accordance with the general requirements of this Section 9.

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Page 3

Access platforms and stairways shall be provided to give operators access to all items of Plant requiring maintenance or operation.

8

Polymer preparation and dosing systems shall be provided complete with all interconnecting pipework and fittings. The system shall be in accordance with the general requirements of Section 22.

9

The control equipment shall comprise new FBAs that shall incorporate a PLC section complete with Human Machine Interface (HMI) suitable for connection to SCADA and telemetry in accordance with Section 21 of this Specification.

10

All plant and equipment shall be housed in an air-conditioned building.

17.3

GRAVITY BELT THICKENER

17.3.1

General

1

Each gravity belt thickener (GBT) unit shall be a complete package plant and the general arrangement of each belt thickener system shall include:-

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Belt thickener Polyelectrolyte mixing system Conditioning tank Drive unit Sludge scraper and lift blades Washwater system Hydraulic power pack Ventilation

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Sludge belt thickeners shall consist of an endless dewatering belt passing around a series of rollers.

3

The design of the plant shall permit a controlled feed of sludge to be mixed with a controlled flow of polyelectrolyte in a mixing drum from which it shall go through a flocculation stage prior to discharge onto the dewatering belt. The flocculated sludge shall then travel along the belt before climbing over a ramp and discharging as a thickened sludge from a horizontal stage of the machine.

4

The belt shall be washed automatically using final effluent, and be arranged for ease of threading, alignment and tensioning.

17.3.2

Polyelectrolyte Mixing System

1

A non-clogging, multiple baffle mixing device shall be incorporated into the inlet of the machine. The mixing system shall ensure intimate dispersion of conditioning polyelectrolyte agent with the incoming sludge. The polyelectrolyte dosing position shall be both multiple and variable to suit the type of sludge being treated.

17.3.3

Conditioning Tank

1

Mixed sludge and polyelectrolyte shall pass to a bifurcated upwardly diverging conditioning tank, which shall be suitably sized to enable good floc formation to occur. The outlet of the tank shall be designed such that the flocculated sludge distributes gently and evenly across the full width of the filter belt.

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Drainage Section:

1

The drainage section shall comprise a woven mono-filament polyester filter belt horizontally supported on a PVC-U perforated support grid to allow rapid drainage of filtrate to a collection system. The edges of the belt shall be raised by means of guides to prevent sludge overflow during peak flow rates.

2

The belt weave selected shall be suitable for the sludge to be dewatered.

3

The belt shall incorporate a simple quick release to enable belt replacement to be effected with minimal delay.

4

Blades shall be located at the entry position to the drainage section to induce drainage furrows in the sludge blanket.

5

Drainage shall be connected into the works drainage system.

17.3.5

Machine Rollers

1

The machine shall be equipped with the following rollers:-

2

Manually adjustable tension rollers to allow pre-setting of the belt tension. The rollers shall be mounted on the top frame member in plummer blocks fitted to manually adjustable slides.

3

A hydraulically sleeved belt alignment roller. The alignment system shall be automatic. The belt shall be maintained central to the roller system. Should the alignment system fail or lose pressure, excessive wander shall be detected by limit switches and the drive shall stop.

4

A drive roller mounted on the top frame member in plummer blocks.

5

Plummer blocks shall be fitted with heavy-duty bearings. Bearings shall have a guaranteed life in excess of 100,000 hours. Auxiliary seals shall be fitted to bearings to prevent the ingress of water.

6

For maintenance purposes, rollers shall be easily removable from the side of the machine, without the need to dismantle any other components.

17.3.6

Drive Unit

1

The drive roller shall be chain-driven through a set of sprockets and manually adjusted hydraulic speed variator by an induction motor or gear motor unit.

2

Gear motors shall be suitably rated and protected.

3

Gear motors bearings shall have a guaranteed life in excess of 50,000 hours. The AGMA service factor of the gear motor shall not be less than 1.5.

17.3.7

Sludge Scraper and Lift Blades

1

An easily replaceable sludge blade shall be positioned at an angle to the drive roller to ensure that sludge is effectively removed from the filter.

2

An easily replaceable sludge lift blade shall be positioned on the horizontal section of the filter belt immediately prior to the drive roller. The blade shall be capable of being locked in or out of position, as the process requires. The blade height shall be adjustable and shall exert a backpressure on the advancing sludge to cause it to back up over the blade and dewater by self-weight.

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Page 5

Sludge shall fall down a stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) chute directly to a thickened sludge pump.

17.3.8

Washwater System

1

The belt wash system shall consist of a high-pressure spray pipe fitted with an integral cleaning device for cleaning nozzles without dismantling or interrupting operation. Final effluent shall be used as washwater. The whole belt wash area shall be totally enclosed to prevent release of spray to the atmosphere surrounding the thickener.

2

A break tank and booster pumps shall be incorporated as part of the system, if the supplied pressure of the final effluent washwater system is not sufficient. The Contractor shall adhere to the appropriate health and safety guidelines, relating to water borne and air borne bacteria arising from high-pressure atomising washwater systems utilising final effluent, in his design.

17.3.9

Hydraulic Power Pack

1

An hydraulic power pack shall be supplied to provide drive and control for each GBT. This shall be floor mounted adjacent to the thickener.

2

The hydraulic power pack shall comprise:-

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A hydraulic fluid tank fitted with filler cap, strainer, fluid level gauge and fluid temperature gauge, bund and lockable drain.

(b)

An electric motor driven hydraulic pump. The pump speed shall not exceed 1500 rpm.

(c)

Hydraulic accumulator, filter, pressure regulators and control valves.

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17.3.10 Machinery Construction and Materials

The machine frame shall comprise structural steel channel and angle sections welded and bolted to form a rigid framework. The frame shall incorporate fabricated steel stops to allow operators to view the horizontal section of belt.

2

Filtrate troughs, filtrate tanks, conditioning tanks, etc., shall be constructed of stainless steel plate to BS970 Grade 361 S31 or shall be of glass reinforced plastic.

3

The sides of the machine shall be enclosed within easily removable GRP or PVC-U panels. Guards and splash plates shall be of steel or PVC-U materials. Guards shall be placed over moving parts of the machine.

4

Scraper, thickening and furrow blades shall be of high-density plastic, to avoid damage to the filter belt.

5

The equipment shall be self-contained, hydraulic power packs, actuating mechanisms and drive units shall be mounted on the structural framework.

6

All steelwork other than stainless steel shall be galvanised.

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17.3.11 Ventilation 1

A ventilation hood and curtain system shall be provided to isolate the thickener from the surrounding building and ensure that high rate ventilation is concentrated on the machines. A ventilation system shall be provided to ensure that odour/gasses are contained within the hood. The ventilation system shall be designed for connection to an odour control unit.

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Page 6

CENTRIFUGE

17.4.1

General

1

Centrifuges shall be of the horizontal decanter type and consist of a high speed rotating bowl containing a scroll conveyor. The scroll shall be designed to rotate in the same direction as the bowl but at different speed. The bowl and the scroll shall be balanced independently. The speed differential will be provided and controlled by using two motors with variable speed control system.

2

The centrifuge shall be designed for use with wastewater sludges. The bowl, scroll and bearing hub of the centrifuge shall be manufactured in duplex stainless steel SAF 2205 or higher grade. The bowl shall be centrifugally cast. All other parts in contact with sludge shall be constructed of stainless steel Grade 316 S31to BS 970-1 (partially replaced by BS EN 10084).

3

Inlet and outlet parts, rotating parts and wear zones shall be designed with either replaceable wearing parts or from abrasion resistant materials. Inlet and outlet parts, rotating parts and wear zones shall be designed such that replacement or adjustment can be completed easily within a single working day. The edge of the screw conveyor shall be protected by spray-on tungsten carbide alloy or tungsten carbide tiles.

4

The centrifugal force at the inner surface of the bowl shall be a minimum of 2500g for thickening centrifuges and 2900g for dewatering centrifuges. For torque based back drive systems, the pond depth in the centrifuge bowl shall be adjustable through the use of replaceable or adjustable dam plates at the liquid discharge end.

5

The solids discharge shall be fitted with field replaceable stellite bushes.

6

The differential speed adjustment between the bowl and the scroll conveyor shall be an energy efficient system driven by an electric motor. Differential speed adjustment of scroll speed shall be infinite within the range of ± 1 to 15 rpm with an accuracy of +/- 0.05 rpm via an electric motor and inverter. The adjustment of the differential speed to accommodate changes in solids content of the feed shall be fully automatic.

7

Torque experienced by the back drive shall be monitored continuously. Two stages of high torque alarm shall be provided. Stage one shall initiate feed shut off. If the torque drops below the torque alarm, the control system shall automatically open the feed. Stage two high high torque alarm initiates the centrifuge shut down sequence. The centrifuge scroll shall be kept running to clear the bowl when the decanter is slowing down under normal shutdown or a high high alarm shutdown sequence.

8

The sludge feed tube shall be designed to allow the dosing of polymer directly into the scroll distribution ports. The sludge inlet zone shall be low shear design to minimise floc destruction.

9

The centrifuge shall be balanced and factory tested with a vibration level less than 5mm/s. The centrifuge shall be equipped with rubber vibration dampers to minimise the transfer of vibration to structures. The centrifuge shall be continuously monitored for vibration, with a two stage alarm. Stage one shall initiate a high vibration alarm warning displayed on the control panel and through the telemetry system. Stage two shall signal a high high vibration alarm and initiate the automatic centrifuge shutdown sequence.

10

The centrifuge noise level shall not exceed 75 dBA when measured one metre from the machine in any direction.

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Page 7

The bearings shall be designed for a L10 life of 100,000 hours. Bowl bearings shall be continuously monitored for temperature with a two stage alarm. Stage one shall initiate a high temperature alarm warning displayed on the control panel and through the telemetry system. Stage two shall signal a high high temperature alarm and initiate the automatic centrifuge shutdown sequence.

12

The main bearings on the centrifuge scroll and gears shall be lubricated for life.

13

The centrifugal bowl assembly and drive system shall be mounted on a base frame. The base frame shall be able to support all the static and dynamic loading. The base frame shall be fabricated from carbon steel with painting and corrosion protection in accordance with Section D Part 4

14

Centrate from the centrifuges shall be discharged directly into the site drainage system.

17.4.2

Sludge Feed Pumps

1

Each centrifuge shall have a dedicated duty and standby feed pump.

17.4.3

Sludge Discharge Arrangements

1

The thickening centrifuges shall have a thickened sludge pump dedicated to each centrifuge outlet with standby pumping facilities that can be immediately utilised for any centrifuge without affecting the flow from any other centrifuge.

2

Dewatered sludge from the dewatering centrifuges shall be transported by a system of conveyors to a sludge loading area outside the building.

3

The Contractor shall size the conveyer system to handle all dewatered sludges from the centrifuges at up to 25% dry solids.

4

The conveyor system shall incorporate an adjustable high level cut out which shall inhibit flow from the centrifuge to prevent overflow.

5

If any one conveyor fails it must still be possible to operate the necessary number of duty centrifuges using the remaining conveyors.

6

Emergency off buttons shall be provided adjacent to each conveyor.

7

The conveyor system installed under this contract shall permit the installation of further duty centrifuges in future.

8

The conveyor system shall be of proprietary manufacture with the detailed arrangements, including the controls, designed by the supplier or a specialist in such equipment.

9

The body and helical screw of screw conveyors shall be of stainless steel construction and the system shall be heavy duty and robust in construction with ample features that will allow for ease of operation, maintenance and repair

17.4.4

Ventilation

1

A sealed inlet and outlet arrangement shall be installed to prevent the emission of gasses from the system into the building. The ventilation system shall be designed for connection to an odour control unit.

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Page 8

The Contractor shall assess the need for ventilation for maintenance purposes in accordance with the centrifuge manufacturers recommendations and provide an appropriate system to protect personnel and equipment from harmful effects of sewage sludge gasses, whilst the centrifuge is either not in use or is being maintained.

17.4.5

Washwater System

1

Each centrifuge shall incorporate a wash system, which shall consist of an automatically operated injector nozzle designed to displace sludge through the process in preparation for when the centrifuge is being shut down. A further manual hose shall be provided for manual washing of the centrifuge during maintenance. Final effluent shall be used as washwater. A break tank and duty/standby booster pumps shall be incorporated as part of the system.

17.5


17.5.1


1

The equipment delivered to Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant Parts of this Section 9 for ancillary equipment installed and the manufacturer’s instructions.

17.5.2

Testing

1

Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those listed below.

2

Unless otherwise stated in the Contract Documents, performance prior to Taking Over shall be judged against the following criteria.

3

Sludge thickening – four spot samples shall be collected each day of the feed sludge and the thickened sludge over a period of 7 days. The quantity of polyelectrolyte used over this period shall also be recorded. The thickening plant will be considered acceptable if during this period the thickened sludge has a dry solids content equal to or greater than stated in the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity stated in the Tender Submission.

4

Sludge Dewatering – four spot samples shall be collected each day of the feed sludge and the dewatered sludge over a period of 7 days. The quantity of polyelectrolyte used over this period shall also be recorded. The dewatering plant will be considered acceptable if during this period the dewatered sludge has a dry solids content equal to or greater than stated in the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity stated in the Tender Submission.

5

Sample collection and analysis shall be undertaken by an approved independent laboratory at the Contractor’s cost.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 18: Mixers and Stirrers

Page 1

18

MIXERS AND STIRRERS ............................................................................. 2

18.1

GENERAL ...................................................................................................... 2


2 2 2

COMPONENTS ............................................................................................. 2

18.2.1 18.2.2 18.2.3 18.2.4 18.2.5 18.2.6 18.2.7 18.2.8 18.2.9

General Bearings (Non Static Mixers) Sealing (Non-submersible mixers) Balance Rating Plate Couplings Guarding Installation and Lifting Equipment Protection from Corrosion

18.3

SUBMERSIBLE MIXERS ............................................................................... 5

18.4

TANK MIXERS............................................................................................... 6

18.5

STATIC MIXERS ........................................................................................... 6

18.6


2 3 3 4 4 4 4 4 5

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18.2

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Page 2

MIXERS AND STIRRERS

18.1

GENERAL

18.1.1

Scope

1

This part specifies the requirement for the design, manufacture, testing and commissioning of mixers and stirrers.

2


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References

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List of ‘Approved Suppliers’ prepared by Public Works Authority

BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes. Submittals

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18.2

COMPONENTS

18.2.1

General

1

Mixers and stirrers generally fall into the following categories:(a)

Static In-line Mixers Submersible Shrouded Mixers

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(c)

Submersible Banana Blade Mixers

(d)

Tank Mixers

(e)

Stirrers/Flocculator Paddles

2

The mixer performance (excluding static mixers), related to its required duty and installed media, shall be stable and the unit shall be non-overloading.

3

Contractors shall select the most economic units given the constraints of the operating parameters and particular requirements of the specification.

4

For static mixers the pressure rating of the associated pipework shall be rated to a minimum of 16 Bar unless otherwise stated.

5

Mixer propellers, casings and all other external parts shall be of stainless steel construction minimum Grade316 S31 to BS970-1

QCS 2014


Page 3

Bearings (Non Static Mixers)

1

The axial thrust generated shall be taken by a thrust bearing arrangement or angular contact bearings. Thrust bearing arrangements incorporated into the motor housing are not permitted. The Contractor shall demonstrate that the bearings are suitably rated in his submittals for approval. Setting of thrust bearings shall account for dynamic loading, albeit setting is carried out with the machinery stationary.

2

Rolling element ball or roller bearings shall be sealed for life and shall be rated to give a minimum life of 75,000 hours at maximum load without replacement. Bearings shall be protected by water throwers and lip seals where appropriate. The bearing housing shall be of the cartridge type to allow removal of the bearing without disturbing the units.

3

Plain/Bush Bearings where utilised, shall be in bronze or equal, split for easy maintenance and positively locked to prevent rotation.

4

Bearing housings shall be of the cartridge type to allow removal of the bearing without disturbing the units.

18.2.3

Sealing (Non-submersible mixers)

1

For soft-packed gland arrangements, packing shall be graphite impregnated PTFE, of approved manufacture. Asbestos based packing will not be permitted.

2

The gland design shall incorporate the following:

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18.2.2

A tapered "lead in" at the mouth of the gland entry to facilitate packing replacement and obviate the risk of damage on assembly.

(b)

The surface finish of the adjacent metal parts shall be 0.4μm CLA on the shaft gland sleeve and 1.6μm CLA on the stuffing box bore.

(c)

Where running clearances are excessive, the packing shall be protected by an independent ring of robust material which reduces the clearance to a minimum.

(d)

The packing must not be used as a bearing.

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All studs, dowels and adjustable nuts shall be manufactured from stainless steel.

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(f)

Lantern rings shall be of gun metal or bronze and shall be split for ease of removal.

3

The stuffing box shall be manufactured from cast iron of a heavy section independent of the mixer body and shall be provided with drain holes.

4

Mechanical seals shall be employed in submersible or closed tank applications with differential pressures greater than 17 Bar or where controlled leakage is not permitted.

5

The Contractor shall specify the type, size and material of the mechanical seal he intends to supply. It shall be the responsibility of the mixer manufacturer to ensure that the tolerances required by the seal manufacturer are not exceeded. Checks shall be carried out on the mixer casing and shafting for: (a)

Shaft straightness

(b)

Rotational Balance

(c)

Shaft run-out

QCS 2014


(d)

Bearing clearance - lateral and radial movement

(e)

Shaft tolerance and ovality

(f)

Concentricity

(g)

Seat squareness

(h)

Coupling alignment

Page 4

The Contractor shall ensure that the seat, face and component materials of the mechanical seal are suitable for the media.

18.2.4

Balance

1

The whole of the rotating assembly, including locking key(s) and mixing element, shall be dynamically balanced as an integral component. The mixing element shall also be dynamically balanced separately and then assembled to the shaft, to form without further adjustment, a dynamically balanced whole.

18.2.5

Rating Plate

1

Rating plates shall be fitted to all mixers, be manufactured and fixed by corrosion resistant material (excluding brass), and include full details of the mixer including size, type and serial number.

2

The weight of the mixer including motor/mounting brackets etc. shall be marked on the data plate

18.2.6

Couplings

1

For large mixers, couplings shall be provided to permit the removal of drive shafts, bearings, etc. without removing the mixer or motor. Couplings between the thrust bearing and motor shall be accommodated within motor/support stools.

2

Couplings shall be of the pin and buffer type unless otherwise specified.

18.2.7

Guarding

1

All machine enclosures shall be safeguarded with guards fixed to the body or motor as practical for the application.

2

Shaft guards shall extend the whole length of the shaft.

18.2.8

Installation and Lifting Equipment

1

Independent of application, the mixer shall be positively located and secured when operating. Methods of installation shall be one of the following methods:-

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(a)

Swivel Mounting (for tank mixers/stirrers) - ease of removal of the mixing element from the media shall be facilitated by means of a swivel mounting arrangement installed on the top of the tank. This shall incorporate an adjustment to enable off centre mixing.

QCS 2014


Page 5

Guide Rail mounting (for submersible mixers) - the mixer shall be supported by the lifting chain from a hanging point and have a sliding guide bracket of stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) mounted on a vertical guide rail. It shall be possible to remove and replace the mixer safely without lowering the level in the sump, or leaning into or entering the sump. The guide rail and hanging arrangement shall permit full adjustment of the depth and direction of the mixer. The guide system shall be retained at the lower end and upper end by stainless steel mounting brackets. Rails shall be installed to within ±05mm/m length of the vertical with no more than +1mm -0mm tolerance between parallel rails.

(c)

Direct flange mounting to a mixing tank shall preferably be from the top. Side entry 3 mounting is acceptable for vessels greater than 4m . The mounting shall be designed to enable removal through the flanged hole. Alternatively and especially for drum applications, the impeller can be of the folding type.

.

(b)

Integral lifting brackets, shackles and lifting eyebolts shall be provided and shall be manufactured from stainless steel with a minimum U.T.S. of 540 MN/m2, and certified by an approved testing authority. Both bolt and hole shall be permanently marked, preferably by punching, with the diameter and thread form used. All eyebolts shall be of the collar type

18.2.9

Protection from Corrosion

1

The internal & external finishes shall be in accordance with Section 8 Part 8.

18.3

SUBMERSIBLE MIXERS

1

Submersible shrouded mixers installed in open or closed topped tanks or chambers, should be considered for the mixing of sewage, slurries, sludges and industrial process solutions where there is an absence of rags and other large debris.

2

The mixer shall be easily removable from the installed position and this shall be achieved by means of a guide rail system which also allows depth adjustment of the unit.

3

The assembly shall be directly driven from a submersible motor through an oil casing and, when the specified duty dictates, also via a reduction gearbox. The motor shaft shall extend to form the drive shaft of the propeller.

4

The oil casing shall provide lubrication and cooling for the seals and create a barrier between the motor and the media. Expansion of the oil within the sealed casing shall be contained by an air volume. Moisture sensor shall be provided for detecting any seal failures.

5

The propeller shall be designed to deter clogging and produce high efficiency, and the shroud shall be fitted over the propeller to improve efficiency and direct the flow from the mixer. The shroud shall be optional and the unit shall be capable of continuous operation without it.

6

Motor cooling shall be achieved by the surrounding media.

7

Submersible banana blade mixers shall be easily removable from the installed position and the blades shall be manufactured from lightweight glass reinforced plastic

8

Shafts shall either be sealed from the media in which they are working or shall be manufactured from grade 316 stainless steel. Coated shafts shall not be permitted.

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Page 6

Submersible mixer motors shall be certified for use in a Zone 1 explosive atmosphere and be capable of working at 20m liquid depth. All other requirements for motors and shaft seals shall be to the requirements of Section 9 Part 2 2.4 (submersible pump fabrication).

18.4

Tank Mixers

1

Tank mixers installed in open topped or closed tanks or chambers should be considered for the mixing of chemicals, slurries, sludges, industrial process solutions where there is an absence of rags and other debris.

2

Tank mixers and stirrers shall be easily removable from the installed position and shall be achieved by means of a flanged connection at the top or side of the tank or, in the case of portable mixers, by means of a positioning bracket which shall be universally adjustable as necessary for the application.

3

The assembly shall be driven from a totally enclosed fan cooled motor or air motor through a reduction gear box.

4

The gear box output shaft shall extend to the propeller shaft via a rigid coupling. Shaft sealing shall be provided between the mixer and a closed tank. The motor shaft shall extend to form the drive shaft of the gear box.

5

Propellers shall be designed to produce high efficiency.

18.5

STATIC MIXERS

1

Static Mixers installed in line within pipework for the blending of liquid to liquid and gas to liquid in waste water treatment applications shall be constructed from materials suitable for use with the chemicals they are associated with and shall be complete with end connections compatible with the mating pipework. Changes in diameter or shape relative to the adjacent pipework shall not be permitted.

2

Mixing shall be achieved by either flow splitting, rotating and recombining, or by vortex action. The mixer shall incorporate sufficient elements to ensure complete and homogenous mixing across the pipe section given the specified flow variations.

3

Assuming complete and homogenous mixing, the mixer shall maximise energy efficiency to reduce the pressure losses through the unit. A characteristic curve of pressure loss against flow shall be provided at the tender stage.

4

Where chemical injection points are integral with the mixer, they shall be designed and positioned to maximise the mixing efficiency. Injectors shall be manufactured from materials that tolerate the chemicals being dosed allowing for the design pressures.

18.6


1

Installation and commissioning shall be in accordance with Part 1 of this Section 9.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 19: Chlorination

Page 1

19

CHLORINATION ............................................................................................ 2

19.1

GENERAL ...................................................................................................... 2


CHLORINATION SYSTEMS .......................................................................... 2

19.3

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19.2.1 General 19.2.2 Chlorinators 19.2.3 Ejectors 19.2.4 Motive Water Pumps 19.2.5 Chlorine Gas Cylinders 19.2.6 Chlorine Gas Header 19.2.7 Automatic Cylinder Change-Over Module 19.2.8 Automatic Isolation Valve 19.2.9 Chlorine Gas Header 19.2.10 Gas Feeder 19.2.11 Residual Chlorine Recorders 19.2.12 Chlorine Consumption and Recording Apparatus 19.2.13 Analyser Cells 19.2.14 Gas Leak Detection Equipment 19.2.15 Drum and Cylinders Handling 19.2.16 Pipework 19.2.17 Ventilation 19.2.18 Emergency Breathing Apparatus and Air Compressor 19.2.19 Warning and Safety Notices

.

19.2

2 2 2 2 3 4 4 4 4 5 5 6 7 8 9 9 9 11 11 11 12 12

ON SITE GENERATION OF CHLORINE ..................................................... 13

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19.3.1 General 19.3.2 Salt Saturators 19.3.3 Brine Feed 19.3.4 Electrolyser 19.3.5 Sodium Hypochlorite Storage 19.3.6 Sodium Hypochlorite Dosing 19.3.7 Pipework 19.3.8 Electrical Installation 19.3.9 Transformer / Rectifier 19.3.10 Control Panel

13 13 13 14 14 14 15 15 15 15

19.4

ANALYSERS ............................................................................................... 16

19.5

NEUTRALISATION SYSTEMS .................................................................... 16

19.5.1 19.5.2 19.5.3 19.5.4

General Neutralisation Tower Circulating Pumping Units Pipework and Electrical Connections

19.6


16 17 17 17

QCS 2014


Page 2

CHLORINATION

19.1

GENERAL

19.1.1

Scope

1

This part specifies the requirement for the design, manufacture, testing and commissioning of gaseous chlorination disinfection plants.

2


References

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19.2

CHLORINATION SYSTEMS

19.2.1

General

1

Gaseous dosing systems shall comprise pressurised and liquefied gas drums or cylinders complete with automatic changeover equipment, gas feeders and solution injection. All gas dosing systems shall be based upon the full vacuum and remote injection principle.

2

Unless otherwise stated the system shall comprise the following equipment:

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19.1.3

(a)

Chlorinator

(b)

Ejector complete with diffuser

(c)

Motive water pump

(d)

Chlorine gas cylinders

(e)

Chlorine gas header

(f)

Automatic cylinder change-over module

(g)

Remote vacuum controller for cylinders

(h)

Pipework

(i)

Gas feeder

QCS 2014


(j)

Dosing control

(k)

Residual chlorine recorders

(l)

Chlorine consumption recording apparatus

(m)

Analyser cells

(n)

Gas leak detection equipment

(o)

Neutralisation equipment

(p)

Lifting and moving facilities for cylinders

(q)

Safety equipment

(r)

Drench shower linked to SCADA system

Page 3

Chlorinators

1

The Contractor shall supply and install the chlorinators, one as stand-by. The chlorinators shall be of the floor mounted vacuum type, and provided with evaporator of suitable capacity. The chlorinators shall feed ejectors with the adjusted dose of chlorine. A diffuser shall be connected to each ejector.

2

All interconnecting pipes between the chlorinators and ejectors shall be under vacuum, and pressure must be prevented from building up in the system by means of pressure relief valves.

3

Chlorinators shall be designed to shut-down automatically the chlorine supply to ejectors vacuum line at the following cases:

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The water supply to the ejectors fails.

(b)

The ejectors vacuum line breaks.

(c)

The water supply pipeline accidentally shuts down due to the closing of a valve or valves.

(d)

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The chlorinators shall be of the compound loop system and suitable for automatic control by signals received separately from the flowmeter and the chlorine residual controller.

5

The accurate dosing scale of the apparatus should have a ratio of about 20:1 between the maximum and minimum dosing rates. The rate will be automatically adjusted by means of the chlorine residual controller according to the free chlorine residual needed. Provision shall be made for manual adjustment.

6

Best chlorine resisting materials shall be used through the whole parts of the system. The unit shall be of modular design, free standing with all control components protected within a rigid fibre-glass cabinet or similar.

7

The components within the cabinet shall be readily accessible from the front for ease of maintenance and shall be easily removable for examination or changing if required.

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Page 4

Ejectors

1

The ejectors shall be of the aspirator type to give maximum efficiency in mixing the chlorine with the water. The ejector water supply must be designed to suit the maximum rated output of the chlorinators offered.

2

Each ejector shall be connected to a diffuser for regular distribution of the chlorine solution at the injection point.

3

The ejectors shall be separated from the chlorinators to give flexibility of placing the chlorinators in their rooms and to inject the chlorine solution by the ejectors at the injection point.

19.2.4

Motive Water Pumps

1

The Contractor shall supply and erect electrically driven boosting pumps. The pumps shall be connected in parallel to supply water to the ejectors.

2

Motive water pumps shall be multi-stage, stainless steel, ring construction and provided on a duty/standby basis. Pumps shall be provided complete with isolation valves, reflux valves and delivery pressure gauges. Suction and delivery pressure gauges shall be provided on each pump and downstream of flow control valves where flow splitting is provided.

3

A filter shall be fitted to each suction pipeline.

4

The discharge and manometric head of each pumping sets shall be chosen to suit the working conditions of the ejectors at their maximum rated output.

5

The pumps shall be of the centrifugal type with high efficiency. Each pump shall be directly coupled to a totally enclosed air cooled electric motor, the motor shall be complete with its starter, rated for continuous running (24 hours) with class (F) insulation.

6

The pumps impellers, shafts, diffusers (if any), shall be made of stainless steel.

7

Ammoniator motive water systems shall be provided complete with base exchange water softeners, complete with local salt saturator for regeneration or from bulk salt saturators if employed at the site. The water softener shall be dual auto-rotation element units complete with auto-timers and regeneration controller.

19.2.5

Chlorine Gas Cylinders

1

Where specified in the Contract the Contractor shall supply chlorine gas cylinders of the pattern and size specified.

19.2.6

Chlorine Gas Header

1

The Contractor shall provide a suitable manifold and header system to convey gas from the cylinders via the changeover panel to the associated gas feeder.

2

The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters and all necessary mild steel pipework.

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19.2.3

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Page 5

Each header shall be complete with electric heater. The heater shall be of suitable power to prevent the freezing of chlorine gas when its flow rate through the header is maximum.

4

On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete with a self-regulating heater.

5

Pipework and valves shall be designed and constructed to withstand the pressure and corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves and couplings shall be provided to each major item of plant to facilitate removal for maintenance. Pressure testing of the pipework and valves shall be carried out by the contractor to the approval of the Engineer, and shall comply with the relevant British Standard or equivalent.

6

Each header shall be suitable for connecting two chlorine drums of capacity one ton each.

19.2.7

Automatic Cylinder Change-Over Module

1

Where specified in the Contract the Contractor shall supply and erect an automatic changeover panel which will change from duty gas supply to standby in the event of low pressure on the duty supply. The changeover panel shall include duty/standby indication, bottle change required, and the pressure of gas in the duty cylinder.

2

The changeover panel shall be mechanically operated and be complete with pressure reducing valves to prevent re-liquification of the gas and changeover valve block heater. The line between the changeover panel and the gas feeder incorporate individual failsafe vacuum gas regulator valves.

3

The automatic change-over module shall not permit a return to the initial source until the secondary source is exhausted.

4

The Contractor shall also supply a remote vacuum controller for each cylinder on duty to shut-down the cylinder on indication of loss of vacuum.

19.2.8

Automatic Isolation Valve

1

The discharge from drums shall be protected by an automatic isolation valve system. The system shall either be a proprietary system, or it shall comply with the following Clauses.

2

The automatic control of the isolation valve system shall be from the gas leak detection equipment.

3

For gas leak testing purposes, a remotely mounted manual opening facility shall be provided for each isolation valve. These shall be spring return push buttons with engraved labels "Press and Hold to Open Drum No 1 (No 2) Valve" and shall be incorporated into a shutdown control panel (mounted in a safe area) with the following features.

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(a)

Lamp (Green)-Drum No 1 Valve Open

(b)

Lamp (Green)-Drum No 2 Valve Open

(c)

Hand/Off/Auto Selector-Drum No 1 Valve

(d)

Hand/Off/Auto Selector-Drum No 2 Valve

QCS 2014


(e)

Push Button-Press and Hold to Open Drum No 1 Valve

(f)

Push Button-Press and Hold to Open Drum No 2 Valve

(g)

Push Button-Reset System

Page 6

The isolation valve shall be a two way PTFE taper plug valve suitable for use with dry chlorine. The body shall be of LCB carbon steel and plug of monel metal.

5

The automatic isolation valve shall be a spring return, giving fail safe operation in the event of loss of air supply.

6

The Contractor shall be responsible for the air supply to the valve. The supply line shall incorporate a moisture trap and drain located as near as possible to the electrically operated solenoid valves to be used for isolation valve control.

7

The solenoid valves shall operate from a 110 volt 50 Hz electricity supply and shall be mounted outside the control box. Valve terminal enclosures shall be fully shrouded and fitted with a propriety cable compression gland. Final connection to these valves shall be via short lengths of flexible multicore cable from an adjacent termination box.

8

The air supply to the automatic isolation valves shall be suitably rated nylon tubing supported in 25mm PVC conduit.

9

A sufficient length of tubing shall be provided adjacent to the automatic isolation valve in order to facilitate maintenance and valve height adjustment.

10

The connections to the automatic isolation valves shall be 2 No special elbows with a 3/4" BSP female rotary union for connection to the existing drum valve and a 3/4" BSP male taper for connection to the isolation valve are required for this purpose.

11

A 3/4" male/male nipple shall be provided on the upstream side of the isolation valve for connection to the gas header pipework system.

12

The pneumatically operated isolation valves shall be supported in a manner which facilitates adjustment in three planes to relieve the pipework connections adjacent to the valve of the weight of the valve and actuator.

13

The Contractor shall supply and install a robust tubular guard rail to protect the vulnerable valve and pipework arrangement on the discharge side of the drum from swinging drums.

14

The framework shall be fabricated in mild steel tubular sections and painted in accordance with Section 8 Part 8 the Specification.

15

The frame floor anchor plates and holding down bolts shall be designed to withstand an impact from a swinging chlorine drum.

16

The guard railing may be utilised for the support of the automatic isolation valves.

19.2.9

Chlorine Gas Header

1

The Contractor shall provide a suitable manifold and header system to convey gas from the cylinders via the changeover panel to the associated gas feeder.

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The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters and all necessary mild steel pipework.

3

Each header shall be complete with electric heater. The heater shall be of suitable power to prevent the freezing of chlorine gas when its flow rate through the header is maximum.

4

On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete with a self-regulating heater.

5

Pipework and valves shall be designed and constructed to withstand the pressure and corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves and couplings shall be provided to each major item of plant to facilitate removal for maintenance. Pressure testing of the pipework and valves shall be carried out by the contractor to the approval of the Engineer, and shall comply with the relevant British Standard or equivalent.

6

Each header shall be suitable for connecting two chlorine drums of capacity one ton each.

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19.2.10 Gas Feeder

Chlorine shall be dosed via duty/standby gas feeders, of the all vacuum/remote ejector principle.

2

The gas feeder shall dose gas automatically in proportion to flow, chlorine levels, super or residual whichever may be applicable.

3

Gas feeders shall be located such that access for maintenance is unobstructed. Rear access is acceptable providing a minimum of 1 metre free space is available for egress in emergencies.

4

The gas feeder shall incorporate the following features:

High Level Vent - in the event of gas vent, gas shall be directed to a high level external non-hazardous area.

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Vacuum Gauge - indicating system vacuum state.

(d)

Flowmeter - indicating as flow thorough feeder.

5

Microprocessor based process controllers shall provide automatic control, changeover monitoring and transmission facilities for disinfection control. The unit shall not be susceptible to memory corruption during normal electrical supply transients and shall be protected by a stabilised power supply.

6

The unit shall provide a continuous display of the actual chlorine residual and also indicate set residual parameters on demand. A separate readout shall also be provided to give operational data including alarm settings etc.

7

Each unit shall be provided complete with its own residual signal transmitter.

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8


Page 8

An integral printer shall provide the following status data on its respective system, on demand or at pre set intervals. (a)

Date

(b)

Time

(c)

Residual chlorine levels

(d)

Water Flow

(e)

Gas Flow

(f)

Alarm Conditions (high and low residual)

In addition a 4-20 mA analogue signal shall be provided to drive a pen of a three pen recorder (the two other pens being driven from the two other controllers associated with its respective pumping system). The pen recorder shall be a 7 day circular recorder and each pen shall be arranged to operate at different radii despite have similar residual chlorine levels. The recorder shall be wall mounted adjacent to the chlorination equipment.

10

The residual chlorine of the effluent shall be measured, indicated and controlled. It is required to supply and erect two chlorine residual sampling, measuring and controlling units, one as stand-by. Each unit shall be mounted with the chlorinator in one panel.

11

The residual chlorine measuring unit shall be of the amperometric type with suitable bimetallic electrodes to measure free available residual chlorine.

12

The electrodes shall be continuously cleaned by a suitable mechanical means. The electrodes shall be stationary and not to be allowed to move during the continuous cleaning operation.

13

The measuring cell shall be designed to measure “free available” chlorine. The signal generated in the measuring cell shall be fed to the recorder for recording. The measuring cell assembly contain equipment for regulating the pressure, flow and pH of the sample water before being passed through it.

14

The instrument shall include control components to provide automatic control of residual chlorine by adjusting the feed rate of chlorinators.

15

The sampling and measuring components shall be complete with all necessary pipe work, sampling pumps, valves and fittings.

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19.2.11 Residual Chlorine Recorders 1

The measured values of residual chlorine shall be automatically recorded by residual chlorine recorders. It is required to supply two recorders (one as stand-by).

2

The recorders shall be of the servo type which receive the residual chlorine signals from the residual measuring unit.

3

These signals shall be current proportional to the residual chlorine. The current shall then be indicated and recorded by the conventional self-balancing amperometric recorder head on a suitable diameter weekly inkless (pressure sensitive) chart.

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Page 9

4

The recorder shall have the same range for residual chlorine as the residual measuring apparatus, which is from “0” to 2.0 mg/lit.

5

The reading of residual chlorine shall be transferred to the chlorine apparatus.

19.2.12 Chlorine Consumption and Recording Apparatus 1

Duty and standby continuous measurement and totalising chlorine consumption measuring and recording apparatus shall be provided.

19.2.13 Analyser Cells Sampling point shall be selected by the Contractor and agreed with the Engineer. The Contractor shall include in his supply individual analyser cells. These units shall be supplied with buffer pump and container together with pressure switches and sample/by pass facilities.

2

The filter shall be mounted outside the unit in a convenient location and in a way which does not require dismantling of the access cover.

3

Sufficient buffer solution shall be provided for preliminary testing and tests before completion.

4

The system shall provide for triple validation of the analyser cells and supply lines.

5

Residual Chlorine analyzers shall be used to monitor the amount of free residual chlorine in final effluent/irrigation water. Each residual chlorine analyzer system shall comprise of a sensor, transmitter, buffer solution and other accessories. The analyzer should be provided with a flow regulating/isolation valve, sample flow indicator (VA type) „Y‟ strainer and associated pipework, skid mounted and installed in a GRP enclosure. The analyzer shall have a maximum response time of ten seconds for step change of 90%.

6

Transmitter shall comprise 3½ digits LCD, have a measurement accuracy of ±2%. These shall be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation for temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface mounting or digital signal if a data bus is specified. The enclosure shall be protected to IP66.

7

The sensor shall be of the Amperometric type sensor with flow through installation, and be complete width with an internal temperature sensor for automatic compensation. The sensor shall be complete with bottle of buffer solution and interconnecting cable.

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19.2.14 Gas Leak Detection Equipment 1

Drum stores, bottle stores and chlorinator rooms shall be provided with a gas sensing alarm system.

2

Each store/room shall be provided with sensors mounted in positions to achieve maximum effectiveness with chlorine sensors mounted at a low level. Multiple sensors shall be provided in larger stores/rooms where single sensor may not effectively sense all leaks.

3

Alarm control panels shall be mounted in a safe area outside the rooms, and shall operate via an integral battery back up system. Where available, the system may be powered from a central uninterruptable Power Supply (UPS) system.

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Page 10

(b)

Warning lamps or LED's for each gas sensor to indicate:

(c)

1st stage leak at 3.0 mg/l

(d)

2nd stage leak at 10.0 mg/l

(e)

Alarm/control contacts for:

(f)

Controlling Drum Shutdown Systems (where applicable)

(g)

Controlling Ventilation Fans

(h)

Controlling Door Access Warning Lamps

(i)

Signalling to Central Control Room or SCADA System

(j)

Signalling to a Site Telemetry Outstation

(k)

Instrument fault lamp or LED and warning contact.

(l)

Audible/visual warning device.

(m)

Power 'ON' or instrument 'HEALTHY' lamp or LED.

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Meter displaying the concentration of the gas leak in mg/l.

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Alarm control panels shall incorporate:

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The automatic Chlorine drum change-over system shall be arranged to change from the duty drum to the standby drum when the 1st stage leak level of 3.0 mg/l is reached. Further drum change-over shall be inhibited until the system is manually reset.

6

Chlorine drums shall be automatically isolated when the 2nd stage leak level of 10 mg/l is reached and the evaporators shall continue operating until the gas pressure reduced to zero. Once isolated, drums shall remain isolated until the system is reset and the drum automatic isolation valves manually re-opened. Operation of the automatic isolation system shall initiate a works shut down.

7

Ventilation fans in the affected room shall automatically be switched ON when the 1st stage leak level of 3.0 mg/l is reached. Ventilation fans in the affected room shall automatically be switched OFF when the 2nd stage leak level of 10.0 mg/l is reached. If the leak level falls below the 1st stage leak level, the ventilation fans shall continue to run on for 10 minutes before stopping.

8

Each access door to stores or rooms shall be provided with warning lamps to permit or prohibit entry. A green lamp shall indicate that it is safe to enter, at leak levels below the 3.0 mg/l threshold: A red lamp shall indicate that a 1st or 2nd stage leak has been detected. Each lamp box colour shall be provided with a minimum of two lamps so that a single lamp failure does not render the indication in-operative.

9

Each building containing a store or room shall be provided with an external flashing/rotating beacon coloured RED and an audible warning device. The audible device shall produce an output of 106dB(A) at 1 metre and shall remain sounding until such time as the alarm is accepted/cancelled, and it shall self cancel after 5 minutes. The flashing/rotating beacon shall remain operational whilst 1st or 2nd stage leak persists.

10

The location of the external flashing/rotating beacon shall be such that it is readily visible to persons entering the site via the main access route.

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19.2.15 Drum and Cylinders Handling The Contractor shall provide a travelling crane complying with Part 7 of this Section 9 as stated in the Particular Specification.

2

Drums shall be moved using a roller system. Each roller shall comprise a set of four trunnions which shall be used as a method of positioning the outlet valves of the drums and also for spacing and supporting the drums. The trunnions shall be fixed to steel I-beams, which shall be fixed rigidly to the floor of store.

3

Cylinders shall be set in racks and provided with positive restraint clamps. These clamps shall be either profile clamps or chain restraints which prevent movement of the cylinders from the stored position.

4

The handling system shall be designed so that it is not possible to pass a hoisted drum over a drum in use.

5

The Contractor shall supply one weighing balance for weighing of the chlorine cylinders. The balance shall be of the spring type with three (3) tons measuring capacity.

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19.2.16 Pipework

The Contractor shall provide and install all pipework and valves etc. necessary for the complete installation for the chlorination equipment system.

2

2 Pipework shall be provided with the necessary valves, bends, tees and unions for easy dismantling. Pipework materials should be provided in accordance with the chlorination equipment manufacturers recommendations and shall comply with international industry standards. Typically uPVC pipe will be used for water and chlorinated water and carbon steel for liquid chlorine.

3

3 All pipework shall be neatly laid and securely fixed in position. Similarly all valves shall be securely fixed, clearly numbered and labelled in accordance with the operating instructions.

4

4 Pipework shall be clean, dry and free from oil and grease and shall not be cleaned with organic solvents.

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19.2.17 Ventilation 1

Drum stores, bottle stores, and chlorinator rooms shall all be provided with forced ventilation systems, design to produce at least 6 volume changes of air per hour, and arranged to provide a negative pressure within the rooms.

2

Automatic control of the extract fans shall be from the gas leak detection equipment.

3

Manual control of the fans shall be provided from a safe area outside the rooms. Manual control shall be available regardless of the action of the gas leak detection equipment. The manual control shall be arranged so that it is not possible for ventilation fans to be turned off when the automatic system is calling for the fans to be turned on.

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Page 12

4

Extract grills and fans shall be positioned at a low level with the fan exhaust arranged to discharge the vented gas away from pedestrian walkways and roadways. If necessary, ducting to a point above building eaves level shall be provided to achieve this, subject to approval by the Engineer.

5

Intake grills shall be positioned at a high level and arranged so that the entire contents of the room are fully replenished with fresh air when the extract fans are running.

19.2.18 Emergency Breathing Apparatus and Air Compressor The Contractor shall supply Masks with air bottles (cylinders) to allow for working in contaminated air for 30 minutes. Their size shall be according to requirements of personnel dealing with chlorine gas. They shall be stored in cupboard.

2

The Contractor shall supply a motor driven portable air compressor. The compressor shall be mounted on a carriage with 2 pneumatic tyred wheels and handles for trailing. Also it shall be provided with an air reservoir of ample capacity. The set (air compressor and air reservoir) shall be complete with safety valves, pressure gauges, valves, piping and necessary safety devices.

3

The air intake shall be from the free atmospheric air.

4

The compressor shall be provided with suitable connection to allow for filling the air bottles (cylinders) of the masks. The compressed air must be free of any lubricating oil traces.

5

The capacity of compressor shall be enough to fill the air bottle of the mask-up to its working pressure in 5 minutes.

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The Contractor shall provide and fix engraved labels with white lettering 20mm high on a Red background. Externally mounted labels shall be provided with a stainless steel backplate for added support. The labels shall be: (a)

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19.2.19 Warning and Safety Notices

External to the gas store:

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WARNING: CHLORINE AND SULPHUR DIOXIDE STORE DO NOT ENTER WHEN WARNING LIGHT AND ALARM IS ON

(b)

Internal to the Gas Store, in a prominent location: WARNING IF ALARM SOUNDS ALL PERSONNEL MUST VACATE THIS DRUM STORE

2

The Contractor shall display first aid advice in Arabic & English and protective clothing for personnel who deal with chlorine equipment. As a minimum notices shall say: Chlorine is a highly irritating gas immediately affecting the eyes, nose, throat and chest. Anyone so affected must be removed to fresh air and medical treatment sought.

3

Warning lamps with alarm to be provided at the entry to the evaporator room and chlorinator room for alerting the personnel in case of a gas leak. Lamps shall indicated

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Page 13

Red > 9 ppm chlorine Yellow >3 - 9 ppm chlorine Green < 3 ppm chlorine

ON SITE GENERATION OF CHLORINE

19.3.1

General

1

Sodium hypochlorite generation, batching, dosing and dechlorination shall be automatically controlled. The Transformer/Rectifier and control panel shall be located in a separate room from the electrolyser and hypochlorite storage tanks where mounted internally. The location of plant within the generation room shall take into account local zoning restrictions.

2

Generation rooms shall be provided with either one full wall free air ventilator or automatic forced extract air systems. High level ventilators shall be provided.

19.3.2

Salt Saturators

1

Salt saturators shall be provided for the storage of fully saturated salt solution (brine). The total storage capacity shall be not less than 1 month‟s consumption at maximum works output. The salt saturators shall be approved with regard to FDA Regulations for use of non-toxic materials.

2

The saturators shall be rated for the peak salt consumption requirement of overnight generation of sodium hypochlorite and incorporate an internal suction discharge limiter to prevent tracking of partially saturated salt solution. The units shall be supplied and installed complete with the filter bed gravel and first salt fill on foundations prepared by the Civil Contractor to the Contractors requirements. The saturators shall be suitable for outdoor use.

3

The saturators shall include

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19.3

Inlet and Outlet connection manifolds.

(b)

Tanker charging connection and manifold.

(c)

Overflow to drain. Vent pipe complete with dust arrester Upper and lower level manway inspection points.

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(a)

(f)

Shrouded inlet float valve.

(g)

Surrounding bund of not less than 110% of the Saturator Volume.

(h)

Visual indication of salt level

19.3.3

Brine Feed

1

Brine feed through the electrolyser to the hypochlorite storage tank shall be provided on a duty/standby basis. Fixed speed, manually adjustable stroke pumps shall be suitable for this application.

2

The feed line shall be fitted with a flow monitor and a sampling point for brine testing. The contract shall include a brineometer for this purpose.

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Page 14

Electrolyser

1

Rating of the electrolysers shall be dependant on the requirement for generation of sodium hypochlorite during the off peak period. Multiple electrolysers shall be provided to achieve the required capacity. Standby shall be provided by either one spare unit or 25% of the capacity which ever is the greater, held in store at the site.

2

The anode/cathode is a consumable item within the generation package. Manufacturers offer a five year guarantee with regard to life consumed during a five year cycle of operation. The Contractor shall transfer this guarantee to the Purchaser which shall become effective from the date of the Take-Over. The Contractor shall therefore ensure that the current density value is commensurate with a five year cycle of operation.

3

The electrolysers shall be rack mounted such that access to all connections is within view of maintenance staff. Disconnection and replacement shall be possible without associated pipework disturbance.

4

Hydrogen release from the electrolysers shall be manifolded for transportation with the sodium hypochlorite for high level discharge in the hypochlorite storage tank. The sodium hypochlorite feed line shall incorporate a flow switch, for process shut-down in the event of low flow, a temperature switch for over temperature shut down of the process and a sample point for sodium hypochlorite sampling.

5

Any equipment which is in the defined Potentially Explosive Atmosphere shall be selected in accordance with BS 5345.

6

The water feed to the electrolyser shall be 'softened' as required via duty/standby water softeners with automatic changeover.

7

A heat exchanger shall be included with the electrolyser to transfer heat generated in the product to the incoming diluted brine solution in order to maximise the overall efficiency of the unit. Where this may not be sufficient, pre-heating with an electric immersion heater shall be provided.

19.3.5

Sodium Hypochlorite Storage

1

The sodium hypochlorite storage tanks shall be provided on a duplicate basis. The capacity shall be sufficient for 48 hours consumption at the maximum works output. The tank shall be suitable for external application and shall include forced ventilation for hydrogen dispersion. The tank(s) shall be installed in bund(s) of not less than 110% of the tank volume.

2

Duty/Standby ventilation fans shall be provided to supply air into the storage tank for high level discharge with dispersed hydrogen from the gaseous space above the stored liquid. Flow sensors shall monitor fan operation and shut down the generation process in the event of low flow detection.

19.3.6

Sodium Hypochlorite Dosing

1

Dosing of sodium hypochlorite shall be via duty/standby dosing pumps. Control of the pumps shall be related to the flowrate through the works chlorine disinfection requirements, and residual requirements.

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19.3.4

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Page 15

Overall control of the whole system shall be by means of a programmable logic controller (PLC) which shall be configured so that failure of the PLC shall not result in danger to personnel or equipment.

19.3.7

Pipework

1

All pipework fittings and valves associated with the generation equipment shall be rigidly fixed and supported, pipe routes over floor areas shall be adequately protected against accidental damage.

19.3.8

Electrical Installation

1

The electrical installation shall be in accordance with Section 21 of this specification.

19.3.9

Transformer / Rectifier

1

A duty transformer/rectifier shall provide low voltage DC for the electrolyser. The unit shall be free standing, the input shall be 415V, 3ph, a.c., output should not be greater than 24V dc with full wave rectification.

2

The unit be in accordance with the specification Section 21 and be capable of operation in ambient temperatures up to 500C. Cooling shall be via natural convection ventilation.

3

The rectifier shall include:A dc voltmeter

(b)

A dc Ammeter

(c)

A dc Centre zero voltmeter

(d)

Lockable input isolator

(e)

Main input contactor

(f)

On/Off push buttons

(g)

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(i)

Mains "on" lamp

(j)

DC "live" lamp

(k)

Hours run meter

All status and alarms shall be provided at the signals and alarms marshalling box.

19.3.10 Control Panel 1

A control panel shall be mounted adjacent to the Transformer/Rectifier to provide overall system control. The panel shall be in accordance with Section 21 - Factory Built Assemblies of Switchgear and Control Gear.

2

The Panel shall include indication and control equipment for the process.

3

In particular the following alarms shall be provided locally and at the signals and alarms marshalling box:-

QCS 2014


(a)

Improper voltage

(b)

Rectifier failure

(c)

Protection voltage failure

(d)

Storage tank low level

(e)

Low/high electrolyte temperature

(f)

Low electrolyte level

(g)

Low air flow

(h)

Bund flood

(i)

Low water flow

Page 16

ANALYSERS

1

Residual Chlorine analyzers are used to monitor the amount of free residual chlorine in final effluent/irrigation water. Each residual Chlorine analyzer system comprises of a sensor, transmitter, buffer solution and other accessories. The analyzer should be provided with a flow regulating/isolation valve, sample flow indicator (VA type) „Y‟ strainer and associated pipework, skid mounted and installed in a GRP enclosure. The analyzer shall have a maximum response time of ten seconds for step change of 90%.

2

Transmitter shall comprise 3½ digits LCD, have a measurement accuracy of ±2%. These shall be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation for temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface mounting. The enclosure shall be protected to IP66.

3

The sensor shall be of the Amperometric type sensor with flow through installation, and be complete width with an internal temperature sensor for automatic compensation. The sensor shall be complete with bottle of buffer solution and interconnecting cable.

19.5

NEUTRALISATION SYSTEMS

19.5.1

General

1

The neutralisation system shall include the following:

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19.4

(a)

Neutralisation tower.

(b)

Circulating pumping units.

(c)

Air exhaust system.

(d)

Caustic soda ash enough for two (2) times use.

(e)

Necessary pipes, fittings, valves.

(f)

Necessary electric connections.

When the concentration of the chlorine gas in the air reaches four (4) mg/lit, by volume, the chlorine leak detectors shall operate the neutralization system.

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Caustic soda solution prepared at the bottom part of the neutralization tower shall be sucked by the pumps and delivered to the spraying nozzles at the top of the tower. In the same time contaminated air shall be delivered to the lower part of the tower by the extraction fans. Contact shall happen, between the contaminated air and the caustic soda solution, through the contact rings and the neutralized solution shall be collected back at the bottom of the tank. The process shall continue until the concentration of the chlorine gas in air becomes normal. The neutralized solution shall be drained out from the lower part of the tower and another volume shall be prepared to be ready for emergency cases.

19.5.2

Neutralisation Tower

1

The tower shall be made from reinforced fibre glass. The neutralizing solution shall be prepared at the bottom of the tower by using of caustic soda ash. In the upper part of the tank, the spraying system with its nozzles shall be installed.

2

Porcelain or P.V.C. rings shall be placed on certain brackets inside the tower for increasing the contact area between the contaminated air and the sprayed neutralization solution.

19.5.3

Circulating Pumping Units

1

One duty and one stand-by pump shall be used to circulate, the neutralization solution from the bottom of the tower to the spraying installations.

2

The pumps shall be of discharge and head to suit the supplied installations.

3

The pumps shall be manufactured from suitable materials to withstand the corrosion action of the handled media.

19.5.4

Pipework and Electrical Connections

1

The price of neutralization system shall include all air ducts, caustic soda pumps, pipes and electric connections required. Air ducts shall be of uPVC complete with necessary valves and fittings.

2

The caustic soda pump suction and delivery pipes including valves and fittings shall be of PVC.

19.6


1


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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 02: Submersible Pumps

Page 1

2

SUBMERSIBLE PUMPS................................................................................ 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References Submittals

2.2

PRODUCTS ................................................................................................... 3

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7

General Design Conditions Materials Fabrication Accessories Factory Inspection and Testing Spare Parts and Tools

2.3


2.3.1 2.3.2

General Site Inspection and Testing

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2 2 2 3 4 5 5 8 8 9 9 9

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2

SUBMERSIBLE PUMPS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies this requirements for the design manufacture, construction, installation, testing and commissioning of submersible pumps, designed to handle raw unscreened sewage with a non-clog type impeller, complete and ready for operation as shown on the Drawings and as specified herein. Pumps may be used for applications other than sewage, in which case they shall be modified accordingly.

.

Related Parts and Sections are as follows: General


General Sewerage Instrumentation, Control and Automation Electrical Works

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References

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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes

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BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper coatings

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BS 3468, (ISO 2892) ..Austenitic cast iron BS 4999,.....................General requirements for rotating electrical machines

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BS 5345,.....................Codes of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres

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BS 5512, (ISO 281) ....Methods of calculating dynamic load ratings and rating life of rolling bearings BS 6007, (IEC 245) ....Rubber insulated cables for electric power and lighting BS 6105, (ISO 3506) ..Corrosion-resistant stainless steel fasteners BS 6861, (ISO 1940) Balance quality of requirements of rigid rotors BS 7671,.....................Requirements for electrical installations BS EN 1092,...............Circular flanges for pipes, valves and fittings BS EN 1561, (ISO 185) Flake graphite cast iron BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial flow centrifugal pumps Part 1 Class C tests ISO 10816 Part 1 & Part 7, Mechanical vibration in rotating and reciprocating machinery 2.1.3

Submittals

1

In addition to the requirements of Part 1 of this Section the Contractor shall provide data and information described in the following paragraphs

2

Design Data

QCS 2014

(a)

Page 3

the Contractor shall provide manufacturer‟s published pump curves, system curves and the necessary hydraulic calculations to justify the sizes of any pumps selected.

Shop Drawings

impeller diameter

(ii)

maximum impeller diameter

(iii)

minimum impeller diameter

(iv)

velocity of liquid in pump suction at duty point

(v)

velocity of liquid in pump delivery at duty point

(vi)

velocity of liquid in the pump casing or impeller eye at duty point

(vii)

net positive suction head (dry well submersibles only)

(viii)

the materials of construction shall be specified in detail and itemised against a sectional drawing of the pump proposed.

(ix)

characteristic curves for the full range of impeller diameters.

.

(i)

after approval of the pump types the Contractor shall submit the test data as required under factory inspection and testing

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(b)

the Contractor shall provide the following:

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Operation and Maintenance Manuals and Instructions. The Contractor shall include all the documentation provided as above and as required in Part 1.

2.2

PRODUCTS

2.2.1

General

1

Pumps and drives shall be rated for continuous duty and shall be capable of pumping the flow range specified in the Project Specification without surging, cavitation, or excessive vibration to the limits specified. All pumps and drives shall be from approved manufacturers.

2

The pumps shall meet maximum allowable shut-off head, and if dry-mounted submersibles, the maximum allowable required net positive suction head (NPSH) designated in the Project Specification.

3

The pumps shall not overload the motors for any point on the maximum pump speed performance characteristic curve and the pump operating range, within the limits of stable pump operation, as recommended by the manufacturer, to prevent surging, cavitation, and vibration.

4

To ensure vibration-free operation, all rotative components of each pumping unit shall be statically and dynamically balanced to BS 6861 and the following requirements shall be met:

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(a)

the mass of the unit and its distribution shall be such that resonance at normal operating speeds is within acceptable limits

(b)

in any case, the amplitude of vibration as measured at any point on the pumping unit shall not exceed the below limits

(c)

at any operating speed, the ratio of rotative speed to the critical speed of a unit, or components thereof, shall be less than 0.8 or more than 1.3.

5

Vibration outside the limits specified in 2.2.2.8 shall be sufficient cause for rejection of the equipment.

6

The completed units, when assembled and operating, shall be free of cavitation, vibration, noise, and oil or water leaks over the range of operation.

QCS 2014


Page 4

All units shall be so constructed that dismantling and repairing can be accomplished without difficulty.

8

The Contractor shall be responsible for proper operation of the complete pumping system, which includes the pump, motor, variable speed drive unit (if designated), and associated controls furnished with the pump.

9

The Contractor shall ensure that the controls and starting equipment are suitable for use with the pump motor, taking into account all requirements including starting currents and number of starts per hour.

10

For the performance curve of the selected pump impeller, the head shall continuously rise as flow decreases throughout the entire curve from run out to shutoff head.

11

The Contractor shall ensure that drive motors, variable speed drive systems (if designated) and pumps shall be supplied and tested together by the pump manufacturer, who shall supply full certification for the proper function of the entire pumping system.

12

If variable speed drive systems are specified, motor and drive system shall be fully compatible, and shall be of sufficient power and torque, and be capable of sufficient heat transfer for starting, accelerating and continuously operating over the entire range of head/capacity conditions, from minimum to maximum pump operating speed, as designated. The motor shall be derated to take into consideration the reduced cooling effect when running at the lowest speed with the variable speed drive.

2.2.2

Design Conditions

1

Pumps shall be designed and constructed to satisfactorily operate and perform within the designated design conditions and the requirements specified herein. They shall be designed for a life of 100,000 hours with service intervals at 20,000 hours.

2

Castings, fabrications, machined parts and drives shall conform to the industry standards for strength and durability and shall be rated for continuous duty over the entire operating range.

3

Bearings shall be of the anti-friction type designed for an L10 life of at least 50, 000 hours in accordance with BS 5512.

4

Pump maximum operating speed shall not exceed 1500 rpm.

5

Pumps shall be designed to pass all suspended solids up to 100mm diameter, including stringy matter, rags, paper, plastics, etc. without choking except in the case of pumps delivering into a 100mm diameter rising main where the capability shall be 80mm diameter.

6

Pumps shall be suitable for use in the conditions specified in Section 1.

7

Renewable impeller wear rings shall be fitted, to the impeller and case, except where not available on a standard production unit.

8

Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7, quality bands A and B.

9

Submersible pumps shall have the duckfoot bends flanged to BS EN 1092 PN16. In the case of dry mounted submersible pump the outlet and inlet shall be flanged to BS EN 1092 PN16.

10

The pump, motor and associated electrical equipment shall be rated for a minimum 10 starts per hour, unless otherwise designated.

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11


Page 5

The Contractor shall ensure that the pump manufacturer provides certification which guarantees the following: (a)

flow rate

(b)

total head

(c)

power input

(d)

efficiency

2.2.3

Materials

1

Pumps shall be manufactured of the following materials as a minimum:

(b)

impellers shall be duplex stainless steel

(c)

casing wear rings (where fitted) shall be brass BS 1400 or for abrasive

(d)

applications nitrile-rubber clad steel or to the approved manufacturer‟s standard

(e)

impeller wear rings shall be stainless steel BS 970 316 S31

(f)

bends shall be cast iron, BS 1452 Grade 250

(g)

motor casings shall be cast iron, grade 250 or SS316 S31

(h)

shafts shall be stainless steel, Grade 316 S31 to BS 970 Part 1

(i)

fasteners shall be stainless steel Grade 316S31 to BS970-1.

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volute casings shall be cast iron, BS EN 1561 Grade 250

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The lifting system shall be manufactured of the following materials: the guide rail system shall be stainless steel, BS 970 Type 316 S31

(b)

lifting chains, rings, hooks and shackles shall be stainless steel BS970 Grade 316 S31.

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(a)

Fabrication

1

General. Pumps shall be fabricated in accordance with the following requirements: (a)

pump shall be capable of handling raw, unscreened sewage in the case of submersible installations no portion of the pump shall bear directly on the floor of the wet well. In the case of dry mounted pumps a substantial purpose built mounting frame shall be provided by the pump manufacturer

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2.2.4

2

(c)

pressure gauge taps and air bleed taps shall be provided as stated under accessories

(d)

all castings shall be produced in accordance with the pump manufacturer‟s specifications under the manufacturer‟s direct supervision

(e)

pumps shall be designed with dual mechanical seals, as below

Wet well pumps shall incorporate the following features: (a)

pumps shall utilise a guide system to permit easy removal and reinstallation without dewatering the pump sump

(b)

discharge connections shall be made automatically with a simple downward motion without rotation when the pump is lowered into operating position. The pump shall be capable of being removed without disconnecting any fasteners

QCS 2014

(c)

Page 6

an appropriate length of chain shall be connected to the motor eyebolts to permit raising and lowering of the pump. The lifting chains shall be fitted with suitable additional rings in order that the pumps can be lifted in stages from the sump invert level using the lifting gear. An additional hook and chain permanently fixed to the bottom of the lifting equipment to support the weight of the pump set during lifting operations shall be provided.

Impeller. Impellers shall be fabricated according to the rated motor size as follows: (a)

non-clog type statically and dynamically balanced, keyed to the shaft

(b)

provided with pump-out vanes to prevent material from getting behind the impeller and into mechanical seal area

(c)

provided with wear ring as necessary to assure efficient sealing between volute and impeller

(d)

impellers shall not be trimmed unless approved by the Engineer

(e)

single/multi vane or vortex type, with a cutter impeller in the case of small flows.

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Discharge Connection and Guide Rails. Sliding guide bracket and discharge connections shall be provided which, when bolted to the floor of the sump and to the discharge line, will receive the pump discharge connecting flange without need of adjustment, fasteners, clamp, or similar devices. The guide rails shall not support any portion of the weight of the pump. The pump discharge connections shall incorporate a sealing face and connection yoke to allow for automatic coupling to fixed discharge connection pipework. The guide rails shall be fabricated in stainless steel BS 970 Grade 316 S31.

5

Pump Shafts:

pump shafts shall be of such diameter that they will not deflect more than 0.05 mm measured at the mechanical seal, whilst operating at full driver output

(b)

the shaft shall be turned, round and polished

(c)

shaft shall be key-seated for securing the impeller.

the drive motor and pump/motor bearings shall be sealed along the shaft with tandem mechanical seals operating in an oil filled chamber. The seals shall require neither routine maintenance or adjustment, but shall be capable of being easily inspected and replaced.

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Shaft Seals:

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(b)

two back to back mechanical seals shall seal the motor off from the pump.

(c)

the upper seal shall be oil lubricated with a carbon rotating component and fixed tungsten carbide component

(d)

the lower seal shall have both parts in tungsten carbide.

(e)

a detector shall indicate when moisture is leaking past the first seal.

Bearings: (a)

bearings shall be capable of taking the static weight of the rotating parts and any thrust generated by the operation of the pump

(b)

the upper bearing(s) shall be of the grease lubricated sealed for life type, the lower bearing(s) shall be lubricated by the internal oil supply

(c)

the bottom bearing(s) shall be of the angular contact ball bearing type in combinations with roller bearing(s)

QCS 2014

(d)

Page 7

if required in the project specification, remote indication shall be provided for bearing high temperature, using a thermistor at the lower bearing, to provide a signal at 95 °C.

Motors: (a)

motors shall be 415 V / 690V or as indicated in project requirements, phase, 50 Hz, rated at 10 % above the maximum power requirement

(b)

motors shall be squirrel cage, induction, air filled, totally sealed to IP 68, suitable for the maximum immersion depth likely to be encountered, rated for zone 2 use with group 1 gases, to BS 5345

(c)

motor insulation shall be Class F, limited to a Class B temperature rise

(d)

motor temperature shall be monitored using a thermistor, in each phase of the winding, set to stop the motor when the monitored absolute temperature reaches 130 °C

(e)

a watertight cable junction box sealed from the motor shall be provided for the motor power and signalling

(f)

cables shall be EPR insulated, Niplas sheathed, flexible 450/750 volts grade, oil and grease resistant, with tinned annealed copper conductors in accordance with BS 6007. The cable shall be brought directly out of the submersible motor without joints, and shall be of sufficient length, minimum 20 m to be terminated in an IP67 junction box outside adjacent to the wet well. They shall be sized in accordance with QGEWC regulations and BS 7671

(g)

cables shall be supported using a proprietary „sock‟ arrangement at the top of the wet well

(h)

Pumps shall be provided with proprietary monitoring and control units for inclusion in the motor controls. Analogue inputs shall include the following:

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winding temperature

(ii)

bearing temperature

(iii)

cooling oil temperature

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Digital inputs shall include the following: high winding temperature

(v)

high bearing temperature

(vi)

loss of coolant oil/seal failure

(vii)

over temperature

(viii)

moisture ingress

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(i)

Motors shall be capable of start up and operation in the event of a completely flooded wet well. Motors shall be selected to meet the maximum power required for the selected impeller at all operating conditions

(j)

Motor cooling shall be an efficient system to the manufacturer's design.

(k)

motors shall be derated for dry well and/or variable speed operation

Coatings and Protection (a)

Cathodic protection with replaceable sacrificial zinc anodes shall be provided if required in the Project Specification.

(b)

The cooling jacket shall be stainless steel

(c)

all other parts shall be to the approved manufacturer's standard protection

QCS 2014


2.2.5

Accessories

1

The following accessories shall be provided for each pump:

Page 8

pressure gauges. The discharge pipework of each pump shall be provided with a 19 mm diameter tapped opening and stainless or brass isolating valves and diaphragm pressure gauges In the case of dry-mounted submersibles a similar tapping valve and gauge shall also be provided on the suction pipework of each pump

(b)

air bleed offs. In the case of submersible pumps automatic brass air bleed ball valves shall be provided on the reflux valves, venting via a 40 mm diameter stainless steel pipe to the wet well. In the case of dry mounted submersible pumps these valves shall be provided on the highest point of the volute casing

(c)

labels. Each pump shall have a stainless steel label permanently fixed to the pump and an identical label fixed to the pump starter compartment.

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(a)

Factory Inspection and Testing

1

The Contractor shall secure from the pump manufacturer certification that the following internal inspections and tests have been conducted on each pump at the factory, and submit to the Engineer prior to FAT witness proposed:

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the pump casing has been tested hydrostatically to 1.5 times the maximum closed valve pressure

(b)

impeller, motor rating and electrical connections checked for compliance with the Project Specifications

(c)

motor and cable insulation tested for moisture content or insulation defects

(d)

prior to submergence, the pump has been run dry to establish correct rotation and mechanical integrity

(e)

the pump has been run for 30 minutes submerged under a minimum of 2 m water

(f)

after the operational test (e) above, the insulation tests (b) above has been performed again, and after the performance test (2) below

(g)

NPSH (dry well mounted pumps only)

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(a)

Each pump shall tested at the factory for performance according to BS EN ISO 9906 Grades 1, 2 and 3, including:

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2.2.6

3

(a)

flow

(b)

inlet pressure

(c)

outlet pressure

(d)

motor power

(e)

torque

(f)

efficiency

(g)

Net Positive Suction Head (NPSH) (valid for all type of pumps).

The Contractor shall secure from the pump manufacturer the following certification and submit to the Engineer prior to shipment: (a)

certified copies of the pump characteristic curves and reports generated by the tests described above and as required by BS EN ISO 9906 Grades 1,2 and 3

QCS 2014


Page 9

(b)

foundry composition certificates for all major castings (pump case, impeller, motor housing) showing exact material composition and tests conducted to ensure compliance with the pump manufacturer‟s material specifications.

(c)

the lifting chains, rings and shackles shall be load tested and Proof tested compare with one of the below mentioned applicable codes requirements, and clearly and permanently tagged with the SWL. Test certificates shall be supplied with Authorised TPA approval. Chain (sling and hooks): BS 4942 part 1 and 6 / ISO 2903 / ISO 7595 Shackles: BS 3551 / BS 3032 / BS 6994 Ring and Links: BS 2902

Spare Parts and Tools

1

The Contractor shall ensure that the pump manufacturer provides all spares and special tools required during the commissioning and maintenance periods, and as required below.

2

In addition to the spare parts required in Part 1 the following spare parts for each pump shall be furnished to the Employer:

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2.2.7

three sets of complete upper and lower bearings

(b)

three sets of wear rings

(c)

three sets of gaskets and three sets of „O‟ rings complete

(d)

three sets of upper and lower mechanical seals

(e)

additional spare parts as recommended by pump manufacturer to cover two years of operation following the maintenance period.

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(a)


2.3.1

General

1

The equipment delivered to the Site shall be examined by the Contractor to determine that it is in good condition and in conformance with the approved working drawings and certifications. All equipment shall be installed in strict conformance with Part 1 of this Section and the manufacturer‟s instructions.

2.3.2


1

If required in the Project Specification, or in the case of submersible pumps rated at 50 kW or greater, the Contractor shall provide the services of the pump manufacturer‟s representative to supervise the installation, commissioning and start-up of the pumping equipment.

2

The commissioning tests shall be performance and reliability trials, mainly for the purpose of satisfying the Engineer that the pumpsets have been correctly assembled and installed and that their performance matches that obtained during the manufacturer‟s works tests. In the event of an unwarranted change in the pump performance characteristics or power consumption, all necessary steps shall be taken as soon as possible to establish the cause and remove the fault. Similar action shall be taken for an undue increase in bearing or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any other fault or defect in the operation of the pumpset.

3

The site reliability trials shall include the following:

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2.3

(a)

a record of bearing and coupling clearance and alignments shall be tabulated to show the “as-built” condition of each pump

(b)

a record of all overload, timing relay and oil pressure relays shall be tabulated to show the “as-built” condition of each motor starter

QCS 2014


Page 10

(c)

all cables shall be “megger” tested to confirm the integrity of the insulation. tabulated record of results shall be made

(d)

the control panel shall be statically tested with motors disconnected to confirm the correct sequence of operation

(e)

each pump shall be operated individually over the range from closed valve to maximum emergency top water level, on a recirculation basis, using fresh water, and for a minimum of four hours continuously. During this test the following parameters will be recorded:motor phase currents

(ii)

pump output

(iii)

ambient and test water temperatures

(iv)

motor/pump casing temperature

(v)

power consumed

(vi)

power factor

(vii)

vibration

(viii)

signs of cavitation noise

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the commissioning trials shall extend until each pump unit has run „continuously‟ for at least 3 days under all operating conditions. The term „continuously‟ shall include running at various speeds or on a start/stop basis as determined by the control system

(g)

the Contractor‟s supervisory staff, and the pump manufacturer‟s representative, if required by the Project Specification or the above, shall be present during the period of the tests and trials. The Contractor shall be responsible for any failure of the whole equipment or any part thereof, whether such failure shall be determined by the methods detailed herein or otherwise. If the pump test or trial is interrupted by the Contractor, or through negligence on the part of the Contractor‟s staff, it shall be completely repeated for the pumpset concerned.

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(f)

END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 20: Washwater Systems

Page 1

20

WASHWATER SYSTEMS ............................................................................. 2

20.1

GENERAL ...................................................................................................... 2


2 2 2

PRODUCTS ................................................................................................... 2

20.2.1 General 20.2.2 Washwater Booster Set

2 2

TESTING ....................................................................................................... 3

20.4


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20.3

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Page 2

WASHWATER SYSTEMS

20.1

GENERAL

20.1.1

Scope

1

This part specifies the requirement for the design, manufacture, testing and commissioning of washwater systems.

2


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References

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BS 1123 .....................Safety valves, gauges and fusible plugs for compressed air or inert gas installation

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PD 5500 ....................Specification for unfired fusion welded pressure vessels

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ISO 10474 ..................Steel & Steel Products Inspection Documents

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20.2

PRODUCTS

20.2.1

General

1

The wash water system shall be capable of delivering a supply of final effluent wash water to the plant at the rate recommended by the manufacturers of the proprietary equipment plus a minimum of 6 l/s at 4 bar(g) with any two hydrants open and all process water requirements being meet simultaneously.

2

The design shall ensure that the hydrant pressure does not exceed 5 bar. reducing valves may be utilised for this purpose.

20.2.2

Washwater Booster Set

1

The wash water system shall comprise a minimum of one duty pump and a standby pump, pressure vessel with adjustable differential pressure switches, interconnecting pipework and valves, and a terminal panel. The motor starters and controls shall be part of a FBA. The pumps shall be provided with a duplex-strainer in the suction piping to prevent any debris from entering the system.

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20.1.3

Pressure

QCS 2014


Page 3

2

The pressure vessel shall be adequately sized to keep the maximum number of pump starts under the worst conditions to 15 per hour. The pressure vessel shall incorporate a butylrubber diaphragm to contain the water and shall be charged with nitrogen or another approved inert gas.

3

The vessel shall be of welded construction and in accordance with the relevant British Standards or ASME VII Div 1, and shall be complete with all necessary fixtures and fittings and shall include the following:Inspection manhole single or double bridged, according to size, which shall seat on pressure.

(b)

Flanged inlet and outlet connections.

(c)

System compound pressure gauge of the diaphragm type.

(d)

Safety valve, to relieve excess air pressure in tank to atmosphere.

(e)

50mm drain connection with valve.

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(a)

The vessel shall be high quality epoxy coated inside and out after all manufacture has been completed, and shall be suitable for the maximum working pressure required by the process.

5

The upper dome of the vessel shall be fitted with a suitable spring loaded pressure relief valve, which shall be arranged to commence to open at 110% of the maximum system working pressure, and be fully open at 120% of this pressure.

6

The pressure vessel, which shall be of vertical or horizontal construction, shall be mounted on a minimum of four mounting feet, to raise the vessel off the base plate a distance of not less than 300mm.

7

The vessel shall be fitted with a 150mm diameter pressure gauge, connected such that it reads the air pressure in the vessel and thereby indicating the pressure in the system.

8

There shall be provided for the vessel a manually operated air release valve, to enable the system to be depressurised to atmosphere before the system is drained and to enable the vessel to be recharged.

9

Pressure switches shall be robustly constructed and suitable for the arduous duties involved, and shall be fully adjustable over their working range, together with adjustable differentials.

20.3

TESTING

1

1 Testing of the vessel to the recommended Code of Practice shall be carried out at the manufacturers works, and a test certificate shall be issued. The working and test pressures shall be stamped onto the outside of the vessel such that they are clearly visible.

20.4


1


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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 21: Miscellaneous Equipment

Page 1

21

MISCELLANEOUS EQUIPMENT .................................................................. 2

21.1

GENERAL ...................................................................................................... 2

21.1.1 21.1.2 21.1.3 21.1.4

Scope References Submittals General

21.2

PROGRESSIVE CAVITY PUMPS.................................................................. 2

2 2 2 2

21.2.1 General 21.2.2 Pump Design 21.2.3 Macerator/Muncher

2 2 3

END SUCTION PUMPS ................................................................................. 3

21.3.1 21.3.2 21.3.3 21.3.4 21.3.5 21.3.6

General Casing Shaft and Impeller Gland Plate Bearings Pump Performance

21.4

PRESSURE FILTERS AND STRAINERS ...................................................... 5

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21.4.1 Pressure Filters 21.4.2 Basket Strainers

3 4 4 4 5 5 5 6

POLYMER PREPARATION AND DOSING SYSTEMS .................................. 6

21.5.1 21.5.2 21.5.3 21.5.4

General Wetting and Dispersing Device Flocculent Storage Tanks Dosing Pumps

21.6


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6 7 7 7

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Page 2

MISCELLANEOUS EQUIPMENT

21.1

GENERAL

21.1.1

Scope

1

This part specifies the requirement for the design, manufacture, testing and commissioning of miscellaneous items of equipment.

2


References

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21.1.4

General

1

The plant shall be complete with electric motors, starters and switchboards, cabling, accessories, valves, piping, holding down bolts, lubricators, appendages and connections to make the plant complete and perfect in every part and detail.

2

There shall be included all necessary stairs, ladders, platforms etc. to provide permanent, fixed safe and easy access for the maintenance of every item of plant.

21.2

PROGRESSIVE CAVITY PUMPS

21.2.1

General

1

Each pump shall be capable of pumping sludge with a dry solids content 50% greater than the design percentage of solids.

2

It should be noted that macerators/munchers might be required in certain applications.

3

The design of the installation shall allow the pump rotor to be removed from the installed pump body without the need to remove the pump casing from its installation.

21.2.2

Pump Design

1

The pumps shall be of the horizontal rotary type, for abrasive service provide hard chrome plated tool steel, for corrosive service provide hard chrome plated SS316 S31 having an abrasion resistant helical rotor operating in a resilient, synthetic rubber stator, suitable for the handling of the sludge.

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21.1.3

QCS 2014


Page 3

The pumps shall be of robust construction throughout suitable for the arduous conditions involved when pumping sludge, and shall be capable of working for long periods without requiring maintenance attention.

3

The rotor speed shall not exceed 400 rpm and provision shall be made for easy inspection of the rotor.

4

The pumps may be direct driven or belt driven and the motors shall be mounted beside the pumps.

5

The pumps and motor shall be mounted on a robustly constructed baseplate which shall incorporate, if belt driven, a positive belt tensioning device and shall be arranged such that access for inspection and maintenance is not unduly restricted or hindered by pipework connections etc.

6

For belt driven pumps, the drive between the pump and motor shall be by Vee Belts and shall be rated such that with half the number of belts broken the remaining belts can transmit the full driving power required by the pump at maximum duty.

7

The belt drive and pulleys shall be completely protected by suitable guards easily removable for inspection.

8

Each pump shall be supplied with a spring loaded pressure relief valve, the discharge of which shall be separately piped back to the suction pipework. To allow an increased head for main clearing purposes the valves shall be arranged to relieve at 45 metres head or at the maximum head under which the pumps may operate, whichever is the lower.

9

The pumps shall be arranged with “suction on gland” and the suction body shall be fitted with a flushing connection from the wash water system.

10

The Contractor shall provide and install all necessary pipework and valves from wash water system to the pumps.

11

Calculations for sizing the pumps shall be supplied with the offer and when tested at the maker’s works, the pumps shall give results that conform to the said calculations.

21.2.3

Macerator/Muncher

1

Macerators if required shall be installed upstream of each pump and shall be able to handle an equivalent flow.

2

The macerator/muncher shall comprise a slow speed, high torque, parallel shaft grinder.

3

The macerator/muncher shall ensure that the progressing cavity pumps are protected from and can adequately cope with the diverse materials likely to be encountered in the sludge.

21.3

END SUCTION PUMPS

21.3.1

General

1

End suction pumps may be close horizontally coupled to the motor as a single compact unit or independent of the motor.

2

The pumps shall be continuously rated and designed for an operating life of 20 years without major overhaul. Components likely to wear in the course of normal operation shall be capable of replacement with readily exchangeable components.

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Page 4

The pump casing and other parts in contact with the liquid shall be suitable for the duties involved.

4

Close coupled pumps shall be directly coupled to the drive motor through a rigid coupling and end thrusts accommodated in the motor bearings. The motor shall be flanged and spigotted for correct alignment, it shall be fitted with jacking bolts to ease removal.

5

Independent pumps shall be coupled to the drive motor through a flexible coupling which shall not be capable of transmitting end thrust to the motor.

6

The rotating unit must be removable type from the pump casing without disturbing the suction and delivery piping and the motor. A spacer type flexible coupling shall be used for power transmission.

21.3.2

Casing

1

The pump casing shall be of duplex stainless steel and be abrasion resistant, capable of taking shock loads and incorporate lifting eyes for removal of the pump. It shall be designed and correctly formed to provide the highest efficiency and absence of turbulence and shall be flanged and spigotted for correct location and jointing.

2

Readily replaceable back and front casing wear rings shall be provided, unless otherwise specified the casing wear rings shall be stainless steel Grade 316 S31 to BS 970 Part 1 and the wear rings shall be locked to prevent rotation by dowels or other similar approved method.

3

The pump casing shall be complete with integrally cast feet and lifting points.

21.3.3

Shaft and Impeller

1

The shaft shall be of stainless steel of minimum Grade 316 –S31 to BS 970-1 and of ample diameter to withstand all stresses imposed.

2

Where shafts are exposed to the process fluid and where they pass through the sealing gland they shall be fitted with positively driven stainless steel sleeves Grade 316-S31 to BS 970-1, which shall extend through the stuffing box.

3

The impeller shall be made of duplex stainless steel DIN 1.4517 and be of robust construction and be machined where possible with the water passages and blades filed and scraped, to produce smooth surfaces so that rags and stringy matter will not adhere. It shall be provided with auxiliary back blades to reduce the pressure at the mechanical seal and prevent the ingress of solids and abrasive matter. Hydraulic balance holes shall not be provided and the impeller shall be tested and adjusted for static and dynamic balance. The impeller shall be fitted to the drive shaft by a fitted impeller key and secured by a contoured nut, provided with a positive locking arrangement. Impellers are to be provided with renewable wear rings. Impeller wear rings shall be stainless steel Grade 316 S31 to BS 970 Part 1. The shaft shall be fully protected from contact with the pumped liquid.

4

The pump shall rotate in a clockwise direction when viewed from the suction end. The rotating element shall be in balance and designed so that the maximum operating speed is not less than 30 per cent below the first critical speed and there is no tendency for any part to unlock due to possible reversal of rotation.

21.3.4

Gland Plate

1

The gland plate shall be flanged and spigotted for correct alignment, it shall be fitted with jacking bolts to ease removal from the pump casing.

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The gland plate shall be fitted with a cartridge type mechanical seal. The gland stuffing box shall be designed for soft gland packing as an alternative.

3

The mechanical seal selected shall be suitable for the pump duty and the media being pumped, the seal shall be water lubricated and shall not in normal use permit any controlled leakage from the pump.

21.3.5

Bearings

1

Independent pumps shall be fitted with an external shaft bearing assembly. It shall positively locate the shaft so that on reassembly the shaft and impeller are in true alignment within the rotating unit and it shall be provided with locating dowels and jacking bolts to ease removal.

2

Bearings shall be generously rated and sized to take all thrust and radial loads and to ensure satisfactory and stable running under all conditions of operation, they shall be to ISO standard with SI unit dimensions. Bearings shall be of anti-friction type designed for an L10 life of at least 100,000 hours in accordance with BS 5512. The bearings shall be arranged for oil or grease lubrication.

21.3.6

Pump Performance

1

The pump head/flow characteristic curve shall be stable, rising steadily to closed valve head and non-overloading. The closed valve head shall be a minimum of 110% of the maximum duty head

2

Where the maximum duty is met by parallel pump operation, a single pump shall be capable of operation without run-out or overloading.

3

The Contractor shall make his own assessment of the friction losses under all operating conditions.

4

The pump quantity/power characteristics shall be stable and non-overloading such that the maximum power absorbed under any condition remains at least 10% less than the rating of the motor.

5

Characteristic curves for the pump shall be supplied with the Tender to a large scale which shall show the capacity of the pumps when pumping singly at minimum and maximum head. Where two or more pumps are installed discharging through the same pumping main, the characteristic curves shall include the system curves for all combinations of pumps. Curves showing pump efficiency and kW loading shall also be included. Where pumps are supplied with variable speed drives provide pump curves for minimum and maximum speed with pump efficiency and kW loading at intersections of the system curve.

6

When tested through their complete range of workable heads at the maker’s works, the pumps shall give results which conform to the curves submitted with the Tender

21.4

PRESSURE FILTERS AND STRAINERS

21.4.1

Pressure Filters

1

Automatic self cleaning filters shall be specifically suitable for use with organic contaminants. Cleaning shall be by a hydraulically powered suction scanner, automatically activated when the differential pressure across the filter reaches an adjustable level, nominally 3.5m.

2

The filter body and all internal parts, including flanges, shall be stainless steel Grade 316S31 to BS 970-1 (partially replaced by BS EN 10084). The screen shall be 150 micron mesh size. The flushing line shall be connected to the works drainage system.

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The control system shall feature a fail-safe timer to prevent continuous flushing due to malfunction. The filter shall not flush when the system or pumps are not working.

4

All the filters shall have isolation valves in the suction and delivery side for easy maintenance. The controller for the filters shall be equipped with a timer and pressure differential control unit.

5

Pressure gauges shall be connected to suction and delivery side of each filter, pressure switches shall be mounted in the electric control panel in an isolated compartment.

6

Input and output flanges dimensions shall be in accordance with BS EN 1092 PN 16.

21.4.2

Basket Strainers

1

The strainer shall be of the duplex in-line basket flanged type, of compact design and shall incorporate large filtration areas giving low pressure drops.

2

The body and cover will be of cast iron to BS EN 1561 grade 250 or equivalent, and shall be fusion bonded epoxy coated internally and externally with a minimum thickness of 300 microns. Flanges shall be PN16 to BS EN 1092.

3

Internal parts shall be of stainless steel Grade 316S31 to BS 970-1 (partially replaced by BS EN 10084) or equivalent.

4

The filter shall be 920 microns mesh inserted into a perforated plate basket.

5

Strainers shall be suitably rated for all working and test delivery pressures.

6

A differential pressure switch shall be connected between the inlet and outlet of the filter, and if the pressure drop across the filter is exceeded by 50% (or other value recommended by the Manufacturer and agreed with the Engineer) a lamp on the panel shall indicate “filter blocked” and operation of the system shall be disabled.

21.5

POLYMER PREPARATION AND DOSING SYSTEMS

21.5.1

General

1

A polyelectrolyte make-up, storage and dosing system shall be provided. The system shall be sized to provide the polyelectrolyte requirements of the sludge thickening system as designed by the Contractor and provide an adequate storage period of the necessary raw materials

2

The Contractor shall provide a facility for dosing by direct injection into the pipework, of preprepared polyelectrolyte, upstream of the conditioning tanks. The facility shall be manually selected via a gate valve and capable of being isolated from the dosing system.

3

The dry granule storage hopper shall be fabricated of stainless steel and shall have a 25kg minimum capacity. The hopper shall be mounted on the polyelectrolyte feeder and shall be provided with supports. The hopper shall be provided with a low-level alarm.

4

The hopper shall be enclosed by a stainless steel cabinet with a tubular heater fitted inside to prevent condensation and maintain polyelectrolyte in a dry condition.

5

The transfer of granules into the hopper shall use a vacuum system designed to operate with 1 tonne bulk bags.

6

The dry granule transfer equipment for the transfer of dry polymer from hopper to wetting device shall include the following: -

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(a)

A granule feeder with single screw discharge. The granule feeder outlet shall be fitted with a heater to prevent condensation.

(b)

A stainless steel funnel to direct the granules from the screw discharge into an air lift venturi. The funnel shall be fitted with a sieve.

(c)

A centrifugal air blower to provide a high velocity air stream. The motor shall be totally enclosed with a degree of enclosure protection appropriate to the equipment. The level of protection shall not be less than IP55.

(d)

An air dehumidifier.

(e)

A venturi granule injector to feed the granules into the air stream.

(f)

An anti-static connecting hose.

All stainless steel parts shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084)

21.5.2

Wetting and Dispersing Device

1

Wetting and dispersing devices shall ensure that every granule of polyelectrolyte delivered by the air stream is wetted and dispersed into the make-up tank. No conglomerates of polyelectrolyte shall be produced. The spray heads shall be of stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) and shall be fitted with a water pressure gauge and a control pressure switch. Potable water shall be used

2

The Contractor shall provide the Engineer with design calculations to demonstrate that he has made all reasonable endeavours to optimise the use of water on works processes.

3

For the polyelectrolyte system, the Contractor must install a break tank of sufficient water capacity to allow batch polymer to be mixed for one day’s use.

4

The Contractor shall design the polyelectrolyte break tank with optimal spare capacity and shall impose a strict regime of control to suppress any peaks and troughs of the water demand pattern.

21.5.3

Flocculent Storage Tanks

1

Flocculent storage tanks shall be fabricated from glass-reinforced plastic or steel reinforced glass fibre and shall include the following: Slow speed propeller or turbine mixer.

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(b)

Level electrodes to control solenoid valves, air blower, mixer, screw feeder and dosing pumps.

(c)

Mounting for wetting and dispersing device.

(d)

Flanged inlet, outlet, drain and overflow connections.

(e)

Removable covers.

(f)

Sight glass.

(g)

Tank contents gauge with analogue output to SCADA system.

21.5.4

Dosing Pumps

1

Duty and standby chemical metering pumps shall be provided complete with all pipework, valves and any necessary metering arrangements. The output of the pumps shall be variable by means of hydraulic variator or adjustable speed drive depending on pump type selected, so as to get accuracy in the dosing rate.

QCS 2014


Page 8

2

Flow meter (analogue-mechanical type) shall be installed in the delivery line of the pump to get the chemical flow rate.

21.6


1


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END OF PART

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Section 09: Mechanical and Electrical Equipment Part 22: Ventilation Systems

Page 1

22

VENTILATION SYSTEMS ............................................................................. 2

22.1

GENERAL ...................................................................................................... 2

22.1.1 Scope 22.1.2 Noise Level 22.1.3 Inlets and Outlets

2 2 2

VENTILATION SYSTEMS ............................................................................. 2

22.2.1 22.2.2 22.2.3 22.2.4 22.2.5 22.2.6 22.2.7

Ventilation Rates Wet Well Ventilation/Process Area Ventilation Dry Well Ventilation Motor Room Ventilation Fans Fan Motors Ducting

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22.2

2 3 3 4 4 4 4

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Page 2

VENTILATION SYSTEMS

22.1

GENERAL

22.1.1

Scope

1

This part specifies the particular requirement for the ventilation systems for sewerage and sewage treatment installations. This section is to be read in conjunction with Section 22. Where there is conflict then the requirements of this Section shall prevail.

2


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Section 1 Section 8 Section 10 Section 13 Section 21 Section 22

.

22

Noise Level

1

The noise level due to ventilation and air conditioning equipment shall be no greater than sound power level 65dB(A) at one metre.

2

The Contractor shall include for sound absorbers and anti-vibration mountings as necessary.

22.1.3

Inlets and Outlets

1

All inlets and outlets through the roof shall be fitted with approved GRP or Aluminium cowls and bird screens. All inlets and outlets through walls shall be fitted with demountable aluminium louvers. All materials used for external fittings shall be highly resistant to ultraviolet light.

2

All louvers shall be of the sand trap type and shall be fitted with internal sand filters and mosquito screens.

22.2

VENTILATION SYSTEMS

22.2.1

Ventilation Rates

1

The minimum number of air changes per hour shall be:

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22.1.2

Toilets

12

Stores

12

Workshops

15

Garages/Car park areas

12

Messes (two speed)

6 – 20

Motor Room

10 – 20

Dry Well

20

Covered areas containing untreated sewage

6 when covered rising to 20 prior to and during man entry

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Page 3

Wet Well Ventilation/Process Area Ventilation

1

Ventilation equipment shall ensure that at all times the wet well area is not hazardous to operators, during operation or shut down of the pumping plant. It should be noted that the gases given off by sewage may include methane (marsh gas), carbon dioxide, nitrogen, oxygen, hydrogen, hydrogen sulphide, water vapour and other constituents. In naturally ventilated wet wells/process area levels of hydrogen sulphide of up to 100 ppm are common and concentrations in excess of 400 ppm have been measured. Methane concentrations above the lower explosive limit are possible. This should be borne in mind when designing the ventilation system and odour control systems.

2

The system shall be capable of treating the specified H 2S concentration such that the operating mean H2S level in the well does not exceed 3 ppm. Removable cell type deodorisers shall not require filter replacement in a period less than 6 months. Bulk carbon deodorisers shall not require carbon regeneration in a period less than 2 years. Pelletised activated caustic or water regenerable carbon shall be used for the bulk type deodorizer units.

3

Where H2S levels are likely to exceed 20 ppm, a chemical scrubber of other suitable pre-filter shall be provided before a carbon filter.

4

The system shall operate on the principle of forced draught ducted outlet/natural ducted inlets and account shall be taken of the fact that the gases to be handled have differing specific gravities. The high and low level ducted inlets and outlets should span the width of the wet well so that there is a constant sweep of clean air across the wet well.

5

A complete fan/motor assembly shall be provided as a spare. This shall include the fan housing on the bulk carbon deodorisers.

6

On bulk carbon deodoriser systems a flow switch shall be fitted into the extract ductwork to actuate an alarm on the annunciator in the event of failure of the extract system.

7

In the event of failure of the wet well ventilation red rotating beacon, high intensity, alarm lights shall be illuminated adjacent to each wet well access door.

8

The extract shall be through a Deodoriser unit as specified elsewhere to remove obnoxious smells.

9

Warning labels worded as follows in English and Arabic shall be fitted at each alarm light location.

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22.2.2

WARNING DO NOT ENTER WHEN RED LIGHT IS ON NO NAKED LIGHTS AT ANY TIME

10

Two identical systems shall be provided, each capable of providing 60% of the overall design requirement for ventilation.

11

The treated air shall be discharged into the atmosphere via a stack which shall extend above the height of the building.

22.2.3

Dry Well Ventilation

1

The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via the stairways and other apertures.

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Page 4

Fans shall be of the double motor type having a standby motor which comes into operation should the duty motor fail. Alternatively two complete fans and motors shall be provided and installed to act as duty and standby.

3


22.2.4

Motor Room Ventilation

1

The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via inlet louvers. All inlet louvers shall be fitted with 2" thick metallic washable filters. Access shall be provided for cleaning/changing filters.

2

Fans shall be of the double motor type having a standby motor which comes into operation should the duty motor fail. Alternatively two complete fans and motors shall be provided and installed to act as duty and standby.

3


22.2.5

Fans

1

Fans shall be of the axial flow or centrifugal types suitable for handling air of high humidity and having concentrations of hydrogen sulphide.

2

They shall be of non ferrous construction or be protected with suitable epoxy resin coatings.

3

Odour Control fans shall be constructed entirely from stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) or fibreglass reinforced plastic of vinyl ester resin.

4

For deodorizer fan units, bearings shall be of the roller or ball type and shall be mounted using adaptor sleeves and plumber blocks with provision for lubrication. Sealed bearings shall be used for small fan units in dry well/motor room ventilation system.

22.2.6

Fan Motors

1

Fan motors shall be suitable for continuous operation in hot, humid atmospheres at an o ambient temperature of up to 55 C at 100% humidity.

2

The degree of protection shall be IP55 and for the wet well a classification of Ex N IIA T3 or better is required.

3

All motors shall comply with the section of this Specification headed "Motors" insofar as it applies.

22.2.7

Ducting

1

Ventilation ducting shall be of GRP, Reinforced uPVC or Stainless Steel to BS 970, Grade 316 S31. Material thickness, stiffening and joint arrangements shall not be of a standard lower than those set out in the Chartered Institution of Building Services (C.I.B.S), Guide (Section B3) 1983 Edition.

2

Ducting shall be complete with all necessary supports. Galvanised or stainless steel nuts and bolts shall be used for all ducting joints and all supports and brackets shall be galvanised. All supports, ducting, brackets and fixings in wet wells shall be stainless steel as specified elsewhere.

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3

Ducting shall be sized so that the air velocity within the ducts shall not exceed 5.5 metres per second.

4

Flexible connections and anti-vibration mountings shall be provided as necessary between the ductwork and fans and provision shall be made for thermal expansion.

5

Where ducts pass through the roof or floor slab the gap shall be sealed with polystyrene or similar approved material. Wood is not acceptable.

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END OF PART

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Section 09: Mechanical and Electrical Equipment Part 03: Centrifugal Pumps (Dry Well)

Page 1

3

CENTRIFUGAL PUMPS (DRY WELL) .......................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3


3.2

PRODUCTS ................................................................................................... 3

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7


3.3


3.3.1 3.3.2

Installation and Commissioning Site Inspection and Testing

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2 2 2 3 4 5 5 9 9 10 10 10

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Page 2

CENTRIFUGAL PUMPS (DRY WELL)

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for the design, manufacture construction, installation testing and commissioning of vertical spindle, single-suction, dry-well, non-clog, centrifugal type pumps, to handle sewage, surface and groundwater as specified.

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This Section Part 1, Section 1, Section 8, Section 10, Section 21,

.

3

References

1

The following standards or revised/updated versions and documents of other organisations are referred to in this Part:

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BS 4,...........................Structural steel sections BS 449,.......................The use of structural steel in building BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper coatings BS EN 1561, (ISO 185) Flake graphite cast iron BS 3100,.....................Steel castings for general engineering purposes BS 3170,.....................Flexible couplings for power transmission BS 3468, (ISO 2892) ..Austenitic cast iron BS EN 1092,............... Circular flanges for pipes valves and fittings (ISO 10816 ) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating machinery BS 4999,.....................(IEC 34,72) General requirements for rotating electrical machines BS 5304......................Code of Practice for the safety of machinery ...................................BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial flow centrifugal pumps BS 5512, (ISO 281) ....Methods of calculating dynamic load ratings and rating life of rolling bearings BS 6105, (ISO 3506) ..Corrosion-resistant stainless steel fasteners BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors BS 7613,.....................Hot rolled quenched and weldable steel plates BS EN 10113..............Hot rolled products in weldable fine grain structural steels ASME V ......................Boiler and Pressure Vessel Code, Nondestructive Examination ASME VIII Div. 1 .........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure Vessels 3.1.3

Submittals

1

In addition to the requirements of Part 1 of this section the Contractor shall provide data and information as described in the following paragraphs.

QCS 2014

Design Data (a)


Shop Drawings

duty impeller diameter

(ii)


(iii)


(iv)


(v)


(vi)


(vii)

net positive suction head

(viii)

the materials of construction shall be specified in detail and itemised against a sectional drawing of the pump motor, drive shafting and flywheel proposed.

(ix)


.

(i)


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(b)


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(a)

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Operation and Maintenance Manuals and Instructions. The Contractor shall include all the documentation provided as above and the results of all the factory and site inspection and testing in the manuals

3.2

PRODUCTS

3.2.1

General

1

Pumps and drives shall be rated for continuous duty and shall be capable of pumping the flow range specified in the Project Specification without surging, cavitation, or vibration.

2

The pumps shall meet maximum allowable shut-off head and maximum allowable required net positive suction head (NPSH) specified in the Project Specification.

3

The pumps shall not overload the motors for any point on the maximum speed pump performance characteristic curve within the limits of stable pump operation as recommended by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the entire pump operating range.

4

To ensure vibration-free operation, all rotative components of each pumping unit shall be statically and dynamically balanced to BS 6861, and the following requirements shall be met:

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4

(a)

the mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided

(b)

in any case, the amplitude of vibration as measured at any point on the pumping unit, motor or drive shafts shall not exceed the below limits 3.2.2.

(c)

at any operating speed, the ratio of rotative speed to the critical speed of a unit, or components thereof, shall be less than 0.8 or more than 1.3.

5

Vibration outside the below limits shall be sufficient cause for rejection of the equipment.

6

All parts of each pump shall be designed to withstand the stresses that will be imposed upon them during their handling, shipping, erection, and operation.

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Page 4


8


9

The pump supplier shall be responsible for proper operation of the complete pumping system, which includes the pump, motor, variable speed drive unit (if designated), and associated controls furnished with the pump.

10

For the performance curve of the selected pump impeller, head shall continuously rise as flow decreases throughout the entire curve from runout to shutoff head.

11

The Contractor shall ensure that drive motors, variable speed drive or softer starter systems (if designated) and pumps are furnished and tested together by the pump manufacturer, who shall supply full certification for the proper function of the entire pumping system, within the limits of the designated design conditions.

12

If variable speed drive systems are specified, motor and drive system shall be fully compatible, and shall be of sufficient power and torque, and be capable of sufficient heat transfer for starting, accelerating and continuously operating over the entire range of head/capacity conditions, from minimum to maximum pump operating speed, as designated.

3.2.2

Design Conditions

1

Pumps shall be designed and constructed to satisfactorily operate and perform within the designated design conditions and the requirements specified herein. They shall be designed for a life of 100,000 hours with service intervals at 20,000 hours.

2


3

Bearings shall be of the anti-friction type designed for an L10 life of at least 50 000 h in accordance with BS 5512.

4

Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower speed is specified in the Project Specification.

5

Pumps shall be of non-clog design, capable of passing spheres of a minimum 100 mm diameter unless other diameters are designated.

6

Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media temperature shall be taken as 40 °C.

7

Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where not available on a standard production unit.

8

Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality bands A and B

9

The pump, motor and associated electrical equipment shall be rated for a minimum of 10 starts per hour, unless otherwise designated.

10

The Contractor shall ensure that the pump manufacturer provides certification which guarantees the following:-

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(a)

flow rate

(b)

total head

QCS 2014


(c)

power input

(d)

efficiency

(e)

NPSH required

Page 5

3.2.3

Materials

1

Pumps shall be manufactured of the following materials as a minimum: volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250

(b)

impellers shall be duplex stainless steel DIN 1.4517;

(c)

impeller wear rings shall be of duplex stainless steel DIN 1.4462;

(d)

casing wear rings shall be of non ferrous or stainless steel BS970-1 Grade 316 S31 with good anti- seizure propertied against the rotating element. There shall be a difference of at least 50 points Brinell hardness of the opposed wear surfaces;

(e)

suction elbows shall be cast or ductile iron, BS EN 1561, Grade 250

(f)

stuffing box covers shall be cast iron, BS 1452, Grade 250

(g)

bearing frames shall be cast iron, BS EN 1561, Grade 250

(h)

pump shafts shall be of Duplex stainless steel conform to DIN 1.4462 or a suitable duplex ferritic – austenitic stainless steel;

(i)

pump shaft sleeves shall be stainless steel Grade 316 S31;

(j)

fasteners shall be stainless steel to BS 970-1 Grade 316 S31.

(k)

fly wheels if fitted shall be steel, BS 3100.

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(a)

Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply with BS 4, BS 449, BS 7613 and BS EN 10113 as applicable.

3

Additional or other requirements for materials of construction may be specified in the Project Specification

3.2.4

Fabrication

1

General: The pump shall be fabricated in accordance with the following requirements, and as described in the following paragraphs. pumps shall be capable of handling raw, unscreened sewage, effluent, storm or groundwater as required

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2

(b)


(c)

components shall conform with the requirements listed in the following paragraphs.

Volute casings: (a)

volute casings shall be large enough at all points to pass any size solid which can pass through the impeller

(b)

wall thickness shall be sufficient to withstand all stresses in service at full operating pressure

(c)

volute casings and integral discharge nozzle shall be cast in one piece, with smooth water passage lined with a proprietary corrosion and erosion liner to the manufacturer‟s recommended specification,

(d)

a hand hole (minimum size 75 mm by 125 mm) shall be provided near discharge flanges for inspection and cleaning. The inner contour of hand hole covers shall conform to that of volute casings

QCS 2014

a minimum 12 mm brass or stainless steel tap shall be provided on the top and bottom of discharge nozzles, next to discharge flanges, for venting and draining

(f)

volute casings shall be so arranged that impellers may be removed without disturbing either suction or discharge piping.

Impellers: impellers shall be cast or machined in one piece

(b)

impellers shall be designed with smooth water passages to prevent clogging by string or fibrous materials

(c)

impellers shall be fitted with a renewable wear ring and the casing shall be fitted with a matching wear ring

(d)

entire rotating assemblies shall be designed so that they may be withdrawn from pump assemblies without disturbing the suction or discharge piping connections

.

(a)

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Suction elbows:

suction elbow shall be supplied by the pump manufacturer as DI flanged long radius reduced elbow with integral lining to resist cavitation.

(b)

(b) a minimum 25 mm brass or stainless steel pipe tap shall be provided near the suction flanges for a pressure gauge connection.

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(a)

Stuffing boxes: (a)

stuffing box covers shall be accurately machined to fit onto the volute casing and shall be of sufficient thickness to withstand the pressure imposed upon it under operating conditions. Stuffing box cover and back vanes of the impeller shall allow water cooling to the gland packing.

(b)

stuffing boxes shall be cast integrally with the stuffing box cover and shall be of sufficient depth to hold at least 5 rings of packing

(c)

soft-packed glands shall be designed for grease or water lubrication and shall be provided with large size grease lubricators with indicators

(d)

glands and lantern rings shall be split to facilitate easy repacking and shall have tapped easy withdrawal holes on the upper face.

Bearing frames, bearing housings, and bearings: (a)

bearing frames shall be cast in one piece

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(e)

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(b)

frames shall carry both radial and thrust bearings

(c)

outboard bearings shall be the thrust bearing and the housing shall be designed to provide an axial clearance adjustment downward between the impeller and suction cover by use of shims or other suitable means

(d)

bearing housings shall be fitted with suitable grease seals to prevent loss of grease and to prevent entrance of contaminants

(e)

frames shall be provided with a tapped hole with a minimum diameter of 25 mm, located as low as practicable to drain the leakage from packing glands

(f)

bearing frames shall be accurately machined, centered, and securely bolted to volutes and stuffing box cover assemblies

(g)

construction shall be such that entire rotating assemblies may be removed without disturbing the suction or discharge piping

(h)

large openings shall be provided adjacent to stuffing boxes to facilitate adjustment and repacking

(i)

upper bearings shall be the thrust type and shall carry the entire pump thrust load

QCS 2014

(j)

bearings shall be grease lubricated with a provision for forcing out the old grease and limiting back pressure.

Supporting bases: pumps shall be furnished with a suitable supporting base either cast integrally with the volute or otherwise attached to the pump casing

(b)

bases shall provide openings large enough to permit access to suction elbows and cleanout hand holes

(c)

bases shall be designed to support the assembled weight of the pump and shall safely withstand all stresses imposed thereon by vibration, shock, and all possible direct and eccentric loads

(d)

pump bases shall be of an adequate horizontal dimension to provide sufficient footing contact area and anchorage facilities

(e)

the height of pump bases shall be such that the suction flange will clear the floor, footing surfaces or ducts, with sufficient space allowed for dismantling bolts.

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(a)

Pump shafts: (a)

pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at the face of the stuffing box while operating at the maximum design speed, as determined by calculations from the manufacturer

(b)

the entire length of shafts shall be turned, ground, and polished

(c)

a renewable shaft sleeve shall be provided over shafts through the stuffing box

(d)

shafts shall be key-seated for securing the impeller and coupling

(e)

sleeves shall be secured either by key or suitable locking screw to the Engineer‟s approval.

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vertical shafting shall be connected to drive motors with a direct, close coupled connection or of the flexible type, consisting of sections with flanged universal joints and intermediate bearings and Plummer blocks as designated or required

(b)

splined connections shall be provided adjacent to the pump

(c) (d)

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Drive shafts:

mating steel flanges for connection to driver and driven units shall be furnished shafts shall be designed for continuous duty to transmit the maximum output torque and power of the units

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(e)

components shall be adequately sized and designed for the service intended, including transient due to power failure

(f)

all shaft sections shall be statically and dynamically balanced individually. sections shall not exceed 3 m and shall run below their first critical speed

(g)

intermediate shaft support bearings shall be of the anti-friction type, grease lubricated, mounted in Plummer blocks dowelled to the supporting steel work

(h)

slip splines in drive shafts shall permit removal of the pump rotating assemblies without removal of any section of intermediate shafting, bearings, or discharge piping

(i)

intermediate bearings shall be supported by steel channel sections either fixed in position on the dry well walls, or mounted on a substantial frame with support from the dry well walls. There shall be no transmission of vibration from each bearing.

Shaft

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Page 8

Ring bases and base plates: (a)

pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base with adequate clearance and openings to provide ready access to the upper shaft coupling

(b)

ring bases shall be a minimum of 250 mm high and shall be rugged enough to support the full weight of the motor

(c)

base plates shall be square and shall be of sufficient thickness to support the drive assemblies

(d)

base plates shall be drilled to accommodate the size and number of anchor bolts required

(e)

where designated, bases shall be mounted on a suitable bolted, removable framing to cover access openings.

fly wheels shall be fitted where required for surge protection and to achieve smooth start and smooth stop to avoid NRV slamming

(b)

fly wheels shall be mounted in a housing directly beneath the drive motor and above the motor room floor, if the motors are mounted in a motor room

(c)

the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the Engineer, the fly wheel shall not be mounted on the motor shaft

(d)

fly wheels shall be statically and dynamically balanced to BS 6861 and shall be positively keyed to the drive shaft

(e)

flywheels shall be designed such that there is an even tangential stress distribution throughout the flywheel

(f)

flywheel speeds shall not exceed 30ms for cast iron and 50ms for cast steel.

-1

-1

Motors:

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(a)

(a)

motors shall be in accordance Section 21

(b)

motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless specified otherwise in the Project Specification

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(d)

motors shall be derated for variable speed operation

(e)

Motors above 75 KW shall be provided with bearing vibration monitoring on 2 axes

(f)

Motors above 75 KW shall be provided with winding temperature monitoring PT100 or similar subject of Engineers/Client approval.

13

Pump Control Systems: Pump control systems shall be furnished and installed in accordance with Section 10 and the Project Specification.

14

Coatings: (a)

all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of 300 microns. External parts and the motor shall be coated as the paint specification in Section 8

(b)

Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level G 6.3 prior to final assembly. (i)

drive motor / flywheel coupling.

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 03: Centrifugal Pumps (Dry Well) (ii)

flywheel / drive shaft coupling.

(iii)

drive shaft / pump coupling.

3.2.5

Accessories

1

The following accessories shall be provided for pumps:

Page 9

guards. Substantial galvanised perforated guards shall be provided at all exposed couplings, drives and shafts, in accordance with Part 1. The guards shall extend the whole length of the shaft and include hinged access doors at lubrication/inspection points for all points requiring maintenance

(b)

pressure gauges. The suction and discharge nozzle of each pump shall be provided with a 19 mm diameter tapped opening, stainless steel or brass isolating valves and diaphragm gauges as Part 1

(c)

volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off brass valve from high point of the volute, venting via pipe to the wet well as below. 25mm tee with isolation valve and piping to drain channel, shall be given below the air bleed-off valve for manual venting of the air in the casing.

(d)

access ladders, stair ways and platforms shall be provided to all points requiring maintenance, including couplings, bearings and sliding joints, as Sections 8, 16 and 17.

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(a)

Arrangements shall be made for draining away to the drainage channel or sump any water which leaks from pump glands or any other source using 50 mm minimum diameter stainless steel pipe.

3

Vibration sensors (in both axial and traverse direction) and temperature sensors shall be fixed on large pumps and motors (i.e. above 75 KW) for condition monitoring. Similarly vibration sensors (in both axial and traverse direction) shall be provided for the plumber block bearings of the drive shaft and the data should be made available in the SCADA panel.

3.2.6


1

The Contractor shall secure from the pump manufacturer certification that the following inspections and tests have been conducted on each pump at the factory, and submit to the Engineer prior to shipment: the pump casing has been tested hydrostatically to 1.5 times the maximum closed valve pressure

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(b)

impeller, motor rating and electrical connections checked for compliance with the Specifications

(c)

motor insulation tested for moisture content or insulation defects

(d)

the insulation test (b) above has been performed again after the performance test (2) below.

Each pump has been factory tested for performance according to BS EN ISO 9906 Grades 1, 2 and 3, including: (a)

flow

(b)

inlet pressure

(c)

outlet pressure

(d)

motor power

(e)

torque

(f)

efficiency

QCS 2014

Page 10

The Contractor shall secure from the pump manufacturer the following certification and submit to the Engineer prior to shipment. (a)


(b)

foundry Composition Certificates for all major castings (pump case, impeller, motor housing) showing exact material composition and tests conducted to ensure compliance with the pump manufacturer material specifications

(c)

non destructive test certificates for major parts as "pump shaft" and "impeller" to be issued under ASME V requirements (i)

Ultrasound test (UT) method for pump shaft shall satisfy the required criteria of ASME VIII Div.1 Appendix 12.

(ii)

Magnetic particle inspection (MPI) and/or dye penetration inspection (DPI) methods for impeller shall satisfy the required criteria of ASME VIII Div. 1 Appendices 6, 8 and/or 7.

driving shaft balancing certificate as ISO 1940 requirements with balancing quality level G16.

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(d)

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3



1

The Contractor shall provide from the pump manufacturer all the spare parts and tools required during the commissioning and maintenance periods as specified in Part 1, including those below:

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3.2.7

one set of complete bearings

(b)

three sets of stuffing box packing

(c)

one complete coupling

(d)

one set of wear rings

(e)

two sets of rubber coupling buffers

(f)

one set of shaft sleeves

(g)

three lantern rings for packing box.

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(a)

The Contractor shall supply, furnished by the pump manufacturer, a complete set of all special tools required for maintenance of the pumping equipment, in a lockable tool box, complete with the list of spares.

3.3


3.3.1


1

The equipment delivered to the Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict conformance with Part 1 of this Section and the manufacturer‟s instructions.

3.3.2


1

The Contractor shall provide the services of the pump manufacturer‟s representative to supervise the installation and commissioning of the pumping equipment.

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2

The commissioning tests shall be performance and reliability trials, mainly for the purpose of satisfying the Engineer that the pumpsets have been correctly assembled and installed and that their performance matches that obtained during the manufacturer‟s works tests. In the event of an unwarranted change in the pump performance characteristics or power consumption, all necessary steps shall be taken as soon as possible to establish the cause and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any other fault or defect in the operation of the pumpset.

3

The site reliability trials shall include the following: a record of bearing and coupling clearance and alignments shall be tabulated to show the “as-built” condition of each pump

(b)


(c)

all cables shall be “megger” tested to confirm the integrity of the insulation. tabulated record of results shall be made

(d)


(e)

each pump shall be operated individually over the range from closed valve to maximum emergency top water level on a recirculation basis using fresh water and for a minimum of four hours continuously. During this test the following parameters will be recorded:-

A

(ii)

pump output

(iii)


(iv)


(v)

power consumed

(vi)

power factor

(vii)

vibration

(viii)


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motor phase currents and voltages


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(a)

(h)

the Contractor‟s supervisory staff, and the pump manufacturer‟s staff if required by the Project Specification, shall be present during the period of the tests and trials. The Contractor shall be responsible for any failure of the whole equipment or any part thereof, whether such failure shall be determined by the methods detailed herein or otherwise. If the pump test or trial is interrupted by the Contractor, or through negligence on the part of the Contractor‟s staff, it shall be completely repeated for the pumpset concerned.

4

The operation, over the entire specified range, shall be free of cavitation, excessive vibration or noise.

5

Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within acceptable limits as 3.2.2.8 Excessive vibration shall constitute sufficient cause for rejection of the equipment.

QCS 2014

6


Page 12

Each pump performance shall be documented by obtaining concurrent reading showing motor voltage and amperage, pump suction head and pump discharge head as follows: (a)

readings shall be documented for a least four pumping conditions to ascertain the actual pumping curve

(b)

one test shall be at shutoff head

(c)

each power lead to the motor shall be checked for proper current balance.

Bearing temperatures shall be determined by a contact type thermometer. A running time of at least two hours shall be maintained at the maximum specified operating head.

8

In the event any of the pumping equipment fails to meet the above test requirements, it shall be modified and retested in accordance with the requirements of this Section until it meets the specified requirements, and approval of the Engineer.

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END OF PART

QCS 2014

Section 09: Mechanical And Electrical Equipment Part 04: Centrifugal Pumps (Split Casing)

Page 1

4

CENTRIFUGAL PUMPS (SPLIT CASING) .................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3


4.2

PRODUCTS ................................................................................................... 3

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7


4.3


4.3.1 4.3.2

Installation and Commissioning Site Inspection and Testing

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2 2 2 3 4 5 5 9 10 10 11 11

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Page 2

CENTRIFUGAL PUMPS (SPLIT CASING)

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for the design, manufacture construction, installation testing and commissioning of single stage centrifugal split casing pumps, to handle treated sewage effluent, surface and groundwater as specified.

2


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General General Drainage Works Instrumentation, Control and Automation Electrical Works

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This Section Part 1, Section 1, Section 8, Section 10, Section 21,

.

4

References

1


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4.1.2

BS 4............................Structural steel sections

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BS 449........................The use of structural steel in building

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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper coatings BS EN 1561, (ISO 185) Flake graphite cast iron

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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes

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BS 3100......................Steel castings for general engineering purposes BS 3170......................Flexible couplings for power transmission

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BS EN 1092................Circular flanges for pipes valves and fittings

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BS 4999, (IEC 34,72) .General requirements for rotating electrical machines BS 5304......................Code of Practice for the safety of machinery

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BS 5512, (ISO 281) ....Methods of calculating dynamic load ratings and rating life of rolling bearings BS 3468, (ISO 2892) ..Austenitic cast iron BS 7613......................Hot rolled quenched and weldable steel plates BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial flow centrifugal pumps BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors BS 6105, (ISO 3506) ..Corrosion-resistant stainless steel fasteners BS 7854 (ISO 10816) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating machinery BS EN 10113..............Hot rolled products in weldable fine grain structural steels 4.1.3

Submittals

1

In addition to the requirements of Part 1 of this section the Contractor shall provide data and information as described in the following paragraphs.

QCS 2014

Design Data (a)


Shop Drawings

duty impeller diameter

(ii)


(iii)


(iv)


(v)


(vi)


(vii)

net positive suction head

(viii)

the materials of construction shall be specified in detail and itemised against a sectional drawing of the pump motor, drive shafting and flywheel proposed.

(ix)


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(i)


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Operation and Maintenance Manuals and Instructions. The Contractor shall include all the documentation provided as above and the results of all the factory and site inspection and testing in the manuals

4.2

PRODUCTS

4.2.1

General

1

Pumps and drives shall be rated for continuous duty and shall be capable of pumping the flow range specified in the Project Specification without surging, cavitation, or vibration.

2

The pumps shall meet maximum allowable shut-off head and maximum allowable required net positive suction head (NPSH) specified in the Project Specification.

3

The pumps shall not overload the motors for any point on the maximum speed pump performance characteristic curve within the limits of stable pump operation as recommended by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the entire pump operating range.

4

To ensure vibration-free operation, all rotating components of each pumping unit shall be statically and dynamically balanced to BS 6861, and the following requirements shall be met:

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4

(a)

the mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided

(b)

in any case, the amplitude of vibration as measured at any point on the pumping unit, motor or drive shafts shall not exceed the below limits 4.2.2.

(c)

at any operating speed, the ratio of rotating speed to the critical speed of a unit, or components thereof, shall be less than 0.8 or more than 1.3.

5

Vibration outside the below limits shall be sufficient cause for rejection of the equipment.

6

All parts of each pump shall be designed to withstand the stresses that will be imposed upon them during their handling, shipping, erection, and operation.

QCS 2014


Page 4


8


9

The pump supplier shall be responsible for proper operation of the complete pumping system, which includes the pump, motor, variable speed drive unit (if designated), and associated controls furnished with the pump.

10

For the performance curve of the selected pump impeller, head shall continuously rise as flow decreases throughout the entire curve from runout to shutoff head.

11

The Contractor shall ensure that drive motors, variable speed drive systems (if designated) and pumps are furnished and tested together by the pump manufacturer, who shall supply full certification for the proper function of the entire pumping system, within the limits of the designated design conditions.

12

If variable speed drive or soft starter systems are specified, motor and drive system shall be fully compatible, and shall be of sufficient power and torque, and be capable of sufficient heat transfer for starting, accelerating and continuously operating over the entire range of head/capacity conditions, from minimum to maximum pump operating speed, as designated. Design Conditions

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Pumps shall be designed and constructed to satisfactorily operate and perform within the designated design conditions and the requirements specified herein. They shall be designed for an operating life of 100,000 hours with service intervals at 20,000 hours. Wearing components shall have a design life of not less than 5 years or 10 years where major dismantling is required.

2


3

Bearings shall be of the anti-friction type designed for an L10 life of at least 100,000 hours in accordance with BS 5512.

4

Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower speed is specified in the Project Specification.

5

Horizontal shaft pumps installed on plinths at ground level are the preferred arrangement.

6

Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media temperature shall be taken as 40 °C.

7

Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where not available on a standard production unit.

8

Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality bands A and B.

9

The pump, motor and associated electrical equipment shall be rated for a minimum of 10 starts per hour, unless otherwise designated.

10

The Contractor shall ensure that the pump manufacturer provides certification which guarantees the following:-

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1

(a)

flow rate

QCS 2014

(b)

Duty Head

(c)

power input

(d)

efficiency

(e)

NPSH required

4.2.3

Page 5

Materials Pumps shall be manufactured of the following materials as a minimum: volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250.

(b)

impellers for sewage, treated effluent and ground water shall be duplex stainless steel DIN 1.4517.

(c)

impeller wear rings shall be of duplex stainless steel DIN 1.4462

(d)

casing wear rings shall be of non ferrous or stainless steel BS 970-1 Grade 316 S31 with good anti seizure propertied against the rotating element.. There shall be a difference of at least 50 points Brinell hardness of the opposed wear surfaces.

(e)

suction elbows shall be cast or ductile iron, BS EN 1561 or BS EN 1563, Grade 250.

(f)

stuffing box covers shall be cast iron, BS EN 1561, Grade 250.

(g)

bearing frames shall be cast iron, BS EN 1561, Grade 250.

(h)

pump shafts shall be duplex stainless steel to DIN 1.4462.

(i)

pump shaft sleeves shall be stainless steel Grade 316 S31.

(j)

fasteners shall be stainless steel to BS 970-1 Grade 316 S31.

(k)

fly wheels if fitted shall be steel, BS 3100.

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Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply with BS 4, BS 449, BS 7613 and BS EN 10113 as applicable.

3

Additional or other requirements for materials of construction may be specified in the Project Specification

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General: The pump shall be fabricated in accordance with the following requirements, and as described in the following paragraphs.

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Fabrication

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4.2.4

2

(a)

pumps shall be capable of handling treated sewage effluent, stormwater or groundwater as required

(b)


(c)

components shall conform with the requirements listed in the following paragraphs.

(d)

components that would come in contact with chlorine shall, as far as practically possible, be resistant to attack by chlorine.

Volute casings: (a)

volute casings shall be large enough at all points to pass any size solid which can pass through the impeller

(b)

volute casings shall be of the double volute type split axially with the suction and delivery branches, bearing housing and feet cast integrally with the same half casing, thus enabling the whole of the rotating assembly to be removed without opening pipe joints or disturbing the alignment of the pumpset.

QCS 2014


Page 6

wall thickness shall be sufficient to withstand all stresses in service at full operating pressure

(d)

volute casing halves shall be cast in one piece, with smooth water passage lined with a proprietary corrosion and erosion lining to the Manufacturer‟s recommended specification,

(e)

two lifting screws eye bolts shall be fitted to the upper casing

(f)

a minimum 12 mm brass or stainless steel tap shall be provided on the top and bottom of discharge nozzles, next to discharge flanges, for venting and draining

(g)

volute casings shall be so arranged that impellers may be removed without disturbing either suction or discharge piping.

(h)

the split casing pumps shall be constructed of two half casings fitted with tapered guide pins to BS EN 22339 to ensure accurate alignment on re-assembly. The casing joint shall be a metal face to face joint with a non hardening sealing compound, no jointing gasket shall be used. Metal face to face joints shall be flat and parallel with a maximum gap of 0.05mm, mating faces shall have a surface finish of 0.8 microns C.L.A or better.

Impellers:

impellers shall be cast or machined in one piece and fusion bonded epoxy coated with a minimum 500 micron thickness.

(b)

impellers shall be designed with smooth water passages and finished to smooth surfaces, they shall be balanced statically and dynamically as a whole assembly together with the shaft and secured on the shaft by a suitable locking nut arrangement..

(c)

impellers shall be fitted with a renewable wear ring and the casing shall be fitted with a matching wear ring

(d)

entire rotating assemblies shall be designed so that they may be withdrawn from pump assemblies without disturbing the suction or discharge piping connections

(e)

impellers shall be double entry shrouded type, and shall be fully balanced and supported between bearings.

(f)

impellers shall be supplied from the manufacturers standard range and shall not be trimmed or cropped to meet the specified duty.

4

5

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Impellers shall be selected from middle range for their pump casing and shall be sized such that a larger impeller (with 10% increase in diameter) capable of supplying an additional 25% flow can be fitted in the pump casing with no modifications.

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(c)

Suction elbows: (a)

suction elbows shall be supplied by the pump manufacturer as DI flanged long radius reduced elbows with integral lining to resist cavitation.

(b)

a minimum 25 mm brass or stainless steel pipe tap shall be provided near the suction flanges for a pressure gauge connection.

Stuffing boxes: (a)

stuffing box covers shall be accurately machined to fit onto the volute casing and shall be of sufficient thickness to withstand the pressure imposed upon it under operating conditions. The stuffing box cover and back vanes of the impeller shall allow water cooling to the gland packing.

(b)

stuffing boxes shall be cast integrally with the stuffing box cover and shall be of sufficient depth to hold at least 5 rings of packing

(c)

soft-packed glands shall be designed for grease or water lubrication and shall be provided with large size grease lubricators or water connections with indicators.

QCS 2014

(d)

(d) glands and lantern rings shall be split to facilitate easy repacking and shall have tapped easy withdrawal holes on the upper face.

Bearing frames, bearing housings, and bearings: bearing frames shall be cast in one piece

(b)

frames shall carry both radial and thrust bearings

(c)

outboard bearings shall be the thrust bearing and the housing shall be designed to provide an axial clearance adjustment downward between the impeller and suction cover by use of shims or other suitable means

(d)

bearing housings shall be fitted with suitable grease seals to prevent loss of grease and to prevent entrance of contaminants

(e)

frames shall be provided with a tapped hole with a minimum diameter of 25 mm, located as low as practicable to drain the leakage from packing glands

(f)

bearing frames shall be accurately machined, centred, and securely bolted to volutes and stuffing box cover assemblies

(g)

construction shall be such that entire rotating assemblies may be removed without disturbing the suction or discharge piping

(h)

large openings shall be provided adjacent to stuffing boxes to facilitate adjustment and repacking

(i)

upper bearings shall be the thrust type and shall carry the entire pump thrust load

(j)

bearings shall be grease lubricated with a provision for forcing out the old grease and limiting back pressure.

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Supporting bases:

pumps shall be furnished with a suitable supporting base either cast integrally with the volute or otherwise attached to the pump casing

(b)

bases shall provide openings large enough to permit access to suction elbows and cleanout hand holes

(c)

bases shall be designed to support the assembled weight of the pump and shall safely withstand all stresses imposed thereon by vibration, shock, and all possible direct and eccentric loads

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(a)

pump bases shall be of an adequate horizontal dimension to provide sufficient footing contact area and anchorage facilities

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8

(e)

the height of pump bases shall be such that the suction flange will clear the floor, footing surfaces or ducts, with sufficient space allowed for dismantling bolts.

(f)

Motors of horizontal pumps shall be mounted on an extension of the pump base plate and shall drive the pump directly through a flexible coupling.

(g)

Motors of close coupled vertical pumps shall be mounted on an extension of the pump support frame and shall drive the pump directly through a flexible coupling.

(h)

Remotely driven vertical pumps shall have a plummer block bearing mounted on an extension of the pump support frame and shall drive the pump directly through a flexible coupling between the plummer block and pump shaft, the drive shaft between the plummer block and motor shall have flexible couplings at each end.

Pump shafts: (a)

pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at the face of the stuffing box while operating at the maximum design speed, as determined by calculations from the manufacturer

(b)

the entire length of shafts shall be turned, ground, and polished

QCS 2014

Page 8

(c)

a renewable shaft sleeve shall be provided over shafts where exposed to the process fluid and through the stuffing box

(d)

shafts shall be key-seated for securing the impeller and coupling

(e)

sleeves shall be secured either by key or suitable locking screw to the Engineer‟s approval.

(f)

shaft sleeves shall be sealed internally to prevent leakage along the shaft.

Drive shafts: vertical shafting shall be connected to drive motors with a direct, close coupled connection or of the flexible type, consisting of sections with flanged universal joints and intermediate bearings and plummer blocks as designated or required

(b)

splined connections shall be provided adjacent to the pump

(c)

mating steel flanges for connection to driver and driven units shall be furnished

(d)

shafts shall be designed for continuous duty to transmit the maximum output torque and power of the units

(e)

components shall be adequately sized and designed for the service intended, including transient due to power failure

(f)

all shaft sections shall be statically and dynamically balanced individually. Shaft sections shall not exceed 3 m and shall run below their first critical speed

(g)

intermediate shaft support bearings shall be of the anti-friction type, grease lubricated, mounted in plummer blocks dowelled to the supporting steel work

(h)

slip splines in drive shafts shall permit removal of the pump rotating assemblies without removal of any section of intermediate shafting, bearings, or discharge piping

(i)

intermediate bearings shall be supported by concrete beam, or steel channel sections either fixed in position on the dry well walls, or mounted on a substantial frame with support from the dry well walls. There shall be no transmission of vibration from each bearing.

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(a)

Ring bases and base plates:

ring bases shall be a minimum of 250 mm high and shall be rugged enough to support the full weight of the motor

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(b)

pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base with adequate clearance and openings to provide ready access to the upper shaft coupling

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(c)

base plates shall be square and shall be of sufficient thickness to support the drive assemblies

(d)

base plates shall be drilled to accommodate the size and number of anchor bolts required

(e)

where designated, bases shall be mounted on a suitable bolted, removable framing to cover access openings.

Fly wheels: (a)

fly wheels shall be fitted where required for surge protection and to achieve smooth start and smooth stop to avoid NRV slamming.

(b)

fly wheels shall be mounted in a housing directly beneath the drive motor and above the motor room floor, if the motors are mounted in a motor room

(c)

the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the Engineer, the fly wheel shall not be mounted on the motor shaft

QCS 2014

Page 9

(d)

fly wheels shall be statically and dynamically balanced to BS 6861 and shall be positively keyed to the drive shaft

(e)

flywheels shall be designed such that there is an even tangential stress distribution throughout the flywheel

(f)

flywheel speeds shall not exceed 30ms-1 for cast iron and 50ms-1 for cast steel.

Motors: shall be in accordance with Section 21.

(b)

motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification

(c)

motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless specified otherwise in the Project Specification

(d)

motors shall be de-rated for variable speed operation

(e)

motor shall be sized to be able to drive the larger impeller (as per 4.2.4.- 3g) with no modification.

.

(a)

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Pump Control Systems: Pump control systems shall be furnished and installed in accordance with Section 10 and the Project Specification.

14

Coatings:

4.2.5 1

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Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level G 6.3 prior to final assembly. drive motor / flywheel coupling.

(ii)

flywheel / drive shaft coupling.

(iii)

drive shaft / pump coupling.

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Couplings:

Accessories

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all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of 300 microns unless otherwise stated. External parts and the motor shall be coated as the paint specification in Section 8

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13

The following accessories shall be provided for pumps: guards. Substantial galvanised perforated guards shall be provided at all exposed couplings, drives and shafts, in accordance with Part 1. The guards shall extend the whole length of the shaft and include hinged access doors at lubrication/inspection points for all points requiring maintenance

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(b)

pressure gauges. The suction and discharge nozzle of each pump shall be provided with a 25 mm diameter tapped opening, stainless steel or brass isolating valves and diaphragm gauges as Part 1

(c)

volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off brass valve from high point of the volute, venting via pipe to the drain channel as below, a 25mm tee with isolation valve and piping to the drain channel, shall be provided below the air bleed-off valve for manual venting of the air in the casing..

(d)

access ladders, stair ways and platforms shall be provided to all points requiring maintenance, including couplings, bearings and sliding joints, as Sections 8, 16 and 17.

Arrangements shall be made for draining away to the drainage channel or sump any water which leaks from pump glands or any other source using 50 mm minimum diameter stainless steel pipe.

QCS 2014

Vibration sensors (axial and radial) and temperature sensors shall be fixed on large pumps and motors‟ upper and lower bearings (i.e. above 75 KW) for condition monitoring. Similarly vibration sensors (axial and radial) shall be provided for the plumber block bearings of the drive shaft, the data from all sensors should be made available in the SCADA panel.

4.2.6

the pump casing has been tested hydrostatically to 1.5 times the maximum closed valve pressure

(b)

impeller, motor rating and electrical connections checked for compliance with the Specifications

(c)

motor insulation tested for moisture content or insulation defects

(d)

the Insulation Test (c) above has been performed again after the performance test (2) below.

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(a)

(b)

inlet pressure

(c)

outlet pressure

(d)

motor power

(e)

torque

(f)

efficiency

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Each pump has been factory tested for performance according to BS EN ISO 9906 Grades 1, 2 and 3, including:

The Contractor shall secure from the pump manufacturer the following certification and submit to the Engineer prior to shipment. (a)


(b)

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The Contractor shall secure from the pump manufacturer certification that the following inspections and tests have been conducted on each pump at the factory, and submit to the Engineer prior to shipment:

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foundry Composition Certificates for all major castings (pump case, impeller, motor housing) showing exact material composition and tests conducted to ensure compliance with the pump manufacturer material specifications.

(c)

(d) 4.2.7 1

non destructive test certificates for major parts as "pump shaft" and "impeller" to be issued under ASME V requirements. (i)

ultrasound test (UT) method for pump shaft shall satisfy the required criteria of ASME VIII Div.1 Appendix 12.

(ii)

magnetic particle inspection (MPI) and/or dye penetration inspection (DPI) methods for impeller shall satisfy the required criteria of ASME VIII Div. 1 Appendices 6, 7 and/or 8.

driving shaft balancing certificate as ISO 1940 requirements with balancing quality level G16 Spare Parts and Tools

The Contractor shall provide from the pump manufacturer all the spare parts and tools required during the commissioning and maintenance periods as specified in Part 1, including those below: (a)

one complete set bearings

QCS 2014


(b)

three sets of stuffing box packing

(c)

one complete coupling

(d)

one set of wear rings

(e)

two sets of rubber coupling buffers

(f)

one set of shaft sleeves

(g)

three lantern rings for packing box.

Page 11

2

The Contractor shall supply, furnished by the pump manufacturer, a complete set of all special tools required for maintenance of the pumping equipment, in a lockable tool box, complete with the list of spares.

4.3


.


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4.3.1

The equipment delivered to the Site shall be examined by the Engineer to determine that it is in good condition and in conformance with the approved working drawings and certification. All equipment shall be installed in strict conformance with Part 1 of this Section and the manufacturer‟s instructions.

4.3.2


1

The Contractor shall provide the services of the pump manufacturer‟s representative to supervise the installation and commissioning of the pumping equipment.

2

The commissioning tests shall be performance and reliability trials, mainly for the purpose of satisfying the Engineer that the pump sets have been correctly assembled and installed and that their performance matches that obtained during the manufacturer‟s works tests. In the event of an unwarranted change in the pump performance characteristics or power consumption, all necessary steps shall be taken as soon as possible to establish the cause and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any other fault or defect in the operation of the pumpset.

3

The site reliability trials shall include the following: a record of bearing and coupling clearance and alignments shall be tabulated to show the “as-built” condition of each pump

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(b)


(c)

all cables shall be “megger” tested to confirm the integrity of the insulation. A tabulated record of results shall be made

(d)


(e)

each pump shall be operated individually over the range from closed valve to maximum emergency top water level on a recirculation basis using fresh water and for a minimum of four hours continuously. During this test the following parameters will be recorded:(i)

motor phase currents and voltages

(ii)

pump output

(iii)


(iv)


QCS 2014

Section 09: Mechanical And Electrical Equipment Part 04: Centrifugal Pumps (Split Casing) (v)

power consumed

(vi)

power factor

(vii)

vibration

(viii)


Page 12


(g)

the Contractor‟s supervisory staff, and the pump manufacturer‟s staff if required by the Project Specification, shall be present during the period of the tests and trials. The Contractor shall be responsible for any failure of the whole equipment or any part thereof, whether such failure shall be determined by the methods detailed herein or otherwise. If the pump test or trial is interrupted by the Contractor, or through negligence on the part of the Contractor‟s staff, it shall be completely repeated for the pumpset concerned.

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(f)

The operation, over the entire specified range, shall be free of cavitation, excessive vibration or noise.

5

Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within acceptable limits as 4.2.2.8 Excessive vibration shall constitute sufficient cause for rejection of the equipment.

6

Each pump performance shall be documented by obtaining concurrent reading showing motor voltage and amperage, pump suction head and pump discharge head as follows:

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4

readings shall be documented for a least four pumping conditions to ascertain the actual pumping curve

(b)

one test shall be at shutoff head

(c)

each power lead to the motor shall be checked for proper current balance.

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(a)

Bearing temperatures shall be determined by a contact type thermometer. A running time of at least two hours shall be maintained at the maximum specified operating head.

8

In the event any of the pumping equipment fails to meet the above test requirements, it shall be modified and retested in accordance with the requirements of this Section until it meets the specified requirements, and approval of the Engineer.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 05: Archimedian Screw Pumps

Page 1

5

ARCHIMEDIAN SCREW PUMPS.................................................................. 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3


5.2

PRODUCTS ................................................................................................... 3

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

General Design Conditions Materials Fabrication Factory Inspection and Testing Spare Parts and Tools

5.3


5.3.1 5.3.2

Installation Site Inspection and Testing

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2 2 2 3 3 4 4 8 9 9 9

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Page 2

ARCHIMEDIAN SCREW PUMPS

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for the design, manufacture, construction, installation testing and commissioning of open type Archimedes screw pumps.

2

Related Sections and Parts are as follows: General Drainage Works Instrumentation, Control and Automation Building Electrical Works Electrical works

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Section 1, Section 8 Section 10, Section 13, Section 21

.

5

References

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BS 970 (ISO 683) ......Wrought steels for mechanical and allied engineering purposes

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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper coatings

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BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester and epoxy resin systems. BS 3532......................Method of specifying unsaturated polyester resin systems

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BS 3749......................E glass fibre woven roving fabrics the reinforcement of polyester and epoxy resin systems

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BS 4395......................High strength friction grip bolts and associated nuts and washers for structural engineering

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BS 4604 (ISO 225, 272, 885, 887, 888, 4759) The use of high strength friction grip bolts in structural steel. BS 4870......................Approval testing of welding procedures

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BS 4871......................Approval testing of welders working to approved test procedures BS 5512......................(ISO 281) Methods of calculating dynamic load ratings and rating life of rolling bearings BS 5950......................Structural use of steel work in building BS 6105 (ISO 3506) ..Corrosion resistant stainless steel fasteners BS EN 287 .................Approval testing of welders for fusion welding BS EN 288 .................Approval of welding procedures for metallic materials AGMA ......................... 5.1.3

American Gear Manufacturers’ Association Standards

Submittals In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and information as described in the following paragraphs.

1

Design data providing the following information:

QCS 2014

2


Page 3

(a)

the calculations justifying the sizing of the screw, speed, flow rate, efficiency, rating of motor, gearbox and bearings

(b)

User certificates shall be supplied.

Shop Drawings The Contractor shall provide calculations for the following: the maximum deflection of the screw

(b)

the maximum static and dynamic stresses on the torque tube, torque tube -to -flight welded joints and radial welded joints on the tube segment

(c)

the calculations shall demonstrate that, including for cyclic stress, the screw has a life in excess of 10 years

(d)

Mill certificates for the steel used, welding consumables and procedures.

.

(a)

Operation and maintenance manuals and instructions. These shall include the documentation required above and the results of any factory tests, site inspections and testing.

5.2

PRODUCTS

5.2.1

General

1

All equipment shall be provided including screw, bearings, gearbox, motor drive, lubrication system, couplings, guards and appurtenances to provide a fully operational system to perform the duties specified herein and in the Project Specification.

2

The Contractor shall be fully responsible for the integrated operation and warranty of all components supplied.

3

The screw pumps welding and NDT to meet the AWS D1.1 requirements.

5.2.2

Design Conditions

1

The pumps shall be designed to handle raw sewage with stringy wastes, rags, paper and plastics.

2

The Contractor shall obtain a chemical analysis of the particular sewage to be pumped, and select the pump materials and coatings accordingly.

3

The equipment shall be capable of continuous duty unattended, be fully automatic in operation, and require the minimum of maintenance.

4

The design criteria for the system are given in the Project Specification. The peripheral speed of the screw blades shall not exceed 3 m/s and the shaft speed shall not exceed 60 rpm.

5

The screw pumps shall be designed taking into account the emergency top water level in the sump. The pumps may operate at this level. The tendency for the rotating assembly of the pump to float shall be taken into consideration when selecting bearings and other components, and also in the design of the screw assembly and fixings.

6

The screw pump and bearings shall be sized for the worst case i.e. the weight of the screw and water, neglecting any buoyancy effect.

7

The design of the screw pump must take into account the following:

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QCS 2014


(a)

start-up inertia forces

(b)

cyclic forces during operation

(c)

deflection induced stresses

(d)

unbalanced stress effects.

Page 4

Materials

1

Screws shall be manufactured from mild steel, to BS 970 Part 1.

2

Screw covers shall be as sub-clause 9

3

Top and bottom bearing shall use life lubricated ball bearings

4

Fasteners. These shall be stainless steel, BS 970 type 316S31, except for those securing the bearing stub shafts to the screws. These shall be to BS 4395 and BS 4604

5

Coating system. This shall consist as follows for the screw. Alternative coating systems shall be to the approval of the Engineer.

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5.2.3

two component polyamide cured zinc epoxy primer, dry film thickness (DFT) 40 microns

(b)

two component micaceous iron oxide pigmented polyamide cured epoxy sealer, DFT 50 microns

(c)

two coats of two component high solids polyamine cured epoxy coating, each coat DFT 200 microns

(d)

the steel shall be blast cleaned to ISO microns

(e)

the remainder of the components shall be painted as Section 8.

SA 2½ with a blasting profile of 40 -70

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(a)

Fabrication

1

Components shall be fabricated as described in the following paragraphs.

2

Screw pumps

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screw pumps shall be of fabricated welded construction and consist of a mild steel screw operating in an inclined steel trough liner which shall be grouted into a concrete channel.

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5.2.4

(b)

screws shall be electric motor driven through a heavy duty speed reducing gearbox

(c)

screws shall consist of a robust mild carbon steel tube onto which are welded two or more cold formed helical mild steel blades to make a continuous spiral, with stub shaft housings at the ends

(d)

screw pumps deflection shall be limited to the screw length between bearing supports divided by 360 in accordance with the value given in BS 5950 Part 1 tables, or the screw manufacturer’s recommendations

(e)

tubes shall have a minimum wall thickness of 9 mm or greater, if required, to limit the deflection in accordance with the above

(f)

welds shall be continuous fillets on each side of each blade, except when crossing a tube weld, which shall be continuous seam welds parallel to the tube axis

(g)

circumferential welds for joining tubes shall not occur at a greater distance than 20% from the extremities of the finished tube. If possible they shall be at the lower end of the tube

(h)

blades shall have a minimum thickness of 12 mm

QCS 2014


Page 5

the tips of the blades shall be reinforced by means of a stainless steel strip 60mm wide and of the same thickness as the screw. This shall be welded onto the side of the blade, with full penetration weld

(j)

the stub shaft housing at each end of the centre tube shall effect a gradual reduction in diameter and shall be weldable steel castings, to BS 6460 1979 equal. The stub shafts shall be steel forging to BS 970 Part 1; 1972 or equal and the fastenings to the housings shall not under any circumstances be subject to cyclical stressing. The stub shaft shall be readily removable from the housing prior to transport and readily replaceable at site. The stub shaft housing at each end should be sealed and equipped with an accurately machined face to which the stub shaft forgings are bolted

(k)

the whole assembly, with the stub shafts bolted on, shall be placed in a lathe and machined true after all the welding has been completed, except for the helix edge reinforcement strips

(l)

pumps shall be equipped with a side rail or splash plate which shall extend the full 0 length of the trough and around 230 of the circumference. The splash plate shall be fabricated from G.R.P

(m)

sufficient tolerances should be provided throughout screws, associated bearings and transmissions to permit thermal movement of units due to ambient and operating temperatures.

(n)

all welding shall be by welders coded to BS 4871 and BS EN 287

(o)

all welding procedures shall confirm to BS 4870 and BS EN 288.

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screws shall be supported at the top by a self aligning double spherical ball or roller bearing designed to accommodate the required axial and radial loads

(b)

thrust shall be transferred from the shaft to the bearing by means of a thrust ring. Circlips or locknuts are not acceptable

(c)

facilities should be provided for adjustment of bearings to permit realignment of the screw if necessary

(d)

bearing supports shall be of fabricated steel or cast iron and shall be of adequate area to transmit all live and dead loads to the concrete structures supporting them

(e)

a minimum of four holding down bolts shall be provided for each support

(f)

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Bearings

screws shall be supported at the bottom by ball bearings. The bottom bearing housing and mounting shall be designed to withstand radial and axial forces including any upward forces due to buoyancy during emergency sump level conditions. A sensing probe for any water entrainment on the bottom bearing housing shall be provided.

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(i)

(g)

the two halves of the bearing shell shall be identical, so that they can be interchanged to equalise wear

(h)

seals shall consist of multiple split packing glands and labyrinth arrangement to protect the seals from any debris in the pumped medium. It shall be possible to renew the seals without removing the stubshaft, or supporting the screw.

(i)

alternatively the bottom bearing may comprise of an eco-friendly lubricated for life bearing, fully self aligning in all three axis. No grease lines shall be provided. Te lower bearing housing shall be suitable for continuous or intermittent operation when submerged or running in air. The lower bearing housing shall be specifically designed to exclude the pumped liquid and shall contain not less than two lip seals running in a hardened section of the shaft. Confirmation that the lip seals are compatible with the lubricant (pumped liquid) shall be provided.

(j)

an external stationary split cast iron shroud shall be provided to prevent detritus damaging the bearing and seal

QCS 2014

Page 6

(k)

an external stationary split cast iron shroud shall be provided to prevent detritus damaging the bearing and seal

(l)

bearings shall be rated for an L10 life of at least 100,000h in accordance with BS 5512.

Gearbox (a)

the screws shall be coupled to heavy duty totally enclosed, robust and oiltight speed reducing gearbox rated for continuous duty, having the output shaft at right angles to the input shaft

(b)

gearboxes shall be designed to operate continuously at the required angle of inclination, and shall have adequate oil capacity to avoid frequent attention and shall be equipped with a level indicator with maximum and minimum levels clearly marked

(c)

backstops shall be fitted to prevent reverse rotation of the screw when the motor is de-energised. This may be contained within main gearboxes, or be fitted externally in the form of a suitable brake

(d)

gearmotors in lieu of separate motor and gearbox are not acceptable

(e)

gearboxes shall be rated as AGMA standards, quality class 12 or higher, to handle the shock loadings appropriate to the prime mover, and shall be suitably derated to allow for frequency of operation, ambient temperature and running time

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the minimum calculated life 100 000 h as AGMA standards

under

normal

operation

shall

exceed

(ii)

adequate cooling facility for the gear box shall be provided. Cooling system equipments from the gear box manufacturer shall be procured.

(iii)

cooling fins on the gearbox and/or fans shall not be permitted.

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(i)

transmissions shall be capable of the withstanding maximum torque generated by the prime movers and shall be rated either 1.5 times the power needed to drive the gearbox at its specified capacity or 1.1 times the motor Kw rating, which ever is greater

(g)

gearboxes shall be directly driven through flexible couplings or `V' belt transmissions, as specified

(h)

pump drives fitted with belt transmissions shall have a means for increasing the screw speed to achieve a future increase in capacity of not less than 10 %

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belts shall be rated at 1.5 times the Kw rating of the motor, and shall be oil, heat and static resistant.

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(f)

(j) 5

access for inspection purposes shall be allowed for in the design of the gearbox castings.

Drive motors (a)

the drive motor shall be a totally-enclosed fan-cooled unit as Section 1

(b)

the motor and transmission shall be continuously rated and of adequate capacity to meet the power requirement of the pump

(c)

the motors shall be foot mounted near the gear box and supplied with slide rails where necessary for the adjustment of belt tension

(d)

motors shall be designed to operate continuously at the required angle of inclination

(e)

motors shall have power rating 1.15 times greater than the power required to drive the pump at its specified capacity, or be rated to drive the pump in emergency conditions, which ever is greater.

QCS 2014

6


Page 7

Bed Plate The drive motor and gearbox shall be mounted on a substantial fabricated steel mounting bed plate. The base of the fabrication shall be suitable for mounting on a horizontal concrete mounting plinth. The fabrication shall be stress relieved when all welding is complete and prior to machining. The bed plate shall be provided with Tee slots for bolts to facilitate removal of the motor without lifting clear of studs or other protrusions.

7

Couplings Two types of coupling shall be fitted on the screw pumps, as follows:

not less than six driving pins and bushes. The bushes shall have an inner sleeve to allow rotation in the pin. The pins shall all be shouldered

(ii)

bosses shall be a tight fit in the shafts and shall be secured with hand fitted keys

(iii)

couplings shall be machined balanced matching sets.

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(i)

the coupling between the motor and gearbox shall be of the fluid coupling type to instantaneously protect the motor and gearbox should the screw become suddenly arrested in rotation. The coupling shall be fully rated to transmit the motor full load power without exceeding normal working temperature. The fluid coupling shall be rated to take account of the specified climate conditions and shall be tested and adjusted for static and dynamic balance. It shall incorporate the following features:

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(b)

coupling between gearbox and screw pump. This shall be a flexible multipin and bush, rated as the gearbox. It shall include the following features:

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(a)

the weight of the coupling shall only be taken on the motor shaft providing the motor shaft and bearing are adequate for the load without significant lift reduction. Alternatively, a separate support bracket shall be provided.

(ii)

a flexible element between the coupling output shaft and the gearbox input shaft shall be provided. Bosses shall be a tight fit on shafts and secured with hand – fitted keys.

(iii)

the casing shall be fitted with filler plugs and fusible plug for high fluid temperature protection in event of the screw pump becoming suddenly arrested in rotation.

(iv)

internal bearings shall be adequately lubricated and all seals shall be efficient.

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(i)

the fluid used shall be inhibited against foaming oxidation and rusting and suitable for operating in the ambient temperature range as specified.

(vi)

the filling of the coupling shall be carefully regulated to suit the torque characteristics of the Screw and Gearbox Unit during both the starting and running conditions.

(vii)

the slip of the fluid coupling shall be taken into consideration when sizing the Screw Pump.

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8

Screw Channel Covers (a)

Insulated covers in glass reinforced plastic material shall be provided over all screw pumps. The manufacturer shall be a specialist firm approved by the Engineer.

(b)

Covers shall be manufactured using unsaturated polyester resin with a corrosion resistant layer on the underside of an approved resin of the vinyl ester type.

(c)

The top (or main) laminate shall be reinforced in the proportions 35% “E” glass as chopped strand mat to 65% resin.

(d)

The first intermediate (or internal) insulating layer shall be of polyurethane foam or polystyrene 50mm thick.

QCS 2014


Page 8

The second intermediate (or internal) layer shall be reinforced in the proportion of 10% “E” glass as chopped strand mat to 70% resin (with 20% filler). This layer shall have a minimum thickness of 0.1mm and a maximum thickness of 1.25mm.

(f)

The lower, corrosion resistant, layer shall be reinforced in the proportion 10% “C” glass veil or polyester tissue of 90% resin, this layer shall have a minimum thickness of 0.75mm and a maximum thickness of 1.00mm.

(g)

The total thickness of the internal and the corrosion resistant layers shall be 2.0mm.

(h)

The lower face of the corrosion resistant layer shall have a smooth surface finish as produced by contact with a mould.

(i)

The upper surface of the top layer shall be provided with a non-slip finish as produced by dusting the surface of the laminate with silica sand as soon as the resin has set to a soft gel and removing surplus sand after 24 hours.

(j)

To prevent weathering the covers shall be treated by painting or the addition of approved additives to the resin, to provide ultraviolet protection and to give a final colour to be approved by the Engineer.

(k)

Covers shall consists of individual units not exceeding 30kg in weight. All joints and fixings shall be made using stainless steel fittings and corrosion resistant gaskets all to the approval of the Engineer. Fixings shall be such that individual units can be removed and replaced from above.

(l)

Covers shall be capable of withstanding vertical loads of + 750 kg/m2.

(m)

Lifting handles shall be manufactured from stainless steel to BS 970 Part 1, Grade 316 S31 and the fixing shall pass through the cover such that the handle and/or fixings can be readily replaced. Handles shall not be part of, or cast into, the covers.

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Trough Liner

Screw pumps shall be mounted in steel troughs supplied and installed by the Contractor. The Contractor shall provide all necessary brackets and fixings for the adequate installation of the trough within the channel.

(b)

The Contractor shall be responsible for the final alignment of the trough to provide the correct clearances, and for the grouting-in of the trough.

(c)

The Screw Pump trough shall be a leak free mild steel fabrication of not less than 5mm thickness formed to give the correct clearances to the Screw Pump.

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The trough shall extend between the pump inlet well and the discharge channel without distortion. The Contractor shall provide all necessary end and intermediate fixing/support brackets.

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(e)

(e)

The trough shall be so shaped as to avoid ‘wedges’ between screw and side walls and to provide for return of any excess liquid or solids without interference with pump rotation.

(f)

GRP side profiles pieces shall be provided to contain the pumped liquid on the high water level side of the screw axis. The profiles shall be fixed to the steel trough and the channel side wall using approved stainless steel fixing bolts, to maintain a small 0 clearance around approximately 230 of the screw circumference.

5.2.5


1

The Contractor shall secure from the pump manufacturer certification that the following inspections and tests have been conducted before shipment from the factory (a)

inspection of all welds and 100% radiographic testing for full penetrated welding/butt welding and 100% Magnetic Particle Inspection (MPI) or Dye Penetration Inspection (DPI) for filet welding as AWS D1.1 requirements

(b)

static deflection test (unloaded)

QCS 2014


(c)

measurement of coating system thickness

(d)

testing of motor as required by Section 21.

Page 9


1

The Contractor shall provide, from the specialist manufacturers of the screw pump equipment, all the spares and tools required during the commissioning and maintenance periods as specified in Part 1, including those required below.

2

Special tools, if required for normal operation and maintenance, shall be furnished with the equipment.

3

The following spare parts shall be provided for each pump size:

1 set

Belt drives

1 set

Top bearing

1

Coupling rubbers

1 set

Torque release coupling

1

Bearing seals

1 set

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Gearbox bearings and gaskets

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Lubricant pump system

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2 sets

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5.3.1

Installation

1

The Contractor shall arrange to have the manufacturer or supplier of the equipment furnished under this Part provide the services of competent factory-trained personnel to supervise the installation and initial operation. Installation of all assemblies and components shall be in accordance with the details indicated on the approved shop drawings and the printed instructions of the manufacturer.

5.3.2


1

The Contractor shall operate each pumping unit over the entire designated operating range. The operation over the entire range shall be free of vibration and noise.

2

The screw shall be run dry and the following monitored over a 1 day period:

3

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(a)

motor power consumption

(b)

gearbox, top and bottom bearing temperature

(c)

lubricant temperature

(d)

Backstop temperature.

The screw shall be run with water in and the following monitored over a 7 day period (a)

water flow rate or depth of water the screw is immersed

(b)

motor power consumption

(c)

gearbox and top bearing temperature

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(d)

lubricant temperature

(e)

backstop temperature

Page 10

4

At the end of the 7 day period the Contractor shall change the lubricants and filter in the bottom bearing lubricant system and the gearbox. The oils shall be analysed for any contaminants at an accredited laboratory. After a further 3 months the contractor shall return and sample the oil in the both systems. These shall be analysed as above. If excessive levels of contaminants are present in the oil, then the Engineer will instruct the Contractor to take action accordingly.

5

The lubricants shall be changed at the end of the guarantee in all the rotating elements of the screw pumps. These shall be analysed as above for contaminants.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 06: Surge Control System

Page 1

6

SURGE CONTROL SYSTEM ........................................................................ 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6

Scope References System Description Submittals Quality Assurance Warranty

6.2

PRODUCTS ................................................................................................... 4

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Design Conditions and Performance Characteristics Materials Fabrication Factory Inspection and Testing Spare Parts and Tools

6.3


6.3.1 6.3.2

Installation Site Inspection and Testing

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6

SURGE CONTROL SYSTEM

6.1

GENERAL

6.1.1

Scope

1

The Part specifies the requirements for the design, manufacture, construction, installation, testing and commissioning of complete surge protection systems, including flywheels, surge vessels, compressors, air valves and necessary accessory items.

2

Related Sections and Parts are as follows: General Submersible Pumps Centrifugal Pumps


General Drainage Works Instrumentation, Control and Automation Electrical Works

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This Section Part 1, Part 2, Part 3,

References

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BS 449, ......................The use of structural steel in building BS 729 (ISO 1459, 1460, 1461) Hot dip galvanised coatings on iron and steel articles

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BS 1387 (ISO 65) .......Screwed and socketed steel tubes and tubulars and for plain end tubes suitable for welding or screwing to BS 21 pipe threads

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BS 1571 (ISO 1217) ...Testing of positive displacement compressors and exhausters

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BS 2872,.....................Copper and alloy stock and forgings BS 3601 (ISO 2604) ...Specification for carbon steel pipes and tubes with specified room temperature properties for pressure purposes

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BS EN 1092,..............Circular flanges for pipe, valves and fittings BS 5304,.....................Code of practice for the safety of machinery ASME VIII Div. 1, ........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure Vessels 6.1.3

System Description

1

Hydraulic Design. Surge control devices are to be provided where necessary at all pumping stations. The Contractor shall assume no inertia assistance from any air valves fitted. Air valves will not be accepted as a primary means of surge suppression. Flywheels may be used. In the case of multiple pumping mains separate surge suppression systems shall be provided for each main. The design shall include for the worst case i.e. surge conditions existing when the system is pumping at maximum rate and a power failure occurs. Surge analysis shall be based on the friction factor used for new pipelines. Pump manufacturer shall carry out surge analysis for the whole system including the pipe work within the pumping station.

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Page 3

System Design. The following types of system may be used for surge protection: (a)

flywheels. These shall be used where there is sufficient reserve capacity of liquid in the wet well or surge tower {see (b)} at all times to allow the flywheel to continuously recharge the main with liquid

(b)

surge towers. Their use is only applicable when the total head developed by the pump is low

(c)

hydropneumatic atmospheric surge vessels. Their use is only applicable when the static head in the rising main is low. They shall incorporate a dip tube and a float air valve which allows air in and out of the vessel depending on the liquid level in the vessel.

(d)

bladder type pressure vessels. Their use is only applicable when no negative pressures occur in the main in either a surge condition or normal operation

(e)

hydropneumatic surge vessels with compressors. Their use is only applicable where there is a substantial static head in the rising main

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Air Valves. Air valves shall be installed on the rising main as specified or required to optimise the hydraulic efficiency of the main. They shall comply with Section 8 Part 5.

6.1.4

Submittals

1

In addition to the submittal requirements of Part 1 of this Section, the Contractor shall submit data and information as the following paragraphs.

2

Design Data:

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Hydraulic Calculations. The Contractor shall submit a complete computer based hydraulic transient analysis showing the performance of the surge control system under various model scenarios. Normal operating modes and the sudden shut down of the pump following a power failure shall be simulated. The program shall have the facility to model the characteristic of the different manufacturer’s air and reflux valves, and any other proprietary equipment

(b)

structural calculations. Structural calculations for the design of the pressure vessel and its supports shall be provided.

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Shop drawings: Shop drawings shall be provided for the fabrication and erection of the whole system, including air compressors, air valves, surge vessels. Layout drawings, pressure vessel calculations, schematic drawings and electrical drawings shall be provided. Catalogue pages, manufacturers’ detail instructions, templates and installation methods shall be provided.

4

Operation and Maintenance Manuals and Instructions. The Contractor shall include all the documentation required by Part 1 of this Section on the surge protection system in the operation and maintenance manuals. A copy of the surge analysis and site tests as described below shall also be included. Documentation for the compressors in accordance with BS 1571 shall be provided

6.1.5

Quality Assurance

1

Both the Company carrying out the surge analysis and the software used for the computer transient analysis shall have a proven record in surge analysis. Software used shall be a recognised water industry standard.

2

The Contractor shall employ Third Party Agency (TPA) to oversee the design, fabrication and testing of pressure vessels as defined in PD5500. The independent testing authority shall report direct to the Engineer.

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Warranty

1

In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall ensure that the Company carrying out the surge analysis provides a warranty of the performance of the entire surge protection system. This shall not in any way relieve the Contractor of his contractual obligations.

6.2

PRODUCTS

6.2.1

Design Conditions and Performance Characteristics

1

Unless specified otherwise in the particular Project Specification, transient surge pressures shall be limited as the following paragraphs.

2

Positive (over) pressure - Positive surge pressures shall not exceed the design pressure of the pipeline, taking into account any de-rating for temperature. The rating of pipeline restraints and thrust blocks shall be considered in limiting the positive pressure.

3

Negative (under) pressure - Negative surge pressures shall not exceed the following:

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6.1.6

GRP, asbestos cement, and cement lined ductile/cast iron and steel-limit 1 metre of vacuum (-1 metre)

(b)

Bitumen lined ductile/cast iron and steel-limit 3 metres of vacuum (-3 metres)

(c)

uPVC, ABS, HDPE, MDPE - limit 3 metres of vacuum (-3 metres).

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(a)

Stress cycling. Certain types of plastic pipeline can fail prematurely due to duty cycling. Where the pump start/stop cycling is likely to be high this should be considered.

5

Pipeline Manufacturer’s Recommendations. In all instances the recommendations of the pipeline manufacturer with respect to positive and negative pressures and stress cycling must be followed. Pipeline seals must be included in these recommendations.

6

Surge Vessels. These must be designed, inspected and tested in accordance with PD 5500 Code 2 with a 2.0 mm corrosion allowance Design pressure ratings shall be 1.25 times the greatest pressure the vessel will be subject to. Vertical vessels shall be used wherever possible for sewage. Any supports or plinths shall designed for the vessel to be completely full of liquid.

7

Surge protection equipment shall be chosen in the following order of preference:

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(a)

flywheel – to be used in all cases where high head is involved to protect against valve slamming,

(b)

surge vessel

(c)

combination of flywheel and surge vessel

6.2.2

Materials

1

Surge Towers. If these are constructed in concrete, then Section 8 shall apply. If in the same material as the pipeline, then the specifications applying to the pipeline shall apply.

2

Surge vessels. These shall be constructed from steel in accordance with PD 5500.

3

Coatings. Surge vessels shall be coated internally with an epoxy paint system of minimum thickness 300 microns. The system shall be proven in use in this application. The external coating system shall be in accordance with paint system in Section 8 Part 8.

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Page 5

6.2.3

Fabrication

1

Flywheels. These shall comply with the requirements of Part 3.

2

Surge Towers (stand pipes). These may be constructed in concrete, G.R.P or steel. The top of the tower shall be vented back to the wet well or through a suitable de-odouriser. An emergency overflow shall be provided, routed to a drain. They shall be capable of withstanding the maximum pressure generated by the pumps or surge transients, assuming the tower is full of liquid. Means shall be provided for draining the tower and cleaning it out.

3

Hydropneumatic Atmospheric Surge Vessels. These shall be constructed in steel as specified above for surge vessels. They shall include the following features: facility for draining the vessel. If possible, this shall be using the pressure pipeline

(b)

manway access if the vessel is large enough to accommodate this, or inspection hatch for cleaning the vessel out

(c)

air/float valve on top of the vessel. This shall be readily accessible for cleaning and maintenance

(d)

vent back to the wet well or a suitable drain for the above valve

(e)

pressure gauge with isolating cock to measure the maximum and minimum pressures

(f)

flanges shall be to BS EN 1092 PN 16.

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food grade iso-butyl rubber bladder. This shall have a guaranteed life of three years in contact with the liquid pumped and at the specified temperatures

(b)

bladder pressurisation valve and gauge. This is for recharging the bladder. Access ladders/platforms shall be provided as necessary.

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Hydropneumatic Surge Vessels with compressors. The vessel shall be constructed in steel as specified above. The vessel shall include the features (a) (b) (e) and (f) described in 3 above and in addition the following: liquid level gauges

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Bladder Type Pressure Vessels. These shall be constructed in steel as specified above for surge vessels. They shall include the features (a) (b) (e) and (f) described in 3 above and in addition the following:

(i)

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(ii)

tubular glass, liquid-level gauges with 20 mm tube outside diameter shall be provided. The minimum viewing length shall be 600 mm per gauge. Sufficient gauges shall be provided to view the entire operating range of water levels in the pressure vessel. Threaded 20 mm connections shall be provided. Isolation valves with ball checks shall be provided to prevent loss of liquid upon gauge breakage. Valves shall be of an offset pattern with integral bonnet. Valve bodies shall be bronze. A drain cock shall be provided on the lower valve. Valves shall have pressure ratings of 1.5 times the maximum surge pressure anticipated, or NP 16, whichever is greater flanges shall be provided, NP 16 for the maximum and minimum level probe locations, respectively.

(b)

safety relief valves. These shall comply with the PD 5500 and shall be capable of passing air and water. Valves shall have a bottom inlet and side outlet. The inlet shall incorporate a calibrated spring set to allow the valve to open at the vessel design pressure.

(c)

air pipework. Air piping shall be galvanised to BS 729 and conform to BS 1387 or BS 3601, of a minimum of 25 mm diameter. A brass ball valve shall be provided as a block valve at the pressure vessel. Brass check valves shall be provided in the air line. All shall be rated for 16 bar.

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Page 6

air compressor assembly (i)

the compressor unit shall be self-contained and consist of a single-acting, two-

(ii)

stage, if necessary, air-cooled, reciprocating-type compressor motor with V-belt drive and regulation, on a fabricated steel skid. Valves shall be of stainless steel and shall be easily removed or inspected without use of special tools.

(iii)

the compressor shall be driven by an electric motor which shall comply with Section 21

(iv)

the air inlet filter silencer shall be of the dry replaceable cartridge type

(v)

the compressor shall shut down at unsafe oil level and shall not restart without adding oil

(vi)

if necessary, the compressor shall be provided with finned tube, air-cooled intercooler to remove the heat of compression. The compressor shall have an automatic centrifugal starting unloader valve which will cause the pressure in the compressor cylinders to be vented to atmosphere upon compressor stopping, thereby allowing the compressor to start against minimum load

(vii)

rotating parts shall be guarded in conformance with BS 5304

(viii)

the oil sump on each compressor shall be fitted with a valve and drain extension pipe of sufficient length to enable the oil to be drained without spilling over the base. Sumps containing 1.0 or less may be fitted with a capped pipe.

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the automatic air volume control system, in conjunction with pressure vesselmounted sensor probes and the air compressor unit, shall control the air/water ratio in the hydropneumatic pressure vessel and maintain the air/water ratio within a range compatible with the surge control system design and established system static and maximum operating pressures

(ii)

contacts shall be provided for remote indication of excessive high or low water level in the vessel. Capacitance type level probes with a probe well plumbed to the side of the hydropneumatic vessel shall be provided as Section 10. A control panel with all necessary controls, relays and time delay circuits to actuate the air add/vent solenoid valves, and signal a high or low tank water level shall be provided.

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(d)


Solenoid Valves

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(i)

solenoid valves of sizes 5 mm through 40 mm for air service shall have forged bronze bodies to BS 2872 with Teflon seats. Internal plunger, core tube, plunger spring, and cage assembly shall be stainless steel BS 970 Part 1 316S12. Solenoid enclosures shall be IP 68. Valve actuators shall be 240Va.c. Seals shall be Teflon. Valves shall have a maximum operating pressure and a maximum differential pressure of 16 bar. Solenoid valves shall be energised to open.

6.2.4


1

The Contractor shall secure from the pump manufacturer certification that the following inspections and tests have been conducted at the factory and submit to the Engineer prior to shipment.

2

Surge Vessels. These shall be inspected and tested in accordance with ASME VIII Div.1 sewer class (Welding, Non Destructive Testing (NDT), Hydro test, etc.)

3

Compressors. These shall be inspected and tested in accordance with BS 1571.

4

Motors and control panels. These shall be inspected and tested as described in Section 21.

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Page 7

Control System. This shall be inspected and tested as described in Section 10.

6.2.5


1

The Contractor shall provide from the specialist manufacturers of the surge equipment all the spares and tools required during the commissioning and maintenance periods as specified in Part 1, including those required below.

2

Special tools, if required for normal operation/or maintenance of any component of the surge control system, shall be supplied with the equipment.

3

Air Valves. A complete seal/gasket set shall be provided for each air valve installed.

4

Control panels and control systems.

5

Compressors.

6.3


6.3.1

Installation

1

All equipment shall be installed and commissioning in accordance with the manufacturer’s recommendations and under the supervision of the surge control system supplier’s factory trained personnel.

6.3.2


1

Surge protection system performance shall be verified by field tests at pumping rates specified for each pressure main and for power failure at the maximum pumping rate. The surge control system supplier shall provide a chart recorder and pressure transducer system to develop a permanent record for each pressure main test.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 07: Lifting Equipment

Page 1

7

LIFTING EQUIPMENT ................................................................................... 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

Scope References System Description Submittals

7.2

PRODUCTS ................................................................................................... 3

7.2.1 7.2.2 7.2.3 7.1.1 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9 7.2.10

General Design Conditions Davits Monorail Travelling Hoists Cranes Manually Operated Chain Blocks Electrically operated Rope Lifting Hoist Mechanical Components Electrical Components Factory Inspection and Testing Spare Parts and Tools

7.3


7.3.1 7.3.2

Installation Site Tests

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LIFTING EQUIPMENT

7.1

GENERAL

7.1.1

Scope

1

This Part specifies the requirements for the design, manufacture, construction, installation, testing and commissioning of hoists, monorails, bridge cranes trolley assemblies, davits and ‘A’ frames.

2

Related Sections and Parts are as follows: General Drainage Works Instrumentation, Control and Automation Electrical Works

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References

1


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ASME B30.9 ------------ Synthetic round sling endless ASME B30.10 ---------- Cranes, hooks

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7.1.2

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BS 466 (ISO 4301, 8306) -- Power driven overhead travelling cranes, semi-Goliath and Goliath chain for general use BS 729 (ISO 1459, 1460, 1461)-- Hot dip galvanised coatings an iron and steel articles BS 449 ------------------- The use of structural steel in building BS 466, Power driven overhead travelling cranes. BS 302 (ISO 2408) ---- Stranded steel wire ropes BS 2853 ----------------- The design and testing of steel overhead runway beams BS 2902 ----------------- Higher tensile chain slings BS 2903 ----------------- Higher tensile steel hooks BS 2903,----------------- Higher tensile steel hooks for chains, slings, blocks and general engineering purposes BS 3032 ----------------- Higher tensile steel shackles BS 3114,----------------- Alloy steel chain, grade 80. Polished short link calibrated load chain for pulley blocks BS 3243 ----------------- Hand-operated chain blocks BS 3243,----------------- Specification for hand operated chain blocks BS 3551,----------------- Alloy steel shackles BS 4942,----------------- Short link chain grade (T) 8 BS 4941 (IEC 292) ---- Specification for motor starters up to and including 1000 V a.c and 1200 V d.c. BS 5304,----------------- Code of practice for safety of machinery BS 5714,----------------- Method of measurement of resistivity of metallic materials BS 5744,----------------- Code of practice for safe use of cranes BS 6231,----------------- PVC-insulated cable for switchgear and control gear wiring BS 6346,----------------- PVC-insulated cables for electricity supply BS 6405,----------------- Non-calibrated short link chain (grade 30) for general engineering purposes BS 2573 (ISO 4301) -- Rules for the design of cranes BS 6994,----------------- Steel shackles BS 7121,----------------- Code of practice for safe use of cranes BS 7613,----------------- Hot rolled quenched and tempered weldable structural steel plates BS 7668,----------------- Weldable structural steels. Hot finished structural hollow sections in weather resistant steels BS 7671,----------------- Requirements for electrical installations BS 4942 (ISO 1834, 1835, 3075-3077) Short link chain for building purposes BS 6994 (ISO 2415) -- Steel shackles for lifting purposes

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BS EN 287 -------------- Approval testing of welders for fusion welding BS EN 288 -------------- Approval of welding procedures for metallic materials BS EN 1492-1 ---------- Flat woven webbing slings BS EN 10113 ----------- Hot-rolled products in weldable fine grain structural steels BS EN 10155 ----------- Structural steels with improved atmospheric corrosion resistance BS EN 10210 ----------- Hot finished structural hollow sections of non-alloy and fine grain structural steels BS EN 13414-2 -------- Specification for information for use and maintenance to be provided by the manufacturer BS EN 13414-1 -------- Slings for general lift services BS EN 60947 ----------- Low voltage switch gear and control gear.

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1

General. Lifting equipment shall be provided as required to remove equipment for replacement and/or maintenance purposes. The design shall ensure safe access is provided for the operation of the lifting equipment. Overhead cranes may also be required to grant access for maintenance of roof mounted equipment such as light fittings, fans, and shall be designed to facilitate this. Davits shall only be used to lift submersible pumpsets and other equipment from wells. Lifting equipment shall be supplied with all the necessary spacers, clamps, harnesses, slings, D links and eye bolts to lift any of the installed plant. Guards shall be provided in accordance with Part 1.

7.1.4

Submittals

1

In addition to the requirements of Part 1 of this Section the Contractor shall provide data and information as described in the following paragraphs.

2

Design data. Complete structural calculations of crane and monorail member and component sizing and design, shall be submitted, as required by BS 2573, BS 2853 and the building requirements.

3

Shop Drawings. These shall be submitted as required by Part 1. Lay-out drawings shall clearly show the lifting height of the equipment and clearances in relation to other equipment and structures where the largest items are lifted.

4

Test certificates shall be submitted as required under factory inspection and testing.

5

Operation and maintenance manuals and instructions. The Contractor shall include all the documentation required by Section 1 on the lifting equipment in the operation and maintenance manuals. A copy of the design data, factory and site tests shall be included in the manuals.

7.2

PRODUCTS

7.2.1

General

1

Hoist monorails, bridge cranes, davits and ‘A’ frames shall include all equipment, appurtenances and auxiliaries to make the lifting equipment fully operational and capable of performing under the specified load conditions.

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Lifting systems, including hoists, as far as feasible, shall use the standard components of one manufacturer to simplify maintenance.

3

Nameplates shall be permanently attached to the monorail hoist and bridge crane hoist assemblies. The lifting capacity shall be stencilled on in tonnes in both Arabic and English on each side and shall be clearly legible from the working level.

4

Warning signs in the Arabic and English languages shall be provided to the approval of the Engineer and affixed to the bottom lift blocks or pendant controllers.

7.2.2

Design Conditions

1

Cranes and lifting equipment shall be suitable for indoor or outdoor installation, as designated.

2

The high ambient temperature in which lifting equipment and particularly cranes may be required to operate shall be taken into consideration, particularly with respect to the electrical load ratings of motors, switchgear, resistors, cables and wiring, as well as mechanical heat sources such as brakes, bearings and gearing. Due allowance shall be made for possibly higher temperatures than the maximum recorded shade temperature near the roofs of buildings, if the lifting equipment is mounted in a building, or for the effect of direct sunlight if mounted externally.

3

Design of travelling monorail hoist and bridge crane hoists and incidental accessories shall be based upon the use of a factor of safety of 5, structural beans shall have a factor of safety of 2 with capacity load on all mechanical parts of the system. The factors of safety shall be based upon the ultimate strength of the material used. The equipment shall be of ratings and sizes designated in the Project Specification.

4

Lifting equipment shall be rated for the load of the heaviest installed item of plant, and designed such that one man can operate it without difficulty.

5

Hooks and load chains shall reach to the floor of the lowest level.

6

Lifting equipment installations shall comply with BS 5744 and BS 7121.

7.2.3

Davits

1

Davits and sockets shall be fabricated from fully welded mild steel, to BS 7668, BS 7613, BS EN 10155, BS EN 10013, galvanised and protected in accordance with BS 729 and Section 8.

2

Davits too heavy to manhandle shall consist of a davit arm, with removable pillar, and rotating removable jib arm.

3

Davits shall have a roller thrust bearing swivel for the upright pillar, with a locking mechanism.

4

Sockets shall be cast-in, unless bolted sockets are specified, or it is not possible to fix cast-in sockets. A rubber socket plug with a stainless steel chain shall be provided to prevent sand ingress when the davit is not in use.

7.2.4

Monorail Travelling Hoists

1

Each hoist shall comprise a manually operated geared travelling pulley block complete with steel runway beams, “A” frame supports where specified and all accessories including slings and spreaders.

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Pulley blocks shall be manually operated up to a height of 6 to 8 m. Above 8 m electric hoists shall be provided.

3

The runway beams shall be designed, tested and certified in accordance with BS 2853.

4

The blocks shall run on the lower flange of the runway beam and shall be of the spur geared close haul type.

5

The blocks shall be complete with a geared travelling trolley and shall be capable of being easily removed from the trolley without the necessity for dismantling. The operating chain for the longitudinal motion of the trolley shall extend to within 600 mm of the floor.

6

Load chain collection boxes shall be provided.

7

Monorail systems shall not be used for loads exceeding 2000 kg.

7.2.5

Cranes

1

Cranes shall comprise end carriages and bridge units to be bolted together on site, during erection.

2

Cranes shall be single girder or double girder as designated.

3

All exposed moving parts of the drive mechanisms shall be fitted with safety guards wherever possible, in accordance with Part 1.

4

The bridge girders, end carriages and crab structures of the crane shall be designed and constructed in accordance with all the relevant requirements of BS 466 and BS 2573. With the crane operating under maximum service load, the stress in any operating component shall not exceed the permissible values stipulated in Part 1 of BS 2573. The crane manufacturer shall supply all the information required in Appendix B of BS 466.

5

The main bridge girders shall be plate or box girder designed as compound beams with the rails for the crab track secured on the top flange.

6

Jacking points and tie downs shall be provided for both bridge and crab.

7.2.6

Manually Operated Chain Blocks

1

The hoisting wheel shall be grooved and pocketed to receive the load chain. The load chain shall be stainless steel chain Grade 80 to BS 3114.

2

Hand chains shall be to Grade 30 BS 6405 or better.

3

Chain guides shall be provided to ensure effective guidance of the load chain into the load chain wheel pockets. A stripper shall be provided to ensure effective disengagement of the load chain from the load chain wheel.

4

The idler wheel scores shall be so shaped as to avoid twisting the chain as it passes round. The pitch diameter of the idler wheels shall not be less than 16 times the size of the chain, unless they are so shaped as to avoid a bending action on the link.

5

The load chain anchorage, associated fittings and framework at the slack end shall be rated at 2.5 times the maximum tension in the load chain when the working load limit is being lifted. Any link used for connecting the load chain to a terminal fitting shall be of the material specified for the chain and heat treated to provide mechanical properties and strength equivalent to those of the load chain.

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The hook shall be made from high grade forged stainless steel complying with BS 2903 ‘C’ type and provided with a safety catch. The hook shall be supported on a ball thrust bearing to allow free swivelling under full loads.

7

The sheaves of the hook block shall be guarded to prevent a hand or fingers being trapped.

8

The crab hoisting gear shall be such that one man is capable of easily raising the maximum load.

9

A galvanised mild steel chain collecting box shall be incorporated.

10

A reliable and effective braking and locking arrangement shall be provided.

11

Lifting blocks supplied for lifting equipment from wet wells shall be of stainless steel and shall include the facility for obtaining a fresh lift on the equipment lifting chains at 1 metre intervals.

7.2.7

Electrically operated Rope Lifting Hoist

1

All hoists above a height of 8 m shall be electrically operated.

2

The hoist rope drum shall be of high quality cast iron with left and right hand spiral grooves to accommodate the hoist rope in one layer. As far as possible, the drive gearing shall be fixed directly to the rope drum to obviate high torsional stress in the drum shaft. The rope shall be securely clamped to the drum.

3

The hoist drum shall incorporate a wire rope rewind system and guides to prevent the hoist rope skipping and damaging the lay.

4

The hoist braking system shall be of the automatic electro-mechanical fail safe type which, when the current is cut off or fails will automatically arrest the motion and hold at rest any load up to and including the rated load. The system shall safely control the lowering of the same load form the highest to the lowest point of lift and shall not allow any slippage of the suspended load to occur when the ‘Raise’ motion is initiated.

5

The hoist rope shall be a flexible wire rope specially designed for usage with cranes and in accordance with BS 302, with a safety factor of not less than six times the maximum tension induced by the safe working load.

6

The crane hook shall be of high grade forged steel trapezoidal section in accordance with BS 2903, ‘C’ type. The hook shall be supported on a ball thrust bearing to allow free swivelling under full loads and shall also be fitted with a safety catch. The safe working load shall be marked in the hook in accordance with BS 2903.

7

The sheaves of the hook block shall be guarded to prevent a hand or fingers from being trapped between the sheaves and the in-running rope.

8

A limit switch shall be fitted to prevent over hoisting. This shall be self-resetting, closing automatically when the hoist motor is put in reverse.

9

Brakes shall be well protected from oil and grease leakage or spillage, and from adverse effects of atmospheric condensation or dust. A simple and easily accessible means of carrying out adjustment for wear of the shoes or linings shall be provided for all brakes.

10

Automatic brakes, operating when the drive motor stops shall be supplied for the long and cross travel motions.

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QCS 2014


7.2.8

Mechanical Components

1

End Carriage

Page 7

both end carriages of electrically operated cranes shall be powered either by a duplicate geared motor drive, or by a single motor unit and a layshaft system. Longitudinal and cross traverse motions shall be provided on the crane such that the operation is speedy without impairing safety in working. The longitudinal and traverse motions shall be operated by means of hand chains extending to within 600 mm of the operating floor. The hoisting and lowering chains shall be of the same length. The hook and load chain shall be such that the hook will reach to the lowest floor level. The operating chain for the longitudinal motion of the crane shall be suitably positioned to enable the operator to move the unit easily, without dragging the operating chains over the control panels or other equipment

(b)

the runner wheels shall be of cast steel, with double flanges, mounted on roller bearings, or fitted with phosphor-bronze bushes running on hardened steel axles.

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Crab Unit(s)

the crab frame shall be in accordance with BS 466 and shall provide a strong rigid framework for the hoist and cross-travel machinery mounted thereon. The placement and layout of mechanical and electrical items shall facilitate easy inspection, service and maintenance of the motors, reduction gearing and braking system

(b)

the runner wheels shall be of cast steel with double flanges and mounted on roller bearings. Gearing shall be of totally enclosed type with machine cut gears. Bearings shall be ball or roller.

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(a)

Endstops. Resilient or spring type buffers shall be provided on all runway/cross beams and crane rails. Where carriages are equipped with electric travel the endstops shall be provided with limit switches at the end of each direction of travel.

4

Crane Rails. These shall comply with BS 449 and BS EN 10155 The line of the rails shall not vary by more than 3mm throughout the whole length of travel. Whenever possible, rails shall be one piece. Where rails are to be jointed this shall be by electrical induction welding.

5

Access Platforms And Ladders

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safe means of access shall be provided for examination and maintenance of the crane or other equipment only accessible from the crane. Guards shall be fitted where possible under the crab and long travel motor and gearbox assembly to prevent persons on the ground being endangered by falling objects during maintenance

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(b)

all ladders, platforms and access ways shall comply with Section 8. Open mesh flooring shall not be used. Access ways shall be not less than 800mm wide. The platforms and access ways shall be securely fenced with double tiered guard rails and steel ‘toe boards’ or ‘kicking plates’.

6

Painting. This shall be in accordance with Section 8.

7

Materials. Steel used for the fabrication of the lifting equipment shall comply with BS 449, BS 7613, BS 7668, BS EN 10113, BS EN 10155 and BS EN 10210 as applicable. Welding procedures shall comply with BS EN 287 and BS EN 288

QCS 2014


7.2.9

Electrical Components

1

Motors

Page 8

motors shall comply with the Part 1 of this Section and Section 21 except they shall be rated for 150 starts per hour (Duty type S7) for not less than one hour with a shaft output power at least 15% greater than the maximum power which will be required for operation and testing of the crane in the ambient temperature specified, at the maximum rated load. Control Gear a triple pole isolating switch with HRC fuses shall be provided at ground level for each lifting assembly. This switch shall be lockable in the ‘OFF’ position only and shall be provided with a Yale type lock and three keys. The switch shall have a label marked ‘CRANE ISOLATING SWITCH’ in English and Arabic.

(b)

starters and controllers for the crane motors shall be designed and constructed in accordance with the requirements of BS 466, BS 4941, BS EN 60947 and section 21. All control circuits shall operate at 110 volts

(c)

mechanically and electrically interlocked reversing contactors shall be provided for each motion including speed control of the hoist. Accelerating contactors shall cut out the rotor circuit resistance of the motor in steps with suitable delays. Contacts shall be adjustable and renewable

(d)

controller and resistors shall be rated such that temperatures do not exceed the limits specified in BS 4941 during operation of the crane under maximum temperature conditions. Starting resistors shall have not less than a ‘ten minute’ rating. Speed control resistors shall be one hour rated

(e)

the control gear and cabling shall be suitable for ‘inching’ i.e. many repeated small movements at both creep and normal speed, in any direction of motion

(f)

the starters and controllers shall be housed in well constructed sheet steel panel cabinets of not less than 2mm thick, sprayed and painted with an anti-condensation paint. The enclosures shall be protected against dust and damp to classifications IP 54. Starting resistors shall be mounted in a ventilated section of each control cubicle. The resistors shall all be fitted with terminal bars. The control cubicles shall be provided with lockable hinged access doors, also interlocked with the main isolating switch.

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(a)

Controls (a)

the long-travel, cross-travel and slow and normal speed hoist motions of each crane shall all be controlled from the lowest level by a pendant push button station. The controls shall operate on a low voltage system supplied by a double wound isolating transformer. Both primary and secondary sides of the transformer shall have HRC fuse protection. One pole of the secondary winding shall be effectively earthed

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(b)

push button controls shall be of the pendant type with ‘hold-on’ type push buttons automatically returning to the ‘off’ state on release of the button. Push buttons shall be provided for ‘SLOW -UP’, SLOW DOWN’ ‘NORMAL UP’, ‘NORMAL DOWN’, ‘LEFT’, ‘RIGHT’, ‘FORWARD’ AND ‘REVERSE’. A larger size red ‘Emergency Stop’ button shall initiate tripping of the control gear main circuit breaker and automatic application of the brakes on all motions. Re-closure of the main circuit breaker shall be initiated by a separate ‘Reset’ button also on the pendant. The pendant shall be oil tight polyethylene, totally enclosed to IP65, shockproof, and shall be suspended from the crab unit. The voltage at the pendant shall not exceed 55 volts to earth

(c)

limit switches shall be provided for all motors at the end of each direction of travel

QCS 2014

(d)

Page 9

infrared or radio remote control shall be provided, where specified, or if necessary for safe operation of the crane. Two battery packs with battery charger, sensors, sensor connecting cables with clips, receiver and decoder shall be provided. Adequate sensors shall be provided at each level (minimum three) to ensure continuous control in all zones of operation. If radio is used then approval shall be obtained by the Contractor for the frequencies used.

Cables wiring and earthing (a)

an insulated conductor system shall be provided for electrically powered cranes supply. The insulated conducted system shall be of the type where each phase is individually insulated and supported on a metal support. The type where all conductors are contained within a single extruded or moulded insulation will not be permitted. A ‘festoon’ insulated cable system shall be provided for the cross-travel supply

(b)

the wiring and earthing of the cranes shall conform to BS 466. Cables and wiring shall be of 600/1,000 volt grade PVC insulated cables in accordance with BS 6231 and BS 6346. Wherever possible, the cables shall be run in screwed heavy gauge galvanised steel conduit. All cable ends shall be clearly labelled with identification of the appropriate terminals

(c)

the selection installation and testing of cables and wiring shall be in accordance with BS 7671 except that maximum current ratings shall be raised by a factor of 1.4 times the rating for continuous duty obtained (after applying all necessary de-rating factors for high ambient temperature, grouping and disposition form of installation, etc). The up-rating factor of 1.4 is based on the one hour motors specified for crane operation

(d)

the crane structure, tracks, motor frames and metal cases of all electrical equipment, including metal conduit and cable guards, shall be earthed in accordance with BS7671.

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1

The Contractor shall secure from the lifting equipment manufacturer certification that the following inspections and tests have been conducted on each lifting equipment at the factory, and submit to the Engineer prior to shipment.

2

Cranes shall be inspected and tested in accordance with the requirements of BS 466 with the difference that the “Tests on Purchaser’s Premises” (Clause 54) shall also be carried out in the manufacturer’s works and witnessed by the Engineer.

3

The works tests shall include overload tests during which a 25% overload shall be lifted by the hoist at the middle of the crane span and sustained under full control whilst it is moved up and down at both normal and creep hoist speeds. Whilst still under overload the crab unit of each crane shall be operated form end to end of its travel.

4

The mechanism and controls for the long travel motions shall be tested under light running conditions without moving the crane.

5

Tests on manually operated cranes and hoists shall comply with the above insofar as they are applicable.

6

Control panels, motor and any factory installed wiring shall be inspected tested in accordance with Part 1 of this Section and Section 21.

7.2.11


1

Two years supply of spare parts and lubricants shall be supplied for each lifting device supplied.

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7.2.10

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Page 10


7.3.1

Installation

1

Lifting equipment shall be installed in accordance with the requirements and instructions of the manufacturer. If specified in the Project Specification, the lifting equipment manufacturer shall provide a representative to supervise the installation and testing.

7.3.2

Site Tests

1

After erection cranes and hoists shall be inspected, tested and certification provided by a qualified independent crane testing specialist in accordance with the requirements of Clause 54 of BS 466 and the tests witnessed by the Engineer. Hand cranes shall be similarly tested.

2

Electrical equipment shall be tested in accordance with the requirements of Section 21

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 08: Electric and Pneumatic Actuators

Page 1

8

ELECTRIC AND PNEUMATIC ACTUATORS ............................................... 2

8.1

GENERAL ...................................................................................................... 2

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5

Scope References System Description Submittals Spare Parts and Tools

8.2

PRODUCTS -ELECTRIC ACTUATORS ........................................................ 3

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5

General Motors Controls Actuator Mounting Factory Inspection and Testing

8.3

PRODUCTS -PNEUMATIC ACTUATORS .................................................... 6

8.3.1 8.3.2 8.3.3 8.3.4

General Cylinder Actuators Diaphragm Actuators Solenoid Valves for Pneumatic Actuators

8.4


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2 2 2 2 3 3 4 4 5 5 6 6 6 7

QCS 2014


Page 2

ELECTRIC AND PNEUMATIC ACTUATORS

8.1

GENERAL

8.1.1

Scope

1

This Part specifies the requirements for the design, manufacturer, construction, installation, testing and commissioning of electric and pneumatic actuators for valves and penstocks.

2


References

1


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This Section Part 1, General Section 8, Drainage Works Part 4, Pipe installation Part 5, Valves Penstocks and Appurtenances Part 8, Protective Coatings and Painting Section 10, Instrumentation, Control and Automation

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BS 5501 (IEC 79) .......Electric apparatus for potentially explosive atmospheres BS 5793 (IEC 534) .....Industrial process control valves BS EN 60534..............Industrial control valves

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PNEUROP .................(European Committee of manufacturers of compressors, vacuum pumps and pneumatic tools) Recommendations System Description

1

Actuators shall be capable of extended and continuous operation under conditions specified in Section 1 and at the specified valve operating pressure. Submersible actuators, if required, shall operate at the specified temperature.

8.1.4

Submittals

1

In addition to the requirements of Part 1 of this Section the Contractor shall provide data and information as described in the following paragraphs.

2

Design Data. This shall include calculations justifying the sizing of valves and actuators for the hydraulic and system requirements.

3

Shop Drawings. including:

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8.1.3

Complete shop drawings for each type of actuator shall be provided,

(a)

specifications for materials of construction of actuators and all appurtenance

(b)

wiring diagrams

(c)

ratings for actuator torque, power input, cylinder or diaphragm pressures, motor ratings and enclosures, operating speeds, and other information requested by the Engineer

QCS 2014

(d) 4


Page 3

actuator dimensions.

Operation and maintenance manuals and instructions. These shall be provided for each type of actuator, including: (a)

list of lubricants

(b)

lubrication instructions

(c)

complete assembly and wiring diagrams

(d)

results of all tests specified above and carried out on site


1

One set of manufacturer’s recommended spare parts for two years shall be provided for each actuator.

2

One set of cover screws, gaskets, ‘O’ rings and ram seals shall be provided for each actuator.

3

Two years’ requirement of consumable supplies shall be provided for operation and maintenance of all actuators.

8.2

PRODUCTS -ELECTRIC ACTUATORS

8.2.1

General

1

Electric type actuators shall include the motor, heaters, operators unit gearing, limit switches, torque switches, declutch lever, auxiliary handwheel, reversing starter, switches, mechanical position indicator, and accessories as required.

2

The valve and gate actuator motor and all electrical enclosures shall be waterproof, IP 67, as a minimum unless explosion proof, to BS 5501, EEXD II BT4, or submersible, IP 68 is specified.

3

When specified, a hammer blow mechanism, that travels sufficiently enough to allow the motor to reach full speed before imparting a hammer blow, to start the valve or gate in motion in either the closing or opening direction, shall be incorporated.

4

The power gearing shall consist of helical gears of heat-treated steel, and worm gearing of hardened alloy steel. All power gearing shall be grease lubricated with high speed parts on anti-friction bearings.

5

It shall be possible to remove the motor operator from the valve and gate without taking the valve or gate out of service.

6

The valve actuating speed shall be at 300 mm per minute unless specified otherwise.

7

Pneumatic type actuators shall include the cylinder or diaphragm actuator, solenoid valves, pneumatic positioners, pressure gauges, manual testing station, and other accessories, as designated to provide a complete, functional actuator.

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8.1.5

QCS 2014


Page 4

Motors

1

Motors shall be totally enclosed non-ventilated construction with Class F insulation with temperature rise limited to Class B, and shall comply with Part 1 of this Section and Section 21.

2

Available operating torque shall be at least two times the valve manufacturer's maximum torque requirements. The motor shall be designed specifically for use on valve operation, having high torque capacity coupled with low inertia.

3

The motor shall be of sufficient size to open or close a valve against the maximum specified differential pressure when the voltage drop at the motor is 10 % of the nominal voltage.

4

Electrical power to the motor shall be 3 phase, 50 Hz, 415V for 0.4 kW or larger and 1 phase, 240V, 50Hz, for smaller than 0.4 kW.

5

The motor shall be pre-lubricated and all bearings shall be of the anti-friction type.

6

Motor rating shall be continuous duty unless otherwise designated.

7

Heaters and thermostats shall be provided for high humidity conditions.

8

Electrical and mechanical disconnection of the motor shall be possible without draining the actuator grease or lubricant

8.2.3

Controls

1

Each actuator shall be equipped with a reversing starter, control relays, 2-position limit switches and torque limiting switches.

2

Additional position, limit switches, hand-off-auto switch, open-auto close hand switch, open, close, stop push-button switches, position indicating potentiometer, position indicating lights, electric braking or a position controller, or both, shall be provided for the specified analogue signal input, unless otherwise specified.

3

Position limit switches shall be double pole, double throw and provided for both open and close positions of travel. They shall be connected directly to the valve through continuous gearing and follow its position at all times. Switches shall be rated 10 amps at 240 V a.c. The actuating point shall be adjustable over at least 50 % of the travel.

4

Torque limiting switches shall be provided and be responsive to the mechanical torque developed in seating, backseating, or by obstruction. The torque switch shall operate a calibrated dial integrally mounted and directly related to the torque output of the operator. Torque control accuracy shall be within ± 5 %. The use of torque wrenches for calibration will not be required.

5

Reversing starters shall include a reversing contactor, mechanical and electrical interlocks, and thermal overload relays as required. The contactor shall break all lines to the motor. All controls shall operate on 110 V.a.c.

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8.2.2

QCS 2014


Page 5

Push-button switches (open-stop-close) shall be located for ease of accessibility. The controls shall be arranged for remote operation by isolated momentary or continuous contact switches rated not less than 2 A at 240 V a.c. Terminals shall be wired such that open and close operation only is possible by appropriate external connections.

7

The hand-off-auto switch shall select between local (HAND) and remote (AUTO) control for open, close, stop operation. In the OFF position both local and remote controls shall have no effect.

8

For all modulating duty operations a 4-20 mA convertor shall be provided, powered internally from a 24 V supply, to transmit the valve position remotely.

9

Position indicator lights shall be at least 2 W, green lens for open, red lens for close; shall be interchangeable and located near the push-button switches. Both shall light when the valve is between open and closed limits.

10

Additional position limit switches shall be fully adjustable, of the same rating, and driven in the same manner as the other limit switches provided.

11

The position controller shall utilise an independent position feedback potentiometer and shall accept a 4-20 mA d.c. signal for modulating the valve position, unless otherwise specified. The final positioning accuracy shall not be less than 1 % of position specified by the signal. A damping circuit shall prevent overshoot in excess of 2 % for a full-scale step input. The controller may be separately housed but must be of the same class as the actuator housing. Power shall be derived from the actuator power supply.

8.2.4

Actuator Mounting

1

Special mounting requirements, such as shaft and neck extensions, shall be provided as shown on the Contract Drawings, and as required for safe operation.

8.2.5


1

The Contractor shall secure from the actuator manufacturer certification that each actuator has been performance tested at the factory and individual test certificates shall be supplied for each actuator. The test equipment shall simulate a typical valve load and the following information shall be recorded, and included with the test certificate.

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2

(a)

current at maximum torque setting

(b)

torque at maximum torque setting

(c)

test voltage and frequency

(d)

flash test voltage

(e)

actuator output speed or operating time

In addition, the test certificate shall display details of specifications such as gear ratios for both manual and automatic drive, closing direction, wiring diagram code number, remote position transmitter resistance and interposing relay voltage, etc.

QCS 2014


Page 6

PRODUCTS -PNEUMATIC ACTUATORS

8.3.1

General

1

The available instrument and operating air pressures and quality are as specified in the particular Project Specification. Pressure reducing valves shall be provided where required for each actuator.

2

Direct mounted pneumatic positioners shall be provided for each valve, mounted on the valve, unless specified otherwise. Positioners shall provide 0.1 to 1 bar (gauge) output. Electronic output of 4 to 20 mA shall be provided

3

Wrench or handwheel operated manual override shall be provided for each actuator, unless otherwise specified. The force to operate these shall not exceed 25 Kgf.

4

Throttling manual override shall be provided for actuators where specified.

5

Where potentiometers are specified for positioning cylinder actuators they shall be 1000 , mounted, enclosed and provided with double pole double throw position indicating switches.

6

Test points shall be provided at each actuator to allow an external supply of compressed air to be connected to checked the operation of the actuator and the position indicator.

7

Where required fail-safe actuators (fail open or fail closed, as required) shall be provided

8

Pressure gauges for pneumatic signal and operating air supply links shall be provided.

9

A filter shall be provided for each pneumatic actuator, unless specified otherwise.

10

Special mounting requirements, such as shaft and neck extensions shall be provided as shown on the Drawings.

8.3.2

Cylinder Actuators

1

Cylinder actuators shall be as follows: type: double acting cylinder, unless otherwise specified or shown. In compliance with BS 5793, BS EN 60534 and PNEUROP recommendations as applicable

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8.3

(b)

actuator cover : cast iron or steel, complete with gaskets and seals, internally coated with epoxy

(c)

piston : cast iron or steel, epoxy coated

(d)

piston rod : chrome plated carbon steel

(e)

solenoid control valves shall be provided with mountings and piping

(f)

actuators shall be suitable for operation at 5-7 bar, unless designated otherwise. Test pressure shall be 10 bar

8.3.3

Diaphragm Actuators

1

Diaphragm type actuators shall not be provided for valves larger than 150 mm nominal diameter unless approved by the Engineer. They shall confirm to the standards in Part 8.3.2 1(a).

QCS 2014

2


Page 7

Diaphragm actuator construction shall be as follows: (a)

diaphragm case and mounting hardware: aluminium is not acceptable

(b)

diaphragm : flexible neoprene or Buna N

(c)

spring : enclosed and corrosion resistant.

cast iron, steel, or stainless steel;

8.3.4

Solenoid Valves for Pneumatic Actuators

1

Solenoid valve actuators shall be as follows, and to the standards in Part 8.3.2. 1(a) above electrical characteristics : 240 or 110 V a.c., 50 Hz, single phase

(b)

enclosure : IP 68, unless otherwise designated

(c)

rated for continuous operation

(d)

fitted with spring return unless otherwise specified

(e)

the inlet shall be normally open or normally closed as required by the control system.

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(a)


1

Electric and pneumatic actuators shall be installed and commissioned in accordance with manufacturer’s instructions.

2

The tests listed under Part 8.2.5 shall be repeated at site. In addition the actuator performance shall be tested as part of the control system.

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END OF PART

QCS 2014

Section 09: Mechanical and Electrical Equipment Part 09: Odour Control Equipment - Carbon Type

Page 1

9

ODOUR CONTROL EQUIPMENT-CARBON TYPE ...................................... 2

9.1

GENERAL ...................................................................................................... 2

9.1.1 9.1.2 9.1.3 9.1.4 9.1.5

Scope References System Description Submittals Warranty

9.2

PRODUCTS ................................................................................................... 4

9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8

General Materials Fabrication Accessories Centrifugal Fan Electrical Control Panel Factory Inspection and Testing Spare Parts and Tools

9.3


9.3.1 9.3.2

General Site Inspection and Testing

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QCS 2014


Page 2

ODOUR CONTROL EQUIPMENT-CARBON TYPE

9.1

GENERAL

9.1.1

Scope

1

This Part includes the requirements for the design, manufacture, construction, installation testing and commissioning of force ventilated and passive odour control equipment.

2



General Drainage Works Electrical Works

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References

1


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9.1.2

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ASTM D2862 ..............Test Method for Particle Size Distribution of Granular Activated Carbon

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ASTM D3467 ..............Test Method for Carbon Tetrachloride Activity of Activated Carbon BS 848,.......................Fans for general purposes

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BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes BS 3532......................Method of specifying unsaturated polyester resin systems

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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester and epoxy resin systems

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BS 5000 (IEC 34, 72)Rotating electrical machines of particular types or for particular applications

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BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester and epoxy resin systems

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BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of electrical apparatus for use in potentially explosive atmosphere BS 7671......................Requirements for electrical installations BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners BS 2782 (ISO 174, 181, 307, 8618) Methods of testing plastics BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans BS EN 779, Particular air filters for general ventilation 9.1.3

System Description

1

Performance Requirements Concentration of hydrogen sulphide specification Other Contaminants: Mercaptans Amines (mono/di/tri) Ammonia

:

500 ppm unless otherwise specified in project

: : :

trace only 10 ppm 50 ppm

QCS 2014


Sulphide Concentration in Solution Removal of hydrogen sulphide gas and ammonia Removal of amines Removal of mercaptans

: :

50 mg/l 99.8 %

: :

95 % No requirement

Page 3

The ventilation for force ventilated systems will operate continuously.

3

Air shall be supplied into the wet well to dilute the air/gas mixture via a fly screened inlet.

2

The deodorisation equipment shall operate continuously.

4

The sizing and design criteria for the system are given in the particular Project Specification.

5

The odour system shall be designed for indoor or door out installation as shown on the Contract drawings and as specified.

9.1.4

Submittals

1

In addition to the requirements of Part 1 of this Section, the Contractor shall provide information and data as described in the following paragraphs.

2

Design data providing the following information:

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calculations to justify the sizing and life of the carbon bed(s) at the concentrations given

(b)

calculations to justify the sizing of the fan(s) if forced ventilated odour control equipment is used

(c)

user certificates

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(a)

(i)

fibreglass resin manufacturer’s technical data on composition and characteristics of resin for fibreglass items including hydrostatic and burn tests

(ii)

manufacturer’s technical data on other equipment used

(iii)

carbon specification including test reports

dimensional layout of stack and all equipment used

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Shop Drawings providing the following information:

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(c) 4

Samples: (a)

5

fan test data as BS 848.

vessel and duct GRP, pre-filter mesh, activated carbon.

Operation and maintenance and instruction manuals including: (a)

odour reduction site test report(s) as specified in Part 9.3.2

(b)

the documentation in 3 and 4 above.

9.1.5

Warranty

1

The Contractor shall obtain from the Odour Control System manufacturer a warranty that his system meets the specified odour level reduction criteria, and life for the carbon bed. This does not in any way alter the Contractor’s guarantee under the Contract.

QCS 2014


Page 4

9.2

PRODUCTS

9.2.1

General

1

All units shall be designed to operate continuously in temperatures up to 55 C with 100 % condensing humidity and to reduce odours to an unobjectionable and unobtrusive level, and shall consist of one of the following types, as specified. passive deodoriser. This system will be used for totally enclosed areas without forced ventilation where positive displacement occurs. The passive deodoriser system shall operate as a free-standing unit suitable for outside use in the conditions prevailing at site and shall contain pre-filter cells, activated carbon filter cells or loose activated carbon and all necessary appurtenances. Access to the filters shall be quick and easy without the requirements of special tools for replacement of carbon, cells and pre-filters. The design of the entire unit shall be such as to ensure a minimum of maintenance time

(b)

forced ventilation deodoriser system. The deodoriser shall contain pre-filter cells, activated carbon filter cells, or loose activated carbon, fan unit, a vent stack and all necessary appurtenances. Access to the filters shall be quick and easy without the requirements of special tools for replacing carbon, cells and pre-filters. The design of the entire unit shall be such as to ensure a minimum of maintenance and operating timing.

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Activated Carbon Support System. This shall be one of two types removable carbon cell type filters. Carbon filters shall be of the rechargeable cell

(b)

type with stainless steel or moulded GRP frames and perforated faces riveted together. The filter cells shall be arranged to give a counter current multiple pass system with the lowest filter taking the heavy load. When the lowest filter is spent it shall be removed and higher filters moved down to replace the one beneath and a new filter fitted in the highest position. Two additional complete sets of carbon filters shall be provided as a minimum

(c)

bulk carbon system. The odour control unit forms a receptable for the granular activated carbon which is placed in, either manually or using a proprietary mechanical vacuum device.

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(a)

Materials

1

Deodoriser Unit and Ducting: These shall be of chemical and ultraviolet light resistant GRP using water resistant ‘E’ glass chopped strand mat or woven glass fabric to BS 3496 and BS 3749. All surfaces and exposed edges shall be gel coat/flow coat covered using resin to BS 3532. Alternatively the deodoriser unit and ducting may be manufactured in uPVC or polypropylene/selmar and wrapped externally with G.R.P, generally as above. All fittings shall be stainless steel and sealing strips shall be neoprene. The units shall have smooth semi-gloss finish in white and shall be fully weatherproof.

2

Moisture Eliminator. These shall be incorporated in each duct. They shall be manufactured from corrosion resistant materials and shall incorporate drain facilities and access panels for cleaning. They shall incorporate a baffle arrangement with air cooling.

3

Prefilters. Prefilters shall be of washable urethane or polypropylene knitted wool to BS EN 779 designed as a particle and moisture barrier. The unit shall have an access plate for easy removal of prefilters. They shall be fabricated such that:

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9.2.2

(a)

maximum efficiency is not less than 95%, based on test dust No. 2

(b)

maximum air velocity is 2.5 m/s at the design airflow

(c)

the clean filter resistance does not exceed 90 Pa

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(d)

filters do not sag, flutter or be obstructed by contact with other filters or duct surfaces

(e)

the size shall be not less than 600 mm x 600 mm x 45 mm thick

(f)

corrosion resistant drain valves are provided

(g)

there are no void areas or short-circuiting

Activated carbon. This shall be as follows: (a)

removable cell type units. Carbon granules shall be coconut based and impregnated with potassium iodide, size 5-10 BS mesh. The cells shall be adequately filled and sealed to prevent short circuiting. Cells shall be rechargeable.

(b)

bulk carbon filters. The activated carbon shall be virgin granular, derived from bituminous coal, vapour-phase type, chemically impregnated with sodium hydroxide, and suitable for control of sewage odours. Sufficient activated carbon shall be provided to fill the adsorber to the full bed depth as designed by the odour control system manufacturer. The carbon shall have the following performance

(c)

specifications:

percentage by weight (ASTM D3467), 60 1000 3.7 mm 8 percent

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as determined by ASTM D2862 on a dry basis. The delivered apparent density shall range from 0.55 to 0.64 g/cu cm calculated on a total product basis dense packing as defined by procedure for apparent density determination where a glass 100 ml graduated cylinder is filled through a funnel with 24 mm inside diameter stem at a uniform rate not exceeding 1 ml/s. Pressure drop is measured across a 900 mm deep carbon bed, at least 125 mm in diameter the determination of H2S breakthrough capacity shall be made by passing a 3 moist (85 % R.H.) air stream containing 1 % H2S at a rate of 1450 m /min through a 20 mm diameter by 230 mm deep bed of uniformly packed activated carbon and monitored to 50 mg/l breakthrough. Results are expressed in g H2S removed per g of carbon the carbon supplied shall be of a type chemically regenerable in-situ by the use of up to 48 % sodium hydroxide for a minimum number of five times, or regenerated by water if appropriate.

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(2) (3)

1450 Pa/bed of 900 mm 25 g H2S removed/100 g of carbon

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notes: (1)

0.55 g/cu cm 95 15 percent

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Carbon Substrate CC1 4 Number Iodine number, minimum Mean particle diameter Percent ash maximum Impregnated Carbon (1) Apparent density minimum Hardness number, minimum (2) Moisture, maximum Maximum head loss (Pa) at 0.254 m/s linear (3) velocity (through a dense packed bed) (4) H2S breakthrough capacity, minimum

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(4)

(5)

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Fittings and fasteners. Fittings shall be stainless steel BS 970 Grade 316S31, fasteners shall be stainless steel BS 970 Grade 316 S31 and BS 6105.

9.2.3

Fabrication

1

Carbon adsorbers shall be fabricated such that the vessel walls are not used to transfer any vertical loads to the foundations or vertically support any portion of the carbon support system. The carbon support system shall be removable for vessels of 1 m diameter or less and shall be constructed of materials resistant to corrosion or deterioration under the service conditions specified.

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Four bed activated carbon units shall be horizontal, cylindrical vessels utilizing vertical media beds and provided complete with supports and anchoring system, all nozzles, and access hatches. Units shall be complete with access platform and ladder, support saddles, flanged inlet and outlet nozzles, grounding rods, carbon bed monitoring system, and manways and sample ports as specified.

3

Vessels shall be constructed in accordance with BS 4994 category III or equivalent.

9.2.4

Accessories

1

Each carbon adsorber vessel shall include the following accessories: manometer: This shall be provided to continuously monitor the pressure drop across each carbon bed

(b)

sample probes: each vessel shall have three 40 mm diameter sample probes per bed which shall extend into the bed a minimum of 300 mm. The sample probes shall be adequate to provide suitable extraction of carbon samples from the carbon bed. The sample probes shall extend outside the vessel wall and shall be isolated with a uPVC ball valve

(c)

grounding rod: a stainless steel rod shall be provided to adequately ground each carbon bed

(d)

H2S monitor: one portable hydrogen sulphide monitor shall be provided for each adsorber vessel to detect hydrogen sulphide concentration via a colour coded detector card. The housing shall be a weatherproof enclosure which also allows easy replacement of detector cards

(e)

PVC-u drainage valves and 20 mm diameter pipework routed back to the wet well to drain off any condensate/regeneration liquid from the prefilters

(f)

PVC-u drain valve and 20 mm diameter pipework routed back to wet well to drain off any condensate/regeneration liquid from the deodoriser unit

(g)

air tight covers with gaskets to facilitate easy removal of carbon cells or loose carbon

(h)

three PVC-u air sample probes which extend outside vessel walls and are fitted with PVC-u isolating valves

(i)

gaskets: 3 mm thick full face constructed of neoprene or equal

(j)

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lifting and holding down lugs

An inlet shall be fitted to the wet well to allow fresh air to be drawn in. This shall be of GRP or PVC-u construction with an insect screen.

9.2.5

Centrifugal Fan

1

The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibreglass reinforced plastic or stainless steel with vibration free mountings. The fan shall be capable of the performance specifications as shown below:

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(a)

unit capacity : as designated

(b)

static pressure : 3000 Pa, or as required

(c)

operating temperature : 0 - 70 C

(d)

Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55;1500 rpm, power as required, rated for zone 2 use with methane gas (BS 5345), to BS 5000.

Exhaust fans shall be suitable for continuous 24-hour operation and shall be nonoverloading. Each fan shall operate such that no point on the fan curve requires more than the rated motor power.

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3

The fan housing, flanges and backward curved impellers shall be constructed of flame retardant GRP laminate or stainless steel, capable of resisting continuous fume temperatures of 70 C. The manufacturer shall state the type of resin used and confirm that it shall perform satisfactorily under the operating conditions. All interior surfaces exposed to the corrosive air stream shall be resin rich.

4

Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of 0.5 m displacement prior to assembly and every fan test run prior to shipment.

5

Fans shall comply with BS 848 and be provided with the following standard features: drive assembly: belts shall be oil, heat and static resistant type, sized for continuous duty. Shafts shall be constructed of heavy duty steel turned, ground and polished, keyed at both ends

(b)

bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings

(c)

shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft leaves the housing along with a viton shaft slinger between the seal and wheel on belt drive units

(d)

bases: heavy gauge hot rolled steel, epoxy coated.

(e)

the fan shall be provided with the following accessories:

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(ii)

drain

(iii)

access door

(iv)

vibration isolation system

(v)

belt and shaft guard as Part 1

(vi)

earthing as QGEWC requirements and BS 7671

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flanged and drilled inlet and outlet to BS 6339

flexible connectors:

flexible connectors shall be installed on the fan inlet and outlet to dampen axial, lateral, and vibrational duct movement

(ii)

the flexible connector shall be resistant to the corrosive gases being processed and shall be able to withstand  3750 Pa. The flexible connector shall be minimum 30 mm long.

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Dampers:

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(a)

(a)

(b)

(a) suitable sized dampers shall be provided as follows: (i)

balancing damper between the fan outlet and the carbon adsorber inlet

(ii)

isolation dampers at each carbon adsorber outlet.

(b) the dampers shall be provided in accordance with the following specifications: (i)

the dampers shall be flanged and drilled to withstand 3000 Pa

(ii)

flange mount channel frame shall be vinylester with reinforced bearing pad

(iii)

the blade thickness shall be as required by the damper manufacturer

(iv)

the bearings shall be moulded plastic material

(v)

fibreglass axles shall extend full length of blade and 150 mm beyond frame

(vi)

the unit shall be equipped with a full circumference blade seal to limit leakage 3 2 to less than 1 m /m min at 3000 Pa

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9.2.6

Electrical Control Panel

1

A prewired, preassembled electrical control panel shall be provided for the odour control system as specified in the Project Specification. The control panel shall contain pushbuttons, indicating lights, fan motor starters, alarms, and other controls for a complete automatic system. The panel shall be wired suitable for connection to 415 V a.c., 3 phase, 50 Hz source. The panel shall comply with Part 1 of this Section and Section 21.

9.2.7


1

The Contractor shall secure from the equipment manufacturers certification that the following factory tests have been carried out, and submit to the Engineer prior to shipment. Fibreglass vessels shall be tested as follows: hydrostatically tested prior vessel for a minimum of 24 h

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(b)

the water must be contained with no visible signs of leaks or excessive wall deflection

(c)

a minimum of two burn tests of cutouts, from areas where access doors or piping cutouts are required, to verify glass resin ratio.

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Activated carbon shall be tested as Part 9.2.2.4

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Fans shall be tested as required by BS 848, Part 1 and 2.

9.2.8


1

The Contractor shall provide from the equipment manufacturer’s all the spare parts and tools required during the commissioning and maintenance periods as specified in Part 1, including those below. In addition, sufficient activated carbon shall be provided for the complete operation of the odour removal system for two years of operation.

2

The following tools and shall be provided in addition to any others required:

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sampling tool

(b)

plastic container for shipping carbon samples.

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The following spare parts shall be furnished as a minimum requirement, in addition to any additional spare parts required for two years of operation.

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Item Quantity Complete Centrifugal Fan (1) Sets of V-belts (2) Sets of bearings (2) Shaft seals (2) (if fitted) Carbon (1) Supplies guaranteed for two years operation Prefilter set (2)

9.3


9.3.1

General

1

If required by the Project Specification, the Contractor shall furnish from the odour control system supplies the services on site of a factory trained service technician or engineer. He shall inspect the equipment installation, advise and assist with commissioning and train the Employer’s operations and maintenance personnel.

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2

The odour control system shall be installed in accordance with manufacturer’s written instructions, by suitably qualified and experienced personnel.

9.3.2


1

Vessel Test. The above water test shall be repeated on site after installation.

2

Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with BS 848 Part 5.

3

Odour Vessels Test: The Contractor shall test as follows: the odour control system to certify that it meets requirements after completion of the installation

(b)

all odour testing conducted by the Contractor in the presence of the Engineer

(c)

the odour control system test shall be conducted after all the air systems are tested and balanced. Separate H2S tests shall be conducted on each odour control system

(d)

the H2S tests shall be repeated at the end of the maintenance period with the equipment in full operation during the time of year determined by the Employer to have greatest odour problems, using the actual gas levels.

(e)

the hydrogen sulphide test shall comprise as follows:

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(a)

hydrogen sulphide (H2S) concentrations shall be measured using a calibrated portable H2S analyser

(ii)

if instructed by the Engineer, bottled H2S gas shall be used to determine if the specified H2S performance requirements are met

(iii)

each test: three sets of samples shall be taken over an 8 h period:

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(i)

final acceptance of the system will only be possible after successful completion of this testing

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 each test shall consist of an inlet and outlet H2S test  the supplier shall be responsible for supplying the H2S for the bottled H2S testing  the three H2S levels to be tested shall be selected by the Engineer. if the odour control system fails to meet the performance criteria, it shall be the Contractor’s responsibility to make all the modifications necessary to improve performance at no cost to the Employer. The Contractor shall pay for all additional testing required to verify that performance criteria are being met

(h)

documentation for all the testing shall be submitted to the Engineer.

END OF PART

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Section 10: Instrumentation Control Part 01: General

Page 1

GENERAL ...................................................................................................... 2

1.1


1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16 1.1.17

Scope References Standards System Responsibility Presubmittal Meeting Submittals Quality Standards Manufacturers Experience Factory Inspection Factory Tests and Test Certificates Shipment, Storage, and Handling Guarantee Job Conditions Approved Manufacturers Approved Installation Subcontractors Spare Parts and Tools Software

1.2

PRODUCTS ................................................................................................... 9

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.12 1.2.13 1.2.14 1.2.15 1.2.16

Materials Structural Steel Fabrications Mountings Instrument Identification Electronic Equipment Equipment Operating Conditions Power Supplies Signal Isolators, Converters and Conditioners Auxiliary Contacts by Others Air Supply Valves Instrument Piping Filter Regulator Manifolds Painting and Protective Coatings Electrical Process Connections

1.3

INSTALLATION ........................................................................................... 12

1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10

Inspection Preparation of Installation Areas Installation and Supervision Instrument Calibration System Validation Commissioning Final Acceptance Commissioning Assistance Instruction and Training of The Owner's Personnel Specialised Training Programme for Owner‟s Personnel

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2 2 3 3 3 6 6 7 7 7 7 8 8 8 8 8 9 9 9 10 10 10 10 11 11 11 11 11 11 11 11 12 12 12 12 13 13 14 14 14 14 14

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GENERAL

1.1


1

This Part covers the general requirements for design, supply, installation and commissioning of all instrumentation, control and automation (ICA) systems complete in every detail as specified in the other Parts of Section 10.

2

The complete ICA system, shall be furnished by a single ICA Subcontractor to ensure system uniformity, subsystem compatibility and co-ordination of all system interfaces. Deviations shall be as specified in the Project Specification or approved by the Engineer.

1.1.2

Scope

1

Provide all tools, equipment, materials, and supplies and perform all labour required to complete the supply and installation, including all instrumentation signal and power conduit and wiring not specifically shown on the electrical drawings, validation, start-up and commissioning of a complete and operable ICA system as indicated in the Project Specification.

2

Provide all the necessary equipment components and interconnections and the services of the manufacturers, engineering representatives for the engineering, implementation, commissioning, operation, and instruction, to ensure that the Owner receives a completely integrated and operational ICA system as herein specified.

3


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General Telemetry/SCADA Primary Elements Panel Mounted and Miscellaneous Field Instruments Panel and Control Room Hardware


Sewerage Mechanical and Electrical Equipment Electrical Works

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References Standards

1

The standards referred to for Manufacturers quality procedures and documentation are:

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ASTM A123, A386......Galvanizing ASTM A36, A500, A501, A570, A618, Structural steel shapes BS 970........................Wrought steel for mechanical and allied engineering purposes BS 5308......................Instrumentation Cable BS EN 10084..............Case hardening steels. Technical delivery conditions BS EN 60654..............Operating conditions for industrial process measurement and control BS ISO 5725 ..............Accuracy of measurement methods and results BS ISO 9000-2 ...........Quality procedures

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System Responsibility

1

Contractor's attention is directed to the fact that the ICA system as specified in these ICA Parts of Section 10 is an integrated system, and therefore shall be provided by a single competent, qualified instrumentation Subcontractor (hereinafter referred to in these ICA Sections as the ICA subcontractor) who shall have total responsibility for the ICA work of this Section. Entire system installation including calibration, validation, commissioning, operational testing, and training shall be performed by qualified personnel, possessing all the necessary equipment and who have had experience performing similar installations. The system shall be integrated using the most modern and proven design and shall, as far as practical, be of one manufacturer. Overall system performance shall be guaranteed by the ICA Subcontractor.

2

The Contractor shall appoint a qualified ICA Subcontractor who shall perform the work under this ICA Section, the Contractor shall be fully responsible at all times for the conduct and performance of the appointed ICA Subcontractor. Although many references made herein are to work requirements and responsibilities of the ICA Subcontractor such references shall only mean that responsibility shall pass through the ICA Subcontractor but in the final analysis shall rest with the Contractor.

3

The ICA Subcontractor shall be responsible for the correct installation of all hardware and systems specified in this ICA Section. Certain primary elements, final control elements, etc., although provided as part of this Section, shall be installed in the process lines under other Sections of these Specifications; however, this installation shall be under the direct supervision of the ICA Subcontractor.

4

The ICA Subcontractor shall be responsible to see that all components of the instrumentation system, including primary measuring, indicating, transmitting, receiving, recording, totalising, controlling, and alarming devices and all appurtenances, are completely compatible and shall function as outlined and he shall furnish and install such additional equipment, accessories, etc. as are necessary to meet

1.1.5

Presubmittal Meeting

1

The Contractor shall arrange a meeting between the ICA Subcontractor and the Engineer within sixty (60) days after award of the Contract for a detailed discussion and verification of the ICA Subcontractor's system engineering methods and equipment and to generally provide a framework for communication and co-ordination. This meeting shall be attended by ICA Subcontractor, Contractor and the Engineer.

1.1.6

Submittals

1

Submittals and approvals schedule shall generally be as specified under Section 9, Part 1, Clause 1.1.4. All items proposed for this section shall be listed. Items shall be identified by tag number, description, function, manufacturer, model number, descriptive literature and statement as to whether items is “as specified or equivalent”. Logic diagrams and flow charts illustrating the process control philosophy, shall be provided.

2

Shop Drawings. Before proceeding with any manufacturing, submit shop drawings for approval in complete bound sets indexed by specification number. Describe the items being submitted. Manufacturer's specification or data sheets shall be clearly marked to delineate the options or styles to be furnished. Submit only complete systems, not pieces of equipment from various systems.

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1.1.4

(a)

show dimensions, physical configurations, loop diagrams and cable termination schedules

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(b)

submit fabrication drawings, nameplate legends, and control panel internal wiring and piping schematic drawings clearly showing all equipment and tag numbers on all panels

(c)

submit panel graphic drawings where applicable. Include material specifications lists where applicable. Include a draft of the theory of operation for all relay or PLC logic circuits and analogue control loops

(d)

Process and Instrumentation Diagrams. Prepare and submit instrumentation loop diagrams for all work included in the ICA Sections in accordance with BS 1646.

Within 90 days from the start of the Contract, submit an "Equipment Specification Data" form for each item of equipment which shall summarise the specification features as called for in these Specifications and include such other necessary data as would provide a complete and adequate specification for reordering an exact duplicate of the original item from the manufacturer at some future date. The assigned tag numbers and manufacturer's part numbers shall be included but will not be considered as a substitute for any of the required statement of specifications. More than one tag numbered item may be included on a sheet.

4

Operation and Maintenance Manuals and Instructions. Furnish instruction manuals and part lists for instrumentation equipment provided under the ICA sections. Obtain distribution method instructions from the Engineer.

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schedule. Deliver two (2) copies of manuals 60 days before commencing the Site Acceptance Tests. After installation is complete, update the manuals to reflect any changes which occurred during installation and deliver the remaining three copies of manuals to the Engineer immediately after the Site Acceptance Test. The manuals shall be in English.

(b)

manuals shall be contract specific, and be fully indexed and sectioned, for allocation and distribution to the specialist staff involved on the particular plant and equipment

(c)

where several sub-contractors and manufacturers have supplied equipment the Contractor shall, if required by the Engineer provide a complete integrated manual which clearly demonstrates the inter-relation of the equipment

(d)

manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring binders. Lever arch binders are not acceptable. The full project title shall appear on the cover and spine

(e)

the manuals shall enable the client to safely operate and maintain all parts of the works

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Original copies of leaflets and instructions provided by the specialist manufacturers shall be provided. Superfluous information shall be clearly deleted and relevant information referred to separately in the text

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(a)

(g)

all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and in accordance with other recognised guidelines on technical manual writing.

(h)

contents. include, in the manuals, not less than the following information, as applicable, for each instrument, equipment, subsystem and/or control loop: (i)

general, introduction and overall description, purpose, functions, simplified theory of operations, etc

(ii)

specifications (including equipment specification data sheet as described above under Shop Drawings)

(iii)

installation procedures, commissioning and operational procedures and precautions

(iv)

shut-down procedures

(v)

suitability based on HAZAN/HAZOP studies

(vi)

maintenance, calibration, and trouble shooting instructions

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(vii)

schematics and wiring diagrams or flow charts

(viii)

detailed circuit operational description including annotated programmable controller ladder diagrams or flow charts

(ix)

parts list and spare parts recommendations as specified in Section 9.

(x)

material, test and calibration certificates

(xi)

copies of final approved equipment specification data forms.

format. Use drawings and pictorials to illustrate the text to the extent necessary to ensure a clear, concise presentation. If manuals have been written to cover a family of similar instruments or equipment, strike out inapplicable information in a neat fashion or emphasise applicable portion by heavily weighted arrows, circles or boxes; whichever provides the clearest and neatest presentation. Where identical instruments are used in more than one control loop or subsystem, include only one instruction manual, however, an index by tag number for all instruments shall identify its location in that manual

(j)

control loop and/or subsystem operational descriptions shall identify the function of each instrument and its relation to the other instruments in the loop

(k)

binding. Bind each manual in a cover which indicates the system name, manufacturer's name, local address and telephone number, and year of purchase. Punch and bind manuals in standard three ring binders and include system name and ICA Subcontractor's name on binding.

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(i)

Further to the above Clause 1.1.5.4, the Contractor shall ensure that the structure of the operation and maintenance manual meets the conditions specified in Section 1 Clause 7.12.2 or otherwise agreed with the Engineer.

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Record Drawings:

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The Contractor shall submit complete schematics, wiring diagrams and installation drawings to include all installed field and panel conduit and piping/tubing runs and routing, tray systems, supports, mounting details, point to point diagrams with a cable, wire, tube and termination numbers. One copy of applicable schematics and diagrams

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shall be placed in each control panel in a protective envelope or binder

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the above are to be supplied to the satisfaction of the Engineer. The Contractor shall provide the Owner prints of each on thick paper and one ISO size A1 negative of each. All drawings shall be prepared on a CAD system and printed on ISO standard sized paper A3 unless specifically requested otherwise. One set of drawings shall also be submitted in Windows based AutoCAD System software version and storage media shall be as approved by the Engineer. Each drawing shall be marked with the Owner‟s, Consultant‟s, Contractor‟s and manufacturer‟s names and references, drawing number, title, scales, date of completion and a full description and date of all amendments, and shall be certified „as-built‟. The project title shall be included in a box at the bottom right hand corner of each drawing.

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(b)

7

ICA Subcontractor's System Validation Report. The ICA Subcontractor, shall submit a report for each control system, panel and associated field instruments certifying that the equipment: (a)

had been properly installed under his supervision

(b)

is in accurate calibration

(c)

was placed in operation in his presence

(d)

has been checked, inspected, calibrated and adjusted as necessary

(e)

has been operated under maximum power variation conditions and operated satisfactorily, and

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(f)


Page 6

fully covered under the terms of the guarantee

This report shall indicate calculated system tolerances, data verifying that the system meets these tolerances, and any provisional settings made to devices. Data sheets shall be similar to those used for Calibration. Factory Acceptance Test (FAT) and Site Acceptance Test (SAT). Submit for approval at least 30 days prior to the test demonstration, a written plan for demonstrating that each system of equipment provided under the ICA Sections meets the specified operational requirements. The plan shall include procedures to be used in final operation testing of entire systems including a description for each system of test methods and materials, testing instruments and recorders, a list of the equipment involved with the functional parameters to be recorded on each item, and shop drawings of required temporary by-passes and like facilities.

9

Final Acceptance Report. Submit three copies of certified test results and records.

1.1.7

Quality Standards

1

Qualification and Manufacturers. The ICA Subcontractor shall be an approved systems integrator, a panel fabricator, and installer of field instruments. The ICA Subcontractor shall have a minimum of 5 years documented experience in providing ICA equipment on a single system responsibility basis, of which at least 3 years shall be for municipal water and wastewater pumping stations and sewage treatment works. The personnel employed for system engineering, supervision, start-up, operational testing and training shall be regular employees of the ICA Subcontractor. The ICA Subcontractor shall be fully responsible for the technical supervision of the installation to ensure that it is proper in all respects.

2

Certification by Single ICA Subcontractor. At the time of quoting to prospective contractors prior to tender opening, each prospective single ICA Subcontractor shall execute and submit a written certification of intent to assume full responsibility for the complete requirements of the ICA Section including deputation of qualified personnel for instructing operating personnel and preparing technical documentation. A certificate of compliance with the ICA specifications shall also be provided.

3

Standard of Quality. Furnish equipment of the types and sizes specified which has been demonstrated to operate successfully. Wherever, in the Project Specification and in these specifications, materials or equipment have been specified by using the name of products or manufacturers, the term "or equal and approved" is always understood to follow immediately. Material and equipment, so specified, has been selected as being most suitable and is regarded as a standard and is not intended to eliminate others of equal quality and performance. Workmanship for the installation of instruments, wiring, piping, painting and labelling shall be equal to the best industrial standards for instrumentation and control work.

4

All equipment shall be suitable for installation and continuous services in the climatic conditions prevailing in Qatar.

5

All electrical equipment and materials, including their installation, shall conform to the standards specified for each equipment, unless specified otherwise in this Section.

6

All equipment of a similar type shall be supplied from a single manufacturer to ensure common spares, operation and maintenance procedures.

1.1.8

Manufacturers Experience

1

The ICA manufacturers shall demonstrate a successful track record of having complete similar ICA installation works. The ICA Subcontractor shall provide a reference list from the instrumentation manufacturers for having installed and commissioned instruments operating under process and ambient conditions similar to the specified works.

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Page 7

Factory Inspection

1

Factory Inspection. The Engineer or his representative may inspect fabricated equipment at the factory. Notify the Engineer at least 30 days prior to shipment, so that factory inspection can be arranged. Factory inspection shall be made only after manufacturer has performed satisfactory checks, adjustments, tests and operations. Tests shall be made using simulated inputs and output loads. Approval of equipment at the factory only allows the manufacturer to ship the equipment to the site, and does not constitute final acceptance by the Engineer.

2

The Engineer reserves the right to inspect the ICA equipment at the factory. The Engineer will indicate on return of the approved submittal, each item requiring factory inspection.

1.1.10

Factory Tests and Test Certificates

1

Factory test carried out for primary elements shall include pressure and calibration tests. Certificates shall be provided for pressure test, calibration test and conformity to specifications. Material certificates shall be furnished if it is so specified.

2

Factory Acceptance Test (FAT) shall be carried out for the control and automation equipment such as control panels. FAT procedure shall be submitted to the Engineer for approval. FAT based on the approved test procedure shall be witnessed by the Engineer or his authorized representative at expense of the Contractor.

3


1.1.11

Shipment, Storage, and Handling

1

Box, crate, or otherwise enclose and protect instruments and equipment during shipment, handling, and storage. Keep all equipment dry and covered from exposure to weather, moisture, corrosive liquids, and gases or any element which could degrade the equipment. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repair any damage or replace defective equipment, as directed and approved by the Engineer.

1.1.12

Guarantee

1

The Contractor shall provide a guarantee during the maintenance period for all the equipment in accordance with the General Conditions of the Contract.

2

Equipment warranty shall cover defects in materials or workmanship for 400 days from date of satisfactory completion of Site performance test and issue of Practical Completion Certificate.

3

Individual warranties by component manufacturer in lieu of single source responsibility shall not be acceptable.

4

Items which fail during the warranty period, excluding expendable items, shall be replaced without cost to the Owner.

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1.1.9

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Page 8

Job Conditions

1

Drawings are diagrammatic and show the intended arrangement for system operation, piping, and appurtenances. Conform to Drawings as closely as possible and exercise care to secure neat arrangement of piping, valves, conduit, and like items, and to overcome structural interferences. Verify dimensions and conditions at the place of work, and install materials and equipment in the available spaces.

1.1.14

Approved Manufacturers

1

The ICA equipment shall be provided by approved, prequalified system manufacturers and suppliers designated in the Project Specification.

1.1.15

Approved Installation Subcontractors

1

Installation Subcontractor shall be approved, prequalified and designated in the Project Specification.

1.1.16


1

Furnish the following items as specified herein. Provide the Engineer, with an itemised list in a letter of transmittal accompanying each shipment.

2

Special Tools and Accessories. Furnish special tools, instruments, and accessories for maintaining instruments and equipment requiring periodic repair and adjustment as specified elsewhere in this Section. Also, furnish special lifting and handling devices for equipment requiring such devices.

3

Maintenance Materials and Spare Parts. Deliver in manufacturer's original containers labelled to completely describe contents and equipment for which it is furnished.

4

Spare parts shall be sufficient for 2 years of normal service from completion of the maintenance period, and shall include, as a minimum, the following basic items:

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1.1.13

five (5) percent but not less than one (1) minimum of each type of plug-in unit, etched or printed circuit board assembly

(b)

ten (10) percent but not less than one (1) of each type relay and timer used

(d)

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(a)

(e)

2 years supply of expendable items, diskettes, toner cartridges etc.

ten (10) percent but not less than one (1) of each type switch used twenty (20) percent but not less than ten (10) of each type light bulb and fuse used

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(c)

1.1.17 1

Software The ICA Subcontractor shall be responsible for obtaining all software user licences for development and runtime systems as necessary. Application software written specifically for the Owner under this contract shall remain the property of the Owner and shall not be disclosed, copied or distributed at any time to a third party without the Owners explicit written consent.

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Page 9

PRODUCTS

1.2.1

Materials

1

The ICA Subcontractor shall provide instruments, equipment and materials suitable for service conditions and meeting the appropriate British Standards. The intent of this Specification is to secure instruments and equipment of a uniform quality and manufacture throughout the plant; i.e., all instruments in the site, i.e., all instruments supplied by the ICA Subcontractor, of the same type shall be by the same manufacturer. This allows the stocking of the minimum number of spare parts.

1.2.2

Structural Steel Fabrications

1

The ICA Subcontractor shall design all fabrications for dynamic and vibratory loading. Use structural steel shapes conforming to ASTM A36, A500, A501, A570, A618, or equal and approved, as applicable. Conform welding to AWS D2.0 Code. Galvanize specific items in accordance with ASTM A123 or A386 as applicable; use galvanized bolts and fasteners with galvanized assemblies. Use minimum 6 mm thickness for steel entirely or partially submerged during equipment operation. Submit design calculations showing adequate structural integrity for the intended purpose.

1.2.3

Mountings

1

The ICA Subcontractor shall mount and install equipment as indicated in the Project Specification. Where not shown, mount site instruments according to best standard practice on pipe mounts, pedestal mounts, or other similar means in accordance with suppliers recommendation. Where mounted in control panels, mount according to requirements of Part 4 of this Section.

2

Equipment specified for Site mounting shall be suitable for direct pipe mounting, pedestal mounting, or surface mounting and non in-line indicators and equipment with calibration adjustments or requiring periodic inspection shall be mounted not lower than 900 mm nor higher than 1500 mm above walkways, platforms, catwalks, etc. so as to provide easy access. All such equipment shall be weather and splash proof, and electrical equipment shall be in IP 66 enclosures. External equipment shall be protected from direct sunlight by a well ventilated cabinet, canopy or other type of sunshade. If mounted in a designated hazardous area, the equipment shall be explosion proof or rated intrinsically safe, whether so specified herein or not.

3

The equipment shall be guaranteed suitable for operation under the climatic conditions specified in under Clause 1.2.6 of this Part and shall be designed:-

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1.2

4

(a)

such that routine and occasional maintenance throughout its life shall be a practical minimum compatible with the preservation of maximum reliability

(b)

to withstand the electrical, mechanical, thermal and atmospheric stresses to which it may be subjected under operational conditions, without deterioration or failure

(c)

constructed to the highest available standards of manufacture, reliability, accuracy and repeatability

(d)

the degree of protection for equipment enclosures shall be in accordance with BS EN 60529

Provide protection from direct sun light for all ICA equipment installed outdoors.

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Page 10

Instrument Identification

1

All instrumentation and equipment items or systems specified in the Project Specification shall be identified by system and tag numbers. This same number shall appear in the tag number designations on the Drawings and on the schedules of the Project Specification. Nameplates for panels and panel mounted equipment shall be as specified in the Project Specification. Field equipment shall be tagged with assigned instrumentation tag number and function. Tags shall be black lamacoid with engraved white characters of 5 mm minimum height. Tags shall be attached to equipment with a commercial tag holder using a stainless steel band with a worm screw clamping device or by a holder fabricated with standard hose clamps and meeting the same description. In some cases where this would 2 be impractical, use 0.5 mm stainless steel wires. For field panels or large equipment cases use stainless steel screws, however, such permanent attachment shall not be on an ordinarily replaceable part. In all cases the tag shall be plainly visible to a standing observer. In addition to tags, field mounted control stations, recorders or indicators shall have a nameplate indicating their function and the variable controlled or displayed. Nameplate shall be attached by one of the above methods.

1.2.5

Electronic Equipment

1

If the equipment is electronic in nature, provide solid state equipment to the extent practicable. Select components of construction for their suitability and reliability. Employ adequate component derating to preclude failures because of transients and momentary overloads reasonably expected in normal operation. Provide units for operation without forced cooling, unless such cooling is an integral part of the device. Provide protection on all relevant circuits and equipment against the effects of lightning and other induced voltages.

1.2.6

Equipment Operating Conditions

1

All equipment shall be rated for normal operating performance with varying operating conditions over the following minimum ranges.

2

Power:

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electrical. 240 V a.c. ± 5 %, 50 Hz ± 1 Hz except where specifically stated otherwise on the drawings or in the specifications

(b)

air. 1.4 bars.

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1.2.4

Field Instruments:

all the ICA equipment supplied shall be suitable for operation in the tropical climate prevalent in Qatar. All ICA equipment shall be designed and constructed to operate satisfactorily and without any deleterious effect for prolonged and continuous periods at the following maximum ambient temperature conditions:

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(a)

(i)

indoors in normally air-conditioned environment -

(ii)

indoors in a ventilated environment

-

55 C

(iii)

outdoors under direct sunlight

-

85 C

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50 C

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1.2.7

Power Supplies

1

The ICA Subcontractor shall provide electrical instruments, transmitter power supplies and control devices for operation on 110 V a.c., 50 Hz. Transmitter power supplies shall be provided for individual transmitters. Where designated in the Project Specification, process critical instruments shall receive power from a UPS, as specified in Section 21.

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Page 11

Signal Isolators, Converters and Conditioners

1

The ICA Subcontractor shall ensure that input-output signals of all instruments and control devices (whether supplied by the ICA Subcontractor or not) are compatible. Unless otherwise specified in the Project Specification, signals between field and panels shall be volt free contacts or 4 to 20 mAdc, unless specifically approved otherwise. Granting such approval does not relieve the ICA Subcontractor from the compatibility requirement above. Provide signal isolators and converters as necessary to obtain the required system performance. Mount the devices behind control panels or in the Site at the point of application.

1.2.9

Auxiliary Contacts by Others

1

The ICA Subcontractor shall provide instruments and equipment to interface with auxiliary contacts provided under other Contracts, for alarms, status of equipment, interlocking, and other functions as indicated and as specified in Project Specification.

1.2.10

Air Supply Valves

1

The ICA Subcontractor shall provide 316S12 valves for instrument air supply shutoff, regulating, switching, metering, valve manifolds, etc. Provide a separate isolation valve for each instrument or actuator feed line.

1.2.11

Instrument Piping

1

The ICA Subcontractor shall provide instrument air header and instrument pneumatic piping, as specified in the Project Specifications and as necessary and/or as specified herein. Connect to main instrument air header at a point not more than 3 m distant from air consuming device(s). Use 10 mm minimum 316S12 tubing. All connections to equipment shall be made with separable or union type fittings and shall include shut-off valves. All hydraulic and/or pneumatic piping shall be tested for leaks prior to placing the system in operation. All instrument pneumatic air fittings, shall be double compression type.

1.2.12

Filter Regulator

1

The ICA Subcontractor shall provide a filter-regulator and discharge pressure gauge with a dripwell assembly for each point of use where regulated instrument air is required. Separate regulators shall be used for each control loop.

1.2.13

Manifolds

1

The ICA Subcontractor shall furnish an integral three-valve manifold for each differential pressure transmitter on a flow application.

1.2.14


1

The ICA Subcontractor shall provide factory paint for all instruments and equipment except where in pipelines. Provide paint as required for structural supports, brackets, etc. Painting and protective coatings shall generally comply with the requirements specified in Part 8 of Section 8.

1.2.15

Electrical

1

The ICA Subcontractor shall provide all the power supply wiring, instrumentation wiring, interconnecting wiring and equipment grounding as indicated, specified and required.

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1.2.8

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Page 12

Wiring installations shall include cables, conductors, terminals connectors, wire markers, conduits, conduit fittings, supports, hardware and all other required materials not specifically included in the work of other Sections.

3

Provide the materials and complete all the required installations for equipment grounding as specified in Section 21 of these Specifications indicated on the Electrical Drawings or necessary to complete the Work.

4

Incidental items, not specifically included in the Contract Documents, that can legitimately and reasonably be inferred to belong to the instrumentation work shall be provided by the ICA Subcontractor.

5

Field Wiring. Ring out signal wiring prior to termination. Provide wire number tags marked in indelible waterproof form of slip-on type or equal for each termination. Provide preinsulated crimp-on connectors for wire terminations and splices. Use ratchet type crimping tool which does not release until proper crimp pressure has been applied.

1.2.16

Process Connections

1

Piping, tubing, and capillary tubing shall be of stainless steel. If this material is unsuitable for ambient or process conditions, piping and tubing shall be of a material approved by the Engineer. Slope lines according to service to promote self draining or venting back to the process. Terminate connection to process lines or vessels in a service rated block valve, that will permit closing off the sense line or removal of the element without requiring shut down of the process. Include drip legs and blow-down valves for terminations of sense lines at the instruments when mounted such that condensation can accumulate. Process vessels, line penetrations, connecting fittings, and block valves shall be furnished and installed under other Sections of these Specifications but coordinated by the ICA Parts. Instrument process taps shall be a minimum 18 mm BSP except flowmeter taps which shall be 12 mm BSP.

1.3

INSTALLATION

1.3.1

Inspection

1

Inspect each instrument and piece of equipment for damage, defects, completeness, and correct operation before installing. Inspect previously installed related work and verify that it is ready for installation of instruments and equipment.

1.3.2

Preparation of Installation Areas

1

Ensure that installation areas are clean and that concrete or masonry operations are completed prior to installing instruments and equipment. Maintain the areas in a clean condition during installation operations.

1.3.3

Installation and Supervision

1

Provide the services of suitably trained and experienced personnel in the installation of the equipment to:

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(a)

complete the installation in accordance with the manufacturers instruction manual

(b)

inspect, check, adjust as necessary, and prepare the equipment for system validation

(c)

calibrate the instruments, in accordance with the specifications herein, until all trouble or defects are corrected and the installation and operation are acceptable.

QCS 2014


Page 13

Instrument Calibration

1

The Contractor shall provide the services of trained and experienced instrumentation technicians, tools and equipment to site calibrate each instrument to its specified accuracy in accordance with the manufacturer's specifications and instructions for calibration.

2

Each instrument shall be calibrated at 10 percent, 50 percent and 90 percent of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated.

3

Test instruments shall hold a valid calibration certificate from a NAMAS accredited calibration centre or alternative, subject to the approval of the Engineer

4

Provide a list and basic specifications for instruments used. Certify to the Engineer that each instrument has been calibrated to its published specified accuracy. The calibration certificate shall include all applicable data as listed below plus any defects noted, correction action required, and correction made. Data shall be recorded on separate proformas attached to the certificate and shall include not less than the following items:

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1.3.4

facility identification (name, location, etc.)

(b)

loop identification (name or function)

(c)

equipment tag and serial numbers

(d)

scale ranges and units

(e)

test mode or type of test

(f)

input values or settings

(g)

expected outputs and tolerances

(h)

actual readings

(i)

explanations or special notes as applicable

(j)

tester's certification with name and signature.

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(a)

System Validation

1

Provide the services of trained and field experienced instrumentation engineer(s) to validate each system to verify that each system is operational and performing its intended function within system tolerance. System tolerance is defined as the root-mean-square sum of the system component published specified accuracies from input to output.

2

Validate each system by simulating inputs at the first element in loop (i.e. sensor) of 10 percent, 50 percent and 90 percent of span, or on/off and verifying loop output devices (i.e. recorder, indicator, alarm, etc. except controllers). During system validation, make provisional settings on levels, alarms, etc. Verify controllers by observing that the final control element moves in the proper direction to correct the process variable as compared to the set point. Verify that all logic sequences operate in accordance with the specifications.

3

Cause malfunctions to sound alarms or switch to standby to check system operation. Check all systems thoroughly for correct operation. Test equipment shall comply with Clause 1.3.4.

4

Immediately correct all defects and malfunctions‟ disclosed by tests. Use new parts and materials as required and retest.

5

System validation report. instrument system.

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1.3.5

Provide a report certifying completion of validation of each

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Page 14

Commissioning

1

Upon completion of instrument calibration and system validation, test all systems under process conditions. The intent of this test is to demonstrate and verify the operational interrelationship of the instrumentation systems. This testing shall include, but not be limited to, all specified operational modes, taking process variables to their limits (simulated or process) to verify all alarms, failure interlocks, and operational interlocks between systems and/or mechanical equipment.

1.3.7

Final Acceptance

1

Final acceptance report. Immediately correct defects and malfunctions with approved methods and materials in each case and repeat the testing. Upon completion of final operational testing, submit certified report, with substantiating data sheets, indicating that total ICA System meets all the functional requirements specified herein. The Engineer will countersign this report and it shall constitute final acceptance of the ICA System.

2

Final Operational Testing shall be witnessed and approved by the Engineer. Notify the Engineer in writing a minimum of 48 h prior to the proposed date for commencing the test. Upon completion of this test the Contractor shall begin or have begun system start-up. The Owner reserves the right to set the schedule.

1.3.8

Commissioning Assistance

1

When specified elsewhere in this section or designed in the Project Specification, provide the services of a factory trained and field experienced instrumentation engineer to assist the Owner‟s personnel during commissioning of the system. Purpose of this assistance is to support in making final adjustments of settings on the instrument systems.

1.3.9

Instruction and Training of The Owner's Personnel

1

After the ICA equipment has been calibrated, installed, tested and placed in satisfactory operation the Contractor shall provide the services of qualified staff approved by the Engineer, or if specified in the Project Specification, of the manufacturer‟s representatives, to instruct and train the Owner‟s personnel in the use and maintenance of the ICA equipment. An instruction and training programme shall be conducted for up to six personnel designated by the Owner. The Contractor shall give the Owner at least one month‟s written notice of the proposed instruction and training programme. Instruction and training covering basic system operation theory, routine maintenance and repair, and “hands on” operation of the ICA equipment shall be included. Each trainee shall be provided with a training manual covering operation and maintenance of the ICA equipment. The duration of the programme shall be based on the complexity of equipment involved, and the Engineer‟s approval of instruction adequacy obtained before terminating the programme. Instruction and training periods shall be acceptable to the Engineer.

1.3.10

Specialised Training Programme for Owner’s Personnel

1

Where designated in the Project Specification the Contractor shall provide a specialised training programme and manual for the Owner‟s key personnel in the equipment, electrical systems and instrumentation systems, to be conducted by the supplier/manufacturer and held at locations outside Qatar. The training programme and manual shall be submitted to the Owner for approval and shall be designed to:

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1.3.6

(a)

provide in depth information and familiarisation of the equipment installed in the Project

(b)

receive specialised training in the design, proper operation, maintenance and replacement of the equipment and components

QCS 2014

Page 15

The Contractor shall provide whatever assistance is requested by the Owner to develop meaningful itineraries for the training programme. The Contractor shall provide hotel accommodation, travelling expenses by air, land transport and per diem allowance as per the Ministry of Education guidelines.

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END OF PART

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QCS 2014

Section 10: Instrumentation Control and Automation Part 02: Telemetry/SCADA

Page 1

2

TELEMETRY/SCADA .................................................................................... 3

2.1

GENERAL ...................................................................................................... 3

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

Scope References Submittals Quality Assurance Delivery, Storage and Handling Site Conditions Commissioning

2.2

DESIGN ......................................................................................................... 6

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

Pre-Design Documentation Hardware Design Software Design System Security Operator Interface

2.3

MASTER STATION HARDWARE ................................................................. 8

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10

Computer Redundancy Visual Display Unit (VDU) Keyboard Logging / Alarm / Report Printers - Continuous Feed Colour Printers Monochrome Printers (Laser) Audible Alarm Data Storage Uninterruptible Power Supply (UPS) System

2.4

MASTER STATION SOFTWARE FUNCTIONS .......................................... 11

2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15 2.4.16 2.4.17 2.4.18

General Display Facilities Monitoring and Alarms Equipment Control Data Archiving VDU Mimic Displays Tabular Representation of Data Trend Displays Manual Data Entry Manually Corrected Data Reports Point Record Profiling Data Manipulation Database Query Facilities Downloading PLC Configuration Diagnostics Access Levels

6 6 6 7 7 8 9 9 9 9 10 10 10 10 11

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3 3 3 5 5 5 5

11 12 13 14 14 14 15 15 15 15 15 16 16 16 17 17 17 17

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2.4.19 Control Loop and Sequence Programming 2.4.20 Program - Documentation

Page 2

17 17

2.5

REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION .... 18

2.5.1 2.5.2 2.5.3

Future Expansion RTU Hardware RTU Software

2.6

PROGRAMMABLE LOGIC CONTROLLER (PLC) ...................................... 20

2.6.1 2.6.2 2.6.3 2.6.4

PLC Hardware Input Modules Output Modules PLC Software

2.7

DATA COMMUNICATIONS LINKS ............................................................. 23

2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6 2.7.7 2.7.8 2.7.9

Communication Standards Control Room Data Highway Leased lines or PSTN Radio Radio Path Profiles Radio Transmitters/Receivers Base Station Radio Transmitter/Receivers Aerials and Aerial Structures Fibre Optic Network

2.8

INPUTS/OUTPUTS ..................................................................................... 26

2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7

General Analogue Inputs Digital Outputs Analogue Outputs RTD Input Thermocouple Input Pulse Input

2.9

POWER SUPPLY REQUIREMENTS .......................................................... 27

2.10

MIMIC DIAGRAM......................................................................................... 28

18 18 19

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26 27 27 27 27 27 27

28 28 29

FACTORY INSPECTION AND TESTING .................................................... 29

2.11.1 General 2.11.2 Test Plan 2.12

23 23 24 24 24 24 24 24 25

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2.10.1 General 2.10.2 Mosaic Tile 2.10.3 Projection 2.11

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20 21 22 22

29 30

INSTALLATION ........................................................................................... 31

2.12.1 Tools 2.12.2 Training for Owner‟s Personnel 2.12.3 Site Inspection and Testing

31 31 32

QCS 2014


Page 3

TELEMETRY/SCADA

2.1

GENERAL

2.1.1

Scope

1

This Part includes the hardware manufacture, system software, factory testing, installation, site testing and training of Owner‟s personnel in Telemetry/SCADA.

2


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General Panel Mounted and Miscellaneous Field Instruments Panels and Control Room Hardware

2.1.2

References

1


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This Section Part 1, Part 4, Part 5,

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2

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BS 1646......................Symbolic representation for process measurement control functions and instrumentation.

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BS EN 60073..............Basic and safety principles for man-machine interface, marking and identification. Coding principles for indicators and actuators BS EN 60255-22-5 .....Surge protection

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BS EN 61000-6 ..........Electromagnetic Compatibility

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BS EN 61131-3 ..........Programming Languages for Programmable Controllers.

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BS EN ISO 9000-3 .....Recommendation for achievement of quality in software

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BS ISO/IEC 6592 .......Documentation of computer based systems

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BS ISO/IEC 9075 .......Structured Query Language (SQL)

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ISO 3511 ....................Process measurement control functions - instrumentation symbolic representation 2.1.3

Submittals

1

Submittals shall generally be in accordance with Part 1 of this Section.

2

Functional Design Specification (FDS). FDS shall be submitted to the Engineer and approved before manufacture and purchasing commences. The ICA Subcontractor shall include the following information as a minimum : (a) (a)

design concept and criteria details of associated equipment

(b)

functional design description including VDU mimics and report format.

(c)

details of data archiving and trend configuration.

(d)

quality plan

(e)

outline of acceptance test procedures

QCS 2014

(f)


implementation program for manufacture, installation and commissioning with Particular reference to interface with existing equipment

(g) (h)

Page 4

manufacturers literature for each item of equipment supplied name of the specialist Subcontractor

Drawings and Documentation. All drawings of telemetry and ICA equipment shall be on A3 or A4 size sheets with title blocks approved by the Engineer. The signature of the Contractors authorised representative shall appear on each drawing to indicate the drawing has been checked prior to submission.

4

Subcontractor‟s Drawings. The ICA Subcontractor shall submit four (4) reproducible copies plus two photocopies of general and detailed dimensioned arrangement drawings, schematics and wiring diagrams of all major items of equipment for the Engineer‟s approval. Manufacture of an item of equipment shall not commence until the associated drawings have been approved in writing by the Engineer. All modifications or revisions to drawings shall be clearly indicated and the revision reference changed. Drawings affecting work by other disciplines shall be provided to the Engineer within 6 weeks from the date of placing of the order for the works. Drawings for electrical equipment shall include:

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3

Contractor‟s general arrangement drawings for all items showing clearly the position of all cable glands and main components including, where appropriate, foundation plans showing the position of all required holes and cutouts

(b)

manufacturers‟ schematic diagrams and connection diagrams for all items showing all internal wiring and terminal connections suitably referenced. Connection diagrams shall include existing and proposed outgoing cable connections

(c)

general layout of equipment showing cable routing

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(a)

block diagram showing all equipment, cable runs and cable reference numbers

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(d)

cable schedules giving full details of use, destinations, size and number of conductors, grade and class

(f)

layout of grounding facilities

(g)

proposed arrangements for cables laid below and above ground showing identification references, voltage, depth of laying or cable rack size , route and length, crossings with other services, location of any joints and position of ducts with cross Sectional arrangements.

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(e)

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Where modifications to existing systems are involved, the Contractor shall modify existing drawings to show the modifications. If suitable existing drawings are not available the Contractor shall provide drawings showing the modifications. 5

As built Drawings. Comply with Part 1 of this Section.

6

Instruction Manuals. Comply with Part 1 of this Section and provide the following additional information: (a) configuration of data base, reports, logs and screen displays (b) data communication interface standards and protocols.

7

The submittal shall be subject to approval by the Engineer. The Contractor shall submit the final documentation based on the Engineer‟s comments. The Engineer‟s comments/approval shall be issued to the Contractor within 21 calendar days of the submittal.

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Quality Assurance

1

All hardware and software proposed shall have been successfully proven in a similar wastewater application for a period of at least three years, and be from established and reputable suppliers. A single hardware vendor for each functional component of the system shall be used exclusively on a given site. If this is not possible full compatibility shall be demonstrated.

2

Upgrades and improvements to the manufacturers standard system that are released before the expiration of the warranty period shall be supplied, installed and commissioned at no additional cost. These shall include all hardware and software necessary to implement the upgrade.

2.1.5


1

The Contractor shall arrange for the delivery to Site, off loading, temporary storage in a suitable environment.

2.1.6

Site Conditions

1

Temperature and Humidity Range. The equipment shall be installed in an environment having a temperature range of 0 °C to 55 °C and a maximum relative humidity of 100 % (non condensing). The Contractor shall use, where required, fans, heaters, and air conditioning units to maintain a correct working temperature for his equipment. All Parts of the equipment shall be constructed of materials or treated to prevent the formation of mould, fungus or any corrosion over the temperature and relative humidity ranges specified.

2

EMI/RFI Noise Immunity. The equipment to be provided shall be adequately protected against interference from the use of the radio transmitters, at any point external to the equipment housings, and no malfunction of the equipment shall result from this cause. Responsibility for the correct and reliable operation of the equipment shall rest with the Contractor, who must ensure that the equipment is adequately protected against the ingress of radiated, mains-borne signal-borne interference.

3

Generated Interference. The Contractor shall ensure that the computer, instrumentation and communications equipment conforms to BS EN 50081-1 for noise emissions.

4

Sequencing. The Contractor shall make applications to Qatar Telecom (Q-TEL) for provision of communications and Qatar General Electricity & Water Corporation (QGEWC) for power supply services. Applications shall be made in time`qw to ensure services are available for installation and commissioning of the telemetry equipment.

5

Coordination. The Contractor shall check with other trades to ensure equipment and material can be installed in space provided. Provide other trades with information necessary for them to execute their work. Details on Drawings which are specific regarding dimensions and locations, are for information purposes. Coordinate with other trades to ensure work can be installed as indicated.

2.1.7

Commissioning

1

The Contractor, the Engineer and any appropriate personnel of the Owner shall be present when the equipment or installation is commissioned.

2

Commissioning shall include operating the equipment in a variety of modes and sequences to prove its satisfactory operation, prior to initialising the formal site inspection and testing.

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2.1.4

QCS 2014


2.2

DESIGN

2.2.1

Pre-Design Documentation

1

Prior to design of the system the following documentation shall be submitted: operational functional requirements including MIS functional description;

(b)

process description, including interlocks and alarms;

(c)

process flow diagrams (PFDs)

(d)

process and instrumentation diagrams (P&IDs)

(e)

SCADA I/Os data base (Instrument data base)

(f)

Programmable Logic Controller (PLC) listing

(g)

process control strategies

(h)

process monitoring requirements (manual & automatic)

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Hardware Design

1

Programmable logic controllers shall be used as the basic SCADA hardware.

2

PLCs shall be installed at strategic locations throughout the plant areas to make optimal use of the LAN and to minimize hardwiring of I/O‟s. Man machine interfaces (MMIs) shall be strategically located and installed within each nominated process area. These installations shall form the nodes of a supervisory and distributed control and monitoring system.

3

PLC nodes and MMI nodes shall be connected via the selected PLC/network communication system to form a Local Area Network (LAN) for the site.

4

Loss of the communication shall not impact on the internal control strategy.

5

All system shall be capable of redundant communication. The failure of either of these links shall not result in loss of system communication functionality and response. The failure shall cause an alarm to the operator and to remote monitoring systems where required.

6

Plant areas and functional groups shall not be split across PLC‟s unless reliability benefits are demonstrated. Any PLCs failure shall not interfere with more than a maximum of one plant area.

7

Investigation of the surrounding environment (physical and other hardware components) shall be conducted for all hardware components to optimize components‟ selection and location for the site.

8

All PLCs shall be programmable via the SCADA network.

9

For retrofit installations, PLCs used to replace conventional hard-wired process system control/starter controls shall be compatible to existing SCADA system and standards.

2.2.3

Software Design

1

PLCs software shall support higher-level languages such as ladder logic or any other language (Function Block concept etc) and should comply with the intent of relevant British Standard and International Standards.

2

Machine coded program segment shall not be offered nor accepted as solutions for control implementation.

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Higher-level programming shall be in structured English statements.

4

Communication protocols shall be able to communication with PLC manufacturer‟s equipment currently in use and any new PLCs.

5

Application software shall be selected from packages with ample support and market base, proven in the industrial field to which it is applied. They shall have adequate local resources for support and program development. Provision for automatic upgrade from the delivered versions and future versions of software for a period of up to five years after delivery, shall be included in the base contract.

6

Application software shall provide information in a clear and simple manner, at both summary and details levels. This information shall include plant operational status, and the ability to adjust and optimize readily start/stop or isolate the plant processes or individual items of equipment. The specific control actions required shall be as described in the functional requirements.

7

The system shall have provisions for an operator to intervene or select alternative predefined control strategies.

8

The software shall allow data exchange and have software to allow external application software developers to add-on to the functionality of the software.

9

The system shall be capable of providing additional parts for communication with the following:

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Existing SCADA systems

(b)

Radio modem where specified in the contract documents

(c)

Existing RTUs

(d)

Future business management systems.

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No degradation of the plant SCADA system response times shall occur because of overhead imposed on the SCADA operating system as a result of these interfaces.

2.2.4

System Security

1

All access to the system shall be via password for operator access control functions and system configuration. A minimum of two-step multi-level security shall be used. An automatic timed log-out shall be provided.

2

Supplementary hardware-type security shall be provided where indicated in the contract documents.

3

An automatic timed log-out shall be provided. Timing configuration for the log-out shall be adjustable and determinable by the site‟s needs.

4

External access to the system shall be secured in such methods as dial-back and encryption.

5

All disk used in the system shall have scanned (including the data) labels and shall have virus protection maintenance schedules.

6

The SCADA software shall provide for „Console Mode Assignment‟ features, giving the plant operational team the ability to limit the use of the MMIs to specific levels of control and monitoring as required.

7

Interfaces with external systems shall be on a read-only basis.

2.2.5

Operator Interface

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Number and location of MMIs and input devices such as touch screens or keyboards shall be determined depending on plant production needs. Full control and monitoring capability shall be available at each screen.

2

There shall be no single point of failure, i.e. the failure of one screen or its associated hardware will not compromise the integrity of other MMIs.

3

The failure of any one screen or its associated hardware shall not compromise the integrity of other MMIs.

4

For services plants a minimum one printer shall be provided for alarms/operator‟s actions. The use of the printer shall be minimized and all alarms and operator records shall be electronically stored and shall be periodically (and as required) printed in reporting format. An additional printer shall be provided as required to satisfy report generation needs. At least one colour printer shall be provided for serviced sites.

5

MMIs shall provide a focus for such activities as alarm reports generation, events logging and the archiving of historical data. Where it can be justified operationally, remote MMI may also be installed in area equipment rooms for the control of adjacent systems and plant items.

6

Where the MMI is used in an office environment, it shall be capable of generating business reports using commonly used packages and shall have access to printer via LAN.

7

For plants with permanent staffing besides MMI, a programming console shall be provide for on-line system modifications and maintenance without disruptions to production activities.

8

For unattended (remote) plants provisions shall be made for the connection of a portable programming console and printing facility.

9

The system shall be designed so that data input shall be collected/entered only once and shall be accessible for various business reports. It shall also be capable of sharing this data with external computing systems as required, to provide the necessary plant information to other applications in an accurate and timely manner.

10

The Plant operator/Management shall be able to access the plant from remote sites through dial-up or secured Internet laptop MMI. Critical alarms shall be reported to the central control room as required for any emergency response during after hours.

11

A standard library of interface screens, graphics, symbols and colours shall be utilized to create uniformity between systems. This shall be in accordance with BS 1646, BS EN 60073 unless otherwise stated in the contract documents.

2.3

MASTER STATION HARDWARE

2.3.1

Computer

1

The SCADA computer shall be an Industrial type PC (personal computer) of server / workstation category running multitasking real time operating system suitable for process control operations. These PCs shall have RAID1 implementation of mirroring and controller duplexing. . The PC shall be latest one available in the market. Unless otherwise specified in the project specification ,PC shall be minimum Intel core i7 processors with 6GB RAM ,1 Terabyte Hard disk, DVD R/W ,Sound cards and speakers ,2 numbers. Integrated 3 COM 10/100/1000 Ethernet Network Cards with other serial, USB, parallel ports, Keyboard and mouse

2

The system shall support hardware and software interconnectivity to Programmable Logic Controllers (PLCs) over RS 232/RS485 serial link or Ethernet over fibre/copper media using appropriate protocols, or similar, subject to the approval of the Engineer.

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The memory capacity supplied shall be sized to accommodate an increase in inputs, outputs or Programmable Logic Controller (PLC) of up to 50% of the original specified without replacement of the memory unit. Further memory expansion shall be possible. The Contractor shall state the maximum memory capacity that may be fitted. 3

Local HMI (Panel Mounted) The local HMI (panel mounted) shall be an industrial type PC of server / workstation category running multitasking real time operating system suitable for process control operations as specified in clause -2.3.1 except RAID1 implementation, unless otherwise specified in the project specification. Redundancy

1

The master station shall be supplied with dual redundant computer equipment and suitable software to ensure high system availability and to prevent loss of operational data.

2.3.3

Visual Display Unit (VDU)

1

Visual Display Units (VDU‟s) shall be 22 inch colour monitor screens unless otherwise stated, capable of displaying information in alphanumeric, bar histogram, graphical.. The TFT shall be color monitor with a 256-color palette as minimum and shall have the ability of displaying mixed alphanumeric/semi graphical information. TFT shall be capable of high resolution graphic displays non - interlaced, low radiation, flat screen with no discernible flicker. Display of characters shall be legible and stable on a shadow mask tube, having a resolution of not less than 1024 by 768 pixels and a refresh rate of not less than 70 Hz.The units shall include all the necessary picture controls to adjust the sharpness, contrast and position of the image. The VDU shall have non-volatile memory of 2MB minimum. The VDU shall be industrial type.

2

Control room VDU‟s (Monitor) shall be 22inch and VDU‟s for local HMI at other locations (PLC panel), shall be 17 inch minimum size.

3

VDU‟s shall be fitted with a power management system to reduce consumption upon detection of a stand-by signal from the PC.

2.3.4

Keyboard

1

The master station keyboards shall be of an enhanced pattern personal computer (PC) keyboard, separate from the VDU, low profile and have non-reflecting surfaces and keys of low intensity to minimise unwanted reflections.

2.3.5

Logging / Alarm / Report Printers - Continuous Feed

1

Printers used for logging of system wide events and alarms shall comply with the following:-

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2.3.2

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

print speed print quality

: :

paper feed paper width print pitch print width

: :

adjustable width tractor feed mechanism

18 to 38 cm fan fold :

character set noise level

letter print with optional draft mode :

:

160 characters per second

10 or 12 cpi

132 characters at 10 cpi :

Full ASCII

 50 dBA.

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Page 10

2.3.6

Colour Printers

1

Laser printers shall be used for the production of colour screen dumps and reports and shall have a sufficiently sized buffer memory such that system performance will not be degraded when the colour printer is operational and comply with the following: (a)

print speed :

text, 80 characters per second

(b)

print speed :

colour graphics, 2 minutes per page full

colours

(d)

paper feed :

(e)

compatible with VDU graphics A3 and A4 with auto sheet feeder mechanism and minimum 50 sheets per tray

paper width :

A4/A3

resolution

:

600 DPI

(g)

RAM

:

8 MB

.

(f)

Monochrome Printers (Laser)

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These printers shall comply with the following: (a) print Speed : 8 pages per minute paper feed

:

A4 with auto sheet 250 sheet paper tray.

(c)

resolution

:

600 DPI

RAM

:

:

and

minimum

full ASCII

4 MB

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(e)

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(d)

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(b)

Audible Alarm

1

An audible alarm located on the control desk, shall be provided which is initiated by any fault condition arising and silenced on operator acceptance of all fault conditions. An alarm mute function shall be provided to silence the audible alarm without accepting any fault conditions. It shall be possible to enable/disable this audible alarm only at the highest system access level.

2

Use of the internal PC audible alarm will not be acceptable.

2.3.9

Data Storage

1

Provide a historical data storage system with removable media for archive and backup.

2

The data storage system shall store alarms and events, with the time of occurrence for one month and selected analogue signals connected to the system. All alarms and events shall be archived in a first in first out buffer, for a period of 40 days.

3

A high speed back up device with removable media, such as streaming tape cartridge or optical disk, shall be provided for each server, suitable for backing up the whole system on a weekly basis.

4

Data selected for archive shall be written to removable media which shall be sized to support at least 180 days worth of archive data. The archive media also shall be sized to store logged analogue data, at a maximum sample rate of 15 min for a period of 15 months.

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Uninterruptible Power Supply (UPS) System

1

The Contractor shall supply a UPS system with sufficient capacity to maintain power to the computer equipment, its peripherals and process critical instrumentation during a mains power failure for a minimum period of 8 hours. Refer to Section 21, Part 18 Uninterruptible Power Supply Systems more detailed specification .

2

In the event of power failure, the master central system shall be supported by the UPS.

3

The central system equipment shall be programmed to degrade gracefully once UPS power is exhausted or execute a shutdown routine after a preset time from the original mains failure.

4

The UPS systems shall be monitored by the SCADA and a fault in the UPS system shall be accorded the highest priority alarm status.

5

The FDS shall detail modes of failure and process shutdowns and itemise signals to be supported by UPS.

6

Power distribution from the UPS in the control room area shall be via protected sockets, the design of which will be such as to prevent inadvertent connections of non-system hardware.

2.4

MASTER STATION SOFTWARE FUNCTIONS

2.4.1

General

1

The Contractor shall be responsible for supplying complete software packages to enable the equipment to operate as stated in this specification. Provision must be made for the adding of further software tasks as and when required. All software functions shall be user friendly with instruction and messages to aid the operator. The Contractor shall make available all standard software functions even if not specifically detailed in the specification. The sever / operator works stations shall be OPC compliant for communicating to other client works station

2

The computers shall utilise a real time multi-tasking and networked operating system with a proven track record in real time control applications.

3

It is a requirement that the system be supported by on line configuration and editing of all VDU mimic displays and database and to create new displays and additional database.

4

The system shall be capable of supporting the allocation of equipment groups into zones and these zones may be allocated for the attention of Particular operator workstations (OWs).

5

Operational mimics and other graphics shall be presented in an industry standard graphical user interface (GUI) format. A minimum of two active windows should be displayable concurrently. Both text and graphics shall resize automatically to accommodate changes made to the size of a window. The system shall be designed to minimise the operators use of the keyboard. All major functions shall be accessible on-screen through use of the mouse or track ball.

6

When designated in the Project Specification additional operator workstations shall be provided for each process area. Functionality shall be identical to that of the master station OW‟s allowing full access to all system functions at the authorised access level. Operator system entry for each area will be password coded with different levels of entry depending on the level of authority of the operator. Development and systems level entry passwords will be provided for engineering workstations. Each action taken by any operator at any level of entry, or, at any operator terminal shall be log file recorded, and time and date stamped. Log in and out time and dates will be printed on the control room event logging printer.

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VDU mimics will display dynamic colour details of flow rates and pressures, pump status, well levels, alarms, electrical power supplies and other general equipment status conditions. All requests and commands shall be via icons, whether menu linked or linked to equipment control actions. A permanent dynamic alarm banner shall be displayed at the bottom or top of each operator screen. Each control action will be routed through a series of confirmation routines.

8

The complete system database shall be available to each master-station OW offering preconfigured reports per process area. These reports shall be available for printing in graph or tabular format. Dynamic trend displays shall also be available for all analogue flow, level and pressure values. Custom, as well as preconfigured reports and trends shall be available to a higher level of entry. A colour A4 size screen dump printer shall be provided for graph and trend prints.

9

An operator help utility shall be provided offering help linked to the particular action being carried out by the operator at that time. At least one help screen per screen page shall be available. This facility shall be preconfigured with an option for updating by operators via a password entry. Typical information available shall consist of guides of actions to take under Particular equipment conditions, general process information and help in operating the telemetry system itself.

10

Provide a software watchdog timer function connected to one set of normally closed relay contacts which are held open whilst the watchdog is healthy.

2.4.2

Display Facilities

1

The displays shall be user configurable, with the user being able to construct any desired symbol for display. Any display shall appear (excluding historical recall) within 3 to 5 s of selection and the displayed data shall be updated from the database as information is recovered from the Programmable Logic Controllers (PLC‟s). Alarms shall typically appear within 3 to 5 s of occurrence and within 1 s of being received into the central system database.

2

The Contractor shall configure all display pages as fully as possible. However, facility must be incorporated to permit easy construction and modification of the display pages by using a standard library of shapes and symbols. The library shall be added to and modified by the user as required. The configuration shall be object orientated for ease of use. All layout details and dimensions, including colours, symbols, line diagrams, legend text and indications, shall be agreed with the Engineer.

3

The initial application software shall provide for the display pages listed below and any pages necessary for the system to function as a complete entity.

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(a)

mimic displays

(b)

alphanumeric configuration pages for the complete I/O and PLC‟s

(c)

graphic displays

(d)

trend displays

(e)

process alarms with tag, date time and cause

(f)

event logs of past 72 h with date and time

(g)

tabular display of data

(h)

inset windows showing an analogue trends may be mixed with mimic displays. In such a display the main mimic and inset trend shall all be live with automatic display updates.

(i)

network status and configuration.

(j)

main power supplies status.

QCS 2014

(k)


Page 13

system alarms with equipment identity, date and time.

Indexing of information and menus shall be presented in the form of active windows on the screen while the mimics etc. are still available for view.

5

No display or function shall effect the logging/monitoring of data. It shall be possible for the master station terminal and auxiliary terminals to perform different tasks within the displays simultaneously.

2.4.3

Monitoring and Alarms

1

The operator shall be able to monitor all of the information at all workstations. He shall be able to view active equipment information on a series of VDU based graphical and tabular displays.

2

In the event of an equipment alarm, the following shall occur at the master station:

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alarm message displayed in the alarm message area of the screen

(b)

the audible alarm shall sound

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(a)

the appropriate Section of the display page shall change colour and flash

(d)

a full message shall be written on the alarm page

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(c)

the full alarm message shall be printed on the alarm printer

(f)

the full alarm message shall be recorded, stored on disk and automatically archived.

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(e)

The operator should be able to acknowledge the alarm by pressing an accept alarm key or icon. This action shall stop all associated alarm messages and displays flashing, however the display shall remain in the alarm state fixed colour to indicate an accepted alarm. When all outstanding alarms have been acknowledged the audible alarm shall be silenced.

4

Once the alarm has cleared, the messages and displays shall return to normal. The alarm message shall stay recorded on the event/alarm log and an alarm cleared message shall also be recorded.

5

If the alarm clears before being acknowledged the sequence of events shall continue as above except the message shall change to indicate a cleared alarm.

6

An audible alarm silence function shall be provided to enable an operator to silence the audible alarm without acknowledging all alarms. On occurrence of any subsequent alarm the audible alarm shall sound.

7

For multiple bit points (where two or more inputs are combined to function as one point) the assignment of status/alarm levels shall be on the combined signals.

8

Each signal within the configured system shall be capable of being assigned an alarm based on the following:

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(a) (b) (c) 9

four levels per analogue (Lo Lo, Hi Hi, Lo and Hi) rate of change deviation from setpoint or other control parameter

Alarms shall be time tagged to 1 second resolution at PLC.

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10

A minimum of four alarm priorities shall be provided so that those requiring immediate attention may be separated from alarms of lower priority. An audible alarm shall sound for alarms requiring operator action. It shall be possible to acknowledge alarms from any operator station provided the operator is logged on to an approved access level.

11

Typical alarm assignments are as follows: (a)

critical alarm

-

an alarm that requires immediate operator action

(b)

non critical alarm

(c)

operator guide alarm -

(d)

event

- an alarm that requires necessarily immediate action

-

operator

action

but

not

an alarm that provides information to the operator

a low priority condition which is recorded.

The alarm software shall produce an alarm summary which will show all currently active alarms in priority and chronological order.

2.4.4

Equipment Control

1

The system shall support a high security equipment control facility and employ revertive checking of control outputs based on a select, checkback and execute philosophy of operation. Any command entered at any OW shall complete its action within 2 s.

2

Command execution performance time excludes the time for call set-up on PSTN and assumes no transmission errors or re-transmission of data occurs.

2.4.5

Data Archiving

1

Continuous process (analogue) data, digital event states, alarms and operator actions shall be archived to a removable media system. The archive media shall be sized to store logged analogue data, at a maximum sample rate of 15 min for a period of 15 months. Data recording shall be on dual media. The archive system shall generate an alarm when a file is 90 % full.

2

Analogues will be stored at a rate selected by the operator in the range 1 second to 1 hour. The operator shall have the facility to select the way in which an analogue is stored. The system will provide any combination of the following:

(b)

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(c)

maximum value

(d)

minimum value

(e)

not stored.

instantaneous value

average value

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(a)

3

Maximum, minimum and average values shall be calculated over a period set by the operator in the range 15 min to 24 h, the default shall be 1 h.

4

The logging of new data and reception of alarms must be carried out at the same time as the operator is viewing archived data. Any alarms received must be displayed as an overlay on the visual display unit.

2.4.6

VDU Mimic Displays

1

The Contractor shall configure all the mimics to provide total detailed coverage of the monitoring and control of equipment as detailed in this specification. It is expected that display modifications will be required in the future and therefore the ability to change the displays without programming skills is essential.

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2


Page 15

Instrumentation shall be displayed using ISO standard symbols. For mimic configuration, it shall be possible to call up a library of standard symbols representing items (e.g. pumps, valves) and add new symbols to the library. Building mimics shall be simple and be achieved by using a mouse or tracker ball pointing device. The mimic displays shall consist of the following pages: (a)

a general diagram covering the whole of the system on a single screen with key data

(b)

a general block diagram for each site or area of Site showing the equipment displayed on a series of single screens with key data

(c)

mimic of the equipment and instrumentation connected to each PLC displayed on as many screens as necessary.

Tabular Representation of Data

1

It shall be possible to put any data into a tabular format, with the data entered in row or columns. The user shall be able to add headings to any of the rows or columns and store the table as a blank for later use.

2.4.8

Trend Displays

1

It shall be possible to plot dynamically updated real time data and archived data on a line graph to represent analogue or digital information. Each graph shall be capable of displaying 8 plots overlaid on a graph of different colours and line texture. Next to the graph, there shall be a key relating each colour to its function. The horizontal axis shall be time based and user selectable in minutes, hours, days, weeks, for example, together with a start time.

2

The vertical axis shall be scaled as a percentage of range and be displayed in the colour of the selected reading. To avoid cluttering, the vertical axis scale shall be changed by selecting the individual display. The vertical axis shall be automatically scaled for each selected point between limits entered by the user. Actual values in engineering units shall be displayed by positioning a cursor at the desired point of the trend graph.

3

The display of the data shall also be available in tabular form.

2.4.9

Manual Data Entry

1

The system shall be provided with facility for entering data manually via the keyboard. This data will fall into two types. (a)

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(b)

maintenance related comments.

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constants which will be changed infrequently. This data may have time and date associated with it

2.4.10

Manually Corrected Data

1

The system shall allow a person with authorised access to manually correct erroneous data via the keyboard.

2.4.11

Reports

1

There shall be a real time spreadsheet facility supplied and installed by the Contractor in the master station. The users shall be able to transfer data from either the archive system or live data to the spreadsheet. The user shall be able to produce daily, weekly, monthly and annual reports using any data and a mixture of formats (tables, graphs, summaries, spreadsheets). Typical reports would be: (a) (b)

power consumption total flows

QCS 2014


(c)

failures of equipment

(d)

maintenance schedules.

Page 16

It shall be possible to configure and store blank templates for later use. Facilities for editing stored templates shall also be provided.

2.4.12

Point Record

1

Each input shall have a record covering every characteristic of the input. This data shall be automatically sent to the appropriate locations when the user has completed entering or modifying data into the record. The Contractor shall compile all input records as indicated in the input/output schedules, plus any other I/O to enable the complete and optimum monitoring and control of the equipment. The user shall be able to modify, amend or create new records. The Contractor shall ensure all possible characteristics are included in the record including the following:

.

2

point identity

(b)

point description

(c)

point type

(d)

point state

(e)

point range

(f)

point units

(g)

status/alarm and priority levels

(h)

alarm set points - high, low, out of range high/low

(i)

log interval - time between logs

(j)

log type - average, total, and others as required

(k)

log in PLC - for communications failures.

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(a)

Profiling

1

From an average, typical or manually entered plot, it shall be possible to set an exception profile whereby readings within an upper and lower level are acceptable. Profiles shall be set graphically via OW. The user may select for the system to alarm if the reading is outside the profile and highlight such exceptions as Part of a report and so reduce the need to examine all data to ensure acceptability. The number of exceptions shall be logged.

2.4.14

Data Manipulation

1

It shall be possible to perform simple mathematical functions on any data, including the following functions:

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(a)

addition

(b)

subtraction

(c)

multiplication

(d)

division

(e) 2

square root

It shall be possible to log, display or use in a control loop the resultant data.

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Database Query Facilities

1

The system shall support the use of database relationships and wild card characters to provide database query facilities. It shall be possible for applications integration to easily configure queries and save them for future use. Support of Dynamic Data Exchange (DDE) or Structured Query Language (SQL), to permit data exchange between the SCADA Master Station and external applications, including spread sheets and databases.

2

Data shall be presented in tabular format and contain any combination of fields from the main system database.

3

It shall be possible to manipulate the data by specifying search and sort criteria to define data range limits.

4

Once a query table has been created it shall be possible to store the configuration and initiate successive look ups using a point and shoot technique.

2.4.16

Downloading PLC Configuration

1

It shall be possible to download configuration to the PLC‟s from the engineer‟s terminal.

2.4.17

Diagnostics

1

The system shall have on-line diagnostic facilities to report system faults as they occur. A set of off-line diagnostic routines shall be supplied for more extensive fault diagnosis.

2.4.18

Access Levels

1

The functions available on the system shall be fully flexible so as to allow users access levels to be customised by the system operator to suit individual user requirements.

2

Access to management and engineering levels shall be restricted by user selectable passwords or keyswitch. The security systems shall be based on a set of privileges which may be granted or denied to individual uses by the system operator.

2.4.19

Control Loop and Sequence Programming

1

The method of programming will depend upon the Manufacturers system requirements. However, the following standards shall be followed: all programs shall be written such that they lend themselves easily to alterations and additions

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2.4.15

(b)

good programming practice shall be followed using structured programming techniques. All programs shall be tidy in format and logical to follow, and shall be accompanied by flow diagrams. Programs should be extensively annotated with comments and be self-documenting

(c)

the system shall be supplied with programs that use a high level language for the OW.

2.4.20

Program - Documentation

1

As Part of the requirements of this specification full documentation is required as below : (a) (b) (c) (d)

software user manuals database point allocation table complete program listing, flow charts for all sequences and control routines application software source code

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(e)


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end user license agreements for the programming software.

REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION

2.5.1

Future Expansion

1

The system hardware, application software and database shall be sized to accommodate a total of 10 % increase in signal capacity overall and up to 25 % increase in an individual RTU.

2

Sufficient plug in modules shall be provided and wired to terminals ready to accept future signals of up to 10 % or a minimum of one module, for each RTU.

2.5.2

RTU Hardware

1

Each microprocessor based RTU will be the main device used to control loops in each RTU process area. Each RTU shall be able to receive analogue and digital inputs from the field, perform input signal processing and alarm checking, perform algorithms control, and output to valves and other actuators.

2

Each RTU controller shall be mounted in an IP65 enclosure and constructed to allow easy replacement and maintenance of cards.

3

The RTU shall be suitably protected against exposure to the severe environmental conditions prevalent in sewerage systems.

4

The RTU shall be an intelligent device capable of handling data collection, logging, report by exception, current data retrieval and pump sequence control programs.

5

Each RTU shall be sized for controlling the specified input/outputs and future expansion.

6

The RTU shall be of single board construction and as a minimum shall include input/output circuits: 16 digital inputs

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8 digital outputs

(c)

4 analogue inputs

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It shall be possible to add one of the following input/output types on a single plug-in module. (d)

16 digital inputs

(e)

8 digital outputs

(f)

4 analogue inputs

(g)

4 analogue outputs

(h)

4 pulse inputs

7

The program and data held within memory shall remain intact and error free if all external power is removed from the RTU for a minimum period of two weeks.

8

The Contractor shall supply batteries for each RTU with sufficient capacity to maintain full power to the RTU for 8 h, or as designated in the Project Specification, after a power failure. The UPS system shall be integral to the RTU. The batteries shall be of a sealed maintenance free type.

9

All field connections shall be made in terminal strips located for easy access. These terminals shall be clearly marked and identified. Terminals carrying voltages in excess of 24 V shall be fully shrouded. All terminals shall be of the „flip up‟ isolator type with test points.

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10

A hand held programmer, shall be provided for local display of signals, programming and fault diagnosis.

11

RTU‟s shall be capable of being equipped with RS232/485 links for interconnection to standalone control systems and standard equipment packages. (a) connection to other devices will use Modbus ASCII or RTU protocol as standard (b) details of other protocols available should be included within the tender RTU‟s shall be configured such that a single RTU failure will not interrupt or degrade equipment monitoring and control functions. RTU failure shall be alerted to the operator at the highest alarm priority.

13

Surge protection shall meet the requirements of IEEE 472-1974

2.5.3

RTU Software

1

The RTU shall be capable of processing locally input equipment information before transmitting it to the master station to reduce transmission overheads.

2

Total internal scan time interval for all inputs and outputs in an RTU shall not exceed 1 s.

3

There shall be two pairs of alarm settings for each analogue input, one an alarm warning of a possible fault, the other warning that the input is outside a valid range of readings.

4

The RTU shall operate on a report by exception basis.

5

The RTU‟s shall have sophisticated in built control facilities to permit control loop configuration using simple building blocks. These blocks shall sequence control, three term control and other control routine components as required by the Specification. The RTU shall be capable of routine signal processing including integration, summation, subtraction and totalisation of one or more inputs. Control loops shall incorporate deviation and rate of change alarms, bumpless transfer facility, set point and output high and low limits.

6

The RTU shall be capable of executing sequential control logic. Programming of sequential control shall be by means of vendor supplied high level function block language or ladder diagram format as Part of an integrated package.

7

The RTU‟s shall have standalone capability, able to continue monitoring equipment and executing control loops if the communication link to the master station fails. In the event of such a failure the RTU shall log all alarms and required analogues until all the total memory is filled. When the communication link is restored the RTU will automatically upload the logged data to the data archiving system.

8

The RTU‟s shall have a watchdog function and full self-diagnostics capable of detecting and reporting faults to the master station and displayed locally.

9

The Contractor shall program the RTU‟s fully under this Contract. It shall be possible to modify the programs remotely by downloading from the engineers terminal.

10

It shall be possible to initiate a current data retrieval on demand, from the master station, leaving the original RTU data contents intact for routine up-loading.

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2.6

PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.6.1

PLC Hardware

1

The PLC system shall comprise of a central processing unit, input/output modules, serial interface modules and programming units. The PLC shall be of modular construction with plug in I/O cards and facility to install expansion racks/modules when necessary. The system shall include 25% spare capacity in hardware and memory for future modifications.

2

PLC‟s shall be installed inside Local Control Panels or in separate cubicles, as specified in the Project Specification. PLC shall be suitable for ambient temperature of up to 50ᴼ C and 95% relative humidity.

Power ok

(ii)

Low battery

(iii)

Forced I/O

(iv)

CPU fault

(v)

I/O status indicators

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Central Processing Unit. The CPU shall perform the following function: (i)

Scan all inputs, execute relay ladder logic programs and generate outputs for the final control elements

(ii)

Monitor status of system hardware and provide diagnostic information .

(iii)

Central Processing Unit ( CPU) shall 80 μs per 1 kb minimum process scan time. Random Access Memory (RAM) for real time program execution with lithium battery backup for data retention and EEPROM flash backup for permanent storage shall be provided. The PLC memory shall be as required for the programs and future requirements with a minimum of 1 MB flash / I MB SRAM, with a minimum of 204 K for IEC Logic or equivalent .

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(b)

PLC diagnostic indications shall include the following:

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(a)

PLCs shall be supplied complete with a laptop programming and diagnostic device plus all necessary leads and programming software & manuals. When a local SCADA computer is installed and connected to the PLC locally, the PLC programming software is to be installed in the same computer and the necessary cables/adaptors required for programming are to be supplied.

4

PLCs shall have a minimum of 1 x RS 232 plus 1 x RS 232 /485 ports and 1 Ethernet port.

5

Compact Version and/or Fixed I/O type PLC shall be considered (physical I/O counts only) at the discretion of the engineer depending upon the application requirements. The compact version CPU‟s specification shall meet all other communication parameters.

6

PLC control equipment shall be housed in the common controls section of the MCC and shall be fed by non door interlocked MCCB. A separate signal marshalling section shall be provided to accommodate all input and output signals to the Control and Telemetry section.

7

The equipment shall accept status and analogue (4-20mA) signals from both field and panel mounted instruments. Analogue inputs shall be scanned into a 12 bit binary (minimum) analogue to digital converter with buffered inputs.

8

PLC power supply shall be 24Vdc, 240 V ac as specified. The equipment shall be maintained in operation during a period of mains failure drawing power from the battery or UPS system for a minimum back-up time of 8 hours. The battery/UPS system shall include diagnostic and automatic self-test routines with volt-free contacts to initiate an alarm in the event of malfunction.

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Panel mounted display (local HMI) units shall be provided for man machine interface, as a permanently connected means of accessing set points, timer settings, control and monitoring locally, unless otherwise specified in the project specification.

10

The HMI shall be pre-programmed to provide a basic graphical display of the process. Realtime numeric display of process variables and alarm messages shall be available. All process control functions shall be accessible for the operator from the HMI. The application program shall be stored in "Non Volatile Memory". Local HMI size shall be as specified in the clause 2.3.3 Visual Display Unit (VDU)

11

A schematic block diagrams for an overview of the PLC system and general arrangement in the MCC section indicating the location and proposed placement shall be submitted for Engineer's review.

12

The Contractor shall ensure while submitting his proposal that the PLC systems selected provides high availability and high level of integrity.

13

PLCs used for controller applications require a minimum built-in redundancy of Power supply ,CPU modules, Communication modules and communications with a hot-backup logic configuration.

2.6.2

Input Modules

1

Digital input modules shall be 16-point (maximum per Card), 24 VDC, signal source type, with individual screw terminal connections. Where space restrictions or high-density signal requirements are apparent 32-point 24VDC digital input modules may be permitted with the approval of the engineer.

2

All digital input units shall be capable of accepting, a volt-free contact signal, the source voltage shall be regulated 24VDC and shall be derived from the PLC panel.

3

Where the input from an external source is not volt-free then suitable isolation devices shall be provided in order to prevent cross-connection of different supplies. This device may be e.g. interposing relay or optical-isolator. For frequencies of operation greater than 30 operations/hours, the use of electromechanical devices shall not be permitted. All interface/isolation devices shall provide visual indication of Signal State.

4

All Input modules shall be segregated into groups, which relate to 24VDC supply commons. Where different supplies are apparent in input connections, these shall be segregated in accordance with supply common grouping.

5

Inputs signals from 'DUTY' equipment shall not be allocated to the same input module as signals from 'STANDBY' equipment performing the same function.

6

The analogue current input module shall be capable of converting 4, 8 or 16 channels of inputs in the range of 4 to 20 mA.

7

Resolution of the converted analogue current input signal shall be minimum 12 bits binary

8

All analogue signals shall be updated each scan into a dedicated area of data registers.

9

The conversion speed for all analogue current input channels shall be within milliseconds

10

All digital input modules shall be provided with LED for each point (channel) for testing and maintenance purposes.

11

All digital input modulus shall be provided with a dual independent power supply.

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Output Modules

1

Discrete AC output modules shall have separate and independent commons allowing each group to be used on different voltages.

2

Discrete AC output where used shall be provided with an RC snubber circuit to protect against transient electrical noise on the power line.

3

Discrete AC outputs shall be suitable for controlling a wide range of inductive and resistive loads by providing a high degree of inrush current (10x the rated current).

4

Discrete DC output modules shall be available with positive and negative logic characteristics in compliance with the IEC industry standard.

5

Discrete DC output modules shall be provided with a maximum of eight output points in two groups with a common power input terminal per group.

6

Discrete DC output modules shall be compatible with a wide range of load devices, e.g. motor starters, valves, and indicators etc.

7

The current rating of the relay output shall be capable of supplying the load according to the applications.

8

The analogue voltage output module shall be capable of converting digital data to analogue outputs in the range of -10 to +10 volts.

9

Resolution of the converted output signal shall be minimum 12 bits.

10

All analogue signals shall be updated each scan into a dedicated area of data registers.

11

The analogue voltage outputs shall be configurable to default to 0 mA, 4 mA or hold-laststate in the event of a CPU failure.

12

Output signals to 'DUTY' equipment shall not be derived from the same output module as 'STANDBY' equipment performing the same function.

13

Digital outputs used for AC inductive loads shall be fitted with arc suppression devices as close to the load as is practicable.

14

Means shall be provided to allow the disconnection of outputs causing unsafe movements or actions without removing power from the PLC Processor or inhibiting program execution.

15

All digital input modules shall be provided with LED for each point (channel) for testing and maintenance purposes.

16

All digital input modulus shall be provided with a dual independent power supply.

2.6.4

PLC Software

1

PLC Software shall be developed within the BS EN 61131-3 environment. Application program shall be developed by using software package that only conform to BS EN 61131-3 requirements.

2

Standard IEC libraries of Functions and Function Blocks shall be used when writing application software.

3

All software shall be suitably documented to include the following as a minimum:

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2.6.3

(a)

suitable comments;

QCS 2014

(b)

Section 10: Instrumentation Control and Automation Part 02: Telemetry/SCADA function description;

(c)

symbolic addressing local data areas;

(d)

symbolic addressing global data areas;

(e)

descriptions of all constants;

(f)

Page 23

list of cross-references.

The PLC shall be suitable to employ minimum two programming devices for development of application programs, a small hand-held device with back-lit LCD readout and a Software programming package running on a PLC compatible laptop or desktop computer.

5

On-line and off-line, CPU and I/O configuration and application program development shall be achieved with a PLC compatible computer and programming and documentation software.

6

Both the PC compatible computer and the hand-held programmer shall be connectable to the PLC via built-in serial communication port. The PLC shall connect to the computer over the computer's RS 232C serial port for programming.

7

In addition to the serial communications, the PLC compatible computer shall be connectable to the PLC via Ethernet TCPIP supporting the SRTP application protocol.

8

The programming devices shall have access to the application program, the CPU and I/O system configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O over-ride capabilities

2.7

DATA COMMUNICATIONS LINKS

2.7.1

Communication Standards

1

Transmission of data shall conform to a recognised Consultative Committee for International Telephone and Telegraphy (CCITT) standard. The data transfer system shall be self monitoring such that any equipment or line failure shall be displayed at both ends.

2

The protocol used shall safeguard against false data transmission, allow for error detection, recovery, failure detection and initiate switchover the redundant data highway. A diagnostic routine shall be included to monitor the highway performance. Data protocols and diagnostics shall be fully documented.

2.7.2

Control Room Data Highway

1

All master station operator workstations and control room hardware shall be linked by a totally redundant local area network to transfer data between the servers, work stations and serial line multiplexers. The system shall continuously monitor the performance of both links and output an alarm on detection of an abnormal condition. Fibre Optic cables shall be provided for control room Data Highway, unless otherwise specified in the project specification

2

The following features shall be provided as a minimum:

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4

(a)

all data highway networks are to monitored at all times

(b)

communications diagnostics are to be continuous such that a failure is alarmed in the minimum time

(c)

each network node shall have message checking capability

(d)

there shall be no single point of failure

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(e)

the maximum distance between nodes shall be up to 600 meters, with a maximum highway distance of 3500 meters

(f)

communication rates shall be at least 10 M baud.

Leased lines or PSTN

1

The system shall use the public switched telephone network (PSTN) or leased data circuits to transfer data between the master station and the RTU‟s located at remote sites. The modems used by the master station and the RTU‟s shall have auto dial, auto answer capability and be PTT approved.

2

All radio equipment shall comply with the appropriate local recommendations and shall have been approved for licensing by the radio frequency allocation authority. Additionally the equipment shall comply with the most recent edition of the appropriate national and international standards specifications.

2.7.4

Radio

1

Type approval numbers issued by the national frequency allocation committee in the country of manufacture shall be supplied, together with CCIR recommendations, national and international standards, specification and recommendations met by the equipment at this time of tender.

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The radio system shall be of the following type : frequency : UHF/VHF as allocated by Frequency Allocation Authority modulation : FM base mode : full duplex outstation mode : two frequency simplex channel spacing : 12.5 kHz Radio Path Profiles

1

The Owner shall provide path profiles and subsequent technical examinations prior to detailed design of the radio system.

2.7.6

Radio Transmitters/Receivers

1

Transmitter/receiver radio units shall be single units without standby facilities. These units shall have sufficient battery back up for the system to function for 8 h in the event of mains failure. Provision for this may be from the main RTU battery back up supply. The units may be either wall mounted or incorporated within the RTU enclosure.

2.7.7

Base Station Radio Transmitter/Receivers

1

Base station transmitter/receiver radio units shall be of a dual main/standby type with auto changeover of the duty units. The Contractor shall supply within the tender document and explanation of how this changeover shall be accomplished. An alarm signal shall be transmitted to the Master Station when a changeover occurs. The base station shall be provided with power supply equipment, including nickel cadmium battery and 240 V 50 Hz a.c. mains fed battery charger and have sufficient battery back up to allow for the system to operate for 4 h in the event of mains failure and capable of automatically recharging the battery to full capacity within 24 h while the radio equipment continues to operate at full duty.

2.7.8

Aerials and Aerial Structures

1

The Contractor shall supply and install all aerials and aerial support structures and shall provide drawings to show how each type of aerial is to be mounted.

2

The base stations shall have omnidirectional aerials plus any associated duplexers.

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UHF outstations shall have a single 12 element, yagi aerial with a gain of 12 dB with respect to a half wave dipole on the corresponding base station. Any VHF outstations shall have 3 element yagi VHF aerials planned on the corresponding base station.

4

The Contractor shall supply and install all necessary low loss coaxial down leads for connection for the radio unit and lightning protection for the aerial system.

2.7.9

Fibre Optic Network

1

The Contractor shall carry out a study whether it is necessary to lay a fibre optic communication media for use as main data highway link. The study shall include the security level required in the designed site communication where fibre optic cable considered being highly secured and highly accurate communication medium.

2

This particular specification is to be read in conjunction with QCS 2010 Section 21 Part 14 Structured Cabling Systems

3

Qualifications and Responsibility of Contractor

4

The Contractor shall furnish and install all fibre optic equipment and materials specified in this section and shown on the tender drawings. The fibre optic system shall be the unit responsibility of one system supplier. The supplier shall use qualified personnel, possessing the necessary equipment and having experience in similar installations (a)

Submittals:

as

Submit the following information:

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3

Catalog data and installation instructions on the splice method, hardware, and splicing

(ii)

equipment (if any).

(iii)

Catalog data on the fiber optic cable, pull boxes, connectors, cable lubricant, duct

(iv)

sealant, closures, pull rope, enclosures, identification tape, and mounting hardware.

(v)

Catalog data on the testing equipment including a written test procedure outlining the

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(vi)

steps and methods that will be used to test the cable during and after installation.

(vii)

Include a sample copy of the test form that will be used in the test procedure.

(viii)

Cable installation procedures for the applicable method of installation, outlining the

(ix)

construction methods that will be used. Identify steps that will be taken to ensure

(x)

that the cable is not damaged during the installation.

(xi)

Complete factory test results for cable reel stating the signal loss for fiber in the cable

(xii)

prior to and after extrusion of duct around cable if applicable.

(xiii)

Record drawings indicating the locations of all splices (if any) and manholes .

(xiv) Certified test results for each cable after installation stating the signal loss of each fiber in the cable between splices, across all splices, and from end to end after splicing is complete. (b)

Qualifications and Responsibility of Contractor (i)

The Contractor shall furnish and install all fibre optic equipment and materials

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specified in this section and shown on the tender drawings. The fibre optic system shall be the unit responsibility of one system supplier. The supplier shall use qualified personnel, possessing the necessary equipment and having experience in similar installations. Material (i)

The Single mode optical fiber cables which are optimized for use in both wave lengths 1310 nm and 1550 nm.

(ii)

The multimode optical fibre cables which are optimized for use in both wave lengths 850 nm and 1310 nm.

(iii)

The optical fibre cables shall meet the requirements stated in ITU-T Rec. by international telecommunication Union, BS EN 50173-3 standard.

(iv)

The cable shall be new, unused and of current design and manufacture. Suitable optical fibre cables shall be selected based on the distance travel, bandwidth, indoor and outdoor application and shall be approved by the Engineer.

(v)

The single mode fiber shall be used for fibre optic network more than 300 m distance data transmission, unless otherwise justified by the manufacturer.

(vi)

The material of the fibre shall be silica glass fibre.

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(e)

The fibre utilized in the cable must meet ITU-T: G651.1, G652 and have maximum attenuation at 850 nm of 3.75 dB/km at 1310 nm of 0.4 dB/km, at 1550 nm of 0.3 dB/km or less. If used for outdoor, then the fibre cable must be loose-tube non-dielectric type.

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Fibre characteristics

Refer to the QCS Section 21 Part 14, clause 14.2.3

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INPUTS/OUTPUTS

2.8.1

General

1

All process I/O and equipment interface boards shall comply with the following:

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Equipment wiring termination‟s shall accommodate up to 0.9 mm diameter conductors. Terminals shall be of the test disconnect type to permit ease of signal isolation and loop monitoring for commissioning and maintenance purposes.

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(a)

2

Hot (powered) removal of I/O boards shall be possible without special tools.

3

Provision to power two wire loop powered transmitters, where required.

4

Digital inputs shall meet the following requirements: (a)

all digital inputs shall be optically isolated.

(b)

all alarm and state indications shall be from dry contacts or 24 V d.c. wet contacts. An isolated +24 V d.c. supply shall be provided to source the opto-isolated inputs when connected to dry contacts, adequate filter circuits and software debounce techniques will be necessary.

(c)

Contact operation shall be as follows : (i)

Alarms: in the healthy condition the contacts shall be closed with the relay coil energised: in the alarm condition the contacts shall be opened with the relay de-energised.

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(ii)

States: contacts shall be open with relay coil de-energised in the off (logic „0‟) condition, and closed in the on (logic „1‟) condition.

(iii)

Two bit Digital: One contact shall close when the equipment is in one state and a second contact shall close when the equipment is in the opposite state.

Analogue Inputs

1

Independently configured channels in the range 4 - 20 mA, 1-5 V d.c., 0-1 V d.c., 0-5 V d.c., 0-10 V d.c. or +/-10 V d.c. All analogues shall be screened and segregated from other cables. The signal ground shall be separate from the system ground. Input impedance shall be greater than 1 M  for voltage inputs. ADC conversion at ten times per second shall be 16 bit, system accuracy ± 0.2% of span.

2.8.3

Digital Outputs

1

All digital outputs shall be optically isolated.

2

All control circuits shall operate from a 24 V d.c. supply. The contact will be normally open and energised to close when an action is initiated. Outputs shall be either open-collector or volt-free contacts as follows:

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2.8.2

Open collector

:

100 mA at 35 V d.c.

(b)

Contact

:

1 A at 24 V d.c. or 120 VA (resistive) 0.5 A at 24 V d.c. or 120 VA (inductive).

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(a)

Analogue Outputs

1

In general all analogue outputs shall be 4-20 mA or 1-5 V d.c., selectable, and drive a maximum loop impedance of 1000  for current outputs and 2000  for voltage outputs. The signal ground shall be separate from the system ground. DAC conversion shall be 14 bit, system accuracy ± 0.2% of span.

2.8.5

RTD Input

1

Capable of receiving 10  copper or 100  platinum resistance temperature devices directly without external transmitter. Conditioned signal must be capable of being directly accessed by the on board RTU controller without external intervention.

2.8.6

Thermocouple Input

1

Capable of receiving type E, J, K, input directly without an external transmitter. Linearisation shall be performed at the PLC without external intervention.

2.8.7

Pulse Input

1

Capable of receiving a zero based pulse or rectangular wave or sinusoidal wave form with amplitude of 4-6 or 21.6-27 V and rate of 0 to 5000 pulses per second for totalizing. Where frequency counting is required a rate of 0 to 1000 pulses per second should be provided

2.9

POWER SUPPLY REQUIREMENTS

1

All power supplies provided by the Contractor shall conform to the following:

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2.8.4

(a)

be comprised of standard available units

(b)

be fitted with adequate input/output fuse protection

(c)

power supplies to be fitted, if applicable, with short circuit protection and current limiting facilities

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(d)

all power supplies to be selected such that they are derated to allow for future expansion to improve the reliability, and help increase the MTBF of the units. With all the expansion described in this specification, the loading on the power supplies shall not exceed 75 % of their total capacity

(e)

modular with one for N redundancy

(f)

modular failure indicated at the PLC and Master Station

(g)

failed module shall be removed without disconnecting system power or affecting control.

MIMIC DIAGRAM

2.10.1

General

1

Where required in the Project Specification a modular mimic diagram shall be provided. The Mimic will be configured to display the status of all principal items of equipment in the area covered.

2

No Part of the mimic panel display area shall be below 760 mm or above 2100 mm from the floor.

3

All layout details and dimensions, including main construction, colours, symbols, line diagrams, legend text and indications, shall be agreed with the Engineer.

4

The mimic diagram driver shall be housed in either the mimic diagram enclosure or a separate enclosure. In either case the driver shall consist of modules mounted in standard 19 inch card frames. The mimic driver shall consist of a client device directly connected to the data centre LAN.

5

Colour coding shall be in as provided below and where not stipulated in accordance with BS EN 60073:2000:

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2.10

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Satus of Operation Equipment running and normal Equipment stopped and normal Equipment tripped Equipment selected “on Auto” Equipment or process unsafe / danger in operation Panel Energised /isolator or ACB ON Process Flow ON (e.g. Valves open) Process flow Stopped OFF (e.g. Valves closed)

Colour Code Green White/Grey Yellow Blue Red White Green White

2.10.2

Mosaic Tile

1

The face of the mimic diagram shall comprise a mosaic of precision formed tiles, which shall clip into a supporting grid to form a robust construction of flush and neat appearance. The tile faces shall have a durable, scratch-resistant non-reflective finish. The background colour of the mimic diagram tiles shall be to the approval of the Engineer. The face dimensions of tiles shall be subject to approval by the Engineer.

2

The face of the tile mosaic shall be engraved and/or printed or painted to provide a diagram. The printing or painting shall be durable throughout the lifetime of the equipment.

3

The mimic diagram face and supports shall be rigidly held in a robust floor mounting frame. The surround to the mosaic tile area and the ends of the frame shall be enclosed in decorative panelling to provide a high quality aesthetic finish. The complete construction shall be formed into an enclosed panel, with a access to enable the ready replacement of defective components and the rearrangement of tiles. Tiles and components shall be replaceable without disturbance to the surrounding areas of the mimic face.

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Wiring troughs or clips shall be provided at the rear of the mimic diagram to enable wiring to electrically driven components to be neatly dressed and supported. Flexible wiring of adequate length shall be used to enable electrically driven components to be relocated on the mimic diagram without the necessity for rewiring.

5

All illuminated indications shall use high radiance, light emitting diodes (LED‟s). Either single peep-through or multiple-element/planar types shall be used, as appropriate. The illuminated area shall have even intensity across the whole face. All LED‟s shall have a wide viewing angle in excess of 60  without significant change in perceived luminosity.

6

A 20 % spare capacity shall be provided (equipped) within the mimic driver and the wiring to the mimic board to allow for future modifications. The spare capacity shall be evenly distributed.

7

All driver outputs shall be protected against overload and short-circuit.

8

Lamp test facilities shall be provided such that operators can initiate the test from their workstation positions. This facility shall ensure that both the mimic LED‟s and the driver circuitry are exercised.

2.10.3

Projection

1

The mimic diagram shall be displayed using high resolution 1280 by 1024 panel rear projection technology onto multiple projectors and screens arranged in a matrix to produce an integrated display, or an equivalent quality as specified in the particular Specifications.

2

The screens shall offer a wide viewing angle, + 40  horizontal and + 12  vertical, and good contrast in full ambient light conditions. The projector and screen assembly shall occupy a floor space of less than 1.5 m, deep by the length of the mimic.

3

Dynamic configuration of the display shall be from X-windows style environment and provide intuitive on screen menu drive display. The ability to interface multiple sources, up to a maximum of 10 using an RS232/422 serial interface shall be provided.

4

A software package shall be provided to adjust brightness, contrast, time, colour, sharpness and geometry and convergence settings from one computer. Image adjustments shall be stored for each source such that the projector will automatically select the correct settings for the Particular source.

5

An auto convergence system shall be provided to automatically align the projected image on the screen, manual convergence shall also be possible.

6

A live video window facility shall be provided to display real time video images anywhere on the screen matrix. The video signal may originate directly from a site security video camera or via a live antenna signal.

7

A remote pointer facility shall be provided to allow the operator to use the local keyboard and mouse to move the cursor on the mimic display and interact with the applications. The system shall support upto three operators simultaneously with a security interlock system to avoid conflicts between users.

2.11

FACTORY INSPECTION AND TESTING

2.11.1

General

1

The Contractor shall advise the Engineer the date on which the equipment is available for factory inspection and tests 30 days in advance. No equipment shall be shipped to Site without written permission of the Engineer.

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Before dispatch from a manufacturer‟s works each item of equipment, software and its components shall be tested in accordance with the relevant specification or code issued by the British Standards Institution or similar internationally recognised standards authority. In the absence of such a specification or code, these tests shall be performed in a manner subject to the approval of the Engineer, and may be witnessed and approved by the Engineer or his representative.The equipment will be inspected by the Engineer and his representative, to ascertain compliance with the functional design specification, satisfactory finish and workmanship, and relevant functional tests shall be carried out with simulated inputs/outputs as necessary.

3

If simulated inputs/outputs are necessary then the simulation equipment shall be provided by the Contractor as Part of the Works unless otherwise agreed.

4

Subject to the Engineer agreement, the works system tests shall take place according to the program detailed by the Contractor.

5

Any surface coating applied prior to the initial inspection of equipment shall be considered sufficient reason for its rejection. Where any attempt to conceal defects is discovered the works may be rejected.

2.11.2

Test Plan

1

A test plan shall be produced for the Engineer‟s approval, by the Contractor, for the factory and site acceptance tests. The plan shall indicate a logical step by step schedule comprising step, action and reaction, e.g.:

(b)

as

All hardware including spares shall be required to pass an agreed preliminary hardware performance test to ensure known hardware operability before software testing begins.

Functional Testing

Functional testing using the system software shall be comprehensive. Simulation of the inputs and responses from equipment operation shall be as realistic a reproduction as possible of Site conditions. Systems to which the PLC/SCADA is required to interface with but are outside the scope of this contract shall be emulated to demonstrate correct operation of the hardware and software.

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(i)

Simulate high level : Tank Symbol Change Colour

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(c)

System Diagnostics (i)

The means of fault detection and diagnostics provided by the system software shall be validated. This will involve making provision for including a sufficient variety of faults and out-of-range conditions in the system to ensure the detection processes are adequately tested.

(d)

The Engineer shall have the option not to attend these tests and to instruct the Contractor to carry them out on a Self Certification basis.

(e)

Three copies of all manufacturers tests certificates, log sheets, performance curves, etc. relating to the tests at manufacturer‟s works shall be dispatched to Site for the Engineer‟s approval prior to system installation and commissioning.

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INSTALLATION

2.12.1

Tools

1

The Contractor shall include for the supply of all spanners, key, special tools, gauges and all other electronic and calibration tools required for the efficient installation, commissioning and operation of the equipment.

2.12.2

Training for Owner’s Personnel

1

Training shall be conducted by personnel employed by the ICA Subcontractor, familiar with the system supplied, experienced and trained in developing and implementing instructional courses.

2

The Contractor shall submit information on the training program for approval prior to shipment of the equipment. This submittal shall include a course outline, time required, course schedule, sample workbook and instructor qualification information for each level.

3

The Contractor make a workbook on each course available to every person taking the courses listed herein. The workbook shall be of sufficient detail so at a later date a trainee could review in detail the major topics of the course.

4

The training times shall be scheduled by Owner in advance so as not to disrupt Owner‟s ability to operate the equipment.

5

Specialised training shall be provided for a minimum of three of the Owner‟s personnel in the operation and maintenance of the system at the manufacturers facility or in Qatar, as specified in the Project Specification. The training programme shall be divided into two segments and each shall consist of at least five, eight hour working days.

6

The maintenance training programme shall be developed for personnel that have electronics maintenance and repair experience and a general knowledge of computer systems, but shall not assume any familiarity with the specific hardware furnished. As a minimum, the following subjects shall be covered:

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2.12

system architecture and layout

(b)

hardware components

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(e)

power supplies

(f)

data highway

(g)

programmer connection

(h)

PLC programming and diagnostic techniques

(i)

battery replacement and recording

(j)

PC and workstation familiarization and maintenance

(k)

troubleshooting

(l)

disassembly

(m)

cleaning

(n)

component replacement

(o)

reassembling.

module switch settings (configuration switches) I/O modules

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(c)

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The operation training program shall include the following topics: (a)

power-up, bootstrapping and shutdown of all hardware devices

(b)

interpretation of all standard displays

(c)

appropriate actions for software and hardware error occurrences

(d)

use of operator interface displays and keyboards

(e)

use of printer including replenishment of supplies

(f)

manual data entries

(g)

creation and editing of graphic operator display screens

(h)

loading of any required software into the system

(i)

data base creation and editing.

System Management:

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The training in this area shall cover the following: (a) the daily supervision of the System: e.g., archiving data, system housekeeping, fault reporting, preventing repetitive alarms system administration e.g., planning and providing system expansion and reconfiguration of hardware, control of users and privileges, software and hardware fault analysis

(c)

Engineering functions, configuration and application programming e.g., additions and changes to the system, points, displays, reports and logs, preparation and downloading of sequence control programs and schedules and software development.

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(b)


1

The Engineer shall have the option to attend the inspection and tests before setting the equipment to work. The Contractor shall notify the Engineer, in writing, 48 hours before commencing tests.

2

A Site Acceptance Test (SAT) shall be conducted as part of the ICA system validation and shall include all equipment and software within the Contractor‟s scope of supply. This test shall be conducted after the above equipment has been installed at the Site and the Contractor is satisfied of the correctness of the installation and of the operation of the equipment.

3

Particular Test Requirements

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(a)

communication test (i)

(b)

hardware test (i)

(c)

demonstrate correct operation of hardware using off-line diagnostics

functionality test (i)

(d)

the Contractor shall firstly conduct a test to establish the correct functioning and ability to correctly transmit data to and from each port on the system communications network. In the event of any problem or deficiency being identified in any equipment supplied by others, this shall be reported fully in writing by the Contractor to the Engineer

demonstrate the system performance and functionality meets the specification

test details (i)

the SAT shall be carried out in accordance with a test specification produced by the Contractor, and approved by the Engineer

QCS 2014

test equipment and test software shall be provided by the Contractor to load the system to the worst case scenario defined in the test specification

(iii)

the Contractor shall prepare a test report following the SAT.

System Commissioning (a)

where required in the Project Specification the Contractor shall provide staff to work in conjunction with the Owner to ensure the satisfactory operation in service of all equipment in the system, and to assist the Owner to adjust configuration data and to develop/modify application programs e.g., sequence controls.

System Takeover The criteria for takeover of the system shall be: submission by the Contractor and approval of as-built drawings

(ii)

submission by the Contractor of all documentation

(iii)

submission of all software design and support documentation and the lodging of source codes in a place of secure safe-keeping and storage with a third Party

(iv)

provision of information and examples of each type of report and each item of user-configurable functionality

(v)

issue of all relevant test certificates

(vi)

successful completion of the SAT

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system commissioning and issue of Final System Test Certificate by the Contractor. Following satisfactory completion of the above, the „Engineer‟ will issue the necessary system takeover certificate.

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Section 10: Instrumentation Control and Automation Part 03: Primary Elements

Page 1

3

PRIMARY ELEMENTS .................................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

Scope References Standards Submittals Quality Standards Warranty

3.2

PRODUCTS ................................................................................................... 3

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.2.12 3.2.13 3.2.14 3.2.15 3.2.16 3.2.17 3.2.18 3.2.19 3.2.20 3.2.21

Electromagnetic Flow Meters In - Line Ultrasonic Flow Meters Rotameters Venturi Flumes Flow Switches Ultrasonic Level Measurement Hydrostatic Level Transmitter Level Sensing System - Air Reaction Type Capacitance Level Transmitter Multiple Level Measurement Systems Tilting Float Level Switches Level Switches - Conductivity Probe Electronic Pressure Transmitters Electronic Differential Pressure Transmitters Pressure Gauges Vacuum Gauges Pressure Switches Limit Switches Temperature Sensors Gas Detection System Guided Wave Radar Level Transmitter

3.3

INSTALLATION ........................................................................................... 10

3.3.1 3.3.2 3.3.3

General Testing and Final Acceptance Spare Parts and Tools

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3

PRIMARY ELEMENTS

3.1

GENERAL

3.1.1

Scope

1

This Part includes specifications for Primary Elements, their design, manufacture, installation and commissioning.

2

Related Sections and Parts General General Telemetry/SCADA

References Standards

1


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This Section Part 1, Part 2,

BS 907........................Dial gauges for linear measurement

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BS 1042......................Flow Measurement

BS 1780......................Bourdon tube pressure and vacuum gauges

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BS 1904......................Industrial platinum resistance thermometer sensors BS 2765......................Dimensions for temperature detecting equipment and their pockets

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BS 3680......................Open channel Flow and Level Measurement BS EN 50014 to BS EN 50020

Protection

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BS EN 60529..............Ingress Protection BS EN ISO 6817 ........Flow measurement for conductive liquids Submittals

1

Submittals shall be in accordance with Part 1 of this Section.

2

Manufacturer’s literature, illustrations, specifications and engineering data including dimensions, weight, instrument set point and range, ambient temperature and humidity rating, process pressure rating, enclosure specifications, installation and wiring diagrams shall be included.

3

The submittal shall be subject to approval by the Engineer. The ICA Subcontractor shall submit the final documentation based on the Engineer’s comments. The Engineer’s comments/approval shall be issued to the Contractor within 21 calendar days of the submittal.

3.1.4

Quality Standards

1

Manufacturer. In addition to requirements of Part 1 of this Section, instrumentation and controls equipment furnished shall be manufactured by a Company regularly and currently engaged in the design and manufacture of similar equipment. All equipment furnished shall be new and of current design. The manufacturer shall be approved and designated in the Project Specification.

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Maintainability. All equipment shall be designed for ease of maintenance and repair, and access to critical parts shall not require a major dismantling. Internal field adjustments, where permitted or required herein, shall be easily accessible upon removal of a panel or cover.

3

Materials and installation shall comply with the requirements of the current editions of referenced electrical codes and standards, and the codes and standards referred to shall be used for establishing the minimum quality of the materials and equipment supplied and installed. All equipment of the same type shall be products of the same manufacturer. Capacities of all equipment shall not be less than that indicated on the Drawings or specified in the Project Specification.

3.1.5

Warranty

1

The equipment manufacturer shall warrant his product to be free from defects in workmanship for a period of 400 days from the date of satisfactory completion of performance test.

2

Warranties and guarantees by the suppliers of various components in lieu of single-source responsibility by the equipment manufacturer will not be accepted. The Contractor shall be solely responsible for the warranty. In the event a component fails to perform as specified or is proven defective in service during the warranty period, excluding items normally expended during operation, the equipment manufacturer shall provide the replacement Part without cost to Employer. The Contractor shall be responsible for the supply for all such spares under warranty.

3

The Contractor shall furnish the Employer with manufacturer’s guarantee and warranty certificates for all equipment, duly registered with the manufacturer.

3.2

PRODUCTS

3.2.1

Electromagnetic Flow Meters

1

General. Electromagnetic flow meters shall use electromagnetic induction to produce a dc voltage proportional to the liquid flow velocity. The flow meter shall be certified intrinsically safe and suitable for hazardous area Zone 1, gas group IIA to EN 50014, where specified in the Project Specification. Flowmeter shall be pressure tested and calibrated by the manufacturer and certified. Overall accuracy shall be better than ±0.5 % of the range throughout the operating range. Repeatability shall be within ±0.2 %.

2

Sensor. Sensor shall have NP16 flanged process connections. Metering tube, flanges and earthing rings shall be of stainless steel 304 to BS 970. Electrodes shall be of stainless steel 316 to BS 970. The sensor lining shall be of Teflon or equivalent material suitable for the application, unless otherwise specified in the Project Specification. The sensor enclosure shall be protected to IP68. Screened and armoured cable between the sensor and the transmitter shall be fitted and potted by the manufacturer. The preamplifier input impedance 5 of the sensor shall be a minimum of 10 megaohms to minimise errors due to sensor coating. Ultrasonic electrode cleaning equipment with all accessories for automatic or manual operations, shall be provided when specified in the Project Specification.

3

Transmitter. Transmitter shall be remotely installed from the sensor. Transmitter power supply shall be 240 V a.c , 50Hz, unless otherwise specified in the Project Specification. Transmitter shall be microprocessor based with programmable range and engineering units. Outputs shall be isolated 4-20 mA d.c. and pulse with adjustable span. Programmable in-built alarm relays shall be provided for empty pipe, low and reverse flows. Transmitter shall have an inbuilt digital display for flow rate, total and alarms. Transmitter enclosure shall be protected to IP65. Calibration and programming kit shall be provided

3.2.2

In - Line Ultrasonic Flow Meters

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General. Ultrasonic Doppler type flow meter with nonintrusive sensor permanently bonded to the pipeline. Overall accuracy shall be within ±2 % of the range with a repeatability of ±0.2 %

2

Transducer. Dual transducers shall be permanently bonded or clamped on to the pipe line to ensure that locked air pockets are eliminated.

3

Transmitter. Transmitter shall be remotely installed from sensor. 240 V a.c. 50 Hz power supply, unless otherwise specified in the Project Specification. Wall mounted with in-built flow rate and total display. Enclosure protected to IP65. Automatic gain adjustments to suit pipe line material shall be available. Alarm contacts configurable for diagnostic or low flow alarm shall be provided. Operating velocity range shall be user selectable. Output shall be isolated 4-20 mA d. and facility for connecting industrial standard fieldbus

3.2.3

Rotameters

1

Rotameters shall have borosilicate glass metering tube, stainless steel 316 float and wetted Parts to BS 970, scale shall have black markings on white background with a nominal length of 250 mm. Graduation units shall be as specified in the Project Specification. Flanged process connection. 2 % accuracy and 10:1 rangeability. Glass tube shall be easily removable for cleaning.

3.2.4

Venturi Flumes

1

Rectangular flumes used for open channel flow measurement to BS 3680 Part 4c, shall be moulded in a single GRP piece with 5 mm thick walls, reinforcing ribs and internal removable blocking to prevent distortion during shipment. Provide staff gauge, 50 mm width by full depth with 1 mm increments recessed into flume. The flume shall be self supporting and be provided with an adequate number of lugs integral to the structure to enable the flume to be cast into a reinforced concrete channel without additional internal or external supports.

2

U-throated flumes to BS 3680 Part 4C, shall be used for measurement of flows in sewers and other conduits running partly full.

3.2.5

Flow Switches

1

General. Flow switches shall sense an adjustable preset flow rate of fluid in a pipe and operate a SPDT switch to actuate alarms or control circuits. The switch shall be rated for 1 ampere load at 110 V a.c., 50 Hz or 1 Ampere at 30 V d.c.

2

Vane type flow switches shall be housed in a watertight case, unless explosion proof is specified in the Project Specification, with electrical conduit connection. Switches for mounting in 40 mm pipe or larger shall be fitted for BSP thread mounting directly in the pipe. Smaller sizes shall be supplied mounted on a pipe fitting with female BSP threads. The switch assembly shall be isolated form the flow by a diaphragm or suitable seal. The actuator vane and other wetted parts shall be stainless steel, monel, brass or other corrosion resistant material suitable for the fluid in the pipe. These flow switches are suitable for gases or clear liquid applications only and shall not be used for raw sewage applications.

3

Thermal type flow switches shall be housed in an explosion proof or watertight case as specified in the schedule with NPT electrical conduit connection and shall be either of the probe type of insertion in the pipe or shall incorporate a pipe spool for installation in the line, end fittings as shown on the Drawings. They shall operate by means of sensing the differential cooling of heated sensor elements caused by flow and no flow condition, and shall be all solid state. The switches shall be available for pressure up to 14 MPa and shall be capable of sensing velocities as low as 3 cm/s. Wetted parts shall be stainless steel to BS 970 or other materials suitable for the application.

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Operating Conditions. The flow switch shall be sized and adjusted for the pipe, fluid and flow rate or velocity shown in the Flow Switch Schedule. Repeatability of sensing shall be within 10 percent for any setting, and differential shall be less than 4.0 percent within the flow range specified. Set point shall be within 10 percent of flow rate of velocity specified. Care should be taken while installing, to avoid locations with turbulent flow conditions.

3.2.6

Ultrasonic Level Measurement

1

General. Unless otherwise specified in the Project Specification, the system shall comprise of a separate transducer and a transmitter. Overall accuracy shall be better than ±1% of the span with a repeatability of ±0.5%. Ultra-sonic level measurement is to be accomplished by the use of non-contact, echo-time measuring equipment operating at ultra-sonic frequency. The equipment is to transmit pulses, which are reflected back to the sensor from the surface of the liquid whose level is being measured. Provide equipment with automatic temperature compensation and suitable for operation in the designated application under the specified climatic conditions.

2

Transducer. The enclosure shall be protected to IP68. Automatic compensation for changes in ambient temperature shall be in-built. The transducer shall be certified for hazardous area use if necessitated by the installed conditions, unless otherwise specified in the Project Specification. The transducer shall be supplied complete with all required mounting accessories.

3

Transmitter. Surface or panel mounted transmitter with 240 V a.c. 50 Hz power supply. Microprocessor based transmitter with programmable range and alarms. Transmitter shall be complete with in-built indication for level or for flow, if used for open channel flow measurement. 4 Nos. in-built relay contacts, shall be provided for process and diagnostic alarms. Transmitter shall be provided with an in-built keypad or a hand held programming unit of programming the instrument. Output shall be isolated 4-20 mA d.c and facility for connecting industrial standard fieldbus.

3.2.7

Hydrostatic Level Transmitter

1

Hydrostatic head type level transmitters shall be used for tank level measurement at atmospheric pressure. Flush diaphragm type capacitance sensor suspended inside the tank. Sensor shall be certified intrinsically safe and protected to IP68. Sensor material shall be stainless steel 316 to BS 970. Two wire transmitter with 4-20 mA d.c. output ±0.5 % accuracy. Flanged process connection on top of the tank.

3.2.8

Level Sensing System - Air Reaction Type

1

General. The level sensing system shall be designed to operate on the back pressure caused by the level of the liquid above the open end of a pipe through which air is being discharged. The device shall be capable of sensing a rising or a falling liquid level and shall translate this rise or fall into a proportional analogue signal. Device shall be two-wire loop powered 4-20 mA dc output and facility for connecting industrial standard fieldbus with an accuracy of +/- 0.5% of span. All equipment such as required to meet the operational requirements set forth herein shall be included and connected to obtain a complete functional system as specified herein.

2

Air Supply. The system shall operate from the auxiliary air sources specified below. To facilitate control, the system shall include a strainer, shutoff valve, pressure regulator with gage, flow control valve and flow metering rotameter with differential pressure regulator. A 4way purging valve or equivalent shall permit purging of the bubbler tube while isolating the pressure sensing line.

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Piping Connections. A "tee" with a removable plug for cleaning purposes shall be provided to connect the air tubing to the bubbler tubing in the wet well. The plug shall be readily accessible for cleaning.. The wet well sensing tube shall be 12 mm diameter stainless steel to BS 970 grade 316 S12 and extend to 150 mm below the low alarm level or as otherwise shown on the Drawings and be supported on not more than 1200 mm centres using stainless steel clamps on the wet well wall to avoid movement due to turbulence. Static pressure connection to the 4-way purging valve shall be 8 mm polyethylene tubing, enclosed in steel conduit or equivalent protection. The pressure output signal shall be sensed by indicator dials, pressure switches, electronic or pneumatic transmitters as specified in the Project Specification.

4

Auxiliary Air Supply. The system shall incorporate and operate from internally mounted dual oil-less heavy duty air compressors, each capable of providing the required air flow. The compressors shall operate in a duty-standby mode. Failure of the duty compressor shall generate an alarm and start the standby compressor. Facility shall be provided to drain out condensate from the system.

3.2.9

Capacitance Level Transmitter

1

General. Radio frequency type level sensors shall sense the varying capacitance admittance of a sensing probe as function of the level of submersion. Varying capacitance is converted to a 4-20 mA d.c current signal or volt free contact output as indicated in the Project Specification.

2

Specific Requirements. The type of process medium, temperature range, pressure other than atmospheric, measurement range, indicators, switches, etc. shall be as specified in the Project Specification. Unless otherwise specified the accuracy shall be ±1 % of full scale. The electronics for the sensor shall incorporate circuitry which shall act to cancel error caused by coating build-up on the probe.

3

Construction. The radio frequency level sensor shall consist of a probe and a solid state electronic unit housed in an IP66 case for surface or panel mounting. Probes shall be designated for mounting through a threaded flange adapter unless otherwise shown on the Drawings. The probe mounting parts shall be stainless steel 316 to BS 970 and the probe shall be in accordance with the manufacturer's recommendation for the application specified. Rigid probes shall be Teflon coated. Local indicators shall be mounted on the electronics housing and shall indicate in the engineering units specified in the Project Specification. The output shall be isolated 4-20 mA d.c. unless otherwise required by the Project Specification.

4

Power. The level sensing system shall either be a two wire transmitter loop powered by the receiver or operate from 110 V a.c., 50 Hz power supply.

3.2.10

Multiple Level Measurement Systems

1

General. Multiple level detection systems shall be used for pump control or multiple level alarm applications. Each system shall comprise of one or more electrode assemblies and a controller.

2

Electrodes. Conductivity type electrode assemblies shall have a weatherproof enclosure to IP56. Electrodes shall be of 316S12 material to BS 970 Part 1. Process connection shall be BSP threaded or flanged to BS 4504. The electrode assembly shall have a glazed ceramic insulator cemented to the metal housing. The measuring electrodes shall be Teflon insulated except at the tip.

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Controller: Controller power supply shall be 110 V a.c. 50 Hz. Provide double pole changeover contact for the output relays. Controller shall have LED indication for relay status. Zener barriers shall be provided for intrinsically safe installations when the electrode assembly is located in hazardous areas. Multiple level detection signals shall be used by the Controller for control of up to 4 pumps or level alarm. The number of control modules in each controller shall depend on the number of level signals and control contacts required.

3.2.11

Tilting Float Level Switches

1

General. Tilting float level switches shall use the tilting movement of a float, whose specific weight is less than that of the process liquid, to actuate switches as the level changes. The switch(es) shall be integrally mounted in the float and connected to a control box by an appropriate, waterproof electric cable. A movable weight shall be mounted on the cable to allow adjustment of the setpoint(s). Sufficient cable length shall be provided to facilitate termination in a control or electrical room unless otherwise stated in the Project Specification. The float shall be polyethylene, stainless steel or other approved material.

2

Specific Requirements. The desired switching action Pump-up ("pump-down”, or alarm), level set-points, cable length and optional features shall be as specified in the schedule. Contractor may utilise either a series of floats or a single float to provide the specified switching action. The "pump-up" type shall close a contact at a low level and open it at a high level. The "pump-down" type shall provide the opposite action.

3

The switch shall be rated for 1 A, 110 V 50 Hz or 1 A, 24 V d.c. inductive load.

3.2.12

Level Switches - Conductivity Probe

1

General. Level sensing switches of the conductivity probe type shall use the electric conductivity property of the sensed fluid to close an electric circuit between two or more sensing probes or between probe and an electrically conductive tank shell. The level switches shall consist of a probe assembly and an electronic sensing unit.

2

Sensing Unit. The solid state sensing unit shall operate from a power source of 110 V a.c., 50 Hz, but shall not apply more than 10 V to probes and the current shall be limited to one milliampere maximum. The unit shall be housed in an IP66 enclosure, unless explosion proof is specified in the Schedule, and shall be for pipe stand or surface mounting. The unit shall be suitable for direct or inverse operation (i.e. output contacts) operate on liquid contact or non-contact. The output shall have two SPDT switches, rated at 5 A resistive load at 110 V a.c., with provision for latching or non-latching operation, by appropriate connection of the output contacts, to provide for "pump-up", "pump down" or alarm type operation.

3

Probes. The probes shall be either of the rod or flexible wire type when not specified the Contractor shall select the type most suitable for the application and submit the choice for approval. Solid rods shall generally be used only where the installation requires less than 2 m in length. Both rod and flexible wire types shall be insulated except at the sensing end. Either type shall be suspended from a holder which provides liquid tight connections, and when installed in a pressure vessel they shall be pressure tight to at least twice the system operating pressure. Exposed probe ends shall be type 316 stainless steel to BS 970 and holder shall be cadmium plated cast iron, unless otherwise stated in the Project Specification. The number of probes per holder shall be as specified in the Project Specification. The holder mount type (i.e. pipe threaded, flanged or conduit style) shall be selected to suit the installation unless otherwise specified in the Project Specification.

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Electronic Pressure Transmitters

1

General. Unless otherwise specified in the Project Specification, the instrument shall be a two-wire loop powered transmitter with a 4-20 mA dc output, with an accuracy of 0.25% of span. The wetted parts shall be stainless steel Grade316S31 to BS 970 and the enclosure protected to IP67. Complete with flush diaphragm or remote seal sensing system. To achieve optimum accuracy, transducers shall be selected to have a range as close as possible to the anticipated operating range. A datum point shall be provided adjacent to the transducer installation. An engraved plate shall define any offsets resulting from its elevation relative to the tapping point (zero level) and also define the range of the transducer. All elevation measurement shall be in metres, with the equivalent bar offset shown. Sensors shall be positioned in a location accessible for safe maintenance. Where separate transducers and transmitters are used, the transmitter where possible, shall be positioned locally to the transducer to facilitate calibration. Site operatives shall be provided with a remote readout at a convenient point.

2

Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified in Project Specification. Enclosure and wetted surface material shall be stainless steel to BS 970 or as indicated in the Project Specification.

3.2.14

Electronic Differential Pressure Transmitters

1

General. Electronic differential transmitters shall convert a differential pressure measurement to a loop powered 4 to 20 mA d.c. output signal. Range shall be as indicated in the Project Specifications and span shall be field adjustable over at least a 10 to 1 range. Elevation or suppression facility shall be provided. Overload protection shall be at least +3.5 MPa. Accuracy shall be +0.5 percent of full scale span or better. Integral adjustable damping shall be provided. An indicating meter shall be provided. Zero and span adjustments shall be provided.

2

Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified is schedule. The process connection shall be 12 mm NPT. Enclosure and wetted surface material shall be stainless steel to BS 970. Vent drain plug shall be provided on meter body. A 3-valve manifold shall be provided such that the transmitter can be removed without disturbing piping connections.

3.2.15

Pressure Gauges

1

Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have black markings on white background. Dial size shall be 100 mm unless otherwise specified. Wetted Parts and case shall be 316 stainless steel to BS 970. Accuracy shall be ±1 %. 1/2 inch NPT process connection unless otherwise specified. Pressure range and units shall be as specified in the Project Specification.

2

Isolation diaphragm shall be stainless steel 316 to BS 970 with silicone fill, pulsation dampeners or vibration snubbers shall be provided where specified in the Project Specification.

3.2.16

Vacuum Gauges

1

Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have black marking son white background. Dial size shall be 100 mm unless otherwise specified. Wetted Parts and case shall be stainless steel 316 to BS 970. Accuracy shall be ±1 %. 1/2 inch NPT process connection unless otherwise specified. 0-760 mm HgA range unless otherwise specified in the Project Specification. Cases shall be black phenolic.

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3.2.13

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Pressure Switches

1

Pressure switches shall have a diaphragm type sensor with a switching differential adjustable within 25 % of the range. Contact shall be micro switch SPDT rated 110 V a.c. 5A, 30 V d.c. 2A. Accuracy shall be ±1 % of span. Stainless steel enclosure certified explosion proof where specified in the Project Specification.

3.2.18

Limit Switches

1

Limit switches shall be provided to sense the limiting positions of equipment, such as valves. The switches shall be non-contact reed type, magnetically coupled to the actuating device. SPST contacts shall be rated 110 V a.c. 3A. Reed switch shall have a life expectancy of one million operations.

3.2.19

Temperature Sensors

1

General. Temperature sensors shall be (RTD) platinum resistance element. RTD sensors shall have a temperature resistance relationship and tolerances for 100 ohm platinum resistance element to BS 1904.

2

Construction. Temperature sensors shall be equipped with accessory equipment as specified in the Schedule. In general, accessory equipment shall consist of general purpose, or explosion proof connection heads; pipe extension with union connectors or bushings; wells or protecting tubes and spring-loading assemblies. Well or protecting tube material shall be to BS 2765. Sensors shall be integrally mounted with transmitters to provide a 4-20 mA, loop powered signal, where specified in the Project Specification.

3.2.20

Gas Detection System

1

General. Gas detection system shall be rack-mounted. The system shall measure and display gas concentration and shall provide audio and visual alarms when preset limits are exceeded. Relay output for alarms and malfunction indications and analogue signal representing gas concentrations shall be provided. The system shall be configured for fail safe operation. Failure of a sensor shall generate an alarm. The system shall consist of a sensor, control module, and calibration check kit including sensor separation accessories and calibration gas tanks. Sensor and transmitter location shall be as shown on the drawings and schedule. The gas detection system shall operate from 110 V a.c., 50 Hz power.

2

Control Module. The control module shall amplify the sensor current signal through a solidstate amplifier for display and alarm functions. The control module shall include a two or three-digit LED display and three discrete alarm levels: Low, high, and malfunction. Output relay contact shall be rated at 2 amp, 110 V a.c. and single pole, double throw. Analogue output signal representing the gas concentration shall be 4-20 mA.

3

Oxygen Gas Detector. The oxygen gas detector shall have a 0-25 percent range, full scale. The oxygen sensor shall be housed in an explosion proof enclosure. The sensor shall be the electrochemical fuel cell type and not require the periodic addition of reagents.

4

Combustible Gas Detector. The combustible gas detector shall have a 0-100 LEL range, full scale calibrated on methane gas. The combustible gas sensor shall be the catalytic bead type. The sensor must have a demonstrated resistance to degradation by silicones and reduced sulphur gases.

5

Hydrogen Sulphide Gas Detector. The hydrogen sulphide gas detector shall have a 1-100 ppm range; full scale. The hydrogen sulphide sensor shall be of the electrochemical type which shall not require periodic addition of reagents.

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3.2.17

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6

Chlorine Gas Detector. The chlorine gas detector shall have a 0-10 ppm range, full scale. The chlorine gas sensor shall detect a minimum concentration of 0.5 ppm by volume and a maximum response time of 30 s for 80 % of range to 10 ppm gas at 20 C. Sensor recovering time shall be 3 minutes for 90 % of range at 10 ppm chlorine.

3.2.21

Guided Wave Radar Level Transmitter

1

The probe shall: have single rod with extended flexible wire, minimum probe diameter 6mm and constructed of stainless steel to BS970-1 Grade316S31 (partially replaced by BS EN 10084);

(b)

have flange mounted and threaded process connections;

(c)

be able to work with ambient rating of 150 C at 20 bar, for a dieletric range of 10-100;

(d)

have ingress protection and hazardous area protection and shall meet the CE requirements on Electromagenetic compatibility

(e)

be energised in an intrinsically safe way.

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The transmitter shall:

(a) have locally remote wall/post mounting with a flexible connection to the probe head;

(b)

(b) give a 4-20mA output with a resolution of 0.01mA;

(c)

(c) have a push button keypad and a HART communicator, with menu language English;

(d)

(d) have ingress protection and hazardous area protection and shall meet the CE requirements on Electromagenetic compatibility.

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(a)

INSTALLATION

3.3.1

General

1

Installation, testing and commissioning shall be in accordance with Part 1 of this Section.

3.3.2

Testing and Final Acceptance

1

All the primary elements shall be calibrated and tested prior to final acceptance, in accordance with Part 1 of this Section.

3.3.3


1

Spare Parts for all instruments listed in the schedules shall be provided for two (2) years of normal service. Refer to Part 1 of this Section for additional spare parts requirements.

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END OF PART

QCS 2014

Section 10: Instrumentation Control and Automation Part 04: Panel Mounted and Miscellaneous Instruments

Page 1

4

PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS ..................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

Scope Reference Standards Submittals Quality Standards Manufacturers Test Certificates Approved Manufacturers

4.2

PRODUCTS ................................................................................................... 3

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

Digital Indicators and Totalizers Trip Amplifiers Relays-Electromagnetic Type Timers Running Time Meters Programmable Logic Controllers (PLC’s) Alarm Annunciators Chart Recorders

4.3

INSTALLATION ............................................................................................. 6

4.3.1

General

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Page 2

PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the panel mounted and miscellaneous instruments and equipment to perform the required functions in conjunction with information and equipment specified in other Parts of Section 10.

2

Unit Responsibility. It shall be the responsibility of the ICA Sub-Contractor as described in Part 1 of this Section to ensure that the panel instruments and equipment supplied under this Part are compatible with the primary elements and telemetry/SCADA equipment and equipment specified under other Sections of these specifications, and that the signal transmission methods are compatible.

3

Enclosures of front of panel mounted instruments shall be of uniform design and colour scheme wherever possible. Front of enclosure colours shall be compatible with panel colours and subject to final approval by the Employer. Normally, compatible standard colours of the manufacturer shall be acceptable.

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Reference Standards

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BS 5515......................Documentation of computer based systems

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IEEE 472-1974 ...........Surge protection ISO 3511 ....................Process measurement control functions - instrumentation symbolic representation ISO 9075 (BS 6964) ...Structured Query Language (SQL) 4.1.3

Submittals

1


2

The following shall be included in the submittals: (a)

shop drawings, product data, and samples

(b)

complete description, specifications, drawings, and descriptive literature on the equipment.

(c)

make and model of each component

(d)

number of sizing electrical and control wires and power requirements

QCS 2014


Page 3

(e)

complete wiring and equipment instrumentation diagram

(f)

list of spare Parts to be provided

(g)

recommended procedure for protection of equipment against damage prior to installation

(h)

complete system diagram showing required components, routing through in-plant ductbank system.

The submittals shall be subject to approval by the Engineer. The Contractor shall submit the final documentation based on the Engineer’s comments. The Engineer’s comments/approval shall be issued to the Contractor within 21 calendar days of the submittal.

4.1.4

Quality Standards

1

Manufacturer: In addition to requirements of Part 1, instrumentation and control equipment furnished shall be manufactured by a Company regularly and currently engaged in the design and manufacture of similar equipment. All equipment furnished shall be new and of the most recent design.

2

Maintainability: All equipment shall be designed for ease of maintenance and repair, and access to critical Parts shall not require major dismantling. Internal field adjustments where permitted or required herein shall be easily accessible upon removal of a panel or cover.

3

Materials and installation shall comply with the requirements of the current editions of referenced electrical codes and standards, and the codes and standards referred to shall be used for establishing the minimum quality of the materials and equipment supplied and installed. All equipment of the same type shall be products of the same manufacturer.

4.1.5

Manufacturers Test Certificates

1

Manufacturers shall test and calibrate each input/output to operate within specified limits Calibration and compliance certificates provided by the manufacturer, shall be authenticated by the Contractor and submitted to the Employer.

4.1.6


1

All ICA equipment shall be provided by approved, prequalified manufacturers and suppliers designated in the Project Specification.

4.2

PRODUCTS

4.2.1

Digital Indicators and Totalizers

1

Digital indicators shall be panel mounted type. 96 mm (w) by 48 mm (H) dimensions. 110 V a.c. 50 Hz power supply. 4 1/2 digit LED or backlit LCD display for process variable. Range shall be programmable in Engineering units. Input shall be 4-20 mA d.c. or volt free contact as specified in the Project Specification. Loop power for 2-wire transmitter shall be provided as required. At least two programmable alarm contacts for high or low alarms. Totalizers shall have 8 digit display with manual reset facility.

4.2.2

Trip Amplifiers

1

Trip Amplifiers shall be surface or rack mounted with 110 V a.c. 50 Hz power supply. Input shall be 4-20 mA d.c. 1 or 2 independent adjustable set points shall be provided as specified in the Project Specification. Outputs shall be SPDT relay contacts rated 110 V a.c. 5A.

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Relays-Electromagnetic Type

1

Relays shall be provided as necessary to perform switching functions required of control panels and other control circuits.

2

Control Relays. Control relays shall be provided for the control and alarm circuits as indicated in the Project Specifications. The relays shall be electrically held, 50 Hz, continuous duty, multiple connected to 110 V a.c. control circuits and mounted inside control panels or separate metal enclosures as indicated. Enclosures shall be IP66. The relay base assembly shall accept from 1 through 8 convertible poles. Relays shall be attached to pre-shaped mounting channels with captive screws.

4.2.4

Timers

1

Timers shall be provided as specified herein or indicated in the Project Specifications. Timers shall have four types of operation: (1) On Delay (2) Off-Delay (3) Single Shot, and (4) Duty Cycle timers. Time ranges shall be as shown in the Project Specification.

2

Panel mounted timers shall be of the motor driven adjustable type with dials and presentable pointers. The timers shall operate from 110 V, single-phase, 50 Hz power and shall be of the square bezel type for flush panel mounting. Output contacts shall be double throw and rated for 10 A at 110 V a.c.. The number of contact sets shall be sufficient to perform the required control functions. Where more contacts are required than supplied as commercial standards, control relays of equal rating shall be used to supplement the timer contacts. When specified, relay contacts shall be supplied as Part of the timer and shall be operated by the timer control power independently of the timed contacts. Repeatability of the preset time delays shall be within ± 2%. Timers shall be of the plug-in type and enclosed in dust-proof cases. Connection shall be by numbered screw terminals in the rear of the timer connector.

3

On delay timers. When a start signal is applied, the timing cycle begins. Output contacts change state after the time delay is completed. Contacts shall return to original state when a reset signal is applied or power is removed.

4

Off delay timers. When a start signal is applied, the output contacts change state immediately. When the start signal is removed, the timing cycle begins and the output contacts return to the original state when the cycle is completed. Timer shall be reset by a reset signal or by removal of power.

5

One shot timers. When a start signal is applied, the output contacts change state immediately and the timing cycle begins. The output contacts return to the original state when the cycle is completed. Timer shall be reset by a reset signal or by removal of power.

6

Duty Cycle timers. Two timer cycles shall be incorporated. When a start signal is applied, the first timing cycle beings. The output Contacts change state at the end of the cycle and the next timing cycle begins. When this delay is completed the output contacts return to the original state. This sequence is repeated until a reset signal is applied or power is removed.

4.2.5

Running Time Meters

1

Running time meters shall be of the synchronous motor driven type having a minimum of six (6) decimal digits where the least significant digit shall represent tenths (1/10's) of hours. Unless specified otherwise in the Project Specification, they shall not be equipped with a reset button. They shall be for panel mounting with a square bezel approximately 60 mm on a side. Motor voltage shall be 110 V a.c.

4.2.6

Programmable Logic Controllers (PLC’s)

1

See Section 10, Part 2, Telemetry/SCADA for PLC specifications.

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Page 5

PLC’s shall be installed inside Local Control Panels or in separate cubicles, as specified in the Project Specification.

3

Data base development and system configuration shall be the Contractor’s and the ICA Subcontractor’s responsibility. The data base developed by using the P&IDs and I/O point list shall be submitted to the Engineer for approval prior to installation in the operating system

4.2.7

Alarm Annunciators

1

All windows in the alarm and status annunciator shall be nominally 36 mm by 76 mm, of white plastic, and rear lighted with two low voltage, heavy filament lamps. The plastic windows shall be engraved with black letters in accordance with the Drawings. The windows shall be removable from the front for lamp replacement. The lamp units and electronic drivers shall be in one case, unless otherwise approved in writing, with a removable cover and designed for panel mounting. The lamps shall be mounted such that replacement is possible from the front of the annunciator panel without tools. Lamp sockets and mountings shall be robustly constructed, so as not to be loosened or misaligned when lamps are replaced. The windows shall be in rows of six, unless otherwise shown. The monitoring modules shall be of all solid state plug-in design. There shall be sufficient electronic modules to drive all required annunciator windows, including spares. When specified, provide repeater contacts terminated on a terminal strip for externally monitoring each alarm status. The annunciator power supply shall be sufficient to drive all required loads. Alarm points shall be driven by modules with the operating sequence shown below. The windows for status indication, when specified shall be off and steady on only, colour shall be white or as shown in Table 4.1:

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Normal Alert Acknowledge Return to Normal after Acknowledge Return to Normal before Acknowledge

Display

Audible

Off Flash Steady On Off Flash

Off On Off Off On

The alarm and status actuators shall be contacts or as shown on the Drawings. The annunciator shall accept either Normally Open (N.O.) or Normally closed (N.C) contacts. The sensing voltage shall not exceed 24 V d.c. The units shall be supplied with audibleflasher cards as required that shall operate on receipt of alarms from any of the alarm points to the panel. A buzzer shall be provided and mounted in the control panel. A horn in a weather proof housing shall be provided for external mounting when specified. On receipt of any alarm the monitor card shall cause the flasher to flash the appropriate indicating window and sound the alarm.

3

There shall be a test button and an acknowledge button. The test button shall actuate all alarm and status points and sound the audible alarm. The acknowledge button shall perform the functions as outlined in the operational sequence, but shall not prevent any future alarm points from being annunciated visually and audibly. The unit shall operate from 110 V a.c., 50 Hz commercial power.

4

When specified, a "first out" sequence shall be provided in which the first alarm in a related group, as designated, shall flash red while subsequent alarms in the group shall be nonflashing white. A first out reset button shall be provided for each designated group.

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4.2.8

Chart Recorders

1

Paperless video graphic recorders with colour LCD display and internal and external storage, networking capability shall be provided having the following specification: screen size 127mm (minimum) front panel to IEC 529 – IP65 standard and cut out size 138mm x 138mm

(b)

required number of input channels but never less than two and capable of 4020mA, mV, V, RTD, thermocouple inputs

(c)

minimum scan rate of 125ms and chart speed of 1mm/hour to 1200mm/hour

(d)

totaliser with mathematical functions

(e)

RS232 serial Ethernet 10 Base T interfaces

(f)

data storage facilities with a minimum of 1MB internal flash

(g)

integral smart media with 128MB smart card and media door lock

(h)

capability of being configured by both PC keyboard and via tactile membrane front door key.

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INSTALLATION

4.3.1

General

1

Installation, testing, calibration, validation, start-up, and instructions shall be in accordance with Part 1 of this Section.

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END OF PART

QCS 2014

Section 10: Instrumentation Control and Automation Part 05: Control Panels and Control Room Hardware

Page 1

5

CONTROL PANELS AND CONTROL ROOM HARDWARE ......................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6

Scope Reference Standards Submittals Quality Standards Approved Manufacturers Delivery, Storage and Handling

5.2

PRODUCTS ................................................................................................... 3

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5

Panels General Panel Construction Panel Wiring and Termination Instrument Labelling Control Desk

5.3

INSTALLATION ............................................................................................. 7

5.3.1 5.3.2 5.3.3

General Site Inspection Testing and Commissioning

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Page 2

5

CONTROL PANELS AND CONTROL ROOM HARDWARE

5.1

GENERAL

5.1.1

Scope

1

This Section covers control panels for work of the ICA Sections, and all unit panels unless modified under other Sections.

2

Related Sections and Parts This Section Part 1,

General

Reference Standards

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BS 546........................Electrical outlets

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BS EN 60439..............Low voltage switchgear and controlgear assemblies Submittals

1


2

Shop Drawings. The ICA Subcontractor shall submit shop drawings for all control panels, including details for the following items, as applicable:

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electric power wiring circuits and schematics

(b)

air supply piping schematics

(c)

electric signal wiring circuits and schematics pneumatic signal tubing schematics fabrication drawings

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(a)

(f)

details of all panels accessories

(g)

listing of all panel mounted (both front and rear) instruments

(h)

control panel layouts and nameplate inscriptions

3

The submittal shall be subject to approval by the Engineer. The Contractor shall submit the final documentation based on the Engineer’s comments. The Engineer’s comments/approval shall be issued to the Contractor within 21 calendar days of the submittal.

4

Factory Test Reports. The Contractor shall submit from the equipment manufacturer, or his authorised representative, a certified test report in accordance with the requirements of the relevant test procedure.

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Page 3

Quality Standards

1

All equipment furnished shall be of a design that has been used in similar applications and shall be demonstrated to the satisfaction of the Engineer that the quality is equal to the specified equipment. The manufacturer shall have successfully designed and furnished similar sized or larger panels for a similar application.

2

The Engineer or his representative may inspect the panel at the factory. The Contractor shall notify the Engineer at least three weeks prior to shipment so that the factory inspection may be arranged. Factory inspection will be made after the manufacturer has performed satisfactory checks, adjustments and tests. Approval of equipment at the factory only allows the manufacturer to ship the equipment to the site and does not constitute final acceptance.

5.1.5


1

Control panels and all the associated hardware shall be provided by approved, prequalified manufacturers and suppliers designated in the Project Specification.

5.1.6


1

Control panels shall be assembled and shipped in sections, properly packed to prevent damage during shipment. Panel sections shall facilitate easy handling and Site installation. Panels and associated instrumentation shall be handled carefully to avoid damage. Proper lifting and handling equipment and accessories such as grounding straps for handling electronic cards, shall be used.

2

ICA equipment shall only be delivered to Site just prior to their installation to minimise the possibility of damage. Delivered instrumentation shall be protected and not scattered or left unprotected on the Site.

3

Materials and equipment not required for immediate installation shall be stored in a separate store protecting them from shock, weather, dust and damage from chemical and construction material

4

ICA equipment shall not be stacked unless crated.

5.2

PRODUCTS

5.2.1

Panels General

1

Control panels shall be free standing and floor mounted cabinets of console or desk pattern. Console layouts shall permit the operator to readily observe all instruments.

2

The panels shall be manufactured to a high standard of quality in terms of visual appearance, colour and finish. The panels located in the main control room shall have an appearance and quality suitable for a pumping installation environment.

3

The panel design including colour, style and appearance and detailed specifications of panel instruments shall be submitted to the Engineer for approval prior to manufacture.

4

Control voltage. Panel instruments and controls shall operate from 110 V a.c. power supply, unless otherwise specified in Project Specification. A separate 24 V d.c. circuit shall be provided for the indicating lamps and panel instruments, as necessary.

5

Where specified in the Project Specification, panel space shall be provided for instruments supplied by others. Installation and wiring of such instruments shall be carried out by the panel manufacturer. Coordination of instrument delivery shall be the Contractor’s responsibility.

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5.1.4

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Page 4

Unit Control Panels for mechanical and electrical equipment can be the manufacturers standard panels. Details of such panels shall be submitted to the Engineer for approval, prior to manufacture. The Contractor shall be responsible for interfacing the unit control panels with the main control panel or central control system, as necessary.

5.2.2

Panel Construction

1

All consoles and auxiliary cabinets shall be fabricated of cold rolled sheet-steel and be of rigid and stable construction without bows and ripples. The front surface shall be flat and the corners and edges shall be rounded to give a smooth appearance.

2

Panels shall be of sufficient size to enclose all the panel instruments with ample interior clearance to allow for installation and maintenance of instruments. Annunciator displays shall be located in the top portion of the console assembly. Control panels shall be of sectional design with provision for easy extension. Pushbuttons shall be provided to enable acknowledgement and resetting of alarm annuciators and lamps on the console.

3

Panels shall be formed of IP55 panel sections and each enclosure shall be a maximum of 2100 mm high, 800 mm wide and 600 mm deep unless otherwise specified in the Project Specification. Each section shall be fully enclosed including the top and bottom with no visible seams on the front. Externally visible screws and bolts shall not be acceptable.

4

Each panel section shall be provided with two door rear access. Door hinges shall be knuckle type. Handles and other hardware shall be chromium plated. Where necessary, removable access covers secured by quick release fasteners shall be provided to facilitate easy maintenance.

5

Undrilled gland plates shall be fitted at a sufficient height above the floor level to provide easy access under the gland plate. Suitable side covers shall provide access to the gland plates and also provide the specified ingress protection.

6

Electrical general purpose outlets for test and repair purpose shall be provided in all consoles and cabinets. The outlets shall be in accordance with BS 546.

7

All consoles and auxiliary cabinets shall be ventilated mechanically or by natural circulation to maintain the internal equipment working temperature to below 10°C above ambient.

8

Panel lighting shall be provided to ensure adequate illumination for carrying out delicate adjustments or repairs on small items of equipment.

9

Finish. After fabrication, all external welds must be ground smooth. The entire unit shall be thoroughly degreased, then filled and sanded. At least one coat of synthetic primer shall be applied, baked on, and sanded. This first coat shall be followed by two coats of baked-on synthetic enamel. The first coat shall be sanded after baking. The final two coats shall provide a glossy or semi-matt finish to a colour and finish approved by the Engineer. The average overall finish shall be at least 1.25 micrometres in thickness. Any minor damage to the finish during installation shall be touched up at Site, provided such remedial works are to the approval of the Engineer.

10

Panel Earthing. A copper earth bar shall be provided within the panel for earthing of the panel, all the panel instruments and the cables to BS 7430, code of practice for earthing.

11

Panel Isolation. Isolating switches shall be provided for all incoming power supplies. These switches shall be clearly identified, labelled and suitably protected from inadvertent operation.

12

Panel Protection. MCBs to BS 3871, shall be provided for the distribution of electrical power within the panel. The MCBs shall be arranged to minimise disruption to the equipment operation and also to prevent unsafe operating conditions. Power supplies from control panels shall conform to BS 5486.

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Panel Wiring and Termination

1

Panel wiring shall be carried out in PVC insulated multi-strand cable of adequate grade and rating. Wiring within each panel shall be done in a structured manner, grouped and supported to give a neat appearance.

2

110 V a.c. wiring shall be colour coded with black-unswitched live phase, red-switched live phase, white-neutral and green-ground. Signal and d.c. wiring shall also be neatly segregated under an approved colour coding scheme. Wiring shall be bundled and laced or tied with plastic ties and supported to prevent ragging or damage.

3

All control and auxiliary cabinets shall be manufactured and assembled with all internal wiring connected to terminals blocks, requiring only connection to external wiring at Site.

4

Separate terminal blocks shall be provided for incoming and outgoing analogue and digital signals and power supply connections. Each terminal block shall be clearly identified and labelled. Layout shall permit convenient access to terminals and wires and enable ferrule numbers to be easily read. Terminals shall be at sufficient height from the cable gland to facilitate easy routing of wires. Terminals shall clamp the wire between two plates using a captive screw. Where wires are terminated on screw terminals, insulated crimp spade lugs shall be used.

5.2.4

Instrument Labelling

1

All panel instruments shall have engraved nameplates showing their tag number and service in the English language.

2

Materials for nameplates shall be selected in accordance with the relevant environmental conditions and shall be of non-metallic material, with black inscription on a white background.

3

Name plates on control panels shall be mounted on or near the relevant instruments to ensure clear identification

4

An additional nameplate engraved with the instrument tag number only, mounted at the rear of the panel, shall be provided for each panel mounted instrument. These plate shall be attached to the instrument, the panel or instrument support near the instrument.

5

For panels where opening the circuit breaker does not shut off all of the power, the following sign shall be provided:

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5.2.3

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"THIS CABINET CONTAINS CIRCUITS SUPPLIES FROM EXTERNAL SOURCES." "OPENING THE CIRCUIT BREAKER DOES NOT TURN OFF ALL POWER". Letters shall be 6 mm high, red colour on a white background. 5.2.5

Control Desk

1

SCOPE (a)

2

This section defines the minimum requirements for the manufacture, supply, inspection, installation, testing of control desks or consoles required to be used on this Contract. Control desks or consoles shall be of the custom made industrial type and material for construction shall comply with MCC’s panel construction as specified in QCS Section 21 Part 2. The requirements for lockable doors, ventilation fans, anticondensation heaters etc. shall complied with as specified in this section.

CODES AND STANDARDS (a)

The following list of standards indicates the minimum requirements. Any other standards not listed below or elsewhere in these documents shall be subject to review and approval by the Engineer.

QCS 2014


Page 6

BS EN 527-1 Office furniture, Work tables and desks BS EN 1335-1 Office furniture, Office work chair BS EN ISO 26800 Ergonomics, General approach, principles and concepts SITE CONDITIONS (a)

.

DESIGN CONSIDERATIONS AND FABRICATION REQUIREMENTS (a)

The control desks and consoles shall be designed so that it is comfortable to use, thus enabling operators to maximize their efforts, incorporating the latest principles of ergonomic design, as described in BS EN ISO 26800.Monitors (and instruments if applicable) shall ideally be arranged so that they are all are equidistant from the operator’s eyes. Similarly, all the associated controls should be equidistant from the operator's shoulder pivot points. This arrangement avoids any body movement, but demands a convex panel in both planes. If this is not a practical proposition then flat panels shall be provided which are angled to each other and which require only some limited body movements, such as bending the trunk or pivoting a chair, to operate the keyboards or view the VDUs (monitors) .The display area shall be divided either vertically or horizontally. Vertical division shall be utilized for mounting VDUs. If small instruments are fitted then parallax errors may be introduced are mounted above or below eye level, although this danger can be avoided by using those with digital displays. In most cases horizontal division is the simplest and gives the greatest area of panel space free from parallax errors within the operator's control. When a large number of instruments or controls are involved, horizontal and vertical division shall be combined. The desk shall then become a winged console.

(b)

Sufficient rack space shall be provided in the base to enclose all control desk equipment and permit access for installation and maintenance purposes. Cable entry shall be via floor mounted cable gland plates with facility to route cables through desk sections as required. All servers/works stations shall be placed inside the control desk with lockable doors. Ventilation louvers and fans are to be fitted in the desk for sufficient air circulation.

PANEL LAYOUTS

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It is the Contractor’s responsibility to furnish and install the control desks or consoles to withstand and operate properly under the prevailing ambient conditions as described in the General Technical Requirements. This Specification serves as a guideline to the Contractor. The Contractor shall include all the necessary equipment based on his previous experience on similar installations. Control desks or consoles shall be able to operate continuously without their normal physical and functional reliability being affected by the tropical environment.

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(a)

6

Where indicators ,Monitors and controls are to be fitted on panels then the actual arrangement must receive careful consideration. When designing the layout, the center of the various instruments should be arranged so as to be opposite the operator's eye position. Controls should be mounted below shoulder level. Space above this level shall preferably be utilized to house indicators, or infrequently used controls.

DESK SIZING (a)

The design shall such that when the operator is sitting correctly (trunk erect, but shoulders relaxed) elbows shall be about level with the working surface. Desks used for keyboards shall be slightly lower than one used for general duties, so as to bring the actual working surface to the correct level. Draw out type tray arrangement shall be provided for keyboard and mouse. Care shall be taken that the underside of the desk will allow the thighs of an operator to fit comfortably between it and the top of the seat; a minimum of 200 mm clearance shall be allowed. The front surface shall be flat and the corners and edges shall be rounded to give a smooth appearance

QCS 2014

7

Page 7

(b)

Desk thickness shall be as specified in Section 21 Part 2 MV Factory Built Assemblies (FBA’s).

(c)

Generous leg space shall be provided to ensure operator comfort. It shall be possible for the operator(s) to move easily to and from the desk to this end a minimum a minimum of 400 mm clearance is to be provided.

SEATING (a)

The seat height shall be no higher than the length of the lower leg when it forms a right angle with the upper leg and the foot is resting flat, to ensure operator comfort,. An adjustable seat shall be provided to achieve this. If this leads to a large difference between the eye positions of short and tall operators then as an alternative a fixed height seat shall be provided which will suit the tall operator together with an adjustable foot rest for the use of others.

CONSTRUCTION

.

8


Materials of construction shall generally comply with the MCC’s panel construction requirements specified in the Section 21 Part 2 MV Factory Built Assemblies (FBA’s). Consoles shall be built on a plinth fabricated from rolled steel. They shall consist of a closed skeletal steel or forged aluminum framework with rigid panels screwed or bonded in place or alternatively hinged or fixed with quick release fasteners . Consoles shall be prefabricated in the factory. Assembly on site is acceptable but on site fabrication is not acceptable.

(b)

Console sizes shall be determined by equipment sizes, number of operators. Where practicable, the unit shall be designed in individual modules, which are then bolted together. Apertures shall be sized and finished to accept specific equipment and/or fitted with standard rack mount fixings. All components shall be protected against corrosion by means of passivation, fusion bonded epoxy coating or high grade epoxy factory applied spray baked finish. Brush painting is not acceptable. Color shall be a RAL shade as directed by the Engineer. Areas subject to abrasion or wear shall be suitably protected with replaceable rubber mats, stainless steel finishes, or similar.

(c)

The desk or console IP rating shall be IP 54 as a minimum or higher to match the grade of any installed equipment.

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(a)

INSTALLATION

5.3.1

General

1

Installation, testing, calibration, validation, commissioning, and instructions shall be in accordance with Part 1 of this section.

5.3.2

Site Inspection

1

Each instrumentation item shall be checked by the Contractor upon receipt for compliance with purchase specifications, damage, shortage and shortage of components. Items shall be repaired, replaced or the vendor notified of non-conformance as instructed by the Engineer.

5.3.3


1

All control panels and instruments shall be tested and commissioned by the Contractor according to procedures outlined in Part 1 of this Section, prior to final inspection and acceptance by the Engineer.

2

Calibration of all panel instruments shall be tested and corrected as necessary.

3

Panel wiring shall be tested to ensure that wiring is done as per the submitted wiring schedules. Correct identification on ferrules and tag plates shall also be verified.

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Page 8

4

Panel power supply voltages shall be checked to ensure that they are within the operational limits of each instrument.

5

Damaged or defective instruments and equipment shall be identified and replaced.

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END OF PART

QCS 2014

Section 11: Health and Safety Page 1 Part 1.01: Qatar Legislation and Management (Regulatory Document)

REGULATORY DOCUMENT

1

1.1

QATAR LEGISLATION AND MANAGEMENT

1

1.1.1

Occupational Health and Safety at Work including Construction Sites ............ 6

1.1.2

Duties, Responsibilities, Offences and Penalties etc. .................................... 11

1.1.3

Safety Policies ............................................................................................... 21

1.1.4

Consultation with Employees ......................................................................... 42

1.1.5

Health & Safety Training and Induction Training ............................................ 54

1.1.6

General Health and Safety ............................................................................. 72

1.1.7

Risk Assessments and Method Statements ................................................... 79

1.1.8

Construction (Design and Management) ....................................................... 82

1.1.9

Safety Inspections and Auditing ................................................................... 142

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1.1.10 Safety at Street Works and Road Works ..................................................... 157

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1.1.11 Setting Up Site ............................................................................................. 176 1.1.12 Security on Site ............................................................................................ 199

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1.1.13 Statutory Forms, Notices and Registers ...................................................... 207

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FORWARD

This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS).

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The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

QCS 2014


Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6


5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.


4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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8

1

17

8

8


6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

9

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Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

QCS 2014


Qatar Regulatory Document Notes for Users Legislation and Management Occupational Health and Safety Introduction This Regulatory Document is designed to help managers, supervisors and safety representatives comply with their legal, moral and social responsibilities and assist in the crucial areas of: accident prevention

(b)

the avoidance of occupational ill health

(c)

Environmental good practice.

.

(a)

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The Regulatory Document seeks to maintain a balance between outlining the requirements of legislation, as it applies to the Qatar construction industry, and providing practical guidance on how to comply with these applicable Regulations.

3

Contractors will therefore be able to assess the legal responsibilities of themselves and others and decide how best to organise work activities in a safe and healthy manner.

4

This Regulatory Document is a set of regulations which makes provision for securing the health, safety and welfare of persons at work, for protecting others against risks to health or safety in connection with the activities of persons at work and for controlling the keeping and use of dangerous substances.

5

It is an essential piece of legislation covering occupational health and safety in Qatar and focuses on the construction industry placing legal obligations as from project design concept. It focuses on planning, design and management of construction projects and places legal obligations on everyone involved at work and in construction.

6

The Regulatory Document is designed to help Clients, Designers, Contractors, Subcontractors and others to comply with their legal, moral and social responsibilities and assist in the crucial areas of: Project planning, design and management for better occupational health and safety performance

(b)

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It imposes legal requirements for safety consideration in the future stages of the project life cycle, namely use, operations and maintenance, cleaning, decommissioning and replacement of facilities, plant and equipment etc

7

(c)

Safety planning for construction, use and maintenance

(d)

Incident prevention at work

(e)

Avoidance of occupational ill health

(f)

Safety, health and environmental good practice.

Designers and Contractors have legal obligations to promote, plan, implement and showcase good health, safety and welfare management in relation to their undertakings.

Structure of the Health and Safety Regulations in QCS 1

The Occupational health and safety legislation of the QCS is formed mainly under Section 11 Part 1: Regulatory Document and guidance is given in Part 2: Safety and Accident Prevention Management Administration System (SAMAS)

2

Other references of Occupational health and safety in QCS are summarised in the table in the above section. The word Regulations is used throughout this document and refers hereafter to the Qatar Regulatory Document

QCS 2014


Definitions / Interpretations These Regulations contain words and phrases with a meaning that is defined in the legislation.

2

Words and phrases such as 'construction work', 'structure', 'approved', 'lifting gear' and 'working platform', have such a legal definition.

3

Definitions of the more common terms are outlined below.

4

Hazard: The potential to cause harm, including ill health and injury; damage to property, plant, products or to the environment; production losses or increased liabilities.

5

Risk: The likelihood that a specified undesired event will occur, due to the realisation of a hazard by, or during, work activities or by the products and services created by work activities.

6

Danger: A person is in danger when they are exposed to a risk. The degree of danger is dependent on the nature of the hazard or degree of risk.

7

Competent person: A person who has practical and theoretical knowledge and actual experience of the work activities that they are required to do. A person's competence will, in some cases, be tangibly demonstrated by the award of a qualification or other recognition of training received.

8

Practicable: Where a legal requirement is qualified by the word 'Practicable', the specified measures must be taken if it is physically possible, irrespective of cost, difficulty or inconvenience.

9

Reasonably practicable: Where a legal requirement is qualified by the term 'Reasonably practicable', the cost (in terms of money, time and inconvenience) of taking precautions may be balanced against the risk being considered.

10

If an assessment of the situation shows that the cost of taking the precautions is disproportionately high in relation to the risk of an accident or injury occurring, the precautions need not be taken.

11

Employer: means any person, company or organisation who has an employment relationship with the employees or workers and has responsibility for the undertaking and/or establishment and includes any ‘self-employed’ in relation to the undertaking. In relation to construction site, the Employer is the Contractor.

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Note: 12

Whenever these Regulations are being applied, attention should be paid to the section at the start of each piece of legislation, entitled 'Interpretation', where definitions and other important provisions may be listed and explained.

QCS 2014


Occupational Health and Safety 1.1.1

Occupational Health and Safety at Work including Construction Sites

1.1.1.1 Key points These Regulations place legal duties on Contractors, Employers, Self-employed, Employees and others with respect to all transactions carried out in Qatar.

2

Under the Regulations, there is a special focus on construction works, construction sites and Contractors who undertakes or manages construction work on site.

3

Legal duties are also placed on manufacturers, designers, contractors, sub-contractors, importers and suppliers of articles for use in the workplace.

4

Contravening these Regulations is a criminal offence and punishable in a Qatar Court of Law

5

These Regulations place a duty on the Qatar Administrative Authority where no other body has been given the responsibility.

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Note: Section 1, Part 7 of the QCS covers submittals associated with construction sites and includes a health and safety organization chart and the health and safety plan. General safety requirements are specified in Section 1, Part 2 of the QCS.

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1.1.1.2 Aims and scope of this Regulatory Document

The regulations aim to promote and enforce high standards of health, safety and welfare in the Qatar workplace especially with special regards to construction workplaces or construction sites. Hence contractors and sub-contractors and others have to implement effective standards of health, safety and welfare management onsite and in connection with their business.

2

This Regulatory Document (Regulations) provides for a comprehensive framework to promote, stimulate and encourage high standards of health and safety in the Qatar construction workplace. Its ultimate aim is to promote health and safety awareness and effective standards of health and safety management by every Contractor.

3

It is a requirement under these regulations that everyone is involved and made responsible for their acts towards health and safety. Hence the scope of this document relates to organisation, companies and individuals and requires everyone to make responsible for health and safety- starting from-management, the employees, the self-employed, the employees' representatives, the controllers of premises and the manufacturers of plant, equipment and materials - in the matters of construction site health and safety. The Regulatory Document (Regulations) also requires that adequate measures are taken to protect the public where otherwise their health or safety would be at risk.

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1.1.1.3 Standards of compliance 1

In many instances the Regulatory Document (Regulations) places a legal duty which is qualified by the words practicable (or best practicable means) or reasonably practicable.

2

Where a legal duty is qualified by the word practicable the duty must be complied with if it is 'capable of being carried out' or 'feasible within the current state of knowledge and technology', at whatever expense, taking note of published information, Guidance Notes or relevant British/International Standards.

3

In practical terms a legal duty qualified by the word practicable cannot be disregarded on the grounds that to comply with it would slow up the building programme, be expensive, difficult or otherwise inconvenient.

QCS 2014


Where a legal duty is qualified by the term reasonably practicable Contractors are allowed to exercise their judgement on the extent of the measures that need to be taken to ensure the health and safety of whoever is carrying out the job and others who may be affected by it.

5

This judgement should be based upon the findings of a risk assessment.

6

Where the risks to health and safety in carrying out a job are found to be low in comparison to what would be disproportionately high costs to overcome the risks totally, the Contractors need only take the measures that are considered to be reasonably practicable.

7

Should there be a legal dispute as to a decision of what was or was not reasonably practicable, the onus of proving in court that all reasonably practicable measures were taken lies with the Contractors.

8

Managers, supervisors, safety supervisors and safety representatives and others with a responsibility for ensuring legal compliance will be mainly concerned with the following:

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1.1.1.4 Duties of Contractors

These Regulations place a general duty on every Contractor to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all their employees.

2

Contractors must, so far as is reasonably practicable

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protect the health, safety and welfare at work of all their employees.

(b)

provide and maintain plant and systems of work that are safe and without risk to health.

(c)

ensure safety and absence of risks in the use, handling, storage and transport of articles and substances.

(d)

provide any necessary information, including information on legal requirements, to ensure the health and safety of their employees.

(e)

provide adequate supervision and training, as is necessary, to ensure the health and safety of their employees.

(f)

provide and maintain a safe and healthy place of work, with safe access and egress.

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provide and maintain a working environment that is safe and without risks to health and is adequate with regard to welfare facilities and arrangements for welfare at work.

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(a)

(h)

3

to ensure, as far as is reasonably practicable, that the conduct of their activities does not endanger persons not in their employment who may be affected by operations under their control, for example, subcontractors or the public.

Contractors must not: (a)

levy a charge, or permit any employee to be charged for anything required to be provided in pursuance of any of the relevant statutory provisions i.e. Personal Protective Equipment (PPE) and Respiratory Protective Equipment (RPE).

(b)

The regulations place a general duty on every contractor to conduct his undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in his employment who may be affected thereby are not thereby exposed to risks to their health or safety.

1.1.1.5 Duties of employees 1

These Regulations place two general duties on employees:

QCS 2014


(a)

to exercise reasonable care for the health and safety of themselves or others who may be affected by their acts or omissions at work.

(b)

to co-operate with the Contractors, as far as may be necessary, to enable them (the Contractors) to carry out their legal duties in health and safety matters.

1.1.1.6 Duty on 'all people' This Regulatory Document (Regulations) places a duty on 'all persons' to: 'not intentionally or recklessly interfere with anything provided in the interests of health, safety and welfare'.

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Not only does it apply to Contractors and employees but it also applies to members of the public.

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QCS 2014


1.1.1.7 Duties of manufacturers, designers, importers and suppliers A general duty is placed on any person who manufactures, designs, imports or supplies any article, materials or substance for use in a workplace or a construction site shall ensure, so far as is reasonably practicable, that articles and substances are, by design and construction, safe and without risks to health when being used, set, cleaned or maintained by persons at work.

2

For example, information on design noise levels under normal working conditions should be supplied if noise levels may be a risk to health, or exceed the lower exposure action value specified in the Noise at Work section of this Regulatory Document. Similarly, manufacturers of tools that may be a source of hand/arm vibration must provide details of the levels of vibration generated.

3

More specifically, a duty exists to ensure that arrangements are made to carry out the necessary testing, examination and research, and that steps are taken to provide adequate information about any conditions necessary to ensure that it will be safe when used.

4

A general duty is placed on installers or erectors of any article for use at work to ensure, so far as is reasonably practicable, that it is safe and without risk to health when used by persons at work.

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1.1.1.8 Administrative Authority

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The Qatar Administrative Authority has the powers under these regulations to examine, to investigate and to seize and take possession of any matter relating to health, safety and welfare of workplaces and construction sites. They have the power to advise and enforce the law on any matter relating to health, safety and welfare of workplaces and construction sites.

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Investigation

Administrative Authority Workplace Inspectors are given a general right to examine and investigate as may be necessary. They may enter premises (accompanied by a police officer or other authorised person if necessary), taking with them any equipment or material required by them for the purposes of the examination. They may direct that anything shall be left undisturbed if required for examination or investigation, take measurements, samples, photographs and such recordings as may be necessary. They may have dismantled or tested any article or substance considered dangerous, or take possession of any article for examination and evidence.

3

Administrative Authority Workplace Inspectors may inspect or take copies of books or documents. They may demand from an employee any information they think necessary and can ask the employee to sign a declaration of the truth of their answers. In general, they can demand the full co-operation of any person to provide them with such facilities and assistance as they may think necessary.

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Advisory 4

Inspectors also act as a source of information and advice. It is their duty to inform employees about anything that may affect their health and safety at work. Enforcement options

5

Administrative Authority Workplace Inspectors can use any of the powers listed below against any person taking part in, or in control of, any work activity, or piece of equipment. 'Any person' means a Contractor, self-employed person, a supplier, or the employee.

QCS 2014

6


(a)

Informal

(b)

Workplace Inspectors may give advice on compliance in the case of minor breaches.

(c)

Formal letter

(d)

A formal letter may contain details of breaches and action needed to comply with the legislation. It may also contain more detailed and formalised advice. Whilst visiting a site, a Workplace Inspector can prepare an Instant Visit Report with a date agreed for work to be completed.

(e)

Improvement Notice

Where a breach is more serious, the Inspector may issue an Improvement Notice, which will outline the work required and the date for completion. This will be at least 21 days from the date of receipt. Prohibition Notice

(a)

Prosecution

In addition to the enforcement outlined above, the Inspector may consider that it is also necessary to prosecute.

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If an activity involves, or is likely to involve, a serious risk of personal injury, the Inspector may serve a Prohibition Notice to stop that activity immediately or after a specified time.

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(a)

Appeals

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on appeal following the issue of an Improvement Notice, the Notice will be suspended until the relevant board meets and decides the issue

(b)

on appeal following the issue of a Prohibition Notice, the Notice will stand until the appeal has been decided, or the relevant board orders it to be suspended.

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Where a person has been prosecuted for failing to comply with a duty or requirement of this Regulatory Document (Regulations), and is claiming that it was not reasonably practicable for them to carry out that duty or requirement, it is the responsibility of that person to prove that it was not reasonably practicable to comply, and that there was no reasonably practicable alternative way in which they could have carried out that duty or requirement.

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Anyone served with an Improvement or Prohibition Notice has the right to appeal. This must be done within 21 days of the issue of the Notice. The Administrative Authority may cancel or modify the Notice:

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QCS 2014


Occupational Health and Safety – Construction Site Safety 1.1.2

Duties, Responsibilities, Offences and Penalties etc.

1.1.2.1 Key points 1

The purpose of this section is to: (a)

Outline the legal duties placed upon Contractors and employees while at work on Qatar construction sites.

(b)

Emphasise that where health and safety legislation places legal duties on the Contractors, in most cases the duties also apply to the self-employed.

1.1.2.2 Introduction

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This section is designed to give both Contractors and employees details of their legal duties / responsibilities at work.

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1.1.2.3 Responsibilities

1.1.2.4 Legal duties of Contractors

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Set out over the following pages are the principal legal duties of Contractors and employees.

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1

The Contractor shall protect the health, safety and welfare of their employees and other people who might be affected by their business. This means making sure those workers and others are protected from anything that may cause harm, effectively controlling any risks to injury or health that could arise in the workplace.

2

Contractors will usually be site-based and in a position to fulfil their legal duties by directly controlling the workforce and monitoring the standards of health and safety on site. By comparison, in larger companies the Contractors will not normally be site-based and it is usual for them to delegate responsibility for day-to-day legal compliance to site-based staff such as Site Managers. It may be necessary for Site Managers to further delegate the responsibility for overseeing the health and safety aspects of some work activities to trade supervisors. Whatever the circumstances, the duty to ensure compliance with health and safety legislation stays with the Contractors.

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1.1.2.5 Legal duties of the self-employed Generally, where legislation places legal duties on Contractors with regard to ensuring the health and safety of their employees, similar duties are also placed on the self-employed with regard to ensuring their own health and safety.

1.1.2.6 Legal duties of the Employees

1

All employees and workers have a right to work in places where risks to their health and safety are properly controlled. The contractor or the employer is responsible for providing for their health, safety and welfare.

2

Employees shall take reasonable care of their own and other people’s health and safety.

3

Employees shall follow the training that they have received when using any work items that the contractor or employer has provided.

4

Employees shall co-operate with your employer on health and safety.

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Employees shall tell the employer, the supervisor, or the health and safety representative if they think the work or inadequate precautions are putting anyone’s health and safety at serious risk.

1.1.2.7 Construction (Design and Management) CDM 1

The CDM Regulations place legal duties on planning and management arrangements for construction works. It places duties on everyone involved in construction and contractors have a set of specific duties under CDM.

2

The CDM regulations forms section 1.1.8 of the Regulatory Document Contractor duties / Responsibilities Plan, manage and monitor construction phase in liaison with sub-contractors

2

Prepare, develop and implement a written plan and site rules. The initial plan must be completed before the construction phase begins. Plan is termed “Construction Phase Health and Safety Plan”.

3

Give sub-contractors relevant parts of the plan.

4

Check competence of all their appointees.

5

Ensure that expert knowledge/advice is available in relation to highly hazardous activities (e.g. explosives, cofferdams, caissons etc.) and when works are undertaken on or in proximity of existing structures.

6

Coordinate temporary works and cooperate with designers and others as relevant.

7

Secure the site.

8

Ensure, as far as is reasonably practicable, the health, safety and welfare of all their employees.

9

Provide and maintain plant and systems of work that are safe and without risk to health and safety and ensure safety and absence of risks in the use, handling, storage and transport of articles and substances.

10

Provide any necessary information, including information on legal requirements, to ensure the health and safety of their employees.

11

Provide adequate instruction, training and supervision as is necessary, to ensure the health and safety of their employees.

12

Provide a safe place of work, with safe access and egress. Provide a safe working environment that is without risks to health.

13

Provide adequate welfare facilities and arrangements for welfare at work.

14

Have a general statement of health and safety policy.

15

Prepare a written health and safety policy, then review and update it as often as is necessary.

16

Bring the company health and safety policy, and any revisions of it, to the attention of employees.

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Carry out risk assessments for all work activities undertaken and record the significant findings of the risk assessment.

18

Implement any control measures identified by your risk assessment.

19

Regularly review risk assessments and any associated control measures.

20

Ensure that work equipment used for working at height and places of work are inspected by a competent person.

21

Ensure that scaffolding is only erected, altered or dismantled by, or under the supervision of, a competent person.

22

Have access to competent advice to assist in matters of health, safety and welfare, where necessary.

23

Establish a safety committee

24

Consult with workers and safety representatives on matters of health and safety.

25

Assess manual handling operations at the workplace and take appropriate steps to reduce the risk of injury to employees.

26

Ensure that all injury accidents, however slight, are entered in the accident book and investigated.

27

Report to the Administrative Authority all reportable accidents, dangerous occurrences and notifiable diseases.

28

Provide employees with personal protective equipment, as necessary.

29

Avoid entry into confined spaces, wherever possible.

30

Protect employees who may be exposed to asbestos at work.

31

Assess all excavations and take appropriate steps to reduce the risk of injury to employees.

32

Appoint trained and competent persons for the purpose of mounting abrasive wheels.

33

Examine, test and properly maintain plant, equipment, cranes, lifting equipment and accessories at regular intervals, and record the findings.

34

Provide adequate first-aid facilities with sufficient trained first aiders and appointed persons.

35

Consult with your employees on health and safety matters.

36

Engage only competent persons to carry out work on electrical installations and appliances.

37

Take measures to prevent or adequately control employees' exposure to harmful dusts and fumes.

38

Take the necessary steps to ensure that the health and safety of the public is not put at risk by works being carried out.

39

Allow only competent people to use plant and equipment and undertake a work activity for which they are competent to do so.

40

Ensure that guard-rails and toe-boards are installed on all working platforms where a risk

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assessment indicates that any person would be injured as a result of the fall. 41

Prevent hearing damage resulting from exposure to excess noise levels.

42

Prevent occupational health problems resulting from exposure to vibration.

43

Use only competent waste carriers and check their documentation regularly.

44

Carry out COSHH assessments and record the significant findings.

45

Protect the environment by preventing avoidable pollution by, for example, installing diesel oil tanks correctly. Employee duties / Responsibilities All employees must have a basic level of health and safety knowledge if they are to be safe when working on site and aware of their responsibilities to their Contractors and work colleagues.

2

To co-operate with the Contractors and follow any information, instructions and training that is provided.

3

Not to interfere with or misuse anything the Contractors has provided in the interests of health, safety and welfare.

4

Take reasonable care at all times and make sure that their actions or omissions do not endanger themselves or any other person.

5

Use all tools and equipment safely and in accordance with instructions given or training received.

6

Report any defects or potential hazards in equipment to the Contractors (or supervisor if appropriate) as soon as possible.

7

Make proper use of any safe system of work or mechanical means provided by the Contractors in connection with manual handling.

8

Only operate plant and equipment for which training has been provided and authority given to use.

9

Use the personal protective equipment supplied by your Contractors correctly, take care of it and report any loss or defects in the equipment.

10

Report to the Contractors any work situation that might present danger.

11

Not to erect, alter or dismantle scaffolding unless competent to do so or under the supervision of a competent person.

12

When operating goods hoists: keep the gates closed except when loading, etc. do not override any controls do not allow any passengers.

13

Use only the proper safe means provided for entering and leaving an excavation.

14

Do not block or obstruct any access or means of escape.

15

Make full use of any control measures provided to prevent or limit exposure to substances hazardous to health, and wear the personal protective equipment provided.

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Observe safe use and handling instructions for hazardous substances.

17

Do not use a mobile elevating work platform for any other use than as a work platform.

18

Co-operate with Administrative Authority Workplace Inspectors, as required.

19

Do not remove safety guards or render inoperative any safety device fitted to any plant or equipment.

20

Do not ride on plant or vehicles in unauthorised and insecure places.

21

Recognise the importance of personal hygiene, especially when working with substances harmful to the skin.

22

Never exceed the safe working load of any lifting equipment.

23

Understand and comply with all signs and notices that are displayed.

24

Wear ear protectors in designated areas where mandatory warning signs are displayed.

25

Know how to report accidents and to whom.

26

Follow all company and site health and safety rules.

27

Report to the Contractors any activity or defect relating to work at height that can be considered unsafe.

28

Use equipment and safety devices for working at height in accordance with training and instructions received.

29

Attend health surveillance procedures, as required, during working hours and at the expense of the Contractors.

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1.1.2.8 Powers of the Qatar Administrative Authority, Workplace Inspectors

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Set out below is a summary of the main powers which Inspectors possess when carrying out their duties under this Regulatory Document (Regulations). Officers of the Qatar Administrative Authority also have enforcement powers when dealing with matters concerning fire prevention.

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1.1.2.9 Qatar Administrative Authority Workplace Inspectors may do the following: 1

Prosecute a company or an individual for a breach of this Regulatory Document (Regulations).

2

Visit or carry out an inspection of a construction workplace at any reasonable time without giving prior notice, engaging the assistance of the police if necessary.

3

Issue a Prohibition Notice stopping a work activity where there is a risk of serious personal injury.

4

Stop the further use of any equipment if it is considered to be a serious risk to health or safety.

5

Issue an Improvement Notice requiring remedial work to be carried out within a specific time, where there is a breach of health and safety legislation.

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Investigate accidents or dangerous occurrences in the workplace.

7

Require that any designated part of a premise remains undisturbed for as long as is deemed necessary.

8

Investigate a particular work activity or any plant or equipment following a complaint or accident.

9

Take measurements, photographs and records as necessary.

10

Inspect or take copies of any books or records.

11

Demand the full co-operation of any person to assist them in their duties.

12

Demand information from a Contractor or employee and require them to sign a statement of their answers.

13

Remove or make safe any article or substance considered to be a source of danger or serious personal injury.

14

Require additional fire precaution work to be carried out on a construction site.

15

Provide information for Contractors and employees about hazards that may affect their health and safety at work.

16

Act as a source of information on construction health, safety and welfare at work.

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1.1.2.10 Penalties that can be awarded Qatar Labor Law Fourteen, Part Sixteen details the extent of penalties that may be charged upon the proof of violations regarding failure to comply with Qatar Construction Regulations.

2

The Contractor shall maintain an acceptable OHS performance at all times throughout the Contract duration. The criteria used for determining acceptable OHS performance are at the sole discretion of the relevant authority. The following items shall be taken into consideration when making assessments of acceptable performance; any stop work instructions issued to the Contractor

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(b)

any adverse comments arising from Occupational Health and Safety inspections

(c)

any adverse comments arising from Occupational Health and Safety audits

(d)

any adverse formal communication from the relevant authority to the Contractor regarding Occupational Health and Safety performance

(e)

any adverse formal communication between the Contractor and enforcing authorities or government organizations

(f)

any incidents occurring as a result of the Work undertaken by the Contractor.

Should acceptable Occupational Health and Safety (OHS) performance not be maintained by the Contractor then the relevant authority may take any action at their discretion in furtherance to their powers (see sections 1.1.1.8 and 1.1.2.8) or may impose the following penalties on the Contractor;

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No.

Unacceptable performance criteria Commencement of Work on the Worksite without an approved Occupational Health and Safety Plan

2.

Commencement of Work on the Worksite without an approved Occupational Health and Safety Manager / Officer appointed and employed on a full time basis at the Worksite

3.

Failure to conduct risk assessments and develop method statements prior to work activities being undertaken

4.

Failure to appoint competent persons for specified activities (other than OSH Staff)

5.

Collapse of any scaffolding, temporary works or excavation

6.

Use of electrical installations in an unsafe conditions or electrocution of any person

7.

Person falling from a height of more than 2 meters due to unsafe working environment

8.

Person working at height of more than 2 meters without fall prevention or arrest

9.

Failure to maintain acceptable housekeeping, site tidiness, waste collection or waste disposal

10.

Collapse of any crane or lifting equipment

11.

Overturning of any mobile plant, equipment or vehicle on the Worksite

12.

Use of cranes, lifting appliances, mobile plant, equipment or vehicles by operators without valid driving license and the related training certificate

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Use of cranes and lifting appliances without valid 3 party inspection / test certificate

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Person entering into a confined space without a permit to work

15.

Failure to provide safe access and egress at the Worksite and to the surround residential area

16.

Failure to provide and maintain proper welfare facilities , first aid box / kits and notice / sign board

17.

Failure to plan and implement fire prevention and firefighting arrangements considering level of risks, type of work, sufficient quantity of fire extinguisher, escapes, signage, escape routes etc

18.

Failure to posses and/or follow 'Permit to Work' system

19.

Permitting Contractor Personnel or Subcontractor's employees to enter the Worksite without proper PPE and clear identification

20.

Failure to conduct emergency drills at periods not exceeding 3 months throughout the duration of the Work

21.

Failure to notify the relevant authority of an incident or failure to provide an incident report to the relevant authority in a timely manner

22.

Failure to provide an accurate monthly OHS report or failure to provide a monthly OHS report in a timely manner

23.

Failure to hold a monthly OHS committee meeting or failure to provide the OHS committee meeting minutes in a timely manner

24.

Failure to attend meetings or other events related to OHS issues organised by the Employer

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1.1.2.11 Health and safety questionnaire The Contractor shall assess the level of knowledge of employees to ensure that they have the understanding and skills to undertake a work activity.

2

Well informed and safety-conscious employees are a key part of health and safety. Before they progress further, the following 20 questions should be carefully read and answered by employees, preferably in writing. At the end of their training or induction, employees should be asked the questions again. You, the Contractor, will then be able to compare the level of their knowledge after studying with the level it was before.

3

If you critically assess the answers you will gain an insight into your employees' need for further training and instruction.

4

Are you playing your part? Check against these questions.

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Are you aware that your company has a health and safety policy?

(b)

Have you read your company's health and safety policy?

(c)

Have you been trained to do the job you do or to operate the plant, machinery or tools you use?

(d)

Do you know who your Safety Representative is or who will represent you?

(e)

Do you know the procedures to be followed if you have an accident?

(f)

Are you aware of the first aid arrangements at your place of work?

(g)

Do you know where to get first aid?

(h)

Do you know where the accident book is kept?

(i)

Would you know what to do if there was a fire at your workplace?

(j)

Do you know how to raise the alarm in the event of fire?

(k)

Do you know the colour coding that is used for fire extinguishers?

(l)

Are you aware of any potentially harmful substances in your place of work?

(m)

Are you familiar with the identification symbols displayed on the containers of harmful and dangerous substances?

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Have you been issued with all the necessary personal protective equipment?

(p)

Are you fully aware of the hazards and risks in your job?

(q)

Are you aware of the health and safety rules applying to your job?

(r)

Do you know what you should do if you discover a potential risk to health and safety?

(s)

Can you identify a 'confined space'? Are you aware of the potential hazards confined spaces may present?

(t)

Are you aware of your company's Permit to Work system, if they have one?

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Do you use correct manual handling techniques when moving or lifting loads?

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1.1.2.12 Points to consider on implementing of health and safety 1

The following points can be used to stimulate thoughts and ideas whilst developing health and safety systems.

2

If you read them through and think about them carefully, there are many 'pearls of wisdom' that you can adapt to your circumstances. No one is accident-prone, they are just badly trained; or perhaps they are the wrong person doing the wrong thing in the wrong place at the wrong time.

(b)

No one wants accidents - not clients, not Contractors, and most of all not employees.

(c)

Safety culture in a company is when people act and behave safely even when no one is looking.

(d)

Personal protective equipment, however good it is, is no substitute for a proper safe system of work.

(e)

Hazards and risks! Eliminate the hazard (the thing that can cause harm) and you can forget about the risk (the chance of an accident occurring) forever.

(f)

Fire destroys property and jobs. Safe systems of work and safe people prevent fires.

(g)

Compliance with these Regulations gives a minimum standard. Do you personally accept minimum standards?

(h)

A safety policy cannot stop ill health or accidents, but the people who put the policy into practice certainly can.

(i)

First aid. If you can check the heart and the breathing, and stop the bleeding you might save a life. If you can't, then you won't.

(j)

In safety, good luck is planning meeting opportunity. Bad luck is just bad management.

(k)

Compliance with rules does not mean that you are doing everything that is 'reasonably practicable'.

(l)

Compliance with a rule or a regulation is not in itself a risk assessment.

(m)

You cannot insure against having an accident, it is just that the insurance company eventually pays some of the costs.

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Accident statistics only really tell you just how often you got things wrong in the past. Good health and safety performance should not be especially praiseworthy - it should be the expected norm.

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(p)

A conviction in a Qatar court of law for a health and safety offence will give you a criminal record.

(q)

The uninsured costs of an accident are always paid for out of profits, or they help towards causing losses.

(r)

Risk assessments. What's the hazard, what's the risk and what's the action?

(s)

Actions speak louder than words. If managers act safely, then the employees will follow the example.

(t)

The three essentials for health and safety are: safe people, safe places, and safe systems of work,

(u)

If you know where you are as regards health and safety, then and only then, can you decide where you want to go.

(v)

Every accident is the visible, the very highly visible, face of failure. Safe performance is the visible face of success.


(w)

If an employee said 'wouldn't it be a good idea if we sought further advice' I would rather the Contractors said MAYBE than NO.

(x)

If there is a system failure, don't just blame the system, do something about it.

(y)

Who? What? Why? Where? And how? Are all very good questions to ask when doing risk assessments?

(z)

“I'm alright. I've never had an accident yet”, are very famous last words.

(aa)

There is no such thing as an accident. Someone, somewhere, sometime did something to cause it.

(bb)

Safety has to start at the top; then, and only then, will it percolate down to everyone else.

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Safety Policies

1.1.3.1 Key points This Regulatory Document requires every Contractor to have a policy on how health and safety will be managed within the company.

2

The policy must explain how matters of health and safety will be organised within the company and the arrangements that the company has put in place for implementing the policy.

3

The policy should be periodically reviewed to ensure that it is still current, and amended when necessary, with the content and changes made available to all employees.

4

‘Off the shelf’’ health and safety policies, obtained from third parties are unlikely to contain sufficient company-specific content.

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A general statement of health and safety policy is the way in which a company sets out its intention to manage health and safety. It will vary from one company to another. There is no such thing as a 'standard' health and safety policy, as a company's policy must be clearly and directly related to its own operations.

2

It is common for companies to obtain policies via the internet or purchase them from third parties. These are generic, rarely reflect the type of work that is carried out and may lead a company into a false sense of security.

3

The content of the 'organisation' and 'arrangements' sections of the policy is specific to each company. If a generic policy is used it is quite likely that there will be serious omissions in its content and therefore in the way the health and safety is managed. Each company's policy must be based upon its own work activities, management and organisational structure, and staff competencies.

4

The act of compiling a health and safety policy, will focus the Contractor or senior member of staff to whom the Job is delegated on the day-to-day management of health and safety issues.

5

This will help them to become aware of shortcomings, duplications of effort and requirements for certain competences, which can then be rectified.

6

Evidence shows that companies with a well-structured and properly implemented health and safety policy, together with the organisation and arrangements for putting the policy into effect, have much better overall health and safety performance.

7

It is through the ongoing development of a company's health and safety policy that shortcomings can be identified and procedures put in place to help eliminate common causes of accidents and reverse this unenviable record.

8

A comprehensive and accurate health and safety policy is the basis of an effective management system.

9

There is no difference in the standard of protection required during a house extension compared to that for a major construction project; what is likely to differ is the complexity of the management system.

10

Health and safety, and the provision of proper welfare facilities, are crucial to the proper running of any building, construction or civil engineering project. They are not an add-on, an

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extra or an afterthought, but should be integrated with the normal day-by-day activities of project planning, tendering and management.

1.1.3.3 Competent contractor Contractors must be able to demonstrate how they effectively manage health and safety. If the company cannot demonstrate competence in health and safety issues, it may not be invited to tender in the future. It is no longer acceptable to simply state that the company has been in the industry for many years without experiencing an accident.

2

Generally, this Regulatory Document (Regulations) requires Contractors to provide for their employees a place of work that is safe and where risks to health are properly controlled. They are also required to ensure that people who are not their employees are not exposed to risks to their safety and health.

3

There should be a carefully planned and systematic approach to health and safety issues, where all risks have been assessed and the appropriate control measures put into place.

4

Irrespective of size, a company must have a general statement of health and safety policy in order to demonstrate to a client or to another contractor that it has committed itself to the principles of health, safety and welfare.

5

A health and safety policy is a statement of how a company will, within its overall business activities, manage health, safety and welfare for the benefit of its employees and all other persons who may be affected by the company's operations.

6

These Regulations require that a safety policy should cover three distinct aspects:

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A general statement of the company's health and safety policy highlighting the intent of the Contractors to have high standards of health and safety in the company, including what they intend to achieve and how they will achieve it.

(b)

The organisation within the company for the effective maintenance and implementation of the health and safety management system.

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The arrangements for the effective implementation and ongoing monitoring of the health and safety management system.

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1.1.3.4 Section 1 - The statement of policy 1

The statement of policy should demonstrate a clear commitment to health and safety from senior management by declaring how the company intends to manage health, safety and welfare matters in relation to employees and other persons.

2

It should specifically state the name of, and be signed by, the person responsible for health and safety, who should be the managing director or another director to whom responsibility has been delegated. The policy should be reviewed at least every twelve months and a new copy signed, dated and displayed to demonstrate that it is a live document.

3

There should be a declaration that the necessary resources will be provided to ensure the health and safety of all employees.

4

It is usual for the statement of policy to state the importance that the company places upon the health and safety of its employees and what is required of them to achieve the aims of the policy. It should also clearly state that all employees will be informed of the contents of

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the health and safety policy and that they will be consulted about its application. 5

An example of a General Statement of Health and Safety Policy for a medium-sized Contractor is given in Appendix 1.

1.1.3.5 Section 2 - Organisation This part of the document should: (a)

identify those people within the company who have specific health and safety responsibilities, including the person who has ultimate responsibility for health and safety

(b)

outline the methods by which health and safety procedures and other health and safety issues will be communicated

(c)

explain the methods by which the effectiveness of the health and safety management system will be measured, reviewed and updated where necessary.

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The section must clearly state 'who has to do what' in terms of health and safety. For example, it might say that the Contracts Manager will receive information from the Site Manager about accidents, how the results of investigations into those accidents will be managed, and that the Contracts Manager will notify the Administrative Authority when necessary.

3

It should also detail how health and safety information is to be discussed with and brought to the attention of employees, especially those with specific duties highlighted within the document.

4

It is important to remember that once this information is written down, if there is a serious accident, it will be used in court by the Administrative Authority (Administrative Authority). This means people need to be aware of their responsibilities, and have the competence to carry them out.

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1.1.3.6 Section 3 - Arrangements This part of the health and safety policy should clearly show the specific arrangements that a company has put in place for managing health and safety during its normal work activities. It should also detail how emergency situations and any other incidents would be handled both from a management and a site perspective.

2

One area for consideration is for companies to indicate how they compile risk assessments and develop safe systems of work. The arrangements in place in relation to compliance with the Construction (Design and Management) CDM Regulations (see Section 1.1.8 of the Regulatory Document) can should also be detailed to demonstrate how compliance with CDM is achieved.

3

The development of the arrangements section is likely to evolve over a period of time and, to an extent, reflect the findings of the company's risk assessments. It should encompass who is responsible, as well as what they will do and when and how they will achieve it. This section should:

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explain how the need for (health and safety) competencies and training are established and satisfied and, if necessary, what interim measures will be put in place whilst shortcomings exist.

(b)

outline the means by which health and safety consultation with the workforce will be achieved including, as necessary, reference to management and safety representatives and safety committees.

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(c)

explain the procedures for ensuring that sub-contractors have a satisfactory health and safety management system and exhibit safe working practices on site.

(d)

list the areas of risk and identify the person who is responsible for managing each risk.

4

Some of the elements that might need to be addressed are: Site activities Hot works

6

Piling

7

Electricity

8

Gas

9

Noise

10

Vibration

11

Confined spaces

12

Protection of the public

13

Authorisation for the use of plant and equipment

14

Asbestos

15

Lone working

16

Machine guarding

17

Portable hand-tool testing

18

Manual handling

19

Working at heights

20

Roofing

21

Scaffolding

22

Ladders

23

Cradles

24

MEWPs

25

Excavations

26

Hazardous substances

27

Working in occupied premises

28

Any trade-specific items e.g. loading and unloading plant.

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Administration procedures Emergency procedures

30

First aid

31

Fire

32

Means of escape

33

Accident reporting

34

Welfare facilities

35

Employee consultation

36

Monitoring procedures for the effectiveness of health and safety procedures.

37

The arrangements section of the policy must demonstrate clearly how the company plans to carry out its work activities and should identify all the specific site risks associated with them. This Regulatory Document (Regulations) requires that Contractors give their employees all the information, instruction, training and supervision that is necessary to ensure their health and safety. However, on small works of short duration or emergency repairs, detailed preplanning may not be possible. Employees may be sent to a client's premises or a customer's house at very short notice. This type of work may create a number of problems for employees, including the need for a short notice or on-site 'risk assessment', and the arrangements section of the company health and safety policy must cater for this type of eventuality.

38

The arrangements section of the policy should also cover the situation where a manager is unable to visit a possible work site whilst tendering or preparing a quotation for a job, but instead sends an estimator. In this case the estimator must be trained to assess the health and safety risks of the work, and to record the work to be done and the risk control measures necessary.

39

These notes should indicate all possible hazards, working height, obstructions, plant and equipment required. Detailed risk assessments can then be carried out and the associated method statements developed. This will allow for employees to be properly instructed on or informed about the work that they are to do.

40

Managing health and safety on a large site offers certain challenges, but it is normally far easier than dealing with a large number of minor works. This is purely down to the level of supervision and control that can be put in place.

41

There is a certain irony that typically it is the smallest and probably least resourced organisations that have the biggest challenges in terms of developing management systems.

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1.1.3.7 Updating of safety policies 1

This Regulatory Document (Regulations) requires Contractors to revise their safety policies 'as often as may be appropriate'.

2

Changes in the type of work carried out and changes in staff will also give rise to the need for a review of the policy. In addition, the policy should be regularly reviewed to ensure that it stays meaningful and relevant to the company's overall operations.

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1.1.3.8 Communication 1

Contractors are legally required to bring their health and safety policy and any subsequent revisions to it, to the notice of all employees. CDM emphasises the need for consultation with the people who carry out the work. Communicating the health and safety policy is a good way of doing this.

2

The only way to find out if the requirements of the policy are realistic and workable is to talk to the people who have to comply with them in the workplace.

1.1.3.9 Construction (Design and Management) CDM Under the CDM regulations (Section 1.1.8), the client is responsible for ensuring all contractors are competent.

2

The Engineer is appointed by the Client to advise and assist the client with his task and shall formally assess the competence of the Contractor, if requested.

3

Part of this assessment process must be a review and critical examination of the contractor's health and safety policy

4

CDM requires that companies bidding for work will compile a 'competence pack' to show how their policies, organisation and arrangements meet the stipulated core criteria for competency demonstration in implementing and managing health and safety.

5

The appendix to this section contains a suggested layout of a health and safety policy for a medium-sized company carrying out small building works. Not all of it will be relevant to some companies and, conversely, it may not contain specific content that some companies require.

6

For most companies, the General Statement of Health and Safety Policy should fit onto one page of A4 paper. The organisation and arrangements sections will be longer depending on the size of the company and the type of work that is carried out. Overall, the final document should be a clear indication to clients, employees and other interested parties such as the Administrative Authority that the company is honestly, openly and totally committed to the proper and effective management of all aspects of health, safety and welfare.

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1.1.3.10 The business case In addition to the legal considerations, for example, compliance with this Regulatory Document, there are very strong economic and social drivers for a robust health and safety policy and its proper implementation. The economic argument is that if there are fewer accidents on site and no occupational ill health, more employees will be at work, rather than off sick. This means improved business continuity with a greater prospect of completing projects on time, to budget and to the satisfaction of the client.

2

The social argument is similar. Clients and customers are far more likely to place business with a company who they see is behaving with integrity, and taking proper care of the health, safety and welfare of their employees and others who might be affected by the activities of the company.

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1.1.3 Appendix 1 GENERAL STATEMENT OF HEALTH AND SAFETY POLICY The Contractor will comply with his duties in order to provide a safe and healthy working environment for its employees and others affected by its activities. It will take positive action to ensure that other contractors' employees, occupiers of premises, and members of the public do not have their health and safety adversely affected by the work operations of the company. The only acceptable standard of health and safety, and for welfare facilities, will be full and proper compliance with the requirements of legislation. Where it is possible and practical to do so, the company will exceed the minimum requirements of the Qatar Regulatory Document (Regulations).

2

The company will seek to ensure that each company with whom it contracts or subcontracts aspires to a similar high standard of health and safety management.

3

In recognition of the importance that this company places on the engagement and wellbeing of its employees, the company will:

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consult, on health and safety matters, with its employees and others who may work under its control to ensure that the arrangements for health and safety management are practical to implement and effective

(b)

as far as is reasonably practicable, fully and effectively control the health and safety risks arising from its work activities, in co-operation with employees, other contractors, clients and other relevant parties

(c)

ensure that accident and ill health prevention is provided the highest priority, commensurate with business objectives, within all company operations

(d)

investigate lapses in health and/or safety performance and implement remedial actions to prevent, so far as is reasonably practicable, their recurrence

(e)

provide and ensure that all plant and equipment owned, used or hired by the company is appropriate, safe to use and properly maintained, inspected and tested

(f)

ensure that all equipment, materials and substances used by the company are appropriate for their intended use and used, handled and stored safely

(g)

ensure that all employees are provided with adequate supervisory training, information and instructions to competently carry out their work activities

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ensure that all working places are maintained in a safe and healthy condition provide adequate resources, including sufficient finance, and access to competent health and safety advice, to achieve the aims of this policy

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(i)

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(h)

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(a)

(j)

review and revise this policy statement at regular intervals and also where necessary due to changes in the company activities.

Signed:.......................................................... Designation: ...................................................................... Date: ............................................................. Review Date: ....................................................................

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ORGANISATION FOR HEALTH AND SAFETY MANAGEMENT The table below can be used to record the area of responsibilities with respect to the organisation for implementation of the policy.

5

First column: Description of the area of responsibility the overall and final responsibility for ensuring that the health and safety policy is properly implemented and that the health and safety standards are achieved and maintained.

6

Second column: Include the contact details of those with the identified responsibility (In addition to the person(s) named in the arrangements section of this policy) to ensure that health and safety standards are achieved, maintained and improved.

POSITION or NAME

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AREA OF RESPONSIBILITY

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Contractors

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The person with responsibility for approving the inclusion of each contractor on to the approved list of contractors is:

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The person responsible for vetting the health and safety procedures and past health and safety performance of contractors who bid for contracts, is:

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Health and safety management

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The person responsible for the management and updating of the health and safety management system is:

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The person responsible for monitoring the day-today standards of health and safety, and instigating improvements where necessary, is:

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 at the company offices:  on each site: The person responsible for compiling and communicating health and safety information to each site is: The person responsible for compiling and comparing year-on-year health and safety accident statistics is: The person responsible for ensuring that the statutory inspections of plant, equipment and places of work are carried out, and that certificates are obtained and displayed where appropriate, is:

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AREA OF RESPONSIBILITY (continued)

POSITION or NAME

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Liaison with senior management The person responsible for keeping senior management informed of day-to-day health and safety performance of the company is: The person responsible for informing senior management of any event which has attracted the attention of the Administrative Authority: The person responsible for submitting the annual health and safety report to senior management is:

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Health and safety procedures The person responsible for ensuring the adequacy of the scope and the accuracy of all health and safety procedures is: To effectively discharge this duty they will:  monitor the adequacy of existing health and safety procedures  develop new health and safety procedures as necessary  maintain the currency of all health and safety procedures  communicate any change to any health and safety procedure and the publication of new health and safety procedure to all users.

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Liaison with external agencies The person who is the contact for any enquiries from the Administrative Authority is: The person responsible for reporting reportable accidents and other reportable events to the Administrative Authority is: The person responsible for liaising with the fire and rescue service about onsite hazards or hazardous work activities is:

Worker consultation The person responsible for ensuring that an effective system of worker consultation is maintained is: The person responsible for ensuring effective worker consultation at site level is:

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Health and safety risks arising from work activities 7

The control of the risks associated with the work done by the company can only be achieved by the proper use of risk assessments. Risk assessments will be carried out for all work done by the company. They will be reviewed at regular intervals.

AREA OF RESPONSIBILITY

POSITION or NAME

Accidents

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The company will investigate accidents as necessary to establish their root cause and prevent recurrence. The investigation will be proportional to the seriousness of the event and its likely implications.



on each site:

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at the company offices:




on each site:

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The person responsible for investigating the causes of accidents and suggesting or implementing remedial action is:

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

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The person responsible for ensuring that all accidents are properly recorded in the accident book is:

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The person responsible for ensuring that completed accident records are securely stored at the company offices is:

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Asbestos

The company will investigate the possible presence of asbestos within its office premises and on the sites that it operates and if asbestos is found to be present, will properly manage it and record its presence in the asbestos register. The person responsible for the management of the presence of asbestos is: 




on each site:

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POSITION or NAME

Competency The company will provide induction training and job-specific training for all employees to ensure that they are fully competent to carry out the work that is required of them. The person responsible for assessing competency requirements and identifying shortcomings is; Competent health and safety advice

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The company will endeavour to fully and effectively consult its employees on matters of health and safety in such a way that upward feedback will be welcomed, evaluated and acted upon where appropriate.

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Employees' health and safety representatives who will provide two-way communication between management and employees are:

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Consultation with employees

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The responsibility for engaging competent health and safety advice lies with:

.

The company accepts that there will be occasions where expert health and safety advice is needed for dealing with matters outside the company's normal scope of work. On such occasions the responsibility for raising awareness of the need for competent health and safety advice lies with:

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POSITION or NAME

Electrical safety The company will endeavour to manage its work activities so that no employee is put at risk by electricity. The following persons are responsible for their respective areas of electrical safety:  Check for hidden services:  Check for underground services:

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 Office installation inspection and testing:

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 On-site installation inspection and testing:

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 The management of risk from overhead cables:

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The company will endeavour to ensure that no person is put at risk from the outbreak of fire. Fire risks will be addressed by a risk-based fire and evacuation plan for the company offices and one for each site.

qa

Emergency procedures - fire and evacuation

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Fire and evacuation plans will be drafted (and amended as necessary) by: at the company offices:



on each site:

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

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Deciding upon the range fire fighting appliances required and suitable locations for them is the responsibility of: 




on each site:

Arranging for the annual maintenance of fire fighting appliances is the responsibility of: Arranging for the maintenance of fire alarms (where fitted) is the responsibility of:

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POSITION or NAME

Emergency procedures - fire and evacuation (continued) Initiating and monitoring the effectiveness of office emergency evacuation (fire drills) is the responsibility of: Initiating and monitoring the effectiveness of on-site emergency evacuation (fire drills) is the responsibility of:

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Arranging for the training of selected employees in the use of fire fighting appliances is the responsibility of:

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The company will endeavour to organise work activities to eliminate or reduce the occasions when employees (or others) must enter an excavation or confined space. When entry into an excavation or confined space cannot be avoided, the company will ensure that the work is carried out in a safe manner by competent persons.

rw

Excavations and confined spaces

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The person responsible for developing safe systems of work, including rescue procedures, for working in excavations or confined spaces is:

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The person responsible for carrying out, or arranging, the training of employees to work in excavations and/or confined spaces is:

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The person responsible for ensuring the attendance of a rescue team during confined space working and their training is:

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POSITION or NAME

First aid, accidents and work-related ill health The company will provide sufficient trained first-aid staff and first-aid equipment to provide adequate cover at all places where company employees are working or make arrangements to share the first-aid arrangements made by others. First-aid box(es) will be provided at the following Maintaining and replenishing the first-aid box(es) will be the responsibility of: locations: Office:

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Trained first aiders or appointed persons work at These people are: the following locations:

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On site:

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Office:

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On site:

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Induction and further training

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The company will ensure that each employee receives an adequate initial induction into the company and further information, instruction and training to enable them to work without risks to the health or safety of any person.

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The person responsible for ensuring the effective health and safety induction into the company of new employees is:

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The person responsible for carrying out, or arranging for, the induction of new persons on site is: The person responsible for carrying out the induction of office-based staff is: The person responsible for compiling and updating the training record of each member of staff is: The person responsible for establishing the need for the additional training of any individual is:

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POSITION or NAME

Induction and further training (continued) The person responsible for carrying out, or arranging, the additional training of any individual, including delivering toolbox talks, is: Training records: will be kept at: by:

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The person responsible for ensuring that employees working at locations under the control of other contractors (Contractors) are given relevant health and safety information and supervision is:

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Supervision of young workers or trainees will be arranged, undertaken and monitored by:

Manual handling

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The company will endeavour to take all necessary measures to ensure that no employee is injured as a result of a manual handling activity.

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The person responsible for ensuring that employees are trained in the correct manual handling techniques, and that these techniques are applied, is:

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Monitoring the health and safety policy

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The company will periodically audit the effectiveness of its health and safety management system, in particular adherence to this policy. Audits will be carried out by: at the company offices: on each site:

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POSITION or NAME

Noise The company will ensure, so far as is reasonably practicable, that the hearing of no employee is damaged as a result of exposure to noise at work. Where necessary, noise assessments will be carried out to protect employees from hearing damage. The person responsible for arranging such assessments is:

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Where the noise survey indicates a noise level of 80 db(A) (lower exposure action value), ear protection will be provided by:

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assessing the need for health surveillance and arranging for it where necessary is the responsibility of:

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the setting up of hearing protection zones and ensuring that employees use the hearing protection provided by the company will be the responsibility of:

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Where the noise survey indicates a noise level of 85 db(A) (upper exposure action value):

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The person responsible for ensuring that no employee is exposed to a noise level above 87 db(A) (exposure limit value) is: Office safety

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The company will ensure that all work conducted in the company offices, including that of external contractors, is carried out without risk to the health or safety of any person. The person responsible for general office health and safety is: The person responsible for carrying out display screen workstation assessments is: The person responsible for ensuring that work in company offices by external contractors is carried out without risk to the health or safety is:

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POSITION or NAME

Permits to Work The company will ensure that where appropriate all potentially hazardous work activities are carried out under a Permit to Work system and that the system is robustly developed and monitored. The person responsible for determining whether or not any particular work activity should be carried out under a Permit to Work is:

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The person responsible for raising, co-ordinating and closing Permits to Work is:

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The person responsible for training, or arranging the training, of employees who will have to work under any form of Permit to Work is:

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The company will organise, so far as is reasonably practicable, its work activities in such a way that the use of PPE is not necessary. However, when it is deemed that PPE must be used, the company will ensure that appropriate PPE is provided and that adequate training in its use and maintenance is provided.

qa

Personal Protective Equipment (PPE)

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The person responsible for ensuring that all PPE provided by the company is suitable, issued free of charge, and maintains an issue log, is:

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The person responsible for ensuring that employees are instructed in the proper use of PPE and ensuring that it is used where needed is:

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POSITION or NAME

Plant and equipment The company will ensure that all plant and equipment is suitable for its intended use, well maintained, inspected/examined where appropriate and operators are trained in its proper use. Identifying appropriate items of plant which must be hired or bought is the responsibility of:

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Ensuring the continued serviceability and fitness for purpose of all plant and equipment is the responsibility of:

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Any employee discovering a defect in, or other problem associated with, an item of plant or equipment should report the facts to:

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Identifying the need for and arranging the training for plant and equipment operators is the responsibility of:

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Monitoring the requirement for routine servicing, testing, maintenance inspections and statutory examinations for all plant is the responsibility of:

Risk assessments / method statements

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The company will carry out suitable and sufficient risk assessments to cover all of its work activities.

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Pre-start site risk assessments will be undertaken and recorded by:

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Risk assessments for site-based activities will be reviewed at appropriate intervals and revised as necessary by: Risk assessments for the company's office-based work activities will be carried out, recorded and reviewed at suitable intervals by: Method statements for site-based activities will be compiled where appropriate and reviewed or revised as necessary by:

QCS 2014



POSITION or NAME

Safe handling and use of substances (COSHH) The company will ensure, so far as is reasonably practicable, that hazardous substances are handled, transported, used and stored in such a manner that the health of no person is harmed by their presence. All substances which require assessment will be identified by:

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COSHH

.

COSHH assessments will be undertaken, reviewed and amended as necessary by:

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The implementation and monitoring of all actions from COSHH assessments will be checked by:

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Providing at-risk employees with appropriate information from COSHH assessments is the responsibility of:

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on each site:

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Arranging for the safe disposal of residues and empty containers, is the responsibility of:

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Where necessary, health surveillance will be arranged by: Transport

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The company will ensure that it operates its transport in a way that does not put the safety of any person at risk.

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Where it is necessary to transport staff or materials by vehicle, either on or off site, the person responsible for ensuring that proper procedures are followed is: The person responsible for ensuring that all company vehicles are maintained in a legal, roadworthy and otherwise safe condition is: The person responsible for ensuring that workrelated road risks are properly managed is:

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POSITION or NAME

Vibration The company will ensure, so far as is reasonably practicable, that the health of no person is put at risk as a result of exposure to vibration resulting from the company's work activities. Where necessary, expert advice on vibration will be given or arranged by:

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The person responsible for implementing organisational and engineering controls, to control vibration at source or reduce exposure, is:

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The person responsible for assessing the need for health surveillance and arranging for it to be carried out, where necessary, is:

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The person responsible for ensuring that appropriate actions are taken if the level of personal exposure reaches the 'exposure action value' or the 'exposure limit value' is:

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The person responsible for monitoring employees' exposure to vibration on site and taking the appropriate actions, is:

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Welfare facilities

ov

The company will ensure that adequate and suitable welfare facilities are provided (or made available) for all staff.

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The person responsible for ensuring that adequate and suitable welfare facilities are provided or made available is:

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at the company offices: on each site: The person responsible for ensuring that welfare facilities are maintained and kept in a clean and order condition is: at the company offices: on each site: Arrangements for shared welfare facilities will be organised by:

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POSITION or NAME

Work at height The company acknowledges that working at height is a major cause of serious injuries and fatalities and will therefore endeavour to ensure that where such work cannot be avoided, it is carried out in a safe manner. The person responsible for deciding whether or not work at height can be avoided is: safe

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developing

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The person responsible for methods of working at height is:

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Young persons in the workplace

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The person responsible for ensuring that the employees who will carry out work at height are suitably and properly trained is:

qa

The person responsible for carrying out the inspections of places of work at height, is:

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The person responsible for carrying out the statutory inspections associated with the equipment used for work at height, or arranging for them to be carried out, is:

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The company will ensure that the health or safety of young persons is not put at risk due to their inexperience, curiosity, lack of hazard awareness or physical limitations.

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If one or more young persons are present in the workplace, the person who will ensure that the risk assessment is suitable and sufficient for their presence is: at the company offices: on each site: The person responsible for managing the presence of young persons in the workplace is: at the company offices: on each site:

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Consultation with Employees

1.1.4.1 Key points Employers, in particular Contractors have a duty to consult all their employees on matters of health and safety.

2

Consultation must involve two-way communication - Contractors passing relevant health and safety information to their employees and, conversely, seeking and encouraging the opinions and views of employees where appropriate.

3

Effective Contractors / employee consultation is an essential tool in highlighting potential problem areas, finding solutions and therefore maintaining a healthy and safe place of work.

4

Construction (Design and Management) CDM places a significantly increased emphasis on consultation.

5

The needs of employees, and others, whose understanding of Arabic and/or English is below average must be allowed for during the consultation process. Section 1, Part 6 of the QCS covers project meetings, Section 1, Part 17 covers project coordination and Section 1, Part 18 covers contractors.

ta

Note:

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Consulting employees on health and safety matters can be very important in creating and maintaining a safe and healthy construction working environment.

2

By consulting employees, a Contractor should motivate staff and make them aware of health and safety issues.

3

Businesses can become more efficient and reduce the number of accidents and work-related illnesses.

4

Consultation involves Contractors not only giving information to employees, but also listening to and taking account of employees’ opinions.

5

When an employee has raised a health and safety issue, it is essential that feedback is given on any decision taken so that the employee can be confident that their suggestions are considered and action taken where appropriate.

6

Where the need for consultation stems from changes to work practices, new work equipment or changes in organisation, etc, it is essential that the Contractor consults with the workforce at a sufficiently early stage to allow them to consider the implications and raise any queries.

7

Furthermore, there may be special considerations when carrying out consultation, such as to establish the needs of particular individuals, for example taking into account the requirements of employees with disabilities.

8

Every Contractor should, as part of their health and safety policy, have documented arrangements in place which outline how effective consultation will be achieved.

9

Consultation cannot take place if there is a barrier to effective communication, such as one of the parties having a limited understanding of Arabic and/or English, either spoken or written. This is becoming an increasing challenge.

10

Those people on site who have a responsibility for consulting with the workforce must identify any such barriers and determine ways in which they may be overcome, such as adapting the means of communication or using interpreters. It is highly unlikely that the use

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of a Labour gangmaster as an interpreter would be judged to be an acceptable means of consultation for the purpose of communicating health and safety information.

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1.1.4.3 Duty of the Contractors to consult It is the duty of the Contractor to consult with their employees in good time on health and safety matters. In particular: (a)

the introduction of any measure that will affect the health and safety of employees

(b)

the arrangements for appointing or nominating the person(s) to assist the Contractors in complying with this Qatar Regulatory Document (Regulations)

(c)

the provision of relevant information as required under this Regulatory Document (Regulations)

(d)

any planning or organisation of training required by this Regulatory Document (Regulations)

(e)

the health and safety implications of the introduction of new technologies into the Contractors' workplace.

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1.1.4.4 Persons to be consulted

Contractors may consult directly with all their employees or through 'representatives of employee safety' elected by a group of employees to represent them in health and safety consultation with the Contractors.

2

The Contractors must provide employees with a list of names of representatives of employee safety and the groups they are representing in the workplace.

3

In addition, the Contractors must inform employees of any changes in the form of consultation, such as a move from dealing with representatives to directly consulting with each employee.

4

Employee representatives must also inform the Contractors when they no longer represent a group or groups of employees.

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1.1.4.5 Provision of information The Contractors must provide all such information as the employees may require in order for them to participate fully in the consultation procedure. This will either be directly with all employees or with the elected 'representatives of employee safety'.

2

This information may cover what the Contractors proposes to do in relation to health and safety and includes giving the safety representatives an opportunity to express their views in the light of the information provided. The Contractors shall take account of the safety representatives' responses.

3

The issues the Contractors will consult on are:

4

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(a)

introduction of measures, at the workplace, which may substantially affect the health and safety of the employees

(b)

arrangements for obtaining or appointing the competent person to assist the Contractors to comply with health and safety requirements

(c)

information on risks to employees' health and safety and the measures taken to remove or minimise them.

Specific areas include: (a)

emergency procedures

(b)

first aid provision

QCS 2014


(c)

display screen equipment

(d)

manual handling

(e)

noise

(f)

asbestos

(g)

work at height

(h)

vibration management

(i)

work equipment

(j)

personal protective equipment

(k)

CDM

They may make representation on hazards, risks, dangerous occurrences, ill health and general health and safety matters, particularly those that the Contractors has a duty on which to consult.

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1.1.4.6 Functions of the representative of employee safety

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1.1.4.7 Training, time off and the provision of facilities

The Contractors must provide the employee representative with appropriate and reasonable training time and reasonable facilities to enable them to perform their functions.

2

This includes the Contractors meeting reasonable costs associated with training and time off to perform the function.

3

The employee is also protected from unfair dismissal or from being otherwise penalised when participating in consultation with Contractors on matters of health and safety in the workplace.

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ov

1.1.4.8 Construction (Design and Management) CDM The fundamental requirements under CDM, for competence, co-operation and co-ordination, imply a need for consultation between the various parties working on a project, at all levels. These requirements apply to all projects.

2

On all projects the CDM Regulations require that all contractors ensure that their workforce is properly consulted on matters which could affect their health or safety.

3

CDM uses the term 'worker engagement' rather than 'consultation'.

4

Worker engagement requires contractors and others to actively engage their workforce in the process of identifying and controlling risks as an essential part of accident and incident reduction; 'one-way consultation' should be a thing of the past. For this process to work successfully, the workforce must:

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(a)

be provided with a means of promptly reporting health, safety or welfare issues to a site-based supervisor or manager

(b)

have sufficient knowledge, gained through training where necessary, to appreciate where health, safety and welfare issues exist

(c)

have sufficient confidence, based upon their knowledge, to report suspected or known unsafe situations

(d)

be provided with feedback to ensure that the issue raised has been investigated and corrective action taken where necessary.

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5

In doing this, the Contractor will have to take into account the diversity of the work being carried out by the various contractors and self-employed people who will be on the project at the same time, and the duration of their particular work activity.

6

In that respect, each contractor, sub-contractor and designer has legal duties under CDM to consult amongst themselves regarding construction work and ongoing design, design changes and they all have a legal duty to provide information needed for the future stages of the project (post construction)..

1.1.4.9 The Management of Health and Safety at Work These Regulations require Contractors to provide information to employees on the arrangements for dealing with 'serious and imminent danger and danger areas'. The information required is the nature of the hazard and the measures taken to protect the employees from it.

2

In addition, Contractors must provide employees with comprehensible and relevant information relating to:

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health and safety risks identified by the risk assessment process

(b)

the preventative and protective measures established

(c)


(d)

health and safety risks that have been notified to the Contractors.

as

qa

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(a)

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1.1.4.10 Functions of the safety representative

er

Consultation with the Contractors Safety Representatives These Regulations require every Contractor to consult with safety representatives with a view to making and maintaining arrangements which will enable them and their employees to co-operate effectively in promoting and developing measures to ensure health and safety at work, and in checking the effectiveness of such measures. To achieve this, safety representatives should encourage co-operation between the Contractors and employees.

2

They should use the established methods of communication within the workplace to keep their members informed of matters affecting their health, safety and welfare at work.

3

Safety representatives will need to establish a close relationship with other appointed safety representatives, including those appointed to develop a common approach to their responsibility for the group or groups they represent.

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Investigation occurrences

and

reporting

of

significant

hazards

and

dangerous

1

This function is placed on the safety representative on behalf of all employees. In practice this means that the safety representative should bring to the Contractors notice unsatisfactory conditions, working practices or arrangements which come to their attention either during formal inspections or day-to-day observation.

2

Any such reports should normally be in writing. The report does not imply that all other conditions and working practices are safe and healthy, or that the welfare arrangements are satisfactory in all other respects. Making a written report should not preclude a direct oral approach to (for example) the supervisor or shift leaders in situations where speedy remedial action is necessary or where it can lead to an immediate resolution of the problem.

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It is important that the safety representative should have access to the Contractors competent representative responsible for safety. Responsibilities for safety should be clearly defined.

4

In order to fulfil their functions, safety representatives should keep themselves informed of the particular hazards and risks of the workplace. They should also keep themselves informed of the measures deemed necessary to eliminate or minimise the risks as set out in the health and safety policy of their Contractors, as well as the organisational arrangements for fulfilling that policy.

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Investigation of accidents in the workplace 5

Safety representatives should examine the causes of accidents at the workplace and make representations to their Contractors on behalf of all employees they represent using recording and reporting procedures like those outlined under 'Investigation and reporting of significant hazards and dangerous occurrences' above. Representation on general health and safety matters

6

Again, all employees should be represented and it is advised that similar recording and reporting procedures are used. Reception of complaints by employees

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The function of the safety representative in this area is similar to that of a shop steward; so the safety representative should ensure that there is no duplication of effort. It is advisable that recording and reporting procedures as outlined previously are used.

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Representation in consultation with the Administrative Authority

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Where safety representatives have been appointed they will be the appropriate persons to represent employees in any consultations with the Administrative Authority, or other Administrative Authority.

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Safety representatives should attend meetings of safety committees in their capacity as safety representatives in connection with any of their statutory functions.

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Attendance at meetings of safety committees

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These may occur in four distinct situations: on a regular basis

(b)

after a substantial change in conditions of work

(c)

after a notifiable accident, dangerous occurrence or contraction of a notifiable disease after remedial action has been taken.

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Inspections of the workplace

On a regular basis 11

Safety representatives are entitled to inspect the workplace, or part of it, at least every three months. However, there may be special circumstances in which safety representatives and their Contractors may wish to agree a different frequency of inspections for different areas or sectors of the workplace, for example, where there is an especially high risk or in rapidly changing circumstances. In all instances, agreement should be reached with the Contractors on the frequency of inspections.

12

Safety representatives must give Contractors reasonable notice in writing of their intention to carry out an inspection.

13

It is preferable that the Contractors and the safety representative should plan a programme of formal inspections in advance. This will fulfil the conditions as to notice. Variations in this planned programme should be subject to agreement.

14

There are advantages in formal inspections being jointly carried out by the Contractors or a representative and the safety representative, but this should not prevent safety

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representatives from carrying out independent investigations or having private discussions with employees. The number of safety representatives taking part in any one formal inspection should be agreed by the safety representatives and the Contractors in the light of particular circumstances and the nature of the inspection.

16

At large workplaces it may be impracticable to conduct a formal inspection of the entire workplace at a single session. In these circumstances, arrangements may be agreed for the inspection to be broken down into manageable units. It may also be appropriate, as part of the planned programme, for different groups of safety representatives to carry out inspections in different parts of the workplace. This can be either simultaneously or at different times, but it should be in such a manner as to ensure complete coverage before the next round of formal inspections becomes due.

17

The inspection may take various forms and the type to be carried out will be for the safety representative to agree with the Contractors.

18

Several types of inspection which, on their own or in combination, will over a period of time be appropriate:

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Safety auditing - systematic checking of every aspect of the company's operations.

(b)

Safety sampling - systematic sampling of the hazardous activities, processes or areas.

(c)

Safety surveys - general inspections of all work activities, processes or areas.

(d)

Safety tours - general inspections of the workplace.

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(a)

Safety representatives should record their findings and notify the Contractors of particulars.

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An inspection may take place after a substantial change in the conditions of work, or new and relevant information concerning hazards in the workplace has been published.

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After a substantial change in conditions of work

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After a notifiable accident, dangerous occurrence or contraction of a notifiable disease When there has been a notifiable accident or dangerous occurrence in a workplace or a notifiable disease has been contracted, safety representatives may carry out an inspection of the part of the workplace concerned and, so far as is necessary for the purposes of determining the cause, may inspect any other part of the workplace.

22

Where inspections are carried out, it must be safe for the inspection to be carried out and it must be in the interests of employees in the group or groups which safety representatives are appointed to represent.

23

Where it is reasonably practicable to do so, the Contractors, or their representative, should be notified of the safety representative's intention to carry out such an inspection.

24

It may be necessary, following an accident or dangerous occurrence, for the Contractors to take urgent steps to safeguard against further hazards. If the Contractors do this, they should notify the safety representative of the action taken and accompany this in writing.

25

The inspection must not interfere with any evidence or the testing of any machinery, plant, equipment or substance which could disturb or destroy the factual evidence before a Workplace Inspector from the appropriate Administrative Authority has had the opportunity to investigate the circumstances of the accident or occurrence.

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After remedial action has been taken 26

Where remedial action has been taken by the Contractors and the safety representative has been notified in writing, the representative should be given the opportunity to make any necessary re-inspection in order to satisfy themselves that the matter(s) notified have received appropriate attention. They should also be given the opportunity to record their views. It is advisable that a formal procedure is used.

27

Any remedial actions that are subsequently taken should be publicised throughout the workplace via the normal channels of communication and should be brought to the specific attention of the safety committee. Inspection of documents Safety representatives are entitled to inspect and take copies of any documents which the Contractors is required to keep, by virtue of any statutory provision, relevant to the workplace or to the employees represented.

29

The safety representatives must give a Contractor reasonable notice of their intention to inspect and take copies of documents.

30

In exercising this right, safety representatives should have regard to the circumstances and allow the Contractors a reasonable period of time. However, the Contractors must ensure access to the documents.

31

The only exception is documents consisting of, or relating to, any health record of an identifiable individual, unless the individual concerned has given their approval.

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1.1.4.11 Provision of facilities

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In addition to the facilities which Contractors must provide for inspections and consultations, the Contractors must provide whatever assistance may be reasonable in the circumstances.

2

Note: Throughout these Regulations, reference is made to the facilities that the Contractors have to provide to the safety representative. All parties should clearly understand that the facilities should be reasonable, allowing representatives to effectively fulfil their functions. The necessary facilities should be discussed and agreed on by all concerned.

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1.1.4.12 Establishment of safety committees 1

Consultation about forming a safety committee should cover membership, function, procedures and the meeting programme of the committee, and take into account start and finish dates of the contractors who will work on the project.

2

Once the committee has been established, the Contractors must post a notice stating the composition and the workplace to be covered by its activities.

1.1.4.13 Objectives and functions 1

The committee should be concerned with all relevant aspects of health, safety and welfare in the workplace.

2

It should draw up objectives and agreed terms of reference. These might include: (a)

study of accidents, dangerous occurrences, disease statistics and trends

(b)

examination of safety audits and other inspection reports

(c)

consideration of reports and factual information from the enforcing authorities

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(d)

reports which safety representatives may wish to submit

(e)

development of safety procedures and safe systems of work

(f)

effectiveness of the safety content of employee training

(g)

adequacy of safety and health communication and publicity in the workplace

(h)

the provision of a link with the appropriate enforcing authorities' inspectors

(i)

the appropriate input into risk assessments, etc.

1.1.4.14 Membership The number of management representatives should not exceed the number of employee representatives. Management representatives should be drawn from all levels of management and supervision, bearing in mind the needs of all contractors. In some instances, safety experts may be co-opted.

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1.1.4.15 Conduct

The frequency of meetings will depend on the nature of the workplace, and prior consultation should take place.

2

It is advisable that meeting programmes should be arranged with agendas and minutes, and that these should be published and freely available.

3

It is particularly important that the standing of the committee in relation to management representatives and safety representatives is clearly defined and that procedures for reaching decisions are understood.

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A safety representative or other employee cannot be dismissed for drawing the attention of a Contractor to genuine health and safety concerns.

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1.1.4.16 Employment protection

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Construction Site Safety 1.1.4 Appendix 1 Examples of information sought from Contractors 1

Information sought from Contractors on health and safety matters might be such as is detailed under the following headings. The list should not be taken as exhaustive.

General safety 2

Information relating to safety, health and welfare, such as: (a)

who the Contractors makes responsible for safety at the office, depot or site; and where that person can be contacted

(b)

the health and safety policy of the Contractors and the organisation, and the arrangements for implementing the policy

(c)

a list of members of any health and safety committees and a list of other safety representatives within the company or on site

(d)

the specific responsibilities of individual managers and supervisors for health and

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Section 11: Health and Safety Page 52 Part 1.01: Qatar Legislation and Management (Regulatory Document) safety in the company and on site. Details of existing procedures for:

(f)

the health, safety and welfare of the workforce and the established procedures for consultation and negotiation

(g)

the issue, maintenance and replacement of any personal protective clothing and equipment

(h)

obtaining first aid treatment

(i)

statutory inspections of the workplace, regular inspections and safety drills

(j)

warning notices and signs to be posted around the workplace and any signals which need to be made during the working day

(k)

accident reporting and investigation

(l)

dealing with unsafe acts and conditions at the workplace, including working with hazardous materials.

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Information relating to the health, safety, welfare and training of young people, such as: induction training, the general training methods to be implemented and the facilities available for that training and how they are to be used

(b)

the people responsible for training and the safety content of on- and off-the-job training

(c)

the provision of specific safety training for certain tasks and activities undertaken within the workplace

(d)

who sets and monitors the required safety standards in training

(e)

the records to be kept to indicate what training has been received; where those records are kept and by whom.

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Training of young people

Details of training related to the health, safety and welfare of adult workers, such as: (a)

the type of training available both on- and off-the-job and the duration of that training the training available and given to skilled, semi-skilled and unskilled people

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Training of adult workers

(c)

the extent to which retraining includes health and safety instruction

(d)

the methods of training which are currently being used

(e)

the arrangements for ensuring the effectiveness of the training given to workers whose first language is Arabic and/or English, for whatever reason, have a lower than average level of understanding of Arabic and/or English.

Training managers and specialists 5

Details of training related to health, safety and welfare of training managers and specialists, which is given when: (a)

any new work methods, equipment or materials are introduced into the company's operations

(b)

any new standards or legislation are introduced which affect the company's operations

(c)

the existing knowledge and skills of the workforce are inadequate to meet the requirements of the job.

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The company's organisation and activities 6

General information on health, safety and welfare related to the company's organisation and activities, such as: (a)

the organisation, structure and specific site organisation

(b)

the numbers of personnel employed for each of the categories of skills employed and of the specialists available for consultation

(c)

the methods of personnel recruitment, selection and placement policy

(d)

any significant changes in the company's activity, such as any proposed or anticipated expansion, or the end of contracts.

Access to documents

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Contractors need to maintain and provide access to the following health and safety information: first aid statistics, along with records of absence

(b)

details of both manufacturers' and suppliers' technical data

(c)

reports, Improvement and Prohibition Notices served by the Administrative Authority Workplace Inspectors

(d)

minutes of meetings, reports and any recommendations made by Safety Committees; reports of safety officers, etc.

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Health & Safety Training and Induction Training

1.1.5.1 Key points Construction and building sites can be dangerous places to work, even for experienced workers.

2

Everyone arriving new on site, whether new to the industry, experienced or even a temporary visitor, should be given an induction to the site.

3

Accident statistics show that the majority of accidents happen to people during their first few days on site.

4

The threats to health and safety will vary from site to site and even on the same site as work progresses and the hazards change.

5

An effective induction process is an essential part of on-site health and safety management.

6

The content of the induction presentation must:

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be understandable, comprehensive and relevant to the hazards present on site at that time;

(b)

anticipate and inform inductees of forthcoming changes to the hazards on site;

(c)

allow for the effective induction of inductees who do not have English as their first language or may otherwise have difficulty in understanding what is being said.

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It is a requirement of these Regulations that employees are provided with health and safety training whenever they are exposed to new or increased risks. When employees first arrive in the company or at a new site, this training takes the form of an 'induction'. It is accepted that providing proper and effective health and safety induction training can have a significant impact on the likelihood of accidents and injuries during a person's first few days, weeks or months with a company or on a particular site.

2

Given that every accident occurring to an employee can be seen as an eventual financial cost to the Contractors, then anything that can be done to reduce accidents is of direct financial benefit to the Contractors. The costs of giving proper and effective health and safety induction training are relatively minor when viewed against the cost benefits that can accrue from accident avoidance and prevention. This also applies to the prevention of long-term ill health and the avoidance of dangerous occurrences.

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1.1.5.3 Types of inductees 1

Mention of the word 'induction' or 'inductee' would cause many people to think of a person arriving on site or into the company totally new.

2

Whilst this is the case for some people, there will be a significant number of people who do not fall into this category. In wider terms inductees may be: (a)

young people joining the industry for the first time. This will generally be persons joining a company as trainees or apprentices

(b)

persons arriving at a new site even though they have been in the industry for some time

(c)

people transferring between companies within the industry

(d)

persons who have been promoted, for example, from tradesperson to chargehand

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3


It must be appreciated that different types of inductee will probably require different levels or styles of induction training because of their varying levels of knowledge, experience and competence within the industry.

1.1.5.4 Health and Safety at Work (Construction Sites) 1

This Regulatory Document (Regulations) requires that Contractors provide their employees with sufficient information, instruction, training and supervision as is necessary for their health and safety.

1.1.5.5 The Management of Health and Safety at Work These Regulations are more specific in that they require the following of the Contractors. (a)

Every Contractor shall, in entrusting tasks to employees, take into account their capabilities as regards health and safety.

(b)

Every Contractor shall ensure that employees are provided with adequate health and safety training:

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on their being recruited into the Contractors undertaking; and

(ii)

on their being exposed to new or increased risks because of:

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their being transferred or given a change of responsibilities within the Contractors undertaking



the introduction of new work equipment or a change regarding work equipment already in use within the Contractors undertaking



the introduction of new technology into the Contractors undertaking



the introduction of a new system of work or a change regarding a system of work already in use within the Contractors undertaking.

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These Regulations specifically require that:

the Contractor takes all reasonable steps to ensure that every worker is provided with a suitable site induction.

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contractors provide all of their workers with the necessary information and training which is necessary for their health and safety, including a suitable site induction, where it is not provided by a Contractor

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1.1.5.6 Construction (Design and Management) CDM

2

The above requirement on contractors to provide site inductions means that inductions must be carried out for all projects

3

The requirements of other Regulations which in themselves indicate a need for competence in certain work situations, when viewed against the type of work to be carried out, might indicate additional topics which need to be covered during site induction.

1.1.5.7 Contractors responsibilities 1

Refer to this section 1.1.2.7

1.1.5.8 Employee responsibilities 1

Refer to this section 1.1.2.7.

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1.1.5.9 Induction training It will be for the Contractors to decide when and where the training takes place. However, the sooner the induction training takes place the more opportunity there is to have a significant influence on the people being inducted. It is important that the induction training is seen as a formal company procedure, which the company provides for the benefit of the inductee, so that the Contractors can be seen to be meeting both the letter and the spirit of the law. If it is seen as 'something that is just necessary, we have to do it anyway' then it will fail to have the desired long-term effects.

2

The style and content of the presentation will vary between company and site. However, the person giving the presentation needs to have both the necessary skills and knowledge, together with the ability or 'presence' to deliver the programme effectively and in a meaningful manner.

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Induction difficulties

It is essential that the health and safety messages put across during site induction are fully understood. Possible barriers to learning will depend largely upon the training methods used. For example, reliance on written training materials will disadvantage those with dyslexia or other reading difficulties. Similarly, amongst the increasing number of workers who do not speak Arabic as their first language, some may find induction training of limited value unless thought is given to how it is delivered.

4

It is up to the person organising the training to establish the limitations of those undertaking induction, remembering that there may be a degree of embarrassment and, therefore, a reluctance to admit limitations.

5

To successfully induct those whose first language is not Arabic, but who have some understanding, it will probably be necessary to modify the presentation in style, speed of delivery and the aids used, depending upon the level of Arabic. Induction aids may need to be more visual, with less reliance upon the written word. Where there are operatives who do not speak Arabic at all, it is likely that specialist help, such as interpreters, will be required. There may also be scope for training someone on the site who speaks both languages to carry out specific induction sessions for specific groups.

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Induction content 6

Different companies will have different issues to include in the induction training. The requirements for on-site training will vary as work on the site progresses. In the early days there may be excavations, exposed reinforcing bars and other problems at ground level.

7

As the site and above-ground works progress, the hazards will change and it will be necessary for the emphasis in the health and safety training to change. As the site develops, temporary or permanent traffic routes may be introduced, or the circulation of traffic on site may need to change, for example, due to the repositioning of a crane or the installation of services. All these issues should be reflected in the induction training that will be provided for people arriving on site or as the project progresses. It is quite possible, or even likely, that the induction session delivered on day one of the project will not be valid after three months.

8

Part of the induction process must be to find out what the audience already knows, identify key areas that must be covered and use plain language, illustrating with diagrams, drawings and pictures to ensure that inductees can easily take in the information.

9

There will undoubtedly be other issues that are specific to a company or site and these will need to be considered and developed by the company concerned.

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Explain that at the end of the induction session, all inductees will be required to add their name and signature to an attendance sheet signifying that they have understood what they have been told.

1.1.5.10 Site and company rules 1

Obviously, users will amend the content in order to reflect the philosophy of their company, site or organisation regarding health, safety and welfare provisions. There may be items covered which you feel are inappropriate and these should be omitted.

2

Conversely, some additional items not covered may be of particular importance to your company, site or organisation and these should be included. Access

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Explain the rules regarding access to, and egress from, the workplace. Are there any oneway systems? Are there any prohibited areas? Are there any special rules or conditions applying to the site or workplace?

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The participants should be in no doubt of the requirements for reporting accidents. Explain when, where and to whom accidents must be reported and, in general, how they will be investigated. Your procedures may go beyond those required by legislation as a company policy decision.

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Asbestos

If asbestos or asbestos-containing materials are potentially present, it is essential to provide elementary asbestos awareness training, including details of any prohibited areas, to reflect the site conditions.

6

You should have a company policy for dealing with any material suspected of being asbestos and employees should be informed of this policy.

7

This may be along the lines of:

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'If you find any material that is off-white or crumbly, or any fibrous material that looks like dirty cotton wool it may be asbestos or contain asbestos, so leave it alone and if practical keep other people out of the area. Contact your supervisor and tell them what you have found.' Assembly points 8

See also Emergency evacuation. Explain where the assembly points are for site evacuation in the event of an emergency. Boundaries

9

Explain the boundaries of the site if there is no perimeter fence. Include the prevention of trespass. Buried services

10

Explain site or company procedures that should be followed if gas, electricity, telecommunications, fibre optics, water, sewerage and other buried services are discovered on site.

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Competence 11

You may need to advise employees and others of the levels of competence required for operating certain types of plant or carrying out particular pieces of work. CDM in particular places a legal duty on anyone who arranges for or instructs any worker to carry out construction work, to ensure that they are competent to do so. Confidential issues

12

Explain the provision for 'whistle blowing'. How can employees raise confidential (including medical) issues if the need arises? Confined spaces Explain the rules that apply on site. Many employees will fail to recognise that a confined space can be above ground, or be as innocuous as a sub-basement boiler room. Unfortunately, confined spaces have been responsible for a number of deaths in the industry, all of which could have been avoided by compliance with proper health and safety procedures.

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what is the mechanism for workers to bring any health and safety concerns they have to the attention of site management?

(b)

If there is a health and safety committee on site?

(c)

If so, who are the members?

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(a)

If there is a suggestion box or scheme, explain how employees can put forward ideas for improvements in health, safety and welfare, waste minimisation and so on, on a day-by-day basis.

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Contractors have a duty to consult the workforce on matters of health and safety, you must explain how such (two-way) consultation is achieved:

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The raised awareness of environmental matters makes the prevention of ground contamination of growing importance. Explain how employees can prevent spillage of diesel fuel, paint, oil, thinners, cement, concrete or any other substance that could lead to contamination.

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Contamination

COSHH (Control of Substances Hazardous to Health) 17

Explain the on-site procedures relating to hazardous substances. Are there any substances that are additional to the usual cement, oils, paints, etc.? Dangerous occurrences

18

Explain the policy in relation to the reporting of dangerous occurrences. It is thought that many go unreported as employees regard them as 'an accident where nobody was injured'. Dermatitis

19

Explain that contact dermatitis can be caused by some relatively common substances such as diesel and mould release oil, paints, thinners and cement. Gloves should be worn on appropriate occasions, and barrier creams should be used properly.

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These occasions should have been identified by the Contractors risk assessments. Discipline

21

Explain the company policy regarding breaches of this Regulatory Document (Regulations), site or company rules. Dress code

22

Explain the effects of sun exposure and the importance of preventing skin cancer. Explain company or site rules on whether shorts or sleeveless vests are permissible on site. Drugs Explain the rules about arriving on site or being on site under the influence of any nonprescribed controlled drugs, or taking these during the hours of employment. It may be that employees will be asked to leave the site.

24

The issue of prescribed drugs should also be covered as some of these can have side effects such as drowsiness. If the user is authorised to operate plant or drive vehicles, this needs to be addressed and resolved with the supervisor or management.

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What standard is used? What is the safe system of work for persons working on or near open or leading edges?

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temporary or permanent repairs by competent persons on site?

(b)

use of 240v equipment?

(c)

use of RCD or similar circuit breakers?

(d)

use of transformers and 110v equipment?

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Are there any other general rules regarding working with electricity?

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What are the site or company rules concerning:

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Electricity

Emergency evacuation 28

Explain site or company procedures. What is the siren or alarm? Where are the emergency evacuation assembly points? Emergency procedure

29

Explain the procedures to be followed in the event of an emergency other than fire. This may be civil disturbance, a bomb scare, structural collapse or other eventuality. Environment

30

Environmental pollution can include the air, as well as the ground or water. Explain any specific issues of environmental protection and control concerning the company or site. It is perhaps worth noting that dust, as well as smoke and fumes, can be considered an environmental pollutant.

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Escape routes 31

Explain the recognised escape routes on site and from buildings in the event of a fire or emergency.

32

Explain that access and egress routes must be - well-defined and kept clear. How are they marked? How will they be lit when it is dark? How will changes to the escape routes be notified as construction progresses? Excavations

(a)

excavation support

(b)

proper entry and exit from an excavation

(c)

edge protection around an excavation.

.

Explain the policy regarding:

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Explain if there are any specific eye protection problems, or rules applicable to the site or any particular work that is taking place. See also Personal protective equipment.

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Eye protection

You may wish to comment on the use of safety nets, safety decking, air bags and other similar systems.

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Fall-arrest

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Explain the hierarchy of control measures that are to be used on site to prevent persons from falling or to catch them safely if they do fall. This will obviously vary depending on the type of site and work undertaken.

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Fire

In the induction session, you should at least cover the following: (a)

fire precautions, fire prevention and good housekeeping who will be responsible for summoning the fire brigade

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Fall prevention

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location of: (i)

fire points

(ii)

fire extinguishers

(iii)

hose reels

(d)

training and competence in the use of fire fighting equipment

(e)

testing of the fire alarm

(f)

fire drills and practice evacuations

(g)

evacuation in the event of an on-site emergency

(h)

policy for 'hot works', including permits.

Explain the company or site policy regarding the burning of rubbish or 'bonfires'. On many sites, this is prohibited due to the danger of fire spreading and the environmental pollution caused by fires.

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First aid 39

If there is to be an on-site first-aid facility that can be used by all contractors, clearly explain the arrangements. (a)

Where is the first-aid kit?

(b)

Who are the first aiders, and how can they be contacted or identified?

(c)

Who are the appointed persons?

(d)

In the event of an accident requiring more than first aid, who will summon the ambulance or emergency services?

Flammable liquids If flammable liquids (such as paint thinners, solvents, spirit-based paints and others) are kept and used on site, explain the rules for:

(b)

withdrawal from storage

(c)

use

(d)

return to storage.

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Health and safety committee

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See also Consultation with employees. If there is a site health and safety committee (and this may also be reflected in earlier comments for CDM or Consultation with employees), explain the terms of reference for: the committee and membership

(b)

how often the committee meets

(c)

agenda items

(d)

how the outcomes of meetings are made known to employees on site (publication of minutes).

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Are there any mandatory protection zones on site? How are they marked? Explain the supply and issue of hearing protectors and when they should be worn.

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High visibility clothing 43

Explain the site or company rules for this clothing to be worn and clearly define the appropriate locations. Also clearly define the standard for high visibility clothing. Hoists

44

For passenger hoists: (a)

who is the competent person to operate the hoist?

(b)

if any person can operate it, do they need training prior to being authorised as competent?

(c)

if the controls are regarded as so simple that the hoist may almost be regarded as a public lift, is there any danger of controls being overridden?

(d)

what is the maximum number of persons permitted in the hoist?

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(e) 45

Section 11: Health and Safety Page 62 Part 1.01: Qatar Legislation and Management (Regulatory Document) which rules apply regarding goods carried in the hoist?

For goods hoists: (a)

who is the authorised competent person to drive it?

(b)

can any other persons be authorised?

(c)

what are the rules for closing the gates?

(d)

what is the safe working load?

(e)

explain that passengers cannot be carried.

Ladders/stepladders Explain the company standards for: securing or tying ladders/stepladders

(b)

use of ladders/stepladders for light work of short duration or gaining access

(c)

any restrictions imposed on the use of ladders and stepladders

(d)

movement of ladders around the site.

rw

.l. l

.

(a)

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46

If lasers are to be used on site, explain what class of laser is to be used and what, if any, hazards could be caused. Levelling lasers (used, for example, by suspended ceiling fixers) are not normally regarded as hazardous as long as appropriate health and safety rules are followed.

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as

47

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Lasers

Explain that different projects and clients will have different rules and that employees should understand the need for each rule and how it will be enforced.

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48

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Site Rules

Explain the following:

(b)

et it

49

o

Lifting equipment

(c)

testing and inspection of equipment

(d)

current colour coding, if such a system is used.

who has the authority to use lifting equipment of varying sizes and types the duties of slingers and signallers

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(a)

Lighting 50

Explain the site or company rules for provision of work lighting and emergency lighting. Include: (a)

the placing of luminaires

(b)

extra lighting during winter months or for work outside normal hours.

Liquefied petroleum gas 51

Explain the rules for: (a)

use and storage

(b)

separation of full and empty cylinders

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(c)

separation from oxygen and acetylene, as appropriate

(d)

use of hose check valves and flashback arresters

(e)

use of fire extinguishers.

Manual handling 52

Explain site or company rules regarding: (a)

the avoidance of manual handling wherever possible

(b)

the use of mechanical devices to aid manual handling

(c)

company policy or procedures regarding dense or heavyweight concrete blocks

(d)

the importance of good manual handling techniques including team lifting.

.l. l

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Medication

Some prescribed medicines, and some medicines which can be purchased from a Pharmacy without a prescription for problems such as hay fever, can cause drowsiness or other side effects.

54

Explain that anyone who is concerned that any medicines prescribed may affect their health and safety performance should discuss the matter with their supervisor.

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ta

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53

Explain the importance of supervisors discussing with employees the method statement to be used for particular tasks, and the benefits to be gained from employee input into method statements.

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Method statements

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Mobile elevating work platforms (MEWPs)

ov

Explain who has the competence to operate or use MEWPs. Give the evidence required to prove competence and training. Where can MEWPs be used? Where they are not allowed? Explain the use of safety harnesses when working from platforms.

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56

Explain the importance of reporting all incidents that are 'near misses'. These can then be investigated and the appropriate remedial measures put into place so that the next 'near miss' does not become an accident.

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Near-miss incidents

Needles and syringes 58

Because of the secretive nature of illegal drug use, these items may be hidden away, which can increase the danger to those finding them. Employees should be warned to be very vigilant, particularly regarding the discovery of used hypodermic syringes, razor blades (needles and needlestick injury’s).

59

Explain the action to be taken on:

60

(a)

finding discarded needles

(b)

receiving a needlestick injury.

It should be noted that most gloves in common use on site do not offer very much protection against a needlestick injury.

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Noise 61

See also Hearing protection zones. Explain the site or company rules concerning the use of equipment that produces excessive noise. Explain the use of hearing protection and noise control zones. Occupational health

62

Stress the importance for employees to report to supervisors any cases of ill health, as it may be potentially work-related. This is particularly important if employees are working where there may be rats, or if the area has been used for illegal drug taking and the related paraphernalia may be found. In the case of refurbishment and renovation works, there may be residual materials from previous occupants likely to cause ill health.

location

(b)

marking

(c)

allowable proximity for vehicles

(d)

working nearby

(e)

precautions.

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Permits to work

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Explain company or site procedures regarding issuing, working with and the cancellation of permits to work. Where 'lock off systems are used, explain the rules regarding padlock keys.

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(a)

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Explain the site or company rules on:

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Overhead electricity cables

Explain the site or company rules regarding: safety helmets

(b)

protective footwear

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(a)

(d)

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Personal protective equipment

(e)

respiratory protection

(f)

any other issues.

high visibility clothing eye protection

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(c)

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Remind the inductees that PPE in general, and respiratory protective equipment (RPE) in particular, should only be used as a means of last resort when all other control measures have been investigated and found to be impracticable. The need for PPE (apart from helmet, boots and high visibility clothing) should be covered in the risk assessment and method statement. Plant and equipment

67

Explain the site rules regarding: (a)

the authority to operate plant and

(b)

equipment, including the requirement for competence cards, where necessary

(c)

any type of plant/equipment that is prohibited, for example mains-powered hand tools

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(d)

the need for noise control where appropriate

(e)

the requirement for permits to work where appropriate.

Powers of Administrative Authority Workplace Inspectors 68

You may want to explain, in general terms, the powers that Inspectors have when they come on site and the requirement for employees to co-operate with them. Reporting defects Explain the importance of reporting all defects in plant and equipment, scaffolding, supports for excavations, and so on. Early reporting will bring about swift remedial measures and help to prevent accidents.

70

The possible consequences of not reporting defects may result in an accident or disciplinary procedures.

.l. l

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69

Explain whether there are any areas on site that are restricted to all people, or a specific class of people. Include what identifies a restricted area. Typical examples are areas where demolition, impact cleaning, water jetting, or asbestos removals are taking place.

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rw

Restricted or prohibited areas

Risk assessments

as

Explain the significant findings of risk assessments, as they will affect staff on site as a whole, or those working on a particular activity. It may be useful to explain the risk assessment process and the health and safety benefits that can be gained by employees. See also Method statements.

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Safe systems of work

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72

The crucial need arising out of risk assessments and method statements is for safe systems of work. Explain that site rules require employees to work in accordance with any safe systems of work that have been developed by the Contractors.

74

Explain also the benefits of working to a safe system of work and the potential for accidents and disciplinary action if it is not followed properly.

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Safety harnesses 75

Explain the company or site requirements for wearing and using safety harnesses and lanyards. See also Fall-arrest. Safety policy

76

Explain any relevant areas of the company's health and safety policy, together with the organisation and arrangements for the implementation of the policy. If relevant, explain where a copy of the policy is displayed on site. Safety signs and notices

77

Remind the audience that all employees must comply with all safety signs and notices at all times. Explain the whereabouts of any site notice board, and how changes and modifications to site rules will be made known to the workforce.

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Scaffolding (including mobile scaffolds)

79

Explain the site rules regarding: (a)

who is allowed to erect, alter or dismantle tube and fitting or system-built scaffolds

(b)

the implications (safety and disciplinary) of unauthorised dismantling or alteration of scaffolds

(c)

assessing competency to erect proprietary aluminium or tower scaffolds

(d)

the safe use of mobile tower scaffolds

(e)

safe access/egress to and from scaffolds.

Explain any other company or site-specific rules about the use of scaffolding as either a working place, or as access to the working place.

.

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rw

Explain whether any specific rules apply to pedestrian and traffic movement. This will depend on the size and complexity of the site. You may also include where contractors may lay down materials and which areas they may use for the prefabrication of components.

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Site layout

Security is very much allied to health and safety in that a breach of security can lead to trespassers on site and possible exposure to a risk of injury. Open a discussion if you have any particular company or on-site rules concerning security. Also consider the issue of health and safety awareness of site security staff, whether they are employees or a subcontracted security company.

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Site security

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Skin protection

It may be appropriate to discuss the need for skin protection, both in terms of gloves and barrier creams. If barrier creams are used, where are they dispensed? Also explain that the types of gloves used must be the most suitable for the levels of protection needed.

83

If it is likely to be a significant hazard, you should also include details of the risk of skin cancer associated with excess exposure to the sun.

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84

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Smoking

Explain the policy on smoking in the workplace and the canteen, clearly identifying those areas where smoking is not allowed. Include details of the measures taken to protect nonsmokers from the discomfort caused by tobacco smoke. Tidiness (housekeeping)

85

Explain the importance of maintaining a tidy site in order to eliminate many of the slip, trip and fall hazards. Include: (a)

rubbish skips

(b)

separation of waste

(c)

who is responsible for organising the delivery of and removal of skips

(d)

good housekeeping

(e)

sweeping up - general tidiness.

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Toilets 86

See also Welfare facilities. Explain the site or company rules regarding cleanliness, abuse of facilities and graffiti, and how such behaviour will be dealt with. Include the reporting of defects. Traffic routes

87

These are dependent on the size and complexity of the site.

88

Explain: one-way systems

(b)

the need to minimise or avoid reversing

(c)

signallers (formerly banksmen)

(d)

segregation of pedestrians from vehicles and machines - pedestrian walkways.

.l. l

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(a)

What training will be given to persons on site? Explain the need for all contractors to ensure that persons working for them on site have been trained and are competent to carry out the work they are required to do.

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Training

Due to the nature of the project or the ground, some sites will have specific issues to deal with and there may be the potential for a particular type of injury. Take the opportunity to explain this in order to prevent injuries occurring. For instance, working at height raises specific issues and working at height over or alongside water may introduce additional hazards.

Explain the site rules for the presence and operation of vehicles on site. Include: the parking of private vehicles

(c)

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(a)

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Vehicles

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Types of injury

(d)

keeping clear of site (working) vehicles

(e)

who is allowed to operate plant on site

(f)

providing proof of competence to operate plant

(g)

the security of vehicle keys when not in use

(h)

security measures to make vehicles unavailable to trespassers and children during non-working hours

(i)

traffic routes and speed limits

(j)

the need for signallers and slingers.

delivery vehicles, for example, constraints on the access to off-loading bays

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(b)

Vibration 92

Many people are still unaware of the problems that can be caused by high-speed rotary and percussive equipment. Explain the potential severity of vibration white finger and the company or site policy regarding:

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(a)

the use of vibrating equipment

(b)

the limitations of personal protective equipment

(c)

design and selection of tools and equipment

(d)

rest breaks and the rotation of work

(e)

the symptoms of vibration white finger

(f)

the need for employees to seek medical advice if they have any symptoms.

Waste disposal Describe the location of skips and other waste containers. Explain the segregation of waste. Who is responsible for the removal of waste from the workplace? Explain the company or site policy if contractors do not clear away their own waste.

.

93

rw

Explain that this is a financial issue as well as an environmental matter. It is also closely linked with site tidiness, pollution control, housekeeping and accident prevention. Effective waste minimisation is also an issue within sustainable construction and there are company and national benefits to be gained. There is more likelihood of a project being completed on time and to budget if waste is minimised.

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Waste minimisation

Welfare facilities

as

Explain:

the location of the welfare facilities

(b)

if appropriate, the opening hours of site canteens

(c)

responsibilities for the cleaning and maintenance of the facilities

(d)

the provision of barrier creams and rehydrating lotions

(e)

the need for good personal hygiene

(f)

the company policy regarding damage and graffiti

(g)

the location of facilities for men

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the arrangements (if any) made for smokers.

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(h)

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Working at height 96

This is allied to fall prevention, safe systems of work and PPE. Explain the company or site rules for: (a)

working at height, including safe systems of work

(b)

competence of employees

(c)

protection of those below, including the public (i)

the prevention of materials falling - use of containment and debris nets.

Working near, on or over water 97

Explain the site or company rules for working near, on or over water, including: (a)

the wearing of life jackets or life preservers or flotation devices

(b)

prevention of falls into water

(c)

safety harnesses

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(d)

the rescue of anyone who has fallen into water

(e)

safety lines and safety boats

(f)

lookouts

(g)

alarms.

Conclusion It is extremely important that records are kept showing which workers have attended site induction, together with details of the training they have received and the date it was carried out.

99

Appendix 1 of this module is an example of an attendance list that can be copied and used for record purposes on induction training. It may also be copied into a computer and electronic records maintained.

100

Appendix 2 is a checklist that can be:

'ticked' as appropriate and attached to the induction attendance list as a record of which topics were covered

(b)

used by the trainer to ensure that the important basic facts are included in an induction training talk.

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(a)

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Operatives may also find the checklist helpful in identifying gaps in their knowledge.

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Construction Site Safety 1.1.5 Appendix 1 Health and Safety Induction Training Title:

Date

Location

Start time

Duration (minutes)

End time

Presenter's name

Presenter's signature

Name of inductee's Contractors

Inductee's signature

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Inductee's name

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Construction Site Safety 1.1.5 Appendix 2 Induction training checklist

CDM

Competence

Confidential issues

Confined spaces


Edge protection

Electricity

Emergency evacuation Emergency procedure

Environment

Escape routes

Excavations

COSHH

et it

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Contamination

Competence

Risk assessments

Safe Systems of Work Safety harnesses

Safety policy

Safety signs and notices Scaffolding (incl. mobile scaffolds)

Eye protection

Fall-arrest

Site layout

Site security

Skin protection

Smoking

Tidiness (housekeeping) Toilets

Health and safety committee

.

Flammable liquids

                 

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Drying rooms

First aid

Hearing protection zones

rw

Buried services

Drugs

Fire

High visibility clothing

ta

Boundaries

Dress code

Fall prevention

Hoists

qa

Assembly points

Discipline

                    

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Asbestos

Dermatitis

se

Working near, on or over water

Dangerous occurrences

er

Accident reporting

                    

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Access

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                    

Ladders/ stepladders Lasers

Legal issues

Lifting equipment

Lighting

Liquefied petroleum gas Manual handling

Traffic routes

Training

Types of injury

Vehicles

Vibration

Waste disposal

Medication

Method statements

Mobile elevating work platforms Near-miss incidents

Needles and syringes Noise

Occupational health

Overhead electricity cables Permits to work

Personal protective equipment Plant and equipment

Powers of Inspectors Registration schemes Reporting defects

Restricted or prohibited areas Waste minimisation

Waste minimisation

Working at height

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General Health and Safety

1.1.6.1 The Management of Health and Safety at Work Contractors are required to access the risks to workers in their undertakings, and to any other person whose health and/or safety may be adversely affected by a Contractors work activities. The phrase 'any other person' clearly encompasses contractors, members of the public, site visitors, employees of other contractors etc.

2

Contractors are required to implements any protective or preventive measure to control a risk or risks, they must do so in line with the following general principles:

3

These include:

.

1

Avoiding risks where possible.

(b)

Evaluating the risks that cannot be avoided.

(c)

Combating risks at source.

(d)

Adapting the work of an individual with a view to alleviating monotonous work and reducing its effects on health.

(e)

Adapting to technical progress.

(f)

Replacing the dangerous with the safe or less dangerous.

(g)

Developing a coherent policy which influences the factors relating to the working environment.

(h)

Giving collective measures priority over measures that protect the individual.

(i)

Giving appropriate instructions to employees.

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(a)

Contractors have a requirement to make effective arrangements, as are appropriate for the nature of the work activities carried out and the size of the company, for the management of all aspects of health and safety. Contractors must record the arrangements made for the effective planning, organisation, control, monitoring and review of the preventative and protective measures implemented.

5

Contractors are required to ensure that employees are provided with health surveillance where the findings of a risk assessment identify risks to the health and safety of employees that can be eliminated or reduced by applying health surveillance techniques.

6

Health surveillance should be introduced where the risk assessment indicates that:

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7

(a)

there is an identifiable disease or adverse health condition related to the work concerned

(b)

there are valid detection techniques

(c)

there is a reasonable likelihood that the disease or condition may occur under the particular conditions of work

(d)

health surveillance has the potential to increase the protection of the health of the employees concerned.

Health surveillance techniques can be as simple as: (a)

hand-checks for the early signs of dermatitis being carried out by a site manager or supervisor, who has received the appropriate training, or

(b)

employees being asked to complete a short questionnaire on occupational health

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Section 11: Health and Safety Page 73 Part 1.01: Qatar Legislation and Management (Regulatory Document) issues.

Alternatively, health surveillance can necessitate the engagement of medically trained persons and specialist equipment, for example, audiometry (hearing) checks.

9

Contractors are required to appoint one or more 'competent persons' to assist them in interpreting and complying with Qatar health and safety legislation, where the Contractors does not have the necessary training, experience or knowledge to carry out this duty themselves. If more than one ‘competent person' is appointed, the Contractors must ensure that there is adequate co-operation between them.

10

Where the Contractors him/herself is not competent in matters of construction health and safety, the requirements of this Regulatory Document are normally satisfied by the employment of a suitably qualified and experienced health and safety adviser or the engagement of an appropriately experienced consultant.

11

The Contractors must ensure that any competent person who is not an employee, for example, a consultant, is adequately informed of all relevant facts in relation to site health and safety.

12

Given that in-house safety advisers or external consultants will usually only visit sites at a frequency that is deemed to be appropriate, the responsibility for the day-to-day management/monitoring of health and safety is often delegated to the site manager. In these circumstances, this regulation places a duty on the Contractors to ensure that the site manager is adequately trained and competent to discharge this duty.

13

A competent person is someone who has sufficient training and experience, or knowledge and other qualities, to enable them to properly assist the Contractors in complying with relevant health and safety legislation.

14

Competence may be indicated by membership of a recognised Institution of Occupational Safety and Health and/or possession of a qualification in Occupational Safety and Health from an appropriate accrediting body.

15

Contractors are required to implement procedures to be developed for any particular serious and - imminent dangers that may arise. This will very much depend on both the activities of the Contractors and the location. Fire is a real risk for everyone almost everywhere, but bomb threats in rural locations may not be.

16

Other serious and imminent dangers may relate to LPG, HFL, collapse of scaffold, excavations, confined spaces or virtually anything else. Again, Contractors should know their industry.

17

Once such procedures have been developed, the workforce must receive the appropriate information, instruction and training.

18

Contractors are required to establish contact with external agencies as necessary, particularly with regard to first aid, emergency medical care and rescue work.

19

Contractors must provide their employees with comprehensible (understandable) and relevant information on:

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20

(a)

the risk to their health as identified by any part of the Contractors risk assessments

(b)

any preventive or protective measures taken to eliminate or reduce the risks identified

(c)

any risks notified to the Contractors that arise out of the work activities of another Contractors.

Where there is more than one Contractor in the workplace, they must co-operate with each

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other with regard to health and safety, to enable both (or all if there are more than two) Contractors to fulfil their legal duties. This may require planning exchanges of information on hazards and risks, or deciding who works where and when and, on larger sites, a health and safety co-ordinator may be needed. The client, the Contractor or a nominated contractor may have, or have been given, by contract or arrangement, the co-ordination role.

22

Contractors are required to ensure that when allocating a task to any employee, the Contractor takes into account the employee's capabilities (knowledge, training, experience etc.) with regards to health and safety.

23

The Contractors also has a duty to ensure that employees are provided with adequate health and safety training:

upon being exposed to new or increased risk.

rw

This training must be:

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(b)

repeated periodically where appropriate

(b)

reviewed and adapted to take account of any new or changed risks

(c)

during working hours.

qa

ta

(a)

Employees are required to:

use all tools, equipment, dangerous substances, safety devices etc, in accordance with any training received.

(b)

report to the Contractors (or Contractors health and safety 'competent person') any work situation which the employee feels is not safe.

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(a)

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on recruitment

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24

(a)

.

21

Contractors (and in some cases self-employed persons) with regard to the employment of workers who are employed under a temporary contract or supplied by a Labour agency.

27

Before starting work, such workers must be supplied with comprehensible (understandable) information on: (a)

any special occupational qualifications or skills required to enable the temporary worker to work safely the requirement for any health surveillance arising out of the work to be carried out.

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(b)

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28

The above bullet points have obvious implications where temporary workers, whose first language is not English, are to be employed. See notes below.

29

Contractors are required to inform any Labour agency who are to supply temporary workers of: (a)

any special occupational qualifications or skills that must be held by the temporary worker(s) to enable them to work safely

(b)

any features of the work to be carried out by the temporary workers insofar as those features are likely to affect their health and safety.

30

Contractors should respond after notification that the employee is pregnant. Exposure limits, working conditions and working hours for such workers must be taken into consideration.

31

Contractors are required to specifically assess and review the risks to the health and safety of young persons who are on site. Due account must be taken of their lack of maturity or experience and their lack of knowledge of potential risks.

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it is necessary for their training

(b)

they are under the supervision of a competent person

(c)

the risks are reduced to the lowest level that is reasonably practicable

No Contractors may employ a young person for work which: (a)

is beyond their physical or psychological capacity

(b)

involves exposure to agents which are toxic, carcinogenic or otherwise have serious specific health implications

(c)

involves harmful exposure to radiation

(d)

involves the risks of accidents because of their lack of experience and/or training

(e)

involves a risk to health from extreme cold or heat, noise or vibration.

A 'young person' is anyone over the minimum school leaving age but under 18 years of age.

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34

(a)

.

33

Unless:

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1.1.6.2 Construction workers for whom Arabic is not their first language Contractors shall, in entrusting tasks to his employees, take into account their capabilities as regards health and safety.

2

Steps must be taken to ensure that effective two-way communication is established so that they can work safely and without risk to their health or to the health and safety of any other person who might be affected by their action or omissions.

3

Ultimately, if a contractor decides to engage workers who cannot speak and/or understand Arabic the situation will have to be managed. This could be achieved by the employment of a bilingual supervisor who, in the appropriate language, can give information, instructions, training and supervision. If a contractor is responsible for engaging workers who cannot speak English then the Contractor should ensure that the contractor provides suitable translators. Equally, the same criteria will need to be implemented on other smaller sites.

4

Contractors are required to ensure that employees are trained and competent for the job they have to do. Not being able to communicate using the language of the country of residence does not mean that workers are not competent in their trade. Provided they are here legally, it would be extremely unwise to ban workers who can prove their competence, just because they cannot speak the language effectively or fluently. Provisions for such situations can and should be made.

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1.1.6.3 Manual Handling Operations 1

These require that simple, common sense measures be taken to prevent injuries to workers resulting from carrying or otherwise moving loads manually.

2

Definitions of the terms injury, load and manual handling, all of which are as would be expected.

3

An injury is any injury, not just to the back, and would include cuts from sharp edges or broken toes caused by dropped objects.

4

A load is virtually anything, including a person, an animal, a bag of cement, heavyweight building blocks - in fact, any moveable object. The only proviso is that a tool is not a 'load' while it is being used. A Labourer carrying a chainsaw to a carpenter would be carrying a load.

5

Manual handling means transporting, supporting, lifting, putting down, pushing, pulling, carrying or moving anything by hand or bodily force.

6

Contractors are required to avoid manual handling operations which involve a risk of

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employees being injured, as far as is reasonably practicable and, where manual handling cannot be avoided, to carry out risk assessments and introduce alternatives to manual handling, control measures and appropriate training.

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Employees are required to make full and proper use of all equipment or systems provided by the Contractors.

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1.1.6.4 Provision and Use of Work Equipment 1

Every Contractor must ensure that all work equipment is constructed or adapted to be suitable for the purpose for which it is intended.

2

Definition of work equipment: Any tool or piece of equipment for use at work.

3

There is a non-exhaustive list of work equipment, and construction-related examples including: dumper truck

(b)

ladder

(c)

air compressor

(d)

crane

(e)

tractor

(f)

hoist

(g)

mobile work platform

(h)

hammer

(i)

lifting sling

(j)

podger

(k)

drill bit

(l)

socket set

(m)

scaffolding.

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(a)

Use is defined as any activity involving work equipment.

5

All vehicles used on site are covered by these Regulations.

6

Contractors are required to ensure that work equipment is suitable for the purpose, and only used under conditions for which it is suitable.

7

Contractors are required to ensure that work equipment is properly and adequately maintained.

8

Contractors are required to ensure that specific risks are identified, information and instructions to employees and the training of employees take place.

9

Contractors must ensure that all work equipment, whether European Conformity (CE) marked or not, complies with all current British or International standards.

10

The basic principle is that every dangerous part of any machine or piece of equipment must be effectively and properly guarded at all times, but provisos do exist for certain circumstances, such as the use of push sticks on woodworking machines.

11

Controls should be efficient, effective, easy to use, clearly marked and easily accessible. The main requirement is to provide safe equipment for the employee, with controls that allow it to be used in a safe manner. It goes without saying that emergency stop controls feature quite significantly.

12

Contractors are required to ensure that lighting must be suitable and sufficient, taking account of the work operation in progress.

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13

Contractors may also have to consider the need for both access lighting and task lighting.

14

Contractors are required to ensure that all ‘markings’ must be clear and appropriate, and 'warnings' which may be audible or visible and they must be unambiguous, easily perceived and easily understood.

1.1.6.5 Personal Protective Equipment The main consideration when dealing with personal protective equipment is that it should always be the last form of protection, or control, considered for the protection of the employees' health and safety.

2

No distinction is made between equipment and clothing. Personal protective equipment (PPE) includes all types of respiratory protective equipment (RPE).

3

Contractors are required to ensure that personal protective equipment is suitable and provided, where a risk cannot be adequately controlled in some other manner.

4

Contractors are required to ensure compatibility if more than one item of personal protective equipment needs to be worn at any time, so that one item does not detract from the protection offered by another.

5

This is of particular importance to the building and construction industry as, on many occasions, a combination of safety helmet, eye protection, ear protection or respiratory protection needs to be worn.

6

Contractors are required to ensure assessments to be made of the suitability of the equipment with regard to the nature of the risk.

7

The requirements of the assessment are specified and, in general, require the problem to be thought through in a structured manner and - the right equipment chosen for the right reasons.

8

A key factor is the competence of the person carrying out the assessments. If they do not get it right, the consequences for the health and safety of employees could be very serious.

9

Assessments must be reviewed when they become out of date or there are any significant changes.

10

Contractors are required to ensure that personal protective equipment provided shall be properly maintained, cleaned or replaced as appropriate; that adequate and suitable storage or accommodation is provided for it; and that employees receive all necessary information, instruction and training.

11

Training must be comprehensible and the question of language use must be considered.

12

Employees are required to use personal protective equipment in accordance with any instructions or training given, and to report any loss or defects.

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Construction Site Safety 1.1.7

Risk Assessments and Method Statements

1.1.7.1 Interpretation “contractor” means any organization or person who carries out or manages construction work or a place of work and includes any ‘employer’ or ‘self-employed’ in relation to a business

2

“business” means a trade, business or other undertaking including construction work (whether for profit or not)

3

Construction work means the carrying out of any building, civil engineering or engineering construction work and includes:

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the construction, alteration, conversion, fitting out, commissioning, renovation, repair, upkeep, redecoration or other maintenance, de-commissioning, demolition or dismantling of a structure;

(b)

the preparation for an intended structure, including site clearance, exploration, investigation and excavation, and the clearance or preparation of the site or structure for use or occupation at its conclusion;

(c)

the assembly on site of prefabricated elements to form a structure or the disassembly on site of prefabricated elements which, immediately before such disassembly, formed a structure;

(d)

the removal of a structure or of any product or waste resulting from demolition or dismantling of a structure or from disassembly of prefabricated elements which immediately before such disassembly formed such a structure; and

(e)

the installation, commissioning, maintenance, repair or removal of mechanical, electrical, gas, compressed air, hydraulic, telecommunications, computer or similar services which are normally fixed within or to a structure

(f)

Any associated temporary works associated with construction works and a work activity

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(a)

Work activity means any activity part of construction work and includes temporary works

5

“Young person” means any person who has not attained the age of eighteen. A young person under 16 years of age cannot be employed at all in a Qatar workplace, as per Qatar Labour Law 14, Article 86.

6

These duties are held by the contractor who carries out the work, irrespective of whether he is an employer or is self-employed.

7

These duties are also held by those who do not do construction work themselves, but control the way in which the work is done or manages construction work or owns and manages a place of work.

8

‘Suitable and sufficient’ means the risk assessment should identify the risks arising from or in connection with the work and the level of detail should be proportionate to the risk. The level of risk arising from the work activity should determine the degree of sophistication of the risk assessment.

9

A method of work shall mean a method statement describing the logical sequence of how a work activity is to be carried out safely and without risk to health

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1.1.7.2 Risk assessment

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1

2


Every contractor shall make a suitable and sufficient risk assessment: (a)

To the health and safety of his employees to which they are exposed whilst they are at work; and

(b)

To the health and safety of persons not in his employment arising out of or in connection with his undertaking

Any assessment referred to in paragraph (1) shall be reviewed if: (a)

There is reason to suspect that it is no longer valid; or

(b)

There has been a significant change in the matters to which it relates.

A contractor shall not employ a young person unless he has undertaken or reviewed his risk assessment in accordance with paragraphs (1) and (4) below in relation to risks to the health and safety of young persons.

4

In making or reviewing the assessment, a contractor who employs or is to employ a young person shall take account of:

The lack of awareness of risks in relation to the work to be undertaken and or the risks impacting on the role of young persons

(c)

The extent of the health and safety training provided or to be provided to young persons

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(b)

Any risk assessment referred to in paragraph (1) shall take into account language difficulties and language barriers of employees

(b)

safety culture and other behavioural safety issues of employees

(c)

The development and implementation of effective techniques as essential mitigations to (a) and (b) above.

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The contractor shall record:

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(a)

The significant findings of the risk assessment; and

(b)

Any group of his employees and others identified by it as being especially at risk.

(d)

the controls to be put in place to control risks

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The contractor is required to ensure that employees are provided with health surveillance where the findings of a risk assessment identify risks to the health and safety of employees that can be eliminated or reduced by applying health surveillance techniques.

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The inexperience and immaturity of young persons;

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1.1.7.3 Method of work 1

Risk assessment shall be supported by effective and suitable written method of work describing the logical sequence of how a work activity is to be carried out in a manner which is safe and without risk to health.

2

Any written method of work referred to in paragraph (8) shall be developed by a competent person who has knowledge and experience of the work activity being assessed and its development shall involve consultation with those undertaking the work activity.

3

Any risk assessment and method of work referred to in paragraph (1) and (8) respectively shall be developed before undertaking of any work activity and shall be communicated to and acknowledged by those who will undertake the work activity.

4

Any risk assessment and method of work referred to in paragraph (1) and (8) respectively shall identify the requirements for the contractor to provide for his employees: (a)

information about how to undertake the work safety and without risk to their health

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(b)

implementation of instructions for undertaking the work safety and without risk to their health

(c)

identify and conduct necessary training to employees so that they have the understanding and skills to undertake the work activity without risk to their health and safety

(d)

implementation of supervision of the work

Note

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Guidance on Risk assessment and written method of work can be found in Section 2.4 (Section 11, Part 2 of QCS).

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1.1.8


Construction (Design and Management)


The overall concept of Construction (Design and Management) (CDM) regulations is to focus on planning, design and management to improve health and safety standards on Qatar construction industry without creating unnecessary paperwork and bureaucracy.

1.1.8.2 Introduction The key aim of the CDM Regulations is to integrate health and safety into the management of construction projects and to encourage everyone involved to work together to: (a)

improve the planning, design and management of projects from the very start involving subject matter experts to ensure that risks associated with all aspects of business, particularly in terms of hazardous activities are properly assessed;

(b)

identify hazards early on, so they can be eliminated or reduced at the design or planning stage and the remaining risks can be properly managed;

(c)

target effort where it can do the most good in terms of health and safety; and

(d)

discourage unnecessary bureaucracy.

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These Regulations are intended to focus attention on planning and management throughout construction projects, from design concept onwards. The aim is for health and safety considerations to be treated as an essential, but normal part of a project’s development – not an afterthought or addition.

3

The effort devoted to planning and managing health and safety should be in proportion to the risks and complexity associated with the project. When deciding what you need to do to comply with these Regulations, your focus should always be on action necessary to reduce and manage risks. Any paperwork produced should help with communication and risk management. Paperwork which adds little to the management of risk is a waste of effort, and can be a dangerous distraction from the real business of risk reduction and management.

4

Time and thought invested at the start of the project will pay dividends not only in improved health and safety, but also in: reductions in the overall cost of ownership, because the structure is designed for safe and easy maintenance and cleaning work, and because key information is available in the health and safety file;

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(b)

reduced delays;

(c)

more reliable costings and completion dates;

(d)

improved communication and co-operation between key parties; and

(e)

improved quality of the finished product.

1.1.8.3 Definitions / Interpretations 1

Client: A client means a person or an organisation or a company who seeks or accepts the services of another person, organisation or company to carry out a project for him. The Client can carry out the project himself.

2

Designer: Any person or organisation or company who in the course of a project or business prepares or modifies a design; or arranges for or instructs any person under his control to do so.

3

Design: Includes drawing, design details, specification, bills of quantities and calculations

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prepared for the purpose of designing all aspects of a structure or any products or electrical or mechanical systems intended for a particular structure. Construction work: Any building, civil engineering or engineering construction work. It includes any of the following: any construction, alteration, conversion, fitting out, commissioning, renovation, repair, upkeep, redecoration or other maintenance, cleaning (using water, abrasives at high pressure, or the use of corrosive or toxic substances), decommissioning, demolition or dismantling of a structure

(b)

preparatory works including site clearance, exploration and investigation (but not site survey) and clearance or preparation of the site or structure for use or occupation

(c)

assembly of prefabricated structures or their disassembly

(d)

demolition or dismantling of any structure and the removal of materials and waste.

(e)

fabrication of elements which will form parts of offshore installations

(f)

the construction of fixed offshore oil and gas installations at the place where they will be used

(g)

the installation, commissioning, maintenance, repair or removal of mechanical, electrical, gas, compressed air, hydraulic, telecommunications, computer or similar services which are normally fixed within or to a structure.

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The activities listed below have been defined as not being construction work. However, given the complexities of many modern projects, thought may have to be given to how health and safety is managed in connection with these activities where they form a part of the project to which CDM otherwise applies: putting up and taking down tents

(b)

normal maintenance of items of plant unless it is structural work, for example, maintaining a large silo, chemical or nuclear reactor

(c)

tree planting and general horticultural work

(d)

work with removable lightweight

(e)

partitions, such as those used to divide open-plan offices or to create exhibition stands and displays

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(f)

erection of scaffolds for support or access in non-construction work surveying - this includes taking levels, making measurements and examining a structure for faults

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(h)

work to or on vessels such as ships and mobile offshore installations

(i)

off-site manufacture of items for later use in construction work (for example, roof trusses, pre-cast concrete panels, bathroom pods and similar prefabricated elements and components)

6

Engineer: Refer to QCS – Section 1 (General) – Part 1 (Introduction) – 1.4 (Terms and Definitions).

7

Contractor: Refer to QCS – Section 1 (General) – Part 1 (Introduction) – 1.4 (Terms and Definitions).

8

Sub-Contractor: means any person or organisation selected by the contractor for execution or management of construction works. A sub-contractor works under the control of the Contractor on site.

9

The construction phase starts when actual construction work on the project commences, and normally ends on the transfer or handing over of the structure to the client. If there is

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more than one structure (or building), the construction phase does not end until the work on the last structure is complete. 10

Construction Phase (Health & Safety) Plan: The Contractor must develop a plan suitable for managing health and safety in the construction phase of the project, which includes developing information provided by the client, designer and Engineer. This must be completed, submitted and approved as suitable and sufficient by the client before construction work on site can proceed.



who is responsible for what



the hazards and risks which have been identified



how the works are controlled

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The Construction Phase (Health & Safety)) plan is the foundation for good management and clarifies:

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The plan should be regarded as a live document, reviewed at regular intervals and, where necessary, amended to reflect changes in the scope of work or programme changes where the planned interface of trades may alter. Construction site: includes any place where construction work is being carried out or to which the workers have access, but does not include a workplace within it which is set aside for purposes other than construction work.

12

Principles of Prevention: means the hierarchy of hazard and risk control specified in section 1.1.8.6 and which applied to every duty holder and everyone on a construction project.

13

Project: means an undertaking (whether for profit or not) which includes or is intended to include construction work and includes all planning, design, management or other work involved in a project until the end of the construction phase.

14

Structure: This is defined as: any building, any masonry, timber, metal or reinforced concrete structure, railway line or siding, dock, harbour, inland navigation, tunnel, shaft, bridge, viaduct, waterworks, reservoir, pipe or pipe-line, cable, aqueduct, sewer, sewage works, gasholder, road, airfield, sea defence works, drainage works, earthworks, lagoon, dam, wall, caisson, mast, tower, pylon, underground tank, earth retaining structure or structure designed to preserve or alter any natural feature, fixed plant and any structure similar to the foregoing;

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(b)

any formwork, falsework, scaffold or other structure that provides temporary support or access

1.1.8.4 Co-operation 1

These Regulations require that every duty holder involved in a project: (a)

2

seeks the co-operation of any other person involved in any project, whether on the same or an adjoining site co-operates with all other persons involved in any project, whether on the same or an adjoining site

So far as it is necessary for all persons involved in the project(s) to comply with their duties or functions under these Regulations.

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3

Every person involved in a project, who is working under the control of another person, must shall inform that person of anything believed to endanger the health or safety of himself or others.

4

Common examples of co-operation are: (a)

one contractor allowing the workforce of another company to use their scaffold to enable work at height to be carried out safely.

(b)

site management on one site allowing oversailing by a tower crane on an adjacent site.

(c)

Designers of a project providing residual hazard and safety information to another designer on an interfacing project.

(a)

carrying out construction work; and

(b)

otherwise affected by the construction work

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These Regulations require that every duty holder involved in a project co-ordinates their activities with the activities with one another in a manner which ensure so far as is reasonably practicable the health and safety of persons who are:

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1.1.8.5 Co-ordination

There are many examples of where the various contractors involved in a project can coordinate their work activities, agreeing who works where and when so that construction work runs smoothly and without the risks created by one set of workers endangering the health and safety of other workers.

3

All construction projects require co-operation and co-ordination between all members of the project team. For low risk projects, a low-key approach will be sufficient. In higher risk projects, for example those involving demolition, a more rigorous approach to coordination, co-operation and planning will be needed. Under the Regulations, any action taken should be in proportion to the risk which the work creates. The architect, lead designer or contractor who is carrying out the bulk of the design work should normally co-ordinate the health and safety aspects of the design work; the main Contractor should co-ordinate construction work.

4

It is vital that those doing the work understand the risks involved and what to do about them. If the risks are low and the precautions well understood by those carrying out the work, then there will be no need for a written health and safety plan. Where the risks are higher, a written comprehensive construction phase health and safety plan will be required. for example where the work involves:

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(a)

structural alterations;

(b)

deep excavations, and those in unstable or contaminated ground;

(c)

unusual working methods or safeguards;

(d)

ionizing radiation or other significant health hazards;

(e)

nearby high voltage power lines;

(f)

a risk of falling into water which is, or may become, fast flowing;

(g)

diving;

(h)

explosives;

(i)

heavy or complex lifting operations;

(j)

demolition works.

A comprehensive construction phase health and safety plan will be required.

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1.1.8.6 Taking account of the general principles of prevention 1

These Regulations require that: (a) Every person involved on a construction project, in relation to its design, planning and preparation shall take account of the general principles of prevention in the performance of those duties during at all the stages of the project. (b) Every person involved on a construction project, in relation to the construction phase of a project shall ensure so far as is reasonably practicable that the general principles of prevention are applied in the carrying out of the construction work

.

When considering what precautions are necessary to control risks associated with a project, everyone who has a duty under these Regulations must take account of the general principles of prevention specified below: avoiding risks;

(b)

evaluating the risks which cannot be avoided;

(c)

combating the risks at source;

(d)

adapting the work to the individual, especially as regards the design of workplaces, the choice of work equipment and the choice of working and production methods, with a view, in particular, to alleviating monotonous work and work at a predetermined work-rate and to reducing their effect on health;

(e)

adapting to technical progress;

(f)

replacing the dangerous by the non-dangerous or the less dangerous;

(g)

developing a coherent overall prevention policy which covers technology, organisation of work, working conditions, social relationships and the influence of factors relating to the working environment;

(h)

giving collective protective measures priority over individual protective measures; and giving appropriate instructions to employees.

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1.1.8.7 Summary of the duties under these Regulations

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A summary of the duties and how they are applied with respect to each duty holder is given in the following table and chart:

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All construction projects

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(a) Check competence and resources of all appointees (b) Ensure there are suitable management arrangements for the project, including welfare facilities (c) Allow sufficient time and resources for all stages

Clients

(d) Provide pre-construction information to designers and contractors (e) Appoint an Engineer (f) Appoint Contractor (g) Make sure that the construction phase does not start unless there are suitable: 

welfare facilities, and



construction phase plan in place

(i) Retain and provide access to the health and safety file

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(h) Provide information relating to the health and safety file to the Engineer

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(j) (*There must be an Engineer and Contractor until the end of the construction phase)

(a) Advise and assist the client with their duties

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(c) Facilitate good communication between client, designers and contractors

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(d) Liaise with Contractor about ongoing design (e) Identify, collect and pass on pre-construction information

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(b) Co-ordinate health and safety aspects of design work and co-operate with others involved with the project

(f) Ensure that expert knowledge/advice is available in relation to highly hazardous activities (e.g. explosives, cofferdams, caissons etc.)

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(g) Prepare and update health and safety file

(b) Eliminate hazards and reduce risks during design

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Designers

(a) Check that client is aware of their duties

(c) Provide information about remaining risks (d) Check client is aware of duties and Engineer has been appointed (e) Provide any information needed for the health and safety file All construction work

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(a) Plan, manage and monitor construction phase in liaison with sub-contractors (b) Prepare, develop and implement a written plan and site rules. (Initial plan must be completed before the construction phase begins. Plan is termed “Construction Phase Health and Safety Plan”.

Contractor

(c) Give sub-contractors relevant parts of the plan (d) Make sure suitable welfare facilities are provided from the start and maintained throughout the construction phase (e) Check competence of all their appointees (f) Ensure all workers have site inductions and any further information and training needed for the work

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(g) Ensure that expert knowledge/advice is available in relation to highly hazardous activities (e.g. explosives, cofferdams, caissons etc.)

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(h) Consult with the workers

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(i) Liaise with Engineer regarding ongoing design

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(j) Secure the site

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(b) Provide Contractor with details of any sub-contractors) engaged (c) Provide any information needed for the health and safety file

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(d) Inform Contractor of problems with the Construction Phase Health and Safety Plan (e) Inform Contractor of reportable accidents, diseases and dangerous occurrences

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(f) Plan, manage and monitor own work and that of workers

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(g) Check competence of all their appointees and workers

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(h) Train own employees and provide information to their workers

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(a) Co-operate with Contractor in planning and managing work, including reasonable directions and site rules

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1.1.8.8 Duty holders under CDM 1

The following groups have specific duties under these Regulations: (a)

Clients

(b)

Designers

(c)

Engineers

(d)

Contractors

(e)

Sub-Contractors

1.1.8.9 Client’s Duties Under these Regulations there is a greater focus on the client's responsibilities. The term 'client' excludes 'domestic' clients; people must be having construction work carried out as a part of their business activities (whether for profit or not) to be classified as a client under these Regulations. Clients must ensure that arrangements are made for managing the projects and providing relevant information.

2

In relation to the arrangements for managing the project, the client must take reasonable steps to ensure that:

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so far as is reasonably practicable, the project will be managed in such a way (including the allocation of sufficient time and other resources) that the construction work can be carried out without avoidable risks to health or safety of any person

(b)

there are suitable welfare facilities for the people engaged in the construction work (appendix 1)

(c)

any structure which is to be built complies with the requirements of the latest revision for QCS

(d)

these standards are maintained and reviewed throughout the project.

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(a)

In relation to the provision of information, the client's duties are to ensure that all designers and contractors are promptly provided with relevant pre-construction information.

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The pre-construction information must include all relevant information which is in the client's possession, or can be reasonably obtained, including information that relates to: anything likely to affect the site or the construction work, for example the presence of asbestos or underground services

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(b)

the proposed use of the structure as a workplace

(c)

the minimum amount of time before the construction phase starts allowed for planning and preparation (mobilisation)

The purpose of the provision of information by the client is to: (a)

(b)

secure, so far as is reasonably practicable, the health and safety of anyone who will: (i)

be involved in the construction work

(ii)

be otherwise affected by the construction work

(iii)

use the structure as a place of work

assist the persons to whom information is provided to: (i)

perform their duties under these Regulations

(ii)

determine the resources allocated to them to manage the project

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6

In situations where there are a number of organisations, any of which could be the client, one of the organisations must elect in writing to take on the role of client. This needs to be by agreement. In this case, none of the other organisations have any duties under these Regulations.

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The client has one of the biggest influences over the way a project is run. They have substantial influence and contractual control and their decisions and approach determine: the time, money and other resources available for projects

(b)

who makes up the project team, their competence, when they are appointed and who does what

(c)

whether the team is encouraged to co-operate and work together effectively

(d)

whether the team has the information that it needs about the site and any existing structures

(e)

the arrangements for managing and co-ordinating the work of the team

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Because of this, they are made accountable for the impact their approach has on the health and safety of those working on or affected by the project. However, these Regulations also recognise that many clients know little about construction health and safety, so clients are not required or expected to plan or manage projects themselves. Nor do they have to develop substantial expertise in construction health and safety, unless this is central to their business. Clients must ensure that various duties are discharged, but are not normally expected to do them themselves.

9

Those clients without construction expertise should rely on the engineer’s advice on how best to meet their duties, but the engineer will need the client’s support and input to be able to carry out their work effectively. The client remains responsible for ensuring that client duties are met.

10

Clients can also, intentionally or unwittingly, take on additional responsibilities. If they specify materials or methods of working they may well become designers in relation to those specific matters. They will also be contractors if they directly manage or carry out construction work on site.

11

Client shall ensure that the construction phase does not start unless:

the contractor have made arrangements for suitable welfare facilities to be provided from the start and throughout the construction phase

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the contractor has prepared a construction phase plan which complies with Section 1.1.8.32); and

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12

In addition to the duties set out above, clients must: (a) appoint an Engineer to advise and assist with their duties and to co-ordinate the arrangements for health and safety during the planning phase; (b) appoint a Contractor to plan and manage the construction work preferably early enough for them to work with the designer on issues relating to building safety issues, usability and maintainability; (c) ensure that the construction phase does not start until the Contractor has prepared a suitable construction phase plan and made arrangements for suitable welfare facilities to be present from the start of the work; (d) make sure the health and safety file is prepared, reviewed, or updated ready for handover at the end of the construction work. This must then be kept available for any future construction work or to pass on to a new owner.

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Getting the right people for these roles and making early appointments is particularly important for clients with little construction or health and safety expertise, as they will need to rely on the advice given by the Engineer on matters relating to the competence of those who they intend to appoint, and the adequacy of the management arrangements made by appointees.

1.1.8.10 Who are clients? 1

A client is an organisation or individual for whom a construction project is carried out. Clients only have duties when the project is associated with a business or other undertaking (whether for profit or not). This can include for example, Qatar Ministry’s, Insurance Companies or Private Developers.

1.1.8.11 Domestic clients Domestic clients are people who have work done on their own home or the home of a family member, that does not relate to a trade or business, whether for profit or not. It is the type of client that matters, not the type of property.

2

Domestic clients have no client duties under CDM.

3

Designers and contractors working for domestic clients have to manage their own work and co-operate with and co-ordinate their work with others involved with the project so as to safeguard the health and safety of all involved in the project.

4

In some circumstances it may not be immediately obvious who is the client and there can sometimes be more than one client involved in a project. To avoid confusion, this needs to be resolved by those involved at the earliest stage possible. Take into account who:

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commissions the design and construction work (the employer in contract terminology);

(c)

initiates the work;

(d)

is at the head of the procurement chain;

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ultimately decides what is to be constructed, where, when and by whom;

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(a)

engages the contractors.

If there is still doubt, then all of the possible clients can appoint one of them as the only client for the purposes of these Regulations. Someone will always be the client. It is in the interests of all possible contenders to identify who it is. If not, they run the risk that all will be considered to carry the client’s duties under these Regulations.

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1.1.8.12 What clients must do for all projects 1

Clients must make sure that: (a)

designers, contractors and other team members that they propose to engage are competent (or work under the supervision of a competent person), are adequately resourced and appointed early enough for the work they have to do.

(b)

they allow sufficient time for each stage of the project, from concept onwards;

(c)

they co-operate with others concerned in the project as is necessary to allow other duty holders to comply with their duties under these Regulations;

(d)

they co-ordinate their own work with others involved with the project in order to ensure the safety of those carrying out the construction work, and others who may be affected by it;


(e)

there are reasonable management arrangements in place throughout the project to ensure that the construction work can be carried out, so far as is reasonably practicable, safely and without risk to health. (This does not mean managing the work themselves, as few clients have the expertise and resources needed and it can cause confusion);

(f)

contractors have made arrangements for suitable welfare facilities to be provided from the start and throughout the construction phase;

(g)

any fixed workplaces (for example offices, shops, factories, schools and any other structures which can be a place of work for end users including maintainers) which are to be constructed will comply, in respect of their design and the materials used, with any requirements of latest version for QCS

(h)

relevant information likely to be needed by designers, engineer, contractors or others to plan and manage their work is passed to them in order to comply with these Regulations.

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1.1.8.13 Co-operation, co-ordination, timeliness and resources Co-operation between parties and co-ordination of the work are key to the successful management of construction health and safety. Co-operation and co-ordination can only be meaningful if the relevant members of the project team have been appointed early enough to allow them to contribute to risk reduction. This is particularly important during the design stage when both clients and contractors should contribute to discussions on building safety issues, usability and maintainability of the finished structure. Clients should seek to appoint those who can assist with design considerations at the earliest opportunity so that they can make a full contribution to risk reduction during the planning stages.

2

Unrealistic deadlines and a failure to allocate sufficient funds are two of the largest contributors to poor control of risk on site. When engaging designers, contractors, and appointing engineers, clients have to consider the resources (for example staff, equipment and, particularly, time) needed to plan and do the work properly. Any contractors who are being considered for appointment should be informed of the minimum time period allowed to them for planning and preparation before construction work begins on site. Contractors should be given sufficient time after their appointment to allow them to plan the work and mobilise the necessary equipment (for example welfare facilities) and staff to allow the work to proceed safely and without risk to health. This is particularly important where the project involves demolition work - contractors must be given sufficient time for the planning and safe execution of any demolition activities.

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Clients should consult with appointees (including the contractor) to find out how much time they will need for planning and preparation before work is expected to start in order that both parties can agree a suitable time period. Similarly, engineers will need sufficient time after their appointment to carry out their duties under these Regulations. Clients must then inform their appointees how much time the client has allowed for planning and preparation before the work starts.

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1.1.8.14 Arranging design work 1

Clients must only employ designers who are competent to carry out their CDM duties.

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Clients often employ more than one designer, for example architects, civil, structural and services engineers. In such cases they all need to know who does what, and the timing of the appointments needs to enable the design work to be co-ordinated from an early stage. Nominating one designer as the ‘lead designer’ is often the best way to ensure co-ordination and co-operation during work which involves a number of designers.

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1.1.8.15 Management Arrangements 1

Clients, particularly those who only occasionally commission construction work, will not be experts in the construction process and for this reason they are not required to take an active role in managing the work. Clients are required to take reasonable steps to ensure that suitable management arrangements are in place throughout the life of the project so that the work can be carried out safely and without risk to health. The arrangements put in place should focus on the needs of the particular job and should be proportionate to the risks arising from the work.

2

The client will need to ensure that arrangements are in place to ensure that: there is clarity as to the roles, functions and responsibilities of members of the project team;

(b)

those with duties under CDM have sufficient time and resource to comply with their duties;

(c)

there is good communication, co-ordination and co-operation between members of the project team (for example between designers and contractors);

(d)

designers are able to confirm that their designs (and any design changes) have taken account of the requirements of their (designers’ duties), and that the different design elements will work together in a way which does not create risks to the health and safety of those constructing, using or maintaining the structure;

(e)

that the contractor is provided with the pre-construction information.

(f)

contractors are able to confirm that health and safety standards on site will be controlled and monitored, and that welfare facilities will be provided by the contractor from the start of the construction phase through to handover and completion.

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(a)

Most of these arrangements will be made by others in the project team, such as designers and contractors. Before they start work, a good way of checking is to ask the relevant members of the team to explain their arrangements, or to ask for examples of how they will manage these issues during the life of the project. When discussing roles and responsibilities, on simple projects all that may be needed is a simple list of who does what.

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When deciding whether management arrangements are suitable and maintained throughout the project, clients will need to make a judgement, taking account of the nature of the project and the risks that the work will entail. If this judgement is reasonable and clearly based on the evidence requested and provided, clients will not be criticised if the arrangements subsequently prove to be inadequate, or if the company who has made the arrangements fails to implement them properly without the client’s knowledge.

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1.1.8.16 Providing the pre-construction information 1

Clients must provide designers and contractors who may be bidding for the work (or who they intend to engage), with the project-specific health and safety information needed to identify hazards and risks associated with the design and construction work (the preconstruction information).

2

The information should be provided as part of the early procurement process or tendering, and responses to the issues identified can be a real help when judging competence of those tendering for the work. It therefore needs to be identified, assembled and sent out in good time, so that those who need it when preparing to bid or when preparing for the work can decide what resources (including time) will be needed to enable design, planning and construction work to be organised and carried out properly. Where design

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work continues during the construction phase, the pre-construction information will need to be provided to designers before work starts on each new element of the design. Similarly, where sub-contractors are appointed during the construction phase, each subcontractor (or those who are bidding for the work) must be provided with the preconstruction information in time for them to take this into account when preparing their bid, or preparing for work on the site. Clients may already have all, or much of the information needed. However, where there are gaps in this information, the client should ensure that these are filled by commissioning surveys or by making other reasonable enquiries. Where no existing information is available from the Client, designers shall identify and commission relevant surveys to enable them to complete their design and prepare preconstruction information that will be used to inform preparation and planning for construction. The information shall consist of relevant health and safety information of anyone affected by the design over the project life cycle.

4

The pre-construction information provided should be sufficient to ensure that significant risks during the work can be anticipated and planned for. It should concentrate on those issues that designers and contractors could not reasonably be expected to anticipate or identify, and not on obvious hazards such as the likelihood that the project would involve work at height.

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The information needs to be in a form that is convenient, i.e. clear, concise and easily understood, but it can be included in other documents, for example the specification, providing the relevant health and safety issues are fully covered. Brief notes on ‘as built’ drawings are particularly useful, but should be checked in case significant alterations have been carried out. will advise the client as to what is needed and arrange for relevant information to be given to designers and contractors.

6

Clients are also required to tell Contractors who they engage to carry out construction work the minimum notice that they will be given before they are expected to start construction work. This is to ensure that Contractors have sufficient time to plan and prepare – for example mobilise their workforce and equipment, and make arrangements for welfare facilities to be provided.

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1.1.8.17 Pre-construction information When drawing up the pre-construction information, each of the following topics should be considered. Information should be included where the topic is relevant to the wor k proposed. The pre-construction information provides information for those bidding for or planning work, and for the development of the construction phase plan. The level of detail in the information should be proportionate to the risks involved in the project.

2

Description of project

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project description and programme details including: (i)

key dates (including planned start and finish of the construction phase), and

(ii)

the minimum time to be allowed between appointment of the contractor and instruction to commence work on site;

(b)

details of client, designers, engineer and other consultants;

(c)

whether or not the structure will be used as a workplace (in which case, the finished design will need to take account of the relevant requirements of the latest version for QCS).

(d)

extent and location of existing records and plans.

Client’s considerations and management requirements

(i)

planning for and managing the construction work, including any health and safety goals project,

(ii)

communication and liaison between client and others,

(iii)

security of the site,

(iv)

welfare provision;

requirements relating to the health and safety of the client’s employees or customers or those involved in the project such as: site fencing requirements,

(ii)

site transport arrangements or vehicle movement restrictions,

(iii)

client permit-to-work systems,

(iv)

fire precautions,

(v)

emergency procedures and means of escape,

(vi)

‘no-go’ areas or other authorisation requirements for those involved in the project,

(vii)

any areas the client has designated as confined spaces,

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(i)

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(viii) smoking and parking restrictions.

Safety hazards, including:

boundaries and access, including temporary access – for example narrow streets, lack of parking, turning or storage space,

(ii)

any restrictions on deliveries or waste collection or storage,

(iii)

adjacent land uses – for example schools, railway lines or busy highways.

(iv)

existing storage of hazardous materials,

(v)

location of existing services particularly those that are concealed – water, electricity, gas, etc,

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Environmental restrictions and existing on-site risks

(vi)

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arrangements for:

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(vii)

ground conditions, underground structures or water courses where this might affect the safe use of plant, for example cranes, or the safety of groundworks, information about existing structures – stability, structural form, fragile or hazardous materials, anchorage points for fall arrest systems (particularly where demolition is involved),

(viii) previous structural modifications, including weakening or strengthening of the structure (particularly where demolition is involved), (ix)

fire damage, ground shrinkage, movement or poor maintenance which may have adversely affected the structure,

(x)

any difficulties relating to plant and equipment in the premises, such as overhead gantries whose height restricts access,

(xi)

health and safety information contained in earlier design, construction or ‘as-built’ drawings, such as details of pre-stressed or post-tensioned structures;

(xii)

Health hazards, including:

(xiii) asbestos, including results of surveys (particularly where demolition is involved),

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Section 11: Health and Safety Page 96 Part 1.01: Qatar Legislation and Management (Regulatory Document) (xiv) existing storage of hazardous materials, (xv)

contaminated land, including results of surveys,

(xvi) existing structures containing hazardous materials, (xvii) health risks arising from client’s activities. Significant design and construction hazards (a)

significant design assumptions and suggested work methods, sequences or other control measures;

(b)

arrangements for co-ordination of ongoing design work and handling design changes;

(c)

information on significant risks identified during design;

(d)

materials requiring particular precautions.

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The Health and Safety File

Description of its format and any conditions relating to its content.

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The information needs to be in a form that is convenient, i.e. clear, concise and easily understood, but it can be included in other documents, for example the specification, providing the relevant health and safety issues are fully covered. Brief notes on ‘as built’ drawings are particularly useful, but should be checked in case significant alterations have been carried out. Engineers will advise the client as to what is needed and arrange for relevant information to be given to designers and contractors.

8

Clients are also required to tell contractors who they engage to carry out construction work the minimum notice that they will be given before they are expected to start construction work. This is to ensure that contractors have sufficient time to plan and prepare – for example mobilise their workforce and equipment, and make arrangements for welfare facilities to be provided

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Clients do not have to provide welfare facilities for construction workers, but if there are particular constraints which make it difficult for facilities to be provided, the client should co-operate with contractors and assist them with their arrangements.

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1.1.8.18 Welfare arrangements

1.1.8.19 Additional duties for clients 1

Refer to 1.1.8.9.

1.1.8.20 Appointment of the Engineer 1

The client must appoint a competent, adequately resourced engineer as soon as practicable after initial design work or other preparations for construction work have begun.

2

The engineer provides clients with a key project advisor in respect of construction health and safety risk management matters. Their main purpose is to help clients to carry out their duties; to co-ordinate health and safety aspects of the design work and to prepare the health and safety file.

3

Early appointment is crucial for effective planning and establishing management arrangements from the start. CDM requires the appointment to take place as soon as is practicable after initial design work or other preparation for construction work has begun.

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This allows the client to appraise their project needs and objectives, including the business case and any possible constraints on development to enable them to decide whether or not to proceed with the project before appointing the engineer. The engineer needs to be in a position to be able to co-ordinate design work and advise on the suitability and compatibility of designs, and therefore they should be appointed before significant detailed design work begins. Significant detailed design work includes preparation of the initial concept design and implementation of any strategic brief. As a scheme moves into the detailed design stage, it becomes more difficult to make fundamental changes that eliminate hazards and reduce risks associated with early design decisions. Proper consideration of the health and safety implications of the design for those who build and maintain the structure will make a significant contribution to reducing its whole life cost, and will make delivery to time, cost and quality more likely.

5

The engineer can be an individual or a company. Engineers can be appointed independently of any other role on the project team, or they may combine this work with another role, for example, project manager, designer or contractor. Where the role is combined, it is crucial that the engineer has sufficient independence to carry out their tasks effectively. The tasks can be shared out, but when this happens it is important to make sure that all of the duties are discharged. On simple projects, one person should be able to provide all of the support that clients need, but a team approach will be more common for larger or more complicated projects because of the workload and skills required.

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1.1.8.21 Appointment of the Contractor

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Clients must appoint one competent, adequately resourced contractor to plan, manage and monitor the construction work. The appointment needs to be in writing.

2

The contractor can be an organisation or an individual. A contractor’s key duties is to coordinate and manage the construction phase to ensure the health and safety of everybody carrying out construction work, or who is affected by the wor k.

3

The contractor must be appointed as soon as the client knows enough about the project to select a suitable contractor. Early appointment allows the contractor and other specialists, for example maintenance contractors and facilities management experts to make a substantial contribution to ensuring the building safety issues and maintainability of the structure under construction. This helps to eliminate and reduce risks to health and safety, and to avoid interruptions, delays and other problems, which can add significantly to the costs of a project.

4

Early appointment is essential for the contractor to have sufficient time to develop an adequate construction phase plan and to arrange for appropriate resources, including welfare facilities, to be available when work commences on site. (Ensuring that welfare facilities are provided when work starts on site is a specific duty of the contractor, but the client also has a duty to make sure that the contractor has done so). Contractors should be told as part of the pre-construction information the minimum amount of time which they will be given for planning and preparation before the construction work is expected to start on site.

5

There can only be one contractor (the main Contractor of construction works and having authority and control of the construction site) at any one time. To ensure continuity, clients should normally keep the same contractor for the whole project from site clearance and preparation to final completion. However, there may be exceptions, for example where:

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preliminary works, for example involving demolition or site preparation work, where there is a substantial delay between site clearance and the start of new

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Section 11: Health and Safety Page 98 Part 1.01: Qatar Legislation and Management (Regulatory Document) construction work;

(b)

separate projects for different clients, for example for a building shell and subsequent fitting-out work.

(c)

In these cases, any change in contractor should:

(d)

be clear to, and agreed by all those involved, particularly in relation to the timing of the change;

(e)

be clearly recorded;

(f)

provide the practical authority to enable the contractor to discharge his duties.

1.1.8.22 Management arrangements Clients must appoint a competent engineer who will assist them with the assessment of the adequacy of the management arrangements made by others in the project team. Having appointed a competent engineer, the client is entitled to rely on their advice when making these judgements.

1.1.8.23 Before the construction phase begins

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Before construction work begins clients must check to ensure that suitable welfare facilities have been provided, and that the construction phase plan has been prepared by the contractor. With the help of the engineer, clients must ensure that the plan is project-specific and suitable. Example content of the construction phase plan is:

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1.1.8.24 Construction Phase (Health & Safety) Plan When drawing up the construction phase plan, you should consider each of the following topics. Information should be included in the plan where the topic is relevant to the work proposed. The plan sets out how health and safety is to be managed during the construction phase. The level of detail should be proportionate to the risks involved in the project. Once the construction phase has begun, it is the responsibility of the Contractor to update the Plan as per the development of the construction works.

2

Description of project

(b)

details of client, engineer, designers, Contractor and other consultants; extent and location of existing records and plans that are relevant to health and safety on site, including information about existing structures when appropriate.

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project description and programme details including any key dates;

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(a)

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Management of the work (a)

management structure and responsibilities

(b)

health and safety goals for the project and arrangements for monitoring and review of health and safety performance

(c)

arrangements for; (i)

regular liaison between parties on site,

(ii)

consultation with the workforce,

(iii)

the exchange of design information between the client, designers, Engineer and contractors on site,

(iv)

handling design changes during the project,

(v)

the selection and control of contractors,

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Section 11: Health and Safety Page 99 Part 1.01: Qatar Legislation and Management (Regulatory Document) (vi)

the exchange of health and safety information between contractors,

(vii)

site security,

(viii)

site induction,

(ix)

on site training,

(x)

welfare facilities and first aid,

(xi)

the reporting and investigation of accidents and incidents including near misses,

(xii)

the production and approval of risk assessments and written systems of work;

site rules (including drug and alcohol policy);

(e)

fire and emergency procedures.

(f)

Arrangements for controlling significant site risks

(a)

Safety risks, including:

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(d)

delivery and removal of materials (including waste) and work equipment taking account of any risks to the public, for example during access to or egress from the site,

(ii)

dealing with services - water, electricity and gas, including overhead power lines and temporary electrical installations,

(iii)

accommodating adjacent land use,

(iv)

stability of structures whilst carrying out construction work, including temporary structures and existing unstable structures,

(v)

preventing falls,

(vi)

work with or near fragile materials,

(vii)

control of lifting operations,

(viii)

the maintenance of plant and equipment,

(ix)

work on excavations and work where there are poor ground conditions,

(x)

work on wells, underground earthworks and tunnels,

(xi)

work on or near water where there is a risk of drowning,

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(i)

work involving diving,

(xiii)

work in a caisson or compressed air working,

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(xii)

(xiv) work involving explosives, (xv)

traffic routes and segregation of vehicles and pedestrians,

(xvi) storage of materials (particularly hazardous materials) and work equipment, (xvii) any other significant safety risks; (b)

health risks, including: (i)

the removal of asbestos,

(ii)

dealing with contaminated land,

(iii)

manual handling,

(iv)

use of hazardous substances, particularly where there is a need for health monitoring,

(v)

reducing noise and vibration,

(vi)

work with ionising radiation,

(vii)

exposure to UV radiation (from the sun),

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Section 11: Health and Safety Page 100 Part 1.01: Qatar Legislation and Management (Regulatory Document) (viii) any other significant health risks.

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The health and safety file (a)

layout and format;

(b)

arrangements for the collection and gathering of information;

(c)

storage of information.

Once the construction phase has begun, neither clients nor engineers have a duty to check that the plan is updated; this is the responsibility of the contractor.

1.1.8.25 Completion and handover (all projects) One of the most important stages in a project is when it nears completion and is handed over to the client. It is rare for all construction work to be completed before handover. Sometimes clients, in their eagerness to have things up and running, assume control when a great deal of construction work remains.

2

Risks to employees and others not engaged in construction work can increase substantially as they visit the site or spend more time there. The risks to the construction workers can also increase, due to the presence and work of others not directly engaged or experienced in construction work.

3

To minimise such risks, the management of this phase needs to be considered well in advance to address:

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the nature, scope and duration of any finishing-off work;

(b)

how this work will be managed and by whom;

(c)

how the site will be split up, and access controlled, to safeguard construction workers as well as clients’ employees and/or members of the public.

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For simple projects these arrangements can be discussed and agreed between the various parties. In more complex situations, the arrangements should be recorded as part of the construction phase plan.

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Clients are not required or expected to:

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1.1.8.26 What clients don’t have to do

(a)

plan or manage construction projects themselves; or

(b)

specify how work must be done, for example requiring a structure to be demolished by hand. Indeed they should not do so unless they have the expertise to assess the various options and risks involved. (They should, of course, point out particular risks that would inform this decision.)

(c)

provide welfare facilities for those carrying out construction work (though they should co-operate with the contractor to assist with his arrangements);

(d)

visit the site (to supervise or check construction work standards) but it is good practice for the client to appoint someone to ensure the contents of the Construction Phase (H&S) Plan is being complied with. This may be in the form of an appointed H&S advisor / consultant and / or the Engineer which may assist in the resolution of any onsite design issues.

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1.1.8.27 The Engineer Appointment of an Engineer 1

The role of engineer may be filled by an individual, an organisation or by a professional practice such as an architect's practice or a specialist consultancy.

2

The more complex the project and hence the more construction disciplines involved, the less likely it is that the role of engineer can be satisfactorily carried out by a single person.

3

The selection of a competent engineer should be based upon the complexity of the work and the range of knowledge required.

4

The duties of the engineer are seen to be to:

(d)

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the start of the construction phase as outlined previously in the client's duties

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ensure that suitable arrangements are made and implemented for the co-ordination of health and safety measures during the planning and preparation phases of the project with regard to: co-operation and co-ordination between all parties working on the project

(ii)

the implementation of the general principles of prevention

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liaise with the contractor with regard to:

the information required for the health and safety file

(ii)

the information needed by the contractor for the preparation of the health and safety plan

(iii)

any design developments which may have an impact on the planning and management of the work

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(i)

take all reasonable steps to identify and collect pre-construction information and promptly provide it, as necessary, to designers and contractors take all reasonable steps to ensure that designers comply with their duties

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(e)

taking reasonable steps to ensure that the necessary arrangements are made for managing health and safety

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(b)

give suitable and sufficient advice and assistance to enable the client to comply with the client's duties under these Regulations, in particular with regard to:

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(a)

(f)

take all reasonable steps to ensure the co-operation between designers and the contractor with regard to designs and any changes in design

(g)

prepare the health and safety file and pass the file to the client at the end of the construction phase

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The purpose of the engineer is to provide the client with key project information about construction health and safety risk-management matters.

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They should assist and advise the client on: (a)

the appointment of competent contractors

(b)

the adequacy of the arrangements for managing health and safety

(c)

ensuring proper co-ordination of the health and safety aspects of the design process

(d)

facilitating good communication and co-operation between all project team members

(e)

preparing the health and safety file,

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7

Early involvement of the engineer with the client and designers should significantly contribute to the reduction of risk to construction workers and to anyone who has to subsequently work on the completed structure.

8

The role demands a comprehensive knowledge of the design process and construction methods, plus a thorough understanding of construction health, safety and welfare issues.

9

It is suggested that if the position is filled by a competent person or organisation who/which possesses the necessary range of knowledge, experience and resources, compliance with the rest of these Regulations should flow relatively smoothly.

10

These Regulations require that the role of the engineer must be filled at all times by a competent person. It has, therefore, to be accepted that the appointment of the engineer can be terminated by the client if the duties are not being carried out satisfactorily, for example: the engineer has not generally displayed the required level of competence

(b)

the job has reached a stage where it involves construction activities outside the scope of the experience of the current engineer and a pre-planned handover to another engineer takes place. For example, the original engineer is appointed for the ground works and structural stage of a project, but another appointment is made for the fitting out and commissioning stages.

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(a)

The role of an engineer is to provide the client with a key project advisor in respect of construction health and safety risk management matters. They should assist and advise the client on appointment of competent contractors and the adequacy of management arrangements; ensure proper co-ordination of the health and safety aspects of the design process; facilitate good communication and co-operation between project team members and prepare the health and safety file.

12

Through early involvement with clients and designers, an engineer can make a significant contribution to reducing risks to workers during construction, and to contractors and end users who work on or in the structure after construction.

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Appointing the Engineer

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1.1.8.28 What Engineers should do An engineer should:

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give suitable and sufficient advice and assistance to clients in order to help them to comply with their duties, in particular: (i)

the duty to appoint competent designers and contractors; and

(ii)

the duty to ensure that adequate arrangements are in place for managing the project;

(b)

co-ordinate design work, planning and other preparation for construction where relevant to health and safety;

(c)

identify and ensure collection of the pre-construction information and advise the client if surveys need to be commissioned to fill significant gaps;

(d)

promptly provide in a convenient form to those involved with the design of the structure; and to every contractor (including the contractor) who may

(e)

be or has been appointed by the client, such parts of the pre-construction information which are relevant to each;

(f)

manage the flow of health and safety information between clients, designers

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(g)

and contractors;

(h)

advise the client on the suitability of the initial construction phase plan and the arrangements made to ensure that welfare facilities are on site from the start;

(i)

produce or update a relevant, user friendly, health and safety file suitable for future use at the end of the construction phase.

Advising the client on competency of designers and contractors 2

Clients are responsible for appointing competent and adequately resourced designers and contractors. A competent engineer will have the knowledge and expertise to assist clients with these assessments. Managing information flow

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Co-operation and co-ordination can only be achieved if there is good communication between all parties involved in a particular aspect of a project. During planning stages the engineer needs to make sure that there are appropriate systems in place to encourage communication and the sharing of relevant information, and engineers should manage the flow of information between the team members. They may need to convene special meetings if they are not satisfied there is sufficient co-operation between designers or with other team members, or if adequate regard is not being given to health and safety. It is, however, better for these issues to be addressed in routine project meetings.

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Clients must provide designers and contractors who may be bidding for the work (or who they intend to engage), with the project-specific health and safety information needed to identify hazards and risks associated with the design and construction work. (The preconstruction information). Clients are required to provide this information to the engineer. The engineer should check the information to ensure that it is complete, advise the client if there are any significant gaps or defects, and ensure these are filled by commissioning surveys or by making other reasonable enquiries. The engineer should then provide designers or contractors who may be bidding for, or preparing to carry out construction work on site, with such parts of the pre-construction information that are relevant to each.

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Advising the client on adequacy of management arrangements 5

Clients must make sure that there are suitable (project-specific) arrangements for managing each project so that the work can be carried out safely and without risk to health. Most clients, particularly those who only occasionally commission construction work, will not be experts in the construction process. These Regulations do not require clients to take an active role in managing the work, but they do require clients to take reasonable steps to ensure that suitable management arrangements are in place throughout the life of the project.

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The engineer should assist with the development of these arrangements, and should advise clients on whether or not the arrangements are adequate. They should assist the client with decisions about how much time a contractor will need to prepare before construction work begins. When advising and assisting the client, the following issues should be considered. (a)

Is the client aware of their duties and do they understand what is expected of them?

(b)

Has the client prepared relevant information about the site?

(c)

Have the necessary appointments been made?


(d)

Is there an established project team who meet regularly to discuss and coordinate activities in relation to the project?

(e)

Are project team members clear about their roles and responsibilities?

(f)

Are there arrangements in place for co-ordinating design work and reviewing the design to ensure that designer’s duties are being addressed?

(g)

Are there arrangements in place for dealing with late changes to the design, and for co-operating with contractors, so that problems are shared?

(h)

Has the contractor been given enough time to plan and prepare for the work, and mobilise for the start of the construction phase?

(i)

Has the contractor made arrangements for providing welfare facilities on site from the outset, and have they prepared a construction phase plan that addresses the main risks during the early stages of construction?

(j)

Are there suitable arrangements for developing the plan to cover risks that arise as the work progresses?

(k)

Has the format for the health and safety file been agreed, and are arrangements in place for collecting the information which it will contain?

(l)

Has the contractor put in place suitable arrangements for consulting with workers on site; for carrying out site induction and for ensuring that workers are adequately trained and supervised?

Not all of these questions will need answers at the start of the project, and the arrangements will need to evolve as the project develops. The key thing is to plan ahead so that arrangements are in place before the risks that need managing materialise on site.

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1.1.8.29 Co-ordinating design work: Design reviews The engineers responsibility in respect of design work only extends to health and safety aspects of the design – checking that the requirements of the designers duties have been addressed and that the different design elements work together without causing danger. This is best achieved through design reviews during which health and safety issues are addressed alongside practicality and cost in a wider review of the design’s building safety issues, maintainability and usability.

2

When considering building safety issues, meetings should where possible include the contractor(s) so that difficulties associated with construction can be discussed and solutions agreed before the work begins. When discussing usability and maintainability, involving the client or those who will be responsible for operating the building or structure will mean that proper consideration can be given to the health and safety of those who will maintain and use the structure once it has been completed. Doing this during the design stage will result in significant cost savings for the client, as rectifying mistakes after the structure has been built is always expensive.

3

As part of design reviews, engineers need to ensure that the designers have identified a safe method for construction for unusual or complex designs, and that the designs include the information needed by other designers and contractors to allow them to work safely and without risk to health. This information needs to be clear and concise.

4

The timing of the reviews also needs careful consideration. Design needs to be far enough developed for people to have a clear view of what is in mind, but not so far developed that it is too late to modify the proposals, if necessary. Design is an iterative process so it may need review at several different stages. The effort devoted to design review should be in proportion to the risks and complexity.

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Engineers who identify important health and safety issues that have not been addressed in the design must draw them to the attention of the designer.

1.1.8.30 The Engineer and the construction phase Design often continues throughout a project and engineers have a continuing role during the construction phase – ensuring that designers, including those engaged by a contractor and contractors who carry out design work themselves, co-operate with each other, and designs meet the requirements of these Regulations. Where design changes and decisions during the construction phase have significant health and safety implications, engineers should liaise with the contractor about any implications for the construction phase plan.

2

The design of temporary works, such as falsework, formwork and scaffolding, falls within the scope of CDM. Engineers have to take reasonable steps to ensure co-operation between permanent and temporary works designers, in particular to ensure that arrangements are in place to ensure that designs are compatible and that the permanent works can support any loadings from temporary works.

3

Engineers need to pay particular attention to late designs or late change s to designs. Examples would be revisions on architects’ instructions, when clients require changes or when unforeseen problems are encountered on site. The engineer should make sure that there are arrangements in place to ensure that such changes do not result in significantly increased risks on site.

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Engineers don’t have to:

approve the appointment of designers, contractors, although they normally advise clients about competence and resources;

(b)

approve or check designs, although they have to be satisfied that the design process addresses the need to eliminate hazards and control risks;

(c)

approve the contractor’s construction phase plan, although they have to be able to advise clients on its adequacy at the start of construction;

(d)

supervise the contractor’s implementation of the construction phase plan - this is the responsibility of the contractor; or

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supervise or monitor construction work – this is the responsibility of the contractor.

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1.1.8.31 The health and safety file 1

Engineers must prepare a suitable health and safety file. It is important that they discuss this with the client before work starts on site so that the format can be agreed, along with who should provide what information and when. This requires the cooperation of several duty holders, so engineers need to make sure that designers and contractors know, early on in the project, what information they will need to provide

2

The health and safety file (‘the file’) is a source of information that will help to reduce the risks and costs involved in future construction work, including cleaning, maintenance, alterations, refurbishment and demolition. Clients therefore need to ensure that the file is prepared and kept available for inspection in the event of such work. It is a key part of the information, which the client, or the client’s successor, must pass on to anyone preparing or carrying out work to which CDM applies.

3

Clients may need to provide incentives or include requirements in contracts to ensure that the information is given to the engineer immediately after relevant design or

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construction work is completed. At the end of a project the engineer should give the completed file to the client for safekeeping. The contents of the health and safety file When putting together the health and safety file, you should consider including information about each of the following where they are relevant to the health and safety of any future construction work. The level of detail should allow the likely risks to be identified and addressed by those carrying out the work: (a)

a brief description of the work carried out;

(b)

any residual hazards which remain and how they have been dealt with (for example surveys or other information concerning asbestos; contaminated land; water bearing strata; buried services etc);

(c)

key structural principles (for example, bracing, sources of substantial stored energy – including pre- or post-tensioned members) and safe working loads for floors and roofs, particularly where these may preclude placing scaffolding or heavy machinery there;

(d)

hazardous materials used (for example lead paint; pesticides; special coatings which should not be burnt off etc);

(e)

information regarding the removal or dismantling of installed plant and equipment (for example any special arrangements for lifting, order or other special instructions for dismantling etc);

(f)

health and safety information about equipment provided for cleaning or maintaining the structure;

(g)

the nature, location and markings of significant services, including underground cables; gas supply equipment; fire-fighting services etc;

(h)

information and as-built drawings of the structure, its plant and equipment (for example, the means of safe access to and from service voids, fire doors and compartmentalisation etc).

The file should be useful to:

(b)

designers during the development of further designs or alterations; engineers preparing for construction work;

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clients, who have a duty to provide information about their premises to those who carry out work there;

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(d)

contractors and sub-contractors preparing to carry out or manage such work.

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The file should form a key part of the information that the client, or the client’s successor, is required to provide for future construction projects. The file should therefore be kept up to date after any relevant work or surveys.

7

The scope, structure and format for the file should be agreed between the client and engineer at the start of a project. There can be a separate file for each structure, one for an entire project or site, or one for a group of related structures. What you must do

8

Clients, designers, contractors, other sub-contractors and engineers all have duties in respect of the health and safety file: (a)

Engineers must prepare, review, amend or add to the file as the project progresses, and give it to the client at the end of project;

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(b)

clients, designers, contractors and other sub-contractors must supply the information necessary for compiling or updating the file;

(c)

clients must keep the file to assist with future construction work; and

(d)

everyone providing information should make sure that it is accurate, and provided promptly.

9

The client should make sure that the engineer compiles the file. In some cases, for example design and build contracts, it is more practical for the contractor to obtain the information needed for the file from the specialist contractors. In these circumstances the contractor can assemble the information and give it to the engineer as the work is completed.

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The file does not need to include things that will be of no help when planning future construction work, for example: the pre-construction information, or construction phase health and safety plan

(b)

construction phase risk assessments, written systems of work and COSHH assessments

(c)

details about the normal operation of the completed structure

(d)

construction phase accident statistics

(e)

details of all the contractors and designers involved in the project (though it may be useful to include details of the contractor and engineer)

(f)

contractual documents

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information about structures, or parts of structures, that have been demolished unless there are any implications for remaining or future structures, e.g. voids

(ii)

information in other documents, but relevant cross-references should be included.

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Storing the file after the work is complete To be useful the file needs to be kept up to date, and retained for as long as it is relevant – normally the lifetime of the structure. It may be kept electronically (with suitable backup arrangements), on paper, on film, or any other durable form.

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Where clients dispose of their entire interest in a structure, they should pass the file to the new owners and ensure that they are aware of the nature and purpose of the file. Where they sell part of a structure, any relevant information in the file should be passed or copied to the new owner.

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1.1.8.32 Designers 1

Designs develop from initial concepts through to a detailed specification, often involving different teams and people at various stages. At each stage, designers from all disciplines can make a significant contribution by identifying and eliminating hazards, and reducing likely risks from hazards where elimination is not possible.

2

Designers’ earliest decisions fundamentally affect the health and safety of construction work. These decisions influence later design choices, and considerable work may be required if it is necessary to unravel earlier decisions. It is therefore vital to address health and safety from the very start.

3

Designers have duties regardless of whether the client is a domestic or non-domestic Client.

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Designer's duties 1

Designers are in a unique position at an early stage of a project to reduce the potential risks to health and safety that could arise during the construction phase or at a later stage such as during maintenance of the completed structure.

2

Designers have duties regardless of whether the client is at work or is a domestic client.

3

No designer shall commence work in relation to a project unless any client for the project is aware of his duties under these Regulations.

4

Every designer shall in preparing or modifying a design avoid foreseeable risks to the health and safety of any person

(b)

liable to be affected by such construction work;

(c)

cleaning any window or any transparent or translucent wall, ceiling or roof in or on a structure;

(d)

maintaining the permanent fixtures and fittings of a structure; or

(e)

using a structure designed as a place of work.

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In discharging their duties, the designer shall

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carrying out construction work;

(a)

eliminate hazards which may give rise to risks; and

(b)

reduce risks from any remaining hazards,

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(a)

and in so doing shall give collective measures priority over individual measures

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The duties on designers are:

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no design work should be carried out unless the client is aware of their duties under these Regulations.

(b)

not carry out detailed design work until an Engineer has been appointed.

(c)

designers must ensure so far as is reasonably practicable that their designs avoid foreseeable health and safety risks to anyone who is:

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carrying out the construction work

(ii)

liable to be affected by the construction work

(iii)

cleaning any window or other transparent or translucent surfaces

(iv)

maintaining the permanent fixtures and fittings

(v)

using the structure as a place of work.

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It will include aspects of design such as positioning a vehicle loading bay to ensure that delivery vehicles are routed safely away from pedestrians. The intention is that all designers consider the implications of their designs with regard to the structures being built and maintained reasonably safely.

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In discharging their duties, designers: (a)

must so far as is reasonably practicable:

(b)

eliminate hazards that give rise to risks, and

(c)

reduce the risk from any hazards that remain

(d)

give collective protection measures priority over individual protective measures.

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An example of hazard elimination is to design out the use of fragile roofing materials or the installation of fragile roof-lights in an otherwise load-bearing roof.

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Reducing risk can be achieved by reducing the likelihood of harm occurring, the severity of any incident that does occur, the number of persons exposed to the harm and the frequency or duration of the exposure to harm.

12

Designers must ensure that any structure designed for use as a workplace conforms to the requirements latest edition of QCS with regard to the design and the materials used.

13

In designing any structure for use as a workplace the designer shall ensure that the design conforms to the requirements latest edition of QCS with regard to the design and the materials used.

14

Designers must take all reasonable steps to provide sufficient information about the aspects of the design or its construction or maintenance to adequately assist the following to comply with their duties:

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the client;

(b)

the Engineer;

(c)

other designers;

(d)

contractors;

(e)

Sub-contractors;

(f)

Other consultant/interfacing organisations identified as relevant

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(a)

Historically, risks were created at the design stage as a result of an attitude by some designers that it 'is someone else's problem to build/clean/maintain' the structure once it has been designed. CDM is emphatically not trying to stifle creative design, but merely ensuring that the practicalities of carrying out any of the above activities are considered during the design process.

16

Having completed their design, designers are obliged to pass on information about the risks that they have not been able to design out. For example, having designed an external overhead pipe run for a factory, the engineer consults the client's maintenance team about the need for access. The designer establishes that the maintenance team will only need to access the pipe-run every 4 years and that they can quite safely use a scissor lift for the task.

17

The designer then simply passes on the information as to how the risk of working at height during maintenance can be carried out in a safe manner.

18

Designers’ responsibilities extend beyond the construction phase of a project. They also need to consider the health and safety of those who will maintain, repair, clean, refurbish and eventually remove or demolish all or part of a structure as well as the health and safety of users of workplaces. For most designers, building safety issue considerations and ensuring that the structure can be easily maintained and repaired will be part of their normal work, and thinking about the health and safety of those who do this work should not be an onerous duty. Failure to address these issues adequately at the design stage will usually increase running costs, because clients will then be faced with more costly solutions when repairs and maintenance become necessary.

19

Where significant risks remain when they have done what they can, designers should provide information with the design to ensure that the engineer, other designers and contractors are aware of these risks and can take account of them.

20

In addition to the duties outlined above designers should:

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(a)

ensure that the client has appointed an Engineer;

(b)

ensure that they do not start design work other than initial design work unless an Engineer has been appointed;

(c)

co-operate with the Engineer, Contractor and with any other designers or contractors as necessary for each of them to comply with their duties. This includes providing any information needed for the pre-construction information or health and safety file.

Early appointment of the Engineer is crucial for effective planning and establishing management arrangements from the start. These regulations require the appointment to take place as soon as is practicable after initial design work or other preparation for construction work has begun.

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Once the Engineer has been appointed, the designer will need to co-operate with them and provide the information which the Engineer needs to comply with their duties.

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Designers are those who have a trade or a business which involves them in: (a)

preparing designs for construction work, including variations. This includes preparing drawings, design details, specifications, bills of quantities and the specification (or prohibition) of articles and substances, as well as all the related analysis, calculations, and preparatory work; or

(b)

arranging for their employees or other people under their control to prepare designs relating to a structure or part of a structure.

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Who are designers?

It does not matter whether the design is recorded (for example on paper or a computer) or not (for example it is only communicated orally).

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Designers therefore include:

architects, civil and structural engineers, building surveyors, landscape architects, other consultants, manufacturers and design practices (of whatever discipline) contributing to, or having overall responsibility for, any part of the design, for example drainage engineers designing the drainage for a new development; anyone who specifies or alters a design, or who specifies the use of a particular method of work or material, such as a design manager, quantity surveyor who insists on specific material or a client who stipulates a particular layout or material for a new structure;

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(e)

building service designers, engineering practices or others designing plant which forms part of the permanent structure (including lifts, heating, ventilation and electrical systems), for example a specialist provider of permanent fire extinguishing installations;

(f)

those purchasing materials where the choice has been left open, for example those purchasing building blocks and so deciding the weights that bricklayers must handle;

(g)

contractors carrying out design work as part of their contribution to a project, such as an engineering contractor providing design, procurement and construction management services;

(h)

temporary works engineers, including those designing auxiliary structures, such as formwork, falsework, façade retention schemes, scaffolding, and sheet piling;

(i)

interior designers who also develop the design;

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(j)

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Section 11: Health and Safety Page 111 Part 1.01: Qatar Legislation and Management (Regulatory Document) those determining how buildings and structures are altered, for example during refurbishment, where this has the potential for partial or complete collapse.

Manufacturers supplying standardised products that can be used in any project are not designers under CDM. The person who selects the product is a designer and must take account of health and safety issues arising from its use. If a product is purpose-made for a project, the person who prepares the specification is a designer under CDM, and so is the manufacturer who develops the detailed design. What designers should do for all projects

make sure that they are competent and adequately resourced to address the health and safety issues likely to be involved in the design;

(b)

check that clients are aware of their duties;

(c)

When carrying out design work, avoid foreseeable risks to those involved in the construction and future use of the structure, and in doing so, they should eliminate hazards (so far as is reasonably practicable, taking account of other design considerations) and reduce risk associated with those hazards which remain;

(d)

provide adequate information about any significant risks associated with the design;

(e)

co-ordinate their work with that of others in order to improve the way in which risks are managed and controlled.

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In carrying out these duties, designers need to consider the hazards and risks to those who: carry out construction work including demolition;

(b)

clean any window or transparent or translucent wall, ceiling or roof in or on a structure or maintain the permanent fixtures and fittings;

(c)

use a structure designed as a place of work;

(d)

may be affected by such work, for example customers or the general public.

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Designers should:

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These duties apply whenever designs are prepared which may be used in construction work in Qatar. This includes concept design and relevant work carried out as part of feasibility studies.

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When do these duties apply?

Making clients aware of their responsibilities 30

Designers are often the first point of contact for a client, and CDM requires them to check that clients are aware of their duties under these Regulations Preparing a design

31

Designers have to weigh many factors as they prepare their designs. Health and safety considerations have to be weighed alongside other considerations, including cost, fitness for purpose, aesthetics, building safety issues, maintainability and environmental impact. CDM allows designers to take due account of other relevant design considerations. These Regulations do not prescribe design outcomes, but they do require designers to weigh the various factors and reach reasoned, professional decisions.

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Designers are required to avoid foreseeable risks ‘so far as is reasonably practicable, taking due account of other relevant design considerations’. The greater the risk, the greater the weight that must be given to eliminating or reducing it. Designers are not expected to consider or address risks which cannot be foreseen, and these Regulations do not require zero risk designs because this is simply impossible. However, designers must not produce designs that cannot be constructed, maintained, used or demolished in reasonable safety.

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Designers should critically assess their design proposals at an early stage, and then throughout the design process, to ensure that health and safety issues are identified, integrated into the overall design process and addressed as they go along. It is pointless to complete the design first, then try to address the risks which the design has introduced. By then, all of the key decisions are likely to have been taken and no one will be willing to make any changes because of the time and cost involved.

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The first thing that designers need to do is eliminate hazards (things with a potential to cause harm) from their designs so far as is reasonably practicable, taking account of other design considerations. Examples would be to design out things like fragile roofing materials or products; eliminating roof lights from areas where roof access is needed; positioning plant which needs regular maintenance at ground level so there is no need for work at height or providing permanent safe access for work at height. Eliminating hazards removes the associated risk, and is therefore the best option and should always be the first choice.

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It is not always reasonably practicable to eliminate hazards, and where this is the case consideration should be given to incorporating design solutions which reduce the overall risk to an acceptable level. This can be done by reducing the:

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likelihood of harm (injury or adverse health effect);

(b)

potential severity of the harm;

(c)

number of people exposed to the harm; and

(d)

frequency or duration of exposure to harm.

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The amount of effort put into eliminating hazards and reducing risks should depend on the degree of risk. There is little point in spending a lot of money, time and trouble on low risk issues. There is also little to be gained by detailed comparison of construction techniques that present similar risks, for example whether to specify a steel frame or concrete portal building. The focus should be on issues that are known to have the potential to cause significant harm, and where there are known solutions that reduce the risks to everyone exposed.

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Designers also need to take account of other relevant health and safety requirements when carrying out design work. Where the structure will be used as a workplace, (for example factories, offices, schools, hospitals and any other structures which can be a place of work for end users including maintainers) they need to take account of the provisions of the latest version for QCS requirements.

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Providing information 38

Designers must provide information that other project team members are likely to need to identify and manage the remaining risks. This should be project specific, and concentrate on significant risks which may not be obvious to those who use the design. For example, providing generic risk information about the prevention of falls is pointless, because competent contractors will already know what needs to be done, but if the design gives rise to a specific and unusual fall risk which may not be obvious to contractors, designers should provide information about this risk.

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Designers also need to provide information about aspects of the design that could

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create significant risks during future construction work or maintenance. If in doubt about the level of information needed, the best way to find out is to ask those who will use it. 40

(a)

not likely to be obvious to a competent contractor or other designers;

(b)

unusual; or

(c)

likely to be difficult to manage effectively.

Information should be brief, clear, precise, and in a form suitable for the users. This can be achieved using: (a)

notes on drawings – this is preferred, since the notes will then be immediately available to those carrying out the work. They can refer to other documents if more detail is needed, and be annotated to keep them up to date;

(b)

written information provided with the design - this should be project specific, and should only contain information which will be useful to those constructing or maintaining the structure;

(c)

suggested construction sequences showing how the design could be erected safely, where this is not obvious, for example suggested sequences for putting up pre-cast panel concrete structures. Contractors may then adopt this method or develop their own approach.

It is not always possible to provide all the information at the same time, particularly when design work is continuing whilst construction work is underway. In these circumstances information should be released as the design develops, but construction work should not be allowed to proceed unless all the information necessary for the work to be carried out safely has been provided.

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Significant risks are not necessarily those that involve the greatest risks, but those, including health risks that are:

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Co-operation

Designers must co-operate with the client, and other designers and contractors, including those designing temporary works. This is to ensure that incompatibilities between designs are identified and resolved as early as possible, and that the right information is provided in the pre-construction information.

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For smaller projects where most of the work is done by a single designer, this can be achieved through discussion with those who use or are affected by the design. For larger projects or those involving significant risks, a more managed approach will be necessary.

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Co-operation can be encouraged by:

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(a)

setting up an integrated team involving designers and contractor.

(b)

the appointment of a lead designer, where many designers are involved.

(c)

agreeing a common approach to risk reduction during design;

(d)

regular meetings of all the design team (including the engineer) with contractors, and others;

(e)

regular reviews of developing designs;

(f)

site visits, through which designers can gain a direct insight into how the risks are managed in practice.

Regular reviews of the design involving all members of the design team are particularly important in making sure that proper consideration is given to building safety issues,

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usability and maintainability. When considering building safety issues, meetings should include the contractor so that difficulties associated with construction can be discussed and solutions agreed before the work begins. When discussing usability and maintainability, involving the client or those who will be responsible for operating the building or structure will mean that proper consideration can be given to the health and safety of those who will maintain and use the structure once it has been completed. Doing this during the design stage will result in significant cost savings for the client, as rectifying mistakes after the structure has been built is always expensive. What designers don’t have to do Under CDM, designers don’t have to: (a)

take into account or provide information about unforeseeable hazards and risks;

(b)

design for possible future uses of structures that cannot reasonably be anticipated from their design brief;

(c)

specify construction methods, except where the design assumes or requires a particular construction or erection sequence, or where a competent contractor might need such information;

(d)

exercise any health and safety management function over contractors or others; or

(e)

worry about trivial risks.

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Designers are not required to keep records of the process through which they achieve a safe design, but it can be useful to record why certain key decisions were made. Brief records of the points considered, the conclusions reached, and the basis for those conclusions, can be very helpful when designs are passed from one designer to another. This will reduce the likelihood of important decisions being reversed by those who may not fully understand the implications of doing so.

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Too much paperwork is as bad as too little, because the useless hides the necessary. Large volumes of paperwork listing generic hazards and risks, most of which are well known to contractors and others who use the design are positively harmful, and suggest a lack of competence on the part of the designer.

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1.1.8.33 The Contractor

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Contractor

Under these Regulations, the duties of the contractor are to: (a)

plan, manage and monitor construction work to ensure so far as is reasonably practicable that it is carried out without risks to health and safety, including ensuring: (i)

that there is adequate co-operation and co-ordination between all parties involved in the project

(ii)

that the general principles of prevention are applied

(b)

liaise with the engineer with regard to ensuring the co-operation between designers during the construction phase

(c)

ensure that adequate welfare facilities are provided in accordance with Appendix 1

(d)

where necessary in the interests of health and safety, draw up site rules which are appropriate to the site and the activities that will be carried out on it

(e)

give reasonable directions to subcontractors to enable the contractor to fulfil their duties under these Regulations

(f)

ensure that all sub-contractors are informed of the minimum amount of time that will

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Section 11: Health and Safety Page 115 Part 1.01: Qatar Legislation and Management (Regulatory Document) be allowed to them for planning and preparation, before their construction work starts

(g)

where necessary, consult with sub-contractors before finalising the parts of the construction phase plan that are relevant to the work to be undertaken by each subcontractor

(h)

ensure that before each sub-contractor's work begins, the sub-contractor is given sufficient time to access the parts of the health and safety plan that are relevant to the sub-contractor's work and that the relevant parts of the plan contain sufficient detail for the sub-contractor's needs

(i)

ensure that before each contractor's work begins, the contractor is given sufficient time to enable them to prepare such information as they need with regard to: the prompt provision of welfare facilities

(ii)

carrying out their work without risks to health and safety so far as is reasonably practicable

.

(i)

identify to each sub-contractor the information needed by the engineer for the health and safety file and to ensure that the information is promptly provided

(k)

take reasonable steps to prevent unauthorised access to the site

(l)

take all reasonable steps to ensure that all workers are provided with a suitable site induction and other information and training as may be necessary

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(j)

There is an emphasis on trying to keep documentation to a minimum. This is based on the idea that a competent workforce only needs to be told about site-specific risks and working practices.

3

While these requirements might seem onerous they are all principles of good management of health, safety and welfare and many companies have been implementing them for a long time.

4

The avoidance of accidents and the prevention of ill health by the use of good management techniques have proven to result in significant benefits, not least to the 'bottom line'.

5

Good management of health and safety on site is crucial to the successful delivery of a construction project. The key duty of contractors is to properly plan, manage and coordinate work during the construction phase in order to ensure that the risks are properly controlled. Contractors must also comply with the duties placed on all contractors under these Regulations.

6

This allows the management of health and safety to be incorporated into the wider management of project delivery. This is good business practice as well as being helpful for health and safety purposes.

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2

Co-operation and co-ordination 7

Good co-operation and co-ordination of work between all of the parties involved in a project is essential if risks are to be identified early on and properly controlled. Contractors should take the lead and actively encourage co-operation and co-ordination between sub-contractors from an early stage. A team approach involving the client, designers, contractors and even manufacturers who work closely together will often produce the best results. This allows the client, designers, contractors and facilities management experts, together, to identify the best solution for the client’s needs, taking account of the practicalities of construction work, maintenance and use. Even on projects where it is not practical to formally establish an integrated team, the client, designer, contractors and others involved in the project still need to work together.

8

If there are other projects on the same or neighbouring sites then the co-operation and

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co-ordination needs to extend to those involved with such projects. If this need can be identified early on, the risks that one project may cause for the other can also be identified and addressed in the early stages of project planning. If potential problems are not identified until the actual work has started they can be much more difficult to address. 9

Good, timely communication is essential to co-operation and co-ordination of activities. Information about risks and precautions needs to be shared sensibly (i.e. relevant information, not everything) when it is needed to plan and manage work. Drawings can be used to highlight hazards or unusual work sequences identified by designers, with advice on where to find more information, if required. Induction training and toolbox talks help to ensure workers understand the risks and precautions, and are a good opportunity to inform workers of site rules or any special risks relating to the project.

.

How many Contractors can there be for each project? There can only be one main contractor for a project at any one time. However, sometimes two or more projects take place on a site at the same time. This can occur if different clients commission adjacent work, or if a client procures two truly independent, unrelated packages of work which do not rely upon one another for their viability or completion.

11

Where overlapping projects are running on a single construction site, it is best to appoint one Contractor for them all. If this is not done, all the contractors must co-operate, and their plans must take account of the interfaces – for example in traffic management.

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Planning and managing health and safety in the construction phase Contractors must plan, manage and co-ordinate work during the construction phase taking account of the information contained in the pre-construction information provided by the client, and any other information provided by subcontractors.

13

The effort devoted to planning and managing health and safety should be in proportion to the risks and complexity associated with the project.

14

The Contractor should work with other sub-contractors to identify the hazards and assess the risks related to their work, including the risks they may create for others. Using this information and applying the general principles of prevention the Contractor, in discussion with the sub-contractors involved, must plan, manage and co-ordinate the construction phase. This includes supervising and monitoring work to ensure that it is done safely and that it is safe for new activities to begin.

15

Where the project involves high-risk work, for example alterations that could result in structural collapse, work on contaminated land, specialist advice is likely to be needed at the planning stage.

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The construction phase plan 16

The way in which the construction phase will be managed and the key health and safety issues for the particular project must be set out in writing in the construction phase plan. This plan should set out the organisation and arrangements that have been put in place to manage risk and co-ordinate the work on site. It should not be a repository for detailed generic risk assessments, records of how decisions were reached or detailed method statements, but it may, for example set out when such documents will need to be prepared. It should be well focused, clear and easy for sub-contractors and others to understand – emphasising key points and avoiding irrelevant material. It is crucial that all relevant parties are involved and co-operate in the development and implementation of the plan as work progresses.

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17

The plan must be tailored to the particular project. Generic plans that do not contain the information relevant to the particular risks associated with the work will not satisfy the requirements of CDM. Photographs and sketches can greatly simplify and shorten explanations. It should also be organised so that relevant sections can easily be made available to designers and sub-contractors.

18

Often the design and preparation for later work is not complete at the start of the construction phase. Nevertheless, the plan for the initial phase of the construction work must be prepared before any work begins. It should also address later activities that will require careful planning. It may only be practical to address such activities in outline form before work starts and most will require revision in the light of developments. Implementing and monitoring the plan A plan is no use if it is treated as merely a paper exercise and gathers dust. To improve Qatar standards, it must be a practical aid to the management of health and sa fety on site. Contractors and other sub-contractors have a particular role in both implementing and monitoring the plan to ensure that it works in practice. Monitoring arrangements will need to be discussed and agreed with the client as they form part of the management arrangements.

20

The purpose of monitoring is to ensure that the precautions described in the construction phase plan are appropriate and followed in practice. Where contractors do not work safely or comply with the plan, Contractors must take appropriate action to deal with the risk.

21

The contractor is responsible for ensuring the health and safety of everyone on site. Everyone on site (including the client, anyone working for the client and workers of utility companies) must co-operate with the contractor to enable them to comply with their duties.

22

The plan needs to be routinely reviewed, revised and refined by the contractor as the project develops. For example, where the plan is not being followed, and health and safety is put at risk, those involved must take appropriate action to deal with the risk. Monitoring may show the plan has shortcomings and needs to be modified. Any significant changes in the plan should be brought to the attention of all those affected.

Contractors should include any necessary rules for the management of construction work in the construction phase plan, which others on the site have to follow. These may cover issues such as restricted areas, permit-to-work systems, hot work and emergency plans. In order to avoid cluttering the plan with detailed arrangements for implementing site rules, the plan should refer to other documents or put detailed arrangements in appendices. Site rules should be:

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Site rules

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19

24

(a)

set out in writing;

(b)

understandable to those who have to follow them;

(c)

brought to the attention of everyone who has to follow them;

(d)

enforced by the Contractor

Copies of the site rules should be displayed on site in a place where they can be seen by those who work there. Controlling access onto sites

25

A contractor must take reasonable steps to prevent access by unauthorised persons to the construction site. Only people who are explicitly authorised, individually or

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collectively, by the contractor, should be allowed access. The authorisation may cover the whole site or be restricted to certain areas. Authorised people should have relevant site rules explained to them and undertake any necessary site induction, and should comply with site rules and co-operate with the contractor. Some authorised visitors may need to be supervised or accompanied while on site or visiting specific areas.

rights of way cross sites;

(b)

sites are in, or next to, other work areas;

(c)

new houses are being built on a development where some houses are already occupied; or

(d)

there are children or other vulnerable people nearby.

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a suitable induction; and

(b)

any further information and training needed for the particular work.

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(a)

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This does not mean that the contractor has to train everyone on the site - this will be the responsibility of individual sub-contractors. Induction

(a)

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Inductions are a way of providing workers with specific information about the particular risks associated with the site and the arrangements that have been made for their control. Induction is not intended to provide general health and safety training, but it should include a site-specific explanation of the following: senior management commitment to health and safety

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Site induction, training and information are vital to securing health and safety on site. The Contractor has to ensure, so far as is reasonably practicable, that every worker has:

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The effectiveness of the arrangements needs to be reviewed in the light of experience. In particular, their adequacy should be carefully reviewed if there is evidence of children playing on, or near the site. Site induction, training and information

28

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(a)

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27

How access is controlled depends on the nature of the project, the risks and location. The boundaries of all sites should be physically defined, where necessary, by suitable fencing. The type of fencing should reflect the nature of the site and its surroundings. Special consideration is needed where:

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(b)

the outline of the project

(c)

the individual’s immediate line manager and any other key personnel

(d)

any site-specific health and safety risks, for example in relation to access, transport, site contamination, hazardous substances and manual handling

(e)

Control measures on the site, including; (i)

any site rules,

(ii)

any permit-to-work systems,

(iii)

traffic routes,

(iv)

security arrangements,

(v)

hearing protection zones,

(vi)

arrangements for personal protective equipment, including what is needed, where to find it and how to use it,

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Section 11: Health and Safety Page 119 Part 1.01: Qatar Legislation and Management (Regulatory Document) (vii)

arrangements for housekeeping and materials storage,

(viii) facilities available, including welfare facilities, (ix)

emergency procedures, including fire precautions, the action to take in the event of a fire, escape routes, assembly points, responsible people and the safe use of any fire-fighting equipment;

(f)

arrangements for first aid

(g)

arrangements for reporting accidents and other incidents

(h)

details of any planned training, such as ‘toolbox’ talks

(i)

arrangements for consulting and involving workers in health and safety, including the identity and role of any:

(ii)

safety committees;

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safety representatives,

information about the individual’s responsibilities for health and safety.

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(j)

(i)

1.1.8.34 Sub-Contractor

Sub-contractors and those actually doing the construction work are most at risk of injury and ill health. They have a key role to play, in co-operation with the contractor, in planning and managing the work to ensure that risks are properly controlled.

2

All sub-contractors (including utilities, specialist contractors, contractors nominated by the client and the self-employed) have a part to play in ensuring that the site is a safe and healthy place to work. The key to this is the proper co-ordination of the work, underpinned by good communication and co-operation between all those involved.

3

Anyone who directly employs, engages construction workers or controls or manages construction work related tasks is a sub-contractor for the purposes of these Regulations. This includes companies that use their own workforce to do construction work on their own premises. The duties on contractors apply whether the workers are employees or self-employed and to agency workers without distinction.

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For all projects sub-contractors must: (a)

check clients are aware of their duties;

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What sub-contractors must do on all projects

(b)

satisfy themselves that they and anyone they employ or engage are competent and adequately resourced;

(c)

plan, manage and monitor their OWN work to make sure that workers under their control are safe from the start of their work on site;

(d)

ensure that any sub-contractor who they appoint or engage to work on the project is informed of the minimum amount of time which will be allowed for them to plan and prepare before starting work on site;

(e)

provide workers under their control (whether employed or self-employed) with any necessary information, including about relevant aspects of other contractors’ work, and site induction (where not provided by a contractor) which they need to work safely, to report problems or to respond appropriately in an emergency;

(f)

ensure that any design work they do complies with these Regulations

(g)

co-operate with others and co-ordinate their work with others working on the project;

(h)

ensure the workforce is properly consulted on matters affecting their health and

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Section 11: Health and Safety Page 120 Part 1.01: Qatar Legislation and Management (Regulatory Document) safety; and

(i)

obtain specialist advice (for example from a structural engineer or occupational hygienist) where necessary when planning high-risk work – for example alterations that could result in structural collapse or work on contaminated land or carrying out modification works on an existing structure.

Planning and managing construction work 5

Sub-contractors should always plan, manage, supervise and monitor their own work and that of their workers to ensure that it is carried out safely and that health risks are also addressed. The effort invested in this should reflect the risk involved and the experience and track record of the workers involved. Where sub-contractors identify unsafe practices, they must take appropriate action to ensure health and safety.

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Site induction, information and training Contractors must not start work on a construction site until they have been provided with basic information. This should include information from the client about any particular risks associated with the project (including information about existing structures where these are to be demolished or structurally altered), and from designers about any significant risks associated with the design.

7

Sub-contractors must ensure, so far as is reasonably practicable, that every worker has:

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6

a suitable induction; and

(b)

any further information and training needed for the particular work

as

(a)

Site induction should be provided by the contractor, and the sub-contractor must cooperate with the contractor to ensure that an adequate site induction is provided.

9

Where sub-contractors are involved in design work, including for temporary works, they also have duties as designers.

10

Sub- contractors must also:

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(b)

co-operate with the contractor, the Engineer and others working on the project or adjacent sites;

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(a)

inform the contractor about risks to others created by their work;

(c)

provide details to the contractor of any supply chain or specialist sub-contractor whom he engages in connection with carrying out the work;

(d)

comply with any reasonable directions from the main contractor, and with any relevant rules in the construction phase plan;

(e)

inform the contractor of any problems with the plan or risks identified during their work that have significant implications for the management of the project;

(f)

inform the contractor about accidents and dangerous occurrences;

(g)

provide information for the health and safety file.

Reporting incidents 11

The Reporting of Injuries, Diseases and Dangerous Occurrences (RIDDOR) require s the

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‘responsible person’ to notify any death, reportable injury, disease or dangerous occurrence to the Qatar Administrative Authority. The responsible person is the employer or, for the self-employed, the contractor. Sub-contractors must co-operate with the contractor, and assist them in the development of the construction phase plan and its implementation. Where subcontractors identify shortcomings in the plan, the contractor should inform the contractor.

13

Sub-contractors must promptly inform the contractor about risks to other site workers or members of the public resulting from their work. This includes anything, for example from risk assessments and written systems of work, which might justify a review or update of the construction phase plan. Sub-contractors must also provide details to the contractor of any other sub-contractors who they engage to assist in the carrying out of the work. Contractors must be in a position to know who is working on the site. Contractors also have duties relating to the provision of information to sub-contractors, and they will not be in a position to discharge these duties if they are not told that such sub-contractors have been engaged.

14

Sub-contractors must also provide information about RIDDOR incidents to contractors so that they can monitor compliance with health and safety standards and, if necessary, review the arrangements for the management of health and safety.

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Site Specific Duties (Contractors/Sub-contractors)

Every contractor and subcontractor carrying out construction work shall comply with the regulatory requirements of this section insofar as they affect him or any person carrying out construction work under his control or relate to matters within his control.

16

Every person (other than a contractor carrying out construction work) who controls the way in which any construction work is carried out by a person at work shall comply with the regulatory requirements under this section insofar as they relate to matters which are within his control.

17

Every person at work on construction work under the control of another person shall report to that person any defect which he is aware may endanger the health and safety of himself or another person.

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Safe places of work There must be, so far as is reasonably practicable, safe access to and egress from a place of work and to any other place provided for the use of any person at work. Such means of access must be properly maintained.

19

Places of work must, so far as is reasonably practicable, be maintained without risk to health or safety of the person(s) who will work there.

20

Suitable and sufficient steps must be taken to ensure, so far as is reasonably practicable, that no-one gains access to any place which does not comply with the requirements of these Regulations

21

Every place of work must, so far as is reasonably practicable, be of sufficient size and be arranged so that it is suitable for any person who has to work there, taking account of any work equipment used.

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Good order (Housekeeping) 22

Every part of a construction site shall, so far as is reasonably practicable, be kept in good order and every part of the site which is used as a place of work shall be kept in a

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reasonable state of cleanliness. 23

Where it is necessary in the interests of health and safety, the perimeter of the site shall be identified by suitable signs so that the arrangements and extent of the site is readily identifiable, or fenced off, or both.

24

No timber or other material with projecting nails or other similar sharp objects shall be used in any work or be allowed to remain in any place where the nails will be a source of danger to any person. Stability of structures All practicable steps must be taken to ensure that any structure or part of a structure which may become unstable or weak due to construction work does not collapse.

26

Any buttress, temporary support or temporary structure:

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must be installed and maintained to withstand any strains and stresses that may be imposed on it

(b)

only be used for the purposes for which it was designed, installed and maintained.

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(a)

No part of a structure may be loaded in such a way that it becomes unsafe.

28

The client is responsible for providing reasonable information, and issues relating to the stability of the structure would fit into that category.

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Demolition or dismantling

The demolition or dismantling of any structure must be planned and carried out in such a way as to prevent danger, or reduce the danger so far as it is reasonably practicable to do so.

30

Demolition or dismantling must not be carried out unless the arrangements for ensuring that is carried out in a safe manner have first been recorded in writing.

31

The demolition or dismantling of any structure must be planned and carried out as safely as possible, under the supervision of a competent person. Demolishing buildings and structures remains high risk work.

32

It will normally be impossible for the contractor to comply with these Regulations without reports such as an asbestos survey, information on underground services and structural surveys.

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Explosives 33

So far as is reasonably practicable, explosives must be stored, transported and used safely and securely.

34

Explosives may only be used when steps have been taken to ensure that there is no danger from the explosion, projected or flying materials.

35

Any blasting would categorically be considered high risk work and a written method statement required. Excavations

36

All practicable steps, such as the provision of supports or battering, must be taken where necessary to prevent danger to any person, to ensure that:

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(c)

no part of an excavation collapses

(d)

any accidental fall or dislodgement of material is prevented

(a)

no person is buried or trapped by the fall or dislodgement of any material.

37

Suitable and sufficient steps must be taken to prevent the fall of any person, equipment or material into the excavation.

38

Suitable and sufficient steps must be taken to prevent, where necessary, any part of an excavation or ground adjacent to it from being overloaded by work equipment or material.

39

Work must not be carried out in any excavation where supports or battering have been provided, unless:

(b)

the person who inspected it is satisfied that work can be carried out in it safely.

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the excavation and any equipment and materials which affect its safety have been inspected by a competent person.

Work must not be carried out in any excavation if an inspection reveals any defect rendering the excavation unsafe, until that defect has been rectified. The decision as to whether or not to install shoring must be made with regard to the circumstances prevailing at the time. Suitable and sufficient steps must be taken to prevent any person working in an excavation from becoming trapped or buried by a fall of materials.

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Excavations must be supported as soon as possible by the provision of sufficient and suitable materials. Such supports must only be installed, altered or dismantled under the supervision of a competent person and without the person(s) installing the supports being put at risk.

of suitable design and construction and have sufficient strength and capacity for the purpose for which it is being used

(b)

equipped to enable workers to gain shelter or escape, if water or materials should enter it

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properly maintained.

Work must not be carried out in any cofferdam or caisson unless: (a)

(b) 44

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(a)

(c) 43

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Every cofferdam or caisson must be:

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42

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Cofferdams and caissons

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(a)

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40

(a)

it and any work equipment or materials which affect its safety have been inspected: (i)

before any person carries out any work at the start of every shift, and

(ii)

after any event likely to affect the strength or stability of the cofferdam or caisson or any part of it

the person who inspected it is satisfied that work can be carried out in it safely.

Work must not be carried out in any cofferdam or caisson if any inspection reveals any defect rendering the cofferdam or caisson unsafe, until that defect has been rectified. Reports of inspections

45

Where a statutory inspection of an excavation, cofferdam or caisson has been carried out, the person carrying out the inspection must, before the end of the shift during which the inspection was carried out:

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(a)

inform the person for whom the inspection was carried out of any matter that renders the excavation or caisson unsafe as a place of work

(b)

prepare a written report.

Note: The report must contain the particulars listed in Appendix 2.

47

The person who prepares the written report must provide a copy of the report within 24 hours to the person on whose behalf the inspection was carried out.

48

The employer Contractor of the person authorised to carry out inspections, or the person in control, must ensure that the inspections are only carried out by persons who are authorised to do so.

49

The report or a copy of it must be kept available for inspection by a Administrative Authority Workplace Inspector

for a period of three months (at the company offices)

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(b)

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on the site until the project is completed, and thereafter

No report of a cofferdam or caisson inspection is required if one has been written within the previous seven days.

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(a)

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46

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Energy distribution installations

Where it is necessary to prevent danger, every energy distribution installation must be located, checked and clearly identified.

52

Where there is a risk from electric power cables, in order of priority, they must be;

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51

repositioned out of the area of risk, or

(b)

made dead by cutting off the current, or

(c)

where it is not reasonably practicable to carry out the above actions erect warning notices and:

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(a)

barriers, or

(ii)

a suspended means of protection where vehicles have to pass beneath overhead cables, or

(iii)

other measures which provide an equivalent or better level of protection.

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(i)

53

Construction work must not be carried out where there is a risk of danger from damaging or disturbing underground services unless suitable and sufficient steps have been taken so far as is reasonably practicable.

54

Whilst electrical cables are specifically mentioned, the title indicates that the general requirement outlined in the first paragraph applies to all sources of energy, for example hydraulic and pneumatic distribution systems. Prevention from drowning

55

Where any person is liable to drown from falling into water or any other liquid, suitable and sufficient steps must be taken to: (a)

prevent, so far as is reasonably practicable, a person falling

(b)

minimise the risk of a person drowning in the event of a fall

(c)

ensure that suitable rescue equipment is provided, maintained and properly used so that anyone who falls into the water may be promptly rescued.

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56

Suitable and sufficient steps must be taken to ensure the safety of any person transported to their place of work by water.

57

Any vessel used to convey a person to or from a place of work, by water, must not be overcrowded or overloaded. Traffic routes Every construction site must, so far as is reasonably practicable, be organised in such a way that pedestrians and vehicles can move about safely and without risk to health.

59

Traffic routes must be suitable for persons or vehicles using them, sufficient in number, in suitable places and of sufficient size.

60

To be suitable, each traffic route must: enable pedestrians and vehicles to use it without causing danger to persons who are near it

(b)

doors or gates used by pedestrians which lead into a traffic route must be adequately separated from that route so that pedestrians may see approaching vehicles

(c)

provide sufficient separation between vehicles and pedestrians to ensure safety, or, where that is not reasonably practicable, provide:

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(a)

other means of protecting pedestrians and

(ii)

an effective means of warning any at-risk pedestrian of the approach of any vehicle

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(i)

have at least one exit in any loading bay for the exclusive use of pedestrians

(e)

provide one or more pedestrian-only gates, clearly marked and kept free of obstructions where it is unsafe for pedestrians to use a gate intended primarily for vehicles.

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Traffic routes must be:

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(d)

identified by suitable signs, where necessary

(b)

regularly checked and

(c)

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61

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58

satisfactorily maintained.

No vehicle must be permitted to drive on a traffic route unless, so far as is reasonably practicable, the route is free from obstructions and permits sufficient clearance.

63

All traffic routes must be indicated where necessary.

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Vehicles 64

Suitable and sufficient steps must be taken to prevent the unintended movement of any vehicle.

65

Suitable and sufficient steps must be taken to ensure that persons who are in control of vehicles give warning to other persons who may be endangered by the movement of the vehicle.

66

Any vehicle being used for construction work must be: (a)

driven, operated or towed in a safe manner

(b)

loaded in such a way that it can be driven, operated or towed in a safe manner.

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67

No person shall ride or be required to ride on any vehicle unless they are in a safe place that is purposely provided (i.e. the vehicle is designed to carry passengers).

68

No person may remain or be required to remain on any vehicle while it is being loaded or unloaded with any loose material unless a safe place of work is provided for them and maintained as necessary.

69

Suitable and sufficient steps must be taken to prevent the vehicle from falling into an excavation or pit, or into water, or over the edge of an embankment or earthwork. Prevention of risk from fire Suitable and sufficient steps must be taken to prevent, so far as is reasonably practicable, the risk of injury to any person during the carrying out of construction work arising from any fire or explosion, flooding, or any substance that is liable to cause asphyxiation.

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70

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Emergency procedures

Where necessary, in the interests of health and safety, suitable and sufficient arrangements must be prepared and, where necessary, implemented to deal with any foreseeable emergency, and such arrangements must include procedures for evacuation of the site, or any part of it.

72

When making these arrangements, account must be taken of: the type of work being carried out

(b)

the characteristics and size of the site and the number of work locations on it

(c)

the work equipment being used

(d)

the number of persons likely to be present on the site at any one time

(e)

the physical and chemical properties of any substances or materials likely to be on the site

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(a)

Such arrangements must be communicated to all persons on site and tested at suitable intervals.

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Emergency routes and exits Sufficient emergency routes and exits must be provided to enable any person to quickly reach a place of safety in the event of danger.

75

Any emergency route or exit must lead directly, or as directly as possible, to an identified safe area.

76

Any emergency route or exit must be kept clear of obstructions and, where necessary, provided with emergency lighting so that it can be used safely at any time.

77

All emergency routes and exits must be indicated by suitable signs.

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Fire detection and fire-fighting 78

Where necessary in the interests of health and safety, suitable fire-fighting equipment, together with fire alarms and fire detection systems, must be installed in suitable locations.

79

A fire risk assessment will be required for the site including storage areas, with particular emphasis on the storage highly flammable or explosive substances, and site welfare facilities.

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80

Fire-fighting equipment and fire detection/alarm systems must be properly maintained and subjected to periodic tests and examination so as to ensure that the equipment remains effective.

81

Any fire-fighting equipment that is not designed to operate automatically must be easily accessible.

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Every person at work on a construction site must, so far as is reasonably practicable, be instructed in the use of any fire-fighting equipment that it may be necessary for them to use.

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Where any work activity gives rise to a particular risk of fire, no person shall be authorised to carry out such work unless that person has received suitable instructions.

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All fire-fighting equipment must be indicated by suitable signs.

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Fresh air

Suitable and sufficient steps must be taken to ensure, so far as is reasonably practicable, that every workplace or approach to it has sufficient fresh or purified air to ensure that the place or approach is safe and without risk to health.

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Where plant is used for the purpose of providing fresh or purified air, it must be equipped with an effective device to give visible and audible warning of the failure of the plant.

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Temperature and weather protection

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Suitable and sufficient steps must be taken during working hours to ensure, so far as is practicable, that the temperature at any indoor place of work is reasonable, having regard for the purpose for which the place is being used.

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Every place of work outdoors must, where necessary to ensure the health and safety of the people at work there, be arranged so far as is reasonably practicable, to provide adequate protection from adverse weather, having regard for the purpose for which the place is used and any protective clothing or work equipment provided.

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Every place of work, every approach to it and every traffic route must be provided with suitable and sufficient lighting. The lighting should, as far as is reasonably practicable, be natural lighting.

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The colour of any artificial lighting must not adversely affect or change a perception of any sign or signal that is provided for the purposes of health and safety.

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Secondary or emergency lighting must be provided where there may be a risk to the health and safety of any person in the event of the failure of any primary artificial lighting.

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1.1.8.35 Competence and training 92

This section gives guidance about assessing the competence of organisations and individuals engaged or appointed under CDM – engineers; designers; contractors and sub-contractors.

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Assessments should focus on the needs of the particular project and be proportionate to the risks, size and complexity of the work.

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To be competent, an organisation or individual must have:

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(a)

sufficient knowledge of the specific tasks to be undertaken and the risks which the work will entail.

(b)

sufficient experience and ability to carry out their duties in relation to the project; to recognise their limitations and take appropriate action in order to prevent harm to those carrying out construction work, or those affected by the work.

Organisations and individuals will need specific knowledge about the tasks they will be expected to perform, and the risks associated with these tasks. This will usually come from formal or ‘on the job’ training.

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Appropriate experience is also a vital ingredient of competence. People are more likely to adopt safe working practices if they understand the reasons why they are necessary, and past experience should be a good indicator of the person’s/ company’s track record.

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The development of competence is an ongoing process. Individuals will develop their competence through experience in the job and through training which is part of ‘life-long learning’. Professionals such as designers, engineers and advisors should be signed up to a ‘Continuing Professional Development’ CPD programme either through their company or professional institution membership schemes. This will allow them to remain ‘up to date’ with changes in best and professional practice. Construction trades workers and labourers should also receive refresher training or regular training updates either through an in-house planned programme of learning and development, or a more formal skills-based training programme.

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What you must do

All those with duties under CDM must satisfy themselves that businesses that they engage or appoint are competent. This means making reasonable enquiries to check that the organisation or individual is competent to do the relevant work and can allocate adequate resources to it. Those taken on to do the work must also be sure that they are competent to carry out the required tasks before agreeing to take on the work.

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A key duty of the engineer is to advise clients about competence of designers and contractors.

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Doing an assessment requires you to make a judgement as to whether the organisation or individual has the competence to carry out the work safely. If your judgement is reasonable, taking into account the evidence that has been asked for and provided, you will not be criticised if the organisation you appoint subsequently proves not to have been competent to carry out the work.

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How to assess the competence of organisations 101

Competency assessments of organisations (including contractors, sub-contractors, designers and engineers) should be carried out as a two-stage process:

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Stage 1: An assessment of the company’s organisation and arrangements for health and safety to determine whether these are sufficient to enable them to carry out the work safely and without risk to health.

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Stage 2: An assessment of the company’s experience and track record to establish that it is capable of doing the work; it recognises its limitations and how these should be overcome and it appreciates the risks from doing the work and how these should be tackled.

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In order to provide more consistency in the way in which competency assessments of companies are carried out, a set of ‘core criteria’ is set out below.

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Competence chart Core criteria for demonstration of competence:

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Companies, contractors, engineers and designers

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You need to meet the standards set out in the core criteria table on the next page.

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Column 1 of the table lists the elements which should be assessed when establishing whether or not a company is competent for the work which they will be expected to do.

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Column 2 lists the standards against which the assessment should be made. Column 3 gives some examples of how a company might demonstrate that it meets these standards.

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Companies do not have to produce all of the evidence listed in column 3 to satisfy the standard - they simply need to produce enough evidence to show that they meet the standard in column 2, taking account of the nature of the project and the risks which the work entails. This requires you to make a judgement as to whether the evidence provided meets the standard to be achieved. If your judgement is reasonable, and clearly based on the evidence you have asked for and been provided with, you will not be criticised if the company you appoint subsequently proves not to be competent when carrying out the work.

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Remember that assessments should focus on the needs of the particular job and should be proportionate to the risks arising from the work. Unnecessary bureaucracy associated with competency assessment obscures the real issues and diverts effort away from them.

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'contractor', 'designer' and 'engineer' relate to your function, not to the type of organisation.

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Section 11: Health and Safety Part 1.01: Qatar Legislation and Management (Regulatory Document)

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Standard to be achieved

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Criteria

Health and safety policy and You are expected to have and implement an A signed, current copy of the company policy (indicating when organisation for health and appropriate policy, regularly reviewed, and signed off it was last reviewed and by whose authority it is published). safety by the managing director or equivalent.

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Stage 1 assessment

Examples of the evidence that you could use to demonstrate you meet the required standard

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The policy must be relevant to the nature and scale of your work and set out the responsibilities for health and safety management at all levels within the organisation.

Arrangements

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Competent advice -corporate Your organisation, and your employees, must have Name and competency details of the source of advice, e.g. a and construction related ready access to competent health and safety advice, safety group, trade federation, or consultant who provides preferably from within your own organisation. health and safety information and advice.

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These should set out the arrangements for health and A clear explanation of the arrangements which the company safety management within the organisation and should has made for putting its policy into effect and for discharging be relevant to the nature and scale of your work. They its duties under CDM . should set out how the company will discharge their duties under CDM. There should be a clear indication of how these arrangements are communicated to the workforce.

The advisor must be able to provide general health and An example from the last 12 months of advice given and safety advice, and also (from the same source or action taken. elsewhere) advice relating to construction health and safety issues.

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Training and information

You should have in place, and implement, training arrangements to ensure your employees have the skills and understanding necessary to discharge their duties as contractors, designers or Engineers. You should have in place a programme for refresher training, e.g. a continuing professional development programme or life long learning which will keep your employees updated on new developments and changes to legislation or good health and safety practice. This applies throughout the organisation - from board or equivalent to trainees.

Headline training records. Evidence of a health and safety training culture including records, certificates of attendance and adequate health and safety induction training for site-based workforce. Evidence of an active learning programme. Sample 'tool box talks'.

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Individual qualifications and Employees are expected to have the appropriate experience qualifications and experience for the assigned tasks, unless they are under controlled and competent supervision.

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Details of qualifications and/or experience of specific corporate post holders, e.g. board members, health and safety adviser etc. Other key roles should be named or identified and details of relevant qualifications and experience provided. FOR CONTRACTORS: details of number/percentage of people engaged in the project that have passed a construction health and safety assessment and hold industry qualifications. For professionals, details of qualifications and/or professional institution membership. Evidence of a company-based training programme suitable for the work to be carried out.

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Individual qualifications and experience (cont'd)

FOR DESIGN ORGANISATIONS: details of number/percentage of people engaged in the project who have passed a construction health and safety assessment Details of any relevant qualifications and/or professional institution membership and any other specific qualifications such as NEBOSH Certificate or equivalent. FOR ENGINEERS: details of number/percentage of people engaged in the project who have passed a construction health and safety assessment. Evidence of health and safety knowledge such as NEBOSH Certificate or equivalent. Details of professional institution membership and any other specific qualifications. Evidence of a clear commitment to training and the continuing professional development of staff.

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Monitoring, audit and review

You should have a system for monitoring your Could be through formal audit or discussions/reports to senior procedures, for auditing them at periodic intervals, and managers. for reviewing them on an ongoing basis. Evidence of recent monitoring and management response. Copies of site inspection reports.

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Workforce involvement

You should have, and implement, an established Evidence showing how consultation is carried out. means of consulting with your workforce on health and Records of health and safety committees safety matters. Names of safety representatives.

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Accident reporting and You should have records of all RIDDOR reportable Evidence showing the way in which you record and enforcement action; follow up events for at least the last three years. You should also investigate accidents and incidents. investigation have in place a system for reviewing all incidents, and Records of the last two accidents/incidents and the actions recording the action taken as a result. taken to prevent recurrence. You should record any enforcement action taken Records of any enforcement action taken over the last five against your company over the last five years, and the years, and what action was taken to put matters right. action which you have taken to remedy matters subject to enforcement action. For larger companies, simple statistics showing incidence rates of major injuries, over three-day injuries, reportable cases of ill-health and dangerous occurrences for the last three years.

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Records should include any incidents that occurred whilst the company traded under a different name, and any incidents that occur to direct employees or Labour-only subcontractors.

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Subcontracting/ consulting You should have arrangements in place for appointing Evidence showing how you ensure subcontractors are procedures (if applicable) competent subcontractors/ consultants. competent. You should be able to demonstrate how you ensure Examples of subcontractor assessments you have carried that subcontractors will also have arrangements for out. appointing competent subcontractors or consultants. Evidence showing how you require similar standards of You should have arrangements for monitoring competence assessment from subcontractors. subcontractor performance. Evidence showing how you monitor subcontractor performance.

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Hazard elimination and risk You should have, and implement, arrangements for Evidence showing how you: control (Designers only) meeting your duties under CDM  ensure co-operation and co-ordination of design work within the design team and with other designers/contractors

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

ensure that hazards are eliminated and any remaining risks controlled



ensure that any structure which will be used as a workplace will meet relevant requirements of the latest revision for QCS.

Examples showing how risk was reduced through design. A short summary of how changes to designs will be managed. (Note: the emphasis here should be on practical measures which reduce particular risks arising from the design, not on lengthy procedural documentation highlighting generic risks.)

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Risk assessment You should have procedures in place for carrying out risk Evidence showing how the company will identify significant leading to a safe assessments and for developing and implementing safe health and safety risks and how they will be controlled. method of work systems of work/method statements. Sample risk assessments or safe systems of work or method (Contractors only) statements. The identification of health issues is expected to feature This will depend upon the nature of the work, but must reflect prominently in this system. the importance of this risk area.

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Co-operating with others and coordinating your work with that of other contractors (Subcontractors)

You should be able to illustrate how co-operation and co- Evidence could include sample risk assessments, procedural ordination of your work is achieved in practice, and how you arrangements, project team meeting notes. involve the workforce in drawing up method statements/safe Evidence of how the company co-ordinates its work with other systems of work. trades.

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Welfare provision You should be able to demonstrate how you will ensure that Evidence could include, for example, health and safety policy (Contractors) appropriate welfare facilities will be in place before people start commitment; contracts with welfare facility providers; details work on site. of type of welfare facilities provided on previous projects.

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Engineers duties

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Standard to be achieved

Examples of the evidence that you could use to demonstrate you meet the required standard

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Criteria

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Stage 2 assessment Work experience

You should give details of relevant experience in the field of work A simple record of recent projects or contracts should be kept, for which you are applying. with the phone numbers and addresses of contacts who can verify that work was carried out with due regard to health and safety. This should be sufficient to demonstrate your ability to deal with the key health and safety issues arising from the work you are applying for. Where there are significant shortfalls in your previous experience, or there are risks associated with the project which you have not managed before, an explanation of how these shortcomings will be overcome.

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Organisations who are bidding for work should put together a package of information that shows how their own policy, organisation and arrangements meet these sta ndards. If regularly updated, this information should then be used each time they are asked to demonstrate competence as part of a tender process.

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Where the project is much larger than any that the organisation being assessed has worked on before, or where the work will involve them managing new risks, this should not automatically rule them out for consideration for the work.

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The assessor should look for an appreciation of these risks; an understanding of how they will be managed, and some indication of how any shortcomings in their current arrangements for managing such risks will be addressed.

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It may be that an organisation is weak in certain areas. This can be addressed by putting arrangements in place to cover these weaknesses, or by employing people with particular expertise for relevant parts of the contract. What really matters is that the organisation has access to the expertise which it needs, and the ability to control the risks which arise from the work.

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Remember that assessments should focus on the needs of the particular project and be proportionate to the risks, size and complexity of the work. Unnecessary bureaucracy associated with competency assessment can obscure the real issues and divert effort away from them.

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How to assess the competence of High Hazard Activities These regulations require clients to ensure that their proposed project engineers, designers, contractor and sub contractors (including their employees) are competent, adequately resourced and appointed early enough for the work they have to do. In turn, these duty holders must assess their own competency and that of their employees and other duty holders (except in the case of a client where the test does not apply) as they cannot accept an appointment unless they are competent to do so.

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In every case, a client must assess the competency of the organisations to be appointed for high hazard activities.

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The client must assess the competence of an organisation using a two-stage process:

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Stage 1: Procedures and arrangements for ensuring health and safety (a client should ask for evidence of written health and safety policies and these must in turn be checked for relevance); and

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Stage 2: Experience and track record.

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Organisations should provide information as to their competence with reference to the above when tendering for work. In the case of high specialist activities such as:

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(a)

Use of explosives

(b)

Cofferdams and caissons

(c)

Work in compressed air

(d)

Tunnelling and underground works

Clients are required when reviewing competences of specialist contractors who are tendering for construction projects involving high hazard activities to appoint consultant health and safety advisers with specialist knowledge pursuant to the high hazard activities. The appointed consultants experience will aid the clients to discharge their responsibilities

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when reviewing duty holders tender and competence documentation. 125

The list of high hazard activities listed above is not definitive and when projects are out of the scope of their internal health and safety advisors capability, the appointment of an external consultant must take place to aid in establishing the competence of construction tendering contractors. How to assess the competence of individuals The information in this section will help clients, engineers or others who control the way in which construction work is carried out to assess the competence of key individuals.

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Remember that assessments should focus on the needs of the particular job and should be proportionate to the risks arising from the work.

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As with organisations, assessing the competence of an individual should be a two-stage process:

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Stage 1: An assessment of the person’s task knowledge to determine whether this is sufficient to enable them to carry out the work safely and without risk to health;

(b)

Stage 2: An assessment of the individual’s experience and track record to establish that they are capable of doing the work; they recognise their limitations and how these should be overcome and they appreciate the risks from doing the work and how these should be controlled.

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(a)

Stage 1 assessments will look at an individual’s qualifications and training records, and arrangements which have been made for their Continuing Professional Development or lifelong learning. This will include an assessment as to whether the individual has a basic understanding of the risks arising from construction work which is essential for all people who work on or regularly visit sites.

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Stage 2 assessments should concentrate on the person’s past experience in the type of work which you are asking them to do. Where the work is more complex than any that the person has done before, or where the work will expose them to new risks, this should not automatically rule them out for consideration for the work. In these circumstances, the assessor should look for an appreciation of these risks; an understanding of how they will be managed, and some indication of how any shortcomings in their current knowledge will be addressed. Working under the supervision of someone who is competent and familiar with the work is one way in which people can learn how to do work safely.

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1.1.8.36 Worker engagement and communication 1

Involving the workforce in identifying and controlling risks is crucial to reducing the high accident rate associated with construction work. The workforce has first-hand experience of site conditions and is often the first to identify potential problems. Worker engagement is the participation by workers in decisions made by those in control of construction activities, in order that risks on site can be managed in the most effective way.

2

Participation will be most effective when the workforce has sufficient knowledge and confidence to provide feedback, and can identify risks and explain their importance. People have the confidence to do this when they are properly trained, know how to report their concerns, and see prompt action being taken as a result. Training should include, where necessary, the skills required to participate in decision-making processes, and consultation with managers.

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What you are required to do for all projects Providing information All those in control of construction work are required to provide workers (including the self-employed) under their control with any information that worker needs to carry out the construction work safely and without risk to health.

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All workers should be provided with a suitable site-specific induction to inform them of the arrangements for health, safety and welfare at their work site. This should include any relevant findings resulting from a risk assessment, including risks arising from the activities of other workers working nearby. If contractors have site rules these should be explained, along with the procedures to be followed in the event of any worker finding themselves in a position of serious and imminent danger. Contractors must communicate to their workers the identity of the person who is responsible for implementing health and safety procedures on site. Every worker has a duty under CDM to report anything, which is likely to endanger the health and safety of himself or others.

5

To ensure involvement of the entire workforce, contractors may need to make special arrangements for workers who have little or no understanding of Arabic and or English, or who cannot read Arabic and or English. These could include providing translation, using interpreters or replacing written notices with clearly understood symbols or diagrams.

6

Arrangements for worker engagement on smaller sites should always be tailored to the size and nature of the project and risks involved. On smaller sites informal arrangements for collecting workers’ views can be effective. An effective way of achieving this is to arrange reviews of method statements immediately before the work itself is being carried out. Those workers who will be involved in the work can then comment directly on the risks and the ways in which these are being controlled.

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Requirements for welfare facilities 1.1.8 Appendix 1 The Contractor must provide: Sanitary conveniences 1

Suitable and sufficient sanitary conveniences must be provided or made available at readily accessible places. So far as is reasonably practicable, the rooms containing sanitary conveniences must be; (a)

adequately ventilated and lit

(b)

kept in a clean and orderly condition.

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Welfare facilities Suitable and sufficient washing facilities including showers, if required by the nature of the work or for health reasons, must, so far as is reasonably practicable, be provided or made available at readily accessible places.

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Washing facilities must be provided:

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adjacent to sanitary conveniences, whether or not provided elsewhere

(b)

adjacent to changing rooms, where provided, whether or not provided elsewhere.

Washing facilities must include:

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(a)

a supply of clean hot and cold (or warm) water, which so far as is reasonably practicable shall be running water

(b)

soap or other suitable skin cleansers

(c)

towels or other suitable means of drying.

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Rooms containing washing facilities must be lit and sufficiently ventilated.

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Washing facilities and the rooms containing them must be kept in a clean and orderly condition.

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Except for washing facilities which are intended for the washing of hands and forearms only, separate rooms must be provided for men and women except where they:

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(a)

are in a room, the door of which can be locked from the inside and

(b)

the room is intended to be used by one person at a time.

Drinking water 7

An adequate supply of wholesome drinking water, conspicuously marked with the appropriate sign, should be provided or made available at readily accessible places.

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Sufficient cups or other drinking vessels must be provided, unless the water supply is in the form of a jet (drinking fountain) from which a person can easily drink. Changing rooms and lockers

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Suitable facilities must be provided or made available at readily accessible places if: (a)

the worker has to wear special clothing for the purposes of work, and,

(b)

for reasons of health or personal privacy, changing cannot be carried out

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Section 11: Health and Safety Page 140 Part 1.01: Qatar Legislation and Management (Regulatory Document) elsewhere.

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Where necessary, in the interests of personal privacy, separate changing rooms for men must be provided.

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Changing rooms must: (a)

be provided with seating

(b)

include, where necessary, facilities to dry clothing and personal effects

(c)

include, where necessary, facilities for locking away: special clothing that is not taken home

(ii)

a person's own clothing which is not worn at work

(iii)

their personal effects (property).

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Suitable and sufficient facilities for rest must be provided at readily accessible places. They must: include suitable arrangements to protect non-smokers from the discomfort caused by tobacco smoke

(b)

be equipped with an adequate number of tables and adequate seating (with backs)

(c)

where necessary, include facilities for any pregnant woman and nursing mother to rest, lying down

(d)

where necessary, include a means of boiling water and suitable arrangements to ensure that meals can be prepared and eaten

(e)

be maintained at an appropriate temperature

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An 'enclosed' workplace is one which has a roof or ceiling and, except for passageways, doors and windows, is wholly enclosed, whether on a temporary or permanent basis.

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A 'substantially enclosed' workplace is one which has a roof or ceiling but there are permanent openings in the walls, the combined area of which is less than 50% of the total wall area. When calculating the total 'open area' of any workplace, doors and/or windows which can be closed must not be counted.

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Particulars to be included in a report of inspection 1.1.8 Appendix 2 Name and address of the person on whose behalf the inspection was carried out.

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Location of the place of work inspected.

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Description of the place of work or part of that place inspected (including any work equipment and materials).

4

Date and time of the inspection.

5

Details of any matter identified that could give rise to a risk to the health or safety of any person.

6

Details of any action taken as a result of any matter identified in paragraph 5 above.

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Details of any further action considered necessary.

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Name and position of the person making report.

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Safety Inspections and Auditing

1.1.9.1 Key points Inspections of the workplace, from a health and safety point of view, can form a productive part of the consultation between management and the workforce.

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There are several forms of workplace inspection described in this section.

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While they are often carried out by a safety professional, they do not have to be.

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The successful outcome of any inspection is that remedial actions are put in place where shortcomings have been identified.

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Workplace inspections should be carried out against a predetermined checklist incorporating some method of recording the findings.

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Whereas workplace inspections tend to be a 'snapshot in time', an audit is a thorough examination not only of the site conditions prevailing at any one time but also of:

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the commitment of management to health and safety;

(b)

the procedures that underpin the health and safety management system.

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Note:

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identifying the hazards which employees face within the workplace

(b)

understanding how accidents are caused by unsafe acts, unsafe systems of work and unsafe conditions on site

(c)

taking steps to control the activity of the worker, the work method and the workplace.

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Contractors, managers, supervisors and safety representatives all have equally important roles to play. By obtaining and providing information through the inspection, investigation and examination of the workplace, they can help provide a basis for effective management action to promote safer and healthier workplaces, and induce a greater awareness of health, safety and welfare on the part of all concerned.

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It is well-established and documented that accidents can be prevented by:

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1.1.9.3 Safety inspections Regular and random inspections 1

Formal inspections at reasonably regular intervals should augment the site manager's dayto-day checks, inspections and examinations which occur as part of any job task. These should involve safety representatives using a properly designed safety checklist for a systematic inspection of the workplace.

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An example of such a checklist can be found in Appendix 1.

3

The advantages of regular safety inspections are that they ensure that good housekeeping is maintained within the workplace and that awareness is developed, amongst employees at all levels, of the need to promote and maintain safety standards. The disadvantage or danger of

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regular inspections is that they may become a rather mechanical routine for all concerned, and that their impact might be lessened. 4

Random inspections, however, carried out without any prior notice to the workforce, on different days of the week, at irregular intervals and at different times of the day, avoid the shortcomings of a predictable inspection and help to encourage a continuous interest in safety by all personnel.

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In practice, a combination of the two approaches of both regular and random inspections is probably the best course of action.

1.1.9.4 Remedial actions A clear understanding of what remedial actions are required to eliminate or less the risks to health and safety, and when those actions should be taken, is an essential part of health and safety management.

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The following lists suggest how shortcomings, as highlighted during health and safety inspections, should be prioritised for remedial action.

3

Items requiring immediate action:

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the contravention of this Regulatory Document

(b)

the occurrence of accidents or incidents which produce situations of immediate danger to the health and safety of employees or other people, including members of the public

(c)

the risk of financial liabilities, as a result of damage to plant and equipment, or compensation to workers or members of the public

(d)

the risks of fire, explosion or other hazards involving electricity, toxic materials or substances

(e)

the existence of unsafe working practices and unsafe places of work

(f)

any shortages of correct and adequate personal protective clothing and equipment

(g)

any accident or incident that is reportable under RIDDOR

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Items requiring prompt action: (a)

any potential hazards which may exist, but which do not cause any imminent or immediate danger any signs of inadequate information, instruction or supervision, which should have been provided by either the management or others

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(c)

any first aid facilities and training that fall short of statutory requirements

(d)

occasions when new plant, new work methods, new equipment, or different materials are to be introduced into the workplace.

Items requiring short-term action: (a)

where there is a lack of planning and control affecting safety within the workplace, either directly or indirectly, e.g. through the inadequate supply of materials and equipment to enable the workforce to carry out their tasks satisfactorily and safely

(b)

where there are signs of inadequacies in the personal skills, knowledge and experience of the workforce, which may have an adverse effect on safety.

Items requiring long-term planning and action: (a)

where there is a lack of certain categories of safety skills and trained personnel amongst the workforce

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(b)

where there is a need for the training of safety advisers, supervisors and safety representatives

(c)

where there is a need for training to take place to keep abreast of the future needs of the company and its employees

(d)

where there is a need for the improvement of standards of health, welfare and safety within the company.

1.1.9.5 Safety tours Managers, engineers, foremen, supervisors and operatives should have the opportunity to take note of safety conditions prevailing within the workplace during normal construction work. Production, however, will often be their first priority and this need to get the job done may adversely affect their judgement on safety matters. Familiarity with certain activities and hazards may further cause them to overlook, fail to recognise or ignore real or potential dangers which are present at the workplace.

2

For these reasons, safety tours (general inspections of the workplace) made by safety advisers, supervisors and safety representatives should take place at regular intervals.

3

In attempting to reach agreement with Contractors on the frequency of safety tours, the following factors should be considered:

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the size of the site to be inspected, the number of people employed and the number of types of activity which are carried out on that site

(b)

the categories of skill and the experience of the operatives

(c)

the existing safety policy and safety organisation within the company

(d)

the accident record of the site, company or organisation

(e)

the degree of risk to employees in carrying out specific activities or to groups of other people.

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1.1.9.6 Safety sampling

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Safety sampling of a particular work activity, process or work area may be necessary in the following circumstances: where the activity, process or work area presents particular health and safety concerns

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(b)

where there have been changes to an activity, process or work area that are relevant to health and safety

(c)

where there is a need to improve the safety performance of the company in a particular area of operations

(d)

where there have been changes in Qatar legislation or safety standards which affect the operations of the company

(e)

where there are high accident rates or increasing accident rates

(f)

where there are areas of high labour turnover.

Safety sampling should be carried out by someone totally familiar with the work activity, process or work area under inspection.

1.1.9.7 Safety surveys 1

These are general inspections which are carried out at longer intervals (yearly or once every two years) to assess the current safety standards and activities of the company, and to

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compare these with other sites of the same company, or other companies within the industry. 2

The survey should be used to determine the future safety objectives and activities of the company, in the light of planned requirements.

3

It provides an opportunity to: compare the current safety performance of the company against previous years

(b)

review safety objectives and determine the future objectives and safety policy of the company

(c)

examine current levels of safety activity and training within the company to decide whether they are adequate and suitable

(d)

decide where changes, if any, need to be made, and to make recommendations to the company as to where and how those changes may be implemented

(e)

improve procedures, records, communications and information supplied by and to the Contractors or their representative

(f)

determine whether any additional resources are required to enable the company's operations to be carried out more safely and effectively

(g)

decide whether the numbers of existing safety staff (including safety representatives) are adequate.

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(a)

1.1.9.8 Hazard-spotting exercises

Hazard-spotting exercises are a modified version of the safety sampling method, where a particular department, section, work area or work activity is singled out for a closer and more thorough examination.

2

The exercises should be arranged by the safety adviser, in conjunction with the company management. It should involve supervisors, safety representatives and operatives.

3

Observers may include first line or senior managers, but there should be at least an equal number of operatives. Some management may prefer a predominant number of operatives up to chargehand/ganger level in the party, thereby encouraging workers to take an active interest in safety and accident prevention at the workplace.

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1.1.9.9 Hazard-spotting party Members of the proposed hazard-spotting party should have had some previous training or experience in safety matters and be able to: (a)

recognise any unsafe acts of people at work

(b)

recognise unsafe or potentially unsafe conditions of work or methods of work.

One person should be appointed leader, and their functions should include: (a)

the collection of the written findings of the members of the party

(b)

the study of these findings and the summary of unsafe acts and conditions which have been observed during the tour

(c)

the preparation of a brief report, setting out the unsafe acts and conditions which were observed during the tour and making recommendations for action by

(d)

the management or their representative to rectify any situation that may have been observed

(e)

noting and recording the response of the line or senior management, satisfying themselves that action will be taken by management to rectify any situations observed

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(f)

reporting back, to members of the party, what action will be taken by the line manager concerned.

3

The participants should be informed in advance of their involvement in the hazard-spotting exercise, given a time and place to meet, and told who is the leader of the party to whom they should report.

4

They should be: briefed on which work processes and activities are to be inspected and the hazards which they will be looking for

(b)

informed that they can ask any questions, but not interfere with the normal work processes and activity

(c)

instructed in the use of any checklists or forms which are to be used to record their findings. See examples in Appendix 2

(d)

asked to differentiate between unsafe acts and unsafe conditions

(e)

instructed to record their findings independently, without fear of recrimination or interference.

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(a)

The leader of the party spots at the same time as everyone else and is responsible for seeing that the inspection tour is completed within the agreed timescale.

6

Employees working in the section to be inspected should be informed of the intent to inspect, but not of the date or time when the inspection will be carried out.

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A set and properly structured programme of inspections and sampling will ensure that all of the main activities of a company are continuously under scrutiny. Hazard-spotting exercises should be used not only where there is seen to be a need to ensure the safety and health of people at work, but also as a continuing monitoring exercises.

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1.1.9.10 Hazard-spotting programme

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1.1.9.11 Inspection reports

Supervisors and safety representatives should record the findings of their inspections. Commercially produced versions of inspection report forms are often multi-copy, and 'self duplicating', with each copy on a different colour paper to identify the intended recipient. These are called PAD format.

2

See an example of a report form in Appendix 3.

3

Whatever the type of checklist or form used, it should provide a record of any action requested to remedy conditions and working practices considered to be unsafe. Space should be provided on the form to record the date and place of the inspection and details of the action taken or, if no action was taken, an explanation of why this was so.

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1.1.9.12 Investigation at the workplace 4

Safety representatives are expected to; (a)

investigate potential hazards and dangerous occurrences at the workplace

(b)

carry out inspections where there has been a RIDDOR accident, occurrence or disease at the workplace

(c)

investigate any complaints by employees relating to health and safety

(d)

make representations to the Contractors on behalf of the workforce on general and

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Section 11: Health and Safety Page 147 Part 1.01: Qatar Legislation and Management (Regulatory Document) specific matters relating to the health and safety of employees at the workplace.

5

These functions do not affect a Contractors rights and obligations to manage an enterprise or site as they should wish, or to investigate any type of accident or occurrence.

1.1.9.13 Safety auditing 1

Many clients are now asking for detailed safety management information, such as that gathered during safety auditing, as part of their pre-qualification procedures. This will be part of the client's competence assessment of contractors, as required under CDM. Such information has the potential to indicate a proactive approach to safety management and whether or not identified issues are satisfactorily dealt with. What is a safety audit, and what is in it for you? A safety audit is a demonstration of the management's commitment to improve the overall safety of the workplace. The typical definition of an auditing system is a systematic, critical examination of an operation in its entirety to identify hazards and levels of risk, to detect falling standards and to ensure that operations are performed in an efficient and safe way in accordance with the policies and procedures laid down by the organisation.

3

Therefore, the key requirements of a safety audit include:

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a critical examination of the whole operation

(b)

an assessment of how the risks to health and safety are being handled

(c)

the identification of the efficient and safe performance of people

(d)

the detection and identification of falling standards, ineffective company procedures, and non-compliance with industry standards and Qatar legal requirements

(e)

the use of meaningful standards consistent with the organisation's operations.

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(a)

Health and safety auditing should also be seen as an integral part of the overall monitoring of health and safety within an organisation.

5

The aim of such an audit is to identify problem areas that may exist, so that you can make improvements to your standard of safety. The audit should look at the interaction of all the activities of your company, as well as at the activities themselves.

6

An audit supports the company's safety policy; it measures performance against it and will help management to judge just how well safety is being managed and, if carried to its logical conclusion, will prompt the question: 'What caused this accident to happen?'

7

By adopting safety auditing, the Contractors will be acting to identify problems and possible causes of accidents before they happen.

8

If any are identified, the Contractors will be able to change the health and safety management system, improve working practices, identify health and safety training needs and strengthen other weaknesses. These changes will help ensure that no unsafe actions occur, thereby preventing accidents, and may include the setting of new standards of health and safety performance by managers and employees.

9

The aim of any health and safety auditing system should be to constructively assist site management to safely organise the company's construction activities. The application of a well thought out auditing system will undoubtedly repay the time and money that the company initially invests in developing it.

10

There is an additional benefit to the company

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The result of safety audits carried out correctly is an improved safety performance so that the ultimate of NO ACCIDENTS is achieved.

12

A good audit will benefit everyone from senior management to the youngest employee, and will hopefully be accepted on its merits as the resultant changes bring improvements in safety performance.

13

The health and safety audit should be carried out, as far as possible, by independent auditors. This overcomes the problems faced by line managers auditing their own area of work, or even a second line manager being critical of their peers. Auditing must be carried out objectively and with a high degree of honesty when identifying non-compliance with management systems and techniques.

14

The frequency of safety audits should ensure that the health and safety management system of the organisation does not degrade over time or through changes in the company organisation, personnel or the activities it carries out.

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performance against internal systems

(b)

performance against legal standards.

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One of the most difficult things about auditing is deciding whether the measured performance is satisfactory. Within health and safety, experienced external auditors will typically audit against two parameters:

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1.1.9.14 Benchmarking

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Construction Site Safety 1.1.9 Appendix 1 Observation checklist The worker

gloves

(b)

clothing

(c)

boots

(d)

helmets

(e)

goggles

(f)

ear defenders?

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safety signs and signals

machine and equipment guards

(ii)

warning notice

(iii)

barriers

safety equipment

(d)

first aid training?

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(c)

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alarm systems

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(b)

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(i)

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use of:

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Is the worker aware that they must exercise good behaviour at work whilst paying attention to the following: (a)

avoiding messing around

(b)

distractions

(c)

staying out of prohibited areas

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(i) use of:

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Is the worker aware of safeguards which exist in relation to: (a)

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(a)

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2

Is the worker able to obtain and correctly wear personal protective equipment, such as:

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machinery plant power tools hand tools transport access equipment working platforms hazardous activities?

When handling materials, does the worker take into account the following: (a)

good manual handling and lifting techniques, including wearing appropriate PPE

(b)

mechanical methods available

(c)

proper stacking

(d)

correct storage

(e)

transporting and moving loads

(f)

loading and unloading

(g)

dangerous materials?

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(a)

at heights

(b)

above or near to water

(c)

near live electrical conductors

(d)

in confined spaces

(e)

in excavations, tunnels and shafts

(f)

in other hazardous environments?

Is the worker aware of, and using, welfare facilities which are provided relating to: first aid

(b)

changing rooms

(c)

canteen

(d)

washing

(e)

seating

(f)

toilets

(g)

drinking water

(h)

drying facilities

(i)

workspace

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(a)

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If required to work in hazardous areas, is the worker competent to work:

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ventilation

(b)

temperature

(c)

lighting

(d)

noise

(e)

dust

(f)

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fumes

welfare facilities?

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(a)

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Is the working environment satisfactory in relation to:

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The workplace and the work method

Is the condition of machinery, plant and equipment, tools and materials acceptable as far as the following are concerned: (a)

machinery, transport, plant

(b)

workplace

(c)

working platforms

(d)

tools, equipment, appliances

(e)

hazardous work areas?

Are adequate fire precautions in place including: (a)

exits and emergency escape routes

(b)

extinguishers

(c)

alarms

(d)

procedures?

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(a)

warning notices

(b)

general health and safety signs

(c)

colour codings

(d)

work methods

(e)

adequacy of:

information instruction supervision work procedures?

Is good housekeeping a part of normal procedures when considering: general layout

(b)

site conditions

(c)

ground, floor conditions

(d)

storage areas

(e)

gangways, walkways

(f)

access, egress?

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(a)

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Are safety notices displayed, relating to:

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Construction Site Safety 1.1.9 Appendix 2 Observation report Unsafe conditions

1.

1.

2.

2.

3.

3.

4.

4.

5.

5.

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Unsafe acts

6.

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6.

7.

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10.

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9.

10.

Location....................................................................... Name...........................................................................

Date.........................................................

Comments:

This illustration constitutes only an example of the kind of form which could be used during a hazard-

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spotting exercise of the workplace. Contractors may choose to use this example or create their own.

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Construction Site Safety 1.1.9 Appendix 3 Health, Safety and Welfare Inspection Report Company..................................................................................Report no.................................................................... Workplace.....................................................................................................................................................

Welfare

Storage areas

Canteens

18 Tidiness

34

Services

2

Rest rooms

19 Flammables

35

Security

3

Changing rooms

20 Gases

36

Fire precautions

4

First aid training

21 Fuels, lubricants

37

Electrical

5

First aid facilities

22 Fire precautions

38

Hoists

6

Washing

23 Tools & equipment

7

Sanitation

24 Access equipment

8

Protective clothing

25 Timber

9

Protective equipment or substances

26 Dangerous materials

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27 Stores procedures

Offices

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39

Tower cranes

40

Mobile cranes

41

Lifting gear

42

Excavations

43

Transport

44

Other plant

Construction site

Accident records

28 Scaffolding

45

Machinery

11

Statutory forms,

29 Ladders, trestles

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Power tools

30 Working platforms

47

Hand tools, equipment

31 Access/egress

48

Tidiness

32 Signs & notices

49

Noise levels

33 Accommodation

50

Traffic management

51

Restricted area

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registers, etc. General cleanliness

13

Fire precautions

14

Environmental factors

15

Seating

16

Access/egress

17

Alarms, notices

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Action required for items........................................................................................................................................ (Details on reverse of form) Signature(s).................................................................

Date of inspection.......................................................

(Safety representative(s) Circulation:

Original 1st copy 2nd copy 3rd copy

(pink) (blue) (white) (yellow)

to safety officer / supervisor to site manager / agent to be retained by auditor for management action and return

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Construction Site Safety 1.1.9 Appendix 4 Contractor NCR Template

SAFETY NON-CONFORMANCE REPORT Contract Name: Contractors Name: NCR No:

Contract Number: Date Opened:

Date Closed:

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PART A: DETAILS OF NON-CONFORMANCE: Details:

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Classification of Defect: Critical Major Minor Cause of Non-conformance: Material Process Equipment Documentation Reference (QCS, Local Legislation, Other Specification / Standard etc.):

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CONSULTANT /ENGINEER REP* *Delete as applicable

Work Area / Location:

Title:

Documentation

Date:

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Name & Signature:

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Reject/Replace Target Date to Close NCR: Name & Signature:

Re-work

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CONTRACTOR

PART B: PROPOSED REMEDIAL / CORRECTIVE & PREVENTIVE ACTION: Details:

Repair

Title:

Use as-is

Date:

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- Contractors proposals are acceptable and remedial work / Corrective & Preventive Action may proceed. - Contractors proposals are unacceptable for the following reasons. (Contractor should revise & resubmit):

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CONSULTANT

PART C: CONSULTANT ACCEPTANCE OF CONTRACTORS PROPOSALS IN PART B:

Name & Signature:

Title:

Date:

PART D: REMEDIAL WORKS / CORRECTIVE & PREVENTIVE ACTION PROPOSED IN PART B ARE COMPLETE & READY FOR INSPECTION: CONTRACTOR Name & Signature:

Title:

Date:

ENGINEER REP.

PART E: FOLLOW UP & CLOSE-OUT: - Remedial Works / Corrective & Preventive Action have been undertaken and are acceptable. This NCR may be closed out. - Remedial Works / Corrective & Preventive Action undertaken by the Contractor are not acceptable for the following reasons and this NCR may not be closed out. (Contractor must address these issues):

Name & Signature:

Title:

Date:

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NOTES AND ATTACHMENTS (Photographs, Sketches etc.):

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Construction Site Safety 1.1.10 Safety at Street Works and Road Works 1.1.10.1 Key points 1

Will someone coming along the road or footway from any direction understand exactly what is happening and what is expected of them?

2

These Regulations specifies minimum safety requirements for: signage and lighting

(b)

working on different classes of roads

(c)

methods of traffic control

(d)

speed control of passing traffic

(e)

works near to tramways and railway level crossings.

(f)

Operatives who carry out work on the highway must be competent to do so, particularly anyone involved in laying out the site, positioning signage or lighting, implementing traffic control measures and undertaking similar jobs.

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(a)

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Note: Section 1, Part 3 of the QCS covers traffic safety management. Section 1, Part 16 of the QCS covers traffic diversions. Section 6 of the QCS covers roadworks..

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This places a duty of care on Contractors, employees and the self-employed. It requires not only the safety of employees to be considered, but also the safety of those affected by the work i.e. members of the public using the highway.

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Health and Safety at Work (Construction Sites)

When you give notice that you intend to start work, they will inform the other utility service providers in an attempt to co-ordinate works so that the utilities may each carry out their work during one excavation in order to avoid the same piece of roadway being continually excavated.

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1.1.10.3 Commencement of work

1.1.10.4 Measures necessary where apparatus is affected by major works (diversionary works) 1

Definition: Apparatus is any pipe or ducting buried within the highway or pavement which is owned by one of the utilities. It may take the form of gas pipes, water mains, sewers, electricity cables, telephone cables and, where installed, cable TV cables.

1.1.10.5 Major works 1

The term major works covers works carried out by the Civil Engineering Department Ministry of Public Works such as: (a)

the reconstruction or widening of the highway

(b)

works on dual carriageways and at roundabouts

(c)

other similar major works

(d)

the construction of vehicle crossings over footways and verges.

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1.1.10.6 Diversionary works 1

The term diversionary works covers: (a)

works to protect apparatus on site

(b)

works to relocate apparatus elsewhere.

1.1.10.7 Construction risk factors Construction factors to be considered in deciding whether apparatus is at risk include: the removal of the footway or carriageway construction

(b)

construction plant crossing or working in the vicinity of apparatus

(c)

the undermining or removal of side support to apparatus

(d)

any deep construction adjacent to apparatus

(e)

piling or ground consolidation operations.

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1.1.10.8 Vehicle crossings

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The construction of vehicle crossings is included because the works put apparatus at risk in a number of ways, such as: the majority of 'service' apparatus is located in footways

(b)

the footway construction layers must normally be excavated to accommodate thicker construction layers

(c)

the new construction may no longer provide adequate cover to apparatus

(d)

the vehicular loading may be greater than the apparatus can withstand

(e)

vibrations from vehicles may weaken joints over a period of time.

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1.1.10.9 Minimising construction risks

(a) (b)

provide suitable and safe vehicle crossing and access points. temporarily move apparatus to a safe location, during any construction work. protect or temporarily support apparatus in situ.

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To minimise construction risks, you should:

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Note: Methods of supporting apparatus during excavation form part of the assessment process incorporated within the relevant operative and supervisor qualifications.

1.1.10.10

Safety of gas apparatus

Depth of cover 1

The normal minimum depth of cover for gas mains operating in the low and medium pressure ranges is: (a)

600 mm in footway or verges

(b)

750 mm in carriageways

2

although these figures may vary, as each area gas companies can have its own standards.

3

In certain circumstances, depending upon the mains material, operating pressure and depth of cover, it may be acceptable for the mains to remain in situ when only subjected to light

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traffic, e.g. a vehicle layby or crossing. 4

It is not generally permissible to allow cast iron mains previously in the footway or verge to be subjected to vehicular traffic. Risks during construction

5

Liaison with the gas services provider during the planning stage is essential because existing mains, specifically older materials such as cast iron, cannot be raised, lowered or moved laterally even for a few millimetres without risk. Gas apparatus must not be undermined and certain apparatus is particularly vulnerable to deep excavations adjacent to the apparatus.

6

Any proposals to dig deep trenches may mean that gas apparatus will have to be diverted.

Safety of water apparatus

Decisions on the protection or diversion of water mains are likely to be influenced by considerations of access to mains for repair purposes.

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1.1.10.11

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Depth of cover

The minimum depth of cover for the three types of water mains, i.e. trunk mains, distributor mains and service pipes, will vary according to its type.

3

Further information can be found by consulting with the Qatar General Electricity & Water Company.

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Risks during construction

Construction plant and lorries travelling over water apparatus with temporarily reduced cover can be an unacceptable risk. Therefore, diversions may be necessary unless protective measures are practicable.

5

Factors influencing the decision to divert water pipes must include:

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the maintenance of the continuity of supply and the water quality

(b)

material types and condition the inability to raise, lower or slew pipes the possible loss of ground support to pipes with the consequential risk of damage.

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1.1.10.12

Safety of telecommunications apparatus

1

The need for the rigorous exclusion of moisture from telecommunication cables and joints places constraints on what can be done to older cables, in respect of their movement during works.

2

For maintenance purposes there is the added need for vehicles to have access and be located at or near jointing chambers. Preferred depth of cover

3

Varying depths of cover may be found with this type of equipment, depending on the types and design of the cables. As a rough guide, television and telecom cabling can be found at depths varying from 250 mm in the verge or footway up to 900 mm in the carriageway.

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Risks during construction According to circumstances, the apparatus may be left in situ if ducts are adequately protected from construction plant and vehicles by the use of metal plates or tracks.

5

In some cases, it may be possible to accommodate small temporary or permanent alterations in the line of a duct track by bodily slewing, raising or lowering a nest of ducts with the cables in situ.

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1.1.10.13 1

Overhead telecommunication lines

Poles must be positioned to: (a)

minimise the risk of damage to cables by vehicles

(b)

give the minimum inconvenience to pedestrians

(c)

avoid obstructing access to premises.

2

Road alterations may necessitate the replacement of poles if the clearance under the cables becomes inadequate.

3

Minimum heights above ground for overhead telecommunication lines are typically: 6.1 m at any point over a street

(b)

6.1 m on bus routes

(c)

6.5 m on designated roads.

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Safety of electrical apparatus

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The following factors should be considered when protecting cables in situ or diverting apparatus.

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1.1.10.14

.

(a)

Underground cables

The need to protect and support potentially hazardous equipment from mechanical impact, damage, strain and vibration during and after road works.

(b)

A requirement to maintain the security of supply if alternative circuits are not available.

(c)

The operating voltage of the apparatus. Depth of cover

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(a)

The depth at which electricity cables or ducts are usually laid in the ground is decided by the need to avoid undue interference or damage.

3

Dependent on the type of cable and the power that it may be carrying, the depth of cover may vary from 450 mm up to 900 mm. It is common to find electrical cables much shallower than these depths, particularly over bridges or culverts and extreme caution must be exercised.

4

In all cases where the depth of cover is likely to increase or decrease, the apparatus owner must be consulted.

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Overhead lines (a)

The supports and stays of overhead lines may have to be relocated.

(b)

Ground clearance may be affected.

(c)

Earth wires from supports may have to be re-sited.

(d)

Buried pilot wires may be associated with the route of overhead lines.

Height above ground of overhead lines 1

The minimum height of overhead lines above ground varies according to the voltage of the cable and as directed by the service provider. They can be as low as 5.2 m for lines carrying 33 kV, up to 6.7 m for lines carrying 132 kV.

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Risks during construction (a)

Additional protection or temporary diversion may be necessary to prevent damage to any apparatus during the construction stage.

(b)

The hazards of accidental electrical contact by persons on site must be fully assessed.

(c)

Damage to underground cables can, in certain circumstances, cause widespread loss of electrical supplies for a long period.

1.1.10.15

Traffic signs and other apparatus for the control of traffic must comply with relevant Qatar Work Zone Traffic Management Guide – latest revision.

1.1.10.16

Basic principles of signing

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1

Signs and equipment

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Fix signs properly

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Visibility of signs

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Traffic on two-way roads

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Surplus signs

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Clearing up

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Refer to Qatar Work Zone Traffic Management Guide – latest revision.

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Be seen

Whether working on site or just visiting, all personnel must wear a high visibility jacket or waistcoat to BS EN 471 at all times. Ensure the garment is in good condition and is properly fastened at the front.

2

Refer to Section 11 – Part 1(RD) – 1.2.2 – (PPE) Personnel Protective Equipment.

3

Refer to Section 11 – Part 2 (SAMAS) – 2.3.9 – (PPE) Personnel Protective Equipment.

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1.1.10.17 1


1.1.10.18 1

Site layout definitions

Signs for Street Works and Road Works


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1.1.10.19

Foamed concrete for reinstatement (FCR)

FCR hazards 1

Cement-based materials that can be poured into an excavation to any required depth without the need for compaction are called FCRs.

2

Because FCRs are fluid, they present a hazard for children and animals. Reinstatements must therefore be guarded until a sufficient set has occurred.

3

Like all cement-based materials, FCRs should be handled with care because: excessive contact with mixed FCRs can cause contact dermatitis or skin burns

(b)

excessive exposure to cement dust when FCRs are mixed on site can lead to respiratory problems.

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Precautions Use barrier creams on hands and wear gloves.

5

Wear long-sleeved shirts, full length trousers and Wellington boots.

6

Cement on skin should be washed off immediately.

Reinstatement

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All utilities that have carried out work upon a highway or pavement, or have employed a contractor to carry out work on their behalf, are responsible for the satisfactory reinstatement of the highway or pavement.

2

Any interim reinstatements must be made permanent within six months.

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Reinstatement faults

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Settlement

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1.1.10.21

This is the most common and obvious fault, and has implications for the short-term acceptability of the reinstatement to the public, and the long-term cost of maintaining the highway.

2

If the reinstatement material is soft in comparison with the surrounding undisturbed material, the latter will tend to move laterally towards the excavation and downwards until equilibrium is reached.

3

The area at risk on each side of the excavation is roughly equal to the thickness of the poorly compacted material, regardless of the vertical position of such material.

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Crowning 4

The practice of deliberately filling the reinstatement high is an acknowledgement that settlement is going to occur.

5

The same processes of adjacent ground movement, and road structure cracking that accompany settlement can also be present with crowning, since they are a function of poor compaction and little influenced by surface profile.

QCS 2014


Edge cracking 6

If the vertical edges between the reinstatement and original surfacing have not been sealed properly with bitumen, water can enter the joint, freeze, and open up a crack.

7

Alternatively, relative movement between the reinstatement and the original surface can cause fretting, initiating a crack which is subsequently worsened by the ingress of water. Lateral spread in the surfacing

8

This can be caused by too soft a binder being used in the surfacing which then spreads due to traffic and temperature. Bleeding or fatting up

.

In hot weather the binder softens. If the binder is soft initially, it may rise to the surface and either be picked up by vehicles or lie on the surface. If this is not rectified, the binder will harden during the colder months and form a very smooth, slippery surface.

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The development of fine surface cracks not accompanied by settlement results from fatigue of the material under traffic loading.

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Crazing

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Fretting

This is defined as the loss of aggregate particles from the surface of bituminous materials.

12

A variety of causes can be identified, including inadequate compaction, low bitumen content, and an excessive degree of fluxing for the conditions.

13

The most serious consequence is the increased risk of skidding on the freshly exposed bitumen and loose particles of aggregate.

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Cracking

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Cracking in reinstatements remote from the edges is generally due to the tensile strain produced by settlement.

15

Another contributing factor is the use of thin surfacing layers which are consequently overstressed and suffer fatigue cracking.

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Open texture 16

Delayed set materials need to be open textured to some degree so that fluxing oils can evaporate through the air passages.

17

By the same token, water can also soak down through the material into the underlying material.

18

Open textured materials should be replaced or surface sealed as soon as possible after they have hardened, especially in winter. Lateral spread due to trenches in the edge of the carriageway

19

This happens in carriageways where the foundations of edge of the carriageway are weakened. Consequently they give way and allow the full depth of construction to spread.

QCS 2014


1.1.10.22

Surface profile

1

The following requirements apply to the immediate, interim and permanent reinstatements of all service providers excavations.

2

If at any time during the immediate, interim or permanent guarantee periods the surface profile of a reinstatement exceeds any of the intervention limits, remedial action must be carried out in order to return the surface profile of the reinstatement to the as-laid condition. As-laid profile The reinstatement of any surface must be completed so that the edges of the reinstatement are flush with the adjacent surfaces and the reinstatement does not show any significant depression in between.

4

The maximum allowable tolerance at the edge of the reinstatement between the levels of the reinstatement and the adjacent surface must not exceed + 6 mm.

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Edge depression - intervention

An edge depression is an essential vertical step or trip at the interface of the reinstatement and the existing surface.

6

Intervention is required where the depth of any edge depression exceeds 10 mm over a continuous length of more than 100 mm.

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Edge depression limits

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Surface depression - intervention A surface depression is a depressed area within the reinstatement. It generally has smooth edges and gently sloping sides forming a shallow dish.

8

Intervention is required where the height of any area of surface crowning spanning more than 100 mm in any plan dimension exceeds the limits shown in the table.

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Surface depression limits

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Intervention limits - surface depression Reinstatement width W (mm)

Intervention limit X (mm) 10

over 400 to 500

12

over 500 to 600

14

over 600 to 700

17

over 700 to 800

19

over 800 to 900

22

over 900

25

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Surface crowning - intervention

Surface crowning is an upstand of the reinstatement above the mean level of the existing adjacent surfaces.

10

Intervention is required where the height of any area of surface crowning spanning more than 100 mm in any plan dimension exceeds the limits shown in the table.

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Surface crowning limits

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Intervention limits - surface crowning

Reinstatement width W (mm)

Intervention limit Z (mm)

up to 400

10

over 400 to 500

12

over 500 to 600

14

over 600 to 700

17

over 700 to 800

19

over 800 to 900

22

over 900

25

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1.1.10.23

Inspections

1

During work and after completion, personnel from the Civil Engineering Department Ministry of Public Works will inspect work being carried out by services providers.

2

There are two distinct inspections: (a)

sample inspections

(b)

defect inspections.

1.1.10.24

Sample inspections

These are routine inspections of random samples of services providers work at various stages of excavation and reinstatement and after reinstatement.

2

It enables the Civil Engineering Department Ministry of Public Works to monitor the level of compliance with prescribed standards including:

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applicable reinstatement specification

(b)

the requirements for signing, lighting and guarding of works in progress

(c)

verification that requirements for qualified supervisors and operatives are met.

Defect inspection

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(a)

This is a procedure for dealing with individual reinstatements which fail to comply with the reinstatement specification.

2

A special procedure applies to non-complying reinstatements which are causing a danger to persons using the street.

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Five stages of inspection have been identified for monitoring purposes:

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Types of sample inspection

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1.1.10.26

Type

Category

During excavation

1

Whilst reinstating (including interim phase)

2

Immediately after permanent reinstatement (within 1 month)

3

Between 6 and 9 months after permanent reinstatement

4

During one month preceding end of guarantee period

5

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1.1.10.27

Inspection checklists

1

Two standard forms are used to report on the inspection carried out and include entries on whether the items checked were acceptable or non-acceptable.

2

The form for categories 1 and 2 covers signing and guarding requirements in addition to excavation and reinstatement works.

3

The form for categories 3, 4 and 5 cover performance requirements of the finished surface.

4

Sample forms are provided in Appendices 3 and 4.

1.1.10.28

.

(b)

by members of the public

(c)

by routine inspections by the Civil Engineering Department Ministry of Public Works

Reinstatements that are found to be defective are divided into two types:

Non-complying reinstatements not causing danger

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These are reported to the party undertaking the work and normally require remedial action to be taken within seven days.

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as a result of sample inspections

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2

Defective reinstatements may be identified:

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Types of defect

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1.1.10.30 Non-complying reinstatements causing danger to pedestrians & vehicles Where the Civil Engineering Department Ministry of Public Works considers a defect to be causing danger, the overriding aim is to remove the danger as soon as possible. The exact procedure may differ in and out of normal working hours.

2

The Civil Engineering Department Ministry of Public Works may make the site safe by signing, lighting and guarding and request the attendance of the service provider.

3

Reported defects trigger a further two inspections.

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1.1.10.31 1

Qualifications

Contractors must ensure that: (a)

the execution of street works is supervised by a person having a prescribed qualification as a supervisor

(b)

there is on site at all times, whilst work is in progress, at least one person having a prescribed qualification as a trained operative

QCS 2014


Construction Site Safety 1. 1.10 Appendix 1 Safety checklist for the supervisor Before work starts Has a site-specific risk assessment been carried out?

2

Have you planned how you will sign and guard the works?

3

Have all the appropriate authorities been notified?

4

Is everyone on the site wearing high-visibility clothing?

5

What are the correct positions for the first warning sign?

6

What other signs are needed approaching the works?

7

What signs are needed at the works?

8

What length of coned taper is required?

9

How many lamps and cones will be needed?

10

What width of carriageway can be kept open and will it be enough for two-way traffic?

11

What width of footway can be kept open and will it be enough?

12

What form of traffic control is needed?

13

Have any misleading permanent signs been covered?

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When work is in progress

If circumstances change, have you altered the signs, cones and lamps to suit?

15

Are signs, cones and lamps being regularly inspected, cleaned, maintained or replaced?

16

Has authorisation been obtained to accommodate any changed circumstances?

17

When traffic control changes are made at night or weekends, have the warning signs been changed?

18

Are traffic control arrangements reviewed and changed to reduce delays as works change?

19

Are the works adequately signed, guarded and lit for the overnight period?

20

Have you cleared away any mud that may have spread onto the surrounding road or footway?

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When work is complete and before you leave 21

Have all signs, cones and lamps been removed?

22

Have all permanent signs been restored?

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Have appropriate authorities been notified that work is complete?

24

Have you cleared away any mud that may have spread onto the surrounding road or footway?

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Construction Site Safety 1.1.10 Appendix 2 Situations where further advice may be needed Examples of situations where an operative will need to consult a supervisor Where the Civil Engineering Department Ministry of Public Works restricts work to certain times of the day.

2

When the roadworks make it impossible for drivers to follow the permanent traffic signs.

3

At times of poor visibility or bad weather conditions, when additional signs may be required or work suspended.

4

When stronger than normal barriers are needed for deeper excavations.

5

Whether traffic control is needed at a site and which type would be appropriate for the circumstances.

6

Where it is intended to use portable traffic signals, as the traffic authority must give approval if these signals are to be used at a site which contains a junction.

7

When tailbacks occur at portable traffic signals.

8

Where a width of at least 3.25 metres cannot be provided on both sides of a site which is in the middle of a two-lane single carriageway road.

9

When the works affect a pedestrian crossing, in which case the traffic authority should be told in advance of the works. This is particularly important in the case of pelican crossings.

10

Where work affects tramways.

11

Where Stop/Go boards are proposed to be used in a shuttle lane containing a junction.

12

Where it may be necessary to close a road and therefore provide a diversion route.

13

When work on the approach to a traffic signalled junction disrupts the traffic flow through the junction.

14

If work has to be undertaken at permanent traffic signals on a road with a speed limit of 64 km/h or more.

15

Where works are located at roundabouts.

16

Where mobile works are located in the centre of carriageways.

17

Where mobile lane closure techniques are to be used.

18

Where works are to be undertaken within 200 metres of a level crossing or are likely to cause congestion in the area around a level crossing or where ramps as part of the works may cause long low vehicles to ground.

19

Where the works are near the junction of roads joining and leaving high speed roads.

20

Where works are located on three-lane single carriageway roads.

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Where work is to be carried out over the carriageway and the headroom is reduced.

22

When work is likely to affect any bus route or bus stop.

23

Where work is located near to schools.

24

Where works are located near buildings likely to be used by large numbers of elderly or disabled people, e.g. old people's homes.

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Construction Site Safety 1.10 Appendix 3 Service Provider works Inspections checklist FOR USE ON INSPECTIONS 1 AND 2 Authority reference

DATE

Service Providers reference

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Location o/s of or from __________________________to __________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Time taken for inspection ____________________________________________________________ _________________________________________________________________________________

Acceptable

Unacceptable

Excavation

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Backfill & reinstatement Surround to apparatus Backfill material Compaction Sub-base Roadbase Basecourse Wearing course

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Signing & guarding Correct type Distance Safety zones Barriers Traffic control Pedestrian control Other

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1. Signing & guarding and excavation Insert inspection number 2. Signing & guarding and backfill and reinstatement

State reasons for unacceptability

Name

Signature

Date

Unseen/inapplicable

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Construction Site Safety 1.1.10 Appendix 4 Service Provider works Inspections checklist FOR USE ON INSPECTIONS 3, 4 AND 5 Authority reference

DATE

Services Providers reference

Insert inspection number

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3. Immediately after permanent reinstatement (within 1 month) 4. Intermediate (between 6 and 9 months) 5. One month preceding end of guarantee period

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Location o/s of or from __________________________to __________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Time taken for inspection ____________________________________________________________ _________________________________________________________________________________

Acceptable

Unacceptable

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Edge depression/trips Surface depressions Surface crowning Edge cracking Texture depth Surface regularity Other

Signature

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Name

Signature

Date

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Construction Site Safety 1.1.10 Appendix 5

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Size and siting distance: details of signs and cones and safety zone dimensions

Type of road

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Minimum and normal maximum Minimum siting distance (D) clear visibility Minimum size of first sign in to first sign of signs (mm) advance of lead-in (metres) taper (meters)

Single carriageway road, restricted to 48 km/h or less

ito

20 to 45

Minimum Sideways Details of lead-in cone tapers (but height of safety zone see Notes below) Recommended cones (S) lengths (mm)

Width of Hazards (metres) including safety zones(s) 1 2 3 4 5 6 7

60

600

450

0.5m

Length of taper (T) in metres Minimum number of cones Minimum number of lamps at night

13 4 3

26 4 3

39 6 5

52 7 6

65 9 8

78 10 9

91 12 11

45 to 110

60

750

450

0.5m


20 4 3

40 6 5

60 8 7

80 10 9

100 13 12

120 15 14

140 17 16

All-purpose dual carriageway road, restricted to 64 km/h or less

110 to 275

60

750

450

0.5m


25 4 3

50 7 6

75 10 9

100 13 12

125 15 14

150 18 17

175 21 20

Single carriageway road, with speed limit of 80 km/h or more

275 to 450

75

750

450

1.2m


25 4 3

50 7 6

75 10 9

100 13 12

125 15 14

150 18 17

175 21 20

All-purpose dual carriageway road, with speed limit of 80 km/h or more

725 to 1600

105

1200

750

1.2m


32 5 4

64 9 8

96 121 1

128 16 15

160 19 18

192 23 22

224 26 25

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Single carriageway road, restricted to speeds of 49 to 64 km/h inclusive

Speed limit (km/h) Minimum longways clearance (L) metres

48 or less

64

80

95

112

1/2

15

30

60

100

Notes: 1. Lead-in tapers used with traffic control, and all exit tapers, shall be at about 45° to the kerb line with cones spaced 1.2 metres apart. 2. The maximum spacing distance of cones in longitudinal lengths of coning shall be 9 metres, but no fewer than 2 cones shall be used in any length between tapers. 3. In certain circumstances on congested roads with speed limits of 48 km/h or under, the taper may also be reduced to 45°.

QCS 2014


Construction Site Safety 1.1.11 Setting Up Site 1.1.11.1 Key points Consideration must be given to the initial design, creation and layout of a site, and its effect upon the people who work on it, visit it, or live nearby.

2

The footprint of the structure(s) to be erected will dictate what space remains for other purposes, which must be used to its best advantage.

3

Consideration should be given to early contact with local residents, local schools, adjacent properties etc. prior to, or at the start of, setting up a site.

4

Time and effort put into properly planning and setting up a site has the distinct potential to forestall problems as the job progresses.

Note:

Section 1, Part 1 of the QCS covers setting up a site and site management.

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CDM places a legal duty upon the client for any project to ensure that every person involved in the design process and every Contractor is provided with adequate and relevant information about the site to enable the health and safety of anyone engaged in the construction phase to be secured. This information should be included in the health and safety plan which then enables decisions to be taken with regard to setting up the site.

2

The health and safety plan should give the Contractor details of specific issues that will need to be considered when setting up a site. These, together with the contracts and architects' drawings and specifications, will give information about specific factors to be incorporated. It is likely that the responsibility for setting up the site will in many cases be delegated to the site manager.

3

Contractors are require to plan, manage and monitor the construction phase (which includes setting up a site) to ensure that, so far as is reasonably practicable, it can be carried out without risks to health and safety.

4

Suggested factors to be considered when setting up a site can be found in the appendix at the end of this section.

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1.1.11.3 Temporary works 1

By the nature of construction, much work will not be left in place at the end of the project but still requires the same care and attention that the main structure attracts. Many accidents occur through poor planning, design and installation of temporary works which begin as soon as site set up commences.

2

These include, but are not confined to: (a)

Foundation assessment for new porta cabin install, and in particular multi-storey complexes.

(b)

Excavation support assessment to be carried out for below ground service connections.

(c)

Services may require protection to prevent damage during site set up. Also material storage areas should be sited away from shallow services that may be susceptible to damage.

(d)

Site hoardings and gates to be designed to withstand wind loadings. Particular

QCS 2014

Section 11: Health and Safety Page 177 Part 1.01: Qatar Legislation and Management (Regulatory Document) attention should be taken with swing gates, and ensuring that these can be managed by an individual under high wind conditions. Any supporting structures on a cabin set-up must be designed, e.g. cabins elevated to provide parking below on congested city sites.

(f)

Generally there will always be a need for craneage on site, so ground bearing capacities require checking for outrigger loadings on and around the site.

(g)

Any temporary access roads on site should be assessed to ensure that they are suitable to withstand loadings that may occur during site works.

(h)

Site establishments that are at risk of objects falling from above should be protected with the use of designed crash decks or fans.

(i)

Where site establishments are close to the public highway or temporary haul roads where heavy plant is to be used, there must be suitable barriers in place to protect the office from collision damage.

(j)

When crane lifts are required from a neighbouring street then the temporary works engineer must be aware of any below ground services, including basements and subways and so on, and their proximity to the crane.

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1.1.11.4 Human factors

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These Regulations require that:'No person may arrange or instruct a worker to carry out or manage design or construction work unless the worker is: competent, or

(b)

under the supervision of a competent person.'

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Competence

This is now the fundamental requirement of the requirement for health and safety in construction. Competence has been defined as: 'possessing practical and theoretical knowledge, which combined with actual experience so as to enable errors, faults and weaknesses to be detected and their importance accurately assessed'.

3

Depending upon the nature of the site and the type of work to be undertaken, the competence of people who will come on to the site might be an issue for the person setting up the site. It may be necessary, for example, to check the competence of those who will; erect, alter or dismantle scaffolds

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(b)

operate site plant

(c)

dig excavations and install the supports

(d)

install traffic management systems.

In any case the most likely competence required early on is that of a crane coordinator to ensure the planning and management of lifts associated with site cabins and welfare units. Consultation

5

Contractors are required to consult on matter of health and safety. Generally, this may be summarised as: (a)

Contractors must consult their employees, or their representatives on issues of heath and safety

(b)

employees must be able to raise any concerns they have over health and safety with the Contractors either directly or through their health and safety representative

QCS 2014

6


As part of the process of setting up a site, consideration must be given to how effective Contractors/employee consultation on matters of health and safety will be achieved. Co-operation

7

CDM requires that everyone concerned in a construction project, whether a contractor, selfemployed person or an individual worker, must- co-operate with each other in the interests of health and safety.

8

How such co-operation can be effectively achieved, must be decided at the stage where a site is being set up. Contact with the emergency services

.

It is advisable: to inform the emergency services of the location of the site, particularly if it is difficult to locate

(b)

particularly to inform the fire and rescue service if materials that represent a significant fire risk will be present on site

(c)

if considered necessary, to display in the site office a road map showing the quickest route to the nearest hospital with an Accident and Emergency Department in the site office

(d)

on larger sites, to identify the position of emergency controller to oversee site actions and communication with emergency services.

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1.1.11.5 Site features and facilities

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Existing buildings, features and ground conditions Consider the current and past uses of the site.

2

This could involve issues such as:

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ground water levels and/or underground water sources and the prevention of their contamination

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(b)

the existence of contaminated ground and the possible need for extensive site transport movements, both within and off site

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(a)

(c)

the previous storage of dangerous goods or hazardous substances in buildings, cellars or tanks

(d)

the location of underground services and whether they have been, or need to be, isolated or protected from surcharging, for example stockpiling heavy materials over shallow services

(e)

the location of overhead cables and whether they need to be isolated or repositioned

(f)

the need for equipment to create barriers and goalposts where overhead cables cross or border the site and remain live

(g)

if working on an existing structure, whether the electrical distribution system is still live and whether or not it should be

(h)

the condition of existing buildings -strength/condition of roofs, floors, stairs, hand-rails, walls and structural members. Advice from a structural engineer may be required to assess the suitability of a structure for its intended use

(i)

the possible presence of asbestos (where existing surveys exist these should be included)

QCS 2014


(j)

the possible presence of other hazardous substances, viruses and organisms such as lead, leptospirosis and anthrax

(k)

the possible need for demolition

(l)

the possible need for site lighting

(m)

the existence of a health and safety file for work on existing structures.

1.1.11.6 Site security Ideally, the site boundary will be secured immediately on possession, with lockable gates and suitable fencing or hoarding to prevent unauthorised access by the general public, particularly children, and to prevent the unauthorised tipping of waste. Where it is not possible to secure the whole site, adequate steps must be taken to ensure that potential locations of hazardous operations can be appropriately secured.

2

Gates and hoardings should be designed and able to withstand wind loadings. Particular attention should be given to swing gates to ensure they can be operated by one person and stops should be in place to prevent gates swinging into pedestrian/public areas.

3

In many cases it will be necessary to make separate provision for the security of individual items of equipment and plant.

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Access will be needed not only for plant, other vehicles and equipment, but also for people, therefore segregation is the safest method. Ideally traffic routes will be organised so that pedestrians are not put at risk by incorporating such measures as: site entrances and exits positioned so as not to cause a traffic hazard on the public road

(b)

segregated traffic and pedestrian routes and, if practical and necessary, segregated site entrances

(c)

one-way systems

(d)

turning areas to avoid the need to reverse

(e)

speed limits that must be enforced as necessary

(g)

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(a)

reversing vehicles being under the control of a qualified signaller the need for published traffic priorities where site vehicles and private traffic both use site roads

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1.1.11.7 Pedestrian/traffic routes, movement of plant and people

(h)

the need for the provision of traffic control measures (e.g. traffic lights), both on and off site

(i)

the provision of parking areas for delivery vehicles which are waiting to unload; if necessary, for example tightly-bound city centre sites, this may need to be off site

(j)

the provision of a car park for privately owned vehicles which preferably: (i)

is entered directly from a public road without having to pass through construction areas

(ii)

does not permit access to the construction area by private vehicles

(iii)

is connected to the site offices and welfare facilities by a safe, segregated pedestrian route

(k)

the possible need for a vehicle wheel wash where there is the potential for mud or other debris to be deposited on public roads

(l)

the possible need for a mechanical road sweeper to keep site and public roads clear

QCS 2014

Section 11: Health and Safety Page 180 Part 1.01: Qatar Legislation and Management (Regulatory Document) of mud or other debris

(m)

the provision of a secure vehicle compound.

2

When planning traffic/pedestrian routes, consideration should also be given to the possible need for rapid emergency evacuation of the site and/or the attendance of the emergency services.

3


1.1.11.8

Provision must be made for the safe storage of materials and equipment. Consideration should be given to: ensuring that site roads and any access road to the site are kept clear of obstructions

(b)

where possible avoiding 'double handling' by arranging for items (particularly heavy items that may have to be moved by hand) to be stored close to where they will be needed

(c)

the provision of proper storage facilities for flammable substances such as bottled gases and fuels

(d)

ensuring that materials that are delivered on pallets are stored in stable stacks, with a safe limit on the height of each

(e)

ensuring that there is no chance of stored materials toppling and breaching the site boundary

(f)

the possible need for access by lifting equipment such as telehandlers, mobile and tower cranes.

1.1.11.9 Utility services

(a)

a 230 volt (mains) supply (or a 415 volt, 3-phase supply where there will be heavy electrical loads such as a tower crane) a supply of fresh water. This should be tested to ensure it is of suitable quality for drinking and, if a new connection, should only be made by Qatar General Electricity & Water Company

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(b)

o

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Where necessary, early consideration must be given to the need for the installation of utility services to support the running of the welfare facilities and other site accommodation. This could include:

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(a)

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Materials storage and lay-down areas

(c)

the drainage of surface and foul water. New connections should only be made with the knowledge of the local authority. Particular attention should be given if hydrocarbons are to be used extensively near to watercourses. Petrol interceptors may be required, as are discharge consents if discharging into rivers

(d)

the provision of gas or oil for heating

(e)

appropriate telecommunication links

(f)

the provision of a stand-by generator and the appropriate fuel.

1.1.11.10 1

110 volt power system

Whilst not strictly speaking a 'utility', consideration must be given to whether a 110 volt distribution system will be required, and if so: (a)

is there a live 230/415 volt system to power it?

(b)

who will design and install it?

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(c)

who will test and inspect to ensure it meets British (BS) or other International standards?

1.1.11.11

Work at height

1

If work at height is to be carried out, it must be done so safely using the most appropriate access equipment.

2

If scaffolds (including alloy towers) are to be used, they must: (a)

only be erected, altered or dismantled by a competent person, or someone who is under the direct supervision of a competent person

(b)

be periodically inspected by a competent person

If mobile elevating platforms are to be used, they must be suitable for the job and only operated by competent persons.

4

Ladders should only be used in situations where the findings of a risk assessment show it is not reasonably practicable to use other safety access equipment.

Excavations

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1.1.11.12

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3

If excavations are to be dug, which by virtue of their depth, size or position could lead to an injury if a person, material or vehicle fell into them, suitable equipment such as guard-rails will be required to form an effective barrier around each such excavation.

2

Where the sides of excavations have to be supported to prevent the fall of soil, rock or other material, the system of support must be designed by a competent person.

3

Usually the competent person, a temporary works co-ordinator, will gather such information as required including ground reports and liaise with designers to ensure adequate support is designed and installed.

4

A safe means of access and egress must be provided for the people who will work in excavations. Where dictated by the depth, this will usually be a ladder.

5

If vehicles have to approach excavations for any reason, for example to tip material, the vehicle should be under the control of a qualified signaller and suitable anchored stop-blocks (or a similar device) must be employed to prevent vehicles getting too near the edge. This must be communicated to the temporary works co-ordinator to ensure the design considers this activity.

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1.1.11.13

The site office

1

It is acknowledged that, depending upon the size of the site and the nature of the project, the term 'site office' can cover office accommodation ranging from a single portable cabin to an office complex comprising multiple-cabins on more than one level in which non-construction workers, such as administrative staff, are employed.

2

Administrative staff, and others who may not usually carry or wear PPE, should ideally have access to site offices from outside the site via a safe route that does not entail passing through the construction area.

3

The site office should offer reasonably comfortable accommodation for all types of weather and normal ranges of temperature.

4

When setting up the site office the following must be considered:

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Section 11: Health and Safety Page 182 Part 1.01: Qatar Legislation and Management (Regulatory Document) a suitable and safe form of heating, including the safe location of LPG cylinders if used

(b)

the need for an electrical supply (with each circuit protected by a residual current device [RCD]) and telecommunications

(c)

obtaining a suitable, fully stocked first-aid kit unless first-aid facilities are located elsewhere

(d)

obtaining a suitable accident book

(e)

displaying information on how to identify and contact site first aider(s), where the firstaid box is located and the actions to take in an emergency

(f)

displaying a copy of the Contractors Health and Safety Policy

(g)

obtaining and displaying as necessary appropriate company-specific information

(h)

obtaining registers for the recording of statutory inspections, for example inspections of excavations and scaffolds

(i)

compiling registers for other purposes, for example:

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(a)

portable electrical appliance (PAT) testing

(ii)

tests of the fire alarm and other emergency procedures

(iii)

a site-visitors' log

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Welfare facilities

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1.1.11.14

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(i)

Workers will need clean and hygienic portable buildings or suitably protected areas where they can change and securely store clothing, make a hot drink, heat and eat their meals, and take shelter in the event of bad weather.

2

Workers will also need access to clean, well maintained toilets and appropriate washing facilities with hot and cold or warm water, soap and towels, for example basins or sinks large enough to wash their faces, hands and forearms in. In appropriate circumstances it will be necessary for showers to be provided.

3

Where there will be males and females on site appropriate provision must be made in relation to: toilets

(c)

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(a)

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(d)

rest facilities.

washing (and if necessary shower) facilities changing rooms

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(b)

1.1.11.15

First aid

1

The appropriate number of qualified first aiders and/or appointed persons for the job will be required. Details of the first aider(s) and the location of first-aid kit(s), with details of emergency telephone numbers, must be displayed and given out during site induction.

2

Where justified by the size of the site, or in a small number of cases the type of work being carried out, it may be decided that it would be beneficial to establish a first-aid room staffed by a qualified nurse at all times that work is being carried out.

1.1.11.16 1

Fire safety

Consideration must be given to the level of fire risk arising out of the work to be undertaken (not forgetting the masses of paperwork, drawings etc. that can accumulate in site offices) and the nature of any other flammable substances that may be stored and used.

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2

A sufficient number of fire extinguishers appropriate to the type of fire which may occur should be obtained and located in highly visible fire points in appropriate places, including office and welfare accommodation.

3

Fire exit and emergency escape route signs must be obtained and displayed and must, in the interests of health and safety, be illuminated in periods of darkness, as necessary.

4

An early decision must be made with regard to whether smoking will be allowed in any area of the site. If smoking is to be allowed in certain areas, those areas must be equipped with signs that clearly indicate the extent of the 'smoking area'. Equipment must be provided for the safe disposal of spent smoking materials. Official signs indicating that smoking is not permitted must be clearly displayed at the entrance(s) to all site accommodation.

1.1.11.17

Emergency plans

During the setting up of a site provision must be made for dealing with emergency situations which may involve evacuation of the site. It is likely that this will be simpler for an open site than, say, for the refurbishment of a multi-floor structure.

2

Liaison with the Civil Defence (Fire Department) may be useful in identifying a fire-fighting strategy within the plan and locations of fire-fighting cores and dry riser locations.

3

Emergency escape routes must be determined, identified by appropriate signs and communicated to all on site. On larger, more complex sites it may be necessary to:

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1

compile a fire safety/emergency evacuation plan, which may or may not as appropriate, be a part of the construction health and safety plan

(b)

appoint evacuation wardens who have responsibility for ensuring that particular areas of the site has been totally evacuated.

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(a)

The location of a suitable assembly point, which can accommodate the maximum number of people expected on site and is a safe distance from the potential hazard, must be determined. On larger sites it may be considered appropriate to designate more than one assembly point.

5

However, unless the evacuation procedure is well thought out and effectively communicated to all on site, this has the potential to make accounting for everyone more difficult.

6

Information must be displayed regarding actions to be taken in the event of an emergency, for example:

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4

7

(a)

what the fire/evacuation alarm sounds like

(b)

the days/times that tests will be carried out

(c)

where the fire assembly point(s) is/are.

Suitable arrangements should also be provided for dealing with environmental emergencies and incidents such as the accidental release of oils or fuels. The site must consider the type and location of spill kits and any necessary training in their proper use and disposal.

1.1.11.18


1

Contractors have a legal duty to provide the necessary personal protective equipment (PPE) for their employees. Depending upon the type of work that will be undertaken and other control measures that are in place, it is quite likely that a stock of appropriate PPE will be required at the time the site is set up.

2

It may be necessary to discuss with a reputable PPE supplier the standards of PPE required

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where there is a choice, for example when purchasing: (a)

respiratory protective equipment

(b)

eye protection

(c)

hearing protection

(d)

gloves

1.1.11.19

It is usual to post one or more signs at site entrances to inform all persons who enter of the health and safety requirements of the site. It is usual for these to specify: the minimum standard of personal protective equipment required (usually safety helmet, safety boots and hi-vis waistcoat)

(b)

that all visitors must report to the site office.

(c)

Other signs that must be obtained for display are:

(d)

a selection of appropriate, mandatory, warning, prohibition and safe condition signs

(e)

appropriate traffic-management signs

(f)

if appropriate, signs to indicate the presence of liquid petroleum gases and other flammable substances, particularly vehicle fuels

(g)

other fire safety signs as are necessary, for example to indicate the location of fire points.

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Consideration must be given to the quantities and types of waste (possibly including food waste) that might be generated and arrangements made for its lawful disposal.

Environmental considerations

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1.1.11.21

(b)

defining responsibilities on site for managing the environmental issues

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(a)

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Much construction work has the potential to impose a severe impact upon the environment. Measures must be taken to prevent environmental damage including:

making everyone on site aware of the project environmental issues through inductions and briefings

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Waste disposal

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1.1.11.20 1

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(a)

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Signs and notices

(c)

identifying and protecting any water courses and drainage systems

(d)

implementing measures that will avoid the spillage of harmful fluids, but where spillage does occur, preventing it from seeping into the ground and contaminating water courses, including sources of drinking water

(e)

the appropriate handling, storage and disposal of construction waste and other types of waste

(f)

adequately protecting the site against theft and damage

(g)

identifying and dealing with the existence of protected species of mammals, insects, plants etc.

(h)

reducing noise pollution as far as it is reasonable to do so, which may involve restricting some construction processes to certain times of the day

(i)

providing well-maintained haul routes to reduce dust, mud and noise

(j)

reducing the amount of substances used that give off environmentally damaging vapours or fumes

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Section 11: Health and Safety Page 185 Part 1.01: Qatar Legislation and Management (Regulatory Document) paying appropriate attention to other sources of nuisance to neighbouring properties and the public in general

(l)

not leaving the engine of any item of construction plant running when it is not in use

(m)

maintaining good housekeeping to prevent wind-blown debris or waste leaving the site and to reduce damage and waste to materials

(n)

turning off other power sources when the equipment is not in use.

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(k)

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Construction Site Safety 1.1.11 Appendix Setting up site checklist This checklist suggests the common factors that should be checked when setting up a site; the list is not exhaustive. If necessary, refer back to the main text of this section, or other sections that cover specific topic areas, for greater detail.

Human factors Competencies Y Have measures been put in place for accurately assessing the competency of everyone who will come on to the site? In particular, attention to competence should be applied to: 1.1 carrying out risk assessments and extracting the significant findings

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1.

1.2 writing method statements and disseminating the content

1.3 raising, monitoring compliance with and cancelling permits to work

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1.4 carrying out any type of training

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1.5 designing, erecting, altering or dismantling scaffolds (including alloy tower scaffolds)

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1.6 carrying out scaffold inspections 1.7 raising scaffold hand-over certificates

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1.8 planning, supervising and working at height, using any means of access

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1.9 designing and installing excavation support systems 1.10 carrying out the inspection of excavations

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1.11 the identification and isolation (as necessary) of buried services

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1.12 operating all types of construction plant 1.13 carrying out inspections and examinations of construction plant

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1.14 planning and supervising lifting operations 1.15 inspecting and examining lifting equipment and accessories

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1.16 planning, supervising and carrying out work in confined spaces 1.17 carrying out rescues from confined spaces 1.18 the use of any power tool or hand tool that has the potential to be harmful if not properly maintained, inspected and/or used 1.19 assessing exposure to noise and/or vibration 1.20 the use of any flammable or hazardous substance 1.21 any work on the public highway 1.22 designing temporary works for site establishment continued on next page

N

N/A

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continued from previous page The spaces below are for competences, not included above, to be added. 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 Consultation

.

Have measures been put in place to ensure effective two-way consultation and communication on matters of health and safety?

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2.

Have measures been put in place to ensure effective co-operation between everyone who will be on site?

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3.

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Co-operation

Has contact been made with the relevant emergency services to ensure that they have sufficient information to deal with any foreseeable emergency that might arise?

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4.

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Contact with the emergency services

Site features and facilities

3. 4.

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2.

Have checks been made of the previous use of existing structures and the land? Have checks been carried out for land that may be contaminated, for example, by leakage of fuels or oils? Have the appropriate authorities been asked for details of water levels and/or underground water sources? Is there evidence of previous storage in buildings, cellars or tanks of dangerous goods or hazardous substances?

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Existing buildings, features and ground conditions

5.

Has all information, relating to any underground services, been provided?

6.

Have the appropriate measures been taken to prevent an electrical hazard from overhead cables?

7.

Has the existing electrical distribution system been made safe?

8.

With regard to buildings on the site, is the strength/condition of roofs, floors, stairs, guard-rails, walls and structural members known?

continued on next page

Y

N

N/A

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continued from previous page 9. Have checks been made to establish whether or not asbestos is present? 10.

Have checks been made to establish the presence of other hazardous agents, such as chemicals, gases, viruses or organisms?

11.

Will any demolition required be carried out by competent contractors?

12.

Has the delivery and installation of site-lighting been arranged?

13.

Has the Health and Safety File for any existing structure(s) been consulted?

Site security N

N/A

Y

N

N/A

Has the delivery and erection of materials to form a secure site boundary been arranged? Have those people who will be on site as it is set up been informed of the security arrangements?

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2.

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1.

Y

Have out-of-hours contact details been displayed at the site entrance?

4.

Have separate security measures been put in place to prevent theft and to prevent access into identified hazardous areas?

5.

Is a plan in place that outlines the actions that should be taken to deal with unauthorised visitors?

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Management of vehicular and pedestrian traffic

Have traffic routes been designed to segregate vehicles from pedestrians?

2.

Have site entrances and exits been positioned so as not to cause a traffic hazard on the public road?

3.

Have traffic management measures such as one-way systems, speed limits and turning areas been implemented?

4.

Are there clear priorities, for example using traffic lights, where site transport and private vehicles use the same routes?

5.

Has a safe area been designated for delivery vehicles waiting to unload?

6.

Has a car-park for private vehicles, with a safe entrance and exits (separate exit for pedestrians), been established? Have measures been taken to prevent mud and debris from accumulating on public roads?

7.

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8.

Has a secure construction plant compound been established?

9.

Have haul roads been designed to prevent blind spots and prevent build up at pedestrian crossings?

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Materials storage and lay-down areas Y Have these areas been planned so that traffic and pedestrian routes will not be obstructed?

2.

Have these areas been positioned to avoiding the 'double handling' of heavy items that may have to be moved by hand?

3.

Have proper storage areas been created for flammable substances, such as bottled gases?

4.

Are palletised materials stored safely, with stacks of materials stable and limited in height?

5.

Are storage areas located away from site boundaries, particularly in areas where the general public have access to the other side?

N/A

Y

N

N/A

Y

N

N/A

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1.

N

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2.

Have arrangements been made for the installation and commissioning of a suitable electrical supply? Is a supply of fresh drinking water available?

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1.

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Utility services

Have arrangements been made for the installation and commissioning of drainage systems for surface and foul water?

4.

Have arrangements been made for the supply of other types of heating fuel?

5.

Have arrangements been made for the installation of the required number of telephone lines and other forms of telecommunication links?

6.

Have appropriate measures been taken for the supply of stand-by power?

7.

Have arrangements been made for the design and installation of a 110 volt distribution system?

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Working at height

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3.

1.

Have arrangements been made for scaffolds to be erected, altered and dismantled by a competent person?

2.

Have arrangements been made for the statutory inspection of scaffolds to be carried out by a competent person?

3.

Will all work at height be planned, supervised and carried out by a competent person?

4.

In all cases, will work at height be carried out using the most appropriate means of access to height?

5.

Have arrangements been made to ensure that competent operators will be available for mobile elevating work platforms (MEWPS)?


QCS 2014


continued from previous page 6. Has consideration been given to whether the ground conditions are suitable for the use of MEWPs? 7.

Will a survey be carried out to investigate the existence of cellars, drains and other underground voids?

8.

Has consideration been given to the possible existence of overhead power lines or other high-level hazards?

9.

Will the use of ladders be restricted to tasks where it is not reasonably practicable to use an alternative, safer means of access?

Excavations

.

Y Has suitable equipment been obtained to form an adequate barrier (for example guard-rails) around each excavation into which a fall could cause a person to be injured?

2.

Where installed, will the system of supporting the sides of all excavations be designed and installed by a competent person?

3.

Will a safe method of installing the supports, that does not involve anyone going into an unsupported trench, be employed?

4.

Will a safe means of access/egress be provided (where necessary) for each excavation?

5.

Where vehicles have to approach an excavation: 5.1 will they be under the control of a trained signaller?

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7.

Have arrangements been made for the statutory inspections of excavations to be carried out by a competent person? If the sides of the excavation are sloped or battered, is the angle of batter sufficient to prevent collapse?

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6.

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5.2 will anchored stop-blocks (or a similar device) be installed to prevent the vehicle over-running?

Has consideration been given to the possibility of any excavation affecting the stability of neighbouring structures?

9.

Will materials, spoil or plant be stored away from the edges of the excavation, to reduce the likelihood of collapse?

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8.

N

N/A

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The site office Y

2. 3. 4.

N/A

N

N/A

Have arrangements been made for the delivery and siting of adequate office accommodation, including carrying out any enabling work? Is the site office located so that it can be accessed without the need to wear PPE? Does the site office have a safe form of heating, with the fuel stored in a safe manner? Are the electrical circuits in the office protected by an RCD and regularly tested and inspected? Is there a suitable, fully stocked first-aid kit in the office?

6.

If the answer to 5 is 'NO', have alternative provisions been made for first aid?

7.

Is information on how to locate and identify first aiders displayed?

8.

Is a copy of the company Health and Safety Policy displayed?

9. 10.

Have registers been set up for recording statutory inspections? Have other registers, as may be necessary, been set up?

12.

Are emergency plans and routes to the nearest hospital available?

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5.

.

1.

N

as

Welfare facilities

Are adequate welfare facilities available in respect of:

se

1.

toilets which are adequately ventilated and lit?

1.2

washing facilities (including showers if necessary), which are equipped with hot and cold (or warm) water, soap and towels or a means of drying? rest areas (including facilities for a female person who is pregnant, or a nursing mother, to lie down)?

ov

o

1.3

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1.1

drying and/or changing rooms with secure lockers?

1.5 1.6

where necessary, separate facilities for men and women? the cleaning and keeping in good order of welfare facilities?

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1.4

a supply of fresh drinking water complete with suitable cups, unless from a 'water fountain' or similar?


Y

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continued from previous page 1.8 a means of preparing hot food? 1.9

arrangements to enable food to be eaten in reasonable comfort (an adequate number of tables and chairs with backs)?

1.10

a means of boiling water?

First aid Y Have sufficient and suitable first-aid kits been obtained?

2.

Has an assessment been made as to whether more extensive first-aid facilities are required?

3.

Have 'travelling first-aid' kits been obtained for site vehicles and anyone who works in a remote location?

4.

Are sufficient qualified first aiders available?

5.

Are sufficient 'appointed persons' available?

6. 7.

Has initial or refresher first-aid training been arranged as necessary? Has a scheme whereby first aiders can be quickly located and identified been implemented?

8.

Has an adequate number of first-aid signs been obtained and displayed?

9.

Has an accident book been obtained and made available?

N

N/A

N

NA

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Fire safety

Has an adequate number of serviceable fire extinguishers of the appropriate type(s) been obtained?

2.

Has an appropriate number of site-staff been trained in the selection and use of hand-held fire extinguishers?

3.

Are fire extinguishers located at well-signed and easy to find fire-points?

4.

Has an effective fire alarm system been devised?

5.

Will everyone on site be made aware of what the fire alarm sounds like?

6.

Has a means of preventing the accumulation of flammable waste material been established?

7.

Have suitable and sufficient fire safety signs been obtained and displayed?

8.

Have proper storage areas for flammable substances like LPG been established?

9.

Will smoking be allowed in well-defined safe areas of the site and/or welfare facilities?

10.

Have signs been erected to clearly define the boundaries of the areas in which smoking is allowed?

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1.


Y

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continued from previous page 11. Has equipment been obtained and positioned to enable the safe disposal of spent smoking materials? 12.

Has a time been set each day, after which smoking is not allowed?

Emergency procedures Y

N

N/A

1. Has an emergency evacuation plan been drawn up and communicated to all on site?

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3. Has an adequate number of 'evacuation wardens' been appointed and informed of their duties?

.

2. Will a nominated person monitor the evacuation plan and ensure that it is always up to date?

rw

4. Have one or more assembly points, which are a safe distance from the potential hazard, been selected?

ta

5, Have 'assembly point' signs been obtained and clearly displayed?

qa

6. Has everyone on site been informed of:

as

6.1 the location of the assembly point to which they are to report in the event of an evacuation? 6.2 what the evacuation signal sounds like?

se

6.3 what to do when they get to the assembly point? 6.4 the days/times when the evacuation signal will be tested?

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6.5 the fact that the evacuation plan will be periodically practised on a 'nonotice' basis?

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o


Has an assessment of the needs for personal protective equipment (PPE) been made, engaging the assistance and advice of a reputable supplier if necessary?

2.

Has everyone on site been issued with all of the PPE that they need to carry out the jobs allotted to them?

3.

Does everyone on site know how and where to obtain any extra PPE that they might need in the future?

4.

Does everyone on site know how to obtain replacement PPE for that which is lost or defective?

5.

Has a PPE issue log been started?

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1.

Y

N

N/A

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Signs and notices

1.

Has a 'combination' safety sign been erected at each site entrance to inform everyone who needs access of the minimum standards of safety on site?

2.

Has an adequate selection of warning, prohibition, mandatory and safe condition signs been obtained and displayed?

3.

Has an adequate stock of other signs, such as traffic management signs, been obtained and displayed?

4.

Has a person been nominated to ensure that additional signs are erected and existing signs are moved or removed to reflect changing conditions as the job progresses?

N

N/A

Y

N

N/A

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Waste disposal

Y

Have arrangements been made for the delivery of sufficient skips or other suitable containers to enable different types of waste materials to be stored?

2.

Have the arrangements for the segregation and disposal of waste been communicated to everyone on site?

3.

Has an area of the site that is readily accessible by large vehicles been set aside for the siting of skips?

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1.

se


Has responsibility for environmental management, monitoring and inspection been defined?

2.

Has the potential overall environmental impact of the project been considered?

3.

Have the project environmental issues been included in the site induction?

4.

Have measures been put in place to avoid or reduce the more obvious environmental problems, such as: 6.1 the spillage of environmentally damaging fluids?

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1.

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6.2 any spillage that does occur is not able to seep into the ground, drainage systems or watercourses? 6.3 the management, storage and disposal of waste materials? 6.4 noise and dust pollution, arising out of construction activities? 6.5 the number and quantity of substances used that give off environmentally damaging vapour or fumes? 6.6 air pollution resulting from the unnecessary running of construction plant engines? 5.

Has the existence of protected species of mammals, insects, plants etc. been investigated?

6.

If protected species are known to be on site, have appropriate measures been taken to ensure that they remain undisturbed or undamaged?

7.

Have arrangements been defined to adequately deal with environmental emergencies such as the accidental release of oil and fuels?

Y

N

N/A

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Action plan

as

If you have answered NO to any of the questions in the checklist, please provide further information in the columns below.

Question number

er

Section

se

Human factors

ito

ov

Competence

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Consultation

Co-operation

Contact with the emergency services

Action to be taken

By whom

Date for completion

Comments

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qa

Question number

Action to be taken

er

se

as

Existing buildings, features and ground conditions

ov

Site security

m

et

ito

Management of vehicular and pedestrian traffic

Materials storage and lay-down areas

Utility services

Working at height

Excavations

ta

Site features and facilities Section

Page 196

rw

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By whom

Date for completion

Comments

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Page 197

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Question number

Action to be taken

qa

Section

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as

The site office

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Welfare facilities

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Fire safety

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ito

First aid



Signs and notices

By whom

Date for completion

Comments

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Page 198

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Question number

Action to be taken

qa

Section

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Waste disposal

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By whom

Date for completion

Comments

QCS 2014


Construction Site Safety 1.1.12 Security on Site 1.1.12.1 Key points Generally, site security is as much about the health and safety of 'other persons' as it is about contractors, employees and other people who would be expected to be on site.

2

Site security must be effective both during and out of working hours.

3

Effective site security will keep children and other trespassers off the site; even outside working hours, construction sites can be hazardous places for the unwary, particularly children.

4

There are actions that can be carried out to prevent the theft of construction plant.

5

The nature of some sites means that whilst they cannot be completely fenced off from the public, for example scaffolds erected in public places, unauthorised access must be prevented.

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Note: Section 1, Part 3 of the QCS covers site access and Section 1, Part 4 covers site protection.

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Security is a subject that in many circumstances is closely associated with health and safety on building, construction or civil engineering sites. A poor standard of security with the resulting risk of trespass, theft and damage can have implications for the health and safety of the trespassers and possibly the people who are authorised to be there.

2

There are several reasons why the security of a site might be breached, not all of which are malicious.

3

There are common examples of construction activities taking place in premises, which are still partially occupied by the owner, landlord, members of their staff and possibly members of the public. For example, where construction work is taking place in a:

newly built, partially occupied housing estate

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(b)

supermarket or department store that is still open to the public but is undergoing an extension or renovation

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(a)

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(c)

block of occupied flats undergoing maintenance or renovation.

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It might be possible for unauthorised persons to inadvertently stray into the site quite innocently unless adequate security measures are taken.

5

However, in many cases, the reasons for trespass have been shown to be malicious. This is usually for the purpose of theft or criminal damage, both of which can have health and safety implications for site staff when they return to work.

6

Children might also try to gain access to sites out of curiosity and the mistaken belief that they are safe and 'fun' places to play.

7

Equipment designed to physically control access to sites is readily available. Even a modest investment (in terms of finance, time and effort) can easily result in a significant improvement in the standard of site security and therefore reduce the potential for financial and other losses.

QCS 2014


1.1.12.3 Site visitors 1

It can be taken that a 'visitor', for the purpose of these Regulations, can be anyone who is not an employee. Therefore, a visitor may be any person who is a lawful visitor with a genuine reason to visit the premises, or a trespasser, who at any time during the day or the night may be intent on committing a crime.

1.1.12.4 Lawful visitors Examples of visitors who may have reason to visit construction sites and are: (a) postmen/women and couriers (b) telephone engineers and other communications specialists (c) electricity, gas, telephone and water company employees (d) visiting engineers and other construction professionals (e) customers and other beneficial visitors (f) Administrative Authority Workplace Inspectors (g) QCS Inspecting Officers (h) delivery drivers (i) trainees.

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1.1.12.5 Unlawful visitors and trespassers

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Examples of unlawful visitors are: (a) any person entering the site for the purpose of theft or to commit criminal damage (b) any person entering the site by accident (c) any (unauthorised ) person deliberately passing through the site, e.g. as a short-cut (d) children entering the site to play. In respect of all trespassers, including those with criminal intent and children, it is illegal to set any form of trap or to deliberately do anything that is intended to cause injury to, or to damage the health of, the intruder.

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Employees may be well aware of the risks, and have safe systems of work, use protective equipment or have procedures that would be unknown to a visitor. In these cases, the occupier must make suitable provision for the protection of all visitors. An example might be the provision of eye, foot or head protection where necessary, or barriers to keep visitors away from machines.

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1.1.12.6 Foreseeable risks

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1.1.12.7 Children and young persons

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3

If children or young persons are allowed on the premises (as children of customers, invited school parties, and so on), it must be remembered that they cannot be considered to have any concept of hazard and risk and cannot be expected to behave as would an adult. Whereas an adult may stand behind a guardrail that is set at a height of 1 metre, a small child could walk under it. It may be necessary to install two intermediate guard-rails at 330 mm and 660 mm. It should also be appreciated that children may not be able to read, understand or comply with safety signs and notices.

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1.1.12.8 Site security and crime prevention The crimes that cause the greatest problem on site include theft, criminal damage and arson.

2

While it may be usual to think about offenders being unauthorised people who come onto site to steal or cause damage, it must be remembered that a substantial number of offences are committed by employees either for the direct gain of what they steal or out of malice against the Contractors. It is not unknown for employees to damage property to delay the progress of work, so they can be employed for longer repairing the damage that they have caused.

3

Sometimes, site employees will give information to other persons who will later come and commit the crime. This is very often the case with regard to the theft of larger items of construction plant and equipment, or where substantial amounts of material are taken. Even if the offenders are caught, it is very difficult to identify the employee who passed on the information.

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The four most important things that can be done for site security are to: remove temptation by hiding from view any 'attractive' item that might tempt a potential thief

(b)

make it more difficult for the trespasser to get onto the site or into the building

(c)

make it harder for the trespasser to gain access to 'attractive' items if they do manage to get onto the site

(d)

make it more difficult for the criminal to profit from their crime.

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Removing temptation

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1.1.12.11

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This simply involves ensuring that 'attractive' items such as hand-held power tools are removed from view when not in use, particularly out of normal working hours. On sites surrounded by a solid hoarding, this should not be an issue.

Making it difficult for the trespasser to gain access to the site

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1.1.12.9 Managing security

The first consideration in attempting to make it difficult for the trespasser to effect an entry will include the provision of site fencing.

2

This should be at least a 2-m high security fence with the posts securely anchored. 'Mesh' type fencing, which includes 'anti climb' panels, can be hired. The panels have small gaps in the mesh to make it more difficult to obtain footholds.

3

Alternatively, a close-boarded wooden perimeter fence or hoarding, at least 2 m high, may be needed in a city or town centre site or at other high-risk premises.

4

It should be remembered that if employees are used as security staff, they must be given the appropriate health and safety training before they start work, or whenever they are exposed to a new or an increased risk.

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Guard dogs 1

As work on most sites only takes place during the normal working week, serious consideration must be given to 'out-of-hours' security.

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2


Again, an assessment is needed and the use of guard dogs may be considered. Locks, alarms and other security measures If buildings are to be made secure, special attention should be paid to doors where high quality locks should be used. Windows may need to be protected by steel grilles as well as locks. The use of padlocks, other than very high security padlocks, is questionable, as criminals using bolt croppers frequently cut the exposed shank.

4

The walls of a building are not very often broken through but it is reasonably common for criminals to gain access through ceilings, particularly to get into shop premises.

5

It is relatively common for thieves to use cutting equipment to enter storage containers. There are a number of proprietary products, particularly toolboxes/chests, which advertise that they are designed to be more thief resistant.

6

A burglar alarm, whilst not adding anything to the physical security of premises, may well deter a criminal from trying to break in, or cause them to run away without stealing anything when the alarm sounds.

7

If perimeter fencing is to be made secure, special attention should be paid to entrance gates, in respect of which high quality locks should be used.

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3

Because of the nature of building, construction and civil engineering activities, it is difficult to have a totally secure site. As unlawful visitors will get onto site occasionally, and some employees may be dishonest, measures need to be taken to prevent criminal offences from being committed. There are two main areas where action can be taken to make it harder for people to steal property:

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Making it harder for the criminal to steal or damage anything

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1.1.12.12

put it somewhere where it cannot be stolen

(b)

secure it or immobilise it.

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(a)

Making it more difficult for the criminal to profit from their crime

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1.1.12.13

This is something that can easily be done with all property that may be stolen, and is probably one of the most cost-effective areas of crime prevention.

2

A simple example is with scaffolding, where many companies, ever mindful of the risk of theft, paint their tubes and fittings with brightly coloured bands. It becomes immediately obvious that something is wrong if they appear on another contractor's site.

3

Highly visible markings may be a deterrent, but professional criminals are still prepared to steal items and then remove the markings.

4

The rising value of metals has made some crime even more lucrative, as there is little need to consider the risks associated with resale and reuse if the stolen item is simply exported for reprocessing. It is important to consider at what stages of construction progress a site is more likely to be the target of theft. For example, one strategy is to move to a full-time security presence at second fix and to install high value white goods immediately prior to handover/practical completion.

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1.1.12.14 1

Construction plant and equipment

The health and safety implications if the equipment is not there, or has been damaged, may be that the job cannot now be done properly or safely. Often shortcuts are taken and such

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'makeshift' or temporary works will expose employees to additional risks to their health and safety. 2

Where possible, isolate plant and machinery at the end of each shift, and park it in a secure area such as a plant compound that is locked and visible to site security.

1.1.12.15 1

Photographic evidence of ownership

It can be difficult to identify stolen property because many people have no idea what a compressor, excavator or a backhoe loader really looks like. Photographs of plant and equipment are useful when trying to describe stolen items to the police or to your insurance company, especially when they are not common or standard pieces.

1.1.12.16

Security of plant

Security of plant has implications for health and safety on building, construction or civil engineering sites as well as for the financial viability of a company.

2

Having a well-managed security programme, to restrict the theft of equipment, may help in reducing premiums to insurance companies.

3

The theft of plant which is not properly secured, or that can be moved or started, could have serious financial consequences for a company.

4

The actual cost of security arrangements can be insignificant when compared with the financial loss that theft incurs.

5

Costs which may be encountered could be in terms of production time lost due to missing equipment, the administration in acquiring replacement equipment, as well as dealing with the police and insurance companies.

6

Losses may also be incurred due to the damage caused to plant and equipment by unsuccessful theft or by wanton vandalism, such as broken cab windows or spray paint graffiti. Steps must be taken to minimise the possibility of either.

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Theft of plant and equipment is one of the most common crimes that occur on site, some by chance and some to order. The damage that the thief does in trying to steal the plant can be substantial, not only to the plant but also to perimeter fencing, even if the theft fails.

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Site security and crime prevention

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1.1.12.17

1.1.12.18

Managing the security of plant and equipment

1

An overall theft prevention plan should be produced and constantly reviewed. Each of the anti-theft methods outlined in the following, and the ways to identify and locate plant, should be considered as part of this plan.

2

There tends to be a lack of responsibility by people towards the security of plant, tools and equipment, particularly where these are hired in.

3

It is the responsibility of management to ensure that staff are aware of the problems created by plant theft, including the possible effect on the company's viability and the consequent damaging effect on jobs.

1.1.12.19 1

Closed circuit television (CCTV)

As the cost of closed circuit television (CCTV) has reduced, the affordability and wider use of

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the equipment has made the deterrent effect of its use considerable. 2

3

Cameras need to be well placed and: (a)

capable of viewing the perimeter in darkness, with or without the aid of security lighting

(b)

difficult for a thief to interfere with or steal.

On an unstaffed site, it is essential that the potential criminal knows recording is taking place and that the recorder itself is in a secure location.

1.1.12.20

Put it somewhere where it cannot be stolen

On most sites, small, valuable hand tools and pieces of plant or equipment will be locked in a site hut or tool store, or in a secure tool chest out of sight. The storage place should be as substantial and secure as possible so that it is difficult to break into.

2

If a mobile tool store or chest is used, it should be recognised that some types of site equipment and lorry-mounted cranes can be used to lift or drag tool chests and stores onto a vehicle and stolen intact with their contents.

3

They should, therefore, be put in a secure site hut or container and securely bolted or welded to the floor. If the tool store or vault has to be left externally, it should be bolted to a concrete floor or block, or chained to an immovable object.

4

Often high security steel freight containers are used. These have no windows, virtually impenetrable walls, floors and roofs, and doors that are designed to be securely locked. This is a great advantage over the average site hut, which is usually a portable building with no integral security features beyond normal door locks.

5

When using these containers, however, it should be remembered that they must never be used for the storage of LPG cylinders or any other gas bottles, or quantities of solvents. There have been instances when cylinders and gas bottles have leaked overnight, allowing a dangerous build-up of gas inside the container.

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Secure it or immobilise it

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1.1.12.21

Non-driven mobile plant and trailers Non-driven mobile plant and trailers should be immobilised by the use of specialist mechanical devices, such as eye-locks and wheel clamps, and should also be secured by a security chain to an immovable object, thus preventing lifting by lorry-mounted cranes or other site equipment.

2

Their visibility acts as a deterrent. Removal requires much physical effort and time and the use of specialised tools. Their removal is also likely to be accompanied by noticeable noise and light.

3

Immobilisation could also include smaller items being chained to larger items of plant, concrete posts or steel columns.

4

'Security' chains should be strong enough to defeat files, hacksaws, levers and large bolt croppers, and be difficult to attack with power tools.

5

Where possible, chains should be kept off the ground as this makes attack more difficult.

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Driven plant Larger items of driven plant and equipment that cannot be put into a store should be immobilised by simple specialist mechanical or electronic devices.

7

It should be appreciated that the smaller the plant, the less likely it is that an electronic immobiliser can be adequately concealed and that mechanical devices will be more practical. Mechanical devices can immobilise stabiliser legs, steering mechanisms, excavator booms and tracks.

8

On items of plant such as large earthmovers, road graders and large dump trucks, or where the machine is complex, it is easier to conceal an electronic immobiliser. A mechanical device to do the same job would be too large to manually handle.

9

Many pieces of plant have either mechanical devices and/or electronic devices fitted by the manufacturer at the time of manufacture. All aspects of their operation should be understood and full use made of them when the item of plant is left.

10

When the plant is left overnight or longer, there should be a disciplined approach to security. The plant should be parked in a location where any wrongdoing would be noticed by passers-by and away from easy access by a lorry-mounted crane to reduce the possibility of it being lifted off site.

11

The ignition keys should be removed which will, in many instances, set an alarm and an immobiliser. If the alarm or immobiliser does not set automatically then it must be set manually.

12

A mechanical immobilisation device, where fitted, should be in such a position that it is visible to passers-by to ensure any suspicious tampering is noticed. If such mechanical devices allow equipment to be locked together, then this facility should be used whenever possible.

13

Immobilisation could also include smaller items being chained to larger items of plant.

14

Any labels supplied by the manufacturer that indicate that immobilisation devices are fitted should be prominently displayed.

1.1.12.22

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Create a series of barriers

One of the key problems for any prospective thief is lack of time, and overcoming barriers is time consuming. For instance, a fence or gate may be the first barrier to overcome, the second a security container, the third a security chest or a series of physical locks and chains within the container.

2

Individually each barrier might not present the prospective thief with too much difficulty but, added together, they may prove so time consuming that the thief abandons the attempt.

3

Similarly, for larger equipment, fencing is the first barrier. The secure location of the equipment, and the setting of mechanical and electronic immobilisers, then adds further barriers, increasing the difficulty and the time required to overcome them.

4

A bright corporate colour scheme for all pieces of plant owned by a Contractor, as well as the vans and lorries visiting the site, dissuades the thief. It identifies the equipment and makes it more difficult to resell without repainting. Also, when a van or truck parked next to the plant is not in the same corporate colours, and any work being undertaken is suspicious, it can alert passers-by.

5

Painting plant and equipment in corporate colours could be used as part of an overall theft

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prevention plan.

1.1.12.23 1

Recovery of plant and equipment

Once stolen equipment has left the site, the cost of inconvenience has started to mount up. Although any subsequent recovery device will mitigate the final cost of the theft, it will not change the cost of lost time and administration. Stolen vehicle and plant location A popular way of recovering plant is through a tracking device. This relies on the ability of the police or a central monitoring station to locate the plant through signals emitted from devices located on the equipment.

3

Although the success of recovering plant fitted with trackers is high, thieves are becoming more sophisticated in their actions and technology, and are finding ways to neutralise the devices.

Keys

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1.1.12.24

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Another recommendation is the elimination of single keys for plant. (As with cars, some sets of keys will give access to a variety of vehicles, not necessarily of the same make or year of manufacture.) Plant manufacturers will eventually undertake this move, but until all machines have different keys, the fitting of either a mechanical or electronic immobilisation device, or both, is essential.

2

Whilst manufacturers will also be upgrading the security of cabs and canopies, it is still necessary to lock them to reduce the possibility of hot-wiring plant to start it or the damage caused whilst trying.

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Plant theft - summary

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Among the items most commonly stolen are mini-excavators, floodlighting equipment, generator sets and compressors. All are of high value and relatively portable. Once removed from site, they may prove impossible to track down.

2

Construction plant or equipment that is securely locked, immobilised, and clearly and visibly marked is less likely to be stolen than plant which is not secured or marked.

3

Equipment that is fitted with an electronic tracking device or is registered with a database is more likely to be recovered after being stolen.

4

Electronic tracking devices may be active or passive. Active devices allow the owner to know exactly where the item of plant is at all times, while passive devices are only activated once that piece of plant has been stolen or unlawfully removed.

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Construction Site Safety 1.1.13 Statutory Forms, Notices and Registers 1.1.13.1 Key points 1

The selection of the forms or notices, etc., will necessarily be as appropriate or applicable to the individual site or premises, and the circumstances that exist on that site.

1.1.13.2 Statutory Forms, Notices and Registers Accident Book The keeping of an accident book is required by these Regulations

2

All accidents that cause any injury to an employee, no matter how slight, must be entered. Entry may be made either by the employee or anyone acting on their behalf.

3

Completed book stubs and records must be kept for three years from the date of the last entry.

4

F100 Report of an injury or dangerous occurrence (Pad of forms) Injuries

5

Form F100, report of an accident or dangerous occurrence, is required by RIDDOR - The Reporting of Injuries, Diseases and Dangerous Occurrences.

6

Unless notification has been made by telephone, fax, email, Form F100 must be completed and sent by the person completing the report to the Administrative Authority which is the Administrative Authority, this action is required under the following circumstances:

7

If an employee or other person dies or suffers any major injury as a result of an accident at work.

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Note: (i) This type of accident must also be reported immediately by the quickest practical method (usually the telephone).

any fracture of any bone other than the fingers, thumbs or toes

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Note: (ii) A major injury or serious condition such as:

(b)

any amputation, the dislocation of the shoulder, hip, knee or spine

(c)

the loss of sight (whether temporary or permanent) or any other listed eye injury

(d)

electric shock or burn causing unconsciousness

(e)

any injury leading to hypothermia, heat-induced illness or to unconsciousness requiring resuscitation or admittance to hospital for more than 24 hours

(f)

unconsciousness due to asphyxia or exposure to a harmful substance or biological agent

(g)

acute illness or unconsciousness caused by any poisoning by any route

(h)

acute illness caused by exposure to infected material or a biological agent

(i)

if an employee has an accident at work and is unfit or is off work for more than three days (weekends and rest days included) as a result of the accident.

Dangerous occurrences 8

Form F100 must be sent to the Administrative Authority whenever a scheduled dangerous

QCS 2014


occurrence has occurred. Alternatively, notification may be given by telephone, fax or email. Dangerous occurrences listed include (briefly): collapse, overturning or failure of any load-bearing part of any lift, hoist, crane, derrick, mobile powered access platform, access cradle, window cleaning cradle, excavator, piling rig or forklift truck

(b)

explosion, bursting or collapse of any closed vessel, boiler, etc.

(c)

contact with, or arcing from, any overhead electric cable caused by any plant or equipment

(d)

electrical short-circuit with fire or explosion

(e)

explosion or fire caused by any material resulting in stoppage of work or plant for more than 24 hours

(f)

uncontrolled release of 100 kg or more of a flammable liquid, 10 kg or more of a flammable liquid above its normal boiling point or 10 kg of a flammable gas, inside a building, and 500 kg or more of such substances outside a building

(g)

collapse or partial collapse of any scaffold over 5 metres in height or fall of any cradle, etc.

(h)

collapse of 5 tonnes or more of any building or structure, or any falsework, or any wall or floor in any workplace

(i)

uncontrolled release of any biological agents

(j)

accidental ignition of any explosive

(k)

failure of any load-bearing part of a freight container

(l)

bursting, explosion or collapse, or fire involving a pipeline

(m)

specific incidents involving road tankers

(n)

specific incidents involving dangerous substances being conveyed by road

(o)

escape of any substance in a quantity sufficient to cause death, injury or damage to health

(p)

malfunction of any breathing apparatus whilst in use or when being tested before use

(q)

contact with or arcing of any overhead power line.

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F100A Report of a case of disease 10

A report on form F100A is required by RIDDOR the Reporting of Injuries, Diseases and Dangerous Occurrences.

11

It must be sent, by the person completing the report, to the Administrative Authority, when a registered medical practitioner has diagnosed in writing that an employee is suffering from a scheduled reportable disease AND

12

the person has been employed in a scheduled work activity by the Contractors.

13

Alternatively, notification may be given by telephone, fax or email. COSHH assessments, etc.

14

The Control of Substances Hazardous to Health require assessments to be made of substances hazardous to health and, except in the simplest and most obvious of cases, for the assessments to be written and kept accessible for those who need to know the results.

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This specifically includes safety representatives. 15

If health surveillance is appropriate, the health records of employees under health surveillance must be maintained and kept for 40 years after the date of the last entry.

16

All mechanical control measures, such as dust extraction, must be subject to routine examination in accordance with the Regulations and records kept.

17

Substances hazardous to health must be properly labelled. Danger areas Identify with signs

19

Dangerous substances and explosive atmospheres

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A substance or preparation which is explosive, oxidising, extremely flammable, highly flammable or flammable, or any dust which can form an explosive mixture with air or an explosive atmosphere.

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Dangerous substances

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Explosive atmosphere

A mixture, under atmospheric conditions, of air and one or more dangerous substances in the form of gases, vapours, mists or dusts in which, after ignition has occurred, combustion spreads to the entire unburned mixture.

22

Where an explosive atmosphere may occur, a specific sign is to be erected.

23

The sign must consist of black letters on a triangular yellow background with black edging.

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24

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Diving

Records have to be kept of the written appointment of all diving supervisors and of the qualifications and medical certificates of divers. All dives have to be recorded in the divers' log books. Diving rules have to be in writing.

Electrical equipment 25

All electrical equipment, including portable equipment, should be inspected on a regular basis by a competent person and records kept. Portable electric tools should be PAT-tested on a three-monthly basis, with a sticker showing the test date and the date the next test is due fixed to each item.

Electric shock placard 26

Notices or placards giving details of emergency resuscitation procedures in the event of an

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electric shock should be displayed in locations where people are at an enhanced risk of electric shock.

Emergency evacuation 27

Emergency routes and exits must be established and indicated by suitable signs. Excavations, cofferdams and caissons

28

Excavations, cofferdams and caissons must be inspected and written reports of the inspections made.

.

Explosives Possession of explosives requires an explosives certificate which is issued by the local Chief Officer of Police.

30

Detailed records have to be kept of all movements or usages of explosives.

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It is required that records should be kept of all design calculations, drawings, estimated loadings and specifications for falsework, together with written permissions to pour concrete or to 'load' falsework, and to dismantle it.

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Falsework

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Documentary information relating to fire safety should include: records of staff training in the use of extinguishers

(b)

record of fire extinguisher servicing

(c)

record of practice evacuations

(d)

written fire risk assessment and a written fire safety plan.

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Fire

33

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First aid

First-aid notices are required to be displayed as an effective means of informing the workforce of the Contractors arrangement for first aid. Food hygiene

34

Toilets adjacent to food rooms must be separated by a lobby. A notice stating 'NOW WASH YOUR HANDS' must be displayed.

35

Employees in food rooms must not smoke. A notice is displayed to that effect. Checks and inspections of equipment and staff training should be recorded. Certificates of staff training in food hygiene and handling must be displayed.

Fragile surfaces 36

Appropriate warning notices must be clearly displayed at all approaches to the area.

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Hazardous substances 37

All containers containing hazardous substances should be clearly marked with their contents and the appropriate hazard warning symbol.

38

Assessments must be made and, with minor exceptions, recorded. Health and safety policy

39

The policy must be brought to the notice of all employees. Holes in floors and similar openings

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If a cover is used over a hole, it must be clearly marked to show its purpose.

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The appropriate warning signs and notices for controlled areas must be displayed.

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Ionising radiation

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Lifting operations

All machinery and accessories used for lifting are marked to indicate their safe working load for each configuration in which they can be used.

43

Lifting equipment designed to lift persons is clearly marked as such.

44

Lifting equipment not designed for lifting persons but which could be easily mistaken for such is marked appropriately.

45

All lifting equipment and accessories are subjected to a scheme of thorough examination. Records of thorough examination are made and kept available for inspection.

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Management of health and safety Risk assessments must be made of all work activities and the significant findings must be recorded.

47

Health surveillance, if it is needed, individual health records must be kept.

48

Emergency procedures need to be displayed

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Manual handling 49

Assessment to be made where risks from manual handling cannot be avoided. It is required that all but the most simple assessments should be recorded. Noise

50

Hearing protection zones need to identified by means of a sign.

51

A hearing protection zone is anywhere where an employee is likely to be exposed to a daily personal noise exposure of 85 dB(A) or a peak sound pressure of 137 dB(C).

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Plant and equipment 52

If it is not otherwise provided for, it is strongly recommended that all plant, tools and equipment are subject to inspection and examination, and proper records kept.

53

A daily inspection and a six-monthly examination may be appropriate. Pressure vessels

54

All pressure vessels intended to contain air or nitrogen at a greater pressure than 0.5 must have details of the maximum working pressure, maximum and minimum working temperatures, and cubic capacity clearly displayed on it.

Assessment of the need for personal protective equipment. In all but the simplest cases the assessments should be recorded.

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Protective clothing and equipment

Where a safety committee has been established, proper minutes and records should be kept. Safety representatives may give written reports to management concerning safety in the workplace.

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Safety representatives and safety committees

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Scaffolding

(1) Display of 'Incomplete scaffold notice.

58

Designated 'danger areas' must be created where there is a risk of a person falling or being hit by a falling object. In the case of incomplete scaffolding, suitable notices must be displayed to discourage attempted access on to the scaffold.

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(2) Reports of inspections

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The maximum working pressure of any steam boiler must be clearly marked. Boilers must be inspected at the scheduled intervals and proper records kept.

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Steam boilers

Training 61

It is most strongly recommended that all such information, instruction and training is properly and fully recorded so that Contractors are in a position to prove that duties under these Regulations have been met. VDUs - Visual display units or display screens

62

Suitable and sufficient analysis of workstations for the purpose of assessing health and safety risks. All but the simplest and obvious cases must be recorded. Work equipment

63

Maintenance, records of maintenance, written instructions. Maintenance log should be recorded. All work equipment must be marked in a clearly visible manner where necessary, in the interests of health and safety.

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64


Warnings, audible or visible, to be incorporated into work equipment as necessary. Working at height

65

Any training carried out to achieve competency should be recorded. Where any person at work may pass across or near to a fragile surface, or actually work on it, prominent signs indicating that it is a fragile surface must be fixed at every approach to that place. Where any person could be injured by falling or being hit by a falling object, 'danger areas' must be created to prevent such an occurrence. Danger areas must be clearly indicated, usually by signs and/or barriers Where inspections of work equipment are carried out a record of the inspection must be made and retained as specified. Safety signs

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END OF PART

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All signs giving health or safety information or instructions must comply with the relevant British Standard. A safety sign is anything that combines geometrical shape, colour and pictorial symbols to give safety information.

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QCS 2014

Section 11: Health and Safety Page 1 Part 1.02: Occupational Health and Hygiene (Regulatory Document)

REGULATORY DOCUMENT........................................................................... 1

1.2

OCCUPATIONAL HEALTH AND HYGIENE .................................................... 1

1.2.1

The Management of Health on Site ............................................................... 4

1.2.2

Personal Protective Equipment .................................................................... 15

1.2.3

Control of Substances Hazardous to Health (COSHH) ................................ 29

1.2.4

First Aid at Work .......................................................................................... 57

1.2.5

Food Safety on Site ..................................................................................... 70

1.2.6

Working with Lead ....................................................................................... 73

1.2.7

Manual Handling .......................................................................................... 88

1.2.8

Asbestos in the Workplace ........................................................................ 104

1.2.9

The Control of Dust and Fumes ................................................................. 112

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1

Control of Noise ..................................................................................... 129

1.2.11

Protection of the Eyes ............................................................................ 149

1.2.12

Protection of the Skin ............................................................................. 161

1.2.13

Control of Vibration ................................................................................ 175

1.2.14

Compressed Air ..................................................................................... 199

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1.2.10

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FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

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Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

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19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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The Management of Health on Site

1.2.1.1 Introduction 1

Note:

One of the reasons why Contractors have safe systems of work is to avoid accidents and keep employees at work instead of being off sick. Section 1, Part 13 of the QCS covers setting out of the works.

1.2.1.2 Benefits The benefits that arise from adopting a positive policy of health risk management can be measured in legal, economic, social and moral terms.

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Freedom from prosecution by the administrative authorities, or either Government Officials stopping or delaying Contractors works.

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Legal

Uninterrupted production and lower staff turnover and having a good reputation with the prospect of future business.

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Economic

Being recognised by employees and others as a 'caring' Contractor and a good company to work for.

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Social

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Moral

Knowing that the Contractor and work activities are not damaging the health of staff or anyone else, given the fact that no Contractor has the right to damage the health of any employee.

6

While social and moral issues are not usually mentioned, it can be seen that they are becoming of greater importance, particularly when clients or contractors are looking for contractors who have a demonstrated commitment to health as well as to safety.

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1.2.1.3 Some of the specific health areas that need to be addressed Manual handling 1

Giving employees the appropriate training in the correct manual handling techniques and the use of mechanical lifting aids is highly cost effective. Adequate supervision is necessary to ensure that employees then use the proper equipment and techniques and do not take 'short cuts'. This will reduce accidents, the amount of time lost on site, and the disruption to work that is caused when something goes wrong.

2

The part of the body most vulnerable if bad manual handling techniques are used is the back, particularly the lower back. Once it has been damaged, it is usually weakened for the rest of a person's life.

3

All the other major joints and muscle groups can also be easily damaged if the correct manual handling techniques are not used.

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4


The consequences of an injury due to bad manual handling, or a musculo-skeletal injury or illness as they are often called, can be a long-term or permanent inability to work. The cost to the Contractor is reduced productivity and having to find others to carry out the work. Noise

annoyance and irritation

(b)

loss of concentration

(c)

reduced efficiency

(d)

fatigue

(e)

increased accident risk

(f)

masking of other warning signals.

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(a)

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The damage can range from temporary hearing loss to total deafness. As well as hearing problems, excess noise is also known to cause:

On site, the failure of an employee to understand instructions that have been given, or to hear a warning signal, can have serious consequences, both for them and for the Contractor.

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1.2.1.4 Vibration

A considerable number of the tools and other pieces of equipment that are currently used in the Qatar building and construction industry have a rotary or percussive action and so can cause hand-arm vibration. This even applies to some widely used small tools, such as hand drills that have a 'hammer' action. Other examples of tools that create vibration include pneumatic breakers, vibrating pokers, vibrating rollers, plate compactors and scabbling machines.

2

The most commonly caused ill-health effect is 'vibration white finger' where the effect of the vibration damages the nerves and blood vessels in the fingers. The fingers become white and there is a loss of feeling which prevents smaller tools from being held or used properly.

3

Hand-arm vibration is also known to cause other vascular, neurological and muscular damage in the hands, wrists, elbows and shoulders.

4

Whole-body vibration, which is caused by the transmission of vibration to the body from sources such as moving plant or vehicles, can bring about long-term back pain.

5

The effects of both hand-arm vibration and whole-body vibration can be reduced by carrying out risk assessments, appropriate purchasing policies, the correct use of the equipment and the use of the appropriate anti-vibration devices such as special handles or grips.

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1.2.1.5 Stress 1

In the workplace, stress is a growing problem but one that has not been widely recognised or generally accepted within the Qatar building and construction industry.

2

Stress can cause physical problems such as: (a)

high blood pressure

(b)

heart disease

(c)

depression as well as behavioural problems, such as:

(d)

anxiety

(e)

irritability

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(f)

failure to cope as usual

(g)

bad time-keeping. Some of the causes of stress are:

(h)

too much work/long working hours

(i)

confusion as to what is expected

(j)

uncertainty as to responsibilities

(k)

conflict of interests.

Work-related factors that lead to stress can be managed but this will require appropriate training for management and operatives. If left unchecked, the following signs of stress may quickly emerge at the workplace and cause problems. Loss of motivation, commitment and work output.

(b)

Increased absence due to sickness and unauthorised reasons.

(c)

Decline in the relationships between staff on site.

(d)

Poor decision-making and increased errors.

(e)

Physical illness, and perhaps stomach ulcers and heart problems.

(f)

Mental illness.

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(a)

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While a reasonable degree of challenge and stress is acceptable as providing an added incentive to work, excess stress among employees is counterproductive and should be avoided if employees are to work to their best potential.

5

Some things that can be done to avoid or prevent stress are:

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1.2.1.6 Management-related

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The fostering of good relationships between staff and management

2

Well-set, clear and achievable objectives

3

Good and effective two-way communications

4

Employee involvement

5

Good management support

6

Staff training

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1.2.1.7 Task-related 1

Well-defined tasks

2

Clear responsibilities

3

Proper use of skills

4

Good control of hazards and risks

5

Support from senior management

6

The benefits that come from reducing stress include:

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(a)

less sickness and absence from the workplace

(b)

increased performance and productivity

(c)

better staff relationships

(d)

lower staff turnover

(e)

increased morale

(f)

lower overall costs.

The elements of the work-related stress standards are:

8

Demands - Issues that should be considered are workload, work patterns and the working environment.

9

Control - How much control does the individual have over the way they do their work?

10

Support - Do workers feel that adequate encouragement and resources is provided by the company, managers and colleagues?

11

Relationships - Workers at any level must not be subjected to unacceptable behaviours by anyone at work and conflicts must be effectively dealt with.

12

Role - Workers at all levels must understand their role (how they fit into the organisation) and there must not be any conflicting roles.

13

Change - People can be suspicious of the real motives behind organisational change which, whether large or small, must be well managed and effectively communicated.

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1.2.1.8 Radiation, sunshine and heat stress If all the signs and other procedures are obeyed, no-one should be at risk from ionising radiation.

2

One area of risk that does exist is the radiation from sunshine. The short-term dangers are blisters and sunburn while the well known long-term danger is skin cancer.

3

On site it is tempting for employees to take their shirts off on sunny days to get a suntan, but a suntan does not protect against the risk of skin cancer.

4

People most at risk include those with fair or freckled skin that does not tan or that burns before it tans. People with red or fair hair and light coloured eyes, and those who have a large number of moles (more than 50), are also at a higher level of risk.

5

As well as protecting against the possibility of sunburn and the long-term risk of skin cancer, a shirt will also provide protection against minor cuts, abrasions and some of the chemicals or dusts that can be found on site.

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Heat Stress 1

The body reacts to heat by increasing the blood flow to the skin's surface, and by sweating. This results in cooling as sweat evaporates from the body's surface and heat is carried to the surface of the body from within by the increased blood flow. Heat can also be lost by radiation and convection from the body's surface.

2

Typical example of a heat stress situation: (a)

Someone wearing protective clothing and performing heavy work in hot and humid conditions could be at risk of heat stress because:

QCS 2014

Section 11: Health and Safety Page 8 Part 1.02: Occupational Health and Hygiene (Regulatory Document) (i) Sweat evaporation is restricted by the type of clothing and the humidity of the environment. (ii) Heat will be produced within the body due to the work rate and, if insufficient heat is lost, deep body temperature will rise. (iii) As deep body temperature rises the body reacts by increasing the amount of sweat produced, which may lead to dehydration. (iv) Heart rate also increases which puts additional strain on the body. (v) If the body is gaining more heat than it can lose the deep body temperature will continue to rise. (vi) Eventually it reaches a point when the body's control mechanism itself starts to fail.

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(vii) The symptoms will worsen the longer they remain working in the same conditions.

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Heat stress effects

Heat stress can affect individuals in different ways, and some people are more susceptible to it than others.

4

Typical symptoms are:

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an inability to concentrate

(b)

muscle cramps

(c)

heat rash

(d)

severe thirst - a late symptom of heat stress

(e)

fainting

(f)

heat exhaustion - fatigue, giddiness, nausea, headache, moist skin

(g)

heat stroke - hot dry skin, confusion, convulsions and eventual loss of consciousness.

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Heat stroke is the most severe disorder and can result in death if not detected at an early stage.

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Workplace examples People might suffer from heat stress because of the hot environment created by the process, or restricted spaces: (a)

construction sites

(b)

confined spaces

(c)

operating machinery

(d)

tunnels

(e)

mines

(f)

compressed air tunnels

(g)

foundries and smelting operations

(h)

brick-firing and ceramics plants

(i)

boiler rooms

(j)

kitchens

(k)

laundries

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Control Measures 7

Over time people adapt to hot conditions by sweating more, and by changing their behaviour to try and cool down, e.g. removing clothing, taking cool drinks, fanning themselves, sitting in the shade or a cool area, and/or reducing their work rate. However, in many work situations such behavioural changes may not be possible, e.g. during asbestos removal. Where there is a possibility of heat stress occurring you will need to carry out a risk assessment.

8

Contractors must undertake a risk assessment.

9

When carrying out a risk assessment, the major factors you need to consider are: work rate - the harder someone works the greater the amount of body heat generated;

(b)

working climate - this includes air temperature, humidity, air movement and effects of working near a heat source;

(c)

worker clothing and respiratory protective equipment - may impair the efficiency of sweating and other means of temperature regulation;

(d)

worker’s age, build and medical factors - may affect an individual's tolerance.

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(a)

Firstly, you will need to talk to the workers involved (and their safety representatives), to see whether they are suffering early signs of heat stress. If it seems likely that there is a problem, you may need to consult with people who are more experienced in determining the risk from hot environments, e.g. occupational hygienists, nurses or doctors.

11

Contractors must remove or reduce the sources of heat by: CONTROLLING THE TEMPERATURE using engineering solutions, e.g. change the processes,

(ii)

use fans or air conditioning,

(iii)

use physical barriers that reduce exposure to radiant heat.

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PROVIDE MECHANICAL AIDS where possible to reduce the work rate.

(c)

REGULATE THE LENGTH OF EXPOSURE to hot environments by:

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(iv) allowing workers to enter only when the temperature is below a set level or at cooler times of the day, (v) issuing permits to work that specify how long your workers should work in situations where there is a risk, (vi) providing periodic rest breaks and rest facilities in cooler conditions.

(d)

PREVENT DEHYDRATION. Working in a hot environment causes sweating which helps keep people cool but means losing vital water that must be replaced. Provide cool water in the workplace and encourage workers to drink it frequently in small amounts before, during (this is not possible in some situations e.g. respiratory protective equipment use or asbestos removal) and after working.

(e)

PROVIDE PERSONAL PROTECTIVE EQUIPMENT. Specialised personal protective clothing is available which incorporates, for example, personal cooling systems or breathable fabrics. This may help protect workers in certain hot environments. Protective clothing or respiratory protective equipment is often required when there will be exposure to some other hazard at work e.g. asbestos. This type of equipment, while protecting from the other hazard, may increase the risk of heat stress

(f)

PROVIDE TRAINING FOR YOUR WORKERS, especially new and young employees, telling them about the risks of heat stress associated with their work, what symptoms to look out for, safe working practices and emergency procedures.

QCS 2014


(g)

ALLOW WORKERS TO ACCLIMATISE to their environment and identify which workers are acclimatised/assessed as fit to work in hot conditions.

(h)

IDENTIFY EMPLOYEES WHO ARE MORE SUSCEPTIBLE to heat stress either because of an illness/condition or medication that may encourage the early onset of heat stress, e.g. those with heart conditions. Advice may be needed from an occupational health professional or medical practitioner.

(i)

MONITOR THE HEALTH OF WORKERS AT RISK. Where it is considered that a residual risk remains after implementing as many control measures as practicable, you may need to monitor the health of workers exposed to the risk. You should then seek advice from occupational health professionals with a good working knowledge of the risks associated with working in heat stress situations.

During the period from June 15th until August 31st, work under direct sun rays is prohibited from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control and ease effect of the direct sun on the workers unless otherwise announced by the concerned authorities. This arrangement should be approved by the Engineer’s Representative and should be agreed upon before implementation.

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Respiratory problems Dust

The inhalation of any dust will eventually cause respiratory problems, including or contributing to such conditions as asthma, bronchitis, pneumoconiosis and certain types of lung cancer. Some dusts cause an allergic reaction where breathing problems are caused immediately after a dust is breathed in. As well as presenting a health hazard, many airborne dust clouds are also flammable or explosive.

14

Whenever practicable, the generation of dust should be avoided, and where it cannot be avoided it should be controlled by ventilation or extraction. The use of personal protective equipment by employees must be regarded as the very last resort when all other methods of control have been examined and found not to be practicable.

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Fumes including solvent fumes

The vapour given off by many substances has the potential to cause respiratory illness or other symptoms of ill health if not adequately controlled. Other symptoms include headaches, coughing, feeling sick, feeling light-headed, shortness of breath or feverishness.

16

As well as being inhaled and causing direct problems in the lungs, many fumes can be absorbed into the bloodstream and bring about complications in other parts of the body.

17

An example of this type of response is cancer of the bladder which can be caused by inhaling certain aniline fumes (a chemical made for use in textile dyes).

18

Potential sources of hazardous fumes, which may be inhaled if control measures are not taken, are:

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(a)

solvent-based adhesives, spirit-based or solvent-based paints

(b)

welding, especially welding galvanised metals

(c)

oxyacetylene cutting

(d)

engine exhausts.

If the generation or release of the fumes cannot be avoided, for example by using a waterbased solvent or paint instead, then adequate natural or mechanical ventilation should be used. The use of personal protective equipment for employees must be regarded as the last resort.

QCS 2014


1.2.1.9 Bird and bat droppings 1

The presence of large populations of roosting birds or a bat colony can present significant risks to health if their droppings are disturbed. This has obvious implications for some types of construction work and preliminary work such as surveys.

2

The main hazard is the inhalation of fungus spores which become airborne as a result of disturbance of the droppings.

1.2.1.10 Dermatitis Occupational dermatitis causes lost time in the building and construction industry. Yet with proper attention to risk assessments, control measures and good working practices it could be avoided. The prevention of dermatitis would save the Qatar construction industry and Contractors large amounts of money, and also assist in improved productivity on site, as well as improving conditions for the workers.

2

The agents which cause dermatitis can be divided into five classes as follows:

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mechanical factors such as friction, pressure and trauma

(b)

physical factors including heat, cold, electricity, sunlight and radiation

(c)

the use of some chemicals

(d)

contact with some plants and their products

(e)

contact with biological agents, organisms, insects and mites.

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(a)

Contact dermatitis

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This is sometimes also called irritant dermatitis. It is the commonest form of occupational dermatitis and results from repeated contact with any substance that irritates the skin. Such substances can include cement, lime, plaster, paint, solvents, adhesives, sawdust, oils, pitch, tar, fibreglass, white spirit, thinners and most acids and alkalis.

5

The effect of the substances is usually to cause the skin to dry out and crack due to the removal of the natural oils. Skin damaged in this way is very vulnerable to other infections.

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Allergic dermatitis 6

This is sometimes also called sensitive dermatitis. It is an allergic reaction by the skin to a specific substance that the skin has been exposed to in the past, and which has caused the skin to become especially sensitive to it. Once a person's skin has become 'sensitised', any future exposure to the substance will cause an immediate skin reaction.

7

The main sensitising substances on site are cement, resins, glues, hardeners, hardwoods, chrome and nickel compounds. The allergic response is usually specific to an individual as opposed to affecting everyone, and can also appear suddenly after many years' exposure.

8

The prevention of dermatitis is basically one of good personal hygiene, good housekeeping, safe systems of work that avoid contact with substances that are known to cause dermatitis, and the use of personal protective equipment (as a control measure of the last resort), in the appropriate cases.

QCS 2014


1.2.1.11 Needlestick injuries A needlestick injury is an accidental puncture of the skin by a hypodermic needle.

2

It is a sad fact that the current drug culture affects the construction industry as much as other industrial sectors. The abuse of both legal and illegal drugs brings with it the risk of discovering discarded hypodermic syringes or discarded needles.

3

Employees in the refurbishment sector of the industry are probably at greatest risk, especially if the property is derelict or has been occupied by unauthorised occupants. However, any work in occupied or previously occupied premises carries with it some risk of finding needles that have been randomly discarded or hidden away in areas where they are difficult to see, until it is too late.

4

If not handled in a safe manner, discarded needles can pose serious health risks to anyone whose skin is accidentally pricked. Blood on a needle could be infected with a hepatitis or HIV virus.

5

As part of site induction in the appropriate circumstances, employees should be told to assume that any needle they find has been used by a drug user and is potentially contaminated by infected blood.

6

Contractor site procedures should cover the actions that employees and supervisors should take whenever discarded needles are found. The removal and disposal of such items should be properly covered.

7

Generally, employees should be clearly told not to touch or move any needles or hypodermic syringes they find, but ask a responsible person to guard it whilst reporting the matter to their supervisor.

8

If a needle or syringe must be moved then suitable instructions to employees might be:

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if possible, use a pair of pliers to pick it up

(b)

carry it with the needle pointing downwards

(c)

do not wrap it in paper or put it into a litter bin

(d)

if available, place it in a clear glass bottle or jar

(f)

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(a)

(g)

wash hands thoroughly.

place the bottle or jar in a secure location carefully follow site or company procedures regarding disposal

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(e)

9

Employees should not panic if a needle punctures the skin. Gently squeeze the area around the wound to encourage bleeding but do not suck the wound. Wash the site of the injury thoroughly with soap and water at the first opportunity, and obtain medical assistance as soon as possible from the nearest hospital with an accident and emergency department. If you can do so safely, take the syringe or needle with you.

10

If dealt with properly and promptly, the risks of a resulting health problem are small.

1.2.1.12 Leptospirosis (Weil's disease) 1

When working near to water or on sites that are otherwise wet, consideration must be given to the health implications associated with the presence of rats.

2

Leptospirosis is an occupational hazard for anyone working near water, damp areas or anywhere else where rats might be present. It is a disease caused by bacteria that is present

QCS 2014


in the urine of infected rats and is therefore also in the water where they live. The bacteria thrives in damp conditions, typical of banks of rivers or streams, and can enter the body through unprotected cuts and scratches, by swallowing infected water and through the lining of the nose. If anyone thinks they may have come into contact with the disease, they should be aware that the early symptoms closely resemble the symptoms of influenza, namely: fever

(b)

headache

(c)

chill. Later symptoms include:

(d)

tightening of the skin

(e)

a yellowing of the skin (similar to jaundice)

(f)

internal bleeding.

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(a)

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It is essential that anyone who is at risk, and who becomes unwell with flu-like symptoms, should visit their doctor, describe where they have been working and that they are at risk from leptospirosis.

5

Persons regularly at risk, for example, canal or sewage workers should carry a card explaining their occupation and the occupational hazard of leptospirosis.

6

Personal precautions that should be taken include the following:

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discourage the presence of rats on site: do not leave food lying about or throw away food scraps

(b)

do not handle the carcasses of dead rats

(c)

avoid inadvertent entry or immersion in water that could be infected

(d)

if this happens and you think that you may be infected, particularly if you swallowed any water, see a doctor as a matter of urgency

(e)

wear appropriate PPE

(f)

prior to entering the work area, wash any cuts or grazes in clean water. Apply antiseptic to the wound, then cover with gauze, a waterproof dressing and PPE as necessary

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upon completion of work, wash hands, forearms and all other exposed areas of skin thoroughly. Remove any wet protective clothing as soon as possible and dry it

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(h)

avoid rubbing your nose, mouth or eyes with your hands during work

(i)

do not smoke, eat or drink without first washing your hands.

Leptospirosis can be fatal, typically within four to six weeks, if the early symptoms are not recognised and treated.

1.2.1.13 Contaminated ground 1

The disturbance of contaminated ground can release hazardous fibres such as asbestos, hazardous gases or fumes.

2

Where ground that has been previously used is to be disturbed, a risk assessment must be carried out to determine whether there will be residual risks to health.

3

The findings of a thorough assessment of the risks will determine exactly what the hazards are and how the risks can be eliminated or controlled to an acceptable level. Given the possible wide range of contaminants, the potential for ill health may result from inhalation,

QCS 2014


ingestion or skin contact with the hazardous substance.

1.2.1.14 Smoking 1

Although smoking is totally prohibited on many sites, Contractors in control of a site may make provision for smoking in areas which are not 'enclosed' or 'substantially enclosed', as long as non-smokers are not exposed to tobacco smoke.

1.2.1.15 Repetitive strain injury

(b)

carpenters

(c)

painters

(d)

plant operators.

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Methods by which workers can limit the potential for RSI are: avoiding long periods of repetitive tasks - job rotation

(b)

alternating the use of the hands - picking up left- then right-handed

(c)

taking more short breaks rather than one long break

(d)

wearing looser fitting clothing to increase ease of movement

(e)

keeping warm - cold muscles don't expand properly

(f)

not overstretching - move closer to the task

(g)

reporting pain or other symptoms immediately - RSI is easier to treat in the early stages.

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(a)

Contractors can make a big difference to the health of their workers, which will have business benefits, by: (a)

assessing each job for the potential for RSI

(b) (c)

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With regard to the construction industry, the jobs where workers are most likely to develop RSI are:

encouraging early reporting allowing workers to organise their work and take breaks as necessary.

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Personal Protective Equipment

1.2.2.1 Key points The correct use of personal protective equipment (PPE) is essential in many cases to protect the wearer from harm.

2

Given the nature of most construction sites, the use of some items of PPE, such as safety helmets and safety footwear, is a daily occurrence.

3

However, it must be remembered that the use of PPE as a means of protecting against risks to health or safety is the last resort; it only protects the wearer and only then if it is:

4

the right PPE for the job

5

in good working order

6

being used properly.

7

Contractors have a legal duty to investigate the use of other protective measures before resorting to the issue of PPE.

8

Employees must look after the PPE that has been issued to them and inform their Contractor if it becomes damaged or is lost.

9

Contractors have a duty to supply the necessary PPE free of charge.

10

Respiratory protective equipment (RPE) is a sub-group of PPE.

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Section 1, Part 11 of the QCS covers safety equipment and clothing.

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Construction workers will have to wear some items of personal protective equipment (PPE), such as safety helmets and safety footwear, as a matter of course. Other PPE will have to be provided and worn as required, as indicated by the findings of a risk assessment. Generally, PPE is thought of as equipment that is designed to protect the head, ears, eyes, respiratory system, skin, hands and feet, and includes such items as gloves, safety goggles and hearing protectors. However, other categories of PPE are designed to protect individuals from falling from height and to keep them afloat in water or other liquids.

2

Respiratory protective equipment (RPE) is a significant sub-group of PPE. As its name suggests, it is designed to protect the respiratory system of users from hazardous and hostile atmospheres.

3

For simplicity, wherever any reference is made to 'PPE', it will include 'RPE', although at appropriate places RPE will be referred to in its own right.

4

All PPE must bear the CE mark to show conformity with European Standards. When Contractors are deciding how best to protect employees from a risk to their health and safety at work, the decision to issue PPE may only be made where it is found that the risk cannot be adequately controlled by other means that are equally or more effective. In effect, the issue and use of PPE is the 'last resort' in terms of risk control.

5

PPE must be selected by a competent person who, if necessary in conjunction with the suppliers, can identify the PPE that will be effective against the hazards present in the workplace. An example of this is the selection of the correct type of respirator or filter to protect the user against the various types of airborne substances, either particles or gases.

6

It must be remembered that failure of an item of PPE, or the wrong type of PPE being used, could expose an employee to the possibility of occupational ill-health, serious injury or death.

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7

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees, or any other persons, might encounter as a result of the work being carried out.

8

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

9

Where the hazard cannot be eliminated or the risks to health and safety controlled in any other way, as determined by a risk assessment, the Contractor must supply suitable PPE and ensure that it is used and looked after.

10

The following requirements of these Regulations all have a relevance to the selection and use of PPE: Contractors must provide employees with comprehensible and relevant information on any risks that exist in the workplace, details of the existing control measures that are in place and any measures to be introduced to reduce the residual risks

(b)

Contractors must ensure that employees are provided with appropriate health surveillance where indicated as necessary by the risk assessment

(c)

Contractors must take into account each employee's capability with regards to health and safety when allocating work, and provide them with adequate health and safety training

(d)

employees, in turn, have a duty under these Regulations to: use equipment (e.g. PPE) in accordance with any training and instruction given

(ii)

inform the Contractor of any work situation or other matter which they consider presents a risk to the health and safety of themselves or others.

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(i)

The emphasis is firmly towards engineering and organisational controls and away from 'person-based' controls such as the wearing of PPE.

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1.2.2.3 Personal Protective Equipment These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide suitable PPE and ensure that it is correctly used and cared for by employees.

2

Detailed requirements of any such risk assessment require the problem to be thought through in a structured manner and the right equipment chosen for the right reasons.

3

A key factor is the competence of the person carrying out the assessments. If they do not get it right, the consequences for the health and safety of employees could well be very serious.

4

In essence, personal protective equipment may only be used as a last resort after all other means of eliminating or controlling the risk have been considered.

5

In deciding which type to issue, the Contractor must take into account the hazard that the PPE is being used to protect against and ensure that the PPE will fit the wearer and allow them to work safely. If more than one item of PPE is being used at any one time, the Contractor must make sure that individual items of PPE are compatible and do not adversely affect the performance of each other.

6

Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable the employees to understand the risks being protected against, the purpose of the PPE and the manner in

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which it is to be used.

properly use the PPE provided, in accordance with the information, instruction and training that they have been given

(b)

return PPE to its storage facility, where provided, after use

(c)

know the procedures for reporting loss of any PPE or defects in it to their Contractor.

The assessment must consider: an assessment of the risks to health and safety that have not been controlled by other means

(b)

the nature of the risks to health and safety against which the PPE is to protect the user

(c)

a comparison of the nature of the risks and the performance capabilities of the PPE

(d)

the compatibility of the PPE under consideration and any other PPE that will be worn at the same time.

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(a)

Contractors and self-employed persons must:

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(a)

(a)

review such assessments if it is thought that they are no longer valid or if there has been a significant change in the matters to which it relates

(b)

incorporate any changes that are indicated by the review.

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8

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has duties to:

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7

These Regulations requires that Contractors ensure that PPE that has been provided to employees is maintained (which includes replacement or cleaning) in an efficient state, efficient working order and good repair.

11

These Regulations require that Contractors provide suitable storage facilities for PPE that has been issued, for when it is not in use.

12

These Regulations require that Contractors who have provided employees with PPE also provide adequate and appropriate information, instruction and training to enable employees to know: (a)

the risk or risks for which the PPE has been provided the purpose for which, and the manner in which, the PPE is to be used

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(c)

any actions that they (users) must take to keep the PPE in the suitable condition.

13

Training can be theoretical and/or practical. Where appropriate the Contractor should, at appropriate intervals, arrange suitable demonstrations in the correct wearing of PPE.

14

These Regulations place a legal duty on: (a)

Contractors to take reasonable steps to ensure that the PPE provided to employees is used correctly

(b)

employees to use the PPE provided in accordance with any instruction and training provided

(c)

employees to take reasonable steps to return PPE to any storage facilities provided.

1.2.2.4 Construction (Head Protection) 1

These Regulations require that all at-risk persons involved in construction and engineeringconstruction activities are provided with, and wear, suitable head protection on site.

QCS 2014


2

Under these Regulations, the term 'suitable head protection' means any head protection that is designed to protect the wearer against any foreseeable risk of head injury, other than by falling. It must, with necessary adjustment, fit comfortably.

3

Whilst generally the Contractor's interpretation of this legislation means that safety helmets are worn at all times on site except when in safe areas such as site offices and canteens, individual Contractors may decide that on certain sites they are able to designate other 'safe areas' or 'safe routes' where helmets need not be worn.

4

This decision must be based on the findings of a risk assessment which must investigate fully the danger of workers being hit by anything falling from above or of them hitting their head and being injured. It is not unknown for 'protected routes' to be created on larger sites enabling people to gain access to office complexes etc. from the site entrance, without the need to wear full PPE. any head protection provided under these Regulations has to comply with any relevant European Standards and must therefore carry a CE mark

(b)

before selecting any head protection for employees, the Contractor or self-employed person must carry out an assessment to determine whether it is suitable.

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(a)

In order to determine whether it is suitable, the assessment must compare the required protection characteristics of the head protection with the known risks.

6

Contractors must:

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review such assessments if it is thought that they are no longer valid or if there has been a significant change in the matters to which it relates

(b)

incorporate any changes that are indicated by the review.

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In general, suitable head protection will be an industrial safety helmet conforming to BS EN 397. For work in confined spaces, a bump cap designed to BS EN 812 may be more suitable, but is restrictive in use.

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1.2.2.5 Contractor's duties

(a)

carry out an assessment to determine the suitability of head protection produce written rules on the use of head protection or provide directions (such as verbal instructions and safety signs) to reinforce when and where head protection must be worn and bring those rules to the attention of any persons who might be affected by them

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(c)

provide each employee with suitable head protection and adequate storage facilities

(d)

ensure that all head protection is adequately maintained and, where necessary, replaced.

The Contractor must also keep records of the assessment and details of the control measures implemented. These will need to be reviewed as a result of any significant change in the work to which the protection relates or when its suitability is no longer valid.

1.2.2.6 Employees' duties 1

Employees must: (a)

co-operate with their Contractor

(b)

wear the head protection provided in accordance with instructions or written rules

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(c)

take reasonable care of the head protection provided and report any loss, defect or concerns about its serviceability.

2

No other workers are covered by this exemption. Provision, maintenance and replacement of suitable head protection Every Contractor must provide each employee with suitable head protection where, due to the nature of the work or activity, they are at risk from head injuries. All self-employed persons have an obligation to provide themselves with suitable head protection in similar circumstances. In both cases, the head protection must be adequately maintained to ensure serviceability, and it should be replaced as necessary.

4

The assessment should be reviewed as a result of any significant change in the work to which the protection relates or it is no longer suitable. Contractors should ensure that storage for head protection is available when it is not in use.

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Every Contractor and anyone who has control over persons at work have a duty to ensure suitable head protection is worn.

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Ensuring suitable head protection is worn

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Rules and directions

As part of pre-planning for the commencement of work, written rules on the use of head protection should be established by site management, particularly on multi-contractor sites.

7

Rules should be clear, unambiguous and brought to the notice of those affected. Persons in control should consult with any interested parties in matters relating to head protection.

8

Where written rules are not in place, verbal instructions or the provision of safety signs may help to provide a procedure and a reinforcement of when and where to use suitable head protection.

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Wearing of suitable head protection In compliance with written rules or instructions given by those in control of operations or works, employees should wear suitable head protection as directed.

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Reporting the loss of, or defect in, head protection 10

Every employee, having been provided with head protection, should take reasonable care of it, reporting any loss, obvious defects or concern about its serviceability to the Contractor, under the arrangements that have been made. These arrangements should enable repairs or replacement head protection to be provided, before the employee concerned is allowed to restart work.

1.2.2.7 Personal Protective Equipment (Control of Substances Hazardous to Health) 1

These Regulations place a duty on Contractors to ensure that the exposure of their employees to substances hazardous to health is either prevented or, where this is not reasonably practicable adequately controlled.

2

These control measures include:


(a)

Contractors must either prevent exposure of employees to substances hazardous to health or, where this is not reasonably practicable, adequately control exposure.

(b)

The preferable method of prevention or control is to substitute the substance or process with a non-hazardous or less hazardous substance or process.

(c)

Controls shall be, in order of priority, by engineering controls, by providing ventilation, by implementing organisational controls then, as a last resort, providing suitable personal protective equipment.

(d)

All employees must make proper use of any PPE, and must take all steps to return it to its place of storage after use and report any defects to their Contractor.

(e)

Adequate maintenance, examination and testing of control measures provided must be undertaken to ensure they are in efficient working order and, in the case of PPE, maintained in a clean condition.

(f)

Information, instruction and training must be provided for persons who may be exposed to substances hazardous to health so that they are aware of the danger of exposure and the precautions which should be taken.

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1.2.2.8 Personal Protective Equipment (Work at Height)

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These Regulations are relevant where PPE in the form of a safety harness, lanyard, a fallarrest block or other personal fall-arrest equipment is used.

2

The key provisions of these Regulations are that Contractors should:

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where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, select the most appropriate equipment for the work and to prevent falls

(c)

reduce the distance of, and potential consequences of, any fall

(d)

ensure that the work is risk

(e)

assessment-based and that it is carried out safely

(f)

ensure the work is carried out by trained and competent persons who are adequately supervised.

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These Regulations require that Contractors follow current best industry practice when selecting equipment for work at height. In particular, Contractors are required to take account of:

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(a)

working conditions and risks to the safety of the persons at work

(b)

access and egress, and distances to be negotiated

(c)

distance and consequences of any potential fall

(d)

duration and frequency of use of the work equipment

(e)

need for and ease of evacuation and rescue in an emergency

(f)

any additional risks posed by the installation, use or removal of the work equipment, and any evacuation or rescue from it.

The requirements are: (a)

a personal fall protection system shall only be used if a risk assessment has shown that the work can be done safely while it is being used, and that the use of other, safer work equipment is not reasonably practicable

(b)

the user and a sufficient number of others have been trained in its use and in rescue procedures

QCS 2014


(c)

it shall be suitable and of sufficient strength for the purpose for which it is to be used and will withstand any foreseeable loading

(d)

it fits the wearer and is correctly fitted or worn

(e)

it is designed to minimise injury to the user in the event of a fall, and is such that the user will not fall or slip out of it if they do fall

(f)

it is designed, installed and used so as to prevent unplanned or uncontrolled movement of the user.

Any anchorage point must be suitable and of sufficient strength to support any foreseeable loading. If designed to do so, the equipment must be securely attached to at least one such anchorage point when in use.

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All safety harnesses, lanyards and other fall prevention or fall arrest equipment must comply with the appropriate British and European standards.

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1.2.2.9 Common-use types of PPE Hearing protection

Construction activity and equipment generate excessive noise, which can cause permanent hearing damage in those exposed to it unless appropriate control measures are put in place.

2

Excessive noise can also cause annoyance, fatigue, loss of concentration and disrupted communication, and may lead directly or indirectly to an increased risk of accidents.

3

There are two basic types of hearing protection:

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ear plugs - either disposable or reusable

(b)

ear defenders.

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(a)

These are made of very fine mineral fibre, sometimes ready shaped. They must be inserted correctly and, if taken out, should not be reused. They should only be handled with clean hands.

5

Employees need to be instructed on how to insert disposable ear plugs correctly or the assumed level of protection will not be reached.

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Reusable ear plugs 6

These are made of rubber or plastic, and need regular and careful washing. They must be a good fit. A competent person should be responsible for instructing employees in their correct fitting and use. Different sizes may be required for each ear. Reusable ear plugs, like disposable ones, must be fitted with clean hands as any contamination by dirt, grease or swarf may cause ear irritation. Ear defenders

7

Ear defenders, sometimes referred to as 'ear muffs', completely cover the ear, and are sealed to the head with a foam or liquid-filled seal.

8

Badly designed or badly produced ear defenders may give little or no protection against the noise.

9

Facial hair and the side arms of spectacles may interfere with the seal and reduce the

QCS 2014


amount of protection given by ear defenders.

1.2.2.10 Eye protection 1

Construction personnel engaged in a wide range of activities (for example, grinding, welding, cutting, hammering, handling chemicals) run the risk of eye injury. The risks include: (a)

impact of solids

(b)

ingress of liquid, dust or gas

(c)

splashes of hot metal

(d)

exposure to glare.

Contractors have a duty to provide eye protection to employees who may be exposed to eye injury, and must take all reasonable steps to ensure that it is worn. Assessments must be carried out to determine when eye protection is required and what type is appropriate for the work activities.

3

The two main types of eye protection -safety spectacles (including safety goggles) and face shields

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comply with British or International Standards

(b)

suit the type of work or risk involved -including resistance to impact, heat, dust and chemical penetration

(c)

suit the user to ensure minimum discomfort and ease of movement whilst working

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be marked to identify their type and suitability be kept clean and disinfected.

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(d)

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Lasers that are now widely used on construction sites for setting datums, levelling, surveying, and so on can pose a particular hazard. They must be operated by competent and fully trained persons. If high powered lasers are used, eye protection equipment will be needed to give the required level of protection to those at risk. A safe system of work must be in place to exclude anyone not involved in the activity from the area.

1.2.2.11 Respiratory protection The hazards 1

Dust has long been known as hazardous to the health of construction workers, especially when inhaled for long periods. While the health issues associated with asbestos are well recognised, the greater part of the dust problem in the industry currently relates to more common substances, for example, cement, plaster, wood, MDF, stone, silica, fillers and plastics. High speed cutting of most materials can produce sufficient dust to cause a health hazard.

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Dust that is visible in the air is generally accepted as being hazardous. However, dust that is too fine to be seen by the naked eye also causes many health problems, the symptoms of which may take many years to manifest themselves. Small dust particles of any material entering the lungs can be absorbed into the body and can cause scarring and sometimes cancer within the lungs. Skin irritation, dermatitis and ulceration can be caused by contact with some dusts.

3

Eating food with dirty or dust-covered hands can cause stomach disorders.

4

Fumes from certain substances, such as solvents, paints and adhesives, can have serious health implications. When used in poorly ventilated or confined spaces, it is not uncommon for fatalities to occur.

5

Whenever respiratory protective equipment (RPE) is to be used for work, a test check that a facepiece (the respirator) matches the person's facial features and seals adequately to the wearer's face. It will also ensure that incorrectly fitting facepieces are not selected for use. This test must be carried out by a competent person.

6

The training of employees in the correct use of RPE is essential before first use and should be repeated at suitable intervals. It is essential that training is carried out by a competent person and covers:

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why the RPE is necessary

(b)

the hazards, the risks and the effects of exposure

(c)

what RPE is to be provided

(d)

how the RPE works

(e)

why facepiece fit testing might be necessary

(f)

how to wear and check the RPE correctly

(g)

fit-checking the RPE before use

(h)

what maintenance is required and when

(i)

where and how to clean the RPE and store it

(j)

how to report defects in the RPE or any other problem with it

(k)

the Contractor's responsibilities and those of employees

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use and misuse of the RPE.

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(a)

Selecting RPE 7

The provision and use of RPE must only be considered when equally or more effective protective control measures cannot be used. The failure of RPE could have serious consequences. The importance of the correct type of RPE being provided and used cannot be overstated as it must be assumed that the user will be working in a hostile environment.

8

However, there are several potential problems arising from the selection and/or use of RPE: (a)

the failure of an item of RPE, where for whatever reason, such as lack of routine maintenance, it fails to provide the necessary level of protection

(b)

the misuse of RPE, such as it being mistreated or not used in accordance with the manufacturer's instructions, or the training given

(c)

it being the wrong type of RPE, for example there would be no protection from a filtering respirator designed solely to capture airborne dust if being used, where the workplace hazard is in fact a toxic gas

(d)

the effectiveness of the 'face fit'. Many types of RPE depend upon a good seal

QCS 2014

Section 11: Health and Safety Page 24 Part 1.02: Occupational Health and Hygiene (Regulatory Document) between the facepiece and the skin of the user at all times, including where physical activity and exertion are required. Factors such as facial hair or the shape of the face can interfere with a good fit.

Each type of RPE is assigned a 'protection factor' which gives the user some idea of the level of protection that the device will provide. For example, a filtering half-mask marked:

10

FF P1

is a low efficiency device offering a protection factor of 4

11

FF P2

is a medium efficiency device offering a protection factor of 10

12

FF P3

is a high efficiency device offering a protection factor of 20

13

A protection factor of 10 means that in controlled conditions, for every 10 units of contaminant outside the mask, only 1 unit will get inside the mask, or for every 20 units outside the mask there will be 2 units inside, and so on. It is important, therefore, that the correct filter is selected for the type and level of contaminant in the air.

14

There are many types of RPE, including:

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disposable face mask respirators

(b)

half-mask dust respirators

(c)

high efficiency dust respirators

(d)

positive pressure powered respirators

(e)

ventilator visor or helmet respirators

(f)

compressed air line breathing apparatus

(g)

self-contained breathing apparatus.

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(a)

It should be noted that nuisance dust masks (simple gauze filters or cup-shaped filters often held in place by a single strap) are not classed as personal protective equipment or respiratory protective equipment. They do not meet any current standards.

16

The Contractor must carry out an assessment to determine when RPE is required and what type is appropriate for controlling exposure to the hazardous material. Selecting RPE that is both suitable for the user and the job must be carried out by a competent person. This is because this choice will depend on a number of interacting factors, such as:

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(a)

the nature of the hazards and materials

(b)

the measured dust concentrations

(c)

the period of exposure

(d)

if working outdoors, the prevailing weather conditions.

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(e)

suitability for each user - field of vision, provision for communication and the need to move in cramped or difficult working places, such as confined spaces.

Using and maintaining RPE Both the Contractor and the employee have a duty to ensure that all RPE provided is used correctly and that it is stored correctly after use.

18

Contractors must also ensure that non-disposable RPE is thoroughly examined and tested at appropriate intervals. Such examinations and tests should be carried out at least every month, and more frequently where conditions are particularly severe. Longer intervals may be more appropriate in the case of certain RPE, for example, half-mask respirators used infrequently for short spells against air contaminants of relatively low toxicity. However, the longest interval between examinations and tests should not exceed three months.

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Disposable RPE, provided it is only used for one working day or shift then disposed of, does not require any examination or tests.

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1.2.2.12 Skin protection

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Industrial dermatitis

Industrial dermatitis is caused by contact between the skin (usually the hands) and irritant substances. Many types of gloves are available to prevent such contact. It is essential that a risk assessment identifies the properties of the hazardous substance so that the correct type of glove can be provided.

2

Dermatitis, an inflammatory skin disease, accounts for over half of all working days lost through industrial sickness. There are two general types:

3

contact or irritant dermatitis - usually where the skin comes into contact with an irritant substance

4

allergic or sensitive dermatitis - where a person develops an allergic reaction to a substance.

5

With different people, some substances are known to have the effect as either an irritant or a sensitiser, such as turpentine.

6

In the course of their work, many construction workers are likely to come into contact with one or more possible skin irritants, such as:

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(a)

cement, lime and plaster

(b)

certain types of wood, resins, fungicides and pesticides

(c)

paint

(d)

tar, pitch and bitumen

(e)

solvents, thinners and degreasers

(f)

mineral oils and grease.

Cuts and abrasions 7

Many people working in the construction industry will carry out manual work that will render them susceptible to cuts and abrasions if the correct type of gloves are not provided and worn.

8

Again, gloves designed to protect the hands against cuts and abrasions are freely available.

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9


Generally, rigger gloves offer adequate protection for most activities although for some activities, such as handling sheet glass, specialist Kevlar-impregnated gloves will be necessary.

1.2.2.13 Hot works 1

Activities such as welding and grinding will require that the hands, forearms and face are protected against high temperatures and welding fumes or grinding sparks. To achieve this level of protection it is necessary for those who carry out such activities to wear specialist PPE made for the purpose. For example, welders should wear welding gauntlets that extend up to the elbow and a face shield.

1.2.2.14 Acid and alkali burns Some substances that are in common use in the construction industry have sufficiently strong acid or alkali properties to cause burns to the skin.

2

Gloves are available to protect the users of such substances from chemical burns.

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Special anti-vibration gloves will help lessen the effects of using rotary or percussive hand tools (which can lead to vibration white finger) but most are ineffective at the most damaging frequencies and are of more value in keeping the hands warm.

1.2.2.16 Selection of hand protection

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1.2.2.15 Vibration

British Standards cover many types of protective glove but care is needed in selecting the right type for a particular hazard. For example, a glove suitable for handling abrasive materials may offer no protection against chemicals, while the appropriate glove to protect the skin against contact with diesel oil may offer no protection against some solvents.

2

All manufacturers offer advice on the most suitable gloves for specific types of hazard, some of which are summarised in the following table.

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Hazard

Recommended type

Acids, concrete, brickwork, stain removers, Neoprene, nitrile, PVC, rubber solvents, alkalis Esters, ethers, ketones (mastic, sealers), aldehydes, petroleum-based products

Medium and heavy weight rubber, neoprene, nitrile, PVC

High and low temperatures

Nitrile, PVC, medium and heavyweight rubber

Abrasion, unloading bricks and blocks, general materials handling

Rubber, nitrile, PVC, neoprene, chrome-leather with reinforced palm

Bitumen, hot work

Asbestos substitute or 'Nomex' gloves

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It should be noted that industrial safety gloves are rated from 1-4 for their resistance to abrasion, tear and puncture, and 1-5 for blade cut. Those specifying and purchasing work gloves must ensure that the correct grade is obtained, if necessary by speaking to the manufacturers or suppliers.

1.2.2.17 Foot protection It is essential that protective footwear is worn when people are on site, both from a Contractor's point of view, in being able to provide a safe place and a safe method of working, and from an employee's position where safety footwear has a benefit in preventing injuries.

2

Wellington boots, for example, whether reinforced with protective toecaps or soles or not, are essential in preventing burns from wet cement or concrete. The cement content, when mixed with water, becomes highly corrosive and will cause severe burns to body tissue.

3

The above picture shows the severely burnt legs of a man who was ignorant of the dangers of wet cement, the effect it can have on skin, and the need to wear Wellington boots to protect the legs. Other clothing

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Other clothing that protects the wearer against any risk to their health or safety, for example a high-visibility waistcoat, is classified as PPE whereas clothing such as uniforms, the primary purpose of which is to promote a corporate image, is not.

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1.2.2.18 Fall protection 1

Items of equipment that are used by a person to prevent that person falling from height are also classified as PPE. Examples of this type of equipment are: (a)

safety harness

(b)

fall-arrest or restraint lanyard

(c)

inertia reel fall-arrest block.

2

All the Contractors' and employees' duties that apply to other types of PPE apply to this type of equipment also.

3

A major additional consideration regarding the use of this type of PPE is the prompt rescue of anyone who has fallen and is suspended in a harness. A medical condition known as suspension trauma, which at worst can result in the death of the suspended person, can occur if rescue is not carried out within 10 minutes.

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1.2.2.19 Life jackets Another category of PPE is that which enables the user to keep afloat should they fall into water or other liquids. These are broadly divided into life jackets and buoyancy aids.

2

In many circumstances it will be necessary for operatives to simultaneously wear more than one item of PPE.

3

Whilst this is entirely acceptable, attention should be given to ensuring that the different types of PPE are compatible with each other, to avoid the possibility of a dangerous situation.

4

For example, hearing protectors that are fitted directly to a safety helmet will not be effective if the safety helmet is poorly fitting and, by moving around on the head, does not allow the hearing protectors to form an effective seal around the ears.

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1.2.2.20 Consultation with employees

Contractors are likely to be far more successful in persuading employees to wear the PPE provided if the employees themselves are involved in the process of selecting the PPE purchased.

2

PPE can be cumbersome and uncomfortable and the cheapest may not be the most suitable for the wearer. In such circumstances the likelihood is that it will not be worn, at least not for long, leaving the worker unprotected against the hazard.

3

It is much better to purchase PPE that fits comfortably and will be used willingly.

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Control of Substances Hazardous to Health (COSHH)

1.2.3.1 Key points Many of the substances used or created during work processes have the potential to cause harm to the health of anyone exposed to them.

2

In construction many COSHH issues relate to substances created such as dust or fumes, as opposed to chemicals that have been bought in.

3

Hazardous substances that are already present on site when it is first occupied can also pose hazards to health.

4

All purchased products that are hazardous to health must carry an appropriate warning symbol on the packaging, however those hazardous substances which are created by the work process or are already present on site will carry no such 'health warning'.

5

Contractors have duties to establish the health risks to their employees, and others who may come into contact with hazardous substances, by carrying out an appropriate assessment and must put in place adequate control measures.

6

The assessment should take into account how the substance is used and should not merely be a copy of the supplier's information.

7

Ideally, exposure to any hazardous substance would be rendered impossible by:

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the substitution of safer substances

(b)

changing the way that the job is carried out so that the substance is not necessary

(c)

modifying the method of its use, for example total enclosure of the process.

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In many cases, none of these measures is practical in a construction site environment: if the prevention of exposure is not possible, the level of exposure must be controlled.

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Using PPE to control exposure must only be considered as a last resort after other methods have been explored and found not to be reasonably practicable.

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In some cases employees exposed to hazardous substances must be offered health surveillance.

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These Regulations are based on very simple principles. The intention of these Regulations is to protect human health from exposure to hazardous substances by either totally preventing exposure or, where that is not reasonably practicable, controlling the level of exposure to safe values, by appropriate means.

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COSHH deals with all harmful substances in relation to their health effects. However, these Regulations do not cover any flammable or explosive properties that the substances might also possess.

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1.2.3.3 Sources of harm 1

Many of the basic substances (products) bought in and used in the construction industry have the potential to harm the health of people using them, for example sand, cement, synthetic mineral fibre, adhesives, solvents, resins, and mineral oils.

2

Additionally, many of the essential construction processes can create potentially hazardous substances, for example the inhalation of: dust from mixing cement, taking down ceilings and walls, chasing out or cutting blocks

(b)

solvent fumes arising from the application of adhesives for surface finishes

(c)

metal fumes and toxic gases, such as carbon monoxide, nitrous fumes and ozone, which can be created by welding or hot cutting processes.

.

A third group of substances, also covered by these Regulations, are harmful substances (including micro-organisms) that may already be on site when a project commences. Examples are:

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(a)

leptospirosis, which can be spread by the urine of infected rats

(b)

discarded needles and syringes, which have the potential to pass on blood-borne diseases such as HIV and hepatitis

(c)

hazardous materials buried or simply left by a previous user of the land.

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The Regulations cover substances that have chronic or delayed effects, for example, substances that are carcinogenic (cause cancer), mutagenic (cause mutation of the body) or teratogenic (cause malformation of an embryo).

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The purpose of these Regulations is to safeguard the health of people using or coming into contact with any substance that is harmful to health.

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These Regulations apply to those substances that are classified as being very toxic, toxic, harmful, corrosive or irritant.

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1.2.3.4 Workplace exposure limits (WEL) Unsurprisingly, some hazardous substances have legal limits to which people may be exposed. All of these substances have a Workplace Exposure Limit (WEL) that represents a concentration of a substance in the air measured over a specific period of time. The taking of such measurements (workplace monitoring) is a specialist activity which must be carried out by someone who is competent to do so and who possess the appropriate equipment.

2

Such monitoring must be carried out where a (COSHH) risk assessment indicates it is necessary.

3

The following substances, all of which have a WEL, are commonly used in or produced by construction activities:

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(a)

general dust

(b)

hardwood dust

(c)

softwood dust

(d)

silica

(e)

white spirit

(f)

pulverised fuel ash

(g)

synthetic mineral fibre - rock wool/ fibreglass

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(h)

asphalt

(i)

welding/cutting fume

(j)

gypsum

(k)

Portland cement

(l)

micro-organisms associated with: (i)

blood products (ii) Weil's disease (iii) tetanus (iv) sewage (v) certain 'black mould' species

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(vi) anthrax.

This list is not exhaustive. Every Contractor has a legal duty to access competent health and safety advice. Failing to establish that an in-use substance has a WEL, or failing to control exposure to it, are criminal offences under Qatar Law.

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A list of all WELs is published by the UK Health and Safety Executive (HSE) in Guidance Note EH40/2005, available in hard copy or for download via the:

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HSE website at www.hse.gov.uk/coshh/table1.pdf

1.2.3.5 Is there a COSHH problem?

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Those who plan and carry out work that could result in exposure to hazardous substances may have difficulty in appreciating that there is a (real or potential) problem. This is particularly true when a hazardous substance is created by the work process.

2

For example, a hardwood plank should not pose any serious health issues in the form that it is delivered to site. However, cutting or sanding it will produce dust that, unless controlled, has the potential to cause irritation of the nasal passages, sensitisation or, on rare occasions, nasal cancer. Cutting, sawing, grinding or sanding any substances has the potential to liberate harmful dust. Furthermore, many types of hot works will create harmful fumes or gasses which may be inhaled unless the process is closely controlled.

3

The COSHH Regulations place a duty on the Contractor to assess whether or not a hazard to the health of the employees, or other persons, will arise from the presence of hazardous substances during work activities. This process is known as carrying out a COSHH assessment.

4

The decision-making process that must be worked through when carrying out an assessment will be familiar to anyone who has completed risk assessments.

5

Establishing the degree of risk can require expertise and experience. For example, if the only way to complete an activity involves using a particularly hazardous substance (for example dry rot treatments), the work will have to be well planned, managed and closely controlled. This would result in a high hazard/low risk situation.

6

Conversely, it is possible to create very high exposures that may be harmful to health from apparently low risk substances like dust, which is a common COSHH problem in construction.

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1.2.3.6 Definitions 1

The meanings of the following words need to be clearly understood.

2

Substance means any natural or artificial substance, in solid, liquid, gaseous or vapour form, and includes micro-organisms.

3

Hazard is the potential for the substance to cause harm, illness or damage to health.

4

Risk is the likelihood that the hazardous potential of the substance will be realised.

1.2.3.7 Control of Substances Hazardous to Health These Regulations place a duty on Contractors.

2

These duties cover:

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people actually working with substances

(b)

other people such as the public or other contractors who might be affected.

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(a)

Significant findings of the COSHH assessment and the actions that will be taken to control exposures must be written down.

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The main requirements of these Regulations are as follows.

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Assess the health risks to employees or other people created by work activities that involves substances hazardous to health.

(b)

Implement suitable control measures to effectively protect employees and others from exposure.

(c)

Review the assessment if there have been any changes that may invalidate it, such as: a change in the way the work is carried out, or

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(ii) the results of monitoring indicating that existing control measures are not effective. The emphasis under COSHH is to avoid exposure to hazardous substances unless it is not reasonably practicable to do so, in which case adequate control measures must be put in place to control exposure to a safe level.

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These Regulations require the following thought process in relation to control:

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(a)

Can the work be carried out by a less hazardous method that does not require the use of hazardous substances?

(b)

If not, can the substance be changed (substituted)?

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If the answer to both of these questions is 'no' then the introduction of measures to control exposure will be necessary.

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'Engineering' controls should be the first controls to be considered, such as pouring devices to stop splashes, the use of dust extraction, increasing ventilation and so on. PPE should not be considered as a control until engineering control options have been exhausted. PPE: (a)

can be expensive

(b)

can be unpleasant to wear

(c)

only protects the wearer and then only if it is being used correctly and maintained

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(d)

Section 11: Health and Safety Page 33 Part 1.02: Occupational Health and Hygiene (Regulatory Document) often requires considerable management effort to ensure that it is used correctly.

9

Removing the need to buy and use it makes good occupational health and business sense.

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The requirements of these Regulations are very thorough and one of those requirements is to ensure that the control measures which have been identified as suitable are properly used.

11

To ensure that the control measures are effective, the Regulations require that: extract ventilation systems must be thoroughly examined periodically

(b)

if using substances which are known to damage health, part of the assessment is likely to identify that health surveillance is necessary. Any records must be kept for 40 years and made available to the people who have been exposed to the hazard

(c)

there is a duty to communicate the information and provide relevant training to people who may be exposed

(d)

emergency arrangements are put in place and, where required, practised.

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(a)

1.2.3.8 Summary of COSHH

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Contractors must carry out a risk assessment of health risks created by work involving substances hazardous to health. Each assessment must take account of: the hazardous properties of the substance

(b)

information provided by the supplier on the potential harmful effects

(c)

the type, level and duration of exposure

(d)

the way in which the job will be carried out, including the amount of the substance used (or present in the case of substances created by a work process)

(e)

activities such as maintenance where there is the potential for high levels of exposure

(f)

any published WEL for the substance (EH40 Benchmarked Standards to which the Qatar Construction Industry will adopt)

(g)

the effects of any control measures which are, or will be, in place

(h)

the results of any health surveillance and/or exposure monitoring that has been undertaken

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the risks where there is exposure to more than one hazardous substance at any one time

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(j)

other information that the Contractor may need or have in order to complete the assessment.

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Any assessment must be reviewed regularly if there is reason to suspect that the assessment is no longer valid, or if there has been a significant change in the work to which the assessment relates, or exposure monitoring results indicate it is necessary.

3

Contractors must record significant findings of the risk assessment and the steps taken to prevent or control exposure.

4

Contractors must either prevent exposure of employees to substances hazardous to health or, where this is not reasonably practicable, adequately control exposure.

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The preferable method of prevention or control is to replace the substance or process with a non-hazardous or less hazardous substance or process.

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Controls shall be, in order of priority: engineering controls, organisational controls, then, as a

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last resort, providing suitable personal protective equipment (PPE). 7

The control measures must: (a)

ensure the safe handling, storage, transportation and disposal of hazardous substances

(b)

ensure maintenance procedures, which involve exposure to hazardous substances, are suitable

(c)

reduce to a minimum the number of people exposed, the level and duration of exposure and the quantity of hazardous substances present in the workplace

(d)

include control of the working environment, including the provision of adequate ventilation

(e)

include adequate hygiene and washing facilities.

These Regulations contain further details of measures that must be taken to control exposure to carcinogens, mutagens and biological agents.

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With regard to these Regulations, it is considered that control of exposure will be generally adequate if:

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work activities are organised to minimise the release and spread of hazardous substances

(b)

account is taken of the routes of exposure - inhalation, skin absorption and ingestion

(c)

the control measures selected:

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(a)

are proportionate to the degree of health risk

(ii)

are effective in minimising the escape and spread of the substance

(iii)

may, where necessary, include a combination of control measures, including PPE

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the control measures selected are periodically reviewed for their effectiveness

(e)

users of hazardous substances are informed of the hazards and risks and trained in the use of the control measures provided

(f)

it does not increase the overall risks to health or safety from other sources.

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1.2.3.9 Control Measures Contractors who provide any control measure are required to ensure that it is properly used or applied. All employees must: (a)

make proper use of any control measure (including PPE) provided

(b)

take all steps to return it to its place of storage after use

(c)

report any defects in the control measure to their Contractor.

2

Where control measures are provided, adequate maintenance, examination and testing of control measures, including any PPE provided, must be undertaken to ensure they are in efficient working order and remain clean.

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Where engineering controls are undertaken, the Contractor must ensure thorough examinations and testing are carried out on a regular basis.

1.2.3.10 Monitoring 1

Where indicated as necessary by the COSHH assessment, monitoring of the exposure to

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hazardous substances must be undertaken using suitable procedures, unless it can be demonstrated by another method of evaluation that exposure is adequately controlled. 2

Suitable records of any monitoring should be kept tor five years, or 40 years if personal exposures occur.

1.2.3.11 Health surveillance Health surveillance, where it is appropriate for protecting employees' health, must be carried out and recorded.

2

Where an employee requires medical surveillance following exposure, and it has been decided that the employee cannot continue in that work, the Contractor must take steps to ensure the employee adheres to the medical decision unless it has been cancelled.

3

Upon reasonable notice, a Contractor must allow the employee to access any medical records applying to them.

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Information, instruction and training must be provided for persons who may be exposed to substances hazardous to health so that they are aware of the danger of exposure and the precautions which should be taken.

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1.2.3.12 Information, instruction and training

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Procedures to deal with accidents, incidents and emergencies involving hazardous substances must be provided. These procedures should include: first-aid provisions

(b)

the use of safety drills and their regular testing

(c)

identification and details of hazards

(d)

specific hazards that are likely to occur during any accident, incident or emergency, together with warning and communication systems and emergency actions.

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1.2.3.13 Procedures

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These procedures must be made available to accident and emergency services, and be displayed on site.

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1.2.3.14 COSHH responsibilities Designers 1

The chain of responsibilities starts at the design stage of a project. Under CDM, designers have a duty to consider the risks created for the construction, maintenance, cleaning and use of a structure that could arise out of their designs. This must include consideration of COSHH issues.

2

It is important to be aware that this may not eliminate all 'COSHH risks'. Consider, for example, the periodic painting of a high level structure. It may be considered preferable to continue to use a solvent-based paint, as opposed to a water-based paint (a less hazardous product) on the grounds that the periods between painting will be longer, thereby reducing the frequency of working at height.

3

Furthermore, designers must take all reasonable steps to provide sufficient COSHH information about aspects of the design or its construction or maintenance, to adequately assist the client, other designers and contractors to comply with their duties under these

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Regulations. Clients 4

CDM places a duty on the client to provide pre-construction information to other parties involved in a project to protect the health and safety of anyone carrying out construction work, anyone affected by it or those who will use the structure as a place of work.

5

This will obviously include providing information on any known existing hazardous substances, such as the presence of hazardous residues in pipework or the existence of contaminated ground. Where necessary, this may involve commissioning surveys or taking samples to enable accurate information to be available for a risk-based control. It is no longer acceptable for the client to say: 'there may be the presence of x'.

co-operate with the Contractor and help them ensure the work is carried out safely

(b)

have undertaken their own COSHH assessments in relation to the work they are to undertake

(c)

have effective arrangements to ensure that control measures are put in place and are monitored.

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(a)

Some risks are likely to have been highlighted in the information provided by the client and designers. Often designers may simply not be aware of what the job entails, or they may believe the risks are commonplace and therefore any competent contractor should be aware of them.

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Under CDM, organisations that share a workplace must:

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Shared Workplace

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Employees have duties to:

work with their Contractor to enable them to comply with the law

(b)

make proper use of any control measures provided (including PPE)

(c)

return any control measure, where provided (mainly PPE), to its accommodation after use report any defects in the control measures to their Contractor

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Employees

(e)

attend health surveillance medicals where required (the Contractor must pay for the medical and it must be in paid work time).

1.2.3.15 Work on another Contractor's premises 1

Under CDM the client has a duty to provide pre-construction information to the Contractor, including the information necessary for maintenance or other work to be carried out, where this work is being done in an occupied premises.

2

Examples of such information are:

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(a)

details of the substances contained in pipework or tanks, if for example a pipefitter is to break into a pipe to replace a valve.

(b)

what gases, vapours or fumes may be discharged through a rooftop ventilation duct during the time a roofer has to work next to it.

There is also a requirement for the client to make sure that contractors are aware of emergency procedures that might arise out of the use of any particular substance(s) on the

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site. Obviously, this duty is reciprocal. The contractor has a duty to inform the client or the site occupier if (the contractor's) work poses risks to the client's staff and visitors and to outline how the risks will be controlled. This is particularly important where the client has outof-hours security staff. Often, arrangements that are effective during the working day, to ensure that the contractor and client liaise, can become non-effective after normal working hours, for example by the security staff entering an agreed exclusion zone due to ignorance of the hazards present.

1.2.3.16 Information 1

Information about hazards from substances purchased can be found in several sources: (a)

Information on labels.

(b)

Information provided by the manufacturer or supplier of the substance

Many suppliers have Material Safety Data Sheets (MSDS) on their websites.

3

Data sheets must contain certain information:

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Identification of the substance or preparation and the company or undertaking providing the substance.

(b)

Composition and information on ingredients.

(c)

Hazard identification.

(d)

First-aid measures.

(e)

Fire-fighting measures.

(f)

Accidental release measures.

(g)

Handling and storage.

(h)

Exposure controls and personal protection.

(i)

Physical and chemical properties.

(j)

Stability and reactivity.

(k)

Toxicological information.

(l)

Ecological information.

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Other information.

Disposal considerations. Transport information.

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If the substance is a carcinogen or a mutagen, i.e. capable of causing cancer or mutation of the body, every possible step should be taken to eliminate the need for its use.

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It is considerably harder to find out information about substances created by the work process.

1.2.3.17 Carrying out an assessment 1

An assessment is the fundamental requirement of COSHH. It is in two parts.

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Firstly, a Contractor must not carry out any work that is liable to expose employees to any substance hazardous to health, unless a suitable and sufficient assessment of the risks created by the work has been made.

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Secondly, if the first step indicates that substances hazardous to health will be used or

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created, Contractors must identify the actions to be taken to comply with these Regulations. The procedure itself is fairly simple but does take time and effort. It involves: (a)

identifying jobs, working processes and procedures that involve the use or generation of substances that are hazardous to health

(b)

identifying all the hazardous substances in use in the workplace, very toxic, toxic, harmful, corrosive or irritant

(c)

identifying how the hazardous substances are stored and used. This means how they are used, not how they should be used

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Very toxic or toxic Substances that, in low quantities, cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin

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Harmful Substances that may cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin.

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Corrosive Substances that may, on contact with living tissues, destroy them.

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Irritant Non-corrosive substances that through immediate, prolonged or repeated contact with the skin or mucous membrane, may cause inflammation.

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(d)

identifying how these hazardous substances might enter the body. Normally these methods are classed as: (i) inhalation into the lungs, when the substance is in the form of a gas, vapour, fume, mist, aerosol or dust (ii)

absorption through the skin or eyes by contact with a substance that can penetrate unbroken skin, or is absorbed through unprotected cuts or grazes

(iii)

injection by contact with contaminated sharp objects or high-pressure equipment, e.g. water jetting

(iv)

ingestion by swallowing particles of a hazardous substance resulting from handto-mouth transfer

(e)

identifying the amount of exposure. This involves knowing how much of the substance will be used, how people will be exposed to it and if there are is a workplace exposure limit

(f)

investigating the possible health effects of such exposure

(g)

identifying who is at risk, for example the persons using it or anyone who enters the

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Section 11: Health and Safety Page 39 Part 1.02: Occupational Health and Hygiene (Regulatory Document) area within the following 24 hours

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(h)

considering the effectiveness of the control measures already in place, for example whether the concentration of vapour is likely to be above the WEL

(i)

identifying the risk to workers if control measures deteriorate or fail or if an emergency occurs, for example if a volatile solvent is accidentally spilt resulting in a high concentration of hazardous vapour in the workplace

(j)

finally, from the above considerations, making a decision upon whether a substance represents a health risk or not. If the answer is 'no', the findings should be recorded. If 'yes', action will be necessary to either prevent or control exposure.

Completed assessments must be made available to the person who is going to carry out the work so that they are aware of the health hazards present and the control measures that they must use.

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Anyone who is competent.

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1.2.3.18 Who can make an assessment?

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1.2.3.19 So how do you do one?

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General requirements

The process must be carried out at an early stage to ensure that safe systems of working are developed before anyone is exposed to potentially harmful substances. However, further details can be added as the job progresses.

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The process of compiling the list of substances must consider the whole lifespan of the site, for example the chemical treatment of vegetation, and the removal and treatment of contaminated land before construction starts to the treatment of new timber fencing at the end of the project.

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When carrying out an assessment, in addition to considering normal usage, it is important to also consider the potential for exposure when the substance is: handled or stored

(b)

transported

accidentally released as the result of an accident

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(d)

used for cleaning or maintenance

(e)

disposed of as waste.

1.2.3.20 Step 1: Find out what is (or will be) on site Bought-in products 1

The first, and easiest, stage is to look at the substances that are bought in. This involves identifying what is used and what is not hazardous to health. Most construction processes are relatively simple as they rarely use a large number of substances or involve mixing of substances. Mechanical workshops, for example where plant is serviced, tend to be more challenging simply because of the amount of chemicals present in the substances that they normally use.

2

Another consideration is the substances that will be brought onto site by other contractors, how those substances might affect other people and the quality of the contractors' COSHH assessments.

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3

Furthermore, the site office and other accommodation must not be overlooked. For example, it is not unreasonable to suppose that strong cleaning materials will be used in catering and other welfare facilities.

4

Having made a list of all substances, it is then sensible to identify any products that are obviously not hazardous, so that they can be ruled out.

5

Taking cleaning chemicals as an example, washing-up liquid does not have any warning symbols on it and therefore, other than noting its presence, no further action is necessary.

6

However, the information on a container of bleach should provide the basis for determining how it can be used safely. Of the two products that have been considered, one requires no control measures to be Identified but the second does.

.

Created by the work process The situation becomes more complicated when potentially harmful substance, such as many forms of dust or fumes, are created by work processes. The situation is further complicated if the substance created has a WEL that must not be exceeded. This may require that exposure levels are measured unless exposure can be eliminated or controlled to a known safe level. Again, it will be necessary to also consider potentially harmful processes that will be carried out by other contractors.

8

Depending upon the complexity of the project, it may not be possible to complete this part of the exercise prior to the start of the project unless all work processes and substances that will be created are known. In these circumstances, it will be a case of building up the COSHH information as the job progresses, but this must be achieved in such a way that noone is exposed to a potentially harmful substance until the assessment of it has been carried out and appropriate controls are in place.

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Already present on site

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A third category of potentially harmful substances is those substances, including microorganisms, that may already be present on site.

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Examples are:

residues of hazardous substances left in pipework, underground tanks and drums

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(b)

land heavily contaminated with fuels, oils and other hazardous liquids which have seeped into the ground over many years

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(a)

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(c)

11

substances such as asbestos and polychlorinated biphenyls (PCBs) that were deliberately buried by the past users of the land.

Also in contaminated land there could be sources of micro-organisms. These include: (a)

leptospirosis (Weil's disease) from the presence of infected rats or their carcases

(b)

infected syringes, needles and other items associated with drug-taking, for example where a derelict site is being refurbished

(c)

tetanus from infected ground or other materials

(d)

a range of respiratory diseases arising from the disturbance of accumulated bird or bat droppings

(e)

pipework and sumps containing sewage sludge residue.

1.2.3.21 Step 2: Substitution 1

If there is a way around using a potentially hazardous substance, designers and planners

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should take advantage of it. 2

Returning to the cleaning materials example, there is no reason why a COSHH assessment cannot be carried out for bleach, but the first rule of COSHH is to not use the potentially hazardous product.

3

Can a safe alternative product be identified? If nothing else, it will be one less COSHH assessment to carry out.

4

There are many similar situations, when simply changing the product is either no risk or a risk that is easier to control.

5

Other examples include: altering the work method so the process that produces the exposure is no longer necessary, e.g. using a demolition shear to cut structural steelwork rather than gas cutting and therefore avoiding a process that may produce metal fumes and toxic gases

(b)

changing the work method to prevent the production of a hazardous waste product, e.g. purchasing panels of the correct size, rather than cutting oversize panels on site and producing dust. Given the pressure on reducing waste and manual handling, this is another example where 'good health and safety is good business'

(c)

it may be possible to obtain and use the hazardous substance in a safer form, e.g. as a liquid or paste rather than as a powder, if using the powder may result in airborne dust being inhaled by workers.

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These examples of controlling the 'COSHH risk' may indicate that some companies are already doing COSHH assessments without realising it.

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(a)

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1.2.3.22 Step 3. Exposures - who, what, how much and how often? Now the assessment process really starts -having identified the substances that may be harmful for health, the assessment needs to consider the exposures.

2

Who is exposed? Is it just the person using the substance or can it affect other people?

3

What are they going to do with it? The decision to either spray or apply paint by brush may make a significant difference. Spray application will probably mean a much smaller droplet size, creating a more severe respiratory hazard. This assessment needs to be honest and objective. For example, paint removal gels state on the tin that they are only for brush application, although it is physically possible to spray them. However, the controls required to spray without potentially damaging the skin, eyes or lungs are completely different to those required for brush application.

4

How often and how much of a substance is used and for how long are also very important factors.

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1.2.3.23 Step 4. Implementing controls 1

The first step is to consider in detail how the work practices involving potentially hazardous substances will be carried out. The person carrying out the assessment must be sufficiently familiar with each process to know exactly how it is carried out.

2

As an example, a woodworking company purchased vacuum cleaners to remove sawdust in the woodworking machine shop. They believed that this would result in airborne dust being reduced to a safe level. However, it was found that the employees continued to use brushes to sweep the dust into large heaps, which they then vacuumed up. This obviously

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circumvented the intended control measure of vacuuming instead of sweeping. Elimination/substitution 3

As has already been stated, the first and most effective controls are elimination or substitution, which means either changing the task completely or changing the substance for a less harmful one. Engineering controls The next tier of control is referred to as 'engineering controls'. This encompasses a wide range of solutions, which traditionally would have been more common in a workshop or manufacturing environment as they encompass such techniques as completely enclosing processes, automating a process or installing high efficiency ventilation. However, as the Qatar construction industry responds to occupational health issues, it is becoming more common to see features such as:

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4

hand-powered tools fitted with dust extraction apparatus (either in-built or with a fitting which enables a vacuum cleaner to be attached)

(b)

free-standing dust extraction and collection units

(c)

air handling units that dilute the concentration of any airborne substance

(d)

motorised table-saws that enable wet-cutting to be carried out

(e)

using hydraulic croppers to cut brick pavers rather than disc-cutting them, to reduce exposure to dust

(f)

lead paint removal by a system that does not heat the paint sufficiently to liberate lead fumes.

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(a)

Some control measures are very simple, for example damping down the dust on a floor slab before sweeping. Other situations may require a little more thought and ingenuity.

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However, it is not always possible or 'reasonably practicable' to introduce engineering controls and so the implementation of certain organisational controls may be possible.

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Organisational controls These are concerned with investigating whether the way in which the job is carried out can be changed so that individual exposure is reduced. For example, by carrying out a job out of normal working hours, the number of persons exposed, who would otherwise have to wear PPE, will be significantly reduced.

8

Further examples include:

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(a)

job rotation so that no individual person is exposed to a substance above its WEL

(b)

moving a work activity into the open air to prevent the accumulation of vapour or fumes.

Personal protective equipment (PPE) 9

If it is found that it is not reasonably practicable to implement any of the above control measures, the use of PPE may be the only control measure that can be effectively used. Where the health hazard is an airborne substance, respiratory protective equipment (RPE) will be required.

10

It is important to remember that anyone wearing a mask must be face-fit tested for that type of mask, and have no facial features, such as a beard, which would interfere with the seal between the face and the mask. This problem can be overcome by using the loose fitting

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'airstream' type of RPE where the mask does not seal to the face and a stream of filtered air from a blower unit not only aids breathing but also creates an 'over-pressure' around the face area to stop substances from entering it. 11

As with all PPE, there need to be arrangements to check that it is: (a)

adequate and suitable for the job

(b)

a proper fit

(c)

stored safely when not in use

(d)

checked for defects and maintained as appropriate

(e)

disposed of safely

(f)

replaced as necessary

Users need to be trained on all these points and must be informed of the operational limits of the equipment, i.e. what it cannot do as well as what it can do.

13

In some circumstances the application of control measures will continue after the actual work activity is completed. For example, some jobs will require the operatives to go through a full decontamination procedure, e.g. working with heavily contaminated land. Anyone who has been in the live working area may have to follow a strict procedure about where they take boots and overalls off, or even go through a shower, and it may involve wearing additional gloves to ensure that contaminants are kept off their skin when decontaminating.

14

Often, simply washing hands with hot soapy water will suffice. Good COSHH practice and the provision of good welfare facilities are very closely linked. This may mean in some circumstances that eating and drinking are not allowed other than in designated clean zones.

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The assessment

The assessment is a 'considered Judgement' that balances the hazardous properties of the substance, the method by which it will be handled and the environment in which it will be used.

16

The skill of the COSHH assessor is to: sift through the information contained on the material safety data sheet (MSDS) and other sources such as on the container

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(a)

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(c)

incorporate their knowledge of how, when and where the substance is used

(d)

from the information available, produce a useful and useable COSHH assessment to guide those who will be doing the work.

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extract the useful information

17

Examples of an MSDS and a COSHH assessment are in Appendices 2 and 3, and show how the mass of information on the MSDS can be condensed into a usable assessment. Emergencies

18

If significant or dangerous accidental releases or leakages of a hazardous substance are possible, despite the control measures which have been implemented, an emergency plan should be drawn up and instigated for achieving suitable control and for safeguarding the health of anyone who may be affected.

19

The emergency plan should include first-aid provisions and safety drills, including the testing of drills at regular intervals. Any particular hazards that are likely to occur as a result of the emergency must be specified.

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20


The emergency plan should be made available to all people potentially affected and be displayed on site. It should also be made available to the accident and emergency services.

1.2.3.24 Review of assessments and control measures 1

An assessment should be reviewed regularly, and at once, if: (a)

there is reason to believe that it is no longer valid, e.g. new information on health risks has come to light

(b)

the work to which it relates has changed significantly, e.g. new substances have been introduced, or the method of working is to change, such as the use of a spray gun to apply paint instead of a brush or roller

(c)

environment and/or health monitoring results indicate it is necessary.

The definition of 'regularly' will depend on a number of factors, such as the nature of the risk. However, the maximum period between reviews should not exceed five years.

3

Each review should trigger an opportunity to consider whether exposure can now be prevented, for example, by substituting a less hazardous substance or by process changes. Similarly, control measures should be reappraised to see whether they are still adequate or if further improvements are necessary and possible.

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Use of control measures

Contractors should have procedures in place to ensure that measures provided to control exposure to hazardous substances, including the provision of PPE, are properly used or applied. These procedures should include regular inspections of working practices and a system to ensure that, where remedial action is found to be necessary, it is promptly taken.

5

Employees have a duty to:

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make full and proper use of any control measures and to properly wear any PPE provided for their use

(b)

take all reasonable steps to return the PPE after use to the accommodation provided

(c)

notify any defects at once to management.

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(a)

These are all common sense measures. Work with hazardous substances also dictates that employees make every effort to practise a high standard of personal hygiene, for example, by:

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6

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(a)

removing any protective clothing (this may be contaminated) and thoroughly washing before eating and drinking

(b)

consuming food and drink only in mess rooms or canteens

(c)

making full use of shower facilities

(d)

using the storage facilities provided and keeping personal protective clothing separate from ordinary clothing, to avoid possible contamination

(e)

smoking only in designated areas and thoroughly washing hands before handling cigarettes or tobacco, otherwise contamination may spread from hands to the mouth and ingested into the stomach, which can lead, in some circumstances, to serious health problems.

Maintenance, examination and test of control measures 7

Contractors are required to ensure that all measures installed to prevent or control exposure to substances hazardous to health under these Regulations are maintained in efficient

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working order and in good repair. 8

Certain engineering controls require thorough examination and tests, as follows. Local exhaust ventilation plant

9

Local exhaust ventilation plant should be examined and tested at least once every 14 months.

10

Any defects in local exhaust ventilation systems must be reported and promptly rectified. Non-disposable respiratory protective equipment (RPE) Thorough examinations and tests of non-disposable respiratory protective equipment (RPE) should be carried out, where appropriate, at suitable intervals.

12

Examinations and tests should be carried out at least every month, and more frequently where the conditions of use are particularly severe. Longer intervals may be more appropriate in the case of certain RPE, e.g. half-mask respirators used infrequently for short spells against air contaminants of relatively low toxicity. However, the longest interval between examinations and tests should not exceed three months.

13

Face-fit testing by someone who is competent is required for any tight-fitting masks. For full face masks, this needs to be quantitative testing using a computerised method.

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Disposable RPE

No examinations or tests are required, provided that the disposable RPE is used for only one working day or shift and then disposed of.

15

Again, face-fit testing by a competent person is required. This can be qualitative testing using a sweet/bitter solution to check the effectiveness of the fit. Records

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All examinations, tests and repairs carried out on engineering controls and non-disposable RPE should be suitably recorded in any format provided they are easily retrievable. These records should be kept for at least five years.

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1.2.3.25 Monitoring exposure at the workplace 1

There are certain situations, outlined below, in which the monitoring of exposure to a hazardous substance is required. Sometimes, however, it is so obvious that there is a problem that the money may be better spent on solving the problem rather than simply confirming what was already suspected.

2

Monitoring is required in the following circumstances:

3

(a)

where a serious health hazard could arise because of failure or deterioration of the control measures

(b)

where it is necessary to ensure that a workplace exposure limit (WEL) or Contractorimposed working standard is not exceeded. Significant exposure to silica dust may require monitoring

(c)

when it is necessary to carry out an additional check on the effectiveness of any control measure

An example of monitoring would be the use of a personal sampler to monitor an airborne

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contaminant in the breathing zone of an employee. Monitoring records 4

Monitoring records must be kept in a suitable format and be available either as individual records or as a suitable summary for five years. If they are representative of the personal exposures of identifiable employees, the records must be kept for at least 40 years.

1.2.3.26 Health surveillance The main purpose of health surveillance is to detect problems with the health of employees at the earliest possible stage. The purpose of control measures is to prevent damage to the health of employees; this is something that health surveillance cannot do. However, adverse health surveillance results may indicate that the existing control measures are not working properly.

2

Health surveillance has to be undertaken when:

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an employee is exposed to a substance that is hazardous to health and there is an identifiable disease or adverse health effect related to this exposure (which may occur because of the conditions of the work) and there are valid techniques for detecting indications of the disease or effect. For example, isocyanates used in 'two pack paints' are respiratory irritants and can result in sensitisation and asthma.

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(a)

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1

Working on contaminated land often requires some form of health surveillance. This may include lung function testing or direct analysis of blood, urine or hair samples. Normally this would occur before during and after the work. It allows a personal baseline to be established and then simply acts as a check that the control measures are working.

4

Suitable health surveillance can be undertaken by an appointed doctor or a registered medical practitioner or an examination by an occupational health nurse. At the other end of the scale, health surveillance could simply involve a trained manager or supervisor inspecting an employee's hands and forearms, looking for the early signs of dermatitis.

5

Contractors are required to keep health records of employees under health surveillance for at least 40 years from the date of the last entry.

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1.2.3.27 Information, instruction and training for people who may be exposed to hazardous substances If an employee is likely to be exposed to substances hazardous to health, the Contractor must provide sufficient information, instruction and training so that the employee is aware of: (a)

the health risks, and

(b)

the precautions that should be taken.

2

It is important that workers do not put themselves at risk due to lack of information, instruction or training.

3

Therefore, they should be knowledgeable of the health risks, the precautions they should take (including the control measures), and be able to use the supplied personal protective equipment effectively.

4

They should also know what procedures to follow in the event of an emergency.

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Construction Site Safety 1.2.3 Appendix 1 Management action plan Compile an inventory of all hazardous substances to which employees may be exposed, which are either purchased (proprietary products) or created by a work process (dust, fumes etc.) or may be already on site (micro-organisms, contaminated land, residues etc.).

2.

Gather relevant technical information about each substance from sources such as labelling, safety data sheets. For each substance, evaluate the work task(s) and working practices associated with it. If necessary, observe the work activity in which the hazardous substance is used or created.

3.

From information and observations made, decide if there are any risks to health.

4.

Assess what action needs to be taken to prevent exposure (PRIORITY), or to control it to an acceptable level. Record the significant findings of the assessment.

5.

Take the actions necessary to ensure that the appropriate control measures are provided, properly used and maintained as necessary. Provide all users of (or those creating) each hazardous substance with the necessary information, instruction and training. From the information gained, decide if there is any requirement for exposure monitoring and health surveillance.

6.

Review the assessment regularly and revise it as necessary.

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Construction Site Safety 1.2.3 Appendix 2 Example of a material safety data sheet - diesel fuel Sheet

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Product name: AUTO DIESEL / DERV Synonyms: G.O.R.V., Ultra-Low Sulphur Diesel, AD10

Last revision

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This is an uncontrolled copy

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1. Identification of the substance / preparation and of the company

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Facsimile:

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Telephone:

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Name and address of manufacturer/supplier:

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Emergency contact:

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Health and safety emergency telephone: Application:

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For use as a fuel in diesel engines only. Any other use implies a processing operation which may change its essential characteristics and liability for safety of the product will transfer to the processor.

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2. Composition / information on ingredients

Petroleum hydrocarbons >99% Saturated olefinic and aromatic: PAHs.

C10 to C26 - may contain Polycyclic Aromatic Nydrocarbons -

CAS No. 068334-30-5. EINECS No. 269-822-7, R40. Additives 1. Middle distillate flow improvers (various) up to 1000ppm. (Dispersion of Ethylene vinyl acetate in an organic solvent). 2. Cetane improvers (AlkyI Nitrates) - up to 500ppm. CAS No. 27247-96-7, EINECS No. 269-822-7. 3. May contain dye and chemical marker - gas oil marker concentrate. CAS No. 68334-30-5. 4. Antistatic additive 1-3ppm 5. May contain a multifunctional detergent

January 2006

QCS 2014


Sheet

AUTO DIESEL / DERV

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3. Hazard identification Health hazards:

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This product contains amounts of Polycyclic Aromatic Hydrocarbons, some of which are known from experimental animal studies to be skin carcinogens. Prolonged and repeated exposure may therefore cause dermatitis and there is a risk of skin cancer. The risk of skin cancer will be very low, providing the handling precautions are such that prolonged and repeated skin contact is avoided and good personal hygiene is observed. Aspiration of liquid into the lungs directly or as a result of vomiting following ingestion of the liquid can cause severe lung damage and death.

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Safety hazards:

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Product can accumulate static charges, which may be a possible ignition source (see Section 7). However product does contain an antistatic additive.

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Environmental hazards:

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4. First aid measures

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Dangerous for the environment. Toxic to aquatic organisms. May cause long-term adverse effects in the environment.

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Eyes:

Rinse immediately with plenty of water until irritation subsides. If irritation persists, obtain medical attention.

Skin:

Immediate flush with large amounts of water, using soap if available. Remove contaminated clothing, including shoes, after flushing has begun. If irritation persists, get medical attention.

Inhalation:

In emergency situations use proper respiratory protection to immediately remove the affected victim from exposure. Administer artificial respiration if breathing has stopped. Keep at rest. Call for prompt medical attention.

Ingestion:

DO NOT INDUCE VOMITING, since it is important that no amount of the material should enter the lungs (aspiration). Keep at rest. Get prompt medical attention.

Pressure injection:

ALWAYS OBTAIN IMMEDIATE MEDICAL ATTENTION EVEN THOUGH THE INJURY MAY APPEAR MINOR.

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Sheet

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Product name: AUTO DIESEL / DERV

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5. Fire-fighting measures

Foam, dry chemical powder, carbon dioxide.

Fire and explosion hazards:

Flammable liquid, moderate hazard. Liquid can release vapours that readily form flammable mixtures at or above the flash point.

Static discharge:

Material can accumulate static charges which may cause an incendiary electrical discharge. However, this product does contain an antistatic additive.

Special fire-fighting procedures:

Water fog or spray to cool fire exposed surfaces (e.g. containers) and to protect personnel, should only be used by personnel trained in firefighting.

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Extinguishing media:

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Cut off "fuel"; depending on circumstances, either allow the fire to burn out under controlled conditions or use foam or dry chemical powder to extinguish the fire. Respiratory and eye protection required for fire-fighting personnel exposed to fumes or smoke.

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Hazardous Smoke, sulphur oxides and carbon monoxide in the event ofincomplete combustion products: combustion.

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6. Accidental release measures

Personal precautions: See Section 8 Environmental precautions:

Land spill: Eliminate sources of ignition. Shut off source taking normal safety precautions. Prevent liquid from entering sewers, watercourses or low lying areas; advise the relevant authorities if it has, or if it contaminates soil/vegetation. Take measures to minimise the effects of groundwater. Water spill: Eliminate the spill immediately with booms. Warn shipping. Notify port and other relevant authorities.

Decontamination procedures:

Recover by skimming or pumping using explosion-proof equipment, or contain spilled liquid with booms, sand or other suitable absorbent and remove mechanically into containers. If necessary, dispose of absorbed residues as directed in Section 13.

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Sheet

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7. Handling and storage

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Store product in cool, well ventilated surroundings, well away from sources of ignition. Provide suitable mechanical equipment for the safe handling of drums and heavy packages.

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Electrical equipment and fittings must comply with local Regulations regarding fire prevention with this class of product. Load/unload temperature: Ambient to 40°C

Storage temperature:

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Special precautions:

Ambient to 40°C

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Use the correct grounding procedure. Store and handle in closed or properly vented containers. Ensure compliance with statutory requirements for storage and handling. Check for and prevent potential leaks from containers.

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8. Exposure controls / personal protection

Substance

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Workplace exposure limit:

STEL

Source / Other Information

5 mgm-3

10 mgm-3 HSE Guidance: not listed in EH 40

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Mineral oil mist

8-hour TWA

Personal protection:

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In open systems where contact is likely, wear safety goggles (EN 166), chemical-resistant overalls and chemically impervious gloves (EN 374). Where only incidental contact is likely, wear safety glasses with side shields. No other special precautions are necessary provided skin/eye contact is avoided. Where concentrations in air may exceed the OES approved respirators may be required (EN 405).

Monitoring methods:

Health & Safety Executive (HSE), Methods for the determination of Hazardous Substances (MHDS); MDHS 84 www.hsl.gov.uk/search.htm


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9. Physical and chemical properties

Appearance:

Clear straw-coloured Odour: liquid

Density at 15°C:

0.82 g/ml

Pungent petroleum

Not applicable

Vapour pressure at 20°C: < 0.3 Kpa

Vapour density (air=1):

< air

Boiling point:

Pour point:

-24°C

Flash point (closed cup): > 55°C

Auto-ignition temperature:

250- 270°C

Flammability limit, in air, % by volume:

LEL: 0.5, UEL: 6.0 4.8

2 -1

3.0

Solubility:

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Kinematic viscosity at 40°C, mm s

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2 -1

Kinematic viscosity at 20°C, mm s

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180 - 390°C

.

pH:

Negligible

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PLEASE NOTE THAT THESE PROPERTIES DO NOT CONSTITUTE A SPECIFICATION.

Stability:

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Conditions to avoid:

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10. Stability and reactivity

The product is stable and not subject to polymerisation. Avoid exposure to extreme heat. Avoid contact with strong oxidising agents such as liquid chlorine.

Hazardous decomposition products:

Product does not decompose at ambient temperature.

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Materials to avoid:


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11. Toxicological information The following toxicological assessment of health effects is based on a knowledge of the toxicity of the product's components. Slightly irritating but does not damage eye tissue.

On skin:

Low order of acute toxicity. Irritating. Prolonged or repeated contact may also lead to more serious skin disorders, including skin cancer. Certain components present in this material may be absorbed through the skin, possibly in toxic quantities.

By inhalation:

In high concentrations and/or at elevated temperatures, vapour or mist is irritating to mucous membranes, may cause headaches and dizziness, may be anaesthetic and may cause other central nervous system effects. Elevated temperatures or mechanical action may form vapours, mists or fumes, which may be irritating to the eyes, nose, throat and lungs. Avoid breathing vapours, mists or fumes.

By ingestion:

Low order of acute/systemic toxicity. Minute amounts aspirated into the lungs during ingestion or vomiting may cause severe pulmonary injury and death.

Chronic:

Contains Polycyclic Aromatic Hydrocarbons (PAHs). Prolonged and/or repeated skin contact with certain PAHs has been shown to cause skin cancer. Prolonged and/or repeated exposure by inhalation of certain PAHs may also cause cancer of the lung and of other sites of the body.

Acute:

Based upon animal test data from similar materials and products, the acute toxicity of this product is expected to be:

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On eyes:

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ORAL LD50 > 5000 mg/kg DERMAL LD50 > 2000 mg/kg

12. Ecological information

Mobility:

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Ecotoxicity:

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In the absence of specific environmental data for this product, this assessment is based on information developed with other crude oils. Gas oils released into the environment will float on water and spread on the surface; on release to soils, gas oils show some mobility and predominantly absorb. Dangerous for the environment. Toxic to invertebrates and slightly toxic to fish. Some mobility in soils.

Persistence and degradability:

Lighter components volatilise and in air undergo photolysis to give half-lives of less than a day. Photoxidation of liquid hydrocarbons on the water surface also contributes to the loss process. Slow to moderate degradation in water and soil.

Bioaccumulation potential:

Potential to bioaccumulate, but metabolic processes may reduce this tendency.

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13. Disposal considerations

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14. Transport information

Rails cars, tank trucks, tankers, barges, drum.

Shipping name:

Diesel Fuel

Packaging group:

III

Marine pollutant:

See Section 6

ICAO/IATA:

Class 3

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Classification for transport:

1202

UN Class:

3

ADR/RID:

Class 3

Emergency action code:

3Y

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UN Number:

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15. Regulatory information Hazard label data:

o R40

N Dangerous for the Environment

Limited evidence of carcinogenic effect

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R & S phrases:

Xn Harmful

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R51/53 Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment

EC Directives: Statutory information:

S2

Keep out of reach of children

S36/37

Wear suitable protective clothing and gloves

S61

Avoid releases into the environment, see Section 6

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16. Other information

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The data and advice given apply when the product is sold for the stated application or applications. The product is not sold as suitable for any other application. Use of the product for applications other than as stated in this sheet may give rise to risks not mentioned in this sheet. You should not use the product other than for the stated application or applications.

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If you have purchased the product for supply to a third party for use at work, it is your duty to take all necessary steps to ensure that any person handling or using the product is provided with the information in this sheet.

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If you are an Contractor, it is your duty to tell your employees and others who may be affected about any hazards described in this sheet and about any precautions that should be taken.

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Construction Site Safety 1.2.3 Appendix 3 COSHH assessment - diesel fuel Auto diesel

Substance hazard classification:

Flammable, harmful/irritant

Trade name(s):

Any auto fuel production company

Substance used for:

Motive power for plant and other diesel powered vehicles

Safety precautions

Emergency procedures Remove to fresh air. Seek medical attention if conditions severe.

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Inhalation: can lead to nausea Avoid inhaling vapour or mist; and headaches. ensure good ventilation. Remove the victim from exposure.

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Potential hazards

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Name of hazardous substance:

Avoid prolonged/repeated contact. Wear PVC gloves. Do not use as a cleaning agent.

Eye contact: will cause irritation.

Wear eye protection if splashing Rinse immediately with plenty of can occur. water until irritation subsides. Seek medical advice.

Remove contaminated clothing. Wash skin thoroughly with soap and warm water.

Do not eat, drink or smoke during use.

Do not induce vomiting. Wash mouth with water. Seek immediate medical attention.

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Ingestion: will irritate mouth, throat etc.

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Skin contact: can be irritating and have a defatting effect.

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Fire: products of combustion Do not smoke during use. Avoid Clear the area. Do not inhale are toxic. Vapour/air mixture is heat sources and open flames. vapours, smoke etc. explosive. Spillage: fumes/vapour likely to Do not allow to enter drains. collect in low areas. Eliminate ignition sources. Ensure good ventilation.

Contain with sand or granules. Remove into a container. Dispose of as hazardous waste.

Additional information: Environmentally damaging. Assessment date

Approved for use by (print name and position) Signature

Next date

review

QCS 2014



First Aid at Work

1.2.4.1 Key points Trained first-aid staff and first-aid equipment must be available on site.

2

The level of provision of trained staff and first-aid equipment will depend upon several factors.

3

Everyone working on site should know where the first aiders and the first-aid kits can be found.

4

All accidents causing injury must be recorded in an accident book.

5

In an emergency, assess the situation but do not put yourself in danger.

6

Don't move casualties who are obviously injured unless it is necessary to do so - summon the first aider immediately and contact external emergency services.

7

Cover severe bleeding with a clean pad and apply direct pressure.

8

First Aiders have the potential to save lives.

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The following four factors will influence decisions: workplace hazards and risks

(b)

the nature of the undertaking and its history of accidents

(c)

the size of the establishment and distribution of employees

(d)

the location of the establishment and the locations to which employees go in the course of their work.

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These Regulations provide a flexible framework within which Contractors can develop effective first-aid arrangements appropriate to their workplace and the size of their workforce.

DANGER

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Your own safety is your first priority RESPONSE Does the casualty respond to voice/touch? AIRWAY Does the casualty have a clear airway? BREATHING Is the casualty breathing? If you are not there are brief notes to be taken in an emergency.

a in

PROMPT ACTION SAVES LIVES!

trained Appendix

3

first on

aider, actions

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1.2.4.3 Definition of first aid 1

First aid is defined as the follows: (a)

in cases where a person will need help from a doctor or a nurse: treatment for the purpose of preserving life and minimising the consequences of injury or illness until such help is obtained.

(b)

treatment of minor injuries which would otherwise receive no treatment or which do not need treatment by a doctor or nurse.

It should be noted that the definition covers any illness at work and not just accidents. You must, therefore, plan for times when someone has a heart attack or just collapses.

3

Emergency fist aiders can give a restricted range of first aid treatment to someone who is injured or becomes ill at work. Fully trained first aiders can do the above, plus apply first aid to a range of specific injuries and illnesses.

4

Contractors are required to:

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provide adequate first-aid equipment and facilities appropriate to the type of work or operations undertaken

(b)

appoint a sufficient number of suitable and trained people to render first aid to employees who are injured or become ill at work

(c)

appoint a sufficient number of suitable people who, in the temporary absence of the first aider, will be capable of dealing with an injured or ill employee needing help from a medical practitioner or nurse, and who are able to take charge of first-aid equipment and facilities

(d)

inform employees of the first-aid arrangements, including the location of equipment and personnel. This will require that notices be posted and signs displayed. Provision should be made for employees with language or reading difficulties.

Shared facilities

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(a)

To avoid the unnecessary duplication of facilities where employees of more than one Contractor are working together, arrangements may be made to share facilities. Whilst there is no requirement for shared facilities to be formally recorded, industry best practice is that the arrangements are recorded in writing, with each Contractor retaining a copy.

6

In such circumstances, it is the responsibility of each Contractor to ensure that the agreed facilities are actually provided, and that all their employees are aware of these arrangements.

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Trained and suitable personnel 7

First aiders must have received training and hold a current first-aid certificate issued by a recognised training organisation.

8

Where first aiders have received first-aid instruction relating to special or unusual hazards in the workplace, they should undergo refresher training and re-examination as necessary. The Contractor must keep a written record of such training. Number of first aiders required

9

For construction, which the table categorises as 'higher risk', the recommendation is as follows.

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Number of employees

Number of first aid trained staff

10

Less than 5: At least one appointed person

11

5-100: At least one first aider or emergency first aider per 50 employees or part thereof

12

More than 100: At least one first aider per 50 employees or part thereof

13

In determining the total number of qualified first aiders required, additional factors should be considered. These are: the type of work or operations being carried out

(b)

whether or not employees work alone or in scattered and isolated locations

(c)

whether there are special or unusual hazards

(d)

whether or not there is shift work -first-aid cover will be required at all times that work is being carried out

(e)

the maximum number of people likely to be on site at any one time

(f)

the remoteness of emergency medical services

(g)

cover for first-aiders' holidays and sickness absence - first-aid cover will be required at all times that work is being carried out

(h)

the presence of work-placement trainees.

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(a)

On sites where special or unusual hazards are present, a proportionately larger number of first aiders, having regard to the factors already mentioned, will be needed. Good practice should encourage all the contractor's site personnel to be trained in basic emergency aid.

15

On major construction projects where there is a site nurse, and/or a doctor on call, their advice in connection with first aid should be followed.

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1.2.4.4 Appointed persons

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An appointed person is someone who has been nominated by the Contractor to take charge of a situation, e.g. to call an ambulance if there is a serious illness or injury.

2

They will act in the absence of the trained first aider or in situations where it is deemed that a first aider is not required, such as in a small non-hazardous working area, and where there is easy access to professional medical assistance, such as a hospital accident and emergency department.

3

Emergency first-aid training should be considered for all appointed persons.

4

Appointed persons must not be regarded as an alternative to qualified first aiders and they must not be required to render first aid. The appointed person is responsible for first-aid equipment in the absence of the first aider or in the circumstances described above.

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1.2.4.5 Equipment and facilities Location of first-aid facilities 1

It is essential that all employees should have quick and easy access to first-aid facilities on site. Where employees are working in large numbers and in close proximity, facilities should be centralised in that area. When employees are spread over a wider area, it is necessary to distribute first aiders and equipment accordingly. Sometimes, a combination of these arrangements may be appropriate.

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2


All employees must be aware of the location of first-aid facilities and the arrangements for providing treatment. The location of first-aid facilities should be clearly marked with the appropriate symbol:

.

White symbol and letters on a green background

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First-aid boxes

Every Contractor must provide one or more first-aid boxes. They should be strategically placed, readily accessible and clearly marked with a white cross on a green background. The container should hold first-aid equipment and nothing else, and should protect the contents from dust and damp.

4

It is essential that the contents of first-aid boxes are replenished after use and checked frequently by the first aider or appointed person. Some of the items are prone to deterioration after a certain period. The minimum recommended contents of the first-aid box are listed in Appendix 1, which should be adjusted following an assessment of the first aid needs of a specific site.

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who are working alone or in small groups in isolated locations, e.g. maintenance gangs

(b)

whose work involves travel in remote areas

(c)

who use potentially dangerous tools or machinery.

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(a)

The first-aid kit should only contain the items as recommended in Appendix 1.

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Special or small travelling first-aid kits should be provided to those employees:

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Travelling first-aid kits

Supplementary equipment 7

Where first aiders are employed, stretchers or appropriate carrying equipment, such as a carrying chair or wheelchair, should be provided in an accessible location clearly identified by a sign. If a site covers a large area, or contains a number of distinct working areas, it will be necessary to provide such equipment at a number of suitable locations.

8

However, it is recommended that, in most incidents, casualties are moved as little as possible before the emergency services arrive.

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First-aid rooms On a large building or construction site, a first-aid room, suitably staffed and equipped, should be provided. The need for such a room cannot be decided purely on the numbers of persons employed, but should be assessed on the type of work being carried out and whether hospital A&E or other emergency facilities are close to hand.

10

The first-aid room will normally be under the control of the first aider who should be nearby or on call, with access to the room when employees are at work. The name of this person should be displayed, together with the names and locations of all other first alders and appointed persons. On some larger sites, the first-aid room will be staffed by a qualified nurse.

11

The room should be clearly identified, available at all times and used only for rendering first aid. It should be of sufficient size to contain a couch with adequate space around it to allow people to work, and provided with an access door to allow the passage of a stretcher or other carrying equipment. Pillows and blankets should be provided and be frequently cleaned.

12

The room itself should be cleaned each working day, have smooth-topped impermeable working surfaces and provision for privacy and refuse disposal.

13

Heating, lighting and ventilation should be effective. In addition to the first-aid materials (see Appendix 1) which should be stored in a suitable cabinet, there should be:

(b)

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(c)

soap, nail brush and paper towels

(d)

clean garments for use by first-aid personnel

(e)

a suitable container for disposal of clinical waste (yellow bags).

a sink with running hot and cold water drinking water

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(a)

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In first-aid rooms that are supervised by the site nurse, other items may be provided on their advice.

15

The room should have a telephone, where possible, and a siren or klaxon to alert personnel on call.

16

A sufficient number of first aiders should be provided in any work area that is not within easy reach (approximately three minutes) of the first-aid room.

1.2.4.6 Training and qualifications 1

The Contractor is responsible for ensuring that those people who have been selected as fully

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qualified first aiders have undergone training and possess adequate qualifications. Additional training may be necessary to cope with any special hazards in a particular working environment. 2

Instruction in emergency first aid, such as resuscitation, control of bleeding and treatment of unconsciousness, is desirable for all staff. Initial selection of first aiders

3

Whilst it is desirable to appoint staff who have already received first-aid training and utilise their skills, in many instances this may not be an option. On most new sites it is unlikely that a trained first aider will be available, and it will be necessary to arrange training for a suitable member of staff.

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In selecting people for this role, the following factors should be considered: friendly, reassuring disposition

5

acceptable to male and female staff

6

able to cope with stressful and physically demanding emergency procedures

7

able to remain calm in an emergency

8

employed on a task which they can leave immediately in order to go to the scene of an emergency

9

capable of acquiring the knowledge and qualifications required.

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The First Aid training course, including examination will: (a)

normally take three full days (18 'classroom' hours), however

(b)

it need not be completed in a period of three consecutive days - 'split courses' will be permitted.

On completion of the course, each student must be able to demonstrate that they are able to:

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Training of fully qualified first aiders

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(a)

recognise minor and major illnesses

(b)

act safely, promptly and effectively with emergencies at work

(c)

use first-aid equipment, including the contents of the first-aid container

(d)

understand the duties of Contractors and the legal framework

(e)

maintain simple factual records on the treatment or management of emergencies

(f)

recognise the importance of personal hygiene in first-aid procedures.

Students must also be able to deal with a casualty who: (a)

requires cardiopulmonary resuscitation

(b)

is bleeding or wounded

(c)

is suffering from shock

(d)

is unconscious

(e)

is suffering from an injury to bones, muscles or joints

QCS 2014


(f)

has an eye injury

(g)

has been overcome by gas or fumes

(h)

has been burned or scalded

(i)

has been poisoned or exposed to a harmful substance.

13

Students must also be able to manage the transportation of the casualty as required by workplace circumstances.

14

It may be necessary to provide specialised instruction in the use of protective equipment or rescue techniques, where these are important in the trainee's workplace or if special hazards exist there.

.

Expiry of certificates First-aid certificates should be valid for three years. Re-qualification training, with reexamination, will be required before re-certification.

16

First aiders can undertake re-qualification training up to 3 months before the expiry of their current first-aid certificate. The certificate will be dated to 'run on' from the expiry date of the previous one. Ideally, Contractors will take advantage of this period.

17

However, where this is not possible or practical, re-qualification training can be taken within 28 days after the previous certificate expires.

18

Where within the 28 day period, the student:

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passes the re-qualification training, a certificate will be issued, backdated to the expiry of the previous one

(b)

fails to pass the re-qualification training, the full First Aid at Work course must be taken again, and passed, for a certificate to be issued.

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(a)

In effect, these arrangements provide Contractors with a four month window in which to get each first aider re-certificated.

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(a) (b)

can be 'split' over a longer period, but

(c)

must be completed within a period of six weeks.

Re-qualification training for fully qualified first aiders including re-examination: must last at least 12 hours (two days)

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Re-qualification training

Refresher training 21

Contractors are strongly recommended that fully qualified first aiders attend a three-hour refresher course each year to brush up on their basic skills and learn about new techniques and developments. Training of first aiders for special or unusual situations

22

First aiders should have completed training in the subjects described for first aiders, and been given any specialised training related to the particular requirements of their workplace and its hazards.

23

Some workers carry their own medication, such as inhalers for asthma or 'Epipens' which contain injectable adrenaline for the treatment of severe allergic (anaphylactic) reactions, for

QCS 2014


example to peanuts. These medications are prescribed by a doctor. If an individual needs to take their own prescribed medication, the first aider's role is limited to helping them do so and contacting the emergency services as appropriate. Training of emergency first aiders 24

Emergency first aiders must undertake a six-hour course, with their certificate being valid for three years. Similar to fully qualified first aiders, the Contractor is recommended that emergency first aiders undertake an annual three-hour basic skills update and refresher course.

25

To requalify and retain their certification for a further three years, emergency first aiders must retake the six-hour course within their three-year qualification period.

what to do in an emergency

(b)

cardio-pulmonary resuscitation

(c)

first aid for the wounded or bleeding

(d)

first aid for an unconscious casualty.

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Training records

Contractors must keep written records of all training that has been given to employees and the results of that training.

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1.2.4.7 Miscellaneous

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Ambulance

The local ambulance service should be informed about large sites and of any particularly hazardous operations being undertaken. It is helpful to supply a map locating the site and its entrances and, where appropriate, the first-aid room.

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(a)

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Training courses cover the following subjects:

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Training of appointed persons

2

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Induction

Induction training for employees and other persons joining the site should include details of the location of first-aid boxes, qualified first-aid personnel and actions to be taken in cases of injury or illness. Record of treatment

3

First-aid treatment should be recorded. The use of an accident book does not normally allow enough detail to be gathered and an additional treatment book may be necessary, particularly in order to keep a record of the use of first-aid materials.

1.2.4.8 Accident reporting 1

All accidents causing any injury must be recorded and, where necessary, reported to the Administrative Authority.

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Construction Site Safety 1.2.4 Appendix 1 Recommended contents of first-aid boxes First-aid boxes

Travelling first-aid kits

Guidance card*

1

1

Individually wrapped sterile adhesive dressings (assorted sizes)

20

6

Sterile eye pads, with attachment

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Individually wrapped triangular bandages

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Safety pins

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Medium-sized, individually wrapped, sterile, unmedicated wound dressings (approx. 12 cm x 12 cm)

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Large, sterile, individually wrapped, unmedicated wound dressings (approx. 18 cm x 18 cm)

Nil

4

2

6

2

6

Nil

2

1

Nil

6

1

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Individually wrapped, moist cleaning wipes (suggested minimum number) Disposable gloves (pair)

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Item

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Where tap water is not readily available for eye irrigation, sterile water or sterile normal saline (0.9%) in sealed disposable containers should be provided.

Travelling first-aid kits Small travelling first-aid kits are designed for use where the workforce is dispersed widely (possibly with hazardous tools), for employees working away from their Contractor's establishment.

QCS 2014


Construction Site Safety 1.2.4 Appendix 2 Health and Safety (First Aid) Checklist First-aid provision How many employees are involved?

2

How is the workforce distributed/grouped? (Widely dispersed, etc.?)

3

Are remote locations involved?

4

Are shirts worked?

5

What is the nature of the work?

6

Does it involve special operations?

7

Can particular hazards be identified, such as falls, electric shock, dangerous substances?

8

How many first aiders are needed -consider holiday and sickness cover? Training

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Which personnel require first-aid training?

10

Does the training offered meet foreseeable needs?

11

Is there a system to trigger a warning to management when a first aider is within three months of their certificate expiring?

12

Are training records kept?

13

Are individuals working in isolated locations trained to cope with emergencies?

14

Where appointed persons are in charge, do they understand their duties?

15

Does induction training cover first-aid arrangements?

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Equipment

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Is first-aid equipment placed in locations where it is likely to be needed?

17

Does it meet foreseeable needs, special hazards, etc.?

18

Are travelling first-aid kits available when required?

19

Is a first-aid room needed, or available, and suitably equipped?

20

Are information signs provided?

21

Are first-aid boxes and kits properly stocked and maintained?

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General 22

Has responsibility for first-aid provision and organisation been assigned to an individual?

23

Are there established procedures for reviewing: (a)

training and equipment needs?

(b)

new work processes?

(c)

special operations?

(d)

changes in work patterns, site locations, size of labour force?

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(e)

Section 11: Health and Safety Page 67 Part 1.02: Occupational Health and Hygiene (Regulatory Document) arrangements with contractors?

Construction Site Safety 1.2.4 Appendix 3 Health and Safety (First Aid) Basic advice on first aid at work What to do in an emergency

Assess the situation - do not put yourself in danger.

2

Make the area safe.

3

Assess all casualties and attend first to any unconscious casualties.

4

Send for help - do not delay.

5

Follow the advice given below.

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Priorities

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Check for consciousness

If there is no response to gentle shaking of the shoulders and shouting, the casualty may be unconscious. Your priorities are to:

7

shout for help

8

open the airway

9

check for normal breathing

10

take appropriate action.

11

The priority is to check the Airway, Breathing and Circulation. This is the ABC of resuscitation.

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A - Airway

To open the airway: (a)

Place one hand on the casualty's forehead and gently tilt the head back. Remove any obvious obstruction from the casualty's mouth.

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(c)

Lift chin with two fingertips.

B - Breathing 13

Look along the chest, listen and feel at the mouth for signs of normal breathing, for no more than 10 seconds. If the casualty is breathing:

14

Place in the recovery position and ensure the airway remains open.

15

Send for help.

16

Monitor that the casualty continues to breathe until help arrives. If the casualty is not breathing:

17

Send for help.

18

Start chest compressions (see CPR below).

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C-CPR To start chest compressions: Lean over the casualty and, with your arms straight, press down on the centre of the breastbone, 4-5 cm, and then release.

20

Repeat at a rate of about 100 times a minute (more than one compression per second!)

21

After 30 compressions, open the airway again.

22

Pinch the casualty's nose closed and allow the mouth to open.

23

Take a normal breath and place your mouth around the casualty's mouth, making a good seal.

24

Blow steadily into the mouth while watching for the chest rising.

25

Remove your mouth from the casualty and watch for the chest falling.

26

Give a second breath and then start 30 compressions again without delay.

27

Continue with chest compressions and rescue breaths in a ratio of 30:2 until qualified help takes over or the casualty starts to breathe normally.

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Severe bleeding Apply direct pressure to the wound.

29

Raise and support the injured part (unless broken).

30

Apply a dressing and bandage firmly in place.

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If a broken bone or spinal injury is suspected, obtain expert help. Do not move casualties unless they are in immediate danger.

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Broken bones and spinal injuries

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Burns

Burns can be serious so, if in doubt, seek medical help. Cool the part of the body affected with cold water until pain is relieved. Thorough cooling may take 10 minutes or more, but this must not delay taking the casualty to hospital.

33

Certain chemicals may seriously irritate or damage the skin. Avoid contaminating yourself with the chemical. Treat in the same way as for other bums but flood the affected area with water for 20 minutes. Continue treatment even on the way to hospital, if necessary. Remove any contaminated clothing which is not stuck to the skin.

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Burning clothing 34

To extinguish the burning clothing of anyone involved in a fire, lay, push or knock the person to the floor to reduce the spread of flames. Cover the burning area with a blanket, coat or other items to smother the flames but do not use synthetic materials (for example, polyester). DO NOT REMOVE ANY OF THE VICTIM'S CLOTHES.

35

Apply large amounts of water to the area of the burns as quickly as possible to cool the affected parts, and then keep them wet with more water. Seek medical help urgently. Eye injuries

36

All eye injuries are potentially serious. If there is something in the eye, wash out the eye with clean water or sterile fluid from a sealed container, to remove loose material. Do not attempt to remove anything that is embedded in the eye.

37

If chemicals are involved, flush the eye with water or sterile fluid for at least 10 minutes,

QCS 2014


whilst gently holding the eyelids open. Ask the casualty to hold a pad over the injured eye and send them to hospital. Record keeping It is good practice to record in a book any incidents involving injuries or illness that have been attended, including the following information in your entry:

39

Date, time and place of incident.

40

Name and job of injured or ill person.

41

Details of injury/illness and any first aid given.

42

What happened to the casualty immediately afterwards (for example, went back to work, went home, went to hospital).

43

Name and signature of the person dealing with the incident.

44

This information can help identify accident trends and possible areas for improvement in the control of health and safety risks.

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QCS 2014



Food Safety on Site


Getting food hygiene wrong can have severe implications for many other people.

2

Anyone who handles food for consumption by others: must have training in basic food handling techniques;

(b)

must report to their supervisor details of any illness that they may be suffering from;

(c)

may have to be suspended from work if they contract an infectious illness.

Premises in which food is handled, prepared and served must conform to certain standards of construction and cleanliness.

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(a)

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Food poisoning is caused by bacteria (germs or bugs) which have lain dormant in most uncooked or unprepared foods, whether meat, fish, poultry and some vegetables.

2

Food poisoning keeps people off work through sickness, just as accidents do.

3

Applying appropriate hygiene standards on site are essential because of the potential for:

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time lost through sickness absence being reduced

(b)

avoiding lost production

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1.2.5.3 Definitions

Food - food or drink of any description, or any of the ingredients used in the preparation of food.

2

Food area - any room or food area in which a person engages in the handling of food, including a server, counter or outside grill preparation area.

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The premises

The siting, design and construction of the premises must aim to avoid the contamination of food and harbouring of pests. It must be kept clean and in good repair so as to avoid food contamination.

4

Surfaces in contact with food must be easy to clean and, where necessary, disinfect. This will require the use of smooth, washable, non-toxic materials.

5

Adequate provision must be made for cleaning foodstuffs, and the cleaning and (where necessary) disinfection of utensils and equipment. You must take all reasonable, practical steps to avoid the risk of contamination of food or ingredients.

6

Washbasins must be designated for washing hands, have hot and cold (or appropriately mixed) running water, and be equipped with soap and suitable hand-drying facilities, such as disposable towels. Lavatories must not lead directly into food rooms and they must be kept clean, maintained in good repair and ventilated.

7

Adequate arrangements and facilities for the hygienic storage and disposal of hazardous and inedible substances and waste (whether liquid or solid) must be available. Food waste must not be allowed to accumulate in food rooms and should be deposited in closable containers.

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8


Adequate facilities and arrangements for maintaining and monitoring suitable food temperature conditions must be available. (See also below.) The food

9

Stored raw materials and ingredients must be kept in appropriate conditions which will prevent harmful deterioration and be protected from contamination likely to make them unfit for human consumption. Water

10

There must be an adequate supply of potable (clean, drinkable) water which must be used whenever necessary to ensure foodstuffs are not contaminated. This includes the use of ice which must also be made, handled and stored in a way that protects it from contamination.

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Foods intended for supply which need temperature control for safety must be held either HOT at or above a minimum temperature of 63°C or CHILLED at or below a maximum temperature of 8°C.

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Temperature control

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Food handlers

Anyone who works in a food handling area must maintain a high degree of personal cleanliness. The way in which they work must also be clean and hygienic. Food handlers must wear clean and, where appropriate, protective over-clothes. Adequate changing facilities must be provided where necessary.

13

Food handlers must protect food and ingredients against contamination, which is likely to render them unfit for human consumption or create a health hazard. For example, uncooked poultry should not contaminate ready-to-eat foods, either through direct contact or via work surfaces or equipment.

14

Anyone whose work involves handling food should:

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observe good personal hygiene

(b)

routinely wash their hands before handling foods never smoke in food handling areas report any illness (like infected wounds, skin infections, diarrhoea or vomiting) to their manager or supervisor immediately.

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If any employee reports that they are suffering from any condition or illness, Contractors may have to exclude them from food handling areas. Such action should be taken urgently.

16

Food handlers must receive adequate supervision, instruction and training in food hygiene. Microwave ovens

17

On sites where microwave ovens are used, the following points must be noted. (a)

Metal containers or utensils must not be placed in a microwave oven.

(b)

Door seals of microwave ovens should be periodically examined to see that they are not damaged.

(c)

Microwave ovens should not be overloaded by trying to cook too many things at the same time.

(d)

Frozen food should be properly thawed.


(e)

Food should be thoroughly cooked. Follow instructions on the packaging and leave to stand.

(f)

Do not attempt to add anything to or stir any liquid which has just been removed from a microwave oven and has not been allowed to stand, by using a metal spoon or utensil. Such an action may cause the liquid to boil violently.

(g)

Always adhere to the supplier's or manufacturer's instructions.

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Working with Lead


Lead can be a major health hazard if exposure is not prevented or adequately controlled.

2

Lead is a cumulative poison that can find its way into the bloodstream and collect in tissues, particularly the bone marrow.

3

The ways that lead is likely to get into the body are through: (a)

the inhalation of fumes or dust;

(b)

the ingestion of lead particles through hand to mouth contact.

All work with lead, or lead-containing products, must be the subject of a risk assessment.

5

Builders, carpenters, decorators etc., who remove old paint, particularly if involved in window renovation, may be exposed to 'significant' quantities of lead without realising it.

6

Where the risk assessment indicates that employees' exposure to lead is likely to be 'significant', certain monitoring actions must be taken with regard to the employees affected and the workplace itself.

7

'Significant exposure' is defined in these Regulations.

8

During health surveillance, employees' exposure to lead is measured by the concentration of lead in their blood or urine.

9

Above a certain level of exposure, Contractors have a legal duty to temporarily suspend the affected worker(s) from further work with lead.

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Exposure to lead, dust, fumes and vapour constitutes a major hazard in the construction industry who work with lead and lead products. Construction workers most at risk include: plumbers working on lead flashing, upstands and gutters

(b)

operatives handling old architectural lead work

(c)

painters rubbing down or burning off old paintwork demolition operatives

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(e)

anyone involved in structural renovation or refurbishment, including conservation or heritage projects.

1.2.6.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks in the workplace and on any control measures in place to reduce those risks.

4

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a

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risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons. The main consideration will be identifying where lead is present and taking the appropriate actions to protect the health of lead workers and, if necessary, other people who may be affected by the work.

1.2.6.4 Control of Lead at Work These Regulations aim to give greater health protection to people at work by reducing their exposure to lead and thus the concentrations of lead in their blood. Where concentrations are too high, Contractors are required to remove employees from work with lead. This is known as the 'suspension level'.

2

Concentration levels of lead in blood, which are below the suspension level and known as 'action levels', have been set.

3

If these lower levels are breached, Contractors have a duty to investigate and remedy the cause. Contractors are also required to take steps to reduce the concentrations of lead in air to a level not exceeding the occupational exposure limits stated in these Regulations.

4

The main requirements of these Regulations include:

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A Contractor who is working with lead, or a substance or material containing lead, has to protect from exposure anyone who may be affected by the work as well as their own employees. This includes: the workers of other Contractors including those not engaged in work with lead, such as maintenance staff and cleaners

(b)

visitors to the work site

(c)

the families of those who are exposed to lead at work who may become affected by lead carried home unintentionally on the clothing and footwear of the employee are particularly at risk of lead poisoning, and therefore have lower blood-lead action and suspension levels than other people.

(d)

the occupiers of premises, including private dwellings, irrespective of whether the occupiers are present whilst the work is carried out or they reoccupy the premises later.

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Duties under these Regulations

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Assessment of the risks to health Every Contractor is required to make a suitable and sufficient assessment of the risk to the health and safety of employees while at work. This includes other people who are not employees but who may be exposed as a result of the way the Contractor carries out the work concerned. The assessment must be reviewed as often as is necessary and in other certain specified circumstances, and a record made of any significant findings. Such an assessment is to allow the Contractor to make a decision whether the work concerned is likely to result in an employee being significantly exposed to lead, and to identify the measures needed to prevent or adequately control exposure. Control of exposure 7

Every Contractor must ensure that the exposure of employees to lead is either prevented or, where this is not reasonably practicable, adequately controlled by means of appropriate control measures.

8

As the preferred control measure, the Contractor must consider the use of alternative materials or processes as a means of eliminating or reducing the risks to the health of

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employees.

(a)

the design and use of the work process, systems and engineering controls

(b)

control of exposure at source, including ventilation systems, and

(c)

where adequate control cannot be achieved by other means, the provision and use of suitable PPE.

The control measure(s) must include: the safe handling, storage and transportation of lead and waste which contains lead

(b)

suitable maintenance procedures

(c)

reducing to the minimum required for the task in hand, the number of employees exposed, the level and duration of exposure and the quantity of lead present in the workplace

(d)

control of the working environment, including, where appropriate, general ventilation

(e)

appropriate hygiene measures, including washing facilities.

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Where it is not reasonably practicable to prevent exposure to lead, the Contractor must introduce protective measures which are appropriate to the work activity and consistent with the findings of the risk assessment. In order of priority, these must be:

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9

Irrespective of these control measures, where the exposure to lead is, or is likely to be significant, the Contractor must provide suitable and sufficient protective clothing.

12

Where the inhalation of lead fumes is possible, the control measures will only be regarded as adequate if:

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the occupational exposure limit is not exceeded

(b)

or if it is, the Contractor identifies the reason and takes immediate steps to rectify the situation.

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(a)

Contractors must take reasonable steps to ensure that any control measure provided is properly used or applied.

14

Employees must make full and proper use of any control measure provided, and: take all reasonable steps, where appropriate, to return anything provided as a control measure to its accommodation (storage) after use

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(i)

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report any defect in any control measure provided to the Contractor.

Adequate control of exposure to lead covers all routes of possible exposure, such as inhalation, Absorption through the skin and ingestion. Eating, drinking and smoking

16

Adequate steps must be taken to control the ingestion of lead. A Contractor must ensure that, as far as is reasonably practicable, employees do not eat, drink or smoke in any place which is, or is liable to become, contaminated by lead. In practical terms, employees must be warned against doing so. Furthermore, under these Regulations employees have a legal duty not to eat, drink or smoke in any place that they have reason to believe is contaminated by lead. Maintenance, examination and testing of control measures

17

All control measures provided, including PPE, must be well maintained, kept in a good state of repair and cleaned as necessary. Any defect in the equipment, or failure to use and apply

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it properly, which could result in a loss of efficiency or effectiveness, thus reducing the level of protection, should be identified and rectified as soon as possible. Air monitoring 18

Where employees are liable to receive significant exposure to lead, Contractors must establish a programme of air monitoring including keeping records of the findings of such monitoring. Medical surveillance Where exposure to lead is significant, the Contractor must: (a)

make sure that employees are under medical surveillance by a 'relevant doctor'

(b)

provide suitable facilities for health surveillance to be carried out where the procedures are to be carried out at the Contractor's premises

(c)

maintain health surveillance records and retain them for 40 years

(d)

allow employees reasonable access to their personal health records

(e)

take steps to determine the reasons why any employee's blood sample exceeds the appropriate action level and take appropriate remedial action

(f)

take the necessary actions, including reviewing the risk assessment, where an employee's blood or urine sample reaches the 'suspension level'.

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Employees for whom health surveillance has been arranged must, when required by the Contractor (and at the cost of the Contractor), make themselves available for the necessary health surveillance procedures and supply the relevant doctor with such health-related information as the doctor may require.

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Contractors who undertake work liable to expose employees to lead shall provide such information, instruction and training as is suitable and sufficient to know the risks to health, and the precautions which should be taken.

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Information, instruction and training

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The Contractor, in attempting to protect the health of employees from an accident, incident or emergency, must ensure that procedures, including the provision of first aid facilities and safety drills, have been prepared and can be put into effect should such an occasion arise. The Contractor must also ensure that information on such emergency arrangements has been notified to accident and emergency services and that all such information is displayed within the workplace.

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Arrangements for accidents, incidents and emergencies

1.2.6.5 Training 1

There is a specific requirement to ensure that the information, instruction and training provided for persons working with lead includes: (a)

the type of lead being worked, the potential health hazards and symptoms

(b)

the relevant occupational exposure limit, action level and suspension level (as explained)

(c)

any other sources of information

(d)

the significant findings of the risk assessment

(e)

the control measures that are in place and which must be used to enable work to be

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Section 11: Health and Safety Page 77 Part 1.02: Occupational Health and Hygiene (Regulatory Document) carried out safely

(f)

the results of any monitoring carried out

(g)

the results of previous health surveillance, in such a way that the confidentiality of individual cases is not breached.

1.2.6.6 Personal Protective Equipment These Regulations require that where a risk of exposure to lead has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, the Contractor must provide personal protective equipment (PPE) and ensure it is properly used by employees.

2

Users of PPE must be trained in its use and care as appropriate.

3

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are not reasonably practicable.

In the context of this section the important requirements of these Regulations are for provision of adequate welfare facilities, particularly in respect of personal hygiene. Contractors must provide or make available:

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suitable and sufficient washing facilities, including showers if necessary due to the nature of the work

(b)

hot and cold (or warm) water, soap or other cleanser and towels or other effective means of drying

(c)

suitable and sufficient changing rooms

(d)

lockers or other facilities in which to secure work clothing that is not taken home and personal clothing that is not worn at work

(e)

suitable rest facilities where meals may be prepared and eaten.

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1.2.6.8 Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job for which the equipment is going to be used.

2

These Regulations also require that users of work equipment are trained in its use, as appropriate.

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1.2.6.9 Control of exposure to lead in the workplace The hazard 1

Lead is a cumulative poison that will find its way into the bloodstream and can collect in tissues, particularly the bone marrow. Lead poisoning may occur through exposure to lead in its pure form or exposure to products containing lead.

2

Lead affects the body's ability to produce haemoglobin, which is the protein in blood that carries oxygen to the tissues.

3

Inorganic lead, the type likely to be encountered during construction activities, can enter the body in one of two ways: (a)

by inhalation of dust or fumes

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(b)

Section 11: Health and Safety Page 78 Part 1.02: Occupational Health and Hygiene (Regulatory Document) via the digestive tract from hand-to-mouth transfer of lead particles.

4

Inhalation is by far the most common route of entry.

5

Whilst the control of exposure through inhalation will be largely controlled by actions taken by the Contractor, the control of exposure through ingestion depends upon the good personal hygiene practices of employees working with lead. Risk assessment

6

Contractors must not carry out any work that may expose employees to lead unless a suitable and sufficient risk assessment has been carried out.

7

The purpose of the risk assessment is to enable the Contractor to: assess whether the exposure of employees to lead is likely to be significant

(b)

identify the measures necessary to prevent or control exposure.

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Control measures

Control measures involve substituting lead with less hazardous substances or, if this is not possible, using engineering and organisational methods, similar to those outlined for COSHH, to control exposure.

9

The control of exposure to lead (by inhalation) will only be regarded as adequate:

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if the concentration of lead in air is kept below the OEL (see below)

(b)

if, where the OEL is exceeded, the Contractor identifies the reasons and takes immediate steps to remedy the situation.

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Air monitoring

Where a risk assessment indicates that employees may be liable to significant exposure to lead, the Contractor must arrange for air monitoring to be carried out to establish the levels of lead in the air at the place of work.

11

Air monitoring will involve using specialist equipment, which is fitted to the employee being monitored, to take an air sample from the employee's 'breathing zone' over a set period of time.

12

Using static air-monitoring equipment to take air samples is not acceptable as the results will not be representative of any employee's personal exposure.

13

Generally, depending upon the circumstances, monitoring must be carried out at either three-monthly or yearly intervals. Air monitoring will determine whether the OEL has been breached.

14

The Contractor has a duty to retain records of air monitoring results for a period of five years.

15

Given the temporary nature of construction sites, and the even shorter periods when employees might actually be exposed to lead, the above requirement is considered to be largely academic for the construction industry. With tradesmen such as plumbers and painters being potentially exposed to lead many times but over relatively short periods, it will be for the Contractor to decide how frequently air monitoring should be carried out to confirm whether or not existing control measures are adequate.

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Occupational Exposure Limit (OEL) 16

The standard for inorganic lead in air is 0.15 milligrams of lead per cubic metre of air determined on an eight-hour time-weighted concentration.

17

This quantifies the standard to be met by the control measures for airborne lead under these Regulations. Medical surveillance Medical surveillance to detect exposure to lead involves measuring the concentration of lead in the blood or urine and therefore necessitates the involvement of suitable trained, medical staff.

19

Where a risk assessment indicates that employees' exposure to lead is likely to be significant, the Contractor has a duty to arrange medical surveillance for the affected employees.

20

If medical surveillance detects blood-lead concentrations at or above those outlined below, this will trigger continued surveillance: all employees: 35 micrograms of lead, or greater, per decilitre of blood.

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young persons (aged 16-17): 40 micrograms of lead per decilitre of blood

(b)

all other employees: 50 micrograms of lead per decilitre of blood.

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If medical surveillance detects blood-lead concentrations at or above these action levels, the Contractor must: recognise that the employee's blood-lead level is near the 'suspension level'

(b)

investigate the effectiveness of existing control measures and take the necessary actions to reduce employees' blood-lead levels below the action level

(c)

prevent the blood-lead level of affected employees from reaching the suspension level.

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The action levels for lead are:

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Action levels

Suspension levels 23

24

If medical surveillance reveals that an employee's blood-lead level has reached or exceeded the levels outlined below, a doctor must decide whether to temporarily suspend them from work which exposes them to lead: (a)

young persons (aged 16-17): 50 micrograms of lead per decilitre of blood

(b)

all other employees: 60 micrograms of lead per decilitre of blood.

In such circumstances, the Contractor must: (a)

ensure that a doctor makes an entry in the health record of affected employee(s) as to whether, in the doctor's professional opinion, they should be suspended from further work liable to expose them to lead

(b)

review the relevant risk assessment

(c)

review the actions taken to prevent exposure to lead

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(d)

provide for a review of the health of any other employees who may have been similarly exposed.

25

If the doctor thinks that there is no need to suspend the affected employee(s) from work, the doctor must note in their health records: (a)

the reasons for that decision

(b)

any conditions under which working with lead may continue.

26

A Contractor must act on the doctor's decision and an employee will not be able to work with lead again or be exposed to it until the doctor considers it safe to do so.

27

(Refer to Appendix 2 for an example of a health surveillance record form.)

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Significant exposure to lead can occur where:

any employee is, or is liable to be, exposed to a concentration of lead in the atmosphere exceeding half the occupational exposure limit for lead

(b)

there is a substantial risk of an employee ingesting lead

(c)

there is a risk of contact between the skin and lead alkyls or other substances containing lead which can be absorbed through the skin.

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Significant levels

Contractors must provide employees with protective clothing, monitor lead in air concentration, and place the employees concerned under medical surveillance.

30

Personal protective equipment will be required where control measures are not practicable.

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Some types of work with lead carried out as part of construction or decorating activities, have the potential to result in significant exposure to lead unless the Contractor provides adequate controls and ensures that they are used. For example:

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Types of work liable to result in significant exposure to lead

burning off old paint

(b)

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high temperature lead-work such as lead smelting, burning and welding

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(d)

working with metallic lead and alloys containing lead, for example, soldering

(e)

disc abrasion of lead surfaces and cutting lead with abrasive wheels

(f)

spray painting with lead-based paints

(g)

work inside tanks that have contained petrol

(h)

manufacture of leaded glass

(i)

hot cutting, demolition and dismantling operations

(j)

otherwise removing or disturbing old lead sheet thereby raising contaminated dust

(k)

recovering lead from scrap and waste

(l)

welding galvanised metal and flame cutting steelwork that has been painted with leadbased paint.

Those operations which do not usually produce significant levels include low temperature work, ordinary plumbing, soldering, handling clean sheets or pipes of lead, rough painting.

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How does lead affect your health? 33

If the level of lead in the body gets too high, it can cause headaches, tiredness, irritability, constipation, nausea, stomach pains and loss of weight. Continued uncontrolled exposure could cause far more serious symptoms, such as kidney damage, nerve and brain damage. A developing unborn child is at particular risk from exposure to lead, particularly in the early weeks before a pregnancy becomes known. Prevention of exposure The Contractor has a duty to assess the nature and extent of the exposure to lead and, on the basis of this assessment, to determine the measures necessary to control exposure and comply with these Regulations.

35

Action should be taken to reduce the amount of lead breathed by operatives to below the lead in air standard.

36

The basic need is to prevent the liberation of lead dust, fumes or vapour into the workplace.

37

If surface finishes are to be disturbed, always check for the presence of lead paint or, if this is not possible, assume the worst (that it is a lead-based paint) and take the appropriate precautions.

38

Ways of testing for the presence of lead include:

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a variety of destructive tests for paint sampling, although these result in damage to painted surfaces in order for samples to be taken

(b)

disposable test kits: instant, on-site lead/no lead result with 95% accuracy. (These are an indicator only, not a laboratory-standard test)

(c)

paint-sampling kits which are ready-to-use (for non-lab professionals) for submission of samples for chemical analysis. A laboratory-standard test

(d)

dust-wipe sampling kits which are ready-to-use dust sampling kits (for non-lab professionals) for submission of samples for chemical analysis. A laboratory-standard test

(e)

hand-portable devices that use XRF (x-ray fluorescence) technology to obtain laboratory standard readings instantly, on site.

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1.2.6.10 Personal protective equipment Respiratory protective equipment 1

Where control measures do not reduce the lead in air levels to below the control limits, respiratory protective equipment of a type suited to the hazard or process involved must be provided, and all employees must be properly trained to use it. All such equipment should be serviced, cleaned, maintained and stored correctly, as is appropriate.

2

Depending upon whether the hazard is lead dust or fumes, adequate protection will be given by the use of compressed air-line breathing apparatus, self-contained breathing apparatus, or a full-face positive pressure powered respirator fitted with a high efficiency filter. Protective clothing

3

Wherever exposure is significant, protective clothing must be provided. It must be suited to the hazard or process involved, should resist the permeation of lead dust, and not collect or harbour dust. Employees must be instructed to report any damaged or defective ventilation plant or protective equipment, without delay, to their supervisor or safety representative.

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1.2.6.11 Working with lead-based paints 1

The residues of lead-based paints are a health hazard. Operatives carrying out the removal of old lead-based paint, and anyone else who might be adversely affected, must be adequately protected when applying or removing paints containing lead.

2

Similarly, the occupiers of premises (including the residents of private housing) must be protected by not being allowed to return to their premises (or contaminated parts of those premises) until they have been thoroughly and effectively cleaned (see below).

3

The findings of a risk assessment, carried out before any surface finish is disturbed, will indicate the most appropriate of removal and safety precautions which must be taken.

4

See Appendix 3 for specimen record details.

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Sanding

Unless appropriate RPE and protective clothing are worn, old lead paint should never be drysanded by hand as this activity will liberate lead-rich dust into the air. Again, unless appropriate RPE and protective clothing are worn and effective measures are taken to clear up the residue, mechanical sanding can only be used if the sander is fitted with a dust extraction/ collection unit incorporating a high efficiency particle air HEPA filter.

6

Wet sanding of lead-based paint is acceptable, providing the residue is collected before it dries out with the potential to become airborne dust.

7

As a result, the subsequent dry sanding of apparently 'clean' wood can liberate a significant amount of lead-containing dust into the air.

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Unless appropriate RPE is worn, blow-lamps or gas torches must not be used to burn off old lead paint as these will heat the paint sufficiently to liberate lead fumes into the air.

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Lead paint may be removed by using a solvent or water-rinseable paint remover. If a solvent is used, the work area must be well-ventilated and no smoking or naked flames allowed. Suitable RPE and other appropriate PPE should be used.

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Solvents

Hot-air gun 10

These must not be confused with blow-lamps and gas torches. A hot-air gun will not raise the temperature of the paint sufficiently to allow lead fumes to be created. When using a hotair gun, the old paint must be scraped off as soon as it is sufficiently soft and before it rehardens. Care must be taken to ensure that the paint does not burn as this indicates that it is reaching too high a temperature where fumes may be given off. The use of RPE to protect against lead-containing dust may be necessary. Infra-red heating

11

A product is available that safely lifts the old paint from the base material by heating it to a safe temperature using an infra-red heater. Whilst warm, the paint can be safely scraped off. This method is particularly suitable where large surface areas have to be stripped.

12

The main benefits of using this method, which acts by heating the resins in the wood and breaking the bond between the wood and the first layer of paint, are:

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(a)

all layers of paint are removed in 'a single hit'

(b)

virtually all residual lead is removed from within the grain of the wood

(c)

large surface areas can be safely stripped more quickly than by using other methods.

Spraying 13

Spraying methods should not normally be employed for applying lead-based paints. Cleaning up the work area All surfaces that have been stripped of paint should be washed down thoroughly, either with a proprietary lead-specific detergent or with a solution of dishwasher detergent in hot water, and then wiped down again with clean water.

15

Any residual dust and other debris should be removed using a vacuum cleaner fitted with a HEPA filter. Depending upon the level of contamination, it may be necessary to wear appropriate RPE whilst doing this.

16

Normal vacuum cleaners (domestic or industrial) should not be used as their filters are not sufficiently efficient to retain the lead-containing dust.

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Anyone who works with lead should take simple personal hygiene measures to prevent the inhalation or ingestion of lead during and after work.

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1.2.6.12 Personal hygiene

To avoid any risk to health or damage to any clothing concerned, the Contractor must provide separate accommodation for an employee's own clothing and any protective clothing the employee may have to wear at work. This requirement will normally apply for protective clothing worn for work with lead.

3

Adequate and suitable washing facilities are required where operatives are exposed to lead. Where employees are exposed to lead, washing and changing facilities provided should allow them to meet a high standard of personal hygiene so as to minimise the risk of them ingesting or otherwise absorbing lead.

4

The design of the washing facilities should be related to the nature and degree of exposure to lead as indicated by the assessment. Where employees are significantly exposed to lead, and if washbasins alone would not be adequate, the washing facilities should include showers or baths.

5

An example would be where work is carried out in dusty conditions which could result in the whole body being contaminated by lead. Then the provision of showers or baths would be essential.

6

Washing facilities should provide at least:

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(a)

one washbasin for every five persons. Basins should be of sufficient size to permit arms to be immersed up to the elbow

(b)

a constant supply of hot and cold or warm water (running water where reasonably practicable)

(c)

soap or other cleaning materials

(d)

nail brushes

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(e) 7

Section 11: Health and Safety Page 84 Part 1.02: Occupational Health and Hygiene (Regulatory Document) warm air dryers or roller towels; communal towels should not be used.

For certain types of work, such as lead work, carried out at premises or sites where such work is not regularly done (for example, certain tank cleaning and lead burning operations), mobile caravan type washing/showering facilities of suitable design should be provided. Eating, drinking and smoking These Regulations require Contractors to reduce the risk of ingestion of lead by ensuring that employees do not eat, drink or smoke in places which are contaminated, or likely to be contaminated, from lead arising from work activities. Therefore, Contractors should reduce the risk of employees ingesting lead by ensuring that they are given adequate information on the specific areas that might be contaminated by lead and in which they should not eat (including chewing gum or tobacco), drinker smoke.

9

The information should be reinforced by displaying a prominent notice to identify those areas in which employees may, or may not, eat, drink or smoke.

10

The following points should be noted:

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clean areas, canteens or mess rooms should be isolated from lead-contaminated work areas

(b)

protective clothing should be removed before entering these areas

(c)

washing should take place before eating meals or drinking

(d)

the Contractor must advise employees where they may not eat, drink or smoke

(e)

Employees are not to eat, drink or smoke in any place where there is risk of contamination by lead.

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Construction Site Safety 1.2.6 Appendix 1 Lead hazards Safety checklist Has a risk assessment been carried out?

2

Have all persons who have to work with lead received adequate information, instruction and training?

3

Has the nature and extent of any exposure to lead been assessed?

4

Is the monitoring of lead in air levels carried out?

5

Is medical surveillance of individuals necessary and, if so, undertaken?

6

If medical surveillance is necessary, are medical records kept as required?

7

Are measures in place to control levels of exposure to lead?

8

Is protective equipment and clothing in use, as necessary and required?

9

Is the correct type of respiratory equipment being used for the hazard being encountered?

10

Are measures being taken to control the spread of any lead contamination?

11

Is there adequate provision of washing and changing facilities?

12

Are separate areas provided for eating and drinking?

13

Are all operatives adequately trained in safe working procedures?

14

Are operatives aware of the risks to health that can arise from not working safely?

15

Are records being kept as required by these Regulations?

16

Are arrangements in place to deal with accidents, incidents and emergencies?

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Construction Site Safety 1.2.6 Appendix 2 Specimen health surveillance record Recorded details of an employee under medical surveillance because of exposure to lead

Employee's details Name:

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Permanent address:

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Place of birth:

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Date of birth:

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Sex:

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Doctor's details

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Name:

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Address:

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Telephone number:

Contractor's details Name: Address: Telephone number:

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Employment details Years exposed to lead before starting of current employment: Date of first exposure to lead in current employment: (Day Month Year)

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Date of end of exposure to lead in current employment: (Day Month Year)

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Additional information

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a) the reason for medical surveillance b) the dates of initial and periodic medical surveillance

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c) the results of clinical assessments

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d) the results of measuring blood-lead concentrations and of any other biological tests in enough detail to allow adverse trends to be identified, and

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e) action taken, including periods moved to work not involving exposure to lead, and periods of suspension.

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Manual Handling


Poorly thought out or badly performed manual handling activities are the cause of many injuries to construction workers.

2

'Manual handling' includes lifting, lowering, pulling, pushing or carrying a load by physical effort.

3

Several factors will determine whether it is safe for an individual to manually handle any particular load.

4

Contractors must:

(b)

where that is not reasonably practicable, assess the risks to the employee;

(c)

put in place control measures to prevent such an injury occurring.

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avoid so far as reasonably practicable their employees having to carry out manual handling activities likely to result in an injury;

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Employees must:

make full and proper use of the Contractor’s safe system of work;

(b)

use (lifting) equipment and machinery in accordance with instruction and training given;

(c)

report to the Contractor any situation where it is considered that the system of working is not safe.

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(a)

Where sustaining an injury is a possibility and handling a load cannot be avoided, using a mechanical means of carrying out the activity is the best solution.

Note:

Section 1, Part 9.2 of the QCS covers the manual handling of materials.


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All construction and building work involves lifting and handling to some extent. Although mechanical equipment should be used whenever practicable, much of the work will inevitably continue to be done manually. The risk of injury can be greatly reduced by a knowledge and application of correct lifting and handling techniques and by taking a few elementary precautions.

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These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity, including those that involve manual handling, to identify any hazard to employees which might be encountered during their work, or to any other person who might be affected by their operations.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place, either to remove the hazard or, where this is not possible, to reduce the risk of injury resulting from manual handling activities, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any (manual handling) risks that exist in the workplace and any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty under these Regulations to inform the Contractor of any work (manual handling) situation that presents a risk to themselves or others.

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2

These Regulations specify how Contractors have to deal with risks to the safety and health of employees who have to carry out manual handling in the course of their employment, as follows: (a)

Assess the manual handling task to identify any risk that may be inherent in the operation.

(b)

Avoid the need to carry out manual handling as far as possible.

(c)

Where a risk is identified, implement control measures to reduce that risk.

The requirements relevant to lifting and handling are described below.

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make a suitable and sufficient assessment of all such manual handling operations to be undertaken by their employees.

(b)

take appropriate steps to implement control measures, thereby reducing the risk of injury to those employees undertaking any manual handling operations, to the lowest level which is reasonably practicable

(c)

take appropriate steps to provide any of those employees who are undertaking any manual handling operations with general indications and, where it is reasonably practicable to do so, precise information on:

(d)

the weight of each load

(e)

the heaviest side of the load whose centre of gravity is not positioned centrally.

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(a)

Any assessment that a Contractor has made must be reviewed where: (a)

there is reason to suspect that it is no longer valid, or

(b)

there has been a significant change to the manual handling operations to which that assessment relates.

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Each Contractor shall, so far as is reasonably practicable, avoid the need for employees to undertake any manual handling operations at work, that involve a risk of their being injured; or where this is not reasonably practicable, each Contractor shall:

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Contractor's duties

Where changes to an assessment are required, as a result of any review, a Contractor shall make them.

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When determining for the purposes of these Regulations whether manual handling operations at work involve a risk of injury, and to determine the appropriate steps needed to reduce that risk, particular regard shall be taken to check:

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(a)

the physical suitability of the employee to carry out the operation

(b)

the clothing, footwear and other personal effects worn by the employee

(c)

the employee's knowledge and training

(d)

the results of any relevant risk assessment carried out

(e)

whether the employee is within a group of employees identified by that assessment as being especially at risk

(f)

the results of any health surveillance already carried out

Contractors must additionally: (a)

provide safe systems and places of work

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(b)

ensure the safety of their employees and, where possible, the absence of risks in the handling, storage and transport of all types of articles and substances

(c)

provide the information, instruction, training and supervision necessary to ensure the health and safety of their employees.

Employee's duties It is the duty of each employee, while at work, to: (a)

make full and proper use of any system of work provided for use by the Contractor in connection with manual handling.

(b)

Use any machinery or equipment provided by the Contractor in accordance with any training or instruction received.

(c)

Inform the Contractor, or anyone else responsible for safety, of any dangerous work practice or shortcomings in the Contractor's arrangements for safety.

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Designers have the potential to minimise the amount of manual handling that is necessary during any construction project and therefore the injuries that might arise from it. Examples of how this might be achieved are: designing site layouts such that 'double handling' is eliminated and manual handling distances are minimised

(b)

incorporating mechanical lifting points into components that would otherwise have had to be manually handled into. place

(c)

taking advantage of technological advances by specifying modern components made from lighter material

(d)

ensuring that designs allow for adequate access for construction plant, such as excavators and dumpers, where excavation work and other earth-moving activities are necessary.

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Strains and sprains to muscles and joints, torn ligaments and tendons, disc trouble and hernias. These are often caused by sudden and awkward movements, for example, twisting or jerking while lifting, or handling heavy loads. They are also caused by persons attempting to lift loads beyond their physical capabilities. The muscles of the abdominal wall are particularly vulnerable, and excessive strain may lead to ruptures.

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1.2.7.6 Common injuries

(a)

Cuts and abrasions from rough surfaces, sharp or jagged edges, splinters, projections, etc. Personal protective equipment and clothing should be worn as necessary, such as leather gloves to protect the hands.

(b)

Back injuries are most frequently sustained while lifting and handling manually. They may be the cumulative effect of repeated minor injuries, or the result of an abrupt strain. Stoop lifting (see below) should be avoided; it greatly increases the chances of sustaining back injuries.


The risk of injury is reduced by a knowledge of correct lifting techniques and by not attempting to lift excessively heavy loads without assistance.

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Crushing of limbs, etc. by falling loads, or by fingers, hands or feet becoming trapped by loads.

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Correct positioning of hands and feet in relation to the movement of the load is essential. Timber wedges or other blocks should be used when beginning to raise or lower heavy loads to enable a secure grip to be achieved and to prevent fingers and hands becoming crushed when lowering the load. Safety shoes with steel toecaps will protect the feet. Soles of footwear should also provide a secure grip.

1.2.7.7 Making an assessment 1

Completing the assessment is the Contractor's responsibility. Expert help may be needed in difficult or unusual cases.

2

Often assessments can be done by a team of people and, although employees should not make their own assessments, their involvement will often be beneficial.

3

A Contractor should make provision for properly trained manual handling assessment teams, but if there are special difficulties and it is decided to call in outside assistance, the Contractor should ensure that the person engaged is competent to make the type of assessments required and that clear instructions are given.

QCS 2014


The wide range of manual handling tasks that arise on every building and construction site need to be fully identified. This should be systematically carried out by looking at individual tasks and the way in which they are carried out.

5

By grading these factors, e.g. low/medium/high, the assessor will be able to more clearly identify the overall risk.

6

Whilst carrying out the assessment, the assessor should consider ways of reducing any risk found.

7

An assessment should not just be a paper exercise but should be used to pinpoint the unsafe features of the work task, so that the Contractor may improve the situation, by implementing control measures.

8

It is quite acceptable to group any manual handling tasks which have common features into a single manual handling assessment, but care must be taken to ensure that the range of risks is common to all tasks covered by the single risk assessment. However, when taking this approach, it can be tempting to make a task fit the assessment rather than make the assessment fit the task. The important thing is to identify any risk of injury, and then point the way to practical improvements.

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Significant findings should be recorded and kept, but this is not necessary if the findings are obvious and the assessments easily repeated.

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1.2.7.8 Lifting capacities

The weight that can be lifted by any individual will vary according to personal physique, age, condition and practice, and the techniques employed. Lifting capacity declines with age and an older person may not be capable of lifting the same load as a younger person; this, however, can be offset to some extent by employing a better technique.

2

The general rule is that the load should not be lifted if it causes a feeling of strain. Assistance should be available if required, and employees must not be required to lift loads beyond their capacity.

3

Youthful exuberance and bravado often tempt younger employees to attempt to lift loads that are too heavy. While they may succeed in the short term, long-term damage may be done to the ligaments, muscles and back.

4

If single person handling is needed, either blocks or other materials of 20 kg or lighter should be specified and used, or other precautions should be implemented to reduce the risk by, for example, the provision of mechanical handling.

5

With blocks or other materials weighing less than 20 kg, manual handling risks are still significant and suitable precautions should be taken to minimise these risks as much as possible.

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1.2.7.9 Abdominal belts 1

Research has shown that abdominal belts do not necessarily prevent manual handling injuries and may, in some cases, make things worse.

1.2.7.10 Preparing to lift 1

Before lifting and handling any load, the following points should be established: (a)

What has to be moved?

(b)

Does it really have to be moved?

QCS 2014


(c)

What does it weigh?

(d)

Can it be broken down into smaller loads?

(e)

Can the process that requires it to be moved be changed?

(f)

Where is the load's centre of gravity?

(g)

Can it be safely handled by one person?

(h)

Will assistance be required?

(i)

Can the move be carried out more safely with mechanical assistance?

(j)

How far does it have to be moved and from where to where?

(k)

Is the route clear of obstructions?

(l)

Can it be put down safely?

Suitable protective clothing should be worn. This may include gloves, safety footwear, safety helmets, and special overalls if hot or corrosive substances are to be carried.

3

Ensure that the lifting and lowering areas are clear of tripping hazards, and likewise check the route over which the load is to be carried.

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1.2.7.11 The load

Large, heavy loads should, if possible, be broken down into smaller, lighter and more manageable sizes. It is obviously easier to lift 10 kg five times than to try and lift 50 kg once.

2

Where the load has to be moved by a woman, the weight should be reduced by approximately 30%.

3

As a rough guide, where lifting is repetitive, weights should be reduced as follows:

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Special factors in operation

Rough guide Reduce weight by 30%

Operation repeated five to eight times a minute

Reduce weight by 50%

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Operation repeated once or twice a minute


'Average' female


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Operation repeated more than 12 times per minute

Handler twists through 45 degrees


Handler twists through 90 degrees


Handler seated and twisting

Less than 5 kg

Handler seated

About 5 kg

About 25 kg for starting or Pushing or pulling a load (assuming that force is applied with stopping a load About 10 kg hands between knuckle and shoulder height) for keeping a load in motion

4

The size and shape of a load may be as significant as its weight in determining whether assistance is required. Large awkward loads, which require the arms to be extended in front of the body, place more strain on the back and abdomen than compact objects carried close to the body.

QCS 2014


The absence of natural or designed handling points can also make it difficult to raise and carry objects without strain and may require barrows or other lifting and handling aids.

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Not all loads need to be carried, of course. It may be easiest to roll or push them, depending on the contents. Even so, assistance might still be required to avoid the risk of injury.

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1.2.7.12 Kinetic method of lifting

Kinetic handling must be taught by trainers. It cannot be 'picked up'. It is important that postural errors are corrected during training before bad habits are established.

2

The main features of this method are that it: utilises the strong leg and thigh muscles - not the weaker back muscles as in stoop lifting

(b)

maintains the natural shape of the spine throughout the lift. Although the body may be bent over, the spine remains straight

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(a)

uses the momentum of body weight to initiate forward movement.

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(c) 3

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The correct posture (such as the position of various parts of the body) in performing a task is essential. Important points are: (a)

correct position of feet

(b)

knees bent

(c)

straight back

(d)

arms close to body for lifting and carrying

(e)

correct grip or hold

(f)

chin in, head up

(g)

use of body weight.

Some lifting and handling techniques employing the kinetic method are described on the next page.

QCS 2014


Bend at the knees (1) 5

The weight to be lifted must be within the lifting capacity of the individual worker and the load should be approached squarely, facing the intended direction of travel. The feet are positioned about a hip's width apart, one foot SLIGHTLY in front of the body. The knees are bent and the body lowered as close to the load as possible while remaining relaxed and balanced. The back should be straight from hips to shoulders, but not necessarily vertical. Grasp the load (2)

6

The load is tilted with one hand (if necessary) so that the other hand can obtain a secure grip at the corner nearest the body. The free hand is then transferred to the furthest corner of the load and drawn as close to the trunk as possible. Arms should be well tucked in to provide maximum support to the load.

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Lift, using the legs (3)

The load can then be lifted by straightening the legs so that the body and load move upwards in unison. All movements should be smooth and natural. Jerking, twisting or straining movements should be avoided.

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Lifting should feel comfortable. Lifting movements will remain smooth and natural providing the back and head are kept naturally erect. This is achieved by looking straight ahead when straightening the legs, instead of looking down at the load.

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Carrying the load (4)

The load should be held firmly into the body and carried to where it is to be deposited. The closer the centre of gravity of the load can be kept to the body, the easier and more natural the lift. It is important to be able to see over or around the load so as to avoid tripping hazards.

10

When the weight is approaching the maximum lifting capacity of the individual, it will be necessary to lean back on the hips with the load to bring the trunk to the erect position before straightening the legs to lift the load. In this instance the body is being used simply as a counterbalance to keep muscular effort to a minimum.

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1.2.7.13 Changing grip 1

Grips should not be changed while carrying the load. First rest the load on a ledge or other firm support, then change

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the grip if necessary.

1.2.7.14 Stacking 1

Loads should not be lifted above shoulder height. When it is impossible to lift and stack with the elbows tucked into the sides of the body, a platform should be used to stand on. An intermediate platform should also be used when lifting loads down from a higher level.

1.2.7.15 Use of a lifting platform The squat position is adopted as near to the load as possible. Keeping a straight back and using the leg muscles, the load should be lifted onto a platform. The person lifting the load then stands as near to the platform as possible and, bending at the knees and hips (NOT the back), eases the load onto their shoulder, adjusts for balance and straightens at the knees and hips.

2

For lowering the load, the procedure is reversed.

3

Carrying a load under one arm, supported on the hip, causes strain and should be avoided.

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1.2.7.16 Hand hook or lifting aids

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Hand hooks or lifting aids should be used if loads are unwieldy or so irregular in shape that a good grip cannot be maintained. If hooks are being used, care must be taken to ensure that the contents of the load are not damaged.

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1.2.7.17 Team lifting

When large or awkward weights are involved, assistance should be sought. The person assisting should be of similar height and build, so that the raised load does not become unbalanced or unevenly distributed.

2

Co-ordinating team activity is important in team lifting. One person should give directions during all lifting, carrying and lowering operations.

3

Properly designed lifting aids will enable some tasks to be performed more quickly and easily, and eliminate the risk of injury or damage.

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1.2.7.18 Using rollers to move a load 1

Lengths of steel pipe or proper rollers can be used to roll or slew heavy crates. The load is

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pushed gently forward on two or more rollers, and further rollers are inserted under the front end as necessary. Care must be taken by the person placing the rollers to avoid being trapped as the load moves forward, and to ensure that those pushing do not trip over the rollers that have previously been used.

3

Whenever practical, mechanical handling and lifting should replace manual techniques. This will reduce the risk of fatigue, improve efficiency and reduce the risk of accidents.

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Construction Site Safety 1.2.7 Appendix 1 Safety checklist Manual handling and lifting Preparation What is being lifted?

2

Where to and how far?

3

Has a manual handling risk assessment been carried out?

4

Would mechanical means be more practical or appropriate?

5

Is the operation part of a routine? If so, could it be more effectively planned and executed?

6

How many people will be needed to move the load safely?

7

Are they all trained in kinetic lifting and handling?

8

Are proper (kinetic) lifting methods being employed?

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What methods and equipment will be required?

10

Is the required equipment available?

11

Is the lifting and handling area clear of hazards?

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Lifting and handling

Is the proper personal protective clothing in use?

2

Is co-ordination satisfactory in dual and team lifting with one person taking charge of the lift?

3

Is the necessary equipment in use or to hand?

4

Are excessively heavy weights being lifted?

5

Are loads being deposited or stacked safely and securely?

6

Is adequate supervision employed where necessary?

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After lifting and handling Are any incidents or accidents reported and recorded?

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Where injuries have been sustained, has medical attention been sought?

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Is the damage or loss of equipment recorded?

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Construction Site Safety 1.2.7 Appendix 2 Manual handling of loads: Assessment checklist Section A - Preliminary Task name:

Is an assessment needed? (An assessment will be needed if there is a potential risk of injury, eg if the task falls outside the guidelines) Yes/No*

Task description:

Load weight:

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Frequency of lift:

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Carry distances (if applicable):

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Are other manual handling tasks carried out by these operators? Assessment discussed with employees/safety representatives

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* Circle as appropriate

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If 'Yes' continue. If 'No' the assessment need go no further.

Diagrams (other information including existing control measures):

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Operations covered by this assessment (detailed description):

Personnel involved:

Date of assessment:

Overall assessment of the risk of injury? * Circle as appropriate

Low/ Medium/ High*

Make your overall assessment after you have completed Section B.

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Section B: Lifting and carrying - More detailed assessment, where necessary If yes, tick appropriate level of risk

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Questions to consider:

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Low

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Do the tasks involve: holding loads away from trunk?



twisting?



stooping?



reaching upwards?



large vertical movement?



long carrying distances?



strenuous pushing or pulling?



unpredictable movement of loads?



repetitive handling?



insufficient rest or recovery?



a work rate imposed by a process?

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

Are the loads:



heavy?



bulky/unwieldy?



difficult to grasp?



unstable/unpredictable?



intrinsically harmful (eg sharp/hot)?

Med

High

Problems occurring from the task (Make rough notes in this column in preparation for the possible remedial action to be taken)

Possible remedial action e.g. changes to be made to the task, load, working environment etc. Who needs to be involved in implementing the changes?

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Section B: Lifting and carrying - More detailed assessment, where necessary If yes, tick appropriate level of risk

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Low

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Consider the working environment - are there: constraints on posture?



poor floors?



variations in levels?



hot/cold/humid conditions?



strong air movements?



poor lighting conditions?

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

Consider individual capability - does the job:

 

require unusual capability? pose a risk to those with a health problem or a physical or learning difficulty?



pose a risk to those who are pregnant?



call for special information/training?

Med

High

Problems occurring from the task (Make rough notes in this column in preparation for the possible remedial action to be taken)

Possible remedial action e.g. changes to be made to the task, load, working environment etc. Who needs to be involved in implementing the changes?

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Section B: Lifting and carrying - More detailed assessment, where necessary Yes/No

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Other factors to consider

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Is movement or posture hindered by clothing or personal protective equipment? Is there an absence of the correct/suitable PPE being worn?

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Protective clothing

Yes/No

Yes/No

Work organisation (psychosocial factors)







Yes/No

Do workers feel that there is poor / communication between managers and employees (eg not involved in risk assessments or decisions on changes in workstation design)?

Yes/No

Are there sudden changes in workload, or seasonal changes in volume without mechanisms for dealing with the change?

Yes/No

Do workers feel they have not been given enough training and information to carry out the task successfully?

Yes/No

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Do workers feel that there has been a lack of consideration given to the planning and scheduling of tasks/rest breaks?

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Problems occurring from the task (Make rough notes Possible remedial action e.g. changes to be made to in this column in preparation for the possible the task, load, working environment etc. Who needs remedial action to be taken) to be involved in implementing the changes?

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Page 103

Section C - Remedial action to be taken

Remedial steps that should be taken, in order of priority: Person responsible for implementing controls

Target implementation Completed date Y/N

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Date by which actions should be completed: Date for review of assessment: Assessor's name:

Signature:

TAKE ACTION ... AND CHECK THAT IT HAS THE DESIRED EFFECT

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Asbestos in the Workplace

1.2.8.1 Key points All asbestos-containing material (ACM) is hazardous when airborne and dangerous when fibres are inhaled.

2

Before any work with asbestos is carried out a written risk assessment must be made.

3

The priority for any Contractor is to prevent exposure to, and spread of, asbestos.

4

A written, site specific plan of work must be kept on site and followed.

5

Anyone who does any work with asbestos must be specifically trained to do it, and this training must be repeated annually.

6

Do not forget other hazards besides asbestos, e.g. working at height or in a confined space, when working with/removing asbestos.

Note:

Section 1, Part 9 of the QCS covers manual handling of materials.

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The key is a risk assessment, which needs to be carried out by someone who is competent in terms of: (a)

working with asbestos

(b)

the requirements of these Regulations

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Asbestos is a risk to health when airborne fibres are breathed in. The greater the number of fibres, and the longer the period over which they are breathed in, the greater the risk of incurable asbestos-related diseases developing. These include cancers in the lungs and chest lining.

3

However, asbestos that is in a good condition, which is not damaged and is not likely to be worked on or disturbed, does not pose any immediate problem.

4

Although asbestos building materials and products have been largely replaced by safer alternatives, there remains the issue of the ongoing and long-term management of existing asbestos where its removal is not practicable.

5

Locating and identifying asbestos can be difficult, as its appearance may be changed by surface coatings, heat or ageing. It may also be encapsulated by, or be concealed beneath, other materials. Past uses of asbestos include:

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Insulation and sprayed coatings using moulded or pre-formed lagging 6

boilers, plant and pipework

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fire protection to steel work

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thermal and acoustic insulation of buildings, including loose packing Insulation board

9

fire protection to doors

10

claddings on walls and ceilings

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11

partitioning

12

ceiling tiles

13

fire breaks in ceiling voids

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Asbestos cement corrugated roof sheets

15

flat sheets for cladding and partitions

16

roof and rainwater drainage goods

17

underground pipes

18

bath panels

19

artificial roof slates

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Other uses vinyl or thermoplastic floor tiles

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insulation of electrical equipment

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some textured coatings

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bakelite sanitary ware, and other products.

24

Asbestos-based friction materials were widely used in brake and clutch linings in vehicles and plant, together with gaskets and packing in engines and heating or ventilation systems. Substitute materials have been developed in most cases.

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1.2.8.3 Types of asbestos and its identification

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Asbestos is a naturally occurring fibrous silicate mineral material, which does not burn and is resistant to most acids and alkalis. The fire protection and insulative properties of asbestos were the main reason for its use over the years. Three main types of asbestos have been used in the construction industry:

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(a)

chrysotile (white)

(b)

amosite (brown)

(c)

crocidolite (blue).

2

Although the colours are often used to differentiate between the different types of asbestos, the actual colour of a material suspected of being asbestos is not necessarily an accurate indication as to whether or not it is asbestos or an asbestos-containing material, or if it is, of what type.

3

Changes in colour may occur due to: (a)

it ageing or simply becoming dirty

(b)

the effects of heat

(c)

surface coatings being applied

(d)

encapsulation

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oil or chemical splashes.

4

The type of asbestos used in the lagging of boilers can be particularly difficult to identify visually. Repairs and modifications can mean that boilers or pipework may be lagged by a mixture of different types of asbestos.

5

Asbestos was widely used as fire protection in building materials, for thermal insulation and also as a sprayed coating to steel structural members. All of these uses now present significant management issues associated with the maintenance of the asbestos over the remaining life span of the building, or the removal of the asbestos during renovation, refurbishment or demolition.

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Working with, among, or alongside asbestos materials demands stringent control, and compliance with recommended precautionary measures and methods of work.

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1.2.8.4 Control of Asbestos

Risk assessment - an assessment of risk carried out by someone with both the theoretical background and practical experience of the intended work with asbestos-containing materials.

2

While a competent construction manager may be able to form an opinion as to whether a material may be asbestos or an asbestos-containing material, the decision as to who can do the work, and the standards that the work should be carried out to, are likely to require specialist advice.

3

If you are a contractor working on someone else's premises, you should be given information about the presence of asbestos and what they expect you to do about it. If you are not given this, you should not start work.

4

Note 1. This requires a survey by a competent person. If representative samples are needed for laboratory analysis, this may well be a task for a competent technician. Where multiple samples are taken, each sample and the sample point should be numbered. If samples are being sent for analysis, it is a requirement that any laboratory carrying out analysis has the necessary facilities, expertise and quality control procedures. Any samples should be well sealed, for example inside two zip lock plastic bags.

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Note 2. If in doubt presume that the material is asbestos or ACM until you can prove that it is not. It is better to 'overprotect', than to expose employees and others to asbestos.

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Note 3. A plan of the premises showing where the materials are will always be extremely useful, and will be essential in larger premises. Such a plan would form an integral part of the ongoing management of the asbestos or ACM.

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Note 4. A risk assessment should be undertaken by a competent person who has sufficient knowledge of the subject.

8

If the materials are in good condition, not liable to be damaged, and will not be disturbed or worked on, then the risk is probably low. If the materials are flaky, crumbling, in a place where they can be damaged by, for example, forklift trucks, then the risk is high. Given the known ill health caused by asbestos, then a high risk of damage calls for urgent actions.

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Note 5. This could be work by your employees, or any contractors or subcontractors brought in for carpentry, flooring, partitioning, ceiling fixing, plumbing, electrical or other work.

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Note 6. If material is not going to be removed by an asbestos removal contractor, consider how you are going to manage the long-term presence of the asbestos. If it is in good condition and not liable to be damaged, then routine inspection and monitoring may be

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enough if records are kept. A sealing coat may be needed, or other protective works necessary, to lower and to further control the risk. Note 7. Make it happen by putting your plan into action. What is the organisation, what are the arrangements for the implementation of the plan and who has the responsibility?

12

Note 8. A regular review of the action plan will ensure that it is working that the control measures are still effective, and that inspection, monitoring and recording are in fact taking place. It may be the case that procedures, notices and policies that have been in place for a length of time tend to be overlooked. A fresh approach may therefore be needed.

13

Note 9. Part of this information will be the signs that will have been placed to identify the asbestos or ACM. In a large workplace or premises, this may also mean keeping a register that describes every individual room or workplace and the asbestos or ACM that is in there. This means that visiting subcontractors can be told exactly what asbestos or ACMs to expect in the areas in which they will be working.

14

These Regulations also impose duties on Contractors for the protection of employees who may be exposed to asbestos at work, and other persons affected or who may be at risk of being affected by such work.

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1.2.8.5 Representative sampling

To confirm or identify the type of asbestos or ACM on the premises, a series of samples may have to be taken for laboratory analysis. Methods employed in taking samples of asbestos will vary according to its type and location. Guidance on taking samples is available in the UK publication MDHS100.

2

Anyone removing samples for analysis must be competent to do so and use appropriate protective clothing and respiratory equipment, particularly if the work involves cutting, boring, drilling or otherwise creating airborne dust or fibres. Precautionary measures to be observed include:

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no people, other than those taking the sample, to be in the area

(b)

the area from where the sample is to be taken should be dampened using a 'killer spray'

(c)

a knife, core borer or hand drill should be used to place the sample in a suitably labelled, scalable container. Do not use any tools that will create airborne fibres

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(e)

any disturbed or damaged surfaces should be sealed after a sample has been taken.

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other surfaces on which asbestos dust may fall should be covered with an impervious sheet. The area should be subsequently cleaned by using a dustless method, e.g. a damp cloth, which should be disposed of in a sealed polythene bag

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The results of the analysis will determine what action should be included in the management plan.

1.2.8.6 Asbestos surveys 1

All asbestos surveys must be carried out by a competent person who can demonstrate the following: (a)

evidence of their training and experience in such work

(b)

types of survey outlined below they are qualified to carry out

(c)

that they are going to carry out the survey in accordance with the HSE guidance MDHS100

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2

If an individual surveyor is to be appointed, a check should be made as to whether they have personnel certification for asbestos surveys from a certification body which has been approved by a recognised accreditation body under the standard ISO 17024,

3

All surveys should be subject to a quality assurance process. It is important to note that ISO 9000 accreditation is not the correct standard for assessing asbestos surveys. ISO 17020 is the relevant standard.

4

The competence schemes are: The United Kingdom Accreditation Service UKAS. This is accreditation by the United Kingdom Accreditation Service against ISO 17020, and is normally held by an organisation such as the surveying division of a licensed contractor or an asbestos laboratory. www.ukas.org.uk

(b)

National Individual Asbestos Certification Scheme (NIACS) is a scheme jointly run by the Asbestos Removal Contractors Association and the Royal Institute of Chartered Surveyors. It accredits individual surveyors. www.niacs.org.uk

(c)

Asbestos Building Inspectors Certification Scheme (ABICS) is a scheme run by the British Occupational Hygiene Society. It also accredits individual surveyors. www.bohs.org/standardTemplate.aspx/Home/Professional/ABICS

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(a)

A UKAS or equivalent laboratory should have carried out all analysis of asbestos samples.

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Three types of survey are defined within HSE's publication MDHS 100:

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Type 1 - presumptive survey - during which the surveyor does not take any samples. Instead, using their skill and judgement alone, the surveyor identifies materials as containing asbestos or not. The survey is of the asbestos risks that the building poses to its occupants in normal use.

(b)

Type 2 - sampling survey - the surveyor makes use of sampling and subsequent laboratory analysis to confirm whether or not a material contains asbestos. The survey is of the asbestos risks that the building poses to its occupants in normal use.

(c)

Type 3 - invasive survey - the surveyor samples and breaks into the structure and fabric of the building to try to find the asbestos-containing materials, before a contractor does so in the course of their work.

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Anyone applying the results of a survey should initially check if the surveyor has written any caveats on the survey. It is common to exclude access to areas which are over 3 metres above ground level, as it is not possible for a single surveyor to safely use a ladder higher than this because they cannot foot it. There may be other areas that have not been accessed.

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Asbestos surveyors are taught to identify the 'spaces' where asbestos is likely to be found and to survey accordingly. The meaning of 'spaces' can be anything from a boiler room, to a roof void, an office, an underground duct, a cavity between the two leafs of a wall or anywhere else that asbestos or an asbestos-containing material might have been used.

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A 'no access' comment on an asbestos report could be simply because:

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(a)

the door of a room was locked and the surveyor could not gain entry

(b)

the 'space' was an underground duct and a mini digger was required to lift the covers

(c)

a suspended floor had no access other than by destroying the floor

(d)

the electrical system being live during the survey.

To understand the difference between a Type 2 and Type 3 survey, the simplest explanation is to consider a studwork wall which forms a firebreak. It was originally covered in asbestos insulation board and then covered over with plasterboard. In a Type 1 and Type 2 survey,

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the surveyor would correctly identify the outer surface as being plasterboard. During these surveys there would be no need to carry out any invasive testing and therefore the asbestos insulation board lies undiscovered. Type 3 surveys would be invasive and the surveyor would be expected to check under the plasterboard for other materials. In the previous case, if a building contractor only commissioned a Type 2 survey upon which to plan their work, they may find the asbestos insulation board unexpectedly. Invasive checks must be made before invasive work is carried out.

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Just because the surveyor did not find any asbestos does not mean that there is no asbestos present. In all cases it is important to remember that surveying is as much an art as a science and there will be mistakes. There are also some asbestos-containing materials which would only be found by luck rather than judgement, for example, asbestos cement shuttering in a slab, or asbestos insulation board used as packers inside a stud work wall. It is important to be wary of unidentified building products and for everyone to have sufficient asbestos awareness training. There should also be management who are in a position to stop work if necessary and question the presence of any 'funny looking plasterboard' found.

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1.2.8.7 Working with asbestos

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A Contractor who carries out any work in a building or structure is required to: make a suitable and sufficient assessment as to whether asbestos is, or is liable to be, present in the premises where work is being carried out. Under CDM, the client has a duty regardless of the size of the project to provide information such as the presence of asbestos

(b)

note that:

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this information should normally be in the form of Type 3 surveys as defined in the HSE publication MDHS 100 for most invasive construction work

(ii)

any information on the presence of asbestos supplied by the client based upon a Type 2 survey, must be closely scrutinised to ensure that the construction work will not disturb more of the structure than the surveyor checked

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Requirements of the Regulations

identify that the material does not contain asbestos or assume it contains brown or blue asbestos

3

ensure that a competent person carries out an assessment to decide the likely exposure for the proposed work methods.

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prepare a suitable written plan of work

5

provide adequate information, instruction and training, for employees and others

6

ensure that training is repeated on an annual basis for any work with asbestos

7

prevent or reduce asbestos exposure to the lowest level reasonably practicable by means other than the use of respiratory protective equipment (RPE), for example use an asbestos H class vacuum cleaner or other fibre suppression techniques

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ensure the proper use of respiratory protective equipment and that face-fit testing is carried out

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maintain respiratory equipment in a clean, efficient state, good order and repair. Regularly examine and test exhaust ventilation equipment

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provide adequate and suitable protective clothing and ensure that it is cleaned or disposed of appropriately

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prevent the spread of asbestos from the workplace

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ensure premises and plant involved in work with asbestos are kept clean

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monitor the air where employees are exposed to asbestos and keep suitable records for a specific period

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ensure that air monitoring is only carried out by a UKAS or equivalent accredited laboratory

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provide washing and changing facilities that are adequate and suitable for employees exposed to asbestos, and storage for protective clothing and personal clothing (not worn during working hours)

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Asbestos areas and respirator zones

Where an asbestos removal contractor is undertaking the removal of asbestos, in order to ensure that people other than those involved in asbestos work are not exposed to asbestos by entering 'asbestos areas', such areas should be designated and clearly identified, using notices.

17

Areas where the removal contractors are working, and where control limits for exposure to airborne fibres are liable to be exceeded, will be designated as respirator zones to ensure that only removal contractors wearing respiratory protective equipment are allowed to " enter.

18

Contractors with asbestos removal contractors on their premises should strictly prohibit entry into these areas by their own employees.

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Medical surveillance

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Asbestos removal contractors must ensure that their employees, who are liable to be exposed to asbestos, are under regular medical surveillance by an employment medical adviser or appointed doctor.

20

Medical examinations should be provided before work with asbestos starts and at prescribed periods thereafter, currently every two years.

21

Health records containing information on medical examinations have to be maintained and kept for 40 years after the date of the last entry.

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Washing and changing facilities 22

Asbestos removal contractors must provide adequate and suitable washing and changing facilities for their employees. Where protective clothing and respiratory equipment are in use, storage must be provided for contaminated items.

23

Separate storage must be provided for personal clothing not worn during working hours. Storage, dispatch, labeling of asbestos waste

24

Asbestos waste is considered to be of two types - combined or fibrous. Combined was previously called bonded and effectively the asbestos is well bound into the material. Roofing felt, vinyl floor tiles and most asbestos cement is categorised as combined. Asbestos insulation board, pipe lagging and sprayed coating are fibrous. Professional advice may be needed to ensure that the waste is correctly categorised.

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25

There is no requirement to bag or wrap asbestos cement sheets, or gutters removed externally, where they can be placed straight into a suitable skip. The skip should be secured if it is left overnight. It is good practice to bag or wrap waste from internal work to guarantee that when the waste is carried outside there will be no asbestos debris dropped. If a van is being used to carry asbestos waste, the material must be double bagged and the bags secured by putting them in a lidded bin, for example.

26

Any fibrous asbestos removed should be sealed in proper containers and correctly marked before despatch. Typically, this will be double-bagged with the inner bag being red and the outer clear.

27

Containers should be designed and constructed so as to retain the asbestos without any spillage or loss during normal handling.

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Labelling of asbestos waste and used protective clothing Where the asbestos removal contractor uses labels on waste or removed asbestos, the label must be clearly and indelibly printed so that the words in the lower half can be easily read. These words must be printed as specified in the diagram.

29

The label has to be firmly affixed to the packaging using an adhesive type label, or directly printed onto the packaging (plastic bag).

Labelling requirement

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Disposal of removed asbestos 30

In essence, there is a duty of care put on everyone in the waste disposal chain. Clients, whether they are at work or domestic, have a responsibility to ensure that the waste is disposed of correctly. They can be prosecuted if the waste is fly tipped. Where asbestos has been removed as part of a project, a prudent contractor would ensure that proof of disposal formed part of the information that was given to the client. Other aspects

31

Concerns regarding aspects of health and safety that are often associated with working with asbestos, such as working at height, the risk of fire, working in confined spaces, the use of machinery, burning, cutting and lifting. It is important not to view asbestos as a hazard in isolation.

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The Control of Dust and Fumes

1.2.9.1 Key points The inhalation of dust or fumes has the potential to cause severe respiratory illness.

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Asbestos fibres and lead dust are particularly hazardous if inhaled.

3

The dust of some types of wood can be irritating to the skin.

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The creation of airborne dust or fumes should ideally be prevented although this is often not possible in a construction site environment.

5

Where the prevention of dust or fumes is not possible, the extent of exposure must be controlled to a level that is safe.

6

Control of dust can be achieved by the:

(b)

collection of dust in 'collector bags' attached to powered hand tools

(c)

wet cutting of solid materials such as thermal blocks, bricks or ceramic tiles

(d)

where practical, carrying out of work activities in the open air rather than in enclosed spaces.

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Hazardous fumes usually result from:

processes in which materials are heated, such as welding, lead burning or grinding

(b)

uncontrolled use of substances such as solvents and adhesives

(c)

the use of equipment and plant powered by internal combustion engines.

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Section 1, Part 15.2.3 of the QCS covers the control of dust.


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Note:

The exposure of employees to airborne dust or fumes can result in severe respiratory illnesses, such as occupational asthma. Such diseases can be totally disabling, causing those affected to give up work or change their employment. Exposure of the skin to some hazardous dusts can result in severe irritation and ulceration of the affected areas.

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1.2.9.3 Dust

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extraction of dust and fumes through stand-alone extractor units

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Dust is the name for a mix of tiny solid particles. It consists of a wide mix of components. In the construction context, the mix will reflect the work activities.

2

It is widely known that almost any excess levels of dust can cause health problems. Harmful effects range from simple skin irritation to severe respiratory illness.

3

Not all harmful dusts are visible. Dusts that are too fine to be seen by the naked eye are the cause of many serious health problems. Like most occupational health problems, it can take several years for symptoms of ill health to manifest themselves.

4

Skin irritation, dermatitis and ulceration can be caused by contact with some types of dusts. Other types of dust, being soluble, may be absorbed through the skin via cuts and abrasions.

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The inhalation of dust can cause wheezing, coughing, breathlessness, bronchitis, nasal and other types of cancer. Dust also contains bacteria and viruses and therefore has the potential to cause stomach disorders. These can result from ingesting airborne dust or from eating food with contaminated hands.

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Such problems are not likely to arise if occupational exposure limits are not exceeded and safe systems of work are maintained.

1.2.9.4 Fumes 1

Hazardous fumes can be produced when some building materials are heated or otherwise worked. A common form of respiratory illness, which has flu-like symptoms, is caused by the inhalation of welding fumes. Other sources of hazardous fumes are: (a)

uncontrolled exposure to liquid substances such as solvents or paints

(b)

the use of equipment and plant which is powered by internal combustion engines.

1.2.9.5 Health and Safety at Work (Construction Sites)

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Contractors must provide and maintain plant and systems of work that are safe and without risks to health.

(b)

Contractors must make arrangements for safe handling, storage, and transport of articles and substances.

(c)

Contractors must provide adequate information, instruction, training and supervision.

(d)

Contractors have a duty to ensure persons not in their employment are not exposed to risks to their health and safety.

(e)

Persons in control of premises must use the best practicable means to ensure that noxious or offensive substances do not enter the atmosphere

(f)

Contractors must not charge an employee for personal protective equipment that is provided in accordance with statutory requirements relating to health and safety.

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Employees have a duty to:

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(a)

exercise reasonable care for their own health and safety and that of others who may be affected by their acts or omissions; to co-operate with their Contractor in enabling him or her to carry out his or her duties under the relevant statutory provisions

(b)

not intentionally or recklessly interfere with, or misuse, anything provided in the interests of health, safety and welfare.

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The relevant provisions are as follows.

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These Regulations place a legal duty on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

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Once those hazards have been identified, it is then the Contractor's duty to put control measures in place to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, so far as is reasonably practicable.

3

Where a hazard is identified that requires it, the Contractor must offer appropriate health surveillance to employees. This must take into account all the risks to their health and safety that have been identified.

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The Contractor must provide employees with comprehensible and relevant information on the risks that exist in the workplace and inform them of the control measures that are in place to reduce those risks.

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Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves and to any other

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person who may be affected. 6

These Regulations require that Contractors assess the health risks to their employees arising out of exposure to hazardous dusts and fumes, and, if reasonably practicable, put control measures in place to eliminate the work processes and the use of substances that cause exposure. If this is not reasonably practicable, Contractors must: (a)

control exposure to an acceptable level, and

(b)

inform employees of the hazards involved and the control measures in place

(c)

mitigate the effects of any exposure by providing health surveillance where necessary.

1.2.9.7 Control of Substances Hazardous to Health When dust is inhaled, the body's defence mechanisms can usually deal with the larger particles. However, they struggle to cope with the very small particles. In occupational hygiene terms, dust is divided into two categories:

(b)

the much smaller particles which are called 'respirable dust'.

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inhalable dust, sometimes called 'total dust', and

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Because dust is a mix of very small particles, all dusts have been assigned a concentration in air above which they are considered hazardous. It is important to remember that this applies to all dusts, for example those caused by: sweeping a dusty floor

(b)

clearing out a building

(c)

driving plant on dusty sites

(d)

mixing sand and cement to make mortar

(e)

sanding down Medium density fibreboard (MDF) or timber.

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The technical descriptions of the two types of dust are: (a)

total inhalable dust approximates to the fraction of airborne material that is inhaled and is available for deposition in the respiratory tract

(b)

respirable dust approximates to the fraction of airborne material that is inhaled and penetrates to the gas exchange region of the lung (the alveoli).

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Any concentration of an inhalable dust in excess of 10 milligrams of dust per cubic metre of 3 3 air (10 mg/m ) averaged out over eight hours, or any respirable dust in excess of 4 mg/m averaged over eight hours, is deemed to be a substantial concentration of dust and therefore within the definition of a substance hazardous to health.

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The official list of exposure limits is updated periodically and published in the Health and Safety Executives Guidance Note EH40. The most recent edition is EH40/2005. This has been supplemented by a table on HSE's website, which is updated more frequently and has the up-to-date list of workplace exposure levels:

6

www.hse.gov.uk/coshh/table1.pdf

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This lists specified workplace exposure limits (WEL) for a number of dusts, in addition to other substances. Dusts are therefore classified as substances that are hazardous to health.

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Further guidance on the health hazards posed by dust is included on pages 29-31 of EH40/2005.

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The principal points of these Regulations place requirements on the Contractor to protect

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employees, or any other persons who may be affected by their operations, by: (a)

assessing the health risks created by work involving substances hazardous to health.

(b)

ensuring that the exposure of employees or others is prevented or adequately controlled, by putting in place any measures necessary to control the exposure to risks

(c)

ensuring that any control methods provided are properly used and maintained, and by monitoring the work environment as necessary

(d)

carrying out health surveillance in specified circumstances

(e)

providing information, instruction and training for employees on the risks to health and precautions to be taken regarding any work with substances hazardous to health

(f)

providing procedures for dealing with accidents, incidents and emergencies, including first-aid and safety drills.

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Designers have the potential to eliminate or reduce the exposure of operatives, and possibly others, to dust or fumes through their designs.

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Examples of how this can be achieved are:

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specifying construction methods that avoid hot-works and therefore the creation of fumes, particularly in enclosed areas and confined spaces

(b)

specifying that construction materials are cut to size at the point of manufacture, eliminating the need for cutting, planing, sanding and so on, on site

(c)

designing enclosures to contain hazardous dust where its creation is unavoidable.

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(a)

Contractors and sub-contractors have the potential to reduce exposure to dust and/or fumes by co-ordinating work activities, co-operating with each other and adopting work methods.

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1.2.9.9 Personal Protective Equipment These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by the at risk employees.

2

In essence, personal protective equipment (PPE) may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are found not to be reasonably practicable.

3

In deciding which type to issue, the Contractor must take into account the nature of the hazard that the PPE is being used to protect against, and ensure the PPE will fit the wearer and allow them to work safely. If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible and suitable for the task that is to be undertaken.

4

Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable the employees to understand the risks being protected against, the purpose of the PPE and manner in which it is to be used.

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Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction and training that they have been given, and know the procedures for reporting loss or defects to their Contractor.

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1.2.9.10 Training 1

It should be noted that these Regulations place a legal duty on the Contractor to provide employees with adequate information, instruction, training and supervision to be able to carry out any work task safely and without risks to their health.

1.2.9.11 Respiratory hazards The following paragraphs describe the main respiratory hazards which may be encountered on site.

2

Dusts are produced when solid materials are broken down into finer particles. The longer that the dust stays in the air then the easier it is to breathe in. Airborne dust is usually respirable dust.

3

Mists are tiny liquid droplets formed by atomisation of the liquid, for example, when spraying or using an aerosol. Mists may be a combination of several hazardous substances.

4

Metal fumes occur when metal is vaporised at high temperatures, for example, when welding and gas cutting. The physical properties of fumes can be confusing, particularly when identifying suitable respiratory protective equipment (RPE). Usually, metal 'fume' is actually a solid particle by the time it is inhaled.

5

When welding is taking place the temperature of the metal at the weld is sufficiently high for the elements in the metal to become gaseous. However, 2-3 mm away from the weld the gases have cooled down sufficiently for the fume to solidify out as small particles.

6

Consequently, when purchasing RPE to protect against fume, a device that protects against solid particles rather than gases is required.

7

Gases are airborne at room temperature and normally mix with the air that we breathe. Examples include propane, butane, acetylene, carbon monoxide and hydrogen sulphide. Gases can spread very quickly.

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Vapours are the gaseous state of substances that are liquids or solids at room temperature. They usually form when substances evaporate.

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One example is the vapour from a tin of glue or solvent that has been left open.

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1.2.9.12 Exposure limits 1

Exposure to any unlisted substance or general nuisance dust should be limited by reducing dust levels to the minimum reasonably practicable. These levels should not exceed 10 milligrams of dust per cubic metre of air, when measured over an eight hour period (10 3 3 mg/m 8H TWA). Within that figure, only 4 mg/m should be respirable dust.

2

Generally speaking, if visible dust can be seen in the air, it is highly possible that the 10 mg limit is being approached (or exceeded), and the application of COSHH should be considered.

1.2.9.13 Control of dust 1

Dust in its many forms has been the cause of health problems throughout the history of the building and construction industry. While much attention has been given to newly recognised hazards, the greater part of the dust problem relates to more common substances.

2

Dust is taken here to mean anything that forms a powder or cloud and is a nuisance,

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including cement, wood, stone, silica, fillers and plastics. The high speed cutting and grinding of most materials can produce dust. Dust in confined spaces is a particular hazard, because of the potential risk of explosion. The most obvious example is in coal mines. Flour dust can also be explosive, and whilst that is normally a process industry risk, for companies who may maintain or cut up extraction plant in bakeries and flour/feed mills, it is something that does require consideration.

4

In all cases, knowledge of the hazards associated with materials, processes and operations is required, and of the specific precautions and protective equipment necessary to reduce or eliminate the risk to health and safety.

5

In many cases, the control of dust will not be difficult to achieve. The accumulation of 'general dust' can be controlled by good housekeeping and simple measures, such as 'damping down'.

6

Where the creation of dust is more localised, such as during the cutting, grinding or sanding of solid materials, satisfactory control will often be achieved by the extraction and collection of the dust through attachments fitted to power tools or by 'wet cutting'. Even where the collection of dust is not practical, it will often be possible to create an enclosure around the activity and ensure that the person carrying it out uses appropriate RPE.

7

Conversely, carrying out some dust-generating activities in the open air may be preferable to allow the dust to disperse, depending upon the hazard posed by the quantity and nature of the dust so created.

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Wood dust

Impregnated timber and some hardwoods (such as teak, African mahogany and iroko) are known to be health hazards. The inhalation of hardwood dusts through the nose is a known cause of nasal cancer.

9

A list of some timbers known to present risks is given below. Protection is not normally required when working on these timbers with hand tools in the open, but harmful dusts can be produced when using machine tools (e.g. sanders or saws) in enclosed or poorly ventilated areas. An assessment should be made and, if ventilation or dust extraction cannot be improved to remove or reduce the dust problem, a dust respirator should be worn.

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Medium density fibreboard 10

Medium density fibreboard (MDF) is a commonly used material in the construction sector. It is manufactured from wood dust glued together with a urea-formaldehyde binder.

11

The risks associated with MDF are exposure to dust and dried urea-formaldehyde during use.

12

The primary issue for construction workers is simply the huge amount of dust that any work with MDF generates. Given the makeup of the product this is not really surprising. The 3 exposure level normally used is the same as softwood dust - 5 mg/m on a time weighted average exposure of eight hours Selection of timbers and their irritant effects

13

The severity and frequency of any symptoms will vary with individuals. They are also doserelated. (a)

Camphor wood - asthma, dermatitis

(b)

Red cedar - asthma, bronchial trouble, sneezing, watering of eyes, rhinitis, dermatitis,

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septic wounds from splinters Dahoma - irritation of mucous membranes and chest, sneezing, coughing, running eyes and nose, dermatitis

(d)

Ebony - irritation of nose and throat, dermatitis

(e)

Guarea (also West African cedar) - mild nasal irritation, sneezing, coughing, running eyes; can cause severe vomiting, chest irritation, blisters around the eyes and dermatitis

(f)

Iroko - skin and eye irritation, asthma and symptoms of the common cold

(g)

Machaerium - dermatitis

(h)

Sapele - dermatitis, allergic extrinsic alveolitis

(i)

Mahogany - asthma, dermatitis

(j)

Chestnut - asthma, dermatitis, rhinitis

(k)

Mansonia - irritation of mucous membranes, sneezing, nasal haemorrhage, eyes sore and bloodshot, dizziness, dermatitis

(l)

Satinwood - dermatitis, headache, coughing

(m)

Teak - dermatitis, eye inflammation. Effects are severe once the skin's protective layer has been penetrated

(n)

Walnut - asthma, dermatitis, conjunctivitis, rhinitis

(o)

Yew - bronchial asthma and dermatitis

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Generally speaking, the greater the amount and the finer the dust, the greater the risk of health problems.

15

Both hardwood and softwood dusts have a workplace exposure limit of 5 mg/m on a time weighted average exposure of eight hours. As both are known causes of asthma dust levels need to be controlled to as low a level as possible.

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Other common sources of dust When cleaning stone, brick and concrete facades, or any metal structure with dry or wet grit blasting, control measures will include the use of respiratory protective equipment. This is likely to be a high performance type such as a powered respirator. When cleaning siliceous masonry, air line equipment may be required.

17

Although this type of cleaning operation is commonly called 'sand blasting', sand must not be used for blast cleaning because of the known health hazard caused by airborne sand and silica.

18

Effective preventative measures must be taken if exposure to crystalline silica is possible.

19

Protection is also necessary when using mechanical cleaning methods.

20

Exhaust ventilation devices should be fitted to power tools, or the operative should be provided with high efficiency breathing apparatus.

21

The cutting and chasing of masonry, stone, brickwork, plaster, thermal insulating blocks and concrete, creates a dust hazard. Therefore, extraction equipment should be provided, the process performed wet or respirators worn, depending on the assessment made.

22

Crystalline silica (also known as quartz) is present in sand and rock and can also be found in building materials such as cement, concrete, plaster, bricks and tiles.

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Dust from plastic fillers can damage the lungs if inhaled, as can dust from resin-based fillers, and fibrous particles of glass fibre, rockwool and similar insulation materials.

24

The dry sanding of lead-based paint can result in exposure to hazardous levels of lead dust. Softening with heat guns and scraping, or the use of chemical stripping agents, will usually be effective. If sanding is required, wet and dry paper with a solution of dishwater detergent can be used. A dishwasher tablet dissolved in about 5 litres of water will give the required solution strength. The form of detergent used for dishwashers is effective at binding and stabilising the lead chromate used in paint.

25

The disturbance of asbestos is likely to result in airborne fibres (dust) which can result in cancer, and other respiratory illnesses, if inhaled.

26

Where a work activity involves the creation or disturbance of dust, a COSHH assessment must be carried out.

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1.2.9.14 Control of fumes

Within the wide range of activities carried out in the construction industry there are numerous operations which liberate fumes into the atmosphere and cause risks to the health and safety of people at work. Every effort must be made to minimise these risks. Fumes may be classified as a substance hazardous to health and thereby require an assessment of the risk to health to be carried out.

2

If a risk does exist, control measures such as mechanical extraction systems and adequate natural air ventilation can prevent high concentrations of fumes forming to create a hazard, particularly in confined areas.

3

The HSE publication EH40 'Occupational exposure limits' lists a level of exposure for each type of fume or pollutant. This represents the maximum limit at which it is considered safe for work to take place.

4

EH 40/2005 has been supplemented by a table on HSE's website, which has the up-to-date list of workplace exposure levels:www.hse.gov.uk/coshh/table1.pdf

5

Every reasonably practicable measure should be taken to reduce any exposure as far below the limit given as is possible.

6

If the fume type is listed in EH40, or is otherwise a hazard to anyone's health, the provisions of the COSHH Regulations will apply. Therefore, an assessment of the risk and the provision of any necessary precautions must be made.

7

Some of the more common causes of fumes are listed below and discussed under subsequent headings:

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(a)

welding or flame cutting

(b)

lead burning (both cutting and melting)

(c)

cable burning (this practice must not be carried out on site)

(d)

the use of solvents, paints, adhesives and soon

(e)

internal combustion engines.

1.2.9.15 Welding 1

During welding and flame cutting, toxic fume hazards can arise from: (a)

nitrogen oxide gases

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(b)

ozone

(c)

phosgene gas

(d)

carbon monoxide gas.

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These are mainly caused by the very high temperatures and the presence of volatile substances, sometimes as contaminants, but often as shielding agents or flux.

3

The inhalation during welding of freshly formed metal oxides (such as zinc, cadmium, chrome, nickel, copper and mercury) may lead to an acute 'flu-like' illness termed 'metal fume fever'.

4

The fever is most commonly caused by fumes created while working with galvanised or zinccoated metals, especially in confined spaces.

5

Fumes arising from the cutting and welding of cadmium are especially dangerous, even in the open air. Prolonged or recurrent exposure may result in cadmium poisoning.

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Precautionary measures

A risk assessment, including a COSHH assessment, as appropriate.

7

The use of extraction systems and fume hoods to remove fumes from the breathing zone.

8

The use of respiratory equipment, particularly in confined spaces where high concentrations of fumes can be anticipated.

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1.2.9.16 Lead burning

Lead burning is the process whereby lead is heated to its molten state so that it can be poured into joints, or flame cut to shape, or flame heated so that it can be bent and formed into various shapes.

2

This process is employed extensively in sheet lead work by workers in the plumbing trades, in the formation of roof drainage, guttering, chimney flashings and so on.

3

This will mean that the operatives will need to be under health surveillance.

4

The creation of fumes by the heating of lead exposes operatives to risk. The following safety points should be observed:

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(a)

the use of local exhaust ventilation, or other means, to evacuate fumes from the immediate working area where reasonably practicable

(b)

the use of respiratory equipment of an approved type in the appropriate cases

(c)

the provision of protective clothing and storage for that clothing, along with adequate washing facilities.

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Wear respirator

Quite simply this is not an acceptable practice at anywhere other than a specialised processing facility. This method of recovering metal from cables, by burning off the insulation, often results in the creation of fumes which can be very toxic.

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1.2.9.17 Cable burning

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Chlorinated solvents, paints, adhesives and thinners all require precautions to be taken during their use. If they are hazardous to health, they must be handled and used in accordance with these Regulations.

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Avoid breathing the vapour

Most solvents are safe when used correctly but, in common with other compounds of hydrocarbons, the inhalation of a high concentration of vapour will cause drowsiness, headaches and giddiness. Severe exposure may lead to unconsciousness or even prove fatal. Extraction or exhaust ventilation may be needed or, where this is not available, respiratory protective equipment must be used.

3

Long term exposure to solvents may affect the central nervous system. Other chemicals may also have adverse effects. An example is isocyanate, which is a component of expanding foams contained in aerosol tins.

4

Some of the vapours are considerably heavier than air and may collect at low levels, particularly in still conditions. This can cause displacement of the oxygen present and lead to the risk of suffocation. It can also lead to a build up of solvent fume at explosive concentrations.

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Other precautions with solvents 5

DO NOT (a)

take solvents internally or 'sniff' any solvent

(b)

smoke when using solvents

(c)

use the solvent in a place which is not well ventilated - but avoid draughts

(d)

lean over any vessel containing the solvent liquid or vapour

(e)

store solvents in buckets or other open storage vessels

(f)

enter vessels which have contained or have been cleaned with solvents, unless proper tests have been made to ensure it is safe to do so

(g)

allow solvent liquid or vapour to come into contact with naked flames or red hot

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surfaces, e.g. welding arcs. Acidic and toxic decomposition products will be formed.

1.2.9.19 Internal combustion engines The nature of the construction industry, the activities carried out and the drive to get a job finished may lead some people into taking unnecessary risks. The majority of people are aware that internal combustion engines should not be used within confined spaces unless the exhaust gases are led directly to the open air. However, when for example the concrete is too hard, or a pipe will not cut by hand and the job is late, people will often ignore such a basic safety requirement and start a petrol engine disc cutter in a cellar. It is an error which could be fatal.

2

There is a potential for excavations to be contaminated by exhaust gases which are heavier than air and could simply roll down into the excavation. On projects with forced ventilation systems such as tunnels and shafts, the additional loading on the system needs to be factored in before petrol or diesel powered equipment is used.

3

In large buildings the use of forklift trucks, and other vehicles with internal combustion engines, can cause carbon monoxide to reach unacceptable levels, if there is no system to extract exhaust pollution. Simply opening the doors may not be enough.

4

In all cases of doubt, a COSHH assessment should be made by a competent person and, where necessary, the appropriate controls introduced.

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The following points are especially important:

the identification of potentially hazardous work processes, materials and substances before work starts

(b)

the provision of information, instruction and training to employees

(c)

the strict observance of all

(d)

recommendations and procedures advised by the manufacturer

(e)

the effective supervision of employees, and the monitoring of work methods and practices

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the provision of protective clothing and equipment before any work starts the correct disposal of waste materials and containers as recommended by the manufacturers

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1.2.9.20 Precautions

(h)

cleaning, for example, by extracting dust using a vacuum cleaner, rather than stirring it up by sweeping

(i)

personal hygiene, including the cleansing of hands before consuming food, the use of barrier creams, the removal and storage of contaminated clothing during meals, and the correct laundering or disposal of contaminated clothing

(j)

to avoid, where practical, carrying out potentially hazardous work activities in confined areas to lessen the chances of dust concentrations or fumes building up.

1.2.9.21 Protective equipment 1

Given the nature of some work activities, it is not always practical to completely contain the airborne dust or fumes created. In these circumstances, if no other control measure is reasonably practicable, respiratory protective equipment (RPE) and other PPE as necessary, must be provided for each person working with, or otherwise exposed to, airborne dust or fumes.

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There are various types of respiratory protective equipment approved for use. Details of types and permissible uses are available from the manufacturers.

1.2.9.22 Respiratory protective equipment Selection Selecting the wrong type of RPE could have serious, even fatal, consequences. Selection must be carried out by a competent person. Some of the factors that will determine the appropriate type of RPE are: the hazardous nature of the substance

(b)

the airborne concentration of the substance

(c)

the period of exposure

(d)

the wearer's required field of vision

(e)

the provision for communication

(f)

the need to move in cramped or difficult working places

(g)

the prevailing weather conditions

(h)

the suitability of the protective equipment for the individual

(i)

the need for an external source of breathable air.

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Notes:

When selecting suitable respiratory protective equipment (RPE) it may be necessary to seek expert advice from manufacturers/suppliers.

2

Training in the types of, and in the use of, respiratory equipment must be given.

3

A face fit test is required for any tight fitting face piece - this will include all disposable masks, half masks and most powered masks.

4

All masks, other than disposables, require regular examination by a competent person and records to be kept.

2

The following are some types of respiratory protective equipment (RPE) that are used in the construction industry: disposable face mask respirators

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(b)

half-mask dust respirators

(c)

powered respirators

(d)

ventilated visor and ventilated helmet respirators

(e)

compressed air line breathing apparatus

(f)

self-contained breathing apparatus.

Each type of RPE is given an 'assigned protection factor' (APF), which gives the user some idea of the level of protection that the device will provide. For example, a disposable mask marked: (a)

P1

offers a protection factor of 4

(b)

P2 offers a protection factor of 10

(c)

P3 offers a protection factor of 20

The APF assumes that the user has passed a face fit test, is wearing the mask correctly, is clean shaven and there is no other interference in fit such as facial piercing.

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The APF is a simple multiplier that can be used in two ways. An example is: (a)

a particle mask with an APF of 10.

This simply means that for every 10 units of contaminant outside the mask, only one unit will get inside the mask, so the mask filters out 9 of 10 of the units.

7

If there is a time exposure limit, then a mask extends the time by the same factor - so if someone can be exposed to a concentration of a contaminate for 10 minutes without needing to wear a mask, then a mask with an APF of 10 would allow the person to be exposed for 100 minutes (10 x 10).

8

The same protection factors are used for all particle masks. This does create some surprising results such as the highest protection level on half masks and disposable masks are the same, P3 or an APF of 20, and the normal protection factor of a powered mask fitted with a P3 filter is an APF of 40.

9

If there is any doubt regarding the level of protection required, which type of respiratory protective equipment should be provided or which cartridge should be used on a respirator, advice should be sought from a competent person, or advice taken from the respiratory protective equipment manufacturers/suppliers.

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Disposable face mask respirators

These are simple face masks designed to filter out harmful dust and particles. They are lightweight, comfortable and cheap. They should only be worn by one person and for no longer than a single eight-hour shift. They should be disposed of after use.

11

In areas of high dust levels, it may be necessary to dispose of dust masks more frequently, since they may become clogged and, subsequently, breathing will become more difficult.

12

The big advantage of disposable masks is that they do not need any inspection or record keeping as they are designed to be simply thrown away. This may be a major factor in choosing them as a solution, particularly if the wearers of such masks are normally out on different sites.

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Nuisance dust masks It should be noted that nuisance dust masks are not classed as personal protective equipment or respiratory protective equipment. They do not meet any current standards o legal requirements, and are dangerous in the respect that they give the uninformed user a false impression that they are providing a level of protection. The filter size used in their construction is so large that any particles that they manage to keep out would have been safely dealt with by the body's own defence mechanisms.

14

They typically come in two forms which are either a metal plate that holds a piece of gauze over the nose and mouth or a lightweight cup-shaped filter, again fitting over the nose and mouth, and looking like a disposable dust respirator.

15

Nuisance dust masks are often identifiable by only having one strap and the device is not marked with a protection factor (e.g. P1, P2 or P3). They should not be confused with approved disposable dust masks which will bear the appropriate EN number and a protection factor.

16

Nuisance dust masks should not be issued or used in any circumstances where these Regulations (COSHH) apply or may apply.

17

People who work with harmful dusts should always be provided with, and use, the correct type of CE-marked dust mask or respirator to ensure proper and effective protection.

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Half-mask dust respirator 18

This is one of the most common types of respirator used. It consists of a face mask which covers the nose and mouth of the wearer, and a suitable filter through which air is drawn by breathing.

19

The main advantages of this type of respirator are its low cost, easy maintenance, and the fact that it provides the wearer with freedom of movement.

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Half masks

The filtering canisters or cartridges used in these respirators may be round, oval or triangular, and are often colour-coded to indicate the type of contaminant they give protection against. If a 'use by' date or shelf life is specified, it must be adhered to.

21

High efficiency dust respirators provide protection by drawing air in through the filter system by inhalation.

22

The advantage that this type of mask offers over a disposable mask is that it is usually possible to fit filter cartridges of different types, for example, changing from a dust filter to a fume filter.

23

The disadvantage is that as well as face fit testing, the mask needs some form of identification and regular inspection by a competent person, who then records the detail of the inspection. This exercise can be logistically challenging.

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Powered respirators 24

A powered respirator has a filtered air supply provided to the wearer by a small, batteryoperated pump and filter unit which will deliver air continuously for approximately seven hours. The air pressure inside the mask facepiece is slightly higher than normal air pressure, and therefore filtered air leaks out rather than letting potentially contaminated air enter.

25

These respirators are most suitable for specialised applications, as they are relatively comfortable, and they can be worn where long periods of exposure are involved. The users must be face fit tested and the fit test method must be the so called 'quantitive test', which usually involves the use of a computer and test equipment called a portacount.

26

Batteries must be changed or recharged and filters cleaned or replaced at scheduled intervals to maintain peak efficiency. Ventilated visor and ventilated helmet respirators

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In this type of equipment, a small axial fan housed in the back of the helmet draws in dustladen air through a series of filters situated in the crown of the helmet. Filtered air is then passed downwards over the user's face, maintaining a positive pressure in the region of the nose and mouth. The unit is powered by a rechargeable battery pack worn on a belt.

28

This type of respirator is comfortable and combines protection against dust with the protection afforded by a safety helmet (manufactured to BS EN 397) and face and eye protection (to BS EN 166). Advice should be taken from the manufacturer with regard to the substances the mask will protect against. They are quite comfortable to wear. Tunnelers will be familiar with a version that includes hearing protection, lamp and hard hat as an all-in-one headpiece.

29

Efficient maintenance and cleansing procedures are essential. If the flow of air is reduced by clogged filters or low battery power, unfiltered air can be drawn in around the side of the facepiece.

30

This type of mask does not require a face fit test as it does not seal tightly on the wearers skin. It is the only type of commonly used mask that someone with a full beard can wear.

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Compressed air line breathing apparatus With this equipment, air is supplied to the user from a compressed air supply, via a hose to the face mask or hood. The correct air pressure, temperature and humidity must be maintained.

32

The air supplied must be of breathable quality, thus the selection, siting and maintenance of the compressor and filtration of the air supply is vitally important.

33

The presence of an air hose can, on some occasions, restrict the user's movements.

34

As with all types of breathing equipment, operators should be properly and adequately trained and, unless experienced in the type of work to be carried out, should be properly supervised.

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Self-contained breathing apparatus 35

In a set of self-contained breathing apparatus, air is usually supplied from compressed air cylinders carried on the worker's back and is fed to a full face mask via a regulator. As with the air line apparatus, operators must be properly and adequately trained and, unless experienced in the type of work to be carried out, must be properly supervised.

36

A limitation is that the typical duration of a compressed air cylinder is between 20 minutes and two hours. The equipment should therefore only be selected by competent persons with a full knowledge of their use.

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1.2.9.23 Dust sampling Sampling is usually carried out by a specialist using metered pumps with membrane filters. The dust collected is weighed in relation to the amount of air sampled. Dust samples can also be examined for type.

2

There are also some direct-reading dust sampling monitors available. However, there is some doubt as to the accuracy of these instruments. They are very useful for a long-term project where they can be calibrated regularly by comparing their readings against samples taken from membrane filters.

3

They are not recommended as the sole means of measuring a personal exposure to dust. It is also important to be aware that there are a number of different laboratory techniques required for analysis, for example, measuring exposure to silica normally requires X-ray diffraction.

4

Use of Tyndall Beam to identify dust clouds

5

The Tyndall Beam is a useful way to determine whether a problem exists before investigating further. It uses the common phenomenon of dust being highlighted in a shaft of light.

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1.2.9.24 Training and supervision 1

New employees should receive full instruction before starting work and should be familiarised with the following: (a)

the health risks associated with dust and the preventative measures in operation, as identified by the risk assessment

(b)

the correct use and cleaning of protective clothing and equipment

(c)

the reasons for air sampling

(d)

their duties in respect of the correct use of equipment and of safe systems of work in operation

(e)

the procedures for reporting defective or inadequate equipment.

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Construction site Safety 1.2.9 Appendix 1 Control of fumes Safety checklist An assessment must be carried out.

2

All hazardous processes and operations have been identified.

3

All personnel have been fully instructed in the types of hazard likely to be encountered.

4

There is adequate supervision of all work operations.

5

All personnel are competent to carry out the work operations.

6

Correct and adequate protective clothing is provided and used.

7

Respiratory protective equipment is provided and used, as necessary.

8

Face fit testing and records for the RPE are available.

9

Exhaust ventilation or extraction equipment is used, as required.

10

The correct type of eye protection is provided and used, as necessary.

11

Safe working methods are being adhered to.

12

No one under 16 years is employed (lead burning).

13

Chlorinated solvents, paints, adhesives, and so on are: stored safely

(b)

used safely.

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Personnel have been made aware of the hazards that exist when working with chlorinated solvents, paints, adhesives, and so on.

15

Engine exhaust gases are led directly out of confined spaces.

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There is adequate supervision of all work operations.

17

Materials, substances and associated hazards have been properly identified.

18

Manufacturers' or suppliers' instructions are available and observed.

19

Power tools are fitted with a dust extraction and collection facility.

20

Local exhaust ventilation is fitted to workshop machinery.

21

The correct protective equipment is supplied and clothing provided.

22

Operatives have been instructed in the use of materials and are aware of the hazards associated with those materials.

23

There is provision for the ongoing training of employees.

24

There is provision for, and operation of, safe systems of work.

25

There is adequate provision of washing facilities, and facilities for storing overalls, and other work wear during meal breaks.

26

Correct procedures for the storage, identification and disposal of waste materials or substances are followed.

27

Adequate arrangements have been made for air sampling, as necessary.

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Construction Site Safety 1.2.10 Control of Noise 1.2.10.1 Key points Contractors and employees have duties under these Regulations.

2

Noise experienced at work, in the home and social environments can cause permanent damage to hearing.

3

There are often early signs that the hearing is being damaged; these should not be ignored.

4

Contractors should seek to control noise by other, equally or more effective, ways before resorting to personal protective equipment.

5

Effective pre-planning of site activities and the active management of noise during the construction process can significantly reduce noise exposure on site.

6

In addition to hearing damage, excessive noise can have other health and safety implications, such as not being able to hear alarms or shouted warnings.

7

Establishing the noise levels on site might not necessarily involve arranging for noise measurements to be taken.

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Note:

Section 1, Part 15.2.3 of the QCS covers noise control.

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High levels of noise on construction sites often come from machinery used for demolition, excavation or piling, from compressors and concrete mixers, etc. Other operations, such as hammering, riveting and the use of cartridge-operated fixing tools, may also be the source of excessive noise.

2

The degree of nuisance or damage caused by noise is related to the nature of the noise generated as well as its loudness. Intermittent noise is often more disruptive than a continuous noise and high-pitched sounds are more disturbing than low frequency ones. Exposure to high levels of noise can cause permanent damage to hearing in the form of partial or total deafness.

3

Contractors have a duty to control noise and protect their workers and other persons from its effects. Noise is also a source of annoyance and disruption, and may directly or indirectly lead to an increase in the risk of accidents. Every reasonably practicable step should be taken to control it.

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These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising from the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

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Employees, in turn, have legal duties under these Regulations to: (a)

tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected by their work activities

(b)

use all machinery and equipment in accordance with any training provided.

5

These Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

6

Contractors must assess the risks to employees' health arising from noise and put effective control measures in place.

1.2.10.4 Control of Noise at Work

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These Regulations: place duties on Contractors and employees

(b)

allow personal exposure to noise to be measured over a weekly, rather than an 8hour, period in situations where employees are exposed to widely varying noise levels

(c)

give employees the right to hearing checks where a noise assessment indicates their hearing could be at risk.

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Action and limit values

These Regulations specify the following three levels of exposure to noise, each of which requires that certain actions be taken:

3

Lower exposure action value. This is reached when a daily or weekly personal exposure reaches 80 dB(A) or a peak sound pressure of 135 dB(C) occurs.

4

Upper exposure action value. This is reached when a daily or weekly personal exposure reaches 85 dB(A) or a peak sound pressure of 137 dB(C) occurs.

5

Exposure limit value. This is the maximum level of noise to which anyone at work may be exposed. It is set at 87 dB(A) at the ear, measured on a daily or weekly basis as appropriate or when a peak sound pressure of 140 dB(C) occurs.

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Contractor's duties 6

These Regulations place a duty on Contractors with respect to the health and safety of employees, the Contractor is, so far as is reasonably practicable, also under a similar duty to anyone else at work who may be affected by the noise created by the Contractor's work activities

7

When applying the 'exposure limit value', Contractors may take account of any hearing protection worn; it is the level of noise actually entering the ear. Therefore, the performance characteristics of any hearing protection worn can be taken into account when assessing the noise exposure of individuals. Similarly, it must be taken into account when decisions are taken on the purchase of personal hearing protectors.

8

If employees are likely to be exposed to noise at or above the lower exposure action value, the Contractor must: (a)

carry out a suitable and sufficient assessment of the risks to employees and ensure that it identifies the measures necessary to adequately control the level of noise at work. When carrying out the risk assessment the Contractor must assess noise exposure by:

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observing work practices

(ii)

referring to information on the probable level of noise issued by tool and equipment manufacturers

(iii)

only if necessary, arranging for noise levels to be measured.

If employees are likely to be exposed at or above the 'upper exposure action value' or the 'exposure limit value', the risk assessment must also include consideration of: the level and type of noise and its duration, including any exposure to 'peak sound pressure'

(b)

the effects that the noise might have on the health of employees exposed to it

(c)

so far as is practicable, the effects on the health of employees resulting from an interaction between exposure to noise and any ototoxic substances (mainly commonuse solvents) that are in use or between noise and vibration

(d)

the possibility of warning alarms or other audible systems not being heard

(e)

information provided by the manufacturers of equipment that generates the noise

(f)

the possibility of using alternative, less noisy equipment

(g)

exposure of employees to noise when not actually working, such as in rest areas and canteens

(h)

the results of previous health surveillance and published information

(i)

the availability of suitable personal hearing protectors, taking into account their performance.

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The Contractor must regularly review the risk assessment and immediately if: there is reason to believe that it is no longer valid

(b)

there has been a significant change in the work to which the assessment applies and implement changes to the risk assessment as identified by the review process.

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(i)

The Contractor must inform at-risk employees of the findings of the risk assessment and record: (a)

the significant findings of the risk assessment as soon as is practicable after it has been made or changed the control measures that have been put in place to eliminate or reduce the noise, including the provision of hearing protection and employee training.

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Records may be kept in any form so long as they are easily retrievable and can be printed.

13

The Contractor must also:

14

(a)

generally eliminate at source the risk of hearing damage or reduce it to the lowest level that is reasonably practicable, irrespective of noise levels

(b)

where exposure is likely to be at or above the upper exposure action value, reduce the noise, as far as is reasonably practicable, by implementing organisational and technical measures other than by providing personal hearing protectors.

Contractors must consider the following: (a)

alternative, less noisy methods of carrying out the work

(b)

alternative, less noisy tools for carrying out the work

(c)

the layout of the workplace, including any rest facilities

(d)

providing employees with adequate information and training so that they can minimise

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their exposure to noise the reduction of noise by technical means

(f)

effective maintenance programmes for equipment that can generate noise, the workplace itself and workplace systems

(g)

limiting the duration and intensity of exposure to noise

(h)

adjusting work schedules and ensuring adequate rest periods.

The Contractor must ensure that employees are not exposed to noise above the exposure limit value, or if they are, immediately: (a)

reduce exposure to below the exposure limit value

(b)

identify the reasons for the exposure limit value being exceeded

(c)

take appropriate actions to prevent it occurring again.

Contractors must:

ensure that the level of noise in rest facilities that are under their control is reduced to a suitable level for their purpose

(b)

adjust and adapt any measures taken to prevent exposure to noise to take account of any person(s) whose health is likely to be particularly at risk from exposure to noise

(c)

inform employees of the measures taken to eliminate or control the level of noise in the workplace.

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(e)

Where employees are exposed to noise at or above the lower exposure action value but below the upper exposure action value, the Contractor must make suitable personal hearing protectors available to employees who request them.

18

Where employees are exposed to noise at or above the upper exposure action value, the Contractor must:

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designate the affected part of the workplace as a 'Hearing Protection Zone'

(b)

identify the extent of the area by signs indicating that hearing protectors are to be worn

(c)

restrict access to the area where practicable and it is justified by the level of risk

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ensure so far as is reasonably practicable that all employees entering the hearing protection zone wear personal hearing protection.

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Hearing protectors must be selected, so as to eliminate the risk to hearing or reduce it to as low a level as is reasonably practicable

20

Contractors must: (a)

ensure so far as is practicable that anything provided to comply with these Regulations, except personal hearing protectors, is fully and properly used

(b)

ensure that anything provided to comply with these Regulations is maintained in good working order and in a good state of repair

21

If the risk assessment indicates that there is a risk to the health of employees exposed to noise, the Contractor must ensure that those employees are placed under suitable health surveillance, including providing them with hearing tests.

22

The Contractor must: (a)

ensure that a record is kept and maintained for each employee who undergoes health surveillance and that records are readily available in a suitable format

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(b)

Where, as a result of health surveillance, an employee is found to have identifiable hearing damage, the Contractor must ensure that the employee is examined by a doctor and, if necessary, a specialist. Where the hearing damage is found to be as a result of exposure to noise at work, the Contractor must: ensure that the employee is informed by a suitably qualified person

(b)

review the risk assessment

(c)

review existing control measures, taking into account any advice given by a doctor, occupational health professional or administrative authority

(d)

consider reassigning the employee to other work where there is no risk of further exposure, taking into account any advice given as above

(e)

continue with the health surveillance of affected employees.

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Where employees are exposed to noise at or above the lower exposure action value, the Contractor must provide the employees with suitable and sufficient information, instruction and training, which must include: the nature of the risks arising from exposure to noise

(b)

the control measures taken to eliminate or reduce exposure

(c)

the exposure limit value and the lower and upper exposure action values

(d)

the significant findings of the risk assessment

(e)

the availability and provision of personal hearing protectors and how to use them correctly

(f)

why and how to detect and report signs of hearing damage

(g)

the employees' entitlement to health surveillance

(h)

how to work safely to minimise noise exposure and thereby avoid hearing damage

(i)

the collective results of any health surveillance carried out, anonymised so as not to reveal the personal health record of any individual.

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The information, instruction and training provided as above must be updated by the Contractor to take account of any significant changes of the type of work carried out or method of working.

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allow employees to see their health surveillance records on being given reasonable notice

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Employees' duties 26

Employees must: (a)

make full and proper use of personal hearing protectors if the noise exposure exceeds the upper exposure action value

(b)

make full and proper use of other control measures provided by the Contractor

(c)

report any defects in the personal hearing protectors or other control measures to their Contractor

(d)

make themselves available for health surveillance checks (during working hours) as required by the Contractor, the health surveillance being at the Contractor's expense.

1.2.10.5 The nature of noise 1

Sound is the transmission of air vibrations at different frequencies. Noise is sometimes defined as unwanted sound. The ear is a pressure-sensitive mechanism, detecting small

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changes of air pressure over a wide range of frequencies of 20-20,000 cycles per second. The unit of frequency is the hertz (Hz). Those with impaired hearing due to age or other forms of hearing loss are less likely to be able to hear the higher frequency range. Audiometry is the technique used to determine the capacity of the ear to detect sounds of varying loudness over a range of frequencies. It can be used to measure an individual's hearing capacity against a recognised standard. Successive audiometric checks can confirm whether or not a person is suffering from progressive hearing loss.

3

When judging the level of noise, the 'rules of thumb' are that if you have to raise your voice to make yourself understood at 2 metres from the other person, the background noise is around 85 dB(A). If the distance is only 1 metre, the noise is around 90 dB(A).

4

A peak sound pressure of 137 dB(C) will be produced by many impact tools such as cartridge-operated tools.

5

Two "types' of noise may damage the hearing of the people who are exposed to it:

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Continual or periodic noise, which even if varying over the course of time, can be measured and averaged out over an eight-hour (or in some circumstances a weekly) reference period. This is known as the 'daily (or weekly) personal noise exposure' as referred to in these Regulations. This is the common everyday noise that is experienced on many construction sites.

(b)

Sudden, short bursts of loud impulsive noise such as experienced during the driving of piles, the use of explosives or the use of some hand tools. The references in these Regulations to 'peak sound pressure' are to this type of noise.

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1.2.10.6 Effects of noise at work

Noise levels may fluctuate widely or be relatively steady. A reasonably steady sound level is where the level fluctuates through a total of less than 8 dB(A) on a slow response scale.

2

Exposure to noise can have the following consequences:

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It can cause annoyance and irritation.

(b)

It may affect concentration and efficiency.

(c)

It may cause fatigue and the likelihood of accident proneness.

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It can mask out other sounds, preventing a person's ears from registering instructions and warnings.

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(e)

It can result in temporary hearing loss.

(f)

Regular exposure to loud noise can cause damage to the ear and permanent loss of hearing.

There is also growing evidence that continued exposure to noise has consequential effects on some other illnesses. Hearing loss

4

Hearing loss can be temporary or permanent. Temporary deafness is often experienced after leaving a noisy place. It is often accompanied by a ringing in the ears. Although hearing usually recovers within a few hours, this symptom should not be ignored. It should be taken as a sign that further or continued exposure to noise is likely to result in permanent damage. Permanent hearing damage can also be caused immediately by sudden and loud noises, for example from explosives or cartridge-operated tools.

5

Hearing loss due to prolonged exposure to noise is usually gradual. It may only be when

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damage caused by exposure to noise over the years combines with normal hearing loss due to ageing that people realise how deaf they have become. 6

Prolonged exposure to noise can also cause tinnitus, which can be described as a permanent ringing, whistling or buzzing in the ears. This distressing condition can lead to disturbed sleep which, in turn, can lead to fatigue even before an employee arrives at work. Other adverse effects of noise

7

At work, noise can also be a safety hazard, interfering with communication, the understanding of instructions and, most serious of all, making warnings harder to hear. Noise can also cause stress.

1.2.10.7 Establishing noise levels

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Unit of measurement

The unit of measurement for sound levels (noise) is called a decibel (dB). This scale is logarithmic and means that 90 dB is ten times the intensity of 80 dB and one hundred times the intensity of 70 dB.

2

An increase of 3 dB doubles the energy in the sound. This means that, for example, 87 dB is actually twice as damaging as 84 dB, even though the 3 dB difference in sound level is difficult to perceive.

3

Sound level meters, used for measuring noise levels, have standard 'filters' built into them that attenuate or emphasise signals at different frequencies in order to simulate how the sound affects the ear. This is known as 'frequency weighting'.

4

An instrument with a frequency weighting known as an 'A' weighted scale is commonly used on construction sites to measure noise from the working environment. Readings are expressed as dB(A).

5

Sudden impact noises, hammer blows, etc. are measured in terms of maximum pressure. In this case measurements are 'C' weighted and therefore expressed as dB(C).

6

Risk assessments should be based on measurements of the 'Leq', which is an average of the level of noise for the duration of the measurement.

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Risk assessments 7

If any employee is likely to be exposed to noise at or above the lower exposure action value, the Contractor must carry out a risk assessment which may or may not result in the need for a competent person to measure the actual level of noise exposure.

8

Any new tool or equipment that generates a potentially harmful level of noise should state the actual level of noise generated, either on the tool itself or in the accompanying documents. This can be useful in identifying potentially problematic tools, but it is important to remember that the actual noise experienced by the operator depends on many factors, such as the acoustics of the working environment, tool configuration and material being worked. Survey of noise levels

9

If it is necessary to resort to the measurement of noise, someone who is competent in evaluating the type of workplace, the use of the equipment and the interpretation of the results must be engaged. They must be able to draw valid conclusions from the information obtained and advise management on the actions needed to comply with the requirements of

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legislation.

(a)

identify workers who may be at risk of hearing damage to enable an action plan to be prepared to control the noise exposure

(b)

determine the daily personal noise exposure (LEP,d) of workers (including times when not actually working (for example, rest areas) and from non-occupational sources such as personal entertainment systems)

(c)

identify additional information to comply with these Regulations, for example, whether noise control measures or hearing protection are needed and, if so, where and what type.

The Contractor must: keep a record of the noise assessments and the employees exposed to the noise

(b)

regularly review those assessments. This should be done biannually or whenever it is considered that the assessment is no longer valid, for example, whenever there is new equipment or a change to the process that may alter noise levels

(c)

use the assessment to develop an action plan for introducing noise control measures

(d)

deal with the immediate risk by providing personal hearing protectors (this should only be until other controls have been investigated and implemented)

(e)

identify what steps are reasonably practicable to reduce the noise exposure of employees by engineering or other organisational means

(f)

establish priorities for action and consider what changes may need to be phased in over the course of time.

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The aim of the noise assessment is to:

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Ideally, one person, with sufficient authority, will be given the responsibility for ensuring that these Regulations are complied with and for co-ordinating and monitoring the noise reduction programme where necessary.

13

Nomograms (see Appendix 4) can be used to establish the equivalent continuous sound level for an eight hour period or daily personal noise exposure (LEp,d)

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Typical sound intensities

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1.2.10.8 Avoiding exposure to noise

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Attention should be given at the planning stage to developing a noise control strategy that considers the following factors: The design of the project, and of the processes and equipment which will be involved.

(b)

The phasing of differing operations, especially if a number of contractors are working on site.

(c)

The location of the site; or sites if the project involves more than one location.

(d)

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The noise levels that are likely to be produced by the work being carried out. The layout of the site, including the siting of access points, batching plants, etc.

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Planning against excess noise levels

2

(f)

The hours of working which are planned.

(g)

The provisions available for controlling noise on site.

(h)

The possibility of disturbance to nearby residents and properties. (If this is likely, the situation and measures to be taken to reduce noise should be explained to persons likely to be affected.)

Failure to plan the control of noise may lead to delay and increased cost later. Where appropriate, noise levels must be a consideration for designers under CDM. Reference BS 5228 Noise and vibration control on construction and open sites Managing noise levels during construction

3

Exposure to noise can be eliminated or reduced by: (a)

controlling noise at source

(b)

employing engineering controls where possible

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(c)

using a purchasing/hire policy for plant, equipment and tools that takes noise into account

(d)

introducing alternative methods and processes that eliminate or reduce noise levels

(e)

giving consideration to the careful siting of noisy plant, and equipment

(f)

where practical, storing bulk materials to form an acoustic screen

(g)

carrying out job rotation for employees to reduce exposure to noise

(h)

providing rest rooms or acoustic refuges for staff during breaks from work

(i)

rearranging work locations for staff, if possible, away from noisy equipment

(j)

as a last resort, providing personal hearing protectors.

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Controlling the noise at its source can be achieved by a variety of means, by: the design and manufacture of the equipment.

(b)

the use of acoustic covers and exhaust silencers for equipment

(c)

the use of alternative, less noisy equipment or methods of working

(d)

enclosing noisy equipment within temporary structures

(e)

regular inspection and maintenance of the equipment being used

(f)

fitting noise-absorbent mountings to reduce the transmission of noise through adjacent structures.

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Control of noise at source

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Reference BS 5228 Noise and vibration control on construction and open sites

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Measures that can be taken include ensuring that all equipment which has the potential to create excessive noise: is kept well maintained

(b)

is kept in good order, including ensuring that there are no loose panels or casing and that exhaust mufflers are in good condition is not left running when it is not actually in use.

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Engineering controls

Siting or location 6

7

Effective siting or location includes: (a)

Removing the source of the noise to a distance whenever possible (see Appendix 2).

(b)

Orientating plant to direct the noise away from the work area.

(c)

Placing site buildings, stores, etc. between the noise source and noise sensitive areas.

(d)

Screening the noise source with a barrier, wall, acoustic screen, spoil heap, or by locating the source behind partly completed buildings.

The effectiveness of a noise barrier will depend on its dimensions, its position relative to the source and the listener, and the material used in the construction of the barrier. Care must be taken to ensure that barriers do not, by reflecting sound, transfer the noise nuisance from one sensitive area to another and so create a health problem for someone else.

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Effect on working hours 8

The effect on maximum working times of exposures to equivalent continuous sound levels without any hearing protection are listed in Appendix 1 of this section.

1.2.10.9 Personal hearing protectors All hearing protectors produced or imported by reputable companies are manufactured to British or International Standards. As with all PPE for use at work, ear protectors should be selected by a competent person who can ensure, in discussion with the supplier, that it possesses the necessary performance characteristics. Most leading manufacturers and suppliers will offer their own advisory service.

2

Competence in the selection of this type of PPE is particularly important as ear protectors that give good protection against noise at a high frequency may not offer very much protection against low frequency noise, and vice versa.

3

All reasonably practicable methods must be used to reduce noise levels, but where these remain at or above the upper exposure action value, after control measures have been implemented, ear protectors must be made available and worn. Ear protectors are not a substitute for other methods of noise control, they are an absolute last resort.

4

Employees may initially be reluctant to wear ear protection and those who are at risk must be made aware of the potential for hearing loss that can be caused by exposure to excessive noise levels.

Mandatory warning sign: 'Wear ear protectors'

Colour: white symbol on circular blue background

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Other considerations 5

Personal hearing protectors must be provided on an individual basis.

6

A competent person must be responsible for any training that may be necessary in the correct use of personal hearing protectors.

7

Personal hearing protectors should normally be provided as an interim measure while more effective and permanent methods of control are sought.

8

Employees must be trained in the use, care and storage of ear protectors.

9

Ear protectors must be suited to the user and suitable for the type of noise.

10

They must provide an effective seal.

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11

They should be stored in a clean place when not in use, unless disposable.

12

They should be inspected regularly for deterioration or damage and replaced when necessary, unless disposable.

13

Personal hearing protectors should not 'over protect' whereby users can become isolated from their work environment and unable to hear warnings.

14

Note: A check should be made to ensure that hazard warning signals are audible to individuals wearing ear protectors, and the volume, tone, or method of signalling changed if necessary.

1.2.10.10

Types of personal hearing protectors

The two basic types of protector are ear plugs and ear defenders.

2

Disposable ear plugs: These are made of very fine mineral fibre or foam, sometimes ready shaped. They must be inserted correctly and, if taken out, should not be reused. They should only be handled with clean hands.

3

Reusable ear plugs: These are made of rubber or plastic, and need regular, careful washing. The initial supply and fitting should be carried out by trained persons. Different sizes may be required for each ear and must be a good fit. They must be fitted with clean hands as any contamination by dirt, grease or swarf may cause ear irritation. Ear plugs are therefore unsuitable on site for intermittent use, such as can occur when operating a breaker.

4

Ear defenders (or muffs): These completely cover the ear and are sealed to the head with a foam or liquid-filled seal. Badly designed or badly produced defenders may give little or no protection against noise. Other points are as follows: pressure from the seal may cause wearers to complain of tightness, but loose defenders lose most of their protective capability and are ineffective

(b)

damage and deterioration to seals also results in ineffectiveness and loss of protection

(c)

in fitting, account needs to be taken of people with different sized or shaped heads or ears, hair styles and spectacles

(d)

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defenders fitted to safety helmets may cause problems by not fitting tightly to the ear, or by moving as the helmet moves

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(e)

facial hair and the arms of spectacles may interfere with the seal on ear defenders

(f)

defenders must be chosen to deal with a particular noise problem; ones that offer protection against low frequency sound may be ineffective at high frequency, and vice versa.

5

Ear defenders which incorporate a sound enhancement system are available. When noise levels are low, sound detected by a microphone is replayed to the wearer enabling them to communicate normally. When noise levels are high, the sound replay system is automatically cut, such that the defenders act as regular ear protectors. Such products are particularly suitable for those exposed to unpredictable short bursts of noise.

6

Ear protectors are only effective while they are being used. If protectors are worn for only half the shift, only some 10% protection is gained; if worn for 7% out of 8 hours, the protection factor is still only 75%.

7

Contractors providing hearing protectors that perform 4 dB better than the required minimum, in order to take into account 'real world' factors such as poor fitting.

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Construction Site Safety 1.2.10. Appendix 1 The effect on maximum working times due to exposure without protection

Maximum exposure in one working day if 80 dB(A) (LEp,d) is not exceeded

80

8 hours

83

4 hours

86

2 hours

89

1 hour

92

30 minutes

95

15 minutes

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Average noise level dB(A)

98

7.5 minutes

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3.75 minutes

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Increase of protection gained in relation to time if ear protectors are worn

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Construction Site Safety 1.2.10. Appendix 2

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How sound levels vary with distance from source

Notes: 1

This assumes that the sound at the measurement point only comes directly from the source and there are no reflections from the ground or any other objects

2

This is the noise level at the ear and not at the source

3

The graphs on pages 14 and 15 of this module are based on the International Organisation for Standardisation standard where an increase of 3 dB(A) is regarded as doubling the noise level or halving the exposure time.

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Construction Site Safety B10. Appendix 3 Calculating personal noise exposure Nomogram for calculation of equivalent continuous sound level for an eight hour period, so giving the daily personal noise exposure.

2

For each exposure, connect sound level dB(A) with exposure duration t and read fractional exposure f on centre scale.

3

Add together values of f received during one day to obtain total value of f,

4

Read equivalent continuous sound level opposite total value of f, by drawing a line through f9 from the time scale t = 8 to read LEP,d on the L scale.

5

The noise exposure figures on the nomogram are illustrative only and do not represent a legal or safe level of exposure to noise.

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Construction Site Safety 1.2.10 Appendix 4 Some typical sound levels of construction and piling equipment (Levels given are average at source) Construction equipment

95

Hand tools - electric

100 101 102

Hand tools - air Forklifts Hammer drill

103

Dumpers

104

Concrete mixer

105

Hand tools - petrol

106 107 108 109

Tower cranes Circular bench saw Trucks Excavators

110

Crawler cranes

111

Heavy lorries

112 113

Ready mix Hoists diesel

114

Loading shovel

115 116

Rock drill Batching plant

117 118

Generators Loaders

119

Cranes - lorry mounted

120

Compressors - compactors

128 136 138

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6 tonne drop hammer (cased piles)

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Bulldozers - graders

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Piling equipment

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Sound level dB(A)

Trench hammer (sheet piles) Rotary bored piles Screen drop hammer (sheet piles) Impact boring (driving case method) 2 tonne drop hammer (pre-cast concrete piles) Vibration system (sheet piles) Resonant system 'h' section Single acting air hammer (pre-cast concrete) Diesel hammer (sheet piles) Double acting air hammer (sheet piles)

These sound levels are for guidance only. Information should be sought from the manufacturer or the plant hire company regarding machines on site. Noise levels emitted from the machines will be affected by the competence of the operator and the quality of maintenance. For accurate measurement of site noise, a survey is necessary.

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Summary of legal requirements

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Contractors' duties

Exposure below the Exposure at or Exposure at or Exposure at or lower exposure above the lower above the upper above the action value of 80 exposure action exposure action exposure limit values of 80 dB(A) values of 85dB(A) values of 87dB(A) dB(A) or peak sound or peak sound or peak sound pressure of pressure of pressure of 140 dB 135dB(C) 137dB(C)

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Assessment of noise exposure







Record of significant findings and control measures put in place

















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Risk assessment to be carried out and reviewed as necessary

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Risk assessment to include extra considerations in higher risk situations General duty to reduce risk Risk of hearing damage to be eliminated or reduced to the lowest level reasonably practicable





Implement organisational and technical control measures, excluding issue of personal hearing protection



Reduce exposure below exposure limit value (ELV), if ELV breached, identify why and modify organisational and technical measures Ensure noise exposure in rest facilities is kept to acceptable level







Adapt control measures as necessary to take account of employee(s) who may be particularly at risk from exposure to noise







Consult with employees on protective measures taken



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

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Exposure below the lower exposure action value of 80dB(A)

Exposure at or Exposure at or Exposure at or above the lower above the upper above the exposure action exposure action exposure limit values of 80 values of 85 values of dB(A) or peak dB(A) or peak 87dB(A)or peak sound pressure of sound pressure of sound pressure of 135dB(C) 137 dB(C) 140 dB

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Contractors' duties (continued)

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Provision of hearing protection

Ensure that personal hearing protectors are: provided to employees who ask for them



provided to all those exposed



used by all those exposed.

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















Create hearing protection zones, designated by appropriate signs and: 

restrict access if justified by the level of risk







ensure as far as is reasonably practicable that all who go into a marked hearing protection zone use hearing protection.



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Exposure below Exposure at or Exposure at or Exposure at or the lower above the lower above the upper above the exposure action exposure action exposure action exposure limit value of 80 dB(A) values of 80 values of 85 values of 87 dB(A) or peak dB(A) or peak dB(A) or peak sound pressure of sound pressure of sound pressure of 135dB(C) 137 dB(C) 140 dB

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

all equipment provided under these Regulations, except personal hearing protectors, are fully and properly used all equipment is maintained in an efficient state and good working order.

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Maintenance and use of equipment Ensure so far as is reasonably practicable that:

the nature of the risks to hearing from noise the organisational and technical measures taken the action and limit values the significant findings of the risk assessment

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Information instruction and training Provide adequate information, instruction and training and update it as necessary, on: } } } }

 how to obtain a personal hearing protector }  how to detect and report signs of hearing damage }  the entitlement to health surveillance }  the results of any collective health surveillance. } Provide information, instruction and training for anyone who has responsibilities for ensuring the Contractor's legal duties are carried out.

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Exposure below the lower exposure action value of 80dB(A)

Exposure at or above the lower exposure action values of 80dB(A) or peak sound pressure of 135dB(C)

Exposure at or above the upper exposure action values of 85dB(A) or peak sound pressure of 137 dB(C)

Exposure at or above the exposure limit values of 87dB(A) or peak sound pressure of 140 dB

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Health surveillance

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Provide as appropriate if the risk assessment indicates there to be } a risk to employees' health resulting from noise at work }

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Keep and maintain records of health surveillance } Enable employees access to their own health surveillance }

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Where employee found to have hearing damage: }  ensure the employee is informed by a suitably qualified person }  review the risk assessment and control measures }  consider assigning the employee to alternative (non-noisy) work }  continue with health surveillance. } Employee's duties Use of equipment Employees must:  make full and proper use of personal hearing protectors  use any other control measures provided by the Contractor 

report any defects discovered in the protective measures to the Contractor. Health surveillance Attend health surveillance procedures as required by the Contractor in working hours and at the Contractor's expense.

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Construction Site Safety 1.2.11 Protection of the Eyes 1.2.11.1 Key points Many eye injuries occur to people at work each year because eye protection is not being worn.

2

These accidents are easily preventable simply by wearing the correct type of eye protection.

3

The loss of sight, even in one eye, will have a profound effect on the sufferer.

4

Given the nature of most construction sites, in many cases protection of the eyes will be achieved by the issue and wearing of appropriate personal protective equipment (PPE).

5

In common with other types of PPE, Contractors must:

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identify the correct type of eye protection necessary;

(b)

provide it at no charge to employees who need it;

(c)

provide adequate information, instruction and training in its use;

(d)

make sure that it is worn.

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Users of eye protection must:

wear it when there is a risk of eye injury as indicated by a risk assessment;

(b)

look after it, particularly with regard to protecting the lenses or face shield;

(c)

return it to any accommodation allocated to it when not in use;

(d)

report to the Contractor any defect, such as scratched or crazed lenses, and obtain a replacement;

(e)

report to the Contractor if it is lost and seek a replacement.

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A person's eyes are very vulnerable and an accident or injury can completely change that person's way of life.

2

Analysis of the injuries to people's eyes shows that damage is caused as follows:

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(a)

75% by impact

(b)

10% by abrasion following ingress of dust or other foreign body

(c)

15% by burns or chemical contamination.

3

The majority of these injuries would have been prevented if the correct eye protection had been worn.

4

Contractors must make a provision for the protection of the eyes of employees at work.

5

The protection provided must conform to the approved specifications and includes goggles, visors, spectacles, face screens and fixed shields, either free standing or attached to machinery or plant.

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The Management of Health and Safety at Work

1.2.11.3 Personal Protective Equipment

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If a risk assessment identifies that employees may be exposed to a risk of injury to their eyes then, unless the risk can be adequately controlled by other means, the Contractor has a duty to supply eye protection and must take all reasonable steps to ensure that it is worn. Selection of all personal protective equipment should be carried out by a competent person.

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Duties of Contractors

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Eye protectors should be:

issued on a personal basis to the person at risk

(b)

maintained and readily available in sufficient numbers for persons occasionally employed.

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Eye protectors and shields Issue and availability

Eye protectors should be kept available in sufficient numbers so that any which become lost, destroyed or defective can be replaced.

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Replacement of eye protectors

All eye protectors and shields provided must comply with British or International specifications and be:

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Construction and marking

(a)

suitable for the type of work or risk involved

(b)

suitable for the user to give them minimum discomfort and ease of movement whilst working

(c)

marked to identify their type and suitability

(d)

maintained, kept clean and disinfected.

Fixed shields 5

Fixed shields provided must: (a)

conform to the relevant European Standard specification

(b)

be cleaned regularly, disinfected and properly maintained

(c)

be so constructed and kept in position as to protect the eyes.

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Duties of employees 6

It is the duty of an employee: (a)

to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or others

(b)

where there is any risk of injury to the eyes, to use the protection provided in accordance with the instructions and training given (i)

to take care of eye protectors

(ii)

to report any loss or defect to the Contractor.

1.2.11.4 Eye Protection

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Identifying the type of hazard Only when the Contractor has carried out a risk assessment to determine the hazards can the correct type of eye protector be supplied.

2

Some of the types of hazard detailed require eye protectors to have sufficiently strong lenses or shield to withstand the impact of particles or fragments striking them.

3

The effectiveness of the seal made between the eye protectors and the operator's skin is very important in affording protection against the type of hazard where irritant or corrosive materials are involved.

4

The ability to withstand high temperatures or reduce strong light and glare is a main requirement for the other types of eye protector.

5

For further information concerning specific requirements or combinations of different kinds of protection, manufacturers' literature should be consulted.

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1.2.11.5 Types of eye protector

There are several types of eye protector and it is important to select and issue the correct type to give the required protection. The types and their markings are listed in Appendix 1.

2

Examples of the types of work for which the various standards of eye protection might be used, are listed in Appendix 2.

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1.2.11.6 Eye protection safety checklist 1

Have operations requiring eye protection been identified?

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Has the work activity been assessed to determine what, if any, hazards exist?

3

Are appropriate types of eye protection available for the various work activities to be carried out?

4

Does all eye protection comply with the relevant standard?

5

Is the eye protection supplied on a persona] basis to employees?

6

Are there sufficient quantities of eye protectors available for occasional users?

7

Is the use of eye protection satisfactorily monitored?

8

Have employees been informed of work activities requiring eye protection?

9

Have employees been trained in the correct use and maintenance of eye protection?

10

Are employees aware of their

11

responsibilities with regards to the care and reporting of loss or defective eye protectors?

12

Are appropriate safety signs displayed?

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1.2.11.7 Lasers

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2

Items of equipment producing light amplification by the stimulated emission of radiation, more normally known as lasers, are widely used on construction sites, mainly for alignment and levelling in civil engineering. Most are of the helium or neon continuous wave type and emit visible light, but some lasers emit in the invisible infrared region of the electromagnetic spectrum, and these require extra caution.

2

The optical radiation produced by a laser is absorbed by the first few centimetres of the body and so the skin and eyes are the tissues most at risk of damage.

3

All lasers should comply with BS EN 60825. This standard groups laser products into five classes (with some subclasses), based on acceptable emission levels, and is intended to ensure that the manufacturer and user of laser products comply with current requirements.

4

Appendix 3 reproduces an extract of information contained in BS EN 60825.

5

The use of Class 1 and 2 products is preferred on construction sites because these represent the lowest risk of eye injury. However, even these lower power lasers can cause eye damage if they are misused, for example, staring directly into the beam or viewing the beam through any magnifying device.

6

Class 3R and 3B lasers, which may sometimes be in use, can involve hazards to both the user and other personnel. Those who maintain, operate and supervise the use of these products must be fully trained, competent and capable of implementing the necessary safety and hazard control procedures.

7

Where lower power lasers are used, the human 'blink reflex' will offer some protection. However, this should not be relied upon and is unlikely to offer any protection from higher power lasers.

8

Appendix 4 outlines the hazards arising out of the uses of the various classes of laser and control measures necessary.

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General procedures Full training and information must be given to persons using lasers.

10

There should be no unauthorised access to any laser equipment.

11

All personnel must be aware of the hazards when working with lasers, the safe working procedures and accident reporting procedures.

12

Any necessary eye protection equipment, hazard signs, barriers, etc. must be available and in use as necessary.

13

Any eye protectors used in conjunction with lasers must be suited to the wavelength of the laser in use. General purpose safety glasses offer no protection whatsoever against lasers and should not be used.

14

All hazard areas must be clearly defined with signs and barriers.

15

The laser beam should only be directed at non-reflecting surfaces. Any adjacent reflective surfaces must be covered, otherwise the beam will diverge and could affect other areas and people not directly involved in the job.

16

Extra care must be taken when working near reflective surfaces (e.g. water, dust, spray) which cannot be marked or covered.

17

Special precautions must be taken when working near roads, airfields and other public areas, where a stray beam could cause a hazard.

18

When work activities require the use of high powered lasers, the work should, when possible, be undertaken when the site is vacated (such as evenings or weekends). If this is not possible, special precautions will be necessary to ensure that unauthorised persons do not enter the work area or any designated area.

19

See Appendix 3 for specific precautions.

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In the event of an eye injury caused by a laser No medication is to be applied to the eye.

21

The eye involved should be covered with a clean, dry material.

22

Immediate medical attention should be sought.

23

A thorough ophthalmic examination should be carried out within 24 hours, with a full biophysical investigation.

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Laser safety checklist Has a risk assessment been carried out?

25

Only competent and trained people must be allowed to operate laser equipment.

26

The hazard area should be defined and clearly marked.

27

Create an 'exclusion zone' when the more powerful classes of laser are being used.

28

When work with lasers is taking place, only authorised people should be allowed in the area.

29

The correct eye protection must be in use during all laser operations.

30

There should be no danger to any other person(s) resulting from stray reflections or from any activity involving the use of lasers.

31

Where necessary, the source and direction of the laser beam should be clearly identified.

32

The laser beam should only be directed at a non-reflecting surface.

33

Any other reflective surfaces should be covered.

34

All laser equipment should comply with British Standard EN 60825.

35

Beam attenuators and any other safety devices must be in use when using Class 3R and 3B products.

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Construction Site Safety 1.2.11 Appendix 1 The standards of eye protection Hazard description

Marking BSEN 166 (1 or 2).S

Low energy impact (45 m/sec)

BSEN 166 (1 or 2).F

Medium energy impact (120 m/sec)

BSEN 166 (1 or 2).B

High energy impact (190 m/sec)

BSEN 166 (1 or 2).A

Droplets and splashes of liquid

BS EN 166 (1 or 2).3

Large dust particles

BSEN 166 (1 or 2).4

Gas and fine dust particles

BSEN 166 (1 or 2).5

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Increased robustness

BSEN 166 (1 or 2).8

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Short circuit electric arc

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Molten metal and hot solids Hard coat (resistance to fine particles)

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Non-mist (resistance to fogging)

BSEN 166 (1 or 2).K BSEN 166 (1 or 2).N BS EN 175

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Face shields (welding)

BSEN 166 (1 or 2).9

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Notes:

The 1 or 2 in the BS EN numbers refer to the optical characteristics of the PPE.

2

Eye protectors manufactured to the British and European Standard are subjected to a number of tests (including temperature, robustness and optical quality) before approval.

3

In the test of robustness, for example, general purpose goggles to EN 166.1 .S must withstand the impact of a 6 mm steel ball travelling at 12 m/sec (43.45 km/h). Impact goggles to EN 166.1.F must withstand the impact at 45 m/sec (160.93 km/h) and for EN 166.1.B they must withstand an impact at 120 m/sec (434.52 km/h).

4

Eye protection to BS EN 166 A is for specialist applications and is only available in the form of a face shield.

5

Safety goggles are marked with a combination of letters and numbers to indicate the standard of protection provided, for example:

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(a)

BS EN 166.1 .F is impact-resistant to a low energy projectile.

(b)

BS EN 166.1.B.3.4 is impact-resistant to medium energy projectiles, droplets, splashes of liquid and large dust particles.

(c)

BS EN 166.1.A.9 is impact-resistant to high energy projectiles, molten metal and hot solids.

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Construction Site Safety 1.2.11 Appendix 2 Selecting eye protection The following hazards are those most likely to be encountered in construction operations. Approved eye protection is required and must be provided for all persons engaged in any of the processes specified below.

2

The protection listed below is recommended as containing good practical value, but should be regarded as the minimum standard required.

3

Eye protection must be selected in the light of the work activity to be undertaken and the assessed level of risk. A suitable and sufficient risk assessment will identify hazards and indicate the control measures required to minimise the likelihood and severity of potential risks. Hazard

Recommended protection

Goggles Face shield

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Use of compressed air with shot or High speed flying other abrasives for blasting or cleaning fragments or particles (1, 2)

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PART I Processes in which approved eye protectors are required

Flying fragments or particles

Use of hand or power tools to strike masonry nails (4)


BS EN 166.B

Goggles Spectacles Face shield

BSEN 166.S


BSEN 166.F

Handling and use of cartridge-operated High speed flying tools (5) fragments or particles

Goggles Face shield

BS EN 166.B

Chipping of metal, chipping; knocking Flying fragments or out or cutting of cold rivets, bolts, nuts, particles lugs, pins, collars etc. using hand or power tools (6)


BSEN 166.F

Chipping or scuffing of paint, scale, slag, rust etc. from metal and other hard materials using hand or power tools (7)

Goggles

BS EN 166.4

Goggles Face shield

BSEN 166.B

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Cleaning by means of high pressure water jets (3)

BS specification

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Process to be considered

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Flying particles, dust

Use of power-driven high-speed metal High speed flying cutting saw, or abrasive cutting-off fragments or particles wheel or disc (8)


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Goggles

BSEN 166.3 and 4

Handling in open vessels or manipulation of the substances described above (12)

Flying particles, chemical splash, injurious dust

Goggles

BSEN 166.3 and 4

Pressure injection of liquids or solutions into buildings or structures (14)

Chemical splashes

Goggles

BSEN 166.3

Use of hand or power tools to drive in bolts, pins, collars etc. (13)



BS EN 166.F

Breaking up of metal by use of a Flying fragments or hammer (whether power-driven or not) particles or a tup


Use of compressed air to remove swarf, dust, dirt etc. (17)


BS EN 166.S

Pouring or skimming molten metal (18) Molten metal, splash, sparks

Goggles Face shield

BS EN 166.9


BSEN 166.F

BS EN 166.F

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Breaking, cutting, dressing, carving or Flying fragments or drilling with hand or power tools the particles following materials:(i) Glass, hard plastics, concrete, fired clay, plaster, slag, natural or artificial stone, and any similar materials. Also any articles consisting wholly or partly of these materials(ii) Stonework, brickwork, or blockwork(iii) Bricks, tiles, or blocks (16)

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Operation, maintenance, dismantling Flying particles, chemical or demolition of plant which contains splash, injurious dust or has contained acids, alkalis, corrosive materials, or other dangerous substances, whether liquid or solid (11)

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Cutting of wire and related operations (21)



BSEN 166.S

Cutting of wire or metal strapping under tension (22)

High speed flying fragments or particles


BSEN 166.B

Processing and handling of glass or cullet (23)



BS EN 166.S

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PART 11 Processes in which approved shields or approved fixed shields are required Electric arc welding (24)

Glare, radiation, heat, spatter

Fixed shield and/or welding Housing BS EN 175 Filters helmet or band screen BS EN 169

PART III Processes in which approved eye protectors or approved shields or approved fixed shields are required

Glare, radiation, heat, splatter

Goggles

Housing BS EN 175 Filters BS EN 169

Cutting, boring, cleaning, surfaceconditioning, or spraying of material using apparatus supplied with oxygen or flammable gas under pressure (27)


Goggles

Housing BS EN 175 Filters BS EN 169

Processes involving the use of lasers (28)

Radiation and burning

Fixed shield Goggles

BS EN 60825

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Gas welding (25)

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PART IV Process in which approved eye protectors or approved shields or approved fixed shields are required

High speed particles or fragments

Fixed shield and/or goggles

BSEN 166 B

Dry grinding of materials or articles using a power-driven wheel, disc or band, or a portable tool (31)

Flying particles or hot sparks


BS EN 166 F

Flying particles

Goggles Spectacles

BSEN 166 S

Flying particles, spatter


BS EN 166 S

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Truing or dressing of abrasive wheels (29)

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Machining of metals including any dry grinding process not elsewhere specified (34)

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Welding of metals by an electric resistance process or a submerged electric arc (35)

Cases in which protection is required for persons at risk from, but not employed in, the process Chipping of metal, chipping; knocking Flying fragments or out or cutting of cold rivets, bolts, nuts, particles lugs, pins, collars, etc. using hand or power tools (1)

Goggles Spectacles Face shield Fixed shield

BSEN 166 F

Electric arc welding (2)

Glare, radiation, spatter

Cover Goggles Spectacles

BSEN 166 S Filters BSEN 169

Process involving lasers

Radiation and burning

Goggles Spectacles

BS EN 60825

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Summary of technical requirements when using lasers

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This table constitutes a quick reference guide for the safe use of lasers. For further authoritative information, consult BS EN 60825:1991. Class 1

Labelling

Hazard warning label Yellow background with black symbol and border, with the words CLASS 1 LASER PRODUCT

Class 2

Class 3R (formerly Class 3A)

Class 3B

Class 4

1) Hazard warning label Yellow background with black symbol and border 2) Explanatory label (black/yellow) LASER RADIATION DO NOT STARE INTO BEAM CLASS 2 LASER PRODUCT

As 1 - 2 except explanatory label to read: LASER RADIATION DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS CLASS 3R LASER PRODUCT

As 1 - 3 except explanatory label to read: LASER RADIATION AVOID EXPOSURE TO BEAM CLASS 3B LASER PRODUCT

As 1 - 3 except explanatory label to read: LASER RADIATION AVOID SKIN OR EYE EXPOSURE TO DIRECT OR SCATTERED RADIATION CLASS 4 LASER PRODUCT

Key control

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Classification Requirement

Beam attenuator

Not required

Remove key when not in use

Not required

When in use prevents inadvertent exposure

Emission indicator device Not required

Indicates laser is energised

Warning signs

Not required

Follow precautions on warning signs

Beam path

Not required

Specular reflection

Not required

Eye protection

Not required

Required if engineering and administrative procedures not applicable and MPE exceeded

Protective clothing

Not required

Sometimes required

Training

Not required

Terminate beam at end of useful length Prevent unintentional reflections

Required for all operator and maintenance personnel

Specific requirements

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Laser health risks and control

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Health risks

Class 1M

Potentially harmful to the eye but only if deliberately viewed through an optical magnifying device, such as binoculars.

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Class of laser

No one must be allowed to deliberately look at the beam or to direct the beam into another person's eyes. Magnifying devices such as binoculars must not be used by any person who may be exposed to a laser beam whilst using them.

May be harmful to the eyes if deliberately misused, for example, if someone stares directly into the beam.

As above.

Harmful to the eyes if viewed through an magnifying optical device.

As above.

Class 3R (formerly Class 3A)

These are higher power lasers that can cause eye injuries, generally exposure is no more hazardous than to a Class 2 device because of the human 'blink reflex'.

BS EN 60825 specifies minimum training requirements for the users of Class 3 and 4 lasers. This will include information on the risks from the beam and the advice against misuse.

Class 3B and Class 4

A higher power laser that can cause eye injury, either directly from viewing the beam or from reflections.

Appropriate eye protection (PPE) must be worn whenever Class 3R or more powerful lasers are used. Class 3B and Class 4 lasers. Particular training on these classes of laser is required. The human 'blink reflex' is not likely to offer any protection to anyone accidentally exposed to the beam.

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Class 2

Control measures

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Construction Site Safety 1.2.12 Protection of the Skin 1.2.12.1 Key points Many of the substances used or created during construction activities have the potential to cause severe skin problems.

2

The (COSHH) risk assessment and the information on the accompanying data sheet and a substance's container should indicate the degree of risk and the preventative measures necessary.

3

Ideally, the risk will eliminated by avoiding the substance altogether, although this will often not be practical.

4

Hazardous substances created by work processes will carry no 'health warning' but must be identified in a (COSHH) risk assessment.

5

Skin conditions can be prevented by such simple actions as wearing the appropriate gloves (PPE).

6

Barrier creams offer limited protection against some substances but should not be relied upon.

7

Most substances can enter the body through openings such as cuts and grazes. Other, more hazardous, substances can penetrate unbroken skin.

8

Periodic 'self-checks' or hand-checks carried out by someone trained to recognise the symptoms are an effective form of initial health surveillance.

9

Prompt medical advice should be sought if there could be an emerging health problem.

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Industrial dermatitis is a major cause of absenteeism.

2

It is an inflammatory skin condition which is neither infectious nor contagious. It is caused by certain irritants contained in many industrial materials. Although dermatitis is not itself an infection, it can lead to infection when the skin's natural barriers break down.

3

There are two general types:

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Irritant dermatitis 4

Irritant dermatitis is usually caused by the skin coming into contact with an irritant substance -usually a chemical, but it can be a mineral.

5

Repeated exposure to extreme heat or cold can lead to physical damage to the skin and make it more likely that irritant dermatitis will occur. Wet work, which involves the hands being wet for long periods (more than two hours a day) or repeatedly getting the hands wet, can also cause dermatitis. Anyone may be affected, and the length of exposure together with the strength of the irritant substance will affect the seriousness of the complaint. Most cases of dermatitis are of this type. Sensitising dermatitis

6

Sensitising dermatitis, also know as allergic contact dermatitis, accounts for about 20% of all work-related dermatitis.

7

Some people develop a sudden allergic reaction following exposure to a specific substance.

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The reaction may be after weeks, months or even years of use or exposure to a substance without any ill effects. However, once that sensitising dermatitis has occurred, any future exposure to the substance will again produce an adverse reaction. The exposure may be to an everyday chemical or mineral, and may be as simple as exposure to nickel in jewellery.

9

The outer layer of skin forms a natural defence against irritants providing it is undamaged by cuts and abrasions, or by solvents (such as hydrocarbons, benzene, tetrachloride, spirits and thinners) that remove the skin's natural protective oils. Reaction of the skin to an irritant varies from one individual to another. The reaction may be only a mild redness or it can develop into swelling, blisters and septic ulcers that are both unsightly and painful.

10

Personal hygiene is particularly important when working with materials which may be irritants, as resistance to an irritant varies with the type of skin. Pores, ducts and hair follicles in the skin may admit irritants to the sensitive inner skin layer and, therefore, washing thoroughly to remove dirt and grime with soap and water is an essential preventative measure.

11

It is equally important that clothing is kept clean. Oil-stained overalls are a known cause of skin problems around the thighs.

12

The best course of action is to prevent skin contact with all potentially irritant substances, even if this is achieved by issuing PPE. When total avoidance of skin contact cannot be guaranteed, it will be necessary in some cases to implement occupational health screening (depending on the hazardous properties of the substance). Initially this should involve establishing whether the persons involved in the job have had any previous adverse reaction to the substance(s) in use.

13

Those people who are found to be allergic to one or more substances should be identified and not be allowed to handle or come into contact with them. Any part of the body that comes into contact with a skin irritant may be affected although it is usually the hands, wrists and forearms that are affected initially. Treatment for dermatitis should be sought as soon as possible because, if neglected, symptoms may spread to other parts of the body.

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Many substances that are used in the construction industry have corrosive properties that can cause severe burns to the skin. These substances have either strong acid or alkali properties.

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1.2.12.3 Skin burns

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1.2.12.4 Abrasion and cuts 1

Manually handling objects with rough surfaces, sharp corners etc. can cause damage to the skin of the hands if appropriate gloves, such as rigger gloves, are not worn. Repetitive manual handling may even make the situation worse. Such damage breaks the surface of the skin making it more vulnerable to absorbing other substances that could potentially have severe health effects. Worn-out gloves must be thrown away and replacements obtained.

2

Where objects with sharp edges such as sheet glass, sheet metal components etc. have to be manually handled, gloves with cut-proof material, such as Kevlar, woven into the fabric must be worn.

3

Ideally, work would be organised so that the manual handling of all such objects could be avoided, however, given the nature of construction activities, total avoidance is usually not possible. For example a roof tiler may now use an inclined hoist to get the tiles up to roof level, but the hoist must still be loaded and the tiles distributed around the roof by hand.

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Contractors have a duty to ensure that, as far as is reasonably practicable, safe systems of work are used, that adequate welfare facilities are available and that appropriate information, instruction, training and supervision are provided, as is necessary to ensure safety and the absence of risks to health in the use, handling, storage and transport of articles and substances.

2

Employees are required to take reasonable care for their own health and safety, and that of other persons who may be affected by their work, and to co-operate with the Contractor so as to enable them to carry out their legal duties and requirements. In addition, employees must not intentionally or recklessly interfere with anything provided in the interests of health and safety.

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1.2.12.6 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard to employees (or any other persons) that might be encountered as a result of the work having been carried out.

2


3

Where a hazard is identified that requires it, the Contractor must offer health surveillance to employees, taking into account the risks to their health and safety that have been identified.

4

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves and any other persons who may be affected.

6

In the context of this module, the risk assessment must identify any substance to be used that can cause an adverse skin reaction and the control measures that are necessary to ensure that the substance can be used safely.

7

Employees are required to use hazardous substances provided in accordance with any training or instructions that they have received from their Contractor.

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1.2.12.7 Control of Substances Hazardous to Health 1

The principal points of these Regulations place requirements on the Contractor to protect employees, or any other persons who may be affected by their operations, by: (a)

assessing the health risks created by work involving substances hazardous to health.

(b)

ensuring that the exposure of employees or others is prevented, or adequately controlled, by putting in place any measures necessary to control the exposure to risks

(c)

ensuring that any control methods provided are properly used and maintained by monitoring the work environment, as necessary

(d)

carrying out health surveillance in specified circumstances

(e)

providing information, instruction and training for employees on the risks to health and precautions to be taken regarding any work with substances hazardous to health

(f)

providing procedures for dealing with accidents, incidents and emergencies, including

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first aid and safety drills.

1.2.12.8 Personal Protective Equipment at Work These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

2

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered.

3

In deciding which type to issue, the Contractor must take into account the risk that the PPE is being used for, and that the PPE will fit the wearer and allow them to work comfortably.

4

Whilst the Contractor must take 'reasonable steps' to ensure that any PPE supplied is worn, employees in turn must ensure that they wear the equipment provided and know the procedures for reporting any loss or defect to their Contractor.

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In the context of this section, the relevant requirements of these Regulations include the provision of: designs that avoid foreseeable risks to health and safety

(b)

adequate washing facilities (including showers, where appropriate)

(c)

a supply of hot and cold (or warm) water

(d)

soap or suitable cleansers

(e)

towels or other means of drying.

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Use of harmful substances

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1.2.12.10

Specifically in relation to skin protection, Contractors must ensure that the appropriate assessments have been made on any articles and substances used at work, and that they are:

(b)

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(c)

properly stored, transported and handled

(d)

properly marked to indicate any special precautions which need to be taken.

safe and free from any risk to health, when properly used used in accordance with the findings of risk assessments, procedures and conditions stipulated

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(a)

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They must ensure that persons using such articles and substances are: (a)

suitable and able to carry out the task which is expected of them

(b)

properly and adequately trained in their use and aware of all necessary precautions which must be taken

(c)

provided with appropriate personal protective clothing and equipment

(d)

supplied with all necessary information

(e)

educated in the dangers of skin

(f)

conditions, and in methods to be used to prevent those conditions arising

(g)

able to detect, and be aware of, the need to report any signs of skin infection or dermatitis.

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Adequate washing and first aid facilities must be provided, and barrier and cleansing creams should be available. In addition, the Contractor is responsible for providing supervision to ensure the above procedures, conditions and correct methods of work are maintained and that the proper facilities and equipment are available.

1.2.12.11

Potentially harmful substances and agents

Substances and physical agents which can be potentially harmful to the skin include: pitch, tar and bitumen

(b)

cement or lime

(c)

brick, stone, tile and plaster dust

(d)

paints, varnishes, lacquers and stains

(e)

certain types of timber (see Appendix 2)

(f)

fibreglass

(g)

certain epoxy resins

(h)

acrylic and formaldehyde resins

(i)

chromates (in primers, cement, etc.)

(j)

organic solvents

(k)

petrol, diesel and paraffin oils

(l)

white spirit and thinners

(m)

acids or alkalis

(n)

ionising radiation

(o)

solar radiation

(p)

other materials (depending on individual reactions).

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1.2.12.12

Effects of contact with some materials

Skin contact with certain materials can cause a variety of reactions and some examples are given below. This list is not exhaustive.

2

Mineral oils, including fuel oils and mould oils, can lead to inflammatory skin conditionsdermatitis, oil acne or even skin cancer.

3

These may be caused by constant contact with oil or oily clothes and rags (e.g. when placed in overall pockets).

4

Chemicals, including strong alkalis and certain acids, chromates, formaldehyde, are substances which can penetrate the skin causing ulcers (for example, chrome ulceration) and dermatitis.

5

Cement and lime can also cause chronic dermatitis. Wetted cement and lime become more alkaline, corrosive and therefore potentially very damaging to the skin.

6

Solvents and de-greasers, including paraffin, turpentine, petroleum products, thinners and similar solvents, affect the skin by dissolving the natural oils (de-fatting) which renders it more vulnerable to attack by other substances and bacteria.

7

Tar, pitch, bitumen products, including cresols and phenols like mineral oil, cause inflammation, blisters and oil acne.

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8

Radiation, light and heat radiation, including X-rays, beta and gamma radiation, extremes of radiation, temperature and humidity, make the skin more susceptible to dermatitis and other skin problems.

9

Epoxy resin hardeners, glass fibres, certain woods, fungicides and insecticides may irritate the skin and lead to dermatitis.

1.2.12.13

Reducing risks

Substitute products Every effort must be made to ascertain which substances have the potential to cause dermatitis and, where possible, to substitute other materials that either eliminate or reduce the danger. An alternative, where possible, may be to use a more dilute form of the substance.

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Reducing contact

If the outcome of an assessment is that there are no alternatives, and substances that cause dermatitis have to be used, methods of work should be implemented which eliminate contact between the skin and the substance.

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The use of mechanical handling equipment may be possible but, if this is not available, simple devices and instruments, including splash guards, drip trays, tongs, and scrapers, will help to reduce the risk.

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Healthy working conditions

It may be possible to use localised ventilation and exhaust systems to deal with dust, fumes and oil spray.

5

Plentiful supplies of clean fresh air and comfortable working temperatures are vitally important, as is the general cleanliness of the working area, the machinery and any other equipment which is in use.

6

Wherever possible and appropriate, the display of warning and information signs should be prominently made, so that all employees are aware of the hazards existing in that area.

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Warning signs (black on yellow background)

Mandatory signs (white on blue background)

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Protecting the worker 7

If a Contractor intends to use any items of PPE (including gloves and barrier creams) as part of their skin protection strategy in the workplace, then it is important that the correct PPE is selected.

8

All PPE for skin protection that is produced or imported by reputable companies is manufactured to British and European Standards.

9

As with all PPE for use at work, skin protection should be selected by a competent person who can ensure, in discussion with the supplier, that it meets the appropriate standards. Protective clothing Protective clothing and other PPE provides one of the most practical ways of limiting contact between the skin and other substances. To be effective, all protective clothing must be the right size, fit for the purpose, maintained in good condition, cleaned regularly and stored carefully when not in use.

11

Protective clothing may include gloves, overalls, eye protectors (such as goggles, face shields), aprons, boots and leggings, depending on the work being undertaken. The protective equipment provided must be suited to the requirements of the job.

12

Regular inspections must be made to ensure it remains sound and adequate.

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Gloves 13

A glove suitable for handling abrasive materials may offer no protection against chemicals. The appropriate glove for sulphuric acid may not be approved for chromic acid.

14

Much care is needed in selecting the right type of glove to be used for a particular hazard. Manufacturers' charts and recommendations should be followed when selecting gloves to

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protect the wearer against specific hazards. A properly selected glove can be useful in the prevention of dermatitis if care is taken to avoid getting contaminants inside the gloves when putting them on and taking them off. 15

The modern materials from which gloves are now made enable them to be effective against hazardous substances whilst generally allowing the necessary amount of 'feel' and dexterity where these factors are an issue. Industrial gloves - some types and uses

Recommended type

Acids, concrete, brickwork, stain removers, solvents, alkalis

Neoprene, nitrile, PVC, rubber

Esters, ethers, ketones (mastic, sealers), aldehydes, petroleumbased products

Medium and heavyweight rubber, neoprene, nitrile, PVC

High and low temperatures

Nitrile, PVC, medium and heavyweight rubber

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Abrasion, unloading bricks and blocks, general materials handling

Asbestos substitute or 'Nomex' gloves

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Bitumen, hot work, etc.

Rubber, nitrile, PVC, neoprene, chrome-leather with reinforced palm

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Barrier substances 16

Where exposure of the skin is unavoidable, the use of barrier creams or other preparations may limit the degree of contact.

17

These substances are applied before starting work and removed by washing after each spell of work. Reapplication is necessary before resuming work.

18

Water-soluble barrier creams are unsuitable where wet work is involved, and some substances are worn off with manual work.

19

There are many types of barrier substances available and it is essential that the right type is used for the work being done.

20

Most barrier substances afford only limited protection and should never be relied on as a sole means of protection.

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Hygiene 21

Personal cleanliness is an important factor in the prevention of dermatitis. The necessary washing facilities and an ample supply of clean warm water, soap and clean towels should be made available near to the workplace, and workers should be encouraged to use these facilities.

22

Facilities for changing out of work-stained or contaminated clothing will also help to promote personal cleanliness.

23

All facilities should be kept clean and inspected regularly. Skin cleansers Soap and water will help restore the skin to its natural state after the use of barrier creams. Skin cleansers may be required where soap and water are not adequate (such as insoluble barrier substances). With some skin cleansers (sanitisers), an additional moisturiser may be needed.

25

Solvents (such as paraffin, turpentine, thinners and petrol) remove the natural oils from the skin and must not be used for skin cleaning. Conditioning creams, designed to replace the natural oils of the skin removed through frequent cleansing, should be used when necessary.

1.2.12.14

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First aid

A healthy, intact skin is an effective barrier against some substances and infection, but the slightest cut or other injury may admit infection.

2

All abrasions to the skin, however minor, should be treated at once. However, be aware that some substances can penetrate unbroken skin.

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Medical advice should be sought as early as possible when there is concern. Any treatment of dermatitis or its symptoms should be left to a doctor.

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Treatment of dermatitis

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Inspections and examinations, educating staff in prevention Regular inspections of the workplace, work methods and precautionary procedures adopted will help ensure that the risk of dermatitis, or other skin complaints, is kept to a minimum. Atrisk employees should be encouraged to carry out 'self checks' for the first signs of dermatitis and, ideally, supervisors should be trained to identify dermatitis. In appropriate circumstances, arrangements should be made for workers to have regular examinations by an occupational health professional to detect early signs of skin complaints, such as dermatitis and skin cancer.

5

Active concern for the welfare of employees will encourage their co-operation in reporting skin irritations at an early stage. Workers are more likely to co-operate in preventative measures if they are told positively what dermatitis is and what can be done to prevent it from occurring.

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Health risks from working in the sun 6

A sunny day usually makes most people feel good, but too much sunlight can actually damage the skin. It is not simply sudden exposure while on holiday that is harmful. Even a tan that has been built up gradually can be harmful to health. A tan is a sign that the skin has been potentially damaged.

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Skin damage is caused by ultraviolet rays in the sunlight. People whose jobs keep them outdoors for a long time (such as building, construction and civil engineering workers) may, if their skin is unprotected, get more sun on their skin than is healthy for them. They will then be at greater risk of developing skin cancer. The dangers

8

In the short term, excess exposure of unprotected skin to the sun can cause blistering and peeling. Even mild reddening of the skin is a sign of skin damage. In the long term, too much sun will speed up ageing of skin, making it leathery, mottled and wrinkled. However, the most serious issue is an increased chance of developing skin cancer.

9

Some medicines, and contact with some chemicals used at work (such as bitumen products), can make the skin more sensitive to sunlight (photosensitivity).

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Some people are more at risk than others - and the effect that strong sunlight can have on the different types of skin is explained below. People with white skin are most at risk. Workers should take particular care if they have: fair or freckled skin that does not tan, or goes red or burns before it tans

(b)

red or fair hair and light coloured eyes

(c)

a large number of moles.

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The risks

Type 1: White skin, never tans, always burns. Often person has red or fair hair, blue eyes, pale skin and freckles.

12

Type 2: White skin, burns easily, but may tan eventually. Person may have fair hair, blue eyes and freckles.

13

Workers with skin types 1 and 2 must take extra care to avoid strong sunshine or cover up with tightly woven clothing and a hat.

14

Type 3: White skin tans easily and burns rarely. Person has dark hair and eyes and slightly darker skin.

15

Type 4: White skin, never burns, always tans. Person has dark hair, eyes and skin.

16

Workers with skin types 3 and 4 should still take care in strong sunshine.

17

Type 5: Brown skin.

18

Type 6: Black skin.

19

Workers with skin types 5 and 6 are still at risk from skin cancer. These skin types can still darken and even burn in stronger sunlight.

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To protect yourself 20

Even if their skin is not fair or freckled, workers should be particularly careful whilst working out of doors in summer in the three or four hours around midday when the sun is most intense.

21

Workers should:

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22


(a)

protect themselves with the type of clothing outlined below

(b)

try to avoid the mild reddening which is a sign of skin damage as well as being a sign of early burning

(c)

try to work and take breaks in the shade if they can. This will reduce the danger of harming the skin

(d)

not be complacent. The skin's most vulnerable areas are the back of the neck and the head. Where possible, keep these areas covered

(e)

not try to get a tan; it might look good but it indicates that the skin has already been damaged.

A suntan does not eliminate the long-term cancer risk, which is associated with prolonged exposure to the sun.

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The main way to avoid the dangers of developing skin cancer is to cover up. Work clothing made from close-woven fabric, such as a long-sleeved shirt and jeans, will stop most of the UV rays.

(b)

Wear a hat. A wide brimmed hat will shade the face and head. A safety helmet will afford protection and the addition of a hanging flap will protect the back of the neck.

(c)

Keep a shirt or other top on.

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Hats and other clothing are the best form of protection, but sun creams and lotions can add useful protection for parts of the body that are not easy to shade from the sun. A sun protection factor rating of 30 or more is recommended.

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Protective clothing 23

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Periodic checking of the skin

The first warning sign is often a small scabby spot that does not clear after a few weeks. Workers should be instructed to look for changed or newly formed moles or any skin discoloration. Workers should pay particular attention to any growths that appear on the face, especially around the eyes and nose, or on the backs of hands.

26

If these signs are noticed, medical assistance should be sought either from the Contractors medical staff or a local general practitioner, drawing attention to any moles that grow, change or bleed.

27

Many of these symptoms may prove to be non-cancerous - but they need to be checked to be absolutely sure.

28

Even if a spot is cancerous, simple modern treatments can usually cure them. This type of cancer very rarely spreads to other parts of the body. The smaller the spot, the easier it is to cure.

29

Don't delay If you think something might be wrong, get it checked out

30

Contractors are strongly encouraged to develop a Sun Safety Policy. An example of such a policy is attached at Appendix 3 to this module.

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Construction Site Safety 1.2.12 Appendix 1 Protection of skin Safety checklist Have the materials or substances in use been correctly identified?

2

Is up-to-date manufacturers' information available on the safe use of the substances?

3

Have the hazardous substances that will be produced by a work process been identified?

4

Have the necessary risk assessments been carried out?

5

Has an attempt been made to control the hazard at source, for example by using a less hazardous substance?

6

Has a COSHH risk assessment been carried out for the substances in use?

7

Have the significant findings of the risk assessment been communicated to those who will be using or otherwise affected by the substance?

8

Are the correct warning and cautionary notices displayed?

9

Are the methods of handling, transport and storage correct for the substances being used?

10

Are there adequate selection and training procedures available for operatives using harmful substances?

11

Is it necessary for workers to have wet hands for long periods or repeatedly get their hands wet?

12

Have operatives been properly trained in the necessary precautions and protective measures required for safe working?

13

Are safe working procedures and methods being properly implemented?

14

Is the correct handling equipment available and in use?

15

Is there adequate ventilation where toxic materials are in use?

16

Are there adequate washing facilities, barrier creams and cleansing agents of the correct type available and in regular use?

17

Are there gloves and protective clothing of the correct type and specification available and in use?

18

Have they been selected by a competent person, who can be the supplier?

19

Is there provision for cleaning protective clothing?

20

Is protective clothing regularly changed?

21

Are there adequate supervision and inspection procedures in place?

22

Is medical surveillance available for operatives when applicable?

23

Have appropriate welfare and first aid facilities been provided?

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Construction Site Safety 1.2.12 Appendix 2 Some timbers known to produce dermatitis and other irritant effects Harmful effects

Severity

Frequency

Afrormosia

Dermatitis, asthma

Can be severe

Quite frequent

African mahogany

Dermatitis

Severe

Infrequent at present

Boxwood

Dermatitis, rhinitis, asthma Mild

Quite frequent

Chestnut

Dermatitis, conjunctivitis, asthma

Usually mild

Infrequent

Dahoma

Irritation of the chest, dermatitis

Severe

East African camphor wood

Asthma, dermatitis

Fairly severe

Ebony

Irritation of nose and throat, Fairly severe dermatitis

Fairly frequent

Guarea (also West African cedar)

Nasal irritation, severe vomiting, chest irritation, blisters and dermatitis

Quite frequent

Iroko

Skin and eye irritation, asthma, symptoms of the common cold

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Commercial name

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Frequent

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Machaerium

Effects vary from mild to severe depending on sensitivity

Usually mild, occasionally Very infrequent serious

Dermatitis

Severe

Infrequent at present

Irritation of mucous membrane, nasal haemorrhage, sore eyes, dizziness, dermatitis

Severity varies with individuals

Frequent

Dermatitis, headache, coughing

Quite severe

Infrequent

Teak

Dermatitis, eye inflammation

Can be severe

Not frequent

Western red cedar

Asthma, bronchial trouble, dermatitis, septic wounds from splinters

Severe

Fairly frequent

Yew

Bronchial asthma and dermatitis

Quite severe

Infrequent

Satinwood

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Construction Site Safety 1.2.12 Appendix 3 Model Sun Safety Policy This Contractor is committed to protecting and educating its workers about the risks to health arising from excessive exposure to strong sunlight. The policy will be implemented as appropriate for all workers who are at risk. Sun protection advice will be provided as part of routine health and safety training for all.

2

All new employees will be made aware of the Sun Safety Policy.

3

Wherever possible, working hours and tasks will be scheduled to avoid the midday sunshine. Wherever possible, work that can be carried out indoors or in the shade will be scheduled during periods of strong sunshine.

4

All workers who are liable to be at risk will receive appropriate training on how to protect themselves from prolonged exposure to strong sunlight, regardless of their skin type or hair colour.

5

Workers who are at risk will be encouraged to wear full-length trousers and long-sleeved shirts throughout the year. They will be made aware that, ideally, clothing will be loose fitting and made from a close-weave fabric.

6

In most circumstances, the mandatory wearing of a safety helmet will provide the necessary protection for the head. In the rare circumstances where a safety helmet need not be worn, workers at risk will be advised to wear a hat.

7

Workers at risk will be given information on the appropriate use of sunscreen creams, including advice on the minimum recommended level of protection.

8

Drinking water will be provided in the shade and all workers will be encouraged to drink plenty of water to avoid dehydration.

9

Rest areas in the shade will be provided and workers at risk will be encouraged to use them for their rest breaks.

10

All contractors working on the site will be made aware of the contents of the Sun Safety Policy and will be required to adhere to its guidelines.

11

The effectiveness of this policy will be monitored and it will be reviewed and updated as necessary.

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Signed ..................................................................... Date .................................................................... Position ...................................................................................................................................................

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Construction Site Safety 1.2.13 Control of Vibration 1.2.13.1 Key points Exposure to hand-arm vibration has the potential to cause disabling injuries.

2

Exposure to whole-body vibration can cause severe back pain.

3

Contractors have a legal duty to reduce the risks to the health of employees by either eliminating exposure to vibration or reducing it to an acceptable level.

4

Contractors have various means at their disposal of estimating exposure to vibration before resorting to having measurements carried out.

5

If it is necessary to have vibration measurements taken, it is essential that the person doing so is trained and competent.

6

Some of the things that can be done to control the potentially harmful effects of exposure to hand-arm vibration are:

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adopting alternative (non-vibrational) work methods;

(b)

ensuring that tools are either low-vibration by design and/or well-maintained;

(c)

adapting work patterns;

(d)

ensuring that ergonomic factors are taken into account;

(e)

preventing those person(s) exposed to vibration from becoming cold and/or damp;

(f)

training workers how to minimise the risks from vibration.

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Exposure to whole-body vibration can be controlled by, for example, improved technology in mobile plant (e.g. improved suspension and driver's seat), operator training, smooth operation of machines and job rotation.

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1.2.13.2 Introduction Hand-arm vibration A wide range of tools commonly used during construction and demolition activities, particularly those with a rotary or percussive action, have the potential to cause serious health problems. The seriousness of the situation will depend largely on how frequently and for how long vibrating tools are used although, as will be explained elsewhere in this module, other factors contribute to the potential for ill health.

2

The most common forms of ill health resulting from exposure to vibration of hands and arms are known as hand-arm vibration syndrome (HAVS) and vibration white finger (VWF), which is also known as Secondary Raynaud's Syndrome.

3

VWF, which is sometimes called 'dead finger' or 'dead hand', is most common in people whose hands are regularly exposed to damaging levels of vibration. Damage to the nerves and blood vessels in the fingers can lead to permanent loss of feeling and eventual disability. At worst, VWF can eventually lead to ulceration or gangrene, possibly resulting in the loss of one or more fingers. There is no effective treatment for the disorder. Exposure to vibration can also cause damage to muscles, joints and bone, which may also contribute to pain and stiffness in the hands and wrists.

4

If the symptoms of VWF can be seen in an employee's hands or fingers, it is clear evidence that any protective or control measures that are in use have not been effective. The damage has already been done.

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The symptoms or effects of vibration white finger are usually triggered when the hands are exposed to the cold. Early indications are the fingertips rapidly becoming pale or white (blanched), with loss of feeling and perhaps also numbness and 'pins and needles'. This phase is sometimes followed by a red flush that signals the return of blood circulation to the fingers and is usually accompanied by a very uncomfortable or painful throbbing. Continued work with vibrating tools will cause the affected area to increase in size and for attacks to become more frequent over time.

6

Vibration damage to the fingers, hands or body is very much dose-related. The greater the exposure to vibration, the more likely there is to be damage. Increased exposure could be due to being exposed to greater magnitudes of vibration or being exposed for longer durations.

7

Other factors that can influence the risk of developing hand-arm vibration syndrome include: the grip, push and other forces used to guide and apply the vibrating tools or pieces of work equipment. The tighter the grip, the more vibration energy is transferred to the hands

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(b)

tools with blunt cutting edges usually require more time to complete the task, higher grip and push forces, and often result in greater vibration emission

(c)

the exposure pattern, length and frequency of work and rest periods

(d)

how much of the hand, and other parts of the body, is exposed to the vibration

(e)

factors that potentially affect blood circulation, such as workplace temperature, smoking and individual susceptibility

(f)

the hardness of the material being worked

(g)

tool maintenance is important in order to keep it running smoothly and efficiently.

1.2.13.3 Whole-body vibration 1

Whole-body vibration, as its name suggests, is vibration or jolting of the whole body through the surface that is supporting the body, such as a machine seat or floor.

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Whole-body vibration, which often results from driving or operating some types of construction plant or vehicles, has the potential to cause back injury or make an existing back condition more painful.

1.2.13.4 1.2.13.5 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3


4

Employees, in turn, have legal duties under these Regulations to:

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tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected by their work activities

(b)

use all machinery and equipment in accordance with any training provided.

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The Contractor must assess the risks to employees' health arising from hand-arm vibration and whole-body vibration and put effective control measures in place.

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1.2.13.6 Control of Vibration

They impose duties on Contractors to protect employees (and others) who may be exposed to risk of ill health because of vibration at work.

2

These Regulations place legal duties on Contractors and employees with regard to the control and management of employees' exposure to vibration.

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Definitions 3

These Regulations give a number of definitions, knowledge of which will help readers better understand the requirements of these Regulations. (a)

Hand-arm vibration (HAV) means mechanical vibration which is transmitted into the hands and arms by a work activity.

(b)

Whole-body vibration (WBV) means mechanical vibration which is transmitted into the body through the supporting surface when a person is seated or standing during a work activity.

(c)

Mechanical vibration means vibration occurring in a piece of machinery, equipment or vehicle as a result of its operation.

(d)

Daily exposure means the extent of the mechanical vibration to which a worker is exposed during a working day, which takes account of both the magnitude and duration of the vibration.

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(e)

Exposure action value (EAV) means the level of daily exposure that, if exceeded, requires specific action to be taken to reduce the risk.

(f)

Exposure limit value (ELV) means the level of daily exposure for any worker that must not be exceeded.

(g)

Working day means a daily working period, irrespective of the time of day, when it begins or ends, or whether it begins or ends on the same day.

(h)

Health surveillance means an assessment of the state of health of an employee as related to their exposure to vibration.

4

Exposure limit and action values

5

For hand-arm vibration: 2

the daily exposure action value is 2.5 metres per second squared (2.5 m/s A(8))

(b)

the daily exposure limit value is 5 metres per second squared (5 m/s A(8)).

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For whole-body vibration:

2

(a)

the daily exposure action value is 0.5 metres per second squared (0.5 m/s A(8))

(b)

the daily exposure limit value is 1.15 metres per second squared (1.15 m/s2 A(8)).

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Note: The 'A(8)' notation after each value indicates that the measurement of exposure to vibration is 'time weighted' over an 8 hour period.

See flowchart at Appendix 1.

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1.2.13.7 Duties of Contractors

Where these Regulations place a duty on Contractors with respect to the health and safety of employees, the Contractor shall so far as is reasonably practicable, also be under a similar duty to anyone else, whether at work or not, who may be affected by the vibration created by the Contractor's work activities, except for the provision of:

information, instruction and training unless the non-employees are at the same place of work as where the noise is being created.

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Contractor's duties to non-employees

Contractor's duties to employees 3

If employees are likely to be exposed to risks from vibration in the course of their work the Contractor must: (a)

carry out an assessment of the risks to the health and safety of the employees exposed to vibration. The risk assessment must identify the measures that need to be taken to meet the requirements of these Regulations

(b)

as part of the risk assessment, assess the daily exposure of employees to vibration by:

(c)

(i)

observing work practices

(ii)

referring to information on the probable level of vibration corresponding to the equipment used in those particular conditions

(iii)

if necessary, arranging for vibration levels to be measured.

assess whether any employee is likely to be exposed to vibration at or above the

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exposure action value or the exposure limit value. 4

The risk assessment must include consideration of: (a)

the magnitude, type and duration of exposure to vibration, including intermittent vibration and repeated shocks

(b)

the effects that the vibration might have on employees whose health is particularly at risk from exposure

(c)

any effects that vibration might have with regard to work equipment, such as: (i)

the proper handling of controls (ii) the reading of indicators (iii) the stability of structures

(e)

the availability of alternative equipment that is designed to reduce exposure to vibration

(f)

exposure of employees to whole-body vibration when not actually working, such as in rest areas and canteens

(g)

specific working conditions, such as working in low temperatures

(h)

the availability of appropriate information obtained from health surveillance.

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any information provided by the manufacturers of the equipment that creates the vibration

The Contractor must regularly review the risk assessment and immediately if: there is reason to believe that it is no longer valid

(b)

there has been a significant change in the work to which the assessment applies

(c)

implement changes to the risk assessment as identified by the review process.

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(a)

The Contractor must record: (a) (b)

the measures taken to eliminate or control exposure to vibration the measures taken to provide information, instruction and training for at-risk employees.

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(c)

the significant findings of the risk assessment as soon as is practicable after the risk assessment has been carried out or changed

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(iv) the security of joints.

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ensure that exposure to vibration is eliminated at source or reduce it to the lowest level that is reasonably practicable

(b)

where exposure is likely to be at or above the exposure action value, reduce exposure to vibration to as low a level as is reasonably practicable, by implementing organisational and technical measures which are appropriate to the work activity being carried out

(c)

Contractors must take in to consideration the following general principals of prevention: (i)

alternative work methods which eliminate or reduce exposure to vibration

(ii)

alternative work equipment or an appropriate ergonomic design which, taking account of the work to be done, produces the least vibration

(iii)

the design and layout of the workplace including any rest facilities

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(iv)

the provision of extra equipment that has the effect of reducing injuries caused by exposure to vibration

(v)

the effective maintenance programmes for equipment that can create vibration, the workplace itself and workplace systems

(vi)

the provision of information and training for at-risk employees such that they are aware of how to use work equipment correctly and safely in order to minimise exposure

(vii)

limiting the duration and intensity of exposure to vibration

(viii)

adjusting work schedules and ensuring adequate rest periods

(ix)

the provision of work clothing to protect at-risk employees from cold and damp.

.

The Contractor must ensure that employees are not exposed to vibration above the exposure limit value or, if they are, immediately: reduce exposure to below the exposure limit value

(b)

identify the reasons for the exposure limit value being exceeded

(c)

take appropriate actions to prevent it occurring again.

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The above paragraph does not apply where the exposure of an employee to vibration is usually below the exposure action value but varies markedly from time to time and may occasionally exceed the exposure limit value, provided that: the exposure to vibration averaged over one week is less than the exposure limit value

(b)

there is evidence to show that the risk from the actual pattern of exposure is less than the corresponding risk from constant exposure to the exposure limit value

(c)

the risk from exposure is reduced to as low as level as is reasonably practicable

(d)

the employees concerned are subject to increased health surveillance, where appropriate.

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Any measures taken to comply with these Regulations must be adapted where necessary to take account of any employee(s) who is/are particularly at risk from exposure to vibration.

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If the risk assessment indicates that: there is a risk to the health of employees who are exposed to vibration

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(b)

those employees are likely to be exposed to vibration at or above the exposure action value;

(c)

the Contractor must ensure that those employees are placed under suitable health surveillance, where appropriate.

The health surveillance will be appropriate if: (a)

a link can be established between exposure to vibration and an identifiable disease or any other adverse effect on health

(b)

it is probable that the disease or other effect on health may occur under particular working conditions

(c)

there are valid ways of detecting the disease or other effect on health.


ensure that a record is kept and maintained for each employee who undergoes health surveillance and that records are readily available in a suitable form

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(b)

Where, as a result of health surveillance, an employee is found to have an identifiable disease or other adverse effect on health, which is considered by a doctor or other occupational health professional to be the result of exposure to vibration, the Contractor must: ensure that the employee is informed by a suitably qualified person, including advice regarding a need for further health surveillance

(b)

ensure that the Contractor is informed of any significant findings of the health surveillance, allowing for medical confidentiality

(c)

review the risk assessment

(d)

review existing control measures, taking into account any advice given by a doctor.

(e)

consider reassigning the employee to other work where there is no risk from further exposure, taking into account any advice given as above

(f)

ensure that the health of any other employee(s) who has been similarly exposed is reviewed, including the provision of a medical examination where recommended by a doctor, occupational health professional or the administrative authority.

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Where the risk assessment shows a risk to the health of employees who are (or are liable to be) exposed to vibration at or above the exposure action value, the Contractor must provide the employees and their representatives with suitable and sufficient information, instruction and training, which must include:

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allow employees to see their health surveillance records upon being given reasonable notice

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the organisational and technical measures taken to eliminate or control exposure to vibration

(b)

the exposure limit value and the action values

(c)

the significant findings of the risk assessment, including details of any measurements taken, with an explanation of the findings

(d)

why and how to detect and report signs of injury resulting from exposure to vibration

(e)

the employees' entitlement to health surveillance

(f)

how to work safely to minimise exposure to vibration

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the collective results of any health surveillance carried out, anonymised so as not to reveal the personal health record of any individual.

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The information, instruction and training provided as above must be updated by the Contractor to take account of any significant changes in the type of work carried out or method of working.

17

The Contractor must ensure that any person, whether an employee or not, who has been given the responsibility to ensure that the Contractor's duties are carried out, for example a site manager or project manager, receives suitable and sufficient information, instruction and training to enable compliance with these Regulations.

1.2.13.8 Duties of employees 1

Under these Regulations, employees have a legal duty to make themselves available for health surveillance checks (during working hours) as required by the Contractor, the health surveillance being at the Contractor's expense.

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1.2.13.9 The Provision and Use of Work Equipment These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

3

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

4

These Regulations require Contractors to provide serviceable and suitable work equipment that will, in conjunction with other vibration management techniques, by virtue of its design or adaptability, eliminate exposure to vibration or reduce it to an acceptable level.

Tools and plant used in the Qatar construction industry that could cause exposure to risks from vibration include:

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Tools likely to cause harmful levels of vibration

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(b)

concrete vibro thickeners

(c)

concrete pokers

(d)

plate vibrators

(e)

chisels

(f)

demolition picks

(g)

compressor guns

(h)

pneumatic drills

(i)

angle grinders

(j)

percussive (hammer) drills

(k)

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sanders, and similar reciprocating tools abrasive wheels (e.g. bench grinders)

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road and concrete breaking drills

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(m)

cutting-off wheels and discs

(n)

power hammers and chisels, including 'Kango' hammers

(o)

needle guns

(p)

chainsaws

(q)

woodworking machinery.

This is irrespective of the tools' power source. Other equipment that may occasionally be used and that is a source of vibration includes rotavators, lawnmowers, brush-cutters and leaf blowers. WBV (a)

rough-terrain forklift trucks and tele-handlers

(b)

vibratory rollers

(c)

mobile crushers

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(d)

dumper trucks and other forms of earth-moving machinery

(e)

delivery vehicles if required to travel on rough terrain.

1.2.13.11

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Managing vibration, vibration risk assessment in practice

A general risk assessment can be briefly defined as a systematic examination of a work process, carried out by a competent person on behalf of a Contractor.

2

A vibration risk assessment follows the same principle but with the emphasis solely on vibration and its potential to cause ill health in employees.

3

The principle of risk assessment is not new. In fact, it is quite likely that many Contractors have been carrying out risk assessments, including vibration risk assessments, during the day-to-day course of their business activities, possibly without thinking of the process in terms of a risk assessment.

4

A survey of what work activities are carried out, using what tools and equipment, and by whom, will establish who is at risk. If there is any doubt as to whether a particular job has the potential to cause vibration-induced health problems or injury, it is better to assume that it has, initially at least.

5

Having established who could be at risk it is necessary to examine work activities in detail to determine which work activities are of genuine concern. As outlined in the summary, only when all other investigative methods have been exhausted should it be necessary to carry out vibration measurements.

6

There are many sources of information available to Contractors, such as:

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the users of vibrating tools themselves; they are the ones who may have experienced the early symptoms of HAVS

(b)

free online vibration measurement databases which are based on the actual vibration measurements achieved during the testing of hundreds of tools of different types in different conditions

(c)

tool manufacturers' published vibration data, although this should be treated with caution as it can be based upon laboratory testing rather than 'field trials' and usually underestimates exposures under real work conditions.

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In construction, it is likely that those exposed to WBV will exceed the exposure action value if they operate machines for several hours per day. The exposure limit value should only be exceeded if the machine is operated very aggressively or with non-approved attachments.

8

For HAV, the guidance is that an employee is probably at risk from HAVS if they are using:

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(a)

hammer action equipment for more than 15 minutes each day.

(b)

rotary equipment for more than one hour each day.

9

Employees who fall into these categories, as well as other at-risk employees, should be asked to complete a short health surveillance questionnaire (details in Appendix 2).

10

An important factor in establishing who is at risk is the actual time that someone is using a vibrating tool, commonly referred to as the 'trigger time'. When asked, it is usual for users to overestimate the length of time that they actually use the equipment. Their response may be 'I use the equipment all day' when in fact what they mean is that they use it on-and-off all day with, for example, a total 'trigger time' of less than 60 minutes per day.

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1.2.13.12

Page 184

The elimination or control of exposure to vibration in the workplace

On the basis of the general principles and hierarchy of control measures, Contractors must ensure that employees' exposure to vibration is either eliminated or reduced so far as is reasonably practicable.

2

Where it cannot be eliminated the Contractor must introduce a programme of organisational and technical measures (control measures) consistent with their risk assessment. This must include consideration of: alternative methods of carrying out the work that eliminate or reduce employees' exposure to vibration, for example, stripping off surface coatings by chemical treatment rather than 'power-sanding'

(b)

choice of work equipment that, because of its design or features, or the nature of the work to be done, produces the least possible vibration

(c)

the provision of ancillary equipment that reduces the risk of injury being caused by vibration, for example, manufacturer approved vibration absorbent handles for handheld equipment

(d)

proper maintenance arrangements for the work equipment, workplace and workplace systems, for example, maintaining ground surfaces over which vehicles regularly travel

(e)

the design and layout of workplaces, workstations and rest facilities

(f)

suitable and sufficient information and training for employees so that they may use the equipment safely and correctly in order to minimise their exposure to vibration, such as training mobile machine operators how to correctly adjust their seats and the benefits from driving less aggressively

(g)

limitation of the duration and intensity of the vibration, for example by job rotation

(h)

appropriate work schedules with adequate rest periods

(i)

the provision of clothing to protect employees from cold and damp

(j)

arranging for operatives to stay warm by providing heating for the workplace where needed and possible, together with suitable clothing and gloves

(k)

ensuring that any new tools have vibration control measures built in

(l)

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by adopting a 'buy smooth'/'hire smooth' policy, in which a commitment is made to choose tools that incorporate low vibration technology the reduction of vibration transmission in the path between the source and the handles or other surfaces gripped by operatives' hands

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(n)

the minimisation of the amount of force required to apply and control the tools, and keeping them in good order.

3

A 'points' system has been developed by the UK Health and Safety Executive (HSE) which allows for quick estimates of the hand/arm vibration exposure for a worker. Each process is assigned a number of points per hour. Adding the points from each process carried out (calculated by multiplying the points per hour by the number of hours use) provides an estimate of the total exposure. For HAV the exposure action value corresponds to 100 points and the exposure limit value corresponds to 400 points. For WBV the exposure action value corresponds to 100 points and the exposure limit value corresponds to 529 points. Points from HAV and WBV should not be combined.

4

Further guidance on estimating exposure is contained in Appendix 5.

5

A further benefit gained as a result of controlling vibration can be the reduction in noise levels; in some circumstances reducing noise will also reduce vibration, hence many noise

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control techniques also involve techniques for controlling vibration. See: www.hse.gov.uk/vibration/hav/vibrationcalc.htm

1.2.13.13

If the risk assessment shows that there is a risk to the health of employees because of vibration, or they are exposed to vibration in excess of the exposure action value, then the Contractor must give employees information, instruction and training on: how the Contractor is 'managing' vibration in the workplace

(b)

the exposure limit values and exposure action values

(c)

the significant findings of the risk assessments, including details of any measurements taken

(d)

what employees should look for in themselves as regards HAVS, VWF and low back pain and how they should inform their Contractor

(e)

the entitlement to health surveillance

(f)

the safe working practices in place to minimise employees' exposure to vibration

(g)

the collective (as opposed to individual) results of any health surveillance undertaken.

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Information and training for employees

Work equipment Selection of tools and equipment

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1.2.13.14

All equipment that is liable to vibrate, and that is manufactured for use as work equipment, should be designed to have low vibration operating characteristics.

2

Manufacturers are required to provide information on all aspects of their equipment, including details of any vibration that may be expected. In particular, suppliers must provide information on vibration levels if the tool or machine is likely to subject workers to levels of vibration exceeding the exposure action value of 2.5 metres per second squared.

3

However, as some manufacturers may base their vibration figures on laboratory simulation rather than field trials, the figures quoted may be unrealistically low. In many cases information is also available from independent real or simulated work measurements.

4

Vibration emission is one of many important factors to consider when selecting a tool. For example, a very heavy tool might not emit much vibration but could cause manual handling risk. Similarly, some tools might emit less vibration than others but be relatively inefficient, resulting in increased exposure times, higher grip and push forces. Always select the right tool for the job.

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Regular maintenance of tools 5

Correctly installed and smooth running machines will, in time, vibrate as the machinery parts become worn.

6

The parts of machinery that contribute to vibration are: (a)

worn bearings

(b)

dirty fan blades (unbalanced fans)

(c)

worn mountings or worn anti-vibration pads

(d)

misaligned shafts

(e)

unbalanced rotating parts

(f)

loose bolts

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(g)

damaged gear teeth

(h)

blunt cutting tools and blades

(i)

worn suspension components

(j)

incorrect tyre pressures

(k)

damaged seats

(l)

damaged tyres/tracks.

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The lack of correct maintenance and lubrication will produce increased vibration magnitudes.

8

Machines should, therefore, be maintained at regular intervals and any detected faults rectified as soon as possible, thus reducing the risk of vibration problems. Cutting tools or blades should be kept sharp by maintenance or replacement, as appropriate.

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1.2.13.15

Health issues

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Health surveillance

If the findings of the risk assessment, feedback from employees or other sources of information show that there is a risk to the health of employees because of their use of vibrating tools, or that employees are exposed to vibration in excess of the exposure action value, then the Contractor must ensure that the employees are under suitable medical surveillance where it is appropriate.

2

A recommended five-stage system of health surveillance for HAV:

1

An initial questionnaire to be answered when employees first move into any job that involves exposure to vibration (see Appendix 2).

2

A short questionnaire answered annually by employees exposed to vibration (see Appendix 3).

3

A formal HAVS health assessment carried out by a qualified person, for example, an occupational health nurse.

4

A formal diagnosis made by a doctor who is qualified in occupational health, and who will assess fitness for work

3

Contractors who consider that their employees are at a potential risk from HAVS should

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appoint a person to manage the health surveillance programme and be actively involved in the initial stages. 4

This person: (a)

does not need to be medically qualified (i)

should not attempt diagnosis or be judgemental as to the causes of HAVS with regard to individual cases

(ii)

should receive training from an occupational health professional

(iii)

must be able to describe the symptoms of HAVS.

The person should have experience of the working environment, be able to gain the trust and co-operation of employees, and understand the importance of confidentiality.

6

For WBV, detailed health surveillance is not possible, as there are many non-vibration causes of back pain. An example of a health monitoring questionnaire is given in Appendix 4.

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Keeping records

Health surveillance records should be stored 'in house' in a way that retains their confidentiality, possibly under the control of the person nominated to manage the health surveillance system.

8

Contractors should create a health record for each individual who is exposed to vibration and keep them for at least as long as they are under health surveillance and possibly longer.

9

Health records should be kept up to date and should include full details of the employee's exposure to vibration and any questionnaires that have been completed.

10

It is considered to be good practice if employees are offered a copy of their health records when they leave the Contractor.

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Maintaining blood circulation Keeping the hands and body warm is essential to help maintain good blood flow to the fingers and reduce the risk of injury due to HAV.

12

Specific measures might include:

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(a)

wearing gloves

(b)

using proprietary heating pads for the hands

(c)

using tools with heated handles

(d)

avoiding tools that have pneumatic exhausts that discharge towards the hands

(e)

allowing operatives to warm up before starting work, and helping them to stay warm

(f)

wearing warm, weatherproof clothing in cold, wet areas

(g)

advising those who smoke to stop or cut down (smoking reduces blood circulation)

(h)

massaging and exercising fingers during work breaks.

Work patterns 13

One of the most simple but also one of the most effective ways of minimising risks arising from vibration is by reducing the time when operatives are actually exposed to vibration.

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14

If the use of a vibrating tool is shared between a team of employees, as opposed to it only being used by one person, the tool may be kept in productive use for the day.

15

Moving any employees not operating the tools at that time onto other areas of work will considerably lessen the effects of vibration on users, by splitting and rotating the work. This will also assist the maintenance of blood circulation, thus lessening the chances of injury or ill health being caused to users by the vibrating tool. Personal protective equipment Some retro-fit products are available that are designed to protect operators from vibration.

17

Only those approved by the machine manufacturers should be used.

18

The wearing of anti-vibration gloves is not recommended. Problems with anti-vibration gloves include:

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reduced flexibility at the hands resulting in higher grip and push forces and loss of precise tool control

(b)

the possibility of gloves amplifying the tool vibration in some cases (these cases are very difficult to predict)

(c)

anti-vibration gloves are only tested in one direction and vibration occurs in three directions

(d)

field trials of gloves have shown that the vibration isolation materials are not always durable.

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(a)

However, if anti-vibration gloves are to be tried, it is essential that they carry the CE-mark and are selected by a competent person. One benefit from gloves is that they keep the hands warm and offer other protection.

20

Therefore, if a Contractor intends to provide items of PPE as part of their strategy to reduce the risks from vibration in the workplace, it is important that the correct PPE is selected. All PPE produced or imported by reputable companies is manufactured to British and European Standards. As with all PPE for use at work, gloves or anti-vibration protection should be selected by a competent person who can ensure, in discussion with the supplier, that they meet the appropriate standards. Most leading manufacturers and suppliers will offer advice on the selection of different types of gloves and other PPE.

21

Ear defenders should be worn to lessen the effects of the noise created by vibrating tools, and eye protection should be worn to avoid the risks from dust or flying particles.

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1.2.13.16

Summary

1

The control of vibration at work makes good business sense for Contractors. Employees who are able to work are of far greater benefit to the Contractor than those who are off sick as a result of work-related ill health, or those who cannot work to maximum effect due to HAVS, VWF or back pain.

2

In summary, these Regulations require that the Contractor should: (a)

assess the risks to the health of your employees from vibration, and to effectively plan for its control

(b)

properly manage the risks

(c)

provide suitable work equipment for your employees, having regard for technical developments in tool design and vibration suppression

(d)

maintain equipment fully and correctly

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give employees and supervisors information and training on the risks to health caused by vibration, and on the safe use of the work equipment that is provided

(f)

provide health surveillance/health monitoring where risks cannot be completely eliminated

(g)

consult employees on your proposals for dealing with vibration.

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(e)

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Construction Site Safety 1.2.13 Appendix 1 Vibration - actions by Contractor

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Construction Site Safety 1.2.13. Appendix 2 Initial hand/arm vibration screening questionnaire Medical in confidence - when completed Initial screening questionnaire for workers using hand-held vibrating tools, hand-guided vibrating machines and hand-fed vibrating machines. Date .......................................................................................................................................................... Name ........................................................................................................................................ Occupation ................................................................................................................................................ Address .....................................................................................................................................................

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Date of birth ..............................................................................................................................................

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Contractor name ......................................................................................................................................... Y/N

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Have you ever used hand-held vibrating tools, machines or hand-fed processes in your job?

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If YES:

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a) list year of first exposure ........................................................................................................

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b) when was the last time you used them? ........................................................................... (detail work history overleaf) Y/N

2 Do you have tingling of the fingers at any other time?

Y/N

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1 Do you have any tingling of the fingers lasting more than 20 minutes after using vibration equipment?

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3 Do you wake at night with pain, tingling, or numbness in your hand or wrist?

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4 Do one or more of your fingers go numb more than 20 minutes after using vibration equipment?

Y/N

5 Have your fingers gone white* on cold exposure?

Y/N

6 If YES to 5, do you have difficulty re-warming them when leaving the cold?

Y/N

7 Do your fingers go white at any other time?

Y/N

8 Are you experiencing any other problems with the muscles or joints of the hands or arms?

Y/N

9 Do you have difficulty picking up very small objects, e.g. screws or buttons or opening tight jars?

Y/N

* Whiteness means a clear discoloration of the fingers with a sharp edge, usually followed by a red flush.

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10 Have you ever had a neck, arm or hand injury or operation? If so, give details .......................................................................................................................

Y/N

11 Have you ever had any serious diseases of joints, skin, nerves, heart or blood vessels? If so, give details .......................................................................................................................

Y/N

12 Are you on any long-term medication? If so, give details ...................................................................................................................

Y/N

Occupational history

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Job title

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Dates

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……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

Signed:

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I certify that all the answers given above are true to the best of my knowledge and belief.

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Return in confidence to:

Date:

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Construction Site Safety 1.2.13. Appendix 3 Annual hand/arm vibration screening questionnaire for health surveillance Screening questionnaire for workers using hand-held vibrating tools, hand-guided vibrating machines and hand-fed vibrating machines. Date .......................................................................................................................................................... Employee name ........................................................................................................................................ Occupation ................................................................................................................................................

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.

Address .....................................................................................................................................................

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Date of birth .............................................................................................................................................. National insurance number .......................................................................................................................

qa

ta

Contractor name .........................................................................................................................................

Y/N

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Date of previous screening ........................................................................................................................ Have you been using hand-held vibrating tools, machines or hand-fed processes in your job, or if this is a review, since your last assessment? (detail work history overleaf)

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If NO or more than 2 years since last exposure, please return the form - there is no need to answer any further questions.

ov

If YES:

Y/N

et it

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1 Do you have any numbness or tingling of the fingers lasting more than 20 minutes after using vibrating equipment?

Y/N

3 Do you wake at night with pain, tingling, or numbness in your hand or wrist?

Y/N

4 Have any of your fingers gone white* on cold exposure?

Y/N

5 Have you noticed any change in your response to your tolerance of working outdoors in the cold?

Y/N

6 Are you experiencing any other problems in your hands or arms?

Y/N

7 Do you have difficulty in picking up very small objects, e.g. screws or buttons or opening tight jars?

Y/N

8 Has anything changed about your health since the last assessment?

Y/N

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2 Do you have numbness or tingling of the fingers at any other time?

* Whiteness means a clear discoloration of the fingers with a sharp edge, usually followed by a red flush.

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10 Have you ever had a neck, arm or hand injury or operation? Y/N If so, give details ..................................................................................................................... 11 Have you ever had any serious diseases of joints, skin, nerves, heart or blood vessels? Y/N If so, give details ..................................................................................................................... 12 Are you on any long-term medication? Y/N If so, give details .....................................................................................................................

Occupational history Dates

Job title

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………………………………………………………………………………………………………………………

rw

……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

ta

………………………………………………………………………………………………………………………

qa

………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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……………………………………………………………………………………………………………………… I certify that all the answers given above are true to the best of my knowledge and belief.

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Signed:

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Return in confidence to:

Date:

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Construction Site Safety 1.2.13 Appendix 4 Sample health monitoring questionnaire Date of assessment................................................................................................................................... Employee No/Payroll No ........................................................................................................................... Name ........................................................................................................................................................ Date of birth .............................................................................................................................................. Job title ..................................................................................................................................................... Yes

No

.

Any change in duties since last questionnaire?

.l. l

Recent experience

Yes

No

Yes

No

rw

Is there currently any movement or activity that causes you pain in your back?

No pain

qa

Please describe the severity of the pain experienced:

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Have you suffered any back/neck/shoulder pain in the last 12 months

Pain as bad as

1

2

3

4

5

6

7

8

9

10

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0

as

it could be

Yes*

No

Yes*

No

Yes*

No

Yes*

No

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Note: If severity above 5 indicated, refer on for further advice. However if rank less than 5, but for three consecutive assessments, then refer for further advice. *

o

Have you had to take any medication to deal with the pain experienced?

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Have you had to seek medical advice regarding this pain?

Has this back/neck/shoulder pain resulted in time off from work?

Have you had any accidents or injury to the back in the last two years? Action/advice Referral for further advice? Other advice provided? * Further advice should be sought from an occupational health professional or GP in these cases.

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I certify that all the answers given above are true to the best of my knowledge and belief. Signed:

Date:

Return to:

Hand-arm vibration syndrome (HAVS): is a disorder which affects the blood vessels, nerves, muscles and joints of the hand, wrist and arm.



can become severely disabling if ignored; and



its best known form is vibration white finger (VWF) which can be triggered by cold or wet weather and can cause severe pain in the affected fingers.

qa

Signs to look out for in hand-arm vibration syndrome:

ta

rw

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.



tingling and numbness in the fingers



in the cold and wet, fingers go white, then blue, then red and are painful



you can't feel things with your fingers



pain, tingling or numbness in your hands, wrists and arms



loss of strength in hands.

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et it

Dates

o

Occupational history

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as



Job title

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……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

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Construction Site Safety 1.2.13 Appendix 5 Estimating exposure to hand arm vibration You may be able to get suitable vibration data from the equipment handbook, or from the equipment supplier. See Table 1 for guidance examples of vibration levels which have been measured on equipment in use. There are also some databases on the internet which may have suitable vibration data.

as

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If you plan to use the manufacturer's vibration data you should check that it represents the way you use the equipment (see 'Duties of manufacturers and suppliers') since some data may underestimate workplace vibration levels substantially. Ask the manufacturer for an indication of the likely vibration emission of the tool when your employees are using it. If you are able to get vibration data from the manufacturer which is reasonably representative of the way you use the equipment, it should be suitable for you to use in estimating your employees' exposure. However, if the only information available to you is the vibration emission declared in the equipment's handbook, it may be safer to double this figure before using it for estimating daily exposures. You also need to check, by observing them, how long employees are actually exposed to the vibration (i.e. the total daily 'trigger time' with the equipment operating and in contact with the employee's hand(s)). Employees are unlikely to be able to provide this information very accurately themselves. You could observe and measure the trigger time over, for example, half an hour and then use the result to estimate the trigger time for the full shift. Alternatively, where the work task is repetitive, e.g. drilling large numbers of holes in masonry, you could measure the trigger time when drilling several holes and multiply the average by the number of holes typically drilled in a shift

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Table 1 Some typical vibration levels for common tools Lowest

Typical

Highest

5m/s

2

12 m/s

2

20 m/s

2

8m/s

2

15 m/s

2

25 m/s

2

Hammer drills/combi hammers

6m/s

2

9 m/s

25 m/s

2

Needle sealers

5 m/s

2

-

18 m/s

2

-

40 m/s

2

-

8m/s

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Road breakers

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o

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Demolition hammers

Scabblers (hammer type)

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Angle grinders

4 m/s

2

2

Clay spades/jigger picks

-

16 m/s

2

-

Chipping hammers (metal)

-

18 m/s

2

-

Stone-working hammers Chainsaws Brushcutters Sanders (random orbital)

10 m/s

2

2 m/s -

6m/s

2

2

30 m/s 2

-

2

-

4 m/s

7-10 m/s

2

2

-

If the employee is exposed to vibration from more than one tool or work process during a typical day, you will need to collect information on likely vibration level and 'trigger time' for each one. Workplace vibration measurements If you want to obtain vibration measurements for your own tools you will need to arrange for a competent person to carry out measurements for you using specialised equipment. Measurement

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results can be highly variable, depending on many factors, including the operator's technique, the condition of the work equipment, the material being processed and the measurement method. The competence and experience of the person who makes the measurements is important so that they can recognise and take account of these uncertainties in producing representative vibration data.

2

Tool vibration (m/s )

3

4

5

6

7

10

12

15

Points per hour (approximate)

20

30

50

70

100

200

300

450

.

Multiply the points assigned to the tool vibration by the number of hours of daily 'trigger time' for the tool(s) and then compare the total with the exposure action value (EAV) and exposure limit value (ELV) points.

.l. l

100 points per day = exposure action value (EAV)

rw

400 points per day = exposure limit value (ELV)

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Table 2 Simple 'exposure points' system

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Construction Site Safety 1.2.14 Compressed Air

it can enter body orifices such as the mouth, ears and anus, causing severe and often fatal injuries;

(b)

at high pressure it can penetrate the skin;

(c)

particles or oil carried in an air jet can damage the eyes;

(d)

oil-coke deposits in a system can spontaneously ignite and cause an explosion;

(e)

vessels containing compressed air, even at comparatively low pressure, can explode violently once their integrity is lost; and

(f)

dirty or 'wet' air can lead to corrosion and blocked valves which may make the system unsafe.

rw

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(a)

This section explains how to minimise the likelihood of such problems, but it does not give specific advice on air separation plant, the pneumatic transportation of materials through pipelines or the supply of respirable air. Reference in this section to a particular standard does not preclude using an equally effective alternative standard.

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2

This section provides for the safe use of compressed air by giving advice to designers, manufacturers, installers, users and others concerned with or responsible for health and safety at work (Note: Section 9, Part 14 of the QCS covers air blowers and compression equipment). There are many ways in which compressed air can be dangerous, for example:

ta

1

4

a blocked outlet or some other restriction to flow;

(b)

failure of automatic controls combined with low air consumption;

(c)

compressor malfunction, e.g. overspeeding;

(d)

an external fire near the pressure system; and

(e)

o

ov

(a)

et it

er

The major hazard associated with compressors is over-pressurisation, which may arise from:

overheating and the build-up of carbonaceous deposits, both of which can lead to fires or explosions. Although they are rare, fires and explosions can also occur as a result of oil or oil vapour being ignited in the pressure system.

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Hazards

To mitigate the risks of the hazards listed above occurring, a structured and audited equipment maintenance plan must be implemented (see standards such as HSG 139). Furthermore in the use of compressed air for activities other than for respiratory purposes, the user must make every effort to avoid the risk of harm to themselves or their colleagues. To this end, compressed air nozzles must be directed away the users and care must be taken to ensure that they are not directed towards other individuals.

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 1

REGULATORY DOCUMENT ...................................................................... 1

1.3

WORKING AT HEIGHTS ............................................................................ 1

1.3.1

Work at Height ........................................................................................................................... 4

1.3.2

Ladders, Steps and Lightweight Staging ................................................................................. 18

1.3.3

Working Over or Near to Water including Liquid Bodies ......................................................... 32

1.3.4

System Scaffolds and Mobile Towers ...................................................................................... 50

1.3.5

Tube and Fitting Scaffolds ....................................................................................................... 63

1.3.6

Safe Working on Roofs and at Heights .................................................................................... 93

1.3.7

Fall-arrest and Suspension Equipment .................................................................................. 110

1.3.8

Safety with Steelwork ............................................................................................................. 135

1.3.9

Roofing and Fragile Surface Practices .................................................................................. 146

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ta

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.

1

QCS 2014


Page 2

FORWARD

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QCS 2014


Page 3

Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

.l. l

rw

ta qa

42

Item Name

.

Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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as

4&5

8

1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

9

et it

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16


9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Page 4


Work at Height


Falls from height are the main source of fatalities and injuries to construction workers.

2

Falls from 'low heights' (below 2 metres) are the cause of many deaths and injuries.

3

Working at height is defined as working at any height from which a fall could cause personal injury.

4

Work at height requires that such work is:

carried out using appropriate equipment to prevent falls

(c)

organised so that the distance and possible consequence of any fall are minimised

(d)

risk-assessment based

(e)

properly planned and supervised by a competent person(s)

(f)

carried out by competent operatives.

ta

rw

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(b)

qa

Accidents that occurred through working at height show that common factors include the failure of: all parties to recognise that there was a problem

(b)

management to provide a safe system of work

(c)

management to ensure that the safe system of work was followed

(d)

management to provide adequate information, instruction, training or supervision

(e)

the victim to use appropriate equipment

(f)

management to provide safe plant and equipment.

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as

(a)

Section 14 of the QCS covers roofing and roofworks and Section 24, Part 1 relates to scaffolding.

o

Note:

avoided if it is reasonably practicable to do the job another way

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5

(a)

et it


The intent of these Regulations is to reduce the number of deaths and injuries resulting from falls, and so improve the safety performance of the industry.

2

They cover all circumstances where a person:

m

1

3

(a)

is working at height or

(b)

is gaining access to or egress from such a place of work, either above or below ground and

(c)

'could fall a distance liable to cause personal injury', that is, any distance whatsoever.

Common examples of tasks carried out within the construction industry classified as work at height include: working on a scaffold; working from a mobile elevated working platform; being on the back of a lorry; using cradles or ropes to gain access; working close to an excavation or a cellar opening; painting at height; working on staging or trestles, and using ladders or stepladders for cleaning and maintenance tasks. Many other jobs in the construction industry also involve working at height and are covered by these Regulations.

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Page 5

1.3.1.3 Requirements of these Regulations 1

The key provisions of these Regulations are that Contractors should: (a)


(b)


(c)


(d)

ensure that the work is properly planned, risk assessment-based and that it is carried out safely.

(e)


The use of a ladder or stepladder is not prohibited by these Regulations; however, a greater degree of consideration must be given to using an alternative means of access before selecting a ladder or stepladder for use. A decision to use this type of access equipment must be justified by the findings of a risk assessment that clearly shows that, given all of the circumstances, it is reasonable to use such equipment rather than safer types of access equipment.

3

It is to be hoped that these Regulations will be a further stimulus to architects and designers to 'design out' work at height for the construction and ongoing maintenance of buildings, or at least make safe working at height easier to further contribute to safety in the Qatar construction industry.

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.

2

'Access and egress' includes ascent and descent.

(b)

'Fragile surface' means a surface which would be liable to fail if any reasonable foreseeable load were to be applied to it. This will obviously include the weight of a person or any work equipment or materials.

(c)

'Ladder' includes any fixed ladder or stepladder.

(d) (e)

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(a)

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Below are the most important definitions from within these Regulations.

'Personal’ fall protection system' means: a fall prevention, work restraint, work positioning, fall arrest or rescue system other than a system in which the only safeguards are collective safeguards, or

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1.3.1.4 Definitions

(f)

rope access and positioning systems.

(g)

'Suitable' means suitable in any respect which it is reasonably foreseeable will affect the safety of any person.

(h)

'Work at height' means work in any place, including a place at or below ground level, along with access there to and egress there from (except by a staircase in a permanent workplace) where, if the measures required by these Regulations were not taken, a person could fall a distance liable to cause personal injury.

(i)

'Working platform': (i)

means any platform used as a place of work or as a means of access to or egress from a place of work

(ii)

includes any scaffold, suspended scaffold, cradle, mobile platform, trestle, gangway, gantry and stairway which is so used.

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Page 6

1.3.1.5 Reasonably practicable 1

The term reasonably practicable is used in these Regulations. Therefore a Contractor can look at what the risks in a task involving work at height actually are, and what it would cost to avoid them. If it would cost a great deal of money or use of other resources to avoid a very small risk, then it may not be 'reasonably practicable' to avoid it.

1.3.1.6 Contractors Duty The requirements of these Regulations are: on a Contractor to apply to work carried out by their employees and by any other person(s) under the Contractor's control, to the extent of that control.

(b)

to self-employed persons, together with persons under their control, to the extent of that control.

(c)

to persons who are not self-employed, in relation to work being carried out for them and under their control, to the extent of their control.

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(a)

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1

1.3.1.7 Duty of employees

These Regulations also apply to employees in that they have duties.

2

Employees must:

qa

report any activity or defect relating to work at height which they know is likely to endanger the safety of themselves or that of any other person

(b)

use any work equipment or safety device provided for work at height in accordance with any training and/or instructions which they have received.

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(a)

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Failure by an employee to comply with the above is an offence which could, in the appropriate circumstances, be dealt with by company discipline procedures.

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1

1.3.1.8 Organisation and planning of work It is the responsibility of every Contractor to ensure that all work at height is properly planned, appropriately supervised and carried out in a safe manner, taking into account adverse weather conditions that could jeopardise the health and safety of employees. Planning must include the selection of appropriate work equipment, and planning for any emergencies or any rescue.

2

A Contractor will probably meet most of the requirements of this regulation if they have carried out and properly implemented a suitable and sufficient risk assessment.

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1.3.1.9 Competence 1

Contractors must ensure that no person engages in any activity concerning work at height (including the organisation and planning of the work, and selection of the work equipment), unless they are trained and competent to do so or, if they are being trained, it must be by a rd 3 party accredited company, trainees must be supervised by a trained and competent person.

2

The level of supervision is important. The supervisor will need to be able to intervene, physically or by virtue of their authority, if an unsafe situation begins to develop and thereby rectify the situation or stop the work in progress. The less experience an employee has of working at height, the greater will be the appropriate level of supervision required.

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Page 7

Competence may be taken to mean: 3

A person who has practical and theoretical knowledge of the appropriate aspects of work at heights, together with actual experience of what they are to do, which will enable them to ensure that all necessary planning and assessments have been prepared, and safety precautions taken, so that the work may be carried out safely, or that they may work safely.

If they will be inspecting work equipment then 'competence' may be taken to mean: A person who has practical and theoretical knowledge together with actual experience of what they are to examine, which will enable them to detect errors, defects, faults or weaknesses that it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

5

Training is an element of the competence necessary to work at height. Similarly, those who deliver such training must also be competent to do so. To assist trainers in this respect British Standard BS 8454:2006 is to be used. The title of this standard is:

6

'Code of practice for the delivery of training and education for work at height and rescue.'

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1.3.1.10 Avoidance of risks from work at height

Contractors to ensure that risk assessments are carried out.

2

In addition, these Regulations require that:

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'every Contractor shall ensure that work is not carried out at height where it is reasonably practicable to carry out the work safely otherwise than at height.' This clearly requires the Contractor to carry out a detailed study or assessment of all the ways in which the work could be carried out. If a way can be found to carry out the work other than at height, then the Contractor should do so, provided that it is reasonably practicable.

4

A good example of how this can be achieved was demonstrated during the construction of an over-bridge. The bridge deck was completed on flat ground before the spoil was excavated from below it, thus virtually eliminating the need for working at height and reducing the height at which people had to work when constructing the upper parts of the structure.

5

Ground-level fabrication is another way of eliminating or at least reducing some tasks that have been traditionally carried out at height.

6

The fact that falls from height often result in fatal injuries should weigh heavily in any risk assessment and 'cost versus risk calculation' in deciding if an alternative to working at height is reasonably practicable.

7

Where work at height has to take place because there is no reasonably practicable alternative, these Regulations require the Contractor to take suitable and sufficient measures, so far as is reasonably practicable, to prevent any person falling a distance likely to cause injury.

8

The measures include, but are not limited to:

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(a)

ensuring that the work is carried out from an existing (safe) place of work

(b)

ensuring that any means of access to or egress from a place of work using an existing

QCS 2014


Page 8

means it is reasonably practicable to do so safely, and under appropriate ergonomic conditions. 9

Where these control measures do not eliminate the risk of a fall occurring, then the Contractor must: (a)

use suitable and sufficient measures, including the provision of work equipment, to minimise the distance and consequences of any fall

(b)

or, if it is not reasonably practicable to minimise the distance of a fall, then to minimise the consequences of a fall

(c)

provide additional training and instructions, or other suitable and sufficient measures, to prevent, so far as reasonably practicable, any person falling any distance likely to cause them personal injury.

In order to minimise the distance and/or consequences of any fall, suitable and sufficient measures may include the use of safety harnesses, safety nets, safety mats and air bags.

11

Where safety harnesses or safety nets are used, a plan must be developed to rescue anyone who has fallen and must allow for the fact that they may be injured or unconscious. This is particularly important if someone is suspended in a safety harness. Suspension trauma can occur very rapidly and result in severe discomfort or even death if the casualty is not rescued quickly.

12

Ideally, safety nets will be rigged immediately below the place of work and rescue should not be a problem. Anyone who has fallen into the net should be able to simply clamber out of it, or an injured/unconscious person easily rescued. However, if any recovery would prove to be unduly difficult, an alternative method of work which does not involve the use of a safety harness or nets would be more appropriate.

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1.3.1.11 Selection of equipment for work at height In selecting work equipment for use in work at height there is a requirement for the Contractor to select work equipment or other measures which will give collective protection to employees as a whole, rather than just individual personal protection for one person.

2

For example, a guard-rail will protect everyone, whereas a safety harness only protects the wearer.

3

These Regulations require that Contractors follow current best industry practice when selecting equipment for work at height. In particular, Contractors are required to take account of:

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1

(a)

working conditions and risks to the safety of the persons at work

(b)

access and egress and distances to be negotiated

(c)

distance and consequences of any potential fall

(d)

duration and frequency of use of the work equipment

(e)

need for and ease of evacuation and rescue in any emergency

(f)

any additional risks posed by the installation, use, or removal of the work equipment, and any evacuation or rescue from it, and

(g)

Any work equipment which is selected must:

(h)

be appropriate for the work intended to be carried out

(i)

have dimensions and load-bearing characteristics

(j)

allow passage of persons and materials without risk

QCS 2014

(k)


Page 9

be the most suitable equipment for avoiding risks while working at height.

Requirements for particular work equipment These Regulations cover the provision of: guard-rails, toe-boards, barriers and similar means of protection

(b)

working platforms such as scaffolds and trestles

(c)

nets, airbags and other collective means of arresting falls

(d)

personal fall protection systems

(e)

work positioning systems

(f)

rope access and positioning systems

(g)

fall arrest systems

(h)

work restraint systems

(i)

ladders.

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(a)

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4

Guard-rails must be installed to at least 950 mm above the work surface or the edge from which a person may fall.

6

Although there is no statutory minimum height for toe-boards, both BS EN 13374 and TG20:08 recommend a minimum of 150 mm. They must be suitable and sufficient to prevent the fall of persons or materials. In line with current industry practice it is anticipated that scaffold boards on edges will continue to be used in most circumstances.

7

The maximum distance or gap between the top of a toe-board and the mid guard-rail, or between the mid guard-rail and the top guard-rail is 470 mm.

8

Where brick guards or similar items are used as a 'means of protection', then they must be:

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placed so as to prevent the fall of persons or materials

(b)

of a suitable size and strength

(c)

placed or secured so that they do not become accidentally displaced.

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Guard-rails may be removed on a temporary basis for the movement of materials, provided that suitable and effective alternative fall protection measures are put in place for the duration of the work, and that the guard-rails are replaced as soon as possible after the work is completed.

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1.3.1.12 The use of scaffolds 1

All scaffolding works must be conducted in accordance with BS EN 12811-1:2003. Temporary work equipment. Part 1. Scaffold -Performance requirements and general design.

2

Additional guidance is produced by the UK National Access and Scaffolding Confederation (UK NASC), which sells TG20:08 A guide to good practice for scaffolding with tubes and fittings' 'SG4:05 Preventing falls in scaffolding and falsework” and NASC User Guide SG4: You. Preventing Falls in Scaffolding & falsework 2006. The use of fall arrest equipment whilst erecting, altering and dismantling scaffolding.

1.3.1.13 The use of ladders, stepladders and trestles 1

Ladders may be used for access to and egress from the place of work, and ladders, stepladders and trestles may be used to work from, provided that all of the requirements are properly complied with.

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The primary objective of these Regulations is to eliminate work at height (and so the possibility of falls) and where that is not possible, to ensure that all work at height is carried out safely and that the work equipment being used, such as ladder or stepladder, is appropriate, suitable and safe for the work.

3

In deciding to use a ladder for access or egress, or a ladder, stepladder or trestle for work at height, the Contractor must have carried out an assessment and found that it is not reasonably practicable to use any safer means, and that a risk assessment has shown that the risks from using the ladder, stepladder or trestle are low.

4

Ladders should be used in accordance with manufacturers' instructions. They must be the right ladder for the job, positioned at the correct angle, placed on a firm level surface, and secured or otherwise prevented from slipping or moving. Users should face the ladder at all times when climbing up or down, have both hands free, and not carry anything that would interfere with their safety or balance.

5

Ladders may be used as a place of work, subject to the above, and if it is light work of short duration. Users should be trained in how to work safely on ladders, for example not to overreach.

6

When stepladders are to be used to carry out work they should be of a suitable size and type. Generally, stepladders should be placed facing the work. They should not be used side-on to the work in any situation where a sideways load could be applied. Again, the work should be light and of short duration.

7

Trestles should be of sound construction, and properly set up on a surface which will bear their weight as well as any loading of persons or materials. If they are adjustable using telescopic adjustment, they should have high tensile pins in the adjusters.

8

If they are fitted with wheels or castors, they should have brakes or other suitable devices on the wheels or castors.

9

Trestles should be fitted with guard-rails and toe-boards, where appropriate.

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1.3.1.14 Fragile surfaces

Contractors must ensure that no person passes across or near, or works on, from or near, any fragile surface when it is reasonably practicable to carry out the work safely without their having to do so.

2

Where this requirement cannot be met, then the Contractor must:

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(a)

provide and ensure that there are suitable and sufficient platforms, coverings, guardrails or other similar means of support or protection, which must be capable of supporting any foreseeable load or loading

(b)

where the risk of a fall still remains, take suitable and sufficient steps to minimise the distance and consequences of any fall should it occur

(c)

place prominent warning notices at the approach(es) to any fragile material

(d)

where such notices cannot be used, ensure that employees (and others as appropriate) are made aware of the fragile materials by other means.

1.3.1.15 Falling objects 1

Contractors must take suitable and sufficient steps (including prohibiting the throwing down of materials) to prevent, so far as is reasonably practicable, the fall of any materials or objects which are likely to cause any injury to any person. 'Suitable steps' will include the use of such items as brick guards, toe-boards and debris nets.

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2

Where such falls cannot be prevented, or in the interests of safety, suitable and sufficient measures must be taken to prevent persons from being hit by falling objects or materials. This will cover the use of protective fans, boarded or roofed walkways and 'exclusion zones' at ground level.

3

Materials on scaffolds and working platforms must be stored so that they cannot fall or pose a risk of injury to anyone by their collapse, overturning or unintended movement.

1.3.1.16 Danger areas 1

In any workplace where there is a risk of any person falling or of persons being struck by falling objects, then Contractors must take all reasonably practicable steps to prevent any unauthorised access to that area, and appropriate warning signs must displayed.

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1.3.1.17 Inspection of work equipment Where the safety of work equipment used for working at height, for example a scaffold, depends upon how it has been installed or assembled, then it must not be used in that place or elsewhere until after it has been inspected by a competent person. Throughout these Regulations, 'inspection' means any visual or more rigorous inspection, and any appropriate testing that a competent person decides is necessary.

2

All work equipment exposed to conditions causing deterioration that may result in dangerous situations must be inspected. This will ensure that it remains safe and that any deterioration can be detected and remedied.

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Inspections must take place: at suitable intervals

4

after each time that exceptional circumstances have occurred that are liable to have jeopardised the safety of the work equipment.

5

In addition to these requirements, any working platform that is used for construction work, and from which a person could fall more than 2 metres, must not be used unless it has been inspected in that position within the previous seven days. A mobile working platform (such as a mobile scaffold tower or a mobile elevating work platform) must have been inspected within the previous seven days.

6

Contractors must ensure that no work equipment is used unless they have evidence that the last inspection required by these Regulations was carried out.

7

If there is no evidence of the last inspection then the work equipment cannot be used on site until an inspection is carried out.

8

These formal inspection(s) should not be regarded as a substitute for any routine pre-use checks that should be carried out by the user.

9

What is a 'suitable interval' should be decided by a competent person, based on the results of risk assessments, and then be reviewed in the light of experience.

10

The purpose of an inspection is to identify if the work equipment is safe to use, and that any defect or deterioration is detected and repaired. If this is not possible, the work equipment should be removed from service and its re-use prevented before it becomes an unacceptable risk.

11

The results of every inspection must be recorded and kept on site until the construction work is completed, and after that they must be kept at one of the company offices for three

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months. 12

Any computer-based system should be secure and cannot be interfered with. Systems may also be in the form of a 'register'.

1.3.1.18 Inspection of places of work at height 1

So far as is reasonably practicable, every Contractor must ensure that the surface of every place of work at height, every parapet and any permanent rail or other such fall prevention measure be inspected visually prior to each use. While there is no requirement to record such inspections, a simple record would provide evidence that they have been carried out.

1.3.1.19 Schedules Much of the information contained in the schedules detailed below is virtually identical to current requirements and/or guidance so if Contractors are actively working to current standards and guidance then there is little extra for them to do.

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Schedule 1

The requirement in this schedule is for existing places of work at height and means of access or egress to and from such places to be stable, of sufficient size and strength and with edge protection as necessary. Ladders in particular must rest on stable, strong surfaces.

3

A place of work is to be properly constructed, used and maintained so as to prevent the risk of tripping, slipping or being trapped between it and adjacent surfaces. It should have no gaps through which materials could fall and injure someone.

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This covers the requirements for guard-rails, toe-boards, barriers and similar means of protection. The top guard-rail must be at least 950 mm above the edge from which any person might fall.

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Schedule 2

This covers the requirements for working platforms. Part 1 deals with requirements for all working platforms, and Part 2 covers the additional requirements for scaffolding.

6

Part 1 Working platforms must be erected and used so that components cannot become displaced and cause danger to anyone. They must be suitable for the work, and of sufficient strength and rigidity. If they are altered or modified (by a competent person) they must remain safe and stable.

7

Any supporting structure for a working platform must itself be suitable and of sufficient strength and stable while being erected, used or dismantled. It must be prevented from slipping or moving, and if it has wheels or castors, they must be capable of being locked or similar. Working platforms and supporting structures must not be overloaded.

8

Part 2 As regards the additional requirements for scaffolding, strength and stability, calculations must be carried out unless it is being assembled in conformity with generally recognised standard configurations. Design calculations will probably only affect manufacturers and scaffolding companies, and if prefabricated scaffolding materials are being used, then following the manufacturers' erection instructions will probably cover 'recognised standard configurations'.

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9

Depending on the complexity of the scaffold, detailed plans may be needed for its erection, use and dismantling. This may be a standard or generic plan, supplemented with specific details as appropriate. A copy of the plan must be kept for the use of any persons concerned with the erection, use or dismantling of the scaffold.

10

The size and layout of the scaffold must be appropriate and suitable for the work to be performed, and it must also permit the work and passage of persons to happen safely (although no explicit dimensions or requirements are given in these Regulations). It is suggested that following the industry guidance on the size and width of working platforms and the provisions of TG20:08, together with any future guidance produced by the UK NASC, should be sufficient to demonstrate compliance.

Schedule 4 This schedule covers the requirements for collective safeguards for arresting falls. Collective safeguards include safety nets, airbags, landing mats and any similar devices or arrangements. All must be suitable and of sufficient strength to be able to safely arrest or cushion a fall.

12

These safeguards may only be used:

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where a risk assessment has shown that the work which is to be done can be carried out safely while the safeguard is being used, and without influencing its effectiveness

(b)

where the use of safer work equipment is not reasonably practicable

(c)

if a sufficient number of employees (or others) have received adequate training specific to the safeguard, including rescue procedures.

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A key requirement is that if the safeguard is designed to be attached to a building or a structure then the safeguard, the structure and all anchorages must be suitable and of sufficient strength for any foreseeable load that a fall might impose on it.

14

Airbags and landing mats must be suitable for the purpose intended, and they must be stable.

15

If a safeguard is designed to distort when arresting a fall, it must give sufficient clearance from the ground or adjacent structures to avoid injury to a person whose fall is being arrested.

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Schedule 5

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16

This schedule covers the requirements for personal fall protection systems (Part 1), work positioning systems (Part 2), rope access and positioning techniques (Part 3), fall arrest systems (Part 4), and work restraint systems (Part 5).

17

Important note. Much of the information in this schedule is quite technical and it is of paramount importance that employees are, or have been, fully trained on and are competent in the use of any of the fall protection systems available to them. There is not sufficient detail within this brief explanation of the schedule to train a person on the requirements, or for them to gain sufficient knowledge to be regarded as competent.

18

All safety harnesses, lanyards and other fall prevention or fall arrest equipment must comply with the appropriate British or International Standard.

19

Part 1 deals with the requirements for all personal fall protection systems. See Interpretation of these Regulations on page 2 of this module for the definition of 'personal fall protection systems'.

20

Regulations apply to all rope-based activities for work at height, including industrial rope

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systems and any other similar activity when carried out as a work activity. The schedule requires that: a personal fall protection system shall only be used if a risk assessment has shown that the work can be done safely while it is being used, and that the use of other, safer work equipment is not reasonably practicable

(b)

the user and a sufficient number of others have been trained in its use and in rescue procedures

(c)

it shall be suitable and of sufficient strength for the purpose for which it is to be used and will withstand any foreseeable loading

(d)

it fits the wearer and is correctly fitted or worn

(e)

it is designed to minimise injury to the user in the event of a fall, and is such that the user will not fall or slip out of it should they fall

(f)

it is designed, installed and used so as to prevent unplanned or uncontrolled movement of the user.

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Any anchorage point must be suitable and of sufficient strength to support any foreseeable loading. If designed to do so, the equipment must be securely attached to at least one such anchorage point when in use.

23

Part 2 deals with the additional requirements for work positioning systems, which may only be used if:

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the system includes a suitable backup system for preventing or arresting a fall, or

(b)

the system includes a line as a back up system and the user is connected to it, or

(c)

where it is not reasonably practicable to do either of the above, then other suitable measures are taken to prevent or arrest a fall.

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Part 3 deals with the additional requirements for rope access and positioning techniques, which may only be used if: it has two separate lines: the working line and a safety line

(b)

the user has a safety harness which is connected to both the working line and the safety line the working line has safe means of ascent and descent, and a self-locking device to prevent falling

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(d)

the safety line has a mobile fall protection system which is connected to and travels with the user

(e)

subject to the type and length of work, and the findings of a risk assessment, it has a seat with appropriate accessories.

25

However, if a risk assessment has demonstrated that a second line would entail a higher risk to the user, then, provided that appropriate safety measures have been taken, a single rope may be used.

26

Part 4 deals with the additional requirements for fall arrest systems. It requires that they must have a suitable energy absorber (often called a shock absorber and which is usually either a folded metal strip that deforms, or 'tear away' stitched webbing), or other suitable means of limiting the force applied to the user's body if they fall. In addition, a fall arrest system must not be used if there is any risk of a line (a rope or a lanyard) being cut, or where there is no safety zone or clear zone to allow for any swinging or pendulum effect after a fall, or in a way which hinders the system's safety performance or makes its use unsafe.

27

Part 5 deals with the additional requirements for work restraint systems (often a safety

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harness with a very short lanyard), and requires that they are designed so that they are used correctly to prevent the user from getting into a position where they could fall. Schedule 6 Requirements for ladders 28

Contractors must ensure that a ladder or stepladder is only used for work at height if a risk assessment has shown that the use of more suitable work equipment is not justified because of the low risk and the short duration of the work, or because of existing features on site that cannot be altered.

29

The remainder of the schedule is in line with current industry best practice and does not contain any further new or changed requirements.

30

The requirements are:

(b)

the ladder to be strong enough for loads which may be put on it

(c)

the ladder to be placed so that it is stable during use

(d)

the suspended ladder to be attached in a secure manner so that it does not swing

(e)

portable ladders to be prevented from slipping by being secured at or near their top or bottom, or with anti-slip or stability devices, or other effective means

(f)

access ladders to be long enough to provide a handhold when getting off at the top, unless other handholds have been provided

(g)

sections on interlocking or extension ladders to be prevented from movement while in use

(h)

mobile ladders to be prevented from moving before being stepped on

(i)

where reasonably practicable, rest platforms to be provided where a run of ladders rises a vertical distance of more than 9 metres

(j)

ladders to be used in such a way that a secure handhold and secure support are always available to the user

(k)

the user can maintain a safe handhold while carrying a load.

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the surface on which a ladder rests to be stable and of sufficient strength

This last point is qualified for stepladders in that:

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'in the case of a stepladder the maintenance of a handhold is not practical when a load is carried, and a risk assessment has demonstrated that the use of a stepladder is justified because of the low risk and the short duration of the work.' Schedule 7 32

This schedule states the details to be recorded.

33

The details are: (a)

The name and address of the person for whom the inspection was carried out.

(b)

The location of the work equipment inspected.

(c)

A description of the work equipment inspected.

(d)

The date and time of the inspection.

(e)

Details of any matter identified that could give rise to a risk to the health or safety of any person.

(f)

Details of any action taken as a result of any matter identified in 5.

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(g)

Details of any further actions considered necessary.

(h)

The name and position of the person making the report.

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Reports of inspection have to be kept on site until construction work is completed and then at the Contractor's offices for three months.

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Construction Site Safety 1.3.1 Appendix

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Work at height flowchart

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Ladders, Steps and Lightweight Staging

1.3.2.1 Key points Ladders, stepladders and lightweight staging are all easily transported means of access to work at height. They can all be used safely in certain conditions.

2

The danger comes when any of them is used for a job for which it is not suitable; this particularly applies to ladders and stepladders.

3

Although newer and safer equipment is available, these still present serious risks if not used correctly.

4

The nature and duration of the job will be significant factors in determining the most appropriate type of access equipment to use.

5

Falls from low heights, that is from a height below 2 metres, are the cause of many fatalities and major injuries.

6

All work at height must be subjected to a risk assessment.

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Ladders, stepladders and trestles (or lightweight staging) are among the most commonly used pieces of access equipment on site and, perhaps, the most misused. Many construction workers have used them at some time and it is essential that safe working practices should be followed if accidents are to be avoided.

2

Most ladder accidents occur because the ladder has not been secured correctly at the top or bottom and then slips. A person climbing the ladder while carrying a load or overreaching and overbalancing often makes an unsecured ladder unstable. Ladders that are badly placed, or set on an uneven or unstable base, are also a contributory cause of accidents.

3

There are many proprietary devices designed to stabilise the top or bottom of a ladder and uneven ground can be accommodated with adjusters bolted to the stiles.

4

Contractors are to provide safe access and a safe system of work. In certain circumstances particularly where work at height is prolonged, difficult or requires freedom of movement and the use of both hands - scaffolding, as opposed to ladders or stepladders should be used. At the same time it must provide both safe access and a safe workplace.

5

All ladders, stepladders and trestles are 'work equipment' for the purposes of these Regulations and, as such must be safe, suitable for the job and well-maintained. Before any work at height is carried out, a risk assessment should be made.

6

Guard-rails and toe-boards are required on all working platforms where a risk assessment indicates that any person would be injured as a result of the fall.

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1.3.2.3 Work at Height 1

These Regulations require that Contractors should: (a)


(b)


(c)


(d)

ensure that the work is properly planned, risk assessment-based and that it is carried

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out safely (e)


1.3.2.4 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity so as to identify any risks which might be encountered during the work, and which might affect the health and safety of employees or of any other persons.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with clear and understandable information on any risks that exist in carrying out the work and on any control measures that are in place to reduce those risks.

4

An employee, in turn, has a duty under these Regulations to follow any instructions or training given and to tell their Contractor of any work situation that presents a risk to themselves or others, or of any matter which affects the health and safety of themselves or any others.

5

If carrying out work at height cannot be avoided, the risk assessment must determine the most appropriate type of access equipment for the job to be carried out.

6

Factors that will enable this decision to be made include:

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the nature of the work to be carried out

(b)

the time that it will take to complete the work

(c)

keeping the risk of anyone falling low.

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1.3.2.5 The Provision and Use of Work Equipment These Regulations require that Contractors supply work equipment that is safe and suitable for the job, ensures that the equipment is maintained and kept in good order, and that employees are properly trained in its use.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to specified, trained and competent workers.

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These Regulations require that Contractors, as far as reasonably practicable, avoid the need for employees to carry out any manual handling operations which involve a risk of their being injured. Where this is not possible, the Contractor must make an assessment of the work to be carried out and take appropriate steps to reduce the risk of injury to employees.

2

All employees must follow any safe system of work, including using any work equipment (or personal protective equipment) that is provided by the Contractor.

1.3.2.7 General 1

Contractor must provide employees with adequate information, instruction, training and

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supervision so that they can carry out their work safely and without risk to their health,

1.3.2.8 General guidelines for the safe use of ladders 1

A ladder must not be used as an access to, or egress from, a workplace unless it is reasonable to do so taking into account the work being carried out, its duration, and the risks to the safety of any person arising from the use of the ladder.

2

Schedule 6 requires that a ladder should only be used in a low risk situation when a risk assessment has shown that the use of alternative equipment is not justified. This is when:

(b)

the work is of a light nature

(c)

there are aspects of the site that cannot be changed.

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the ladder is to be used for a very short time, or

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A ladder must be of the correct class for the intended use, of sufficient strength, suitable for the job that is to be done, and be so erected that it does not become displaced. Ladders should be set on a firm, level base, strong enough to support the ladder and any load that may be placed upon it.

(b)

There should be no makeshift use of bricks, blocks or timber packing, etc. to gain extra height or to level up the stiles.

(c)

Ladders should be sited clear of any excavation, and in such a position that they are not causing a hazard, or placed anywhere they may be struck or dislodged. Barriers should be placed around the foot as added protection where necessary.

(d)

Ladders should not be placed on or leant against any fragile surface or fitting.

(e)

Proprietary stand-off devices should be used where the point of rest would otherwise be unsuitable, for example, against plastic gutters.

(f)

Ladders should be set, as near as possible, at an angle of 75° (a ratio of 1 unit of length out to 4 units of length up).

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(g)

Ladders must not be secured by their rungs; lashings should be around the stiles, or proprietary ladder ties should be used.


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Lashing or clamping, at the mid-point of a ladder, will make it safer and help to prevent sway, particularly with ladders that are over 6 metres in height.

(i)

A ladder must not be placed in such a position that any adjacent scaffold tubes interfere with the footing of the person on the ladder.

(j)

If the vertical height of a ladder is over 9 metres, safe landing areas or rest platforms should be provided at suitable intervals.

(k)

Only one person should be climbing a ladder at any one time.

(l)

Always face the ladder when climbing or descending it.

(m)

Footwear worn by persons using a ladder must be suitable for maintaining a satisfactory grip.

(n)

When climbing or descending a ladder, both hands must be kept free for holding onto the ladder and free of any other items.

(o)

Tools and materials required for work can be carried in a shoulder bag, on a special belt, or be hoisted up or lowered afterwards.

(p)

When using a ladder, secure handholds and secure support must always be available.

(q)

Tools not in use should be hooked or otherwise secured to the ladder.

(r)

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The top of the ladder must not be repositioned, by jumping, while standing on the rungs.

(s)

When a ladder must be left standing after working hours, a board should be lashed between the rungs to prevent unauthorised access; ideally, they will be removed.

(t)

Ladders must extend at least 1 metre (approximately 5 rungs) above the landing place, unless an alternative, secure handhold is available.

(u)

As far as possible, ladders must be placed so that there is adequate space behind each rung for a proper foothold.

(v)

Overreaching leads to overbalancing. The most satisfactory method for working safely on a ladder is for both thighs and hips to be kept between the stiles, and one hand always holding the ladder. The working position should be not less than five rungs from the top of the ladder.

(w)

Ladders must be properly maintained, of sound construction and materials, free from any defects and kept in good repair. If a rung is missing or damaged, the ladder must not be used.

(x)

Ladders must be supported on each stile and prevented from sagging or swaying.

(y)

All ladders should, in the interests of safety, be securely fixed or lashed to prevent

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slipping, either near the top or, if this is not possible, at the bottom. Ladders must not be painted or otherwise treated in any way that would hide or conceal any defects. They may be treated with a transparent coating such as varnish, shellac or clear preservative. It should be remembered that some timber preservatives might not be compatible with aluminium fittings.

(aa)

Ropes or lashings which are used to secure a ladder must be in good condition.

(bb)

Ladders should only be used as a working place for light work, e.g. maintenance or painting for short periods. Where longer periods of work are anticipated, other access equipment, such as trestles or scaffolds, should be used.

(cc)

No part of a building should be used to support a ladder unless it is safe to do so and strong enough for the purpose.

(dd)

BS EN 12811-1 Scaffolds. Performance requirements and general design (Schedule 6) and good practice

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(z)

'Footing' ladders:

is generally ineffective in preventing most types of ladder incidents

(ff)

must only be used as a last resort, for example when initially climbing a ladder to tie it off, and only if a risk assessment shows a low risk of a fall

(gg)

is only effective on short ladders.

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The person on the ladder must keep their weight between the stiles (no over-reaching or straddling onto adjacent structures).

5

Depending upon circumstances, it may be possible to improve ladder stability by using antislip, stand-off devices towards the top and/or anti-slip feet under the stiles.

6

If possible, seek manufacturer's guidance with regard to extra loading imposed by the weight of two persons on the ladder.

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1.3.2.9 Types of ladder 1

Note: Whichever of the following types of ladder is to be used, it should be Class 1 (suitable for industrial use.

2

Standing ladders: single stage ladders up to 5 metres or 6 metres in length.

3

Pole ladders: a variant of the above type, but with the stiles having been made from a long whitewood pole cut down the middle to give even strength and flexibility. Lengths can vary up to a maximum of 10 metres.

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The practice of shortening a pole ladder to fit a particular situation should be discouraged. The only time shortening a pole ladder is acceptable is when an end is damaged. Care must be taken to ensure that the fabric of the ladder remains stable if a tie wire is removed.

5

Extension ladders: these consist of two or three sections coupled together and extended by sliding over or inside each other.

6

Longer multi-stage ladders are extended by means of a rope and pulley. A three-section ladder, fully extended, may reach over 16 metres.

7

Stepladders: these are of various types, have flat rectangular treads and are usually free standing.

8

Roof ladders (for pitched roofs): a ladder with a hook on the top end of it for securing over the ridge of a roof.

9

Aluminium ladders: various types are available. Their main advantage is that they are light and weather resistant. They can be prone to slipping at the base if the rubber or wooden feet are not properly maintained.

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1.3.2.10 Classes of ladder (British Standards 1129: 1990, 2037: 1994 and BS EN 131) 10

Portable ladders, steps, trestles and lightweight staging are covered by BS 1129: 1990, BS2037: 1994 and BS EN 131.

11

A duty rating indicates their suitability of use.

12

Class 1: Industrial. Heavy duty - can be used frequently and in the tough conditions that can be found on site. These are the only ladders that are recommended for use on site.

13

Class 2: Light trades. Medium duty - can be used only in good conditions. Suitable for light trade purposes. (This class of ladder is now covered by BS EN 131.)

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14

Class 3: Domestic. Light duty - suitable only for domestic and household use.

15

Class 2 and 3 ladders are not recommended for general use on site.

16

All ladders should be marked with a unique identification number and the class or duty rating.

1.3.2.11 Inspection of ladders Every ladder should be inspected on a regular basis and should carry an identification mark, as detailed above. A written record should be kept of all inspections, defects and repairs.

2

Ladders should not be used if defective in any way and, if damaged beyond repair, they should be destroyed.

3

During the inspection of ladders, attention should be paid to the following points.

4

There should be no:

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damaged or worn stiles, particularly at the head or foot of the ladder

(b)

broken, missing, loose or worn rungs

(c)

mud or grease on the rungs

(d)

rungs supported solely by nails, screws or spikes

(e)

movement in the rungs or stiles

(f)

decayed timber, or the corrosion of fittings

(g)

insecure tie wires

(h)

warping, sagging or distortion; check that the ladder stands firmly.

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The condition of any ropes and cords, along with pulleys, hinges and any other fittings, should be checked for fraying to ensure that they are all secure with no sign of damage.

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1.3.2.12 Carrying a ladder 1

A short ladder may be carried comfortably by having it vertical against the shoulder and holding one of the lower rungs, using the other hand to hold the stile. Longer ladders should be carried horizontally by two people. Care should be taken in negotiating comers and obstacles.

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2

Ladders must not be taken into the vicinity of overhead power lines unless a permit to work has been issued. Even then, extreme care should be taken with the head of the ladder so that it is not allowed to get close to the overhead power lines.

3

Timber ladders generally do not conduct electricity (unless wet) but aluminium ladders are extremely conductive, and are dangerous to use in close proximity to overhead lines.

1.3.2.13 Erecting and lowering ladders The procedure for erecting a ladder, when the ladder is flat on the ground, is as follows.

2

One person stands on the bottom rung while the other takes position at the head of the ladder and takes hold of the top rung, raising the ladder off the ground.

3

Then, rung by rung, that person moves towards the foot of the ladder, lifting as they go. The person at the foot grasps the lower rungs as soon as possible and draws the ladder towards them, steadying it at the same time.

4

The sequence is reversed when lowering.

5

Short ladders may be raised by one person placing the foot of the ladder against a wall or fixture and pushing the ladder upwards starting at the top, walking, under-running and raising the ladder as they go.

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1.3.2.14 Extension ladders 1

Extension ladders are raised one section at a time and slotted into position. The minimum recommended overlap on extension ladders is as follows:

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Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document) Closed length

Approx. no. of rungs

Under 5 metres

2 3

Overlap of rungs

under 18

2

18-23

3

5-6 metres

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over 6 metres over 23 Latching hooks must be properly engaged.

4

Ordinary ladders must never be lashed, tied or spliced together in an attempt to make an extension ladder.

1.3.2.15 Roof ladders Roof ladders (shown below) should be erected as follows.

2

First, a standing ladder is erected for access to the eaves of the roof. It should extend at least 1 metre or five rungs above the eaves of the roof and be properly secured, but not to the guttering, downpipes or any other plastic or fragile material.

3

The roof ladder should then be brought up and pushed up the roof on its wheels, with the anchor hook or ridge hook uppermost.

4

Once over the ridge, the ladder is turned over and the hook engaged. It may be necessary to secure the ladder with a rope if ridge tiles are unsound.

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1.3.2.16 Storage of ladders 1

Ladders, especially if made of wood, deteriorate when exposed to the weather for prolonged periods. Where indoor storage is not available, they should be covered or stored in a protected, well ventilated position. They should not be exposed to steam pipes, boilers or other sources of radiant heat.

2

Ladders should be stored on racks, supported on the stiles only, with sufficient supports to prevent them from sagging. They must not be hung from the rungs or stiles.

3

Aluminum ladders should be kept away from wet lime or cement, which may corrode them.

4

Pulleys and hinges should be lubricated and the condition of ropes and cords checked.

5

Any damage or deterioration should be noted and made good before further use.

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1.3.2.17 Stepladders and alternatives Stepladders Many of the general rules for the safe use of ladders also apply to Stepladders. In addition, the following points should be considered. (a)

Stepladders are not to be used if a fall from one would cause the user to be injured (based upon a risk assessment).

(b)

The treads (or steps), hinges, bolts, screws and fixings must all be sound and secure.

(c)

Retaining cords or hinges should be of equal length and in good condition.

(d)

The stepladder must be stable when open and standing on a level base.

(e)

The legs of Stepladders should be positioned as far apart as the retaining cord or hinges allow, with all four legs firmly and squarely on the ground.

(f)

Wherever possible, the stepladder should be positioned so that the person climbing it is facing the work to avoid twisting and possible instability.

(g)

Unless the design permits, the knees of the person using the stepladder should be kept below the top step.

(h)

The user should not work from the top third of a stepladder unless it has been designed for this purpose.

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If it is not practicable to maintain a handhold when a load is being carried, a risk assessment must demonstrate that the use of the stepladder is justified because of: the low risk, and

(b)

the short time the stepladder is to be in use.

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Podium steps/mini mobile towers

The use of this type of equipment is preferred to Stepladders in most circumstances as it provides a small but stable working platform, complete with guard-rails. This type of access equipment has the advantage over a stepladder in that it allows the user to work in a safer manner facing any side of the working platform without it becoming unstable.

2

Podium steps and mini towers are lightweight in construction and some types will fold flat for transportation and are designed to be wheeled through a standard-sized door. Some types of this access equipment can be fitted with outriggers to increase stability.

3

Whilst providing a high degree of safety in most situations, there are a number of specific hazards with the use of this type of equipment and the Contractor should ensure the following precautions are considered in selecting and using podium steps.

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(a)

There are many differing types of podium steps with different arrangements of use. Some are just wheeled platforms and others have specific installation requirements. The instructions for each individual podium must be available and understood by the

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user. (b)

The height of the working platform should be assessed: too low and the user will not reach; too high and the user may be inclined to work from the steps rather than the platform.

(c)

Where adjustable height platforms are in use, ensure that the user is trained in how to adjust the platform and handrails to ensure protection.

(d)

Brakes must be used whilst the platform is in use and users must not be permitted to pull themselves along from the top of the podium.

(e)

Podium steps, like any other access equipment, must have an individual identifying mark and be subject to frequent inspection.

1.3.2.18 Lightweight staging and trestle scaffolds

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Split head trestles and trestle frames

These older type of trestle either consisted of two or more support-trestles supporting scaffold boards to form a working platform, or were made up using four split head trestles with the forks of the split head trestle taking a bearing timber (or two scaffold boards on edge) with boards or staging laid on top.

2

Both split head trestles and telescopic frames need a sound, level base.

3

Where a trestle system is used in which the positioning of trestle supports is variable, they should comply with the following criteria:

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(a)

(b)

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trestle supports must be spaced at the following distances apart: (i)

1 metre when using 32 mm thick boards

(ii)

1.5 metres when using 38 mm thick boards

(iii)

2.6 metres when using 50 mm thick boards.

The amount that the end of any board may overhang any trestle should not exceed four times (4 x) the thickness of the board used for the working platform, unless it is effectively secured to prevent it from tipping.

This type of trestle is now unacceptable in most circumstances because of the inability to fix guard-rails or toe-boards to the 'working platform' and the tripping hazard caused by boards that overlap. There may be rare circumstances where they can still be used safely, for example: (a)

where a fall is not possible because the working platform is completely and tightly

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enclosed by the walls of a room or other solid structure (b)

the working height and the surrounding floor surface are such that a fall could not result in a personal injury.

Modern trestle systems More modern trestles are similar in many ways to system scaffolding, including the fact that guard-rails and toe-boards are an integral part of the working platform. The spacing of the supports is fixed by the system design which enables platform boards to fit snugly without overhang or overlapping.

6

All lightweight staging should be marked with the maximum permitted distributed loading. This can be done by either specifying the maximum number of persons, allowing for their tools and equipment, or by specifying the maximum safe weight.

7

Guidelines are as follows:

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trestles must be set on a firm, level base

(b)

only one working platform is installed

(c)

guard-rails, barriers and toe-boards are required where a fall would cause a personal injury, as indicated by a risk assessment

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where fitted, guard-rails should conform to the standard outlined and dimensions specified in these Regulations

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(e)

if a guard-rail is removed, for example to allow materials to be stacked on the working platform, the guard-rail must be replaced as soon as practicable

(f)

scaffold boards used on trestles to form a working platform must be of a consistent length and of equal thickness

(g)

the trestle assembly must be completely stable when in use

(h)

a safe means of access to the working platform must be provided, for example a ladder that is of sufficient length, properly positioned and securely lashed

(i)

where locating pins are used, they should be of the correct size and type and not rebar off-cuts or other makeshift items.

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Construction Site Safety 1.3.2 Appendix Safety checklist Ladders Is a ladder the right piece of access equipment to be using?

8

Are ladders only used for very light work of short duration, or access?

9

Are all ladders properly stored and inspected regularly?

10

Are the ladders that are being used suited to the purpose or use to which they are being put?

11

Are there any damaged, loose or missing parts?

12

Are the rungs of ladders clean and free of mud or grease?

13

Are sufficient persons available to handle and place ladders properly and safely?

14

Are ladders set on firm and level ground?

15

Are ladders properly erected and secured?

16

If there is not an alternative suitable hand-hold, does the ladder project sufficiently above the landing place?

17

Is there the correct overlap on extension ladders?

18

Are the methods for raising tools or materials safe?

19

Are ladders placed so that the work does not involve overreaching?

20

Is suitable footwear that will give a satisfactory grip and prevent slipping being worn?

21

Are ladders set at the correct angle of 75°?

22

Are ladders clear of excavations or other potential hazards?

23

Are ladders being leant against or secured to any fragile material?

24

Are all lashings used of sound material, and made properly secure?

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Stepladders 25

Is the stepladder level and stable?

26

Is it open to the full extent of the retaining cords or hinges?

27

Are steps set at right angles to the workface wherever possible?

28

Are the user's knees below the top step?

29

Could the person using the stepladder fall a distance that would cause an injury?

30

Is the person using the ladder not using the top third?

Trestles Are trestles, and any boards that are being used with the trestles, safe, undamaged and of adequate strength?

32

Are the trestles set on a firm and level base?

33

Is the working platform of a sufficient width for the job in hand?

34

Are guard-rails and toe-boards fitted to trestle platforms if indicated as being necessary by a risk assessment?

35

Where indicated as necessary by a risk assessment, is the trestle tied to the adjacent structure?

36

Is a safe ladder access provided?

37

Is the maximum permitted distributed load indicated and complied with?

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Podium steps

Are the podium steps of sufficient size and the correct type for the task?

39

Have the operators been supplied with and fully understood the supplier's instructions for use?

40

Are all of the components available and in good condition?

41

Is the floor surface sound and of a level construction?

42

Are brakes provided, in working order and used?

43

Do all podium steps carry unique identifying marks and are they subjected to frequent inspection?

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Management responsibilities Management should: 44

Understand these Regulations and guidance on work at height that is appropriate to ladders, stepladders, podium steps, trestles and other access equipment

45

consider whether any safer system of work or access can be provided

46

know how and where access equipment is being used by employees

47

install permanently fixed ladders wherever possible

48

provide any necessary safety equipment

49

provide adequate storage for ladders and access equipment

50

institute a system of proper inspection and the keeping of records for all ladders and access equipment

51

ensure that all ladders, stepladders, podium steps, trestles and boards are of sound design and manufacture, and kept in good condition

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52

ensure that all users have been properly instructed and trained, and are competent to use the equipment safely and without risk to themselves or others

53

provide proper supervision of all employees who are using any form of access equipment.


Working Over or Near to Water including Liquid Bodies

1.3.3.1 Key points Working over water will often, although not always, involve working at height. The potential risks arising from both hazards will have to be managed.

2

Ideally, work will be carried out from a stable working platform that may prevent an unplanned fall into the water.

3

Where there is a risk of someone accidentally entering the water, appropriate rescue equipment and people who are competent to use it must be available.

4

Working over water may result in a greater emphasis on the wearing of PPE than other types of work at height.

5

Suddenly falling fully clothed into water may induce shock and an increased risk of drowning if appropriate PPE is not worn.

6

Rescue drills should be planned and practiced.

7

If the use of a rescue boat is not appropriate, an established hierarchy of rescue methods should be followed; if a (powered) rescue boat is appropriate, it must only be operated by someone trained in rescue procedures.

8

Working near to deep water, for example adjacent to Mariner Quays can be as dangerous as working over water if appropriate control measures are not put in place.

9

Working over or near water can pose risks to health as well as safety.

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If employees have to work over or in the vicinity of water, a safe system of work must be developed, usually formalised in a method statement, and all those involved must be made aware of the risks and informed of the protective measures that have been put in place.

2

Equally important is the provision of proper rescue equipment and suitable emergency procedures, together with the information and training necessary to use the equipment and respond effectively in an emergency. While every possible effort must be made to prevent people falling into the water, it is essential to make sure that anyone who does fall in can swim or at least is sufficiently confident in water to float (assisted by a buoyancy aid) without panicking. Recovery of the person from the water must take place as quickly as possible.

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Contractors must do everything that is reasonably practicable to provide information, instruction, training and supervision; must provide a safe place and safe systems of work with safe access and egress; and must ensure provision is made for safe use and handling of materials, etc.


Every Contractor must make a suitable and sufficient assessment of risks to the health and safety of employees (and others) arising out of work activities and introduce risk control measures as are appropriate to reduce the risks to health and/or safety to an acceptable

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level. In the context of working over or near water, the risk control measures should include: (a)

ideally, ensuring that it is not possible for anyone to fall into water, by preventing falls

(b)

where that is not reasonably practicable, arresting any falls that do occur, providing there is sufficient clearance height for fall arrest measures to be effective or, where that is not reasonably practicable

(c)

ensuring that anyone who does enter the water is rescued in the shortest possible time

(d)

issuing appropriate PPE such as immersion suits and life jackets

(e)

making sure that appropriate rescue equipment and trained staff are available

(f)

providing information, instruction and training to those persons who have to work over or near water.

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2

The following summary of these Regulations is limited to their requirements as far as they apply to working over or near to water.

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prevent falls and to minimise the chance of drowning should a fall occur

(b)

ensure that rescue equipment is provided, maintained and used when necessary, to enable a prompt rescue

(c)

ensure the safe transportation of anyone to and from the place of work, when they are transported by water

(d)

ensure that vessel used to convey people to and from a place of work is not overcrowded or overloaded.

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These Regulations require that when, during construction work, a person is liable to fall into liquid (with a risk of drowning) appropriate measures are taken to:

The Regulations also place duties on: (a)

all contractors to ensure the competence of anyone working under their control the client to provide adequate pre-construction information on site conditions that might adversely affect health and safety, including in the context of this section, any known hazards arising out of the presence of water

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All construction projects

(c)

designers, by way of their designs, to eliminate the hazards or reduce the risks arising out of construction activities, so far as is reasonably practicable, including in the context of this section, working adjacent to, or over water.

All Projects 4

Duty holders must: (a)

ensure that the Engineer promptly provides the Contractor and all other subcontractors with health and safety information relevant to the site

(b)

take the information supplied by the Engineer and incorporate it into the construction phase health and safety plan

(c)

must take reasonable steps to ensure that everyone engaged in construction work is provided with a suitable site induction and adequate other training that is relevant to what they are required to do.

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On many occasions, working over water will also involve working at height.

2

Contractors are required to: avoid the need for working at height, where reasonably practicable

(b)

when it cannot be avoided, select the most appropriate equipment to prevent falls

(c)

reduce the distance and consequences of any falls that do occur

(d)

ensure that all work at height is properly planned, based upon a risk assessment and carried out safely by competent persons

(e)

ensure that equipment used for working at height is appropriately selected and inspected as specified

(f)

ensure that measures are taken to prevent anyone being injured by falling objects.

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In the context of these Regulations, common-use personal protective equipment (PPE) will include such items as life jackets, safety harnesses, lanyards and immersion suits.

2

Where risks to health and safety cannot be adequately controlled by other means, Contractors must:

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identify appropriate and suitable PPE that will control the risks to an acceptable level

(b)

provide the PPE free of charge to those who are at risk

(c)

provide the users of the PPE with adequate instruction and training with regard to:

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the risks that the PPE will protect against

(ii)

the purpose for which it has been issued and the manner in which it is to be used

(iii)

maintaining the PPE in good working order.

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(i)

The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

4

Employees for their part must:

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(a)

use any PPE that has been issued as instructed and in accordance with any training received

(b)

return the PPE to any storage area that has been assigned to it, after use

(c)

report any loss or defect in the PPE to the Contractor.

Risk areas 5

Hazardous areas include docks, locks, canals, wharves, lakes, ponds (natural and artificial), reservoirs, water-filled pits, sewage ponds, slurry ponds, rivers, streams, swimming pools, water-holding tanks (if of sufficient size) and the sea. Working alongside or near the water's edge can be as hazardous as working over the water. Extra care is needed in the vicinity of culverts, outfalls and other discharge points, and at coastal sites, where drag or undertow due to tidal conditions may be encountered.

Leptospirosis (Weil's disease) 6

When working over water, consideration must be given to the health implications arising from

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the accidental entry into contaminated water. 7

The possibility of contracting leptospirosis whilst working over or near to rivers or streams must be considered.

Accidental entry into water Every effort must be made to eliminate the risk of accidental entry into water. This will involve protecting employees against: falls from heights (including a failure to use the fall prevention or arrest measures provided)

(b)

trips and slips from low level

(c)

persons being knocked over by moving objects, e.g. crane loads

(d)

loss of balance, e.g. caused by high winds, particularly when handling sheet materials

(e)

failure or absence of barriers

(f)

failure of ropes or lines

(g)

rising swell or swell from passing waterborne traffic

(h)

horseplay

(i)

being under the influence of prescribed drugs.

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The most immediate danger is of drowning. Causes or contributory factors include: shock of sudden immersion in cold water

(b)

weight of waterlogged clothing

(c)

incapacity following injury after striking an object during the fall or in the water

(d)

fatigue or hypothermia where rescue is not immediate.

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Hazards of falling into the water

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1.3.3.8 Prevention of falls Scaffolds and platforms

Where reasonably practicable, a stable working platform such as a scaffold is the best method of ensuring safe working over water. It should be designed for the task so that it is stable and of sufficient size for the proposed work.

2

Guard-rails and toe-boards should be fitted to prevent falls of persons or materials and it

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may be advisable to fit double height toe-boards, double guard-rails and brick guards or nets. Boards should be lashed to prevent high winds causing displacement. If a ladder is used for access to the scaffold or platform, it should be of sufficient length, extend at least five rungs above the stepping off point, be properly secured (preferably at the top) and set at the correct angle. If it is necessary for a long access ladder to be used, landing places should be provided every 9 metres. There should be a proper system for the inspection of ladders.

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Safety nets

If safety nets are to be used, they should be erected as close as possible below the working level and, if cantilevered nets are erected on the outside of the structure, the outermost edge should be higher than at the inner edge.

5

Nets are intended to save lives and prevent injury; they are not a substitute for the effective prevention of falls.

6

The manufacturer or supplier of a safety net must supply an instruction manual in accordance with BS EN 1263-1:2002. This guidance should contain:

maximum falling height

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(b)

the required anchorage forces

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(c)

minimum catching width

(d)

safety net linkage

(e)

minimum distance below the safety net

(f)

storage requirements

(g)

inspection and replacement requirements.

7

These instructions may need to be supplemented by special installation instructions, depending on the specific application of the net. Reference should be made to BS EN 12632:2002.

8

There are two main types of safety net: (a)

Personnel nets: 100 mm mesh. Intended to catch a person falling from above.

(b)

Material or debris protection nets: smaller mesh 12 mm-19 mm. Intended to protect those below from falling objects.

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The size and siting of the nets are of critical importance; the further a person may fall, the larger the net needs to be.

10

The maximum recommended distance a person should fall before contact with the net is 6 metres.

11

For a fall of 1 metre, an out rigged net must have a horizontal projection beyond the outermost working point of 2.6 metres, while for a fall of 6 metres a projection of 4.4 metres is necessary.

12

Erection of safety nets should be carried out by competent and qualified persons who should ensure that any supporting framework can withstand impact or shock loadings and that the framework itself does not present a hazard to personnel who may fall into the net.

13

Nets should be securely attached to support framework with tie cords, hooks, rings or thimbles spaced at a maximum of 750 mm. The actual tie should be at least double the strength of the net and, if hooks are used, they must have positive locking of some description. See diagram below.

14

Nets can be out rigged on scaffolding provided that the scaffolding is securely tied into the structure and has been designed to take shock loading.

15

The risk assessment must take into account the rescue of anyone who has fallen into a safety net, including what to do if they are injured or unconscious. Where the safety net has been rigged immediately below the place of work, someone who is uninjured should be able to simply climb out of it.

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Safety nets are provided with short lengths of test cord attached, normally eight. They must not be used as tie cords. At intervals not exceeding three months, one cord should be removed and tested (see BS EN 1263) and a record kept. For nets which have been in continuous use for two years (i.e. eight times three months) or if there is any visible deterioration, advice should be sought from the manufacturers. Nets should be inspected weekly for damage, loose ties, etc., together with the framework and anchorage points. A net should also be inspected for damage and replaced, if necessary, subsequent to a person or other significant load falling into it. All such inspections should be recorded.

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Periodic testing

Care should be taken to reduce to a minimum unnecessary wear and mechanical damage likely to weaken the net. Materials must not be stacked on it and deliberate jumping onto, or dropping of objects into, nets must be prohibited. Sources of damage or wear such as accumulations of debris in the net should be avoided as far as possible.

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Care of nets

These Regulations permit the use of safety harnesses and lanyards where it is not possible to provide a standard working platform or safety net, provided that they are always worn and always secured to a safe anchorage.

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Training

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Training should refer to the manufacturer's instructions and the importance of following them. It should cover fitting, adjustment and use of the belt or harness and the choice of suitable anchorage points. Personnel should not be permitted to use the equipment before instruction has been received.

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Selection and use of equipment

The selection of the correct type of harness for the work planned is essential. If any doubt exists concerning the suitability for a particular task or type of work, further information and advice should be sought from manufacturers or suppliers.

4

Whatever type is chosen it should give a high degree of safety, allied to mobility and wearer comfort.

5

Contractors should consider:

(b)

the selection, attachment and inspection of lanyards the selection of alternative fall-arrest devices

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(c)

the selection of anchorage points

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(d)

the implications of suspension trauma

(e)

the selection of alternative types of access equipment.

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1.3.3.10 Rescue equipment and procedures 1

2

Although every effort should be made to prevent people falling into the water, the risk of this happening remains. In the event of there being a casualty, two things are of paramount importance: (a)

the person must be kept afloat

(b)

location and rescue must be achieved as quickly as possible.

Both of these aims should be kept in view when selecting rescue equipment and establishing rescue procedures. In addition, the effective use of the equipment and the speed and effectiveness of emergency procedures and rescue operations will depend on the training, instruction and information given.

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Life jackets and buoyancy aids All employees working over or near water, and at risk of falling in, should wear some form of life jacket or buoyancy aid. Both life jackets and buoyancy aids are designed to keep the wearer afloat. There are, however, important differences. It is recommended that life jackets are used in preference to buoyancy aids.

4

Life jackets to the relevant British Standards are designed to support an unconscious person in the water and turn them face upwards, by inflation when in the water. Inflation is by means of a CO2 cartridge, activated manually or automatically.

5

Selection of suitable life jackets must be made by the Contractor, having taken advice from the manufacturer or supplier, if necessary.

6

Refer to Appendix 2 for advice on the selection of life jackets and buoyancy aids.

7

Buoyancy aids are intended to provide a conscious person with enough extra buoyancy to stay afloat and achieve a reasonable flotation position. A basic buoyancy aid may not turn an unconscious person over from face-down. Buoyancy is usually incorporated in the form of closed cell foam.

8

Buoyancy aids are bulky and, in some people's view, hinder movement and may slow the progress of work, whereas life jackets are less bulky. Manually inflated life jackets, which are inflated by mouth after entry into the water, should not be used. Automatically inflated life jackets offer a high degree of freedom of movement and do not depend upon the wearer being conscious for them to inflate.

9

Decisions on the type of equipment needed for specific types of work should be based on an assessment of the factors involved. These may include, for example, whether a person is a competent swimmer, the length of time a casualty may be in the water, the risks of injury, water temperature, current and the proximity of assistance.

10

Specialist advice can be obtained from manufacturers on the suitability of equipment for a particular purpose, e.g. type of water, type of environment.

11

Where safety harnesses are to be worn in addition to flotation equipment, it is important to ensure each of these items functions effectively and will not interfere with the other.

12

Safety harness and buoyancy aid combinations are available from

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some manufacturers, though it is necessary to make sure that the harness is not merely a restraint for use in small boats, or a rescue harness, neither of which may be satisfactory for use in construction and similar work. 13

The provision of whistles and lights as aids to the location of people in the water may be advisable in some circumstances.

14

Wearers should be fully trained in the use of safety harnesses, life jackets and buoyancy aids. The functions of the equipment and, where appropriate, its limitations should be clearly understood by users.

Management A clear policy needs to be in place on the use, inspection and storage of automatically inflated life jackets. This policy also needs to address the training needs of the life jacket users.

16

Life jackets, if used regularly, should be allocated to individual users. Each individual, having been adequately trained, can then be responsible for carrying out pre-wear checks and inspections, and report defects according to company procedures. This will help ensure correct inflation of the life jackets is not jeopardised by the carelessness of others.

17

Management needs to enforce its policy on life jackets. This can be achieved by spot checks of both the condition of the life jackets in use and the records of inspection and servicing.

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19

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All workers who use automatically inflated life jackets need to be trained and competent in their care and use, including pre-wear checks and inspection procedures. Training should cover: an explanation of the risks present and the need for life jackets

(b)

operation, performance and limitations of the equipment provided

(c)

instruction and practice on the selection, pre-wear checks, inspection, use and storage of the life jackets, including the use of the manual override lever and oral inflation tube

(d)

factors which can affect the correct operation of the life jackets, such as the working conditions, inadequate fitting, defects, damage and wear (recognising defects in life jackets and arrangements for reporting loss or damage).

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Training

Extra or refresher training may need to be given, for example, if a new type of life jacket or automatic inflation mechanism is introduced.

Pre-wear checks 20

21

A pre-wear check needs to be carried out each day the life jacket is used. This should be carried out in accordance with the manufacturer's instructions and will normally include visual checks to ensure: (a)

the firing mechanism has not been activated. This is usually made obvious by the fact that the life jacket is found inflated

(b)

the automatic firing capsule and gas cylinder are correctly screwed in place

(c)

there are no signs of corrosion, cracks or dents in the gas cylinder or automatic firing capsule

(d)

unwanted movement within the firing mechanism (creepage) has not occurred.

Some automatic inflation mechanisms have colour-coded indicators to show when

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compression in the spring has been lost. Those that do not have such indicators will require careful inspection to judge whether the spring has lost any compression. Examination of the piston or other visible component may also show whether creepage has happened. Make sure: (a)

the whistle and light (when fitted) is in position

(b)

the oral inflation tube is capped

(c)

the straps and main body of the jacket are not worn or damaged

(d)

the jacket is correctly packed in accordance with the manufacturer's instructions (ensuring that any Velcro is correctly fastened and the manual inflation lanyard is accessible).

Inspection and maintenance As well as pre-wear checks, a more thorough inspection and testing programme needs to be carried out in accordance with the manufacturer's instructions. Where life jackets are used heavily, for example, off-shore, the periods between inspections may need to be shorter than the quarterly inspection recommended by some manufacturers.

23

As a general guide, where life jackets are used daily, inspections on at least a monthly basis may be necessary.

24

Inspection and testing need to be carried out by those competent in recognising defects and the remedial action to be taken. Records need to be kept of all inspections and repairs made.

25

Testing the air-tightness of the life jacket will involve orally inflating the life jacket and leaving it overnight (or submerging it in water) to check for leaks. The automatic inflation mechanism will need to be dismantled to make a detailed examination of its condition. Make sure:

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all screw threads are examined for signs of rust. Rust can lead to problems in locating the cocking cap or the gas cylinder in the correct position

(b)

the gas cylinder is examined for corrosion, cracks, dents and other defects. Particular attention will need to be paid to the cylinder cap as any indentations found could mean that the automatic firing mechanism has fired but failed to pierce the cylinder. If this is the case, the reason for activation and the cause of failure needs to be identified the cylinder fitting and groove of the firing pin are checked so that they are free from dirt

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(d)

the automatic inflation mechanism is operated manually (with the gas cylinder removed) to ensure that it operates smoothly, and that there is no obstruction to the movement of the pin which prevents it piercing the cylinder. The pin also needs to be checked to ensure that it is sharp

(e)

the 'salt' or 'paper ring' is inspected for any cracking, dissolving or tearing which has taken place since the last inspection

(f)

where fitted, the rubber '0' ring is inspected for damage and that it is correctly seated

(g)

the mechanism is checked for signs of 'creepage'.

26

Once the inspection is complete, the life jacket should be reassembled according to the manufacturer's instructions.

27

Manufacturers generally recommend life jackets to be serviced every two years by their appointed agents. However, where life jackets are used very regularly, an annual or more frequent service may be needed.

28

If any defects are found with either the gas cylinder or the automatic inflation mechanism,

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these parts must be replaced. If the life jacket is in need of repair, return it to the manufacturer. Repairs should only be carried out by people approved by the manufacturer. Storage Exposure to damp, humid conditions can lead to deterioration in the automatic inflation mechanism, known as 'creepage'. This has the potential to lead to failure of the pin to pierce the carbon dioxide gas cylinder. Life jackets need to be stored in suitable dry conditions. The following advice should be observed when storing life jackets: do not hang life jackets with wet oilskins or other damp clothing

(b)

if the life jacket is wet, unpack it and leave it to dry out on a hanger

(c)

do not store life jackets close to or directly above heat sources, such as convection heaters

(d)

to prevent water getting into the automatic inflation mechanism, do not store wet life jackets upside down or lying flat

(e)

make sure there is enough space around the life jacket, when it is stored, to allow the air to circulate.

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Lifebuoys

Lifebuoys should be available wherever people are working on, over or near water. Standard 760 mm diameter lifebuoys with rope or cord lifelines (usually 30 metres) attached should be placed in conspicuous positions near the water's edge.

31

A lifebuoy can be thrown only a short distance, perhaps 6-8 metres and then with little accuracy.

32

Handling 30 metres of rope may also present problems to the inexperienced person, although lifebuoys are available with the rope packed into plastic containers, from which it reels out when the lifebuoy is thrown.

33

Lifebuoys should be suspended from a suitable hook or bracket, with the lifeline coiled ready for use.

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Rescue lines

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Various types of rescue line are available. One type employs 25 metres of line in a canvas bag with a small flotation chamber. The free end of the line is held, while the bag is thrown underarm towards the casualty. The line can be delivered accurately up to its full length, but underarm throwing may be hindered by guardrails and other forms of edge protection.

35

Another method of delivering the line is the capsule emergency lifeline. A light but strong line, 40 metres in length, is packed into a small plastic capsule. The free end of the line is secured to a cord grip which is held while the capsule is thrown, the line paying out as it goes.

36

The capsule may be thrown or flicked to the full distance of 40 metres using an extension rod which fits into the handle. Both line and capsule will float, allowing the casualty to grab the line and be hauled to safety. If the first throw misses, it can be very quickly used again. The ability to deliver the line up to 40 metres may avoid the

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need to launch a boat or for somebody to enter the water. 37

The capsules are small enough to be carried in a belt or, alternatively, can be mounted in cabinets (with the extension rod) at convenient locations.

.

The majority of drownings occur close to the bank or water's edge; safety provision should take account of this, where it is the dominant risk. Lightweight throwing lines or similar equipment should be provided to supplement lifebuoys, especially if workers are moving from place to place, adjacent to the water. The mere provision of a standard lifebuoy may not be regarded as doing all that is reasonably practicable to secure the safety of employees.

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Rescue packs

This method requires the rescuer to swim out on a lifeline with a buoyancy aid for the casualty or, alternatively, wearing a deflated rescue life jacket which is inflated when the casualty is reached. Both are then pulled in on the lifeline.

39

The 100 or 200 metre floating line supplied in the pack ensures the rescuer is secured to the shore or edge at all times. In rough or tidal waters, this is an important consideration. If using this method, account must be taken of the fact that the person who has fallen may be panicking and, therefore, the rescuer must be trained in rescue techniques.

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Rescue boats

A rescue boat should be provided whenever work is being undertaken over or adjacent to deep, tidal or fast flowing water; it may also be advisable to provide a boat in some areas of still water, dependent upon the findings of a risk assessment.

41

The craft may be rigid (wooden or fibreglass) or inflatable. It must have a reliable engine and carry oars and possibly a first aid kit. The operator should be experienced and competent at handling small craft on flowing water, particularly in rescue situations that involve special boat-handling and skills.

42

Note Where there is a possibility that a rescue might have to be carried out using a powered rescue boat, it is strongly recommended that the operator is trained to a minimum standard. Rescuing a person from the water in a power boat with a rotating propeller demands skill and experience, particularly if there is a current flowing. Ideally, there will be two people in the boat, the driver and a 'rescuer'.

43

Whether the rescue boat is to be permanently manned and constantly afloat, or not, will depend on the circumstances, as will its size and the equipment to be carried. If any work is to be done during the hours of darkness, the rescue boat will require high efficiency lighting.

44

Two-way radio communication between boat and shore may be necessary on large areas of water. Grab lines should be provided for persons in the water and a boat hook should be carried. Practice rescue drills should be held, so that the best method of rescuing, securing and landing a potential casualty is known in advance.

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Stop nets or lines 45

Given the right circumstances, including still or gently flowing water and no waterborne traffic, nets may be suspended just into the water or lines trailed across or in the water to

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allow a conscious person to hold on while awaiting rescue, or to pull themselves to the bank. These cannot be totally relied upon, because a casualty may be unconscious or otherwise unable to help themselves. 46

If there is a weir or sluice, nets should not be relied upon unless they can be positioned well upstream of it.

Rescue techniques Methods of rescuing a casualty, other than by using a rescue boat, may be summarised as follows: involve the emergency services

(b)

reach out from the bank or edge

(c)

throw out a means of flotation or recovery

(d)

wade out

(e)

go out.

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Emergency services. In many cases, the Civil Defence (Fire Department) or Qatar Coastguard service in appropriate circumstances will have the expertise and equipment to carry out rescue procedures. A judgement will have to be made as to whether it is advisable or practical to await their arrival. This must be balanced against the risks involved in attempting the following means of rescue.

49

Reach out. If the casualty is near enough to the bank or edge, it may be possible to grab their hand, or use a sturdy stick, boat-hook, oar, broom handle, or anything they can seize to pull them in to safety. The rescuer should ensure that they have a secure foothold and sufficient grip and balance to counteract the weight of the casualty in the water.

50

Throw out. When the casualty is some way out in the water, a lifebuoy and rescue line or any buoyancy aid with line attached should be thrown to them. This technique is preferable to entering the water to reach the casualty, especially if the depth of water and state of currents is not known.

51

Wade out. A shelving bed or shore may enable a rescuer to reach the person in the water while keeping their feet on the bottom. Care is needed, since currents, underwater obstacles and sudden changes in the depth of water may put the rescuer at risk.

52

Go out. Assistance should be summoned first when possible. Individuals should only act alone if they really have to. A boat should preferably be used to reach the casualty. If not, the rescuer should swim out with a lifeline secured to the shore or edge and a buoyancy aid.

53

Avoid becoming a casualty. People who cannot swim should not enter the water, but must raise the alarm and wait for assistance.

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1.3.3.11 Onshore facilities and procedures 1

First aid. Almost irrespective of the size of the operation, first aid facilities should be provided, and trained and qualified first-aiders should be present at the site of all work adjacent to water.

2

Facilities should include provision for transferring casualties from boat to shore and ambulance access.

3

Alarms. Some effective means of raising an alarm must exist. Gongs, bells, whistles, pressurised canister fog horns, klaxons or similar items of equipment should be provided. All people on site should be instructed in the correct use of the alarm and the actions to be

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taken when the alarm sounds. Lighting. Water surfaces should be illuminated at night so that victims of falls can be seen and constantly watched while awaiting rescue.

5

Communications. The telephone number for the ambulance, coastguard and lifeboat services should be stressed to operatives and adequate provision should be made for effective on-site communications.

6

Rescue equipment. Rescue equipment is for use in an emergency. It must be properly maintained, not misused and never relied upon as a primary safeguard against accidents.

7

Clothing. High visibility vests or jackets should be worn. These will assist in keeping the casualty in view while the rescue operation is being mounted. High visibility immersion suits will be appropriate in some circumstances.

8

Checking personnel. Periodic checks should be made to ensure nobody is missing. Personnel should work in pairs or in sight of each other to enable one person to raise the alarm in the event of an emergency.

9

Weather and tides. Details of weather and, where appropriate, tides should be obtained before each shift.

10

Recovery of equipment from the water. In the event of tools, equipment or small plant falling into the water, no attempt should be made to recover them using amateur divers or improvised techniques.

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Training

A clearly defined and documented rescue procedure should be devised. All personnel should be familiar with the procedure and understand the actions they must take in an emergency.

12

The location of emergency equipment should be known and any special training in its use given to the personnel involved. Responsibility for co-ordinating and supervising rescue operations must be allocated to identify individuals, trained and competent to discharge it. Practices in rescue procedures should be held where appropriate.

13

Locally employed site-based staff and the employees of subcontractors should receive instruction in emergency procedures and the use of life-preserving equipment, and must be given such information as is necessary to enable them to act effectively in an emergency.

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Construction Site Safety 1.3.3 Appendix 1 Safety checklist: working over or near to water Management and planning Risk assessment carried out.

2

Safe system of work, usually specified in a method statement.

3

Permit to work system implemented where necessary.

4

Frequent accounting for all staff.

5

Lone working prohibited.

6

Regular auditing that safety rules are being adhered to.

7

Competence of all staff confirmed.

8

Site induction and relevant toolbox talks for all.

9

Other training provided where necessary.

10

Serviceability and suitability of all rescue equipment periodically checked.

11

Lighting available, if necessary.

12

Weather forecast monitored where the state of the weather could be an issue.

13

Tide-tables checked where the state of the tide is an issue.

14

Preparedness to suspend work, where appropriate.

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Keeping out of the water

Scaffolds: guard-rails, toe-boards fitted; inspections made.

2

Safety nets: secure mountings, correct size of net, at the right place.

3

Safety harness: right type, properly worn, good anchorage, attached constantly.

4

Effective rescue procedures developed, for example, from a safety net.

Keeping afloat

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Life jackets: right size and type, always worn.

2

Buoyancy aids: suitable for purpose.

3

Prompt response by rescue craft.

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Rescue procedures 1

Lifebelt: correctly positioned, ready for action.

2

Rescue lines: available, personnel trained in use.

3

Rescue pack: requires a good swimmer.

4

Rescue boat: properly equipped, experienced crew.

5

Stop nets or lines, just in or on water.

6

Rescue hierarchy: (a)

emergency services

(b)

reach out

(c)

throw out

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(d)

wade out

(e)

go out.

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Avoid becoming a casualty.

Onshore emergency procedure Audible alarm.

9

Good communications: telephone, radio.

10

Emergency services: phone numbers displayed, clear directions to accident location.

11

Site access for emergency vehicles.

12

Trained first aiders/rescue team.

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Construction Site Safety 1.3.3 Appendix 2 Classes of life jacket Life jackets are divided into different buoyancy classes. The criterion of each class is the support (buoyancy) provided by each class, which is expressed in Newtons (N).

2

The EU standards which cover life jackets also require a level of protection for the unconscious person in the water. This means that life jackets must distribute the weight of the wearer in such a manner that the person is turned face-up. The standards require that automatic life jackets must self-inflate within 10 seconds of contact with water.

3

The buoyancy level in the standards relate to a person weighing 70 Kg, thus the amount of actual buoyancy provided by any life jacket will depend upon the weight of the wearer.

4

Consider the following situations:

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wearing a life jacket with too little buoyancy poses obvious problems as there may be too little support for a heavy person to keep their face out of the water or possibly even turn them face-up if unconscious

(b)

conversely, wearing a life jacket with too much buoyancy could also pose problems; wearers who are not particularly heavy will be more buoyant and, for example, could find it difficult to escape from an air pocket if they have to fully immerse themselves and their life jacket to 'duck under' an obstruction.

The selection of the most appropriate life jacket is therefore essential and the following text provides a guide.

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(a)

For use by good swimmers in safe water only as long as assistance is at hand. Not safe for unconscious persons.

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Suitable for adults who are swimmers and for use in inland waters and safe areas, providing limited protection for unconscious persons depending upon the clothing worn.

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50 N buoyancy aid

150 N life jacket 8

Suitable for swimmers and non-swimmers in all waters. Only limited protection for unconscious persons wearing heavy waterproof clothing or in heavy seas.

275 N life jacket 9

For offshore use and extreme conditions. Immediate protection for unconscious persons, with turnover guaranteed in 5 seconds. Adequate buoyancy even in heavy clothing.

10

Buoyancy aids incorporate closed-cell foam inserts sewn into the material of the device.

11

Life jackets incorporate a gas cartridge which inflates a bladder within the life jacket. Actuation can be either manual (usually by pulling a toggle on an actuating chord), or automatic (when an inbuilt 'trigger' device comes into contact with water). If operated, either in an emergency or by accident, the bladder can be deflated and repacked and the life jacket can be fitted with a rearming kit so that it can be reused if undamaged.

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System Scaffolds and Mobile Towers

1.3.4.1 Key points Scaffold of any type must only be erected, altered or dismantled by operatives who have been trained, or are under the direct supervision of someone who is competent to do so.

2

The modular construction of system and tower scaffolds could increase the temptation for unqualified persons to tamper with them. Site managers must be aware of this and monitor the situation.

3

Scaffolds must be subjected to statutory inspections with reports raised where appropriate.

4

All scaffolds must be properly erected, stable, tied to the structure as appropriate, suitable for their purpose and equipped with toe-boards and guard-rails on all working platforms.

5

BS EN 12811 series of standards highlights requirement for additional ties and bracing.

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1.3.4.2 System Scaffolds

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System scaffolds and the components of mobile scaffold towers are generally of a modular layout. They comprise standards with welded node connectors to which ledgers and transoms are fastened, usually with proprietary wedges or rings (rather than loose coupler connections) or frames with both standards and transoms welded into one unit.

2

The safety requirements of system scaffolds are broadly similar to traditional scaffolds, but there are some significant differences.

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Work at Height

The height at which guard-rails and toe-boards must be fitted is determined solely by the findings of a risk assessment. The requirement now is that a Contractor must:

4

'take suitable and sufficient measures to prevent, so far as it is reasonably practicable, any person falling a distance liable to cause personal injury.'

5

Experience has shown that falls from less than 2 metres can cause serious and fatal injuries.

6

Contractors must consider:

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(a)

the organisation and planning of work at height

(b)

avoidance of risks from working at height

(c)

the competence of those who work at height and are involved with work equipment used for working at height

(d)

the general principles for the selection of work equipment for working at height

(e)

the requirements for particular work equipment

(f)

work on or near fragile surfaces

(g)

danger areas

(h)

the inspection of work equipment used for working at height

(i)

the inspection of places of work at height

(j)

the duties of persons at work in relation to work at height.

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Of relevance to this section, these Regulations refer to applicable Schedules in section C1, these include: (a)

the requirements for working platforms, guard-rails and toe-boards

(b)

additional requirements for scaffolding

(c)

additional requirements for fall-arrest systems

(d)

additional requirements for work restraint systems

(e)

the requirements for ladders

(f)

the particulars to be included in a report of inspection.

1.3.4.4 The Provision and Use of Work Equipment System scaffolds, including individual components and associated equipment, are classified as 'work equipment'. As such, all equipment must be suitable for its intended purpose, well maintained and inspected as necessary.

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Manual handling will be an activity linked to the erection, alteration and dismantling of scaffolds. It is also likely that those who work from scaffolds will be involved in manual handling activities during the course of their work.

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1.3.4.5 Manual Handling Operations

Before undertaking the erection of a system scaffold, the following points must be clearly defined:

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1.3.4.6 Basic system scaffolding considerations

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The management of risk

A risk assessment should be carried out.

3

The scaffold, so far as it is reasonably practicable, should be the safest and most suitable 'work equipment' for the task it is intended to carry out.

4

The purpose of the scaffold is usually to provide a safe place of work, primarily at height and the configuration of a system scaffold may vary depending on its intended use. For example, scaffolds for bricklaying, masonry, refurbishment, glazing or painting may differ in their design and construction.

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Who will erect the scaffold? 5

Scaffolds must only be erected, altered or dismantled by, or under the direct supervision of, a competent person.

Where will it be erected? 6

Care will be required in the initial setting out of the system scaffold as far as leg or jack adjustment and the positioning of fixed length ledgers are concerned.

7

Measuring the length of the building and then positioning the first frames or standards and ledgers in relation to door openings will be important.

Are the ground conditions suitable? 8

Bay lengths may often differ from those associated with tube and fitting scaffolding, which

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can cause loads to be concentrated in particular spots. Initial ground inspection and levelling is essential to reduce the amount of jack levelling and adjustment required during scaffold erection. As with tube and fittings scaffolds, care should be taken with regards to manholes, slopes and the general load-bearing capabilities of the area on which the system scaffold is to be placed. What materials are to be used? 9

The availability of space for the standards and the width of the working area are prime considerations in deciding which type of scaffold should be used. An allowance must be made for the fact that heavy or bulky materials may be deposited on the scaffold.

Stability of the scaffold structure The scaffold structure must be of sufficient strength and rigidity when erected and, if appropriate, secured or 'tied-in' to the structure against which it is built to ensure stability.

11

If the scaffold is later adapted or altered, this must be done in such a way as to ensure that the scaffold structure remains stable.

12

A requirement of BS EN 12811 -1:2003 is that all but 'standard scaffolds' must be properly designed.

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Can safe access to the working place be provided?

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System scaffolds provide a variety of options for safe access to the working place, such as pole ladders, internal ladder systems or staircase towers. A decision must be made at an early stage in order that provision may be made for the particular type of access required.

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13

Platforms may have to be installed at every level, whether or not they are working places. This is a feature of some types of system scaffold. However, it is often the case that only one or two may be used as working places, and in such cases the manufacturer's recommendations must be followed as to whether or not platforms can be omitted.

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How many working platforms will there be?

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How and where will the scaffold be tied in? The principle of tying a system scaffold to the supporting structure is the same as for a tube and fitting scaffold. The pattern of ties and the frequency of their use will vary between manufacturers, and the different types of system scaffold will often incorporate their own proprietary ties instead of the conventional through ties or Hilti rings that are used on tube and fitting scaffolds.

16

It may be necessary to tie-in the scaffold at different places compared to the tying-in of tube and fitting scaffolds, and so consideration should be given to the exact locations available.

17

Note that BS EN 12811-1:2003 recommends the installation of additional ties in some circumstances, when compared to the requirement previously required under BS 5973.

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What bracing will be required? 18

Ledger bracing is not generally required in system scaffolds. This has the benefit of providing a clear walk-through at platform level. However, the frequency of facade bracing will vary from product to product, and plan bracing may be required if tie or anchor positions are not readily achievable or, if deemed necessary, under BS EN 12811-1:2003.

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Unauthorised alteration 19

Due to their design features, most types of system scaffold are generally easier to alter than is a tube and fitting scaffold. This makes unauthorised alteration, for example the removal of a guard-rail or the repositioning of a working platform, that much easier.

20

Unauthorised alteration can make a scaffold an unsafe place of work for the unwary and possibly breach the scaffold design criteria from a stability point of view.

21

It is for site management to make clear to anyone who has to work on a system scaffold that unauthorised alteration must not be carried out and that appropriate actions will be taken against individuals who do so.

1.3.4.7 System scaffold specifications

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Materials

Components should be free from any weld defects, bends, distortion or corrosion that may affect the safe functioning of the items. Many scaffold systems are galvanised, so the risks from corrosion are reduced.

2

Fittings employed for tying and adaptations to the scaffold should be free from worn threads and damaged bolts.

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The requirement for any supplementary support or load-spreading capability will depend upon: the nature of the surface on which a system scaffold is to be erected

(b)

the weight of the scaffold itself

(c)

loading that will be imposed upon the completed scaffold by materials, people and equipment.

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Foundations and levelling

In most cases, the installation of either base plates alone, or base plates plus sole boards, will be sufficient.

5

On system scaffolds, the ledgers and transoms connect to the standards at fixed points so there is not the degree of vertical adjustment that there is with tube and fitting scaffolds.

6

Because of the difficulty of levelling a system scaffold as erection progresses, all such scaffolds should be properly levelled and located at the first level. If this is done correctly, components should be vertically self-aligning, but great care must be taken to check the initial vertical alignment at the base.

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Platform decking 7

As the scaffold frames and components have been designed by the manufacturer to meet the requirements then, if used in accordance with the manufacturer's assembly instructions, platform span and thickness requirements will be met.

Types of platform 8

There are several different types of platform available for use with system scaffolds: (a)

conventional scaffold boards (225 mm x 38 mm x 3.9 m) (plus steel and aluminium versions of similar dimensions)

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(b)

timber battens (typically 225 mm x 60 mm x 2.5 m)

(c)

decking platforms of plywood and aluminium (650 mm x 50 mm x 2.5 m or 3.0 m or 3.5 m)

(d)

steel decking platforms (330 mm x 50 mm x 2.5 m or 3.0 m)

Only scaffold boards, whether timber, steel or aluminium, require supporting at 1.2 m or 1.5 m centres. Other decking products have been generally designed to span distances of up to 3.0 m or 3.5 m. The manufacturers of the various types of decking will provide specific guidance.

Requirements for scaffold boards Any scaffold boards used should comply with BS 2482:2009 Scaffold boards should not be warped, twisted, split or badly worn. They should be banded or nail plated.

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All scaffold boards or decking platforms should be secured against the possibility of wind uplift. There are several types of fitting and straps available to achieve this. Design features such as locking devices to prevent wind uplift are increasingly built into proprietary platforms.

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Reaction to windspeed

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Platform widths

There is a requirement for a minimum width of a working platform, 600 mm, as specified in BS EN 12811-1 is 'standard' minimum.

13

The actual width chosen will depend largely upon the nature of the application, for example, bricklaying will not be suitable on a 750 mm-wide scaffold, but painting and cladding may be well suited to this width.

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Additional ledger bracing is not generally required within system scaffolds due to the inherent stiffness of the joints. However, if the system scaffold is to exceed the design boundaries of a 'standard scaffold', the layout should be specified by a competent scaffold designer.

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Ledger bracing

Longitudinal or facade bracing The requirement for longitudinal or facade bracing will be specified by the manufacturer or scaffold designer, and will vary from product to product.

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Ties 16

The need for ties on a system scaffold is the same, in principle, as on a traditional scaffold.

17

However, a system scaffold has different characteristics (for example, its components are shorter and lighter) so the tie pattern will need to be specified by the manufacturer, or a competent scaffold designer. Requirements for ties may vary from product to product.

18

Increasingly, new methods of tying are being used to replace conventional through ties or Hilti rings. Eyebolt and plastic plug type ties are now used on some systems.

Sheeting of scaffolds 19

Caution must always be exercised before a decision is taken to sheet any scaffold. The sheeting of any scaffold increases the wind-loading on it. The requirement for additional ties

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will be determined by the manufacturer or a competent scaffold designer.

1.3.4.8 Access Requirements for ladders Any ladder (including those used in conjunction with a system scaffold) must be in good condition, and of sufficient strength.

2

It must be prevented from slipping during use either by securing it at the top or bottom or by an effective anti-slip device or other equally effective means. However, industry best practice is that all ladders, irrespective of length, should be properly secured at all times.

3

The top of the ladder should extend to a sufficient height above the platform level unless alternative means are used to provide a safe handhold. (It is suggested that 1 metre or five rungs is a suitable height.)

4

If a ladder, or a series of ladders, rises a vertical distance of 9 metres or more, rest platforms or safe landing areas must be provided.

5

Pole ladders and steel ladders are still used for access to system scaffolds even though they have been a contributory factor in many falls from height.

6

Staircase towers or built in ladder sections for access onto the working platform are now widely available and used as an alternative to conventional ladders.

7

Staircase towers may be more appropriate for the movement of higher numbers of people and particularly for heights in excess of 10 metres.

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1.3.4.9 Concentrated loads 1

Where concentrated loads, e.g. pallets of bricks or tiles, are to be placed on the scaffold, loading towers may be required. These specially designed and braced scaffolds provide support for concentrated loads, the weight of which would be excessive on standard scaffold working platforms.

1.3.4.10 Incomplete scaffolds 1

Where a loading tower constructed in a system scaffold is erected adjacent to the working scaffold, the two structures should be securely tied both to each other and to the building.

1.3.4.11 Safe places of work, and stability of working platforms Any working platform on a scaffold must:

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have safe access to it and egress from it

(b)

be of suitable and sufficient strength and rigidity for the purpose for which it is to be used

(c)

be so erected and used so that none of the components can come loose or be displaced and endanger anyone

(d)

be stable when being erected, used and dismantled

(e)

be of sufficient dimensions to permit safe passage of persons and materials, and provide a safe working area for the work that is to be done there

(f)

have a suitable (non-slip) surface so as to prevent slipping or tripping

(g)

not have any gaps through which a person or materials could fall

(h)

be used and maintained so that persons cannot be caught between the working platform and any adjacent structure

(i)

be dismantled in such a way as to prevent accident displacement.

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Each item of plant and equipment used in conjunction with any scaffold must be of sound construction and materials, and must be sufficiently strong and suitable for the job it has been designed to do. It must be maintained in such a condition.

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1.3.4.12 Plant and equipment

1.3.4.13 Requirements for guard-rails and toe-boards 1

Where the proper erection of a scaffold has not been completed, it should not be left unattended without the display of a notice stating: Scaffolding incomplete - do not use

2

It is also a good idea to remove and secure access ladders.

3

For Mobile Towers, please see the next page.

1.3.4.14 Mobile Towers 1

The use of lightweight aluminium mobile towers on construction sites is a popular alternative to the use of traditional tube and fitting towers. However, these systems have some limitations and should only be used when they can satisfy both legislative and general site requirements.


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Five different items make up a basic mobile aluminium tower: frames

(b)

braces

(c)

platforms

(d)

legs

(e)

wheels or castors.

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General conditions and provisions

The UK Prefabricated Access Suppliers' and Manufacturers' Association (PASMA) has developed two methods of installing guard-rails that do not require the erector to stand on a working platform until the guard-rail frames have been installed:

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advanced guard-rail system

(b)

through-the-trap (3T method)

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(a)

These methods should be adopted by Contractors as best industry practice in Qatar.

5

The advanced guard-rail system involves the use of specially manufactured, hinged guardrail frames that can be raised and slotted into position from below.

6

The 3T method involves the erector only passing through the platform trap-door far enough to be able to locate the guard-rail frames in place. In many cases, safe erection of the guardrail sections can be achieved with the erector sitting on the platform with their legs through the trap and their feet supported on the ladder section below.

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Materials 7

Mobile towers may be constructed from steel, but are principally of aluminium.

8

All components must be free from any welding defects, dents, bends or distortion, or any corrosion that could prevent their safe use. Platform boards must be free from holes, cracks, splits or any delamination would affect their safe use.

Competence 9

Any person erecting a mobile tower must be competent to do so, having received adequate

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training or, if not fully competent, be under the supervision of an experienced and competent person. 10

The tower must start off and remain vertical as it is built and used.

Maintenance 11

All aluminium mobile towers are work equipment.

12

As such, mobile towers (including individual components) must be suitable for the job in hand and properly maintained.

Preparation and planning A risk assessment should be carried out to determine whether or not a mobile aluminium tower scaffold is a suitable item of work equipment for the type of work that is to be carried out and the environment in which it is intended to be used.

14

Factors that should be considered when deciding whether or not it is safe to use a mobile tower are:

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The ground surface (1) - is the surface sufficiently level to use a mobile tower if there is no adjustment on the legs for levelling the tower? A tower scaffold should not be erected if it cannot be levelled and therefore made stable.

(b)

The ground surface (2) - mobile towers only have a small area of each wheel in contact with the ground and therefore each wheel imposes a high loading at each point of contact. Is the surface strong enough to take the loading? It may be possible to use sole boards on soft ground to effectively spread the load and allow a mobile tower to be used, providing that there is no chance of the tower sinking, tilting or otherwise becoming unstable.

(c)

The ground surface (3) - are there any features such as drain covers or underground pipes that may not be able to take the direct or indirect loading imposed by one or more wheels?

(d)

The weather (outdoor use) - aluminium tower scaffolds are lightweight structures which can become unstable in moderately high winds. Has a check of the weather been made for the period that the tower will be erected? Is it possible to tie-in the tower to the structure against which it is to be erected? If any doubt exists on the limitations of the tower in high winds, has the manufacturer or supplier been consulted?

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(a)

(e)

Overhead power lines - are there any lines that are close enough to render the use of a metal scaffold unsafe? Remember, it is not necessary to touch a high voltage cable to get a shock. Many overhead power lines are not insulated and the electricity can 'arc' through the air to an adjacent metal object.

Pre-assembly inspection 15

The competent person who is to erect a mobile tower should check that all the components are present and undamaged and ensure that they are all from the same manufacturer/supplier, and are for the same type of tower.

16

A check should be made that the castors and wheels rotate and swivel freely and that they have a functioning locking device (brake).

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Safety during use Stability Due to their lightweight nature, stability can be a problem with aluminium tower scaffolds, the more so the higher they are built.

18

Individual manufacturers carry out tests on their products to enable them to provide specific guidance on height-to-base ratios, including circumstances where the installation of outriggers will be necessary. Such guidance should be available to the competent person erecting the tower.

19

As general guidance, it should be assumed that stabilisers will be required if an aluminium tower is to have a working platform higher than 3 metres above ground level.

20

In addition to the dimensions of the erected tower scaffold, there are several other factors that can affect its stability:

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Sheeting (out of doors) - will increase the wind-loading on a tower scaffold. In many instances it will not be acceptable to sheet a tower scaffold unless it can be tied-in to the structure.

(b)

Overreaching - if this is so severe that the centre of gravity is moved to a point outside the base area of the scaffold, it will overturn. It is far safer to move the tower scaffold.

(c)

Work activity - any work that involves applying a sideways pressure to the adjacent structure, for example water-jetting, at a point that is high on the tower, will create an equal and opposite pressure that may overturn the tower. In many cases, tying-in the tower to the adjacent structure may overcome this problem.

(d)

Hoisting materials - if heavy items are hoisted up the outside of the tower, it could become unstable and overturn. Again, tying-in the tower to the adjacent structure may overcome this problem.

(e)

Climbing the tower - access to the working platform should be gained by using the built-in stair or ladder sections. If a vertical ladder is built into an end frame of the tower, the person climbing the ladder must do so on the inside of the tower. Climbing the outside could overturn the tower. Never gain access to the working platform by leaning a ladder against the tower.

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Tying-in a tower scaffold

Care should be taken to avoid couplers causing damage to the aluminium tubing and, accordingly, only special couplers should be used. Advice on the horizontal and vertical frequency of ties will be supplied by the manufacturer or supplier or, in the case of substantial or 'linked' towers, the scaffold designer.

The working platform 22

The access hatch to the working platform must be closed as soon as everyone working from the tower is on the working platform.

23

The working platform must be fully boarded unless a design feature of the scaffold enables safe access and egress and effective guard-rails and toe-boards to be installed around a partially boarded platform.

24

These state that a working platform must be of sufficient dimensions for the safe passage of people, plant and materials with due regard to the type of work being carried out. However, BS EN 12811-1 recommends that platforms on all types of scaffold should not be less than 600 mm wide.

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Gaining extra height 25

Placing stepladders and ladders on the working platform of a mobile tower to gain additional height is particularly dangerous and must be prohibited. Adjustable legs are only to be used for levelling, and not to gain additional height. If additional height is needed then a further lift should be added, providing this is within the manufacturer's height limitations.

The brakes 26

The wheel brakes must be locked in the 'ON' position at all times when the tower is not being moved. The lightweight nature of aluminium tower scaffolds presents the potential for unattended towers to be moved by the wind if the brakes are not applied, particularly where they are used on exposed floor slabs at height.

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Moving a tower scaffold The tower must not be moved whilst anyone is on the working platform. Any item that could fall or cause the tower to be unstable whilst being moved, taking into account the condition of the floor surface, must also be removed. A tower scaffold must only be moved by pushing or pulling at the base.

28

The tower must never be moved by:

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towing it with a vehicle

(b)

a person who is on the platform pulling the tower along using an adjacent structure.

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Avoiding collisions

Suitable barriers should be erected to prevent people or vehicles from accidentally colliding with a tower scaffold, particularly where it is erected in a public place.

30

It may be necessary to create a safety zone around a tower simply because of the nature of the work being carried out above.

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The capacity of each platform and tower structure is often shown on labels attached to the frame of the mobile tower, or will be in the manufacturer's assembly guide. Never exceed the recommended loading levels as this may cause the tower to become unstable.

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Loading capacity

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Incomplete towers 32

Where the proper erection of a mobile tower has not been completed, it should not be left unattended without the display of a notice stating:

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Inspection and reporting 33

34

Where the tower constitutes a working platform, it must be inspected: (a)

before being used for the first time

(b)

after any substantial addition, dismantling or other alteration

(c)

after any event which is likely to have affected its strength or stability

(d)

at regular intervals not exceeding seven days since the last inspection.

An inspection report is not necessary, however, for any mobile tower, unless it has remained erected in the same place for a period of seven days or more.

Wind strength Aluminium structures are very vulnerable to the strength of the wind. It is recommended by many manufacturers that if the wind reaches a speed of 17 miles per hour then all work should cease on the tower.

36

If the wind speed is likely to reach 40.23 km/h, the tower should be tied-in to a rigid structure. If there is a possibility of the wind reaching speeds approaching or in excess of 64.37 km/h, the tower should be dismantled.

37

Operators should be aware of the possibility of sudden high winds in exposed or gusty conditions.

38

It must be remembered that winds at high levels are often higher than at ground level. The wind speed can also increase as it funnels between buildings or other solid structures.

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Construction Site Safety 1.3.4 Appendix Wind strengths and effects (Beaufort Scale)

0-1

Light air

Direction of wind shown by smoke drift, but 1.1-5.5 not by wind or weather vanes.

1-2

Light breeze

Wind felt on face. Leaves rustle. Wind or weather vanes move.

5.6-11

2-3

Leaves and small twigs in constant motion. Wind extends light flags.

12-19

3-5

Gentle breeze

Wind raises dust and loose paper. Small branches move.

20-28

5-8

Moderate breeze

29-38

8-11

39-49

11-14

50-61

14-17

62-74

17-21

Chimney pots, slates and tiles may be blown 75-88 off. Other slight structural damage may be caused.

21-24

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Fresh breeze

6

Strong breeze

7

Near gale

8

Gale

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Small trees in leaf begin to sway. Little crested wavelets form on inland waters.

Large branches in motion. Umbrellas used with some difficulty.

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Strong gale

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Calm, smoke rises vertically

3

9

≤1

Speed m/sec

Calm

1

2

Speed Km/h

Wind effect locally

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Description of wind

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Windforce number

Whole trees in motion. Becoming difficult to walk against the wind.

Twigs break off trees. Progress is generally impeded.

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Tube and Fitting Scaffolds

1.3.5.1 Key points Scaffolds must only be erected, altered or dismantled by operatives who have been trained to do so and are competent, or are under the direct supervision of someone who is.

2

Scaffolds are subject to statutory inspections, with reports of inspections raised where appropriate.

3

All scaffolds must be properly erected, stable, tied to the structure as appropriate, suitable for their purpose and equipped with toe-boards and guard-rails on all working platforms.

4

The BS EN 12811 series is supported by the UK National Access and Scaffolding Confederation's technical guidance note TG20 'Guide to good practice for scaffolding with tube and fittings'.

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The purpose these Regulations is to give readers an understanding of the safety issues that relate to the use of scaffolds, particularly where site managers or other readers have to manage scaffolding operations and assess the suitability of scaffolds which have been erected by others.

2

The majority of guidelines for good practice in scaffolding can be found in UK NASC safety and technical guidance notes.

3

The main British and European Standard for scaffolding is BS EN 12811 (Part 1) Scaffolds Performance requirements and general design.

4

This latter standard, which focuses more on scaffold design, does not cover the same range of good practice as the old Code of Practice BS 5973 (now withdrawn) and readers are directed to the range of UK National Access and Scaffolding Confederation (UK NASC) particularly 'Guide to Good Practice for Scaffolding with Tubes and Fittings TG20.

5

They must also be used in accordance with the manufacturers' instructions or the scaffold should be designed by a competent engineer.

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1.3.5.3 UK NASC Technical Guidance TG20:08 Wherever TG20' appears in the text, it refers to UK National Access and Scaffolding Confederation publication Guide to Good Practice for Scaffolding with Tubes and Fittings (TG20:08).

1.3.5.4 Competent persons 1

For the purposes of scaffold inspection, a competent person may be defined as:

2

A person who has practical and theoretical knowledge, scaffold inspection training and actual experience of what they are to examine, in respect of a scaffold, so as to enable them to detect errors, defects, faults or weaknesses that it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

3

As regards the competence of individuals in relation to the erection of scaffolds, 'competence' may be taken to mean:

4

A person who has practical and theoretical knowledge, together with actual experience of

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scaffolding, and has acquired, or who is being supervised while being trained to acquire, a recognised qualification in scaffolding.

1.3.5.5 Work at Height These Regulations are covered in detail in Section C1. The key provisions of these Regulations that can apply to scaffolding are: to ensure that the work is risk assessment based and that it is carried out safely

(b)

the definition of 'work at height'

(c)

fall prevention and protection

(d)

falling object prevention and protection

(e)

danger zones where people would be at risk of falling or being struck by falling objects

(f)

fragile surfaces

(g)

competence for planning, organising and working at height

(h)

weather conditions

(i)

emergencies and rescue

(j)

requirements for guard-rails, toe-boards and similar barriers

(k)

requirements for working platforms

(l)

requirements for access and egress and the use of ladders.

(m)

statutory scaffold inspections

(n)

scaffolding design

(o)

a scaffolding plan

(p)

duties on employees to report hazards and work at height safely.

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1.3.5.6 The Management of Health and Safety at Work In general terms, these Regulations place a requirement on the Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazards to employees that might be encountered during their work, or to any other persons who might be affected by what employees are doing. This includes the work of those who erect, alter and dismantle scaffolds and also those who use scaffolds as a place of work.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put into effect control measures to reduce the risks to health and safety arising from the hazard, so far as it is reasonably practicable to do so.

3

The Contractor must provide employees with information on the risks which exist and the measures that are put in place to control them.

4

The employees then have a duty to comply with any instructions they have been given, and to tell the Contractor about any work situation, or any aspect of the work, which presents a risk to them or anyone else. These Regulations, therefore, cover the duty of the Contractor to carry out 'work at height' risk assessments.

5

These Regulations include a specific requirement to produce a scaffolding plan (or method statement) covering the assembly, use, alterations and dismantling, which is a form of risk assessment.

6

Contractors must consider the physical capabilities of employees who are required to erect, alter or dismantle scaffolding, due to the physical nature of the occupation.

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Scaffolding, including individual components and associated equipment, are classified as 'work equipment'. As such, all equipment must be suitable for its intended purpose, well maintained and individual components inspected as necessary.

1.3.5.8 Manual Handling Operations Manual handling will be an activity linked to the erection, alteration and dismantling of scaffolds. It is also likely that those who work from scaffolds will be involved in manual handling activities during the course of their work.

2

Contractors carrying out scaffolding activities must assess the risks arising out of manual handling. This is usually undertaken as part of the general risk assessment and method statement/scaffold plan.

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Architects and designers have duties under these Regulations to consider the design of temporary works such as access scaffolding, falsework and formwork structures. Where these temporary structures would be required for construction or future maintenance, designers have a duty to carry out a 'design risk assessment' to design out risk and communicate any residual hazards that remain.

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When selecting a scaffolding contractor you must check that they are competent and consider: the competence of management and operatives for the type of work

(b)

a proven track record for the type of work

(c)

the past health and safety performance

(d)

the allocation of sufficient physical and human resources to service the contract (e.g. scaffolding equipment, transport, qualified scaffolders and supervision)

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Before engaging a specialist scaffolding contractor, it is a good idea to prepare information on the intended use of the scaffolds for the scaffolding contractor to take into account. For further information reference should be made to TG20 (Volume 1 clause 37.2.2) 'Client's brief.

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1.3.5.10 Planning for a scaffolding contract

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1.3.5.11 Basic scaffolding considerations 1

Before the erection of any scaffold, the following points must be clearly defined. (a)

What is the scaffold for?

(b)

Is it to be a 'standard scaffold' as defined in UK NASC guide TG20 Volume 1?

(c)

Exactly where is it to be erected?

(d)

What materials are to be used?

(e)

Can safe access be provided for the erection and use of the scaffold?

(f)

How many working platforms will there be?

(g)

Is the ground condition where the scaffold is to be erected suitable?

(h)

How and where can the scaffold be tied-in?

(i)

What bracing will be required?

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(j)

What loadings will be imposed upon those working platforms, and on the scaffold as a whole?

(k)

Will it be sheeted?

1.3.5.12 Scaffold design These Regulations require all scaffolds to be calculated unless constructed to a generally recognised standard configuration. This means for tube and fitting scaffolds they must be a 'standard scaffold' as defined in TG20 Volume 1 Section 2. Otherwise the scaffold MUST be designed and calculated by a competent engineer.

2

Further sections of Volume 1 and Volume 2 of TG20 provide information for engineers to design and calculate 'special scaffolds' in tube and fittings.

3

Scaffolding contractors should have suitable arrangements in place to manage and control the erection, alteration and commissioning of special scaffolds (such as issuing drawings; managing variations to the design; inspection and handing over designed scaffolds).

4

Note that for all standard scaffolds erected, a simple procedure must be followed to determine the maximum safe height as required by TG20 (Volume 1 Section 2 Clause 4.4.3). This basic calculation is intended to be carried out by those planning and organising scaffolding and not necessarily an engineer.

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1.3.5.13 Fall prevention and protection while scaffolding While a scaffold structure is actually being built, the scaffolders do not always have the protection afforded by guard-rails and toe-boards until such time as they themselves have installed them. They rely upon the use of personal fall protection equipment (harnesses) to arrest a fall during this time.

2

In order to assist Contractors, the UK National Access and Scaffolding Confederation (UK NASC) has produced UK NASC Guidance Note SG4:05, Preventing Falls in Scaffolding and Falsework. This is the accepted industry standard to which all scaffolding contractors should be working.

3

Under the heading of 'Step 1 - Planning for work at height', the guidance states:

4

'Scaffolding contractors should consider measures that prevent falls from height, such as providing adequate work platforms with suitable guard-rails or other collective measures, before resorting to fall arrest equipment (i.e. harnesses).'

5

Devices and systems of work that provide collective fall protection, such as Advanced Guardrail Systems and Step-ups, are now available for certain scaffolding operations. These collective measures enable scaffolders to provide guard-rail protection in advance of erection and to maintain fall protection for alterations and dismantling. Such systems do not completely eliminate the risk of a fall in all circumstances and UK NASC still recommends the use of personal fall protection equipment. Most of the current industry guidance is based on the content of BS EN 13374.

6

Scaffolding plans must also consider the rescue and recovery of a scaffolder suspended by their personal fall protection equipment. For further information on rescue planning see UK NASC safety guidance note SG19.

7

Personal fall protection equipment used for scaffolding should be inspected:

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(a)

before use by the user

(b)

thoroughly by a competent person every three months and recorded

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thoroughly at other intervals if the need is identified via a risk assessment.

8

For further information on the inspection of fall protection equipment see UK NASC safety guidance note SG16.

9

To ensure compliance with the above requirements: (a)

scaffolders and their supervision should be trained in the requirements of SG4:05 and the rescue plan

(b)

site managers and others who run construction sites should check that the scaffold contractors coming on to their sites have been adequately trained in the requirements of SG4:05.

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1.3.5.14 Scaffold features

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Foundations The foundations for all scaffolds must be of adequate strength to support and disperse the load. On hard surfaces, such as steel and concrete of sufficient strength and thickness, standards may be placed directly on the surface, although it is generally preferable to use a base plate which is 150 mm x 150 mm in size. Sheeting or proprietary plastic treaders can also be used to protect sensitive floors from damage or marking.

2

On other surfaces, the load should be spread by using base plates and sole boards (see above). The soil or ground beneath the sole board should be level and properly compacted.

3

When a sole board is used on hard ground, the area beneath any one standard should be at 2 least 1,000 cm . If a timber sole board is used, it must be not less than 35 mm thick.

4

On soft or disturbed ground, the sole board area should not be less than 1,700 cm . Each sole board should support two standards.

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Sole board minimum dimensions 5

These should be: on hard ground 450 mm x 225 mm x 35 mm on soft ground 760 mm x 225 mm x 35 mm

6

Bricks, blocks and scraps of odd timber must not be used as sole boards.

7

On sloping ground, steps should be cut into the ground to accept base plates or sole boards (see below). If the slope exceeds 1:10, an engineer should check that the ground has sufficient stability.

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.

Scaffolds founded on roofs or other suspended surfaces will need special consideration for the loads imposed. An assessment and calculations may need to be made by an engineer to ensure the loads can be supported, or whether temporary supports (shoring) will be required. Alternative scaffolding materials, such as aluminium, can also be used to reduce the loads imposed by the scaffolding.

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Materials

Scaffold tubes and fittings must comply with BS EN 39:2001 (older tube to BS 1139). Ends should be cut square and clean, free from any bends or distortion, corrosion, lamination splits or surface flaws.

10

Fittings must comply with BS EN 74:3 2007 and BS 1139 Part 2.1. Fittings should not have worn threads or damaged bolts and excess surface oil which may reduce friction grip.

11

All scaffold boards should comply with BS 2482:2009 and should not be warped, twisted, split or badly worn, painted or otherwise treated so as to conceal any defects.

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Standards

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Standards should be: (a)

placed vertically spaced closely enough to provide an adequate support (see TG20 Table 1 Load classes)

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(c)

on a base plate and sole boards to prevent displacement

(d)

near to ledgers

(e)

positioned so that joints are staggered ensuring there are no more than three joints in any one bay.

Ledgers 13

Ledgers should be: (a)

horizontal and fixed securely to the inside of standards with right-angled, load-bearing couplers

(b)

fitted so that joints are staggered, and not situated in the same bay

(c)

positioned so that joints in ledgers are in the end thirds of the bay, adjacent to the standards.

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Putlogs and transoms The length of putlog tubes and transoms will vary to suit the width class of the scaffold in accordance with TG20 Table 7.

15

In order to avoid injury to site workers (and in some circumstances, the public), the outermost ends of the putlogs or transoms should not project an unnecessary distance beyond the face of the scaffold and/or be shielded by the use of purpose-made protective plastic cups or other suitable protection.

16

Where appropriate, transoms should be long enough to butt up against the supporting structure and enable the attachment of facade bracing tubes.

17

Putlogs should be:

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securely fixed to ledgers or standards with right-angled or putlog couplers

(b)

supported with the blade placed in the mortar bed joint of the brickwork, and pushed right into the wall to provide a sufficient support (see above). The blade should be horizontal and bedded approximately 75 mm into the brickwork.

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(a)

When putlogs are used on existing buildings for tasks such as refurbishment or repointing, each putlog blade can be installed either with the flattened end located in a vertical joint (pert) or the horizontal bed in the brickwork.

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1.3.5.15 Boarded lifts

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Width

The recommended minimum width in accordance with BS EN 12811-1 is 600 mm.

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Lift height

BS EN12811-1 requires a minimum headroom height of 1.75 m on working lifts.

3

Under TG20, the maximum lift height is 2.0 m for standard putlog and independent tied scaffolds.

4

Where pedestrian access is required under the first lift, a 2.7 m base lift is permissible, provided that the scaffold is tied at the first level to alternate standards.

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Transom (or putlog) spacing 5

The spacing of transoms or putlogs for boarded lifts will be determined by the standard or grade of scaffold board used and the load class of scaffold required.

6

The spacing between transoms or putlogs must not result in an unsupported length of board greater than that specified in Table 8 of TG20.

Loading 7

It is essential that scaffolds are not loaded beyond their maximum design load. Materials should be distributed as evenly as possible with heavy items, such as piles of bricks, positioned adjacent to standards. See Table 1 of TG20.

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1.3.5.16 Non-boarded lifts 1

For scaffolds up to 15 metres high, transoms and putlogs used for non-boarded lifts should be fixed at every pair of standards, including the pair at each end of the scaffold, to either the standards with right-angled couplers, or to the ledgers with putlog couplers, and should be within 300 mm of the ledger and standard connection. For scaffolds higher than 15 metres, specialist guidance should be sought.

2

Note that SG4 requires all platform boards to be correctly supported as part of the safe system of work. Transoms provided as temporary board supports on non-boarded lifts must be left in place for alterations and dismantling.

1.3.5.17 Ledger bracing Ledger bracing on 'standard scaffolds' should usually be fixed to alternate pairs of standards to all lifts.

2

BS EN 12811-1 requires unimpeded access along the working lift. For this to be achieved in tube and fittings, reference needs to be made to TG20 Volume 2 and the structure classed as a 'special scaffold'.

3

Ledger bracing should be fitted on alternate pairs of standards, except where the width of the bays is 1.5 m or less. Then they may be fitted on every third pair.

4

Ledger bracing should be fitted:

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to ledgers or standards using load-bearing fittings, which will have a minimum slip resistance of 5 Kn

(b)

to the full height of the scaffold

(c)

to start at base plate level (unless a pavement lift is required).

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1.3.5.18 Facade bracing

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(a)

Facade bracing runs parallel to the face of the building or structure and is also known as longitudinal, face or sway bracing. It is fixed to the outside standards for independent tied scaffolds.

2

Facade braces can be attached to transoms with right angle couplers at every lift, or to every standard using swivel couplers.

3

Facade bracing must be fixed to every sixth bay and set at an angle between 35-55 degrees. All joints should be made with sleeve couplers. However, when joint pins are used, a splicing tube should overlap by a minimum of 300 mm and be fixed with two swivel couplers on either side of the joint.

4

There are three standard facade bracing patterns.

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(a)

Zigzag across two bays (ledger braced).

(b)

Continuous for wider facades.

(c)

Zigzag across one bay only*.

*Note that plan bracing is required for this form of facade bracing (see Plan bracing below).

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1.3.5.19 Plan bracing 1

Plan bracing is required horizontally across the scaffold on all standard scaffolds taller than 8 m where the facade bracing is fixed across one bay only (see Facade bracing above).

2

Plan braces are fixed to the standards with right angle couplers, except where headroom is critical, when it may be fixed with swivels to the ledgers.

3

Plan bracing should be fitted every 8 m (four lifts) vertically and every 12th bay to correspond with the facade bracing.

4

Greater detail on the fitting of plan bracing can be found in UK NASC guide TG20.

1.3.5.20 Scaffold ties A tie secures the scaffold to the supporting structure and is provided to resist the inward and outward movement of the scaffold and also to give some additional longitudinal stability.

2

Ties are generally designated as 'moveable' or 'non-moveable', the terminology being selfexplanatory. Where possible, ties should be left undisturbed until the scaffold is dismantled. Where it is necessary for ties to be removed, even for a short period, the scaffold will be less stable and the fitting of additional temporary ties will be necessary unless the initial tiepattern was designed to allow for the temporary removal of some ties.

3

Ties must not be removed by anyone other than a competent scaffolder or someone who is under the direct supervision of one. The removal of scaffold ties must be carried out in compliance with a method statement.

4

Scaffolds fitted with debris netting, sheeting and tarpaulins will be subjected to extra loading due to wind pressure and will require the scaffold designer to increase the number and frequency of ties, or the tie capacity.

5

Ties often pass through openings into the building, although alternative methods of tying can be employed.

6

Generally, each tie must have a minimum tensile or compressive capacity of 6.1 kN, although designers can consider heavy duty ties at 12.2 kN and light duty ties at 3.5 kN.

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1.3.5.21 Layout and frequency of ties 1

Ties should be evenly distributed over the scaffold, both horizontally and vertically with a vertical spacing of no more than 4 m.

2

TG20 offers alternative tie patterns. If these minimum tie patterns cannot be achieved, the pattern will need to be calculated by an engineer. At least 50% of ties must be fixed to ledger braced standards.

3

The density of ties will be decided by the scaffold designer based on all the factors that have the potential to affect the loading on the scaffold.

4

Full details of tying scaffolds are included in UK NASC guide TG20.

1.3.5.22 Rakers 1

For lower level and domestic scaffolds, where it is not possible to install normal ties, the stability of a scaffold can be achieved by the use of rakers. A single, unjointed raking tube not more than 6.4 m in length may be coupled at the top to the ledger at the second lift,

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extending at an angle not greater than 75° to the horizontal (4:1). The foot of the raking tube must be well founded and must always be tied back to the main scaffold. This arrangement can be used in place of a single tie.

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1.3.5.23 Freestanding access scaffolds 1

Freestanding access scaffolds for modern methods of construction, such as timber frame structures, require calculations to be made for stability. These scaffolds would therefore be classed as special scaffolds.

2

Engineers can utilise alternative methods of achieving stability, such as buttressing, kentledge (ballast or counterweights), guys and ground anchors. Returns around corners, access towers and loading bays can also be taken into account by engineers when calculating stability.

3

For further information see UK NASC safety guidance SG28 Safe systems of work for scaffolding associated with timber frame construction.

1.3.5.24 Types of tie The following methods may be employed.

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Through tie: This type of tie relies on a tube, usually placed vertically inside an opening or window in a building. The tie tube should preferably rest on the sill, as close to one edge of the opening as possible.

2

Through ties should be placed as close as possible to the window reveal and secured with right-angled couplers.

3

Reveal tie: In cases where it is not possible to open or leave windows open or where it is impractical to fit other types of tie, a reveal tube may be wedged or jacked tight between the opposing faces of the window opening. Timber packing should be thin (10 mm) to reduce the possibility of timber shrinkage and approximately 75 mm x 75 mm. It should be checked frequently for tightness.

4

A bridle tube should then be attached to the reveal tube with a right-angle coupler, within 150 mm of end opposite to the reveal pin (whether this is horizontal or vertical). The bridle tube is usually fixed to the scaffold in two places with right-angle couplers although other satisfactory arrangement may be used.

5

It should be noted that reveal ties generally depend entirely upon friction for their integrity and therefore:

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they should be checked frequently for tightness

(b)

their use is limited to a maximum of 50%. Refer to UK NASC guidance TG20.

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(a)

Box tie: This forms an assembly of tubes and couplers around columns or other parts of a building. It should preferably be at the level of the scaffold lift and joined to both inside and outside ledgers or uprights.

7

Lip ties: An alternative form of tie, where box ties cannot be used; these take the form of an 'L' shaped arrangement of tubes and couplers which hook the scaffold behind elements of the building, such as parapets. Lip ties do not resist inward or sway movement of the scaffold; adjacent butting and sway transoms should be used to prevent this.

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1.3.5.25 Cast-in or drilled-in anchorages 1

A selection of screwed plates, eyes, sockets and nuts are available for setting into concrete during pouring. These may be used as anchorages.

2

There is a wide range of drilled-in anchorages available, also known as masonry anchors.

3

The accepted industry standard for the selection, use and testing of masonry anchors is UK NASC technical guidance TG4:04 'Anchorage Systems for Scaffolding'.

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4

Masonry anchors must be used in accordance with the manufacturer's instructions. Scaffolders who install these anchors should be trained in accordance with those instructions.

5

TG4 requires two levels of testing. (a)

Preliminary testing, wherever there is doubt about the base materials to help select the correct type of anchor.

(b)

Proof testing, to check the installation and that the required tensile loads can be achieved. A minimum of three ties must be tested and 5% (1 in 20) thereafter. Ties must be tested to 1.5 times the required tensile load e.g. 6.1 kN tie requires a 9.2 kN tensile test load.

If any anchor fails the test the cause must be investigated and the test frequency increased to 10%. A test report should be provided with the test results as part of the handover process.

7

Ring bolts are produced in two sizes.

A smaller ring for use with wire or steel banding ties, which should be turned around a node point of the scaffold or otherwise prevented from slipping.

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A ring of 50-55 mm internal diameter, through which a scaffold tube could be passed.

The strength and pull-out capabilities of all cast or drilled anchorages must be confirmed before use.

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1.3.5.26 Wire or steel banding ties

Scaffolding may be secured to the building using the small ring bolt described previously, with 6 mm wire rope threaded through the ring and around a scaffolding member with a minimum of three turns. Steel banding of the equivalent strength may be used for the same purpose.

2

This method does not prevent movement inwards; butting or sway transoms should be used to prevent this.

3

Some architectural features of a structure may be of sufficient strength for attaching wire or banding ties although they must not be used until their suitability has been verified, by testing if necessary. If there is any doubt, they must not be used and an alternative method of tying must be found. Rainwater guttering and soil pipes must never be used for the attachment of ties.

4

When viewed in plan, tie tubes or banding ties should be set at right-angles to the building.

5

Information regarding design loads for ties can be obtained from UK NASC guidance TG4:04.

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1.3.5.27 Scaffold boards 1

The minimum amount by which any scaffold board should overhang any putlog or transom must be no less than 50

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mm. 2

The maximum overhang varies with the thickness of the scaffold board used. For further information, see Table 8 of TG20.

3

All scaffold boards which comply with BS 2482:2009 should: be free from splits, shakes, excessive knots, paint, oil or concrete

(b)

be usually 225 mm wide and not less than 220 mm

(c)

not be painted or otherwise treated to conceal defects

(d)

be banded or nail-plated at ends

(e)

be supported by putlogs or transoms at the appropriate spacings

(f)

overhang at least 50 mm but not more than four times the thickness of the board, unless secured from tipping

(g)

be guarded against the wind causing the boards to lift

(h)

be secured to prevent movement if short boards less than 2.13 m are used.

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1.3.5.28 Working platforms and decking

All working platforms and decking should be closely boarded to their full width and free from tripping hazards. Where reasonably practicable, overlapping boards should be avoided. Where an overlap is unavoidable, the lapped board should be secured to prevent movement and, if necessary, bevelled pieces should be installed.

2

The platform should be of an adequate width for the work to be carried out and safe passage of people. The suggested widths as shown in Table 7 of TG20 may be taken as current industry guidance.

3

When material is deposited on a platform, a clear passage must be maintained for access.

4

The space between the inner edge of a working platform and the adjacent structure should be kept as small as possible to prevent falls. However, there can be circumstances in which this gap has to be left wider. This is usually due to the nature of the work being carried out, for example to enable the craning-in of sections of curtain wall between the scaffold and the building under construction or where there is only primary steelwork inside the scaffold.

5

In such circumstances, suitable compensatory measures must be taken if there is a risk of people falling, or people being struck by falling objects. For example:

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(a)

use of inner guard-rails and toe-boards

(b)

segregation of the areas below the scaffold and post warning signs

(c)

areas of the scaffold designated as 'danger areas', where access is restricted by guard-rails and warning signs

(d)

use of personal fall protection equipment (harnesses).

6

The space between scaffolding boards should be kept as small as possible and in any case should not exceed 25 mm.

7

Boards should be securely fixed and present no risk to any person below.

1.3.5.29 Gangways and runs 1

All gangways and runs should be:

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(a)

600 mm wide (3 boards) if used for harrowing and the passage of materials

(b)

preferably horizontal, but where this is not possible they may slope up to a maximum gradient of 20% (1 unit vertical to 5 units horizontal) without the requirement for stepping laths.

If the gradient is unavoidably over 20%, or if the conditions are slippery, stepping laths must be provided. Whilst there is no recommended distance between stepping laths, a 300 mm separation is suggested. Stepping laths may incorporate a maximum central gap of 100 mm for barrow wheels.

1.3.5.30 Guard-rails Guard-rails are just one of the options a Contractor may consider as a 'suitable and sufficient measure' or means of protection when a person could fall any distance liable to cause them personal injury. As guard-rails are generally a collective measure, by offering protection to everyone, they are to be preferred to other measures that only protect individuals, such as safety harnesses.

2

A guard-rail must be 950 mm above the edge (or above a working platform) from which any person is liable to fall.

3

A second guard-rail (or mid guard-rail) may be placed approximately halfway between the top edge of the toe-board and the top guard-rail, so that there is no gap larger than 470 mm between the guard-rails or between the mid guard-rail and the toe-board.

4

All guard-rails must be fixed inside the standards with right-angle couplers to each standard.

5

Brick guards should always be installed where there is a possibility of materials toppling from working platforms. If using the common type of brick guard, mid guard-rails should also be fitted.

6

There will be occasions when it is possible to fall from the working platform into the structure under construction. In these cases, it will be necessary to consider installing guard-rails to the inner edge of working platforms or using other fall prevention/arrest measures.

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1.3.5.31 Temporary removal of guard-rails 1

Where it is necessary to load out scaffolds with bulk materials and so on, ideally there will be a purpose-built loading bay with a lifting safety gate or similar. Where this is not the case, it

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is permissible to temporarily remove guard-rails and toe-boards, provided that;

2

(a)

unless other work is stopped, other equally effective fall prevention/arrest measures are put in place (such as safety harnesses) whilst there is an exposed edge

(b)

once the loading has been completed, the guard-rails and toe-boards are replaced immediately.

The removal and refitting of guard-rails and toe-boards must only be carried out by a competent scaffolder or a trainee who is under the direct supervision of a competent scaffolder.

1.3.5.32 Toe-boards

fitted in conjunction with all guard-rails

(b)

a minimum height of 150 mm in accordance with TG20

(c)

fixed inside the standard, at a minimum of two positions.

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Toe-boards must be:

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1.3.5.33 Access to scaffolds

Contractors are required to specify the use of existing structures as a means of access to height, for example lifts or a permanent staircase, in preference to temporary measures such as ladders.

2

Whilst ladders have been the commonly used means of access to scaffolds, the use of other, safer means of access, such as stair towers, should now be considered in preference.

3

BS EN 12811 recommends that where extensive work is carried out, stairways should be provided for access, and for taller scaffolds consideration should be given to the use of a passenger hoist.

4

Note: Where passenger hoists are used, then additional non-mechanical access must also be provided in case of breakdown or emergencies.

5

The UK NASC recommends the following hierarchy of access from TG20.

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(c)

Ladder access bays with multiple lift ladders.

(d)

Internal ladder access with protected ladder traps.

(e)

External ladder using a safety gate.

Stairways.

Ladder access bays with single lift ladders (to reduce the potential fall distance).

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Where a ladder protrudes through a working platform (known as a ladder trap), the remaining width of the platform must be at least 450 mm (2 boards wide).

1.3.5.34 Ladder access 1

Straight ladders used for access to a scaffold must: (a)

be manufactured to BS EN 131/BS 1129

(b)

not be defective in any way

(c)

not be painted or treated in any way that might hide defects

(d)

be placed on a firm footing, with each stile equally supported

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(e)

be so positioned that there is sufficient space at each rung to give an adequate foothold

(f)

be positioned approximately at an angle of 75°, that is: 1 measure horizontal to 4 measures vertical

(g)

be secured at the top using square lashings or a proprietary ladder clamp. For longer ladders, additional ladder supports (stays) can be used to prevent the ladder deflecting when used. The stay must not obstruct the rung of the ladder

(h)

extend approximately 1 m above the working platform, unless there is another adequate handhold

(i)

be provided with suitable rest platforms if rising more than 9 m

(j)

be the 'right way up' (tie wires or bars positioned under the rungs).

Where scaffolds are designed with internal ladders, working platforms must be provided with access holes for each ladder. Such access holes should be at least 450 mm wide (across the platform) and not less than 600 mm in the other direction. The access hole should be protected with a ladder trapdoor as good practice.

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Note: Shorter/Ladders, which provide access to only one lift, are recommended.

be fitted with guard-rails and toe-boards, as previously detailed

(b)

not be used for the storage of materials

(c)

be installed at a maximum vertical height of 9 metres and multiples thereof

(d)

be equipped with access holes of similar dimensions to working platforms as detailed above.

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Lateral gaps in guard-rails and toe-boards for access and egress must be kept to a minimum and protected with a ladder safety gate as good practice.

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Landing platforms should:

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1.3.5.35 Landing platforms

1.3.5.36 Incomplete scaffolds 1

Where the erection of a scaffold has not been completed, physical measures must be taken to restrict access to the scaffold, e.g. remove or board over the access ladder(s) and warn people of the fact

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that the scaffold is not safe to use. The method of warning will usually be 'scaffold incomplete' signs at each point of access. 2

On larger scaffolds that are substantially complete, it may only be necessary to deny access to the part of the scaffold that remains incomplete, providing: (a)

the part of the scaffold that is complete is safe to occupy

(b)

all access points from the completed part of the scaffold, beyond which the scaffold is incomplete, are clearly defined by warning signs and access to the incomplete part of the scaffold is effectively prevented with guard-rails or other barriers.

1.3.5.37 Loading of scaffolds Any working platform on a scaffold should not be so loaded that it gives rise to a danger of collapse or to any deformation which could affect its safe use.

2

Any scaffold, or part of, that is to be loaded by mechanical means (e.g. crane or fork lift truck), must be specially designed and calculated as a loading bay or tower.

3

The scaffold should be checked periodically to ensure that the loads are within the permissible limits. Refer to Table 7 of TG20.

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1.3.5.38 Loads on scaffold fittings

BS EN 74 Part 1 contains specifications for scaffolding couplers, including the 'slip-load' of scaffold fittings. Load-bearing fittings such as right-angle and swivel couplers have much higher slip values than non-load-bearing items such as putlog clips.

2

Other considerations are:

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scaffold fittings must not be oily or greasy. This will cause reduced frictional resistance between the tube and the fitting

(b)

the correct spanner or podger must be used, and used in the correct manner, otherwise the screw threads may be overstressed

(c)

scaffold fittings and tubes must be free from corrosion or other obvious defects.

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1.3.5.39 Hoisting of materials When working at heights, various items of lifting equipment or ancillary lifting equipment will usually be required. These may include block and tackle, motorised winches, wire ropes, chains or slings.

2

Goods and passenger hoists should not be tied to the scaffold unless specially designed and calculated for the purpose.

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1.3.5.40 Inspection of scaffolds 1

All scaffolds and working platforms (together with all other protective measures) are 'work equipment' and so the inspection requirements of these Regulations apply:

2

'Every Contractor shall ensure that where the safety of work equipment depends on how it is installed or assembled, it is not used after installation or assembly in any position unless it has been inspected in that position.'

3

This clearly applies to all scaffolds including mobile and static tower scaffolds.

4

The inspection must be carried out by a competent person. A Contractor may wish to have a

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commercial arrangement with a scaffolding contractor in order to carry this out. 5

There is a further requirement in that every Contractor must ensure that work equipment exposed to conditions that may cause any deterioration liable to result in dangerous situations is inspected at suitable intervals, and also when any exceptional circumstances that are liable to jeopardise the safety of the work equipment have occurred.

6

In addition, Contractors must ensure that working platforms used for construction and from which a person could fall more than 2 metres are not used in any position unless they have been inspected in that position within the previous seven days.

1.3.5.41 Inspection of places of work at height An additional requirement as regards inspection (or checking) is that every Contractor must ensure, so far as it is reasonably practicable, that every surface, parapet, permanent rail or other such fall protection measure of every place of work at height is checked before each use.

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1.3.5.42 Reports

Where an inspection has been carried out, a written report of the findings of the inspection must be made before the end of the working period.

2

The person who prepares the written report must provide a copy within 24 hours to the person on whose behalf the inspection was carried out. The report, or a copy of it, must be kept on the site where the inspection was carried out until the construction work is completed, and then kept at the company offices for three months.

3

Contractors are free to design their own inspection report forms or purchase pads of them from commercial suppliers.

4

In either case the following details must be included:

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The name and address of the person for whom the inspection was carried out.

(b)

The location of the work equipment inspected.

(c)

A description of the work equipment inspected. The date and time of the inspection. Details of any matter identified that could give rise to a risk to the health or safety of any person.

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(f)

Details of any action taken as a result of any matter identified in 5.

(g)

Details of any further actions considered necessary.

(h)

The name and position of the person making the report.

5

Where someone has carried out an inspection of a scaffold and believes that it is not safe to use, they must inform the person for whom the inspection has been carried out that the scaffold is unsafe. The scaffold must not then be used until it has been made safe.

6

An example of an inspection report form is included in Appendix 7 of this module.

1.3.5.43 Use of scaffolds by other employees 1

Scaffolds erected for one Contractor may (provided that permission has been sought and given) be used by employees of another company, providing that the second Contractor is satisfied that the scaffold is safe for its intended use and conforms to these Regulations.

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1.3.5.44 Protection of the public 1

Protection of the public and other persons against falling materials should be provided by the use of nets, brick guards, toe-boards and protective fans, etc.

1.3.5.45 Scaffold in a public place These can cause particular problems to people with physical and visual disabilities, unless adequate steps are taken to reduce 'contact' hazards with such items as tube ends and threads on fittings.

2

This can usually be achieved by cladding the run of standards or binding the scaffold poles and fittings with suitable padding and/or brightly coloured bunting and tape.

3

All joints should be wrapped to protect the public and other persons from sharp edges, and plastic protective cups should be placed in or over the ends of tubes.

4

In most cases the scaffold will need to be designed to allow for ledger braces to be omitted at ground level so that members of the public can pass under the scaffold.

5

The bottom or 'pavement' lift of the scaffold should be at a height no greater than 2.7 m. The lift above pavement gantries must be fully close boarded, with a double layer of scaffold boards and a layer of impervious sheeting.

6

It is not sufficient to warn the public of the hazard just by placing safety signs on the, scaffold. Contractors must have acted to reduce the hazard as far as reasonably practicable.

7

To ensure the scaffold is not struck by vehicles, no part of it should be allowed to project into the roadway, unless appropriate measures are taken, such as traffic control or a road closure. The provision of lighting at night may also be necessary.

8

Supplementary lights should be installed on the scaffold where it has been erected in a place to which the public has access (whether pedestrians or vehicles), unless the level of 'background' lighting after dark is thought to be sufficient.

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1.3.5.46 Handover certificates 1

Contractors may, in their own interests, require that scaffold handover certificates are issued by the scaffolding contractor.

2

Such certificates usually specify: (a)

that the scaffold is complete and complies with the requirements of relevant standards or guidance

(b)

the maximum distributed loads which are permitted on the working lifts

(c)

the guarding of working platforms

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(d)

that the bracing and ties are complete

(e)

that inspection is required every seven days or following exposure to adverse weather conditions

(f)

that the findings of the inspection should be recorded

(g)

that the Contractor is responsible for their employees working on the scaffold

(h)

that sheeting or netting is not to be fixed to the scaffold structure unless the scaffold has been specifically designed for it

(i)

that unauthorised modifications or alterations are not to be made to the scaffold.

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A specimen handover certificate is shown in Appendix 9.

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Construction Site Safety 1.3.5 Appendix 1 Widths of access scaffold platforms Table 7 from TG20:08 (1)

Minimum number of 225 mm nominal width boards mm

Effective width of boarded platform for (2) loading calculations mm

Working platforms for men without materials or only for the passage of materials

500

3 boards

705

For men and materials provided there is 430 mm left clear for the passage of men or 600 mm if barrows are used

800

4 boards 4+1 boards 4+2 boards

1,050

For use in dressing or roughly shaping (3) stone

1,300

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1,155 1,435 1,655

6 boards 7 boards

1,350 1605

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930 1205 1430

5 boards 5+1 boards 5+2 boards

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For carrying trestles or other similar higher platforms

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Minimum clear width (4) mm

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Purpose

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Notes:

Where internal ladders are incorporated the minimum width may be 430 mm, i.e. two boards

2

Effective width as defined in BS EN 12811-1 includes a 30 mm allowance for toe-board

3

These scaffolds should be specially designed

4

For hop-up platforms, a minimum width of 450 mm is required

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Construction Site Safety 1.3.5 Appendix 2 Maximum and target span of scaffold boards Table 8 from TG20:08

Board specificatio n

Thickness

Transom spacing (span of board) Target span

Maximum span

Span

Tolerance

Minimum

Maximum

mm

mm

mm

mm

mm

mm

38

±2

1,200

+100

ns

50

150

38

±2

1,500

+100

ns

50

150

50

±3

ns

ns

2,600

50

200

63

±3

ns

3,250

50

250

rw

mm

ns

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BS 2482-2

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(1)

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38-1.5m

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BS 2482-1 38-1.2 m

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Nominal Tolerance

Board overhang

(1)

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Notes:

Board properties verified by machine stress grading

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1.3.5 Appendix 3 Load classes for access and working scaffolds made from tube and fittings Table 1 from TG20:08 (Extract)

Load class

Likely use of platform

Duty

Max. bay length

Max. spacing Max. number board of boards transoms

m mm Inspection and very light duty

Inspection, painting, stone cleaning, light cleaning and access

2.7

2

Light duty

Plastering, painting, stone cleaning, glazing and pointing

2.4

3

General purpose

General building work including brickwork, window and mullion fixing, rendering and plastering

1,200

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2.1

1,200

4

1,200

5 4+1

as

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Masonry work, concrete block work, and very heavy cladding

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Heavy duty

4+2 5+1 5+2 1.8

900

54+1 4+2 5+1 5+2

The above table is an extract of Table 1 from UK NASC Guidance Notes TG20:08. It is reproduced only for the purpose of highlighting to readers the different load classes to which scaffolds may be erected and examples of work activities for which each class might be used.

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Putlog scaffold

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Safety checklist Check from the ground:

Check from inside building or on the scaffold: 9. Spade end of putlog laid horizontally where possible, fully home (75 mm) in brickwork (bed joint)

2. Line of standards and ledgers. Standards vertical

10. Ties, particularly on lift below working platform or, in early stages, rakers on alternate standards. Special attention to 'through' ties on large flank ends without windows. Load-bearing couplers to be used

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1. Base soundness; adequate spread of load; particularly as there is only one line of standards, avoidance of pavement lights, manhole covers, etc.; no nearby excavation

3. Spacing of putlogs

11. Platform loading (not overloaded)

4. Working platform. Check line and even support of boards; overhang; lapped boards and fillets

12. Security and correct use of all fittings (couplers), particularly on transoms and bracing

5. Guard-rails and toe-boards

13. Condition of tubes and fittings

6. Security of boards, toe-boards and guard-rails

14. Damage from falling material

7. Longitudinal bracing

15. Security of stacked materials

8. Means of access

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Safety checklist Check from the ground:

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Independent tied scaffold

Check from the scaffold:

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1. Base soundness; adequate spread of load; 9. Ties, particularly on lift below working platform or, in early stages, avoidance of pavement lights, manhole covers, etc.; no rakers on alternate standards. Special attention to 'through' ties on nearby excavation large flank ends without windows. Load-bearing couplers to be used

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2. Line of standards and ledgers; standards vertical

10. Special loadings by protective fans, wind sails, etc.; anchorage and spread of load

3. Staggering of joints (vertical and horizontal)

11. Security of boards, toe-boards and guard-rails

4. Spacing of transoms

12. Security and correct use of all fittings (couplers), particularly on transoms and bracing

5. Working platform. Check line and even support of boards; overhang; lapped boards and fillets

13. Condition of tubes and fittings

6. Security of guard-rails and toe-boards

14. Damage by loads swinging from cranes or by falling material

7. Longitudinal, ledger and plan bracing

15. Overloading

8. Means of access

16. Security of stacked materials

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Safety checklist 1. 2. 3. 4. 5. 6. 7. 8. 9.

Base Line of standards and ledgers Line and spacing of transoms Diagonal bracing (in both directions) Plan bracing Security of boards, toe-boards and guardrails. Maximum gap at wall Security and correct use of couplers and fittings Condition of tube and fittings Even spread of load on platform

10

Means of access

11. Overloading 12. Security of stacked materials

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With birdcage scaffolds, the floor of the building has to carry the full weight of the scaffold and its load. Sole plates are therefore necessary to help distribute the load as widely as possible - and they should always be set at right angles to the underlying floor beams or joists.

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Construction Site Safety 1.3.5 Appendix 7 Report of inspection on *scaffolding, *work equipment or working platform (*delete as appropriate) Inspection carried out on behalf of: ........................................................................................................... Inspection carried out by (name and position): .........................................................................................

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Details of any further action required

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Details of any action taken as a result of any matter identified

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Description of Details of any place of work, matter identified or part giving rise to the inspected health and safety of any person

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Date and time of inspection

.

Address of site (or location of work equipment): .......................................................................................

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Construction Site Safety 1.3.5 Appendix 8 Short checklist Check at each inspection that your scaffold does not have these faults:

Footings

Bracing (facade 1 2 3 4 and ledger)

Ties 1

2 3 4

1 2 3 4

Some missing

Some missing

No base plates

Loose

Loose

No sole boards

Wrong fittings

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Soft and uneven

2 3 4

Boarding

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1

qa

1 2 3 4 Putlogs and transoms

Not plumb

Loose,

Jointed at same height

Wrongly spaced

Wrong spacing

Wrongly supported

Incomplete boarding

Damaged

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Standards

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Undermined

Insufficient supports

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1

2 3 4

Guard-rails and toeboards 1 2 3 4

Wrong fitting

Loose

No check couplers

Wrong height

Joint in same bays

Loose

Some missing

Damaged

Damaged

Not level

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1 2 3 4

Bad boards Trap boards

Couplings

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Ledgers

Bridles

1

2 3 4

Ladders

Weak support

Not tied

Wrong spacing

Damaged

Wrong couplings

Insufficient length

Key: 1 = good, 2 = average, 3 = poor, 4 = N/A

1 2 3 4

1 2 3 4

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Construction Site Safety 1.3.5 Appendix 9 Specimen handover certificate (This is a type of handing over certificate which could be used.) SCAFFOLDING - HANDING OVER CERTIFICATE To (Contractor): .............................................................................. Date: ................................................ Site: ................................................................................................ Time: ...............................................

.

Description of scaffold or section of scaffold handed over: .....................................................................

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...............................................................................................................................................................

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...............................................................................................................................................................

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Drawing No: .............................................................................................................................................. (where applicable)

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Scaffolding as described above has now been completed and complies with current standards. It is structurally sound and should only be used and loaded in accordance with our Quotation No:

Use only for:.......................................................................................................................................

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(.....................................)

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b) Loading to be: ..................................................................................... working lifts with distributed

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Load of: ......................................................................................................... .....(kN/m2 (lb/ft2) per lift)

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The detailed requirements of the Regulations with regard to guard-rails - working platforms - toeboards - bracing and ties have been complied with.

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In order to comply with the Regulations, this scaffold must be inspected before being taken into use for the first time, at regular intervals not exceeding 7 days since the last inspection, after any event likely to have jeopardised the safety of the scaffold and after any substantial addition, dismantling or other alteration. Particulars of each inspection must be recorded in a Report of Inspection. This scaffold has / has not (delete as appropriate) been designed to take tarpaulin sheets (or other windsails). Scaffold Contractor: .................................................................................................................................. Depot: ....................................................................................................................................................... Certificate received on behalf of the Contractor: ......................................................................................

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Safe Working on Roofs and at Heights

1.3.6.1 Key points Gravity is the only rule that works every time! Those who work on roofs are, by the nature of their work, at risk of falling if appropriate measures are not taken.

2

Those who plan, supervise or carry out roof work must be competent to do so.

3

A risk assessment and, where considered necessary, a method statement, must be compiled for all such work.

4

Integral features of roofs such as a steep pitch, valleys, fragile cladding or roof lights can increase the risk of falling.

5

Falls through fragile roofing materials continue to be the cause of many deaths and injuries.

6

Bad weather can have a significant impact on the risk control measures that have to be taken.

7

Ideally work will be carried out from a stable working platform, fitted with guard-rails and toeboards.

8

Where such fall prevention measures cannot be used, effective fall arrest measures must be put in place, ideally 'collective' measures such as safety nets or other soft landing systems.

9

Those who work on roofs must also take into consideration the safety of anyone passing below to protect them from falling materials or tools.

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Roof work, including work on fragile roofing materials, gives rise to a substantial number of fatal and serious accidents.

2

It needs to be emphasised, however, that there is not just the actual roof working to be considered, but the whole process - including planning the job, creating a safe access, the safe storage of equipment and materials etc.

3

There is no such thing as a 'safe height'; anyone who is off the ground is at risk of falling. The hazard exists on working platforms, scaffolds, ladders, flat and pitched roofs, open steelwork and any area in which work is being done in proximity to fragile materials, openings, holes and roof edges.

4

Most accidents could be avoided, given the provision of appropriate equipment and the adequate information, instruction, training and supervision of those who use it.

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These Regulations require that a 'suitable and sufficient' risk assessment of all work activities is carried out and that significant risks are recorded. By its very nature, work carried out on roofs will entail a significant risk of falls from height unless appropriate control measures are put in place.

2

The risk assessment must:

3

(a)

identify the hazards arising from working on roofs which will include working at height

(b)

specify the control measures that will be put in place to reduce the risk of falls to an acceptable level.

These Regulations then require that the control measures identified are put in place.

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1.3.6.4 Work at Height

Contractors to ensure that work at height is planned, supervised and carried out in a safe manner by competent persons

(b)

work at height to be carried out using appropriate work equipment, particularly that which provides collective fall protection

(c)

suitable and sufficient steps to be taken to prevent falling objects which are likely to cause injury to any person

(d)

give consideration to the weather conditions

(e)

where appropriate, the need to plan how the rescue of someone who has fallen but is suspended might be achieved

(f)

where there is a risk of a person falling or being struck by a falling object, steps to be taken to prevent unauthorised access into that area.

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2

The relevant requirements of these Regulations with regard to roof work are considered to be:

The key areas are planning and competence to ensure that the control measures will be put in place and followed.

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1.3.6.5 Provision and Use of Work Equipment

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1

All equipment used in connection with work carried out at heights is classified as 'work equipment' for the purposes of these Regulations. This will include not only items such as scaffold components and ladders, but also the tools used such as slate rippers, screw guns and the like.

2

These Regulations require that whoever supplies work equipment must ensure that it is suitable for the job in hand, maintained in good working order and subjected to inspection as necessary.

3


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In the context of roof work, these Regulations apply to those items of work equipment that are used for mechanically lifting or lowering any load to or from a place of work at height, such as:

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1.3.6.6 Lifting Operations and Lifting Equipment

2

(a)

mobile cranes

(b)

mobile elevating work platforms

(c)

passenger lifts

(d)

inclined hoists

(e)

tele-handlers

(f)

powered hoists

(g)

gin-wheels.

Also covered by these Regulations are the accessories that are used in conjunction with lifting equipment, such as: (a)

ropes

(b)

hooks

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(c)

chains

(d)

eye-bolts

(e)

slings.

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1.3.6.7 Personal Protective Equipment Where a risk to health and safety has been identified by a risk assessment and cannot be adequately controlled by other means that are equally or more effective, the Contractor must provide suitable personal protective equipment (PPE) and ensure that it is used by employees. PPE should only be used as a last resort after other methods of controlling the risk have been considered and deemed not to be reasonably practicable.

2

In the context of roof work, the definition of PPE includes items of fall-arrest equipment such as safety harnesses and lanyards.

3

In deciding which type to issue, the Contractor must take into account the risk that the PPE is being used for, and also ensure that the PPE will fit the wearer and allow them to work comfortably.

4

The Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable them to understand the risks being protected against, the purpose of the PPE and the manner in which it is to be used.

5

Whilst the Contractor must take reasonable steps to ensure that any personal protective equipment supplied is used, the employee in turn must ensure that they use the equipment provided in accordance with instruction and training given and know the procedures for reporting loss or defect to their Contractor.

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These Regulations place legal duties on several categories of duty-holder, each of which has the potential to reduce the risks to health and safety during and after the construction phase.

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Designers

The definition of designer under CDM is extremely wide and many contractors will also be designers. A common scenario would be where the client simply asks the contractor to sort out a leaking roof and the contractor designs the solution.

3

Whoever devises the specification for the work is likely to be considered a designer. This is very important as the designer has a legal duty to consider health and safety issues in relation to not only carrying out the work, but also the maintenance, cleaning and eventual removal (demolition) of the roof.

4

In common with all aspects of design, the person carrying out the design should be sufficiently knowledgeable of the construction process to specify how the work can be carried out safely.

5

Roofers working on industrial type buildings are commonly faced with the problem of fragility. This may be because the roof itself is made of a fragile material such as asbestos cement sheets or simply because the rooflights are not load bearing. As the standard specification for rooflights is 10% by area, this represents a significant amount of fragile roof surface.

6

When designing roofs, designers should also consider such things as ongoing maintenance activities, for example how rooflights and gutters can be cleaned safely and whether the safe access for this type of work can be designed-in at the design stage.

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Clients Under these Regulations the client must provide relevant pre-construction information to other parties such as the Contractor and Engineer to enable the job to be planned so that it can be carried out safely. The client, along with other duty-holders, must take reasonable steps to ensure that all parties involved are competent to do what is required of them.

8

The main type of information that would be relevant for roof work would be the presence of asbestos, areas of damage, loading limitations of the roofing material, the existence of fallrestraint systems, the location of safe access routes where known, as built drawings where available and so on.

9

It should be noted that the client may not be aware of such factors as damaged areas of the roof or the existence (or lack) of safe access routes. The client may well assume that the job will be carried out by a method that is neither practical nor safe. They commonly expect roofing contractors to be able to access places and do tasks that they would simply not allow their employees to do.

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There are various stages to any roofing project: Design

(b)

Selection of contractors/staff

(c)

Planning

(d)

Carrying out the work

(e)

Post-completion information (at the end).

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Selection of contractors/staff

Where a Contractor is using its own employees to carry out roof work, it is essential that several factors are taken into consideration. Both training and operational work on roofs can be hazardous, strenuous work, often involving: work at considerable heights for long periods of time

(b)

work outdoors usually in hot, cold or wet weather and possibly high winds repetitive materials handling

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(a)

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The stages of a roofing project

(d)

reaching, stretching, and maintaining balance in awkward postures whilst carrying loads on varying roof terrains.

12

This means that fitness to work is particularly important and needs to be considered by the Contractors.

13

It is vital that people working on roofs do not suffer from: (a)

any neurological condition likely to cause seizures

(b)

weakness of limbs, loss of balance including vertigo (dizziness from being at height)

(c)

any heart or lung condition likely to be aggravated by strenuous work

(d)

any disability/impairment of limb function

(e)

any other disease, disability, medication, alcohol, drugs or effects of toxic substances (lead etc.) likely to impair mental or physical activity, especially at a height

(f)

temporary ailments such as influenza or other conditions that may affect judgment

(g)

uncorrected sight problems

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a physique that would be unsuitable for the work.

It is very strongly suggested that Contractors should establish a policy on fitness for work.

Planning Planning the work should include consideration of the progression of the work with regard to: (a)

site-specific risks

(b)

weather conditions

(c)

emergencies (including rescue)

(d)

safe means of access and egress

(e)

materials handling and storage.

.

15

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The site-specific risks could include:

working above public areas such as shopping malls or public streets

(b)

the difficulties in delivering materials and transferring them to roof level

(c)

the presence of site traffic or road traffic on a public road

(d)

awkward working environments, such as occupied houses or factories

(e)

emergency situations, such as rescuing someone who has fallen and is suspended at high level in a safety harness

(f)

vent pipes that may suddenly shower unsuspecting roof workers with anything ranging from high pressure steam to noxious chemicals

(g)

certain species of bird that will aggressively defend their territory

(h)

the presence of accumulated bird droppings.

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Weather conditions

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Site-specific risks

It goes without saying that the weather can have a significant impact upon the intention to carry out roof work and may ultimately be the reason for the start of a job being delayed, or it being suspended part-way through.

18

Heavy rain, high winds, frost or snow might make it unsafe for operatives to work at height.

19

The only note of caution is that the forecast wind speed is given for 'ground level'. The wind speed can be considerably higher at height, for example, if installing a glass atrium roof on top of a multi-storey tower block.

20

If a roofing job has started and the weather is forecast to be changeable, with perhaps extremes of conditions, it will be essential to monitor the forecast so that work can be halted before it becomes unsafe to continue.

21

The wind speed could have an impact upon whether or not it is safe to handle or store certain types of materials, such as roofing sheets, at height.

22

Work involving the handling of sheeting and cladding requires extra care in windy conditions, when a sheet may act like a 'sail' causing the person holding it to lose their balance.

23

Working in gusty wind conditions can be particularly dangerous. Industry Guidance suggests that the following activities should cease when the average wind speeds shown are

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exceeded: (a)

27.36 km/h - handling lightweight materials and any materials over 5 metres long or rolls of felt

(b)

37.01 km/h- general roofing activities.

Emergencies (including rescue) Several types of emergency, such as a fire, could occur either at ground level or at height, which requires that an emergency evacuation of the whole site or the roof be carried out. For this reason the planning stage must ensure that safe access and egress will be available at all times. Depending upon the nature of the job it may be necessary to have more than one access/egress route.

25

If the site layout necessitates that the asphalt/bitumen boiler has to be sited on the roof, the question will have to be asked as to whether it is still possible to get off the roof safely if a fire occurs.

26

It may be necessary to deal with medical emergencies where someone becomes incapacitated at height through illness or injury and is unable to make their way back to ground level. In such circumstances, the local fire and rescue service may have to be involved to effect a safe rescue. It is not unknown for someone who has been incapacitated at height to be recovered to ground level in an empty skip suspended from a tower crane whilst being attended to by a paramedic.

27

Carrying out roof work will often involve the use of fall-arrest equipment such as safety nets or safety harness and lanyard. Anyone who falls will have to be rescued promptly, particularly if they are suspended in a harness.

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Safe means of access and egress

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24

The means of gaining access to height and safely working there will depend upon many factors such as the nature of the roof structure, whether there is room to erect a scaffold or bring in a MEWP and even the length of time that the job is expected to take.

29

Some common means of gaining access to height or actually working at height are:

(b)

mobile access equipment fixed or mobile towers

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ladders

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(a)

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(d)

stair towers

(e)

independent scaffolds.

Materials handling and storage 30

Part of the planning process will involve taking decisions on: (a)

what roofing materials are required and quite possibly where they can be stored safely at ground level

(b)

a safe means of transferring roofing materials to height and in what quantities

(c)

avoiding the overloading of any part of the roof by stacking materials prior to installation

(d)

the safe storage of sheet materials if they are to be stored for any length of time, particularly during windy weather

(e)

the safe distribution of materials around the roof during installation

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the safe transfer of waste materials back to ground level.

1.3.6.9 Carrying out the work 1

To a large extent, the risks of doing the job, the risk-control measures that will be necessary and therefore the way in which the work is carried out will depend upon the type of roof.

Flat roofs On flat roofs, falls most frequently occur from: the edge of a completed roof

(b)

from the leading edge where work is being carried out

(c)

through openings or gaps

(d)

through fragile material.

.

(a)

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A roof with a pitch of less than 10° is classed as a flat roof. Safe access to the roof, and to any working place on that roof, must be provided and maintained.

4

If there is no parapet or similar barrier to stop anyone from falling, edge protection must be provided. This may take the form of standard guard-rails and toe-boards or, providing nobody will approach the edge, a barrier set back from the edge.

5

Where works are to be undertaken which could result in materials or equipment falling onto people passing below, protective measures must be taken. This can range from adding netting, close boarding or debris fans to scaffolds or establishing exclusion zones. These could range from permanently fenced off areas to simply having someone stopping people from accessing the 'drop zone' at critical times.

6

There will be times when operatives need to work at exposed leading edges, but it is not reasonably practical to install guard-rails or other fall prevention measures. In these circumstances, it will be necessary to install or provide fall-arrest systems. The most suitable type of fall-arrest system will be indicated by a risk assessment. Where safety nets, air bags or other soft landing systems are used, they will provide collective safety for anyone working above them who falls.

7

Alternatively, it may be decided that operatives should wear a safety harness with a lanyard clipped to a strong anchor point or a horizontal 'running line'. The effectiveness of this system depends upon the training of operatives in the use of the equipment and the operatives actually 'clipping on'.

8

When a safety harness and lanyard is used, consideration must be given to the position of the anchor point, which ideally will be above the head-height of the user. Where the anchor point is at ankle level, for example, there will be more slack in the lanyard and the fall will be further before it is arrested. It has been calculated that in some circumstances a person could fall up to 5.5 metres before the fall is arrested. In this situation, where the person is working less than 5.5 metres above ground level, impact with the ground would occur before the fall could be arrested.

9

Sometimes, guard-rails have to be moved or removed to enable work to be undertaken. If this is to happen:

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(a)

an equally effective safe system of work must be in place and maintained, which will prevent falls of persons or materials

(b)

the guard-rails must be replaced or re-erected as soon as practical.

Some flat roofing systems will involve the use of various chemicals or hot-works and the

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liberation of fumes or solvents may occur, Consideration to COSHH should be given as well as the significant possibility of fire, explosion or burns from hot bitumen. Traditional pitched roofs On traditional pitched roofs, most falls occur: from the eaves, by slipping down then falling from the roof

(b)

into the structure during truss erection

(c)

from gable ends during salvage prior to demolition

(d)

through fragile roofing materials, particularly fragile roof lights

(e)

when passing along valley gutters with fragile materials alongside the access way.

A sloping roof is defined as any roof having a pitch of more than 10°.

13

Work on pitched roofs should only be carried out:

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by persons who are physically capable and adequately trained

(b)

using roof ladders or a temporary work platform equipped with guard-rails and toe-boards as necessary and securely fixed to prevent it slipping

(c)

providing either a suitable catch barrier or a working platform with guard-rails is erected at the eaves of the building.

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(a)

This requirement applies to any work on a sloping roof, including access to and egress from other workplaces.

15

If the steepness of the roof is such that it prevents a secure foothold, a working platform must be erected. Roofs pitched at over 50° should be regarded as 'steep', as should shallower slopes if they are slippery.

When working on a curved roof such as a glass barrel-vault structure, providing:

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(a)

the roofing material is load-bearing, and

(b)

there is a secure anchorage at the apex of the roof

17

it is usually necessary to employ rope access techniques such as work-positioning or abseiling. It is essential that any such system incorporates a self-locking device to prevent the uncontrolled descent of anyone who loses their footing.

18

Additionally, proprietary 'rubber steps' are available that follow the exact contour of a curved roof, with sections being joined to extend the overall length. These steps must be regarded as a foothold only as they are not equipped with a hand-rail. They must therefore only be used in conjunction with another form of fall protection, such as a fall-arrest block.

19

Where there is a risk of falling through a curved roof, consideration should be given to installing safety nets inside the roof.

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Profiled roofs These range from a single asbestos cement sheet on an outside toilet to the latest continuously extruded system formed in situ to cover large portal frame buildings. The systems will differ in complexity and range from single skin through to composite factoryproduced units.

21

New build profiled installation will normally be carried out over a system of safety nets which provide fall protection.

22

There are other means of providing safe access for roofs. Traditionally for new build systems this was called leading edge protection and used working platforms in the form of lightweight staging. This system advances along the roof in line with, or previously, in advance of the installation of the roof sheets.

23

If a double skin roof system is being installed, the inner sheet or liner tray must be fixed by at least four fixings before it can be stood on.

24

Metal profile roof sheets are therefore still fragile until they have been fixed. Furthermore, many rooflight assemblies, which are often installed as part of a profiled roof system, are also fragile. This will necessitate proprietary work platforms such as 'Youngman' boards are used to enable safe access.

25

Any working platform must be a minimum of 600 mm wide with hand-rails on one or both sides, depending on whether a fall can occur. This does create practical difficulties in terms of moving them due to their bulk and weight. In a new build situation it can be possible to run the boards on a wheeled system referred to as purlin trolleys.

26

The only other option therefore is to physically step on the roof and lift the staging’s. A 5 metre platform with guardrails weighs about 50 kg. Given that the platforms should be joined together, then physically moving them does offer challenges. Also, how the stagings are put in place to start with can often be an issue. It is not a safe system of work to simply carry the staging up the steelwork. They may need to be craned up and positioned at the same time as the packs of sheets.

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Fragile roofs

Fragile roofing materials include asbestos, glass, plastic, cement sheets and similar brittle surfaces.

28

Non-fragile roof lights should be fixed with a red coloured fixing to allow people to differentiate between them.

29

As far as the strength of the materials is concerned, the appearance of fragile roofs is often misleading. Surface coatings, dirt or moss may conceal the fragile nature of the material, thereby giving a false appearance of soundness to glass, plastic, asbestos, etc. Even if the roof is clad in a load-bearing material, roof lights are often fragile.

30

Asbestos and various plastic materials are particularly brittle and will shatter without warning.

31

Many deaths and serious injuries have occurred as a result of roof workers falling through fragile surfaces. Most of the falls could have been easily prevented had a risk assessment been carried out and a safe system of work developed. Even if the falls did occur, the deaths and injuries could have been prevented by the use of safety nets or another soft landing system.

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Ideally, another way of carrying out the job would be found that does not require anyone to work on or near to fragile roofing materials. However, in many cases, this may not be practical.

33

If it is necessary to pass across a fragile roof, a roof-board complete with a guard-rail should be used to spread the weight and provide a good handhold. Depending upon the job, it may be necessary to use more than one roof-board: one to support the person whilst the other is moved to a new position.

34

The practice of trying to 'walk the line of the bolts' or 'the line of the purlins' is very dangerous and must not be attempted. Where walkways with a hand-rail are not an integral part of the roof structure, a safe system of work must be devised.

35

Walkways near fragile surfaces (in valleys, parapets, gutters or channels) must be provided with suitable guard-rails or, if not, the fragile surface should be over-laid with a load-bearing material to prevent the possibility of anyone falling through.

36

Warning signs must be fixed at all approaches to roofs constructed with fragile materials……….

37

Where such signs are not fixed in place, it is essential that the presence of fragile material is identified in advance and those doing the job are made aware of it by other means.

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1.3.6.10 Access arrangements Ladders 1

All ladders used for access to elevated work positions, including working platforms or roofs, must comply with the following requirements. (a)

A risk assessment must be carried out before a ladder is used either for access or as a place of work.

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The risk assessment must show that it is not reasonably practicable to use an alternative, safer means of access.

(c)

Ladders should only be used as a place of work for light work of short duration where the risk assessment shows the risk of falling to be low.

(d)

30 minutes is a guide to short duration. This is not 30 minutes in one place and then 30 minutes having moved the ladder 1 m along the wall.

(e)

Such work could be an inspection or light maintenance work involving the use of one hand only. Removing cast iron gutters would obviously not fall under this definition.

(f)

All ladders should be to the correct industrial specification and not domestic quality (Class 3).

(g)

The ladder must be securely fixed near to the top of the stiles or, if this is not physically possible, footed near to the bottom to prevent undue swaying or displacement.

(h)

9 metres is the maximum height suggested for footing a ladder.

(i)

The ladder must be set on a firm level footing (for example, not on loose bricks).

(j)

Both stiles must be properly supported.

(k)

The ladder must extend at least 1 metre (5 rungs) above the landing place, unless another suitable handhold is provided.

(l)

There must be sufficient clear space at each rung to allow a safe foothold.

(m)

The vertical run of the ladder should not exceed 9 metres, unless an intermediate landing has been provided, where practical.

(n)

The ladder must be set at the correct angle, approximately 75° - one measure out for every four measures up.

(o)

The ladder must not be lashed to any gutter or soil stack or similar item, which may be fragile or insecure.

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(b)

Where two-handed operations are necessary, a risk assessment must be carried out to determine a safer method of working, e.g. a static or mobile tower erected by a competent person, scissor lift or cherry picker.

3

Independent or putlog scaffolds, which provide safe access to and around the roof edge, storage space and possibly a loading bay, are another solution.

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Pitched Roof ladders 4

Ideally, where it is necessary to use a pitched roof ladder, access to the lower end of it will be from a working platform at the eaves.

5

Pitched roof ladders must be: (a)

only used by persons who are competent to use them

(b)

positioned to enable easy and safe transfer between:

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Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document) (i)

any other ladder used to get to the eaves and the roof ladder

(ii)

the roof ladder and the place of work

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designed for the purpose

(d)

of good construction, strong enough to enable the planned work to be carried out and regularly inspected

(e)

adequately supported to take the user's weight without damaging the roof

(f)

securely fixed to the sloping part of the roof by means of a ridge hook placed over the ridge. Ridge hooks must not bear down on ridge tiles or capping tiles.

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1.3.6.11 Landing places

All landing places must be of adequate dimensions.

2

If a person is liable to fall from a height that would result in injury, landing places must be provided with: a guard-rail at a height of not less than 950 mm

(b)

an intermediate guard-rail

(c)

a toe-board

a gap not exceeding 470 mm between the toe-board and guard-rail, or between any two guard-rails

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(e)

an intermediate guard-rail if standard, light-gauge brick guards are used.

1.3.6.12 Openings, corners, breaks, edges and joisting in a floor 1

2

Where reasonably practicable, edge protection, in the form of guard-rails and toe-boards, must be provided if people have to work close to what would otherwise be an unprotected edge, where: (a)

a person who fell would be injured as a result of the fall

(b)

material, tools or equipment could fall

(c)

the work is over water, other liquid or dangerous materials.

All holes in floors, etc. must be similarly guarded or securely covered. The covering must be of a suitable material, securely fixed and clearly marked 'Hole below'.

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Open joists through which a person could fall must be boarded over to provide safe access to a working place.

4

Guard-rails, toe-boards and covers may be removed to allow access for people and materials, but must be replaced as soon as possible. This does not apply to demolition work unless it is left unattended.

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1.3.6.13 Mobile access platforms

Mobile access platforms are often used as an alternative to ladders, scaffolds and cradles.

2

The range of equipment includes mobile elevating work platforms (MEWPs), forklift trucks equipped with work platforms, and mast climbing work platforms (MCWPs). Each of these types of equipment can be suitable for carrying out particular types of roof work. For example, using a telescopic boom MEWP (cherry picker) might be a suitable and safe way of accessing a job that would otherwise require someone having to cross a fragile roof. This is particularly important for inspection work. Truck mounted cherry pickers now have sufficient reach to enable inspection of nearly all buildings to be made without having to directly access the roof.

3

Where people are working from these platforms, calculations of the real loads must be made. Typically an allowance for each person of 100 kg covers operative and tools. If materials are to be carried as well, then the weight must be estimated to ensure that the platform is not overloaded.

4

Finally, thought must be given to emergencies, and how aerial rescue could be carried out if necessary.

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Mobile elevating work platform (MEWP) 5

Easily moved from place to place, MEWPs are particularly suitable for short duration tasks requiring a work platform.

6

Work platforms may be towable units, lorry or trailer-mounted, or self-propelled.

7

Also, it must not be overlooked that MEWPs are classified as lifting equipment and as the task is so called 'man riding' the inspections must be at six-monthly intervals.

Working platforms on forklift trucks 8

Forklift trucks equipped with work platforms may be used for access to limited heights, usually for maintenance work. The platform or 'cage' must be designed for the purpose, fitted to the forklift truck in a manner that prevents it from becoming accidentally detached.

9

If the use of a forklift truck for this purpose becomes part of an established pattern of work, consideration should be given to

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introducing a purpose-built mobile platform. 10

The use of so-called 'non' integrated work platforms on forklift trucks is not seen as a particularly safe practice. They are very concerned on the use of rough terrain telescopic forklifts.

11

These are very commonly used on demolition sites when stripping roofs for salvage or removing asbestos cement sheets. To be able to use them, as a minimum the platform and forklift must have the following: tested under Lifting Operations Lifting Equipment (LOLER) every six months

(b)

the basket must have a plate displaying information about loading etc.

(c)

harness points identified

(d)

dipper ram controls isolated

(e)

signage on the forklift confirming that it is suitable for the use.

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Crane and 'man riding basket'

One way to overcome the access difficulties associated with fragility is simply not to land on the roof at all. It is possible to use man riding baskets from a mobile crane. The crane itself would normally be expected to be fitted with a 'dead man's' handle so that the driver cannot inadvertently lower the basket to the ground, and must be on 'power lower' as opposed to 'free fall'. This may rule out some older crawler cranes.

13

All physical parts of the system will require thorough examination under LOLER every six months. It would be expected for the operatives to be harnessed in and typically the harnesses are attached to the hook block of the crane, which offers a second level of safety so-called redundancy.

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(a) (b)

they should be erected only by skilled and competent persons they should be used only by trained operatives they should be inspected daily before use, by the user

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With this equipment, the platform or cradle rises up one or more static masts in a similar way to a hoist, providing a temporary work platform at height, usually on the side of a building. Some of the procedures to be observed in the erection and use include:

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Mast climbing work platforms (MCWPs)

(d)

they should be regularly inspected by a competent person and records maintained of the inspection

(e)

they should be thoroughly examined every six months

(f)

they should be clearly marked with the safe working load and permitted numbers of persons allowed on the platform at each configuration

(g)

they should not be used as a substitute for using stairs or a passenger lift for travelling to higher levels.

Access to chimneys 15

Various purpose-designed lightweight stagings are available for work on or around chimneys. Alternatively, tube and fitting scaffolding should be erected or a MEWP used. In no circumstances should work be carried out on a chimney without the use of a properly constructed and stable working platform.


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1.3.6.14 Other considerations Stacking materials on roofs

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Care must be taken at all times when stacking material on or at roof level. Attention should be given to the following: the size of the load involved

(b)

the types of material involved

(c)

the methods of raising the load, whether manually or mechanically

(d)

the means of communication (signals) and the competence of the slinger or signaller

(e)

the position authorised for stacking materials

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the distribution of the loads (loading plan)

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(g)

the maximum load or stack size

(h)

the loading limitations of the roof

(i)

adequate support or packing to the truss

(j)

protecting the existing roof surface and any weather-proofing

(k)

preventing the displacement of loads which should be: (i)

secured against the wind, especially split bundles and sheets

(ii)

secured against sliding down sloping roofs (sheet stop).


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Permission to load roofs

the owners or occupiers, or

(b)

the architect or a consultant engineer, or

(c)

the Contractor.

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1.3.6.15 Danger areas

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Contractors are to ensure:

the safety of those working at height (from falls)

(b)

the safety of others who may be working or passing below (from falling objects), by the creation of 'danger areas', either around the high-level workplace and/or below it.

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Permission to place a load on a roof structure must be obtained from:

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This is achieved by preventing unauthorised access into any danger area, so far as is reasonably practicable, by the use of equipment such as barriers and appropriate signs.

3

Contractors may find in particular situations that it is not practical to create a permanent 'exclusion zone' beneath the work being carried out above. In these circumstances a solution would be to deploy 'safety marshals' at the lower level to enforce exclusion from the danger area as and when it is necessary.

4

In such circumstances it is essential that an effective means of communication be established between those working at height and the workers controlling the danger area.

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Roof trusses 5

The placement and installation of roof trusses and their associated bracing has the potential to be a very hazardous activity and a safe system of access and protection must be planned and implemented. The risk assessment should have considered these and all other aspects of the work.

6

A safe working platform around the perimeter of the roof should be erected and, where access is required within the trusses, safe access provided. This can be achieved by boarding out the bottom chord of the trusses, so long as they are stable and capable of taking the imposed loads.

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Safety nets can be used, provided a safe clearance distance can be achieved below the net. However, it is difficult to arrange a strong fixing for a net on a new build house. The most common fall protection systems in use in building are 'bean bags', air bags or crash decks.

8

There are a number of proprietary soft-landing systems available in which the fall-arrest bags simply interlock to provide a cushioned landing if someone falls.

9

Crash decks could be as simple as a tower scaffold under the place of work.

10

Roof trusses can be boarded out if access is needed or timber sheets

11

Safe access within the trusses

12

They do require moving periodically so that they remain under the place of work and of course they are nowhere as comfortable to land on as a soft-landing system.

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Working over water

Where there is a risk of persons falling from a structure into water, a secure form of fencing, barrier or fall arrest equipment (preferably safety nets) must be provided. This can be briefly removed for access and the movement of materials, but must be replaced as soon as possible.

14

Other points to be considered include:

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ensuring that a risk assessment has been carried out

(b)

if possible, providing a suitable working platform

(c)

safety nets, if used, must be properly erected and periodically inspected

(d)

warning notices must be placed near to all edges

(e)

adequate lighting must be provided as necessary

(f)

special care must be taken in inclement weather such as fog, frost, snow and rain

(g)

special attention must be paid to the possibility of tides or storm surges changing water levels or flow rates

(h)

life jackets must be provided, and worn by all operatives involved in working over water

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preferably only operatives who can swim should be used

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(j)

suitable rescue equipment must be provided, maintained and operated by trained and competent staff

(k)

frequent checks must be carried out to ensure that the correct number of personnel can be accounted for

(l)

all persons must work in pairs, or in larger groups, as necessary (no lone working)

(m)

all persons must be trained in the procedures for raising alarms and in rescue drills.

The presence of birds 15

The accumulated droppings of birds, if disturbed into airborne dust and then inhaled, can cause severe respiratory problems. It is anticipated that this will mainly be a problem during refurbishment and repair work or demolition.

16

If during the early visits to site it is evident that pigeons have been, or are present, measures must be taken to clean up the droppings before work starts, using a safe system of work, and to discourage the return of the birds.

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Fall-arrest and Suspension Equipment


In situations where the prevention of falls from height cannot be guaranteed, it is essential that measures are put in place to ensure that any fall that does occur is arrested, without injury to the person who has suffered the fall.

2

In many cases safety nets are the preferred method of arresting falls because: they provide what is termed 'collective' fall protection

(b)

if rigged immediately below the work area, they limit the height of the fall to the minimum and recovery of the 'faller' should not be a problem

(c)

they are a 'soft landing system' that should cause no injury to the person who has fallen.

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Safety nets can suffer wear and damage and must be inspected periodically.

4

Other forms of soft-landing systems, such as air-bags or bean-bags, also offer collective protection and are more appropriate for some types of work.

5

If fall-arrest is to be achieved using a safety harness and lanyard, the wearer must be trained in fitting and adjusting the harness and selecting the appropriate lanyard and a secure anchorage.

6

Harness and lanyard offer personal fall-arrest protection only.

7

Some items may need a regime of inspections and thorough examinations.

8

Personal suspension equipment, such as rope-access equipment and a boatswain's chair must only be used by people who have been trained and are competent.

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Where a risk assessment has identified that the risk of falls from height cannot be eliminated by the installation of barriers, guard-rails or other similar measures, the use of fall-arrest equipment may then be the best option.

2

Safety nets or the use of other soft landing systems are preferred to the use of safety harnesses and lines, as they protect the whole area and all persons working above them. They do not rely on individual workers wearing a safety harness and lanyard connected to a secure anchorage point.

3

In situations where people and traffic pass below others working at height, a safety net used in conjunction with a fine mesh debris net will protect those below from falling tools and materials, as well as providing fall-arrest for the people working at height.

4

Where safety nets cannot be rigged for any reason, and it is not practical to use another form of soft-landing system, it may be necessary to resort to the use of a safety harness and lanyard, providing:

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(a)

operatives have been trained in the use and care of the equipment and wear it correctly

(b)

the work environment enables falls to be arrested without injury to the person who has fallen

(c)

a secure anchor point is available

(d)

the person working at height actually 'clips-on'.

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Whichever system is used for minimising injury from falling, whether it be safety nets, another soft-landing system or harness and lanyard, the system must be: (a)

designed to provide a safe system of work

(b)

installed by competent persons

(c)

maintained, inspected and supervised to ensure it is used correctly.

1.3.7.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify the hazards arising out of that work and the persons or groups who might be affected.

2

When hazards are identified, it is then the Contractor's duty to either remove the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3


4

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected.

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1.3.7.4 Provision and Use of Work Equipment Safety nets, equipment used in other soft landing systems, and harnesses/lanyards are all classified as work equipment and must therefore comply with these Regulations.

2

These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

3

Contractors must ensure that where the safety of work equipment depends upon the way it is installed, it is inspected as necessary.

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1.3.7.5 Personal Protective Equipment 1

These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

2

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered.

3

In deciding which type to issue, the Contractor must take into account the hazard that the

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PPE is being used to protect against, and that the PPE must fit the wearer and allow them to work comfortably. 4

The idea of comfort is important and needs to take account of other items of equipment and other PPE that will also be worn.

5

Whilst the Contractor must take 'reasonable steps' to ensure that any PPE supplied is worn, employees in turn must ensure that they wear the equipment provided and know the procedures for reporting any loss or defect to their Contractor.

1.3.7.6 Work at Height The fact that some form of fall-arrest equipment is to be used is indicative that work at height is to be carried out. These Regulations place duties on Contractors, the self-employed and employees to ensure that such work is carried out safely.

2

The key provisions of these Regulations are that Contractors should:

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(b)

where such work cannot be avoided, make sure to select the most appropriate work equipment for the work and to prevent falls

(c)

reduce the distance, and potential consequences, of any fall

(d)

ensure that the work is risk assessment based and that it is carried out safely by competent persons

(e)


(f)


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1.3.7.7 Lifting Operations and Lifting Equipment The definition of 'load' within these Regulations includes a person. This means that if it is foreseeable that the equipment may be used for lifting a person, then these Regulations will apply. So inertia reels, harnesses, strops and other equipment are likely to be covered.

2

The main requirements of these Regulations are that: lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

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(b)

lifting equipment used for lifting persons is constructed and used so as to protect the safety of the person(s) being carried

(c)

the load must be under full and proper control at all times

(d)

lifting equipment and accessories must be clearly marked with their safe working load and other markings if designed for lifting persons

(e)

every lift must be properly planned by a competent person, properly supervised and carried out safely

(f)

generally lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate.

1.3.7.8 Inspection and thorough examination 1

The frequency and type of inspections and thorough examinations should be determined by a competent person. This is quite simply because the risk of damage will depend on the work activity and environment. For example, a harness worn by a demolition burner will probably require more frequent checks than that of a utility engineer inspecting street lighting

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columns.

1.3.7.9 Safety nets Nets are an area where complying with best practice means testing, inspection record keeping and storage facilities are required to ensure that the net itself is fit for use. It is important that the end users appreciate that a safe net is not simply about whether the net erectors have a training records card, but also look deeper to check that the net itself has been checked and inspected.

2

There are a number of British Standards which relate to safety nets. They should be manufactured to the requirements of BS EN 1263-1 and erected in accordance with BS EN 1263-2. This latter standard gives information on the installation and use of safety nets.

3

A further standard, BS 8411, contains construction-specific information and more importantly a list of duties for the parties usually involved in construction projects.

4

This standard specifies that anyone who is planning the installation of a safety net system should take into account the:

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experience and competence of the net erectors

(b)

sequence and type of work being carried out during installation and removal

(c)

sequence of construction work to be carried out whilst the nets are in position

(d)

provision of effective anchorages

(e)

means of access for erecting and removal

(f)

access for inspection, debris removal and temporary repair

(g)

clearance distances below the net

(h)

protection of anyone below

(i)

recovery of anyone who has fallen into the net.

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(a)

Modern safety nets are efficient at saving lives and preventing injury. They are an energyabsorbing system designed to minimise the consequences to the person who has fallen. Safety nets should be erected as close as possible to the working level to minimise the height of any fall that may occur.

6

There are two types of net manufacture.

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(a)

Knotless. These provide energy absorption by permanent plastic deformation (stretching) of the net material.

(b)

Knotted. This, generally heavier and older type of net, provides energy absorption by tightening at the knots and permanently deforming.

7

Safety nets are manufactured in square or diamond mesh, with two mesh sizes: 60 mm and 100 mm. The 100 mm is the normal mesh size used in the UK.

8

All safety nets should carry an identification label. This includes the date of manufacture; the net type, class and size; and reference to the British Standard BS EN 1263-1. It should also carry a unique serial number for record purposes and traceability.

Fall heights 9

The positioning of a safety net system is critical to minimise the height of falls that may occur. Although safety nets are designed for a maximum fall height of 6 m, the maximum fall, if installed directly under the workplace, should be under 1 m.

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10

When nets are installed, the maximum amount of sag in the net should be no more than 10% of the bay width.

11

When a load or person falls into a correctly erected net, the net material will deform as it absorbs the energy from the fall.

12

It is therefore critical to provide adequate clearance below the net, to allow the deformation to occur without the load or person striking the ground or some other object.

13

If a person were to fall 2 m into a net between 5 m and 9 m wide, the total deformation, including the erection sag, may be between 2.6 m and 3.5 m, depending on the width of net. It is essential to check the manufacturer's specification to ensure that there is adequate clearance below the planned net position.

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Competence The way in which safety net systems are installed is critical. Not only must those installing the net system be trained and competent, so must the people who carry out the routine inspection of safety nets.

15

The issue of competence is important, as a handover certificate should be issued. Always receive a handover certificate from the riggers for each section of netting as it is completed.

16

There are industry agreed standards and qualifications for training in the rigging and inspection of safety nets. The training of inspectors is aimed at site management staff as well as professionals within the industry.

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Safety nets are provided with short lengths of test cord attached to the net. These cords carry the net's unique serial number and are so fitted that they receive the same environmental exposure as the net material. At yearly intervals, a test cord should be detached from the net and sent back to the manufacturer so that it may undergo a tensile failure test, to monitor the degradation of the net material through exposure to sunlight. Typically a net is made with three so called 'test diamonds'. The presence or absence of these gives the site manager a clear indication as to whether the basic testing regime is in place.

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Periodic testing

18

Where safety net systems are erected, they should be inspected on a weekly basis by a competent person to ensure that they are still in a safe condition, fixed correctly and will provide the fall-arrest capability if required.

19

Inspections should be carried out more frequently if circumstances indicate that the integrity of the net system is in doubt.

20

A net should also be inspected after a person or substantial load has fallen into it, to determine whether it should remain in service or be replaced. In some cases, it may be necessary to seek specialist advice.

21

Findings of all inspections need to be recorded.

Care of nets 22

Care should be taken to reduce to a minimum unnecessary wear and mechanical damage likely to weaken the net. Materials must not be stacked on it and the deliberate jumping into, or dropping of objects on to nets must be prohibited, as permanent deformation may occur.

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The following sources of damage or wear should be avoided as far as possible: (a)

dragging the net over rough surfaces

(b)

contact between the net and sharp edges

(c)

an accumulation of debris in the net

(d)

any sparks from hot work, welding, grinding, burning operations, hot gases from blowlamps, or hot ash from chimneys or furnaces

(e)

chemical attack

(f)

any form of radiation.

Special care should be exercised and precautions taken to prevent the net and any supporting framework from being struck by loads on moving vehicles or by the vehicles themselves.

25

Regular inspection is necessary to ensure that the nets remain serviceable. The net manufacturer should be consulted when there is any doubt about the suitability of nets for use in hazardous conditions, after any known contamination or when deformation has occurred.

26

When erecting nets in the vicinity of electricity lines or overhead power cables, the appropriate authority should be consulted before work starts.

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Maintenance

Nets must always be inspected after use and before storing to identify any damaged areas. Glass, metal, grit and other debris should be removed to prevent abrasion.

28

If contaminated by acids or alkalis, nets should be thoroughly washed, preferably by hosing, and allowed to dry naturally away from heat.

29

If areas of damage are found or chemical damage is suspected, contact the manufacturer to obtain a list of competent people able to repair or clean the nets.

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Storage

Nets should be stored away from heat, chemicals and solar radiation.

31

Nets should be stored in dry conditions.

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Nets should be stored to minimise vermin attack.

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Wet nets should be dried naturally.

34

Storage cupboards should be well ventilated.

35

Nets should be turned periodically to allow air circulation.

36

If stacked, nets should be packed up clear of the ground.

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Rescue from a net system 37

Where the net is erected as close as possible below the work area, many of the situations where persons enter a net will be minor 'step-ins', with the person able to climb out unaided.

38

On other occasions, a person may fall a considerable height into a net. They may fall onto materials lying in the net, or strike their head or body on, for example, structural steelwork

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during the fall. 39

When such accidents occur, extreme care must be taken during the rescue of the person lying injured in the net. Due to the 'stretching' nature of the net, it is possible that any rescuer entering it could inadvertently and unavoidably cause further injury to the victim.

40

It is therefore essential that Contractors using safety net systems have, as part of their risk assessment process, emergency procedures written for: (a)

treating first aid needs whilst the injured person is in the net

(b)

emergency recovery from a rigged net system.

1.3.7.10 Other soft landing systems Alternative soft landing systems are an effective alternative to safety nets in some circumstances.

2

Designed to be used in buildings with a storey height of up to 2.5 m, one type of system comprises large polypropylene bags (typically 2.5 m long x 0.55 m wide x 0.55 m deep) that are packed with polystyrene chippings or another energy-absorbing material. The depth of the bags both cushions a fall and reduces the distance of that fall (by the depth of the bag).

3

The bags are linked together with plastic snap-clips to completely fill the area over which protection is required. They can also be used on the first or subsequent floors while trusses are being installed or in the roof space when fixing bracings.

4

An alternative system that may be considered in appropriate circumstances is the use of airfilled bags. Similar to the above, bags of varying sizes may be clipped together to completely fill the area over which fall-arrest protection is required. Air bags require an air compressor running all the time that fall-arrest is required, to maintain the pressure in the air bag system. These devices work on the principle of a controlled rate of constant inflation and leakage so that the air bags will absorb the energy of someone falling on to them without bouncing.

5

Whilst soft landing systems do not prevent falls, they are very effective in eliminating injuries in falls of less than 2 m.

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1.3.7.11 Safety belts, harnesses and lanyards If fall prevention measures (for example, working platforms, barriers, guard-rails) or collective fall-arrest measures (safety nets or other soft landing systems) are not practical, an alternative safe system of work must be employed. This safe system may require the use of safety harnesses and lanyards, but it should be a last resort. Whereas safety nets and other soft landing systems are 'collective measures', i.e. they automatically provide protection for everyone working above them, safety harness systems only protect the user, and only then if the equipment is used correctly.

2

Care must be taken when planning to use a safety harness, lanyard and energy-absorbing system since, depending on where the lanyard is anchored, a falling person may fall around 4 m before the fall is arrested.

3

One of the limitations of using such fall-arrest equipment is that it only protects a person if they adjust and wear the harness properly and connect the lanyard to an appropriate and secure point. The use of any such system requires a high degree of training, competence and supervision.

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Training 4

Training should only be carried out by competent accredited third party trainers, following

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industry guidelines. Training should refer to the manufacturer's instructions and should emphasise the importance of following those instructions. It should cover the selection, fitting, adjustment, maintenance and use of the safety belt or harness, and explain the choice and use of suitable anchorage points. Employees should not be permitted to use the equipment before adequate instruction has been received, and they have been judged to be competent in its use.

6

Safety belts and harnesses are wrongly regarded by some workers as an encumbrance and a restriction on their freedom of movement. The fact that a safety belt or harness can prevent serious injury or even save a life is often ignored.

7

The problems arising from such attitudes can and must be solved by applying the principles of good health and safety management. These include educating employees in the need for the equipment, training them in its use, ensuring it is provided and, through adequate supervision, ensuring it is always used.

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Types of belt or harness

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While the British Standard which defined the various types of belt and harness has been replaced by a European Standard, the common construction industry terminology for these pieces of equipment is as shown on the next page. A - Pole belt

(b)

B - Chest harness

(c)

C - General purpose safety harness

(d)

D - Safety rescue harness.

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Selection of equipment

The correct selection of a safety harness or safety belt is important. If a person falls more than 600 mm when using a safety belt, serious injury can be sustained due to a heavy load being exerted on the spine and internal organs. Safety belts should only be used for pole access or other similar specialist access needs.

10

If any doubt exists concerning the suitability of a piece of equipment for a particular task or type of work, further information and advice should be sought from the manufacturer.

11

Whatever type is chosen, it should give a high degree of safety allied to mobility and wearer comfort.

12

The main characteristics of the types of appliance, together with an indication of their uses, are given below.

13

A - Pole belt. A simple waist belt for use by pole linesmen and for other similar tasks. They are not intended for situations where a drop may exceed 600 mm.

14

B - Chest harness. A safety belt with shoulder straps, for use where a lanyard and anchorage point limit the drop to a maximum of 600 mm. It must be worn quite tightly to prevent any slippage after a fall.

15

Both A and B above are for very specific and for restricted use only.

16

C - General purpose safety harness. A full harness with thigh and shoulder straps. In the event of a fall, a person is suspended in a reasonably upright position from the attachment

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point. If the harness is of the right size and properly adjusted, the wearer cannot fall out. 17

D - Safety rescue harness. Designed to be worn by anyone in a confined space or location where they may be overcome or incapacitated and need to be rescued. A safety rescue harness looks similar to Type C, but will support a person almost upright for rescue purposes. It is intended for a maximum drop of 600 mm.

18

A competent person should draw up a schedule for testing and examination, which is likely to also include a requirement for thorough examinations at six-monthly intervals and userchecks each time the equipment is used. The six-monthly examination is a detailed visual examination, typically following cleaning where the harness is checked for contamination by oils and other solvents as well as abrasion and damage. The user check is simply to make sure that 'all the bits' are still there and there are no obvious defects.

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1.3.7.12 Type of lanyard There are several types of lanyard, each intended for a particular purpose.

2

Fall-arrest lanyards incorporate an energy-absorbing feature to reduce the shock loading on the body of the person who has fallen when the fall is arrested.

3

Twin tailed lanyards are a type of fall-arrest lanyard that allows greater mobility at height by enabling the repositioning of one tail at a time so that the user is constantly 'clipped on'.

4

However, this type of lanyard can pose additional risks to safety if it is not used correctly. If only one tail is clipped to a secure anchorage and the second tail is not located correctly, then during a fall the second tail could loop over a fixed object and arrest the fall before the energy-absorber has deployed, which may cause severe personal injury.

5

The second tail must never be clipped back on to the user's harness unless it is fitted with purpose-fitted 'parking points' that will break away from the harness if the second tail comes under tension. Alternatively, the second tail can be either left to hang free or (on this type of lanyard only) be simultaneously clipped to the same secure anchorage. If there is any doubt about these lanyards' safe use, the supplier or manufacturer should be consulted.

6

Restraint lanyards are shorter and used as a means of limiting the range of movement of the wearer to stop them entering an area of danger, for example to prevent a cherry picker operator from being thrown out of the basket. These lanyards are not designed to arrest falls and have no energy-absorbing feature. Sometimes two of these may be worn at the same time, with each lanyard fixed to a clip on either side of the harness to make the harness what is termed a 'work positioning harness'.

7

Irrespective of the type of lanyard used, they are only effective if the free end is securely anchored to a suitable anchorage point.

8

Manufacturers and suppliers will advise on the appropriate type of lanyard for particular work situations.

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Selecting the anchorage point 9

In order to limit the drop, the anchorage points should always be as high as possible above the person and as near to vertical as possible in order to avoid 'the pendulum effect'.

10

Anchorage points must be capable of withstanding the anticipated shock loading.

11

Consideration should also be given to how persons would be rescued following an arrested fall, particularly when work is from high structures. Some harness manufacturers also produce rescue systems that enable a single rescuer to raise a suspended person back to

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the working platform or safely lower them to ground level. Markings on belts and harnesses Safety belts and harnesses must be clearly and indelibly marked or permanently labelled with the following information: (a)

the British Standard, or International Standard, to which it conforms

(b)

the name, trademark or other means of identification of the manufacturer

(c)

the year in which the harness or belt was manufactured

(d)

the type of belt or harness

(e)

the manufacturer's serial number

(f)

the company serial number, or other recognition system, for recording maintenance and inspections.

Under these Regulations the safe working load would also be required, and it would be common to see some form of marking that indicates that the harness has been tested.

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the British Standard, or International Standard, to which it conforms

(b)

the name, trademark or other means of identification of the manufacturer

(c)

the year of manufacture

(d)

the manufacturer's model number and the type of belt or harness with which the lanyard is designed to be used

(e)

the company serial number, or other recognition system, for recording maintenance and inspections.

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Ideally, lanyards will have a label with the words (or similar):

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Lanyards which are not permanently attached to belts or harnesses must be clearly and indelibly marked or permanently labelled with the following information:

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Markings on lanyards

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'For maximum safety attach the free end to a point as high as possible above you and avoid looping the lanyard around small joists and angles with narrow edges.'

Lanyards should preferably be permanently attached to belts so that 'longer' lanyards cannot be substituted.

Shock absorbers 17

If a person wearing a harness and lanyard falls, there is a considerable shock loading to the body. The further the fall, the greater the shock. Generally speaking, the maximum distance a person should fall before a fall is arrested is 2m.

18

Shock absorbers in the form of tear-away stitching, stretch springs or a deforming metal strip are built into fall-arrest lanyards as a means of reducing the shock loading. Once a lanyard has been used to arrest a fall and the energy-absorber has been deployed, it must be discarded.

Arrester devices 19

These devices are similar in operation to the 'inertia reel' safety seat-belts fitted in cars.

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The safety harness is attached to a self-reeling cable which is securely anchored. The wearer is free to move normally but, in the event of a sudden movement (i.e. a fall), the locking device is brought into operation.

21

Most 'inertia reel' type arresters are only designed to safely arrest someone who has fallen from a position directly below, or very close to, the anchorage point (which should be above the head-height of the user). They are not designed to compensate for the 'pendulum effect', which will occur when the faller is a significant horizontal distance from the suspension point.

22

A typical misuse would be to see a line rigged along the ridge of an industrial roof with inertia reels fixed to it by carabiners. The work being carried out is not actually on the roof but on a lower level, resulting in the safety lines being stretched, and possibly abraded, across the lower edge (eaves) of the pitched roof.

23

The issue is that most examples of this type of device are not tested for 'over the edge' type falls in which the retractable lanyard is pulled tight across the edge of a surface, for example a roof sheet or floor slab, by the weight of the fallen person. In these circumstances it has been reported that the lanyard could snap or fail to limit the height of the fall to a safe distance.

24

If this is the proposed work method, then advice needs to be taken from the manufacturer that their equipment will work satisfactorily in this manner.

25

Various other types of fall-arrester are often incorporated as a permanent fixture into the structure being built, such as a traveller on a pre-tensioned vertical cable. There are also proprietary systems where the lanyard is attached to a traveller which moves along a prepositioned and tensioned horizontal or vertical steel cable. This permits movement around corners and past obstacles without the need to unclip.

26

Where the client provides this equipment as is common in many cases, care still needs to be taken that it has been inspected and checked as required and that the users understand how it works.

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Storage 27

While not being worn, appliances should be stored in a cool dry place and not subjected to direct sunlight. The use of purpose-designed cabinets which allow ventilation is recommended. If the appliances get wet, they should not be dried by direct heat.

28

The equipment should not be subjected to unnecessary strain or pressure and must be kept free from contact with sharp implements, corrosives and other possible causes of damage.

29

Recommended cleaning instructions should be followed.

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Inspection The wearer must make a visual inspection of safety equipment before use. The equipment should be examined by a 'competent person' at least once every six months and a record kept of this inspection.

31

Safety belts, harnesses and lanyards should be examined by a 'competent person' after a fall or other circumstances in which the equipment has been deployed, before it is reissued for use.

32

Safety belts, harnesses and lanyards should be taken out of use if found to be damaged or defective.

33

Under most circumstances, knots in lanyards would be considered to be a significant problem. Typically, a knot is presumed to reduce the strength of the rope or strop by 50%.

34

Particular attention should be directed to the points below.

35

Webbing and leather. Examine for cuts, cracks, tears or abrasions, stretching and distortion, damage due to deterioration, contact with heat, acids or other corrosives and rot.

36

Snap hooks. Examine for damaged or distorted hooks, faulty springs and strained jaws.

37

Buckles. Carefully examine the shoulders of buckles; inspect for open or distorted rollers, and undue wear.

38

Sewing. Examine for broken, cut or worn threads, open seams and failed stitching.

39

Lanyards, ropes and chains. Examine for damage or signs of wear and, in the case of ropes, inter-strand wear, unravelling extension and fusion.

40

For webbing lanyards, specific attention should be given to:

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(b)

surface abrasions to surface or edges

(c)

damaged stitching

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(a)

a knot in the lanyard other than the manufacturer's results of chemical attack.

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30

Unauthorised modifications. Examine equipment for 'home-made' attachments or adaptations. It should be impressed upon the wearers that their lives could depend upon the continued efficiency and durability of their safety equipment and that, by frequent personal inspections, the possibility of equipment failure will be reduced to a minimum.

Records 42

A card or history sheet should be kept for each harness and lanyard, and particulars of all examinations and other details of interest recorded. Each harness and lanyard should be marked with an individual serial number for identification purposes.

Dead weight anchor devices 43

The use of dead weight anchors in accordance with International and British Standards BS EN 795 and BS 7883 (Class E) has become an acceptable means of providing a safe fallarrest anchor device on flat roof surfaces, particularly where it is not possible to penetrate the roof surface.

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44

However, the increased usage and range of devices developed over recent years has revealed a number of factors not previously considered.

45

To ensure the safety of users, Contractors should consider the following points: (a)

Have the BS EN 795 and BS 7883 tests been carried out in accordance with the latest version of BS 7883?

While many dead weight anchor devices have been tested for use on single-ply membrane roofs, it has recently been found that the performance of some (and, possibly all) is far less satisfactory on embossed membranes rather than on plain, smooth membranes. This is thought to result from the reduced contact surface area between the anchor device and the roof surface. This effectively reduces the amount of friction,

47

Anyone who wishes to use a dead weight anchor device on an embossed membrane surface or a surface that is not smooth should seek advice from the anchor device manufacturer before proceeding.

48

The attention of users is drawn to the fact that no standard, at present, specifies tests for fallarrest systems in the following circumstances.

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When a full body harness is connected via a retractable fall-arrestor to a dead weight anchor device using a connector.

(b)

When a full body harness is connected via an energy-absorbing lanyard to a dead weight anchor device using connectors.

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Users who wish to connect such a system to a dead weight anchor device are advised to seek confirmation from the manufacturer of the retractable fall-arrestor or energy-absorbing lanyard that their products are safe to use in this way.

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Suspension trauma

One of the effects of being suspended in a harness is a tightening of the leg straps that bear the body weight of the suspended person. This can affect the blood circulation in the legs and cause the suspended person considerable discomfort, possible kidney failure and eventually unconsciousness and death. This is known as suspension trauma. It is essential that someone suspended in a harness is recovered in the shortest possible time.

51

Fall victims may be able to slow the onset of suspension trauma by relieving the pressure on their legs by pushing down vigorously with the legs, by positioning their body in a horizontal or slight leg-high position, or if there is something nearby upon which the feet can be rested, by standing up. However, the design of the harness and injuries sustained during the fall may prevent these actions being taken.

52

Some harnesses are fitted with stirrups that are secured out of the way by Velcro during normal use but can be lowered after a fall to enable the person to effectively 'stand up' in the harness.

53

The person must be placed in a horizontal position, preferably the standard 'recovery' position. It is essential that the emergency services are summoned immediately if it becomes apparent that there could be a medical emergency situation.

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1.3.7.13 Rope access (abseiling) 1

rd

This technique is only to be carried out by 3 party accredited fully trained and competent persons. It is generally suitable for inspection and other similar activities but not for general construction work except in exceptional circumstances. An example might be the rigging of safety nets where it is not reasonably practicable to do it by using other means of access such as a MEWP or another form of working platform.

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2

Generally anyone carrying out roped access uses a system that incorporates two separately anchored lines: the 'working line', which is the means of access, and a 'safety line', which prevents a fall if the working line fails.

3

This requirement may be ignored in exceptional circumstances where: (a)

the risk assessment shows that the use of a second line would increase the risk to the person

(b)

effective alternative safety measures are taken.

The person must be connected to both lines by automatic locking devices that prevent an uncontrolled descent should the person lose control of their actions.

5

The ropes, harnesses and other equipment are covered by the six-monthly thorough examination and inspection requirements.

6

Protection must be installed if there is a danger of materials or equipment falling onto persons below.

7

It is essential that only persons trained and competent in the use of rope access equipment, to current industry standards, are allowed to carry out such activities.

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1.3.7.14 Boatswain's chairs

Boatswain's (or bosun's) chairs should only be used where the work is of a relatively short duration and where no other means of access or working, such as a suspended scaffold, is practicable.

2

Note: Independently anchored safety line and safety harness not shown

3

A person in a boatswain's chair is extremely vulnerable. They are suspended high above the ground and, if anything goes wrong, the chances are that they are beyond rapid or immediate help. The risk assessment should cover rescue procedures should an emergency occur.

4

The installation and use of a boatswain's chair must be supervised by an experienced and competent person. Only properly trained and competent operatives should be permitted to use them. These Regulations must be strictly observed.

5

The traditional non-British Standard boatswain's chair is still used by specialist trades such as steeplejacks and lightning conductor engineers. Operatives need to be fully trained and competent before being permitted to use and work from it.

6

Where possible, consideration should be given to the provision of a second safety line connected to a harness being worn by the operative. In this way, should there be a problem with the Boatswain's chair, this safe system of working will prevent a fall. It may not always be possible and if this is the case, then the reason for this should be recorded as part of the work at height risk assessment.

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Rigging 7

A boatswain's chair should always be rigged with a pair of single sheave pulley blocks, having a safe working load of at least 225 kg. Outriggers and other supports must be strong enough, and be securely fastened down. Where weights are used, a safety factor of four is required.

8

A boatswain's chair is classified as a 'roped access system', therefore, the system should be rigged with a separately anchored safety line complete with an automatic locking device attached to the user of the seat that prevents or limits a fall should the primary suspension system fail.

Chair

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A boatswain's chair should meet the following requirements: compliance with BS 2830. A certificate of compliance should be available from the manufacturer

(b)

be of a recommended size:

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(a)

between 450 mm and 610 mm wide

(ii)

not less than 225 mm deep

(iii)

have a back not less than 250 mm high

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(i)

if the chair has a single central leg or suspension member, this should be without sharp bends and be securely fixed to the seat as far back as practicable, so that the user sits with one leg at either side

(d)

be provided with a safety harness to prevent the occupant falling out

(e)

the back and the suspension member should be placed so that no one can fall out

(f)

the suspension point must be at least 500 mm above the seat, with provisions for suspension. No part should be able to become detached

(g)

be made for a safe working load of 115 kg. A proof test of 150 kg is recommended.

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When the risk assessment identifies that work from a boatswain's chair will take place above areas where people may be present, adequate protection must be installed to prevent them being injured from falling equipment or materials.

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Safety factor 11

The counterweight (W) x tail length (T) should be at least four times the projection length (0) x weight of the person, the chair and any tools or equipment being carried (C).


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Note: Independently anchored safety line and safety harness not shown

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Lifting equipment

All ropes and chains used should be thoroughly examined before their first use for any sign of chafing or wear, and then every six months. They must be securely attached to the chair and to the anchor. Swivel connections should be used to prevent spinning.

14

Fall ropes should not be less than 18 mm in diameter. They should be tied off correctly in the working position. The rope must not be removed from the cleat while the chair is in use; a controlled descent is achieved by removing the locking-hitch from the rope in the 'tied-off' position and easing it around the cleat.

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Hooks should be 'moused', 'C' shaped, or fitted with a spring-loaded device to prevent the displacement of the load.

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Cradles

Cradles, which come within the category of suspended access equipment, may be used for window cleaning, painting, exterior maintenance and inspection.

17

They may be permanently rigged and attached to the roof, or be a temporary installation which can be dismantled. Safe access to the cradle must be provided, either at ground or roof level. Cradles, as 'man riding' equipment must be inspected at appropriate intervals and subjected to six-monthly thorough examinations.

18

Two main types of cradle in use within the construction industry are:

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(a)

those 3.2 m or less in length, suspended on pulley blocks with natural or synthetic fibre ropes

(b)

those more than 3.2 m in length, suspended on wire ropes controlled by handoperated or power winches which are mounted on the cradle.

Both types can be installed as: (a)

Fixed cradle - Rise and fall only

(b)

Travelling - Capable of moving horizontally across the workface as well as rising and falling.

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Rigging 20

The erection of a cradle must be carried out and supervised by an experienced, competent person who is familiar with the type of equipment being erected.

Outrigger 21

Timber poles, roller steel section or specially stiffened scaffold tube may be used. The framework must be secured at intersections to prevent displacement and the counterweight must be sufficient to give a resisting moment at least three times the overturning moment, i.e. W = 3 x O x C T W = Counterweight 0 = Overhang

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C = Total weight of fully loaded cradle

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Where:

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T = Tail length

Where a traversing track is required, this should be an alloy or steel section, properly joined or shackled to the outriggers. If the track is joined to provide a continuous run, this must be with both the load-bearing connectors and the join supported by an outrigger. End stops must be in place at either end of the track, to prevent the trolley from running off.

23

When installing temporary cradles, a check must be made that nothing on the face of the structure, for example, satellite dishes, will obstruct its range of travel.

24

Care must be taken not to damage the roof or structure, and adequate packing should be used on copings.

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Markings

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To identify compliance with BS 2830, markings should clearly show the safe working load and maximum number of persons held.

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25

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Working platform 26

Should be not less than 600 mm wide.

27

Should be closely boarded (except for drainage).

28

There must be no gaps in platforms through which materials may fall and injure people below.

29

Timber boards should overhang the stirrups by at least 100 mm but not by more than 200 mm.

30

Should be supplied with a non-slip surface, if possible.

Toe-boards 31

Ideally will not be less than 150 mm high.

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Guard-rails 32

Should be at least 950 mm above the working platform.

33

There should be an intermediate guard-rail or other substantial barrier.

34

The space between guard-rails and toe-board should be not more than 470 mm.

Suspension points 35

Should be positioned centrally in the width of the platform.

36

Heights should be not less than 1.67 times the clear width of the platform.

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Safe working distributed load 225 kg when there is a 2 m clear working length.

38

295 kg when there is 2-3.2 m of clear working length.

39

The maximum number of persons allowed on a platform should be displayed. (This does not take into account the weight of any materials.)

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1.3.7.15 Stirrups

Stirrups should pass under the platform and be secured.

2

If hinged for operational purposes:

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the pivot point should be non-detachable

(b)

the stirrup should be able to be locked in the vertical position.

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(a)

The stirrup should be hinged to a metal strip of the same strength as the stirrup which is fixed under the platform.

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Demountable stirrup

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Should be designed so that it cannot become accidentally detached.

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Guard-rails required for hinged and demountable stirrups should be secured with captive devices.

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Suspension 6

Ropes should be not less than 18 mm in diameter and should be either natural fibre or synthetic fibre, conforming to BS EN standards, as appropriate.

7

Wire ropes used to suspend cradles should have a safety factor of at least eight.

8

The proper inspection of wires and ropes is essential to safety, with renewal as soon as necessary.

9

Suitable devices should be fitted or other steps taken, where practicable, to prevent the carrier falling if the main support fails.

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Pulley blocks 10

Must be suitable for the ropes which are to reeve through them.

11

The safe working loads for cradles are: (a)

250 kg for cradles with 2 m clear working lengths

(b)

380 kg for cradles with 2 - 3.2 m clear working lengths.

Winches or similar The safe working loads for winches are: (a)

225 kg for cradles up to 2 m in length

(b)

295 kg for cradles up to 3.2 m in length.

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Hooks As for boatswain's chairs

When working above areas where people may be present, adequate protection must be installed to prevent people being injured from falling equipment or materials.

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Fall-arrest devices

These are provided to avoid the consequences of a suspension rope failure. They must be installed in accordance with the manufacturer's instructions.

16

If such a device is not used, operatives must wear a safety harness attached via a selflocking device to an independently anchored safety line.

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General

Care must be exercised when planning works at elevated positions, where the 'safe distance' from electric cables may be reduced. The risk assessment should specify appropriate distances and precautions.

18

Only competent and properly trained personnel should be employed in the erection and use of cradles.

19

All equipment must be thoroughly examined at six-monthly intervals and tested in compliance with the relevant legislation and standards, and proper records must be kept,

20

The public should be warned of operations.

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Typical suspended cradle

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Construction Site Safety 1.3.7 Appendix 1 Safety nets Safety checklist Before use Has a risk assessment been carried out?

2

Are the safety nets rigged to minimise the height of any fall such that an uninjured person can simply climb out?

3

If not, have emergency rescue procedures been established?

4

Have checks been made to ensure that free fall distances are not more than specified?

5

Have the safety nets been rigged by trained and competent persons?

6

Is the use of safety nets to be supervised by competent persons?

7

Have safety nets been inspected prior to current use?

8

Are complete and proper records kept of all inspections and examinations?

9

Has the safety net system been inspected within the previous week?

10

Are all anchors and supports secure?

11

Is the safety net clear of all debris?

12

Have checks been made to ensure that nothing is positioned under the net to reduce the minimum clearance distance required?

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During use

Is the net being kept clear of debris?

2

Are the safety nets inspected: after a fall

(b)

for the effects of contamination

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every seven days during use

to ensure that the safety net is not damaged and that the anchorage points and ties are sound.

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After use 1

Are safety nets inspected for any damage following use and before being stowed away?

2

Are any defects reported promptly and correctly?

3

Are repairs only carried out by a competent person?

4

Are adequate records maintained as to the use and condition of safety nets?

5

Are safety nets dried and stored correctly?

6

Are the annual condition tests being undertaken?

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Construction Site Safety 1.3.7 Appendix 2 Safety belts, harnesses and lanyards Safety checklist Before use Has a risk assessment been carried out?

2

Have emergency rescue procedures been established?

3

Has the most suitable harness or belt been selected for the type of operation and hazard?

4

Are the operatives who are to use the equipment adequately trained in its inspection and use?

5

Is it all in good order and fit for purpose?

6

Is a secure and appropriately positioned anchorage point available?

7

Have checks been made to ensure that the weather conditions are such that an operative can work safely in the prevailing conditions?

8

Is there a schedule of detailed examination of the equipment?

9

Are records of the examinations kept?

10

Have steps been taken to see that adequate warning notices are displayed?

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During use

Have safety lines been set by a competent person?

2

Are only authorised, trained and competent personnel allowed to use the equipment?

3

Is all equipment inspected before the start of work each day, following an established routine, particularly for damage to webbing lanyards?

4

Have set procedures been established and implemented?

5

Is horseplay strictly prohibited?

After use

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Is the equipment inspected for damage?

2

Are defects reported promptly and correctly?

3

Is defective equipment quarantined (if it can be repaired) or discarded?

4

Is the equipment cleaned and stored correctly?

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Construction Site Safety 1.3.7 Appendix 3 Boatswain's chair Safety checklist Before use Has a risk assessment been carried out?

2


3

Has a separately anchored safety line been installed?

4

Is the installation and use of a boatswain's chair supervised by trained, experienced and competent personnel?

5

Are the chair and associated equipment carefully examined for defects prior to use?

6

Is confirmation at hand that test and examination certificates are valid?

7

Has the safe working load been established?

8

Have checks been carried out to ensure that the user is both trained and competent in the use of the chair?

9

Are warning notices displayed and has notification of intention to carry out work been given?

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During use

Is the chair free of materials or articles which could interfere with the user's control of the chair?

2

Has the fall rope been properly tied off whilst the chair is in use and always under or around a cleat to act as a brake?

3

Has a safe area been created below the work area or protection installed?

4

Is the safety line being properly used?

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After use

Is the chair inspected for defects following its use?

2

Are chairs and ropes left in a safe condition, i.e. is the chair raised to the first floor level if possible, and the top rope secured?

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(b)

have the chair and rope been secured to prevent swing?

(c)

have the ropes (and chair, if timber) been dried before storage?

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Construction Site Safety 1.3.7 Appendix 4 Cradles Safety checklist Before use Has a risk assessment been carried out?

2


3

Are cradles installed and supervised by a competent person?

4

Are cradles inspected and appropriate reports made?

5

Are current test certificates available for winches, wire ropes, blocks and so on?

6

Have users been properly trained?

7

Has adequate protection been installed and proper warning given to members of the public and other people who might be affected?

8

Have occupiers of the building been warned not to open windows?

9

Have steps been taken to erect the correct warning signs?

10

Have secondary safety ropes and harnesses been provided as necessary?

11

Is the safe working load of the cradle marked?

12

Has a check been carried out for obstructions on the face of the structure?

13

Have effective fall-arrest measures been installed?

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During use

Is a competent person in charge of all operations when cradles are being used?

15

Are operations being carried out with authorised operatives only?

16

Are inspections carried out weekly?

17

Have checks been made to ensure that there are no knots or kinks in the ropes?

18

Are ropes correctly reeved on the drum with at least two turns left when the cradle has reached its maximum operating distance? (Power-operated cradles only.)

19

Have both power supplies and cables been checked before operating?

20

Have checks been carried out to the controls for correct function and to ensure that pendant controls are secured to the cradle?

21

Have all ropes been securely anchored?

22

Are the stops and over-runs operational?

23

Are secondary safety devices properly secured and anchored?

24

Has the cradle been tied-off to the building to prevent sway?

25

Have checks been made to ensure that the safe working load is not being exceeded?

26

Is the cradle kept clean and clear of rubbish?

27

Have all necessary precautions been taken to ensure that the platform is not slippery?

28

Are all tools carried in the cradle secured?

29

Is there adequate protection from above to stop any falling materials?

30

Are all necessary steps being taken to ensure that the proper access is being used?

31

Is the practice of climbing down ropes strictly prohibited?

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32

Are all personnel aware that there must be no transferring between adjacent cradles?

33

Have all possible steps been taken to ensure that personnel do not allow ropes and cradles or connections to lie in gutters?

34

Are all operatives aware that use in high winds or adverse weather conditions is not safe and is prohibited?

After use Are the cradle and all ropes, in a secure position to prevent unauthorised access or usage?

36

Are checks carried out to ensure that power supplies are isolated and control equipment is removed and secured?

37

Are defects and breakdowns reported promptly and correctly?

38

Are all warning signs removed after the completion of work?

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Safety with Steelwork

1.3.8.1 Key points The majority of jobs that involve erecting steelwork will also involve working at height, and exposure to the associated potential hazards.

2

A schedule of erection should be in place to ensure the safe erection and stability of the structure until it is complete.

3

All steel erection must be the subject of a risk assessment and carried out in accordance with a method statement.

4

Ideally, the erection of steelwork will be carried out in such a way that those doing the job are on a stable working platform at all times, be that a scaffold or a mobile elevating work platform (MEWP). Operatives having to go onto the steelwork should be a last resort.

5

Ground conditions must be suitable to take the weight of MEWPs and their loads.

6

Designers have the potential to ensure that the erection of steelwork can be carried out safely, for example, designing-in lifting eye attachment points, or specifying ground-level fabrication.

7

The erection of steelwork will usually involve extended crane operations, the use of MEWPs in and around the new structure, lorry movements, steel laydown areas and possibly a lorrypark, all of which must be planned for when the site is first set up.

8

All lifting operations, including the use of cranes and MEWPs, must be carried out by, and under the control of, competent persons.

9

The presence of overhead power cables and the possible need to manually align steelwork components for connection are other potential hazards associated with the erection of steelwork.

The majority of fatal accidents are as a result of falls from height. In addition, many serious accidents occur due to workers being struck by falling materials.

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1.3.8.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify the hazards arising out of that work and the persons or groups who might be affected.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazards or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide all employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

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By its very nature, the erection of steelwork will usually involve a degree of working at height.

2

These Regulations require that Contractors: (a)

avoid the need to work at height where it is reasonably practicable to do so

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(b)

where this is not possible use work methods or equipment to prevent falls

(c)

where this is not possible, use work equipment or other measures to minimise the distance or the consequences of falls

(d)

ensure that all work at height is based on a risk assessment and is carried out safely by competent persons

(e)


(f)

ensure that measures are taken to prevent anyone being injured by falling objects

(g)

ensure that adequate emergency arrangements are in place in the event of an incident (rescue).

.

1.3.8.5 Provision and Use of Work Equipment Any work equipment used in the handling or erection of steelwork, such as tirfor winches, wire rope slings, lifting gear, lifting tackle, MEWPs and even hand tools, must comply with these Regulations.

2

They require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

3

The Contractor is also required to provide employees with all necessary information, instruction and training to ensure that they are competent to use any work equipment provided.

4

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and authorised workers only.

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1.3.8.6 Lifting Operations and Lifting Equipment Any lifting activity and the equipment used to carry it out must comply with the requirements of these Regulations. The term lifting equipment not only includes machinery such as cranes but also any device used to connect the machinery to the load, such as eye-bolts, hooks, slings. These are known as lifting accessories.

2

Briefly, these Regulations place legal duties on the Contractor to ensure that: all lifting equipment is stable in use and of adequate strength for the purpose for which it is being used - safe working loads

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(b)

lifting equipment used to lift persons, for example a passenger hoist, is designed for the purpose and is safe to use

(c)

lifting equipment is positioned and

(d)

installed so as to keep the load under full control

(e)

lifting equipment is marked with its safe working load

(f)

lifting activities are properly planned, appropriately supervised and carried out in a safe manner

(g)

lifting equipment (including lifting accessories) is subjected to a scheme of periodic thorough examination for which reports are raised.


Many risks can be eliminated, avoided or reduced by careful attention to design and planning aspects before construction work starts. Any remaining risks can be controlled by the

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effective management of health and safety risks during the construction phase. Both planning and management are key requirements of these Regulations. 2

These regulations place duties on (amongst others) the client, the contractor and designers, and provide a framework for the management of risks, including those inherent in the handling and erection of steelwork.

3

These Regulations require that:

(b)

all parties involved in a project co-operate with each other in the interests of health and safety

(c)

all parties involved in a project coordinate their activities in the interests of health and safety

(d)

only authorised persons are allowed on to site.

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everyone working on a project is competent to do what is required of them

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In addition to the design and general health and safety management issues outlined above, in the context of steel erection, these Regulations cover: the stability of structures

(b)

demolition and dismantling

(c)

the presence of overhead cables (and in some instances, buried services)

(d)

establishing traffic routes

(e)

the safe use of vehicles

(f)

temperature and weather protection

(g)

lighting (if working in reduced level of light)

(h)

are considered to be particularly relevant.

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(a)

Steel erection, by its very definition, involves creating structures, which these Regulations require to be stable at all times. In particular: all practicable steps must be taken to ensure that no person is put at risk by the collapse of any structure which may become unstable or weakened

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1.3.8.8 The stability of structures

(c)

any temporary means of supporting a permanent structure must be:

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structures must not be loaded to an extent that they become unsafe

(i)

designed and maintained to withstand any stresses and strains that are put on it

(ii)

only used for the purpose for which it was designed, installed and maintained

(iii)

not overloaded so as to render it unsafe.

1.3.8.9 Traffic routes and vehicles 1

Prior to and during steel erection, deliveries of steel on articulated lorries will be a feature of many jobs. In the context of this section, these Regulations place a legal duty on the person in charge of the site to ensure: (a)

that pedestrians and vehicles can move safely and without risks to health, so far as is reasonably practicable

(b)

there are sufficient traffic routes, all of which must be suitable for the vehicles using them

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there is sufficient segregation between pedestrians and moving vehicles but where this is not reasonably practicable: (i)

other means of protection are provided, and

(ii)

a means of warning pedestrians of the approach of vehicles, where the pedestrians would otherwise be at risk, is provided

(d)

that (vehicle) loading bays have one exit for the exclusive use of pedestrians

(e)

appropriate signs are erected in the interests of health and safety

(f)

steps are taken to prevent the unintentional movement of any vehicle

(g)

each vehicle must be operated in a safe manner with its load arranged safely

(h)

every vehicle is fitted with means of warning persons who may be at risk when the vehicle is moving.

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1.3.8.10 Manual Handling Operations

These Regulations require that where there is a risk of injury, Contractors must, so far as is practicable, avoid the need for employees to carry out any manual handling operations. Where this is not possible, the Contractor must make an assessment of the work to be carried out and take appropriate steps to reduce the risk of injury to employees.

2

Contractors must provide employees with adequate and suitable training in manual handling, and employees must follow any such information or instructions given and use the safe systems of work that have been put into place by their Contractor.

3

It is anticipated that the amount of manual handling involved in steel erection has been significantly reduced due to the improved standards of design and modem methods of access and working.

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Design and planning considerations Contractors should follow:

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Structural stability

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1.3.8.11 Design and planning

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The structure must be stable at all times from when the first piece of steelwork is put into position until it is completed.

3

Temporary supports, such as bracing, guys or stays, must be used during the erection of any structure which may be unstable or liable to collapse before it is completed. Additionally, where any work is carried out which is likely to adversely affect the foundations or stability of any existing building or structure (or one under construction), all practicable precautions, such as shoring, must be taken.

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Temporary structures 4

Any temporary structure must be of good construction, adequate strength and stability, made of sound materials free from obvious defects and be properly maintained.

1.3.8.12 Safe means of assembly or making connections 1

Assembly of steelwork components or making connections should be planned so that erectors can do as much of the work as possible at ground level.

2

Where erectors have to work at a height, provision must be made for safe means of access to the connecting points and any other working places. Ideally, work will be carried out from

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MEWPs operating on a suitable floor surface. However, where this is not possible, design consideration should be given to: (a)

ensuring there is adequate working space and a suitable work platform for a crane

(b)

connections between steelwork components that are simple to make off-site or ground-level assembly or fabrication to reduce work at height

(c)

the provision of fixed work platforms and ladders

(d)

the provision of anchorage points for safety nets and fall arrest devices.

Steelwork components The size, weight and shape of individual steelwork components will influence safe handling and erecting. The designer should therefore consider the following steps: marking components as an aid to identification (also to prevent costly mistakes)

(b)

optimising the length of structural members in an attempt to reduce the number of connections at height

(c)

calculating the weights of components to assist in the estimation of safe crane capacities and the location of cranes

(d)

identifying the positions where components should be lifted

(e)

indicating centres of gravity where these are not readily evident

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1.3.8.13 Site features

Potentially hazardous features should be identified that will conflict with health and safety.

2

Some typical examples include the following items.

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If there are any overhead power lines near the proposed erection site, the local electricity company should be consulted. Either the power lines should be made dead, temporarily rerouted or other suitable precautions taken to prevent any close approach to, or contact with, live overhead lines

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Overhead electric cables

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Buried services

As well as a visual inspection for marker posts or obvious signs, a check should be made with the owner or occupier of the land and the various utility companies, including electricity, gas, water, telecommunication and cable TV companies.

Other site features which require attention 5

These features include: (a)

lack of space for the handling and storage of steelwork

(b)

restricted (crane) oversailing rights and safety

(c)

restricted area(s) for vehicle movements

(d)

low resistance to ground bearing pressures

(e)

poor access onto the site

(f)

any buildings close to the site that may affect the erection process

(g)

any rights of access that may bring members of the public close to the erection site

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ground contamination from previous use of the land.

Other contractors and their activities 6

Certain activities or processes on, or adjacent to, the site may have the potential to adversely affect the health and safety of workers on site. For example, noxious gases, vapours or dusts may be given off from chimneys, stacks, tank vents and ventilation ducts. These may not cause a problem at ground level but may affect steelwork erectors working at a height.

Managing the safe erection of steelwork Following a detailed risk assessment of the work activity, the next step in ensuring safe work practices in erection is the preparation of a method statement.

8

This important document should detail the proposed erection scheme and should form part of the health and safety plan for the project.

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Method statements

The amount of detail required in a method statement will depend on how big or complex the job is. However, method statements should be written for even small steel erection jobs. It is clear evidence that attention has been given to design and planning aspects, as well as being a plan to ensure that the project is completed without risks to health and safety.

10

A typical method statement should include the following points: details of how the project will be managed and health and safety risks eliminated, avoided or reduced

(b)

information on the site, including any hazardous features, such as overhead electric power lines, and what effect these will have on the project

(c)

details of plant requirements such as cranes, MEWPs and other lifting equipment, and the competencies required to operate them

(d)

arrangements for the safe receipt, offloading, storage and handling of steelwork components on site

(e)

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the sequential method of erecting the structure and how stability will be ensured at all times

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(f)

details on where and how steelwork will be assembled prior to erection

(g)

how activities such as slinging, lifting, unslinging and the initial and final connecting of steelwork components will be carried out safely

(h)

the safety precautions to prevent falls from height. For example, arranging for as much assembling as possible to be done at ground level, minimising the number of connections to be made at a height

(i)

the means of providing safe access and a safe place of work by methods such as mobile towers, temporary platforms and walkways

(j)

details of the means of communication during lifting operations

(k)

any requirement for safety nets, safety harnesses and fall arrester devices (provisions for design features should be specified, for example, attachment points for ladders, safety nets and fall-arrest devices)

(l)

how people will be protected from falling objects. For example, use of screens, fans and debris nets, installation of barriers and warning notices at ground level

(m)

a contingency plan for dealing with any problems that may arise.

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Site access/egress The Contractor should check that all of the vehicles associated with the erection or dismantling of steelwork can access and egress the site safely. It is envisaged that the vehicles will mainly be cranes and delivery lorries (delivering steel and MEWPs).

12

A safe location for lorries to park must be identified and communicated to employees. This area must not be immediately outside the site or on any access road if doing so would create an unacceptable obstruction or other hazards for passing traffic or pedestrians. On larger sites space should be allocated as a dedicated lorry or trailer park.

13

On sites where there is simply not space to park large vehicles, appropriate arrangements, such as a road or lane closure, must be made for delivery lorries (and possibly the mobile crane) to be parked on the public highway adjacent to the site boundary for the off-loading of the steel.

14

Where there is a loading/unloading bay for only a single lorry, a strict schedule of delivery times must be written, communicated to the steel delivery company and adhered to. In this instance it is highly advisable to identify a 'lorry holding area', to which lorries that 'miss their slot' can be sent pending the allocation of another unloading 'slot'.

15

Every effort should be made to avoid the need for vehicles to reverse, particularly out of the site gate and back on to a public road. Where this is not possible, suitable precautions must be taken, for example, the use of one or more signallers or an alternative traffic-control system.

16

Where it is considered unsafe for vehicles and pedestrians to use the same site entrance, one or more separate pedestrian entrances must be provided, clearly indicated and kept free of obstruction.

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1.3.8.14 Housekeeping

Construction sites must, so far as is reasonably practicable, be kept in good order and a reasonable state of cleanliness.

2

Platforms, gangways, floors and other places must not be obstructed by loose materials.

3

Projecting nails or similar sharp objects in timber or other materials must be removed or knocked down to prevent injury.

4

Materials must be stacked safely.

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1.3.8.15 Lighting 1

The following areas must be adequately and suitably lit: (a)

every working place

(b)

access to working places

(c)

where lifting operations are in progress

(d)

all dangerous openings.

1.3.8.16 Protection from falling material 1

At any place where people work, steps must be taken to prevent them from being struck by any falling material or article.

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Scaffold components, tools and other objects must not be thrown or tipped down from a height where they are liable to cause injury, but should be properly lowered.

1.3.8.17 Lifting and slinging Competent people must be used to operate lifting equipment and give signals in line with BS 7121.

2

All critical lifts, including tandem lifts, should be carefully planned and supervised.

3

Reference - BS 7121:2006 Code of Practice for safe use of cranes

4

Appropriate precautions must be taken to ensure the stability of lifting appliances when used on soft, uneven or sloping ground. These could include measures such as ground levelling, use of mats or hard standing.

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A safe means of access and a safe workplace must be provided when off-loading components from delivery lorries. Two examples of recently developed safety systems are: a tensioned steel wire running the length of the lorry trailer, at above head-height of anyone standing on the trailer. Each slinger wears a safety harness and a restraintlanyard, the free end of which is clipped to the tension steel wire. In the event of a trip or stumble, the slinger is prevented from falling from the trailer

(b)

a 'U' shaped inflatable air bag or a 'bean-bag' that fits around the back and sides of the trailer to act as a soft-landing system, should anyone fall off the trailer.

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1.3.8.18 Offloading, stacking and storage of steelwork

Many accidents have occurred during the off-loading of lorries when the load-securing mechanism was released. This is because the load was either not stable when loaded or because it moved and became unstable during the journey.

3

The stability of the load on the lorry, or in the stack, must be ensured at all times. Suitable timber wedges or packing pieces can be used as an aid to stability.

4

Precautions should be taken to prevent slingers being struck by the load. For example, taking up a safe position off the lorry before the load is lifted.

5

The stack must be constructed so that components can be removed without risk of someone being trapped or struck.

6

There may be an advantage in using a suitable transportable storage rack (stillage) for smaller components.

7

Anyone not directly involved in the off-loading activity should not be allowed into the area.

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1.3.8.19 Safe means of access and safe place of work 1

2

To comply with these Regulations, consideration must be given to reducing the need to work at height. The following are a way of doing this: (a)

doing as much of the connecting work at ground level or from erected floor decks, as the work progresses

(b)

use of a releasing device so that lifting gear can be released remotely

(c)

ensuring that, wherever possible, inspection and testing is carried out at low level.

When people must work at height, consideration should be given to the following measures:

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(a)

installing permanent stairways, ladders, walkways and floor decking, so that these can be used by erectors as the work progresses

(b)

providing hard standings or floor slabs so that mobile access platforms can be used

(c)

providing temporary access and working platforms, including scaffolds, lightweight staging, purpose-built platforms with safe means of access

(d)

working from mobile elevating work platforms (MEWPs).

Whilst the increased use of MEWPs has brought about safer working at height, it has also created the need to ensure that: (a)

MEWP operators are adequately trained and competent

(b)

ground conditions on the site are properly surveyed and prepared to enable the safe use of such heavy plant without risk of sinking or overturning.

Traditionally, scaffolding was the main form of edge protection, which could only be installed, modified or removed by trained scaffolders, after the steelwork was in place. However, the development of various types of 'system edge protection' has provided opportunities for preinstalling edge protection before work at height commences. The use of such systems can also eliminate the need for successive trades to install their own edge protection and then remove it when leaving site, only for it to be replaced by the next trade's edge protection. The elimination of such duplication has obvious safety benefits.

5

It may be appropriate in some circumstances to use other means of access to height, such as the use of roped access techniques, which must be carried out by trained and competent persons, alternatively, access may be achieved by using a 'man-riding' basket suspended from a crane.

6

There may be occasions when it is necessary to use fall arrest rather than fall prevention measures, with safety nets or other soft landing systems being the preferred method of fall arrest.

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1.3.8.20 Beam 'straddling'

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There may be occasions where the work cannot be done from a MEWP or other platform and erectors may have to work from the steel. This is known as beam 'straddling'. This form of access is only permissible for specific short-duration jobs where the beam is of I beam section.

2

A full body harness with a twin-tailed lanyard system may be used. However users must ensure that this system is used correctly and that the second leg is not attached to the user's harness as this may interfere with the operation of the energy absorber.

3

The erector can sit astride the flange with the sole and heel of each foot resting on the bottom flange and both hands able to grasp either side of the top flange.

4

Alternatively, proprietary 'beam gliding' devices are available to improve ease of mobility.

5

The risk assessment must consider how anyone carrying out this practice is going to be rescued following a fall.

6

The use of a safety harness or lanyard requires a minimum clearance below the high-level place of work to allow the lanyard to function properly in arresting a fall. Expert advice should be sought.

7

The safe system of work must also ensure the operative's safety:

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(a)

whilst getting up to the place of work and down again

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during the period of time at high level before the operative is able to 'clip on'.

If access has to be made inside a structural' steel box section, or any configuration of steelwork where ventilation is poor, it should be treated as a confined space and appropriate precautions taken. The atmosphere should be tested by a competent person, before entry is made, to ensure that there is sufficient oxygen present. Continuous monitoring for oxygen deficiency is strongly recommended. Tests for flammable or toxic gases or vapours and oxygen enrichment should be carried out as appropriate, depending on the proposed work activity. For example, oxy-propane cutting or burning may lead to a build up of toxic gases or toxic metal fumes, or there may be a leakage of propane or oxygen.

1.3.8.21 The weather A regular weather forecast should be obtained by the manager in charge of the erection programme. Erection should not take place where weather conditions impose an adverse effect, such as: wind strengths

(b)

rain or dew

(c)

poor visibility (fog, mist or glare)

(d)

Sand storms.

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If erection work is stopped, measures should be taken to ensure that the structure remains stable.

3

After a stoppage due to the weather, stability of the structure should be checked before work is allowed to restart.

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Construction Site Safety 1.3.8 Appendix Safety checklist: steelwork Is the contractor responsible for erection competent?

2

Has a risk assessment been undertaken for the project?

3

Does the contractor have a method statement?

4

Does it specify the sequence of erection and how the structure will be kept stable at all times?

5

What types of temporary support will be used?

6

Does everyone know the requirements for safe erection?

7

How will the structure components be erected and connected safely?

8

Will as many connections as possible be done at ground level?

9

Where work must be done at height, have safe means of access and safe places of work been planned?

10

Has the site been surveyed for hazardous features such as overhead power lines?

11

Is there sufficient access for off-loading lorries?

12

Is there a planned delivery sequence of components?

13

Are there plans to deal with lorries that have to reverse?

14

How will components be offloaded, stacked and de-stacked safely?

15

Are the weights of individual components known?

16

Does all lifting gear that is to be used have adequate safe working loads?

17

Have crane capacities been calculated?

18

Have steps been taken to eliminate the need for manual handling?

19

Are the steel erectors competent? Have they been adequately trained?

20

Will all lifts be supervised by a competent person?

21

If MEWPs are to be used, are all the operators trained and competent?

22

Is it necessary to survey and prepare the ground so that MEWPs can operate safely?

23

Will work at height be carried out other than from a MEWP?

24

What measures will be taken to prevent or arrest falls?

25

Are emergency rescue procedures in place?

26

Have any special risks been identified, for example, work in confined spaces?

27

Is there a plan to monitor the weather?

28

Is there a contingency plan?

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Roofing and Fragile Surface Practices

1.3.9.1 Roof work and fragile surfaces The main causes of accidents are falling off the edges of roofs and falling through holes, roof lights and other fragile surfaces.

2

Compliance with well-established safety procedures could save lives and prevent injuries. All roof work requires a risk assessment and, if the work is extensive, a method statement that sets out a safe system of work. Most accidents could be avoided if the most suitable equipment was used and those carrying out the work were given adequate information, instruction, training and supervision.

3

If work is going to be done on any roof, the Contractor is to make sure there is:

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safe access onto the roof, e.g. a general access scaffold, tower scaffold (preferably of the stairway design) or mobile access equipment etc

(b)

a safe means of moving across the roof, e.g. using proprietary staging or purposemade roof ladders.

(c)

a means of preventing falls when working on the roof, e.g. edge protection consisting of guard rails and toe boards, a proprietary access system or a MEWP.

(d)

measures to prevent falls through fragile materials (e.g. barriers or covers) and mitigate the consequences should a fall occur (e.g. nets).

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(a)

Independent scaffolds that provide safe access onto the roof, a safe working platform and the capacity for material storage (always check with the scaffold designer before stacking material at roof level) are the ideal solution.

5

However, it is not always possible to use a general access scaffold. In these circumstances, for a sloping roof, edge protection erected at eaves level, with or without a scaffold platform, or for a flat roof, edge protection erected around the edges provides an alternative fall prevention measure. Figure 23 shows some of the options for sloping-roof edge protection and Figure 24 shows examples of flat-roof edge protection.

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Figure 23 - Typical sloping-roof edge protection


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Figure 24 - Example of flat-roof edge protection

6

Irrespective of the type of edge protection used, safe access onto the roof and a safe way of lifting materials up to roof level must be provided and maintained.

7

Alternatively, mobile elevating work platforms or proprietary access systems (see Figure 25 ), which are easy to transport from site to site and quick to erect, provide good access and should be considered as an alternative to fixed edge protection. Figure 25 - Proprietary access system for roof-work


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On sloping roofs, roof workers should not work directly on the tiles or slates. Roof ladders and proprietary staging should be used to enable safe passage across a roof. They must be designed for the purpose, of good construction, properly supported and if used on a sloping roof, securely fixed by means of a ridge hook placed over the ridge. They should be used in addition to eaves-level edge protection and if the work requires access with 2 m of the gable ends, edge protection will be needed there as well.

9

Short-duration work means tasks that are measured in MINUTES rather than hours. It includes such jobs as inspection, replacing a few tiles or adjusting a television aerial. Work on a roof is still dangerous even if it only lasts a short time and appropriate safety measures are essential.

10

For short-duration work it may not be reasonably practicable to provide full edge protection, but you will need to provide something in its place. The minimum requirements for shortduration work on a roof are:

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8

a safe means of access to roof level; and

(b)

a safe means of working on the roof (e.g. on a sloping roof, a properly constructed roof ladder, or on a flat roof, a harness attached to a secure anchorage and fitted with as short a lanyard as possible).

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(a)

Many roof assemblies are, or can become, fragile. Asbestos cement, fibreglass and plastic generally become more fragile with age. Steel sheets may rust. Sheets on poorly repaired roofs might not be properly supported by the purlins. Any of these materials could give way without warning. Do not trust any sheeted roof. Do not stand directly on any sheeted roof.

12

On fragile roofs, the work has to be carefully planned to prevent falls through the roof. All work should be carried out from beneath where practicable. Where this is not possible, consider using a mobile elevating work platform (MEWP), which allows the operatives to carry out the work from within the MEWP basket without standing on the roof itself (see Figure 26 ). NEVER try to walk along the line of the roof bolts above the purlins, or along the roof ridge, as the sheets can still crack and give way. The sheets are not designed to support your weight and you should therefore approach the roof as if the sheets were not in position.

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Figure 26 - A mobile elevating work platform being used to replace a roof sheet


Page 149

If access onto a fragile roof cannot be avoided, edge protection should be installed around the perimeter of the roof and staging should be used to spread the load. Unless all the work and access is on stagings or platforms that are fitted with guard rails, safety nets should be installed under the roof or a harness system should be used (see Figure 27 ).

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Figure 27- Workmen wearing harnesses attached to a work positioning line, which is fitted to the staging

14

Roof openings and fragile roof lights are a particular hazard. Some roof lights are difficult to see in certain light conditions and others may be hidden by paint. Protection from falling through openings and fragile roof lights must be provided using either barriers or covers that

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Page 150

are secured or labelled with a warning. If the work is the replacement of roof lights, nets slung close beneath the roof lights, or a harness attached to a work positioning line which is fixed to the staging, provides protection should a fall occur. 15

Do not throw materials such as old slates, tiles etc from the roof or scaffold - someone may be passing by.

16

Refer to Section 11 – Part 2 (SAMAS) – 2.2 (2.2.9)

1.3.9.2 Industrial roof work Industrial roof work involves all the hazards already mentioned and in addition, falls from the 'leading edge' also need to be prevented. Leading edges are created as new roof sheets are laid or old ones are removed. Fragile and lightweight materials, such as liner trays which will buckle and give way under the weight of a person, can also be a problem and should be protected.

2

Work at the leading edge requires careful planning to develop a safe system of work, including measures to mitigate the distance and consequences of a fall. Work platforms or staging used in conjunction with nets is the preferred method, as nets provide protection to everyone on the roof. Nets should only be installed by trained and competent net riggers.

3

If this is not practicable, work platforms or staging (fitted with guard rails and toe boards) in advance of the leading edge can provide protection in some circumstances. However, these will need to be used in conjunction with harnesses attached to a work positioning line which is fixed to the work platform. If a harness is used, you must ensure that workers can attach themselves to the anchorage without putting themselves at risk of a fall. Using the harness in work-restraint mode is the preferred option, as this does not allow the operative to approach the leading edge and enter into a fall position. Close supervision of this system of work will be required as it is difficult for harnesses to remain clipped on at all times throughout the work activity.

4

When developing a safe system of work the Contractor needs to consider the following: how the first sheets will be laid - a separate platform may be required (a pack of roof sheets is not a safe working platform) - and how hip ends and other special details are to be fitted.

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how sheets will be raised to roof level - decide what type of lifting machinery, such as a crane or an inclined hoist, will be the preferred method. This will eliminate unnecessary risks when placing packs of sheets on the roof supports or when breaking open packs spread over the roof supports.

1.3.9.3 Roof truss installation 1

When installing roof trusses, their placement and associated bracing is a hazardous activity, which requires careful planning to ensure a safe system of access and protection against falls is implemented. You must provide a safe working platform around the perimeter of the roof together with measures to mitigate the distance and consequences of a fall should one occur. This can be achieved by providing a working platform or 'crash deck' immediately beneath the bottom members of trusses. Either conventional scaffolding or (if appropriate) proprietary plastic decking systems can be used for this. Alternatively, nets can be used providing a safe clearance distance can be achieved below the net and a suitable fixing point is available. Providing nets or soft landing systems is particularly important when installing temporary bracing or before boarding out along the bottom chord of the trusses, where access within them is required.

END OF DOCUMENT

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1

Section 11: Health and Safety Page 1 Part 1.04: Safe Use of Plant Equipment (Regulatory Document)

REGULATORY DOCUMENT ............................................................................... 1

1.4 SAFE USE OF PLANT EQUIPMENT ................................................................... 1 Abrasive Wheels .............................................................................................. 4

1.4.2

Portable Fixing Tools ..................................................................................... 16

1.4.3

Lifting Operations, Equipment and Accessories ............................................ 29

1.4.4

Mobile Elevating Work Platforms ................................................................... 69

1.4.5

Hoists and Hoist Towers ................................................................................ 86

1.4.6

Plant and Work Equipment .......................................................................... 100

1.4.7

Woodworking Machines ............................................................................... 120

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1.4.1

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FORWARD

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Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12


10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

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4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

4&5

1.6

Temporary Fencing

14

6

7

Asphalt Plants

15

7.8.13

Safety Requirements

15

6

14


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety


6

8.1.9

Safety


7

9.2.5

Safety Requirements


4,5&6

10.1.7

Safety Requirements

11


9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

8

8

18

8

9

19

8

10

20

8

21

9

42

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Item Name

4.9.1.13 Protection of Testing Equipment

22

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37 & 38

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Page No. Item No.

9

1

General

19

1.2.16


23

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Abrasive Wheels

1.4.1.1 Key Points Abrasive wheel machines of all types have the potential to cause severe injury if they are not used with care.

2

Anyone who uses an abrasive wheel machine must be trained and competent to do so.

3

The potential for danger arises not so much from the machine itself but from the grinding wheel or cutting-off disc used with the machine.

4

Many accidents are caused by the abrasive wheel being rotated faster than it was designed to go, which results in it breaking up ('bursting') at high speed.

5

It is essential to check the compatibility of the abrasive wheel or cutting-off disc with the machine to which it is about to be fitted.

6

The fitting of any abrasive wheel or cutting-off disc to a machine ('mounting') must only be

7

Carried out by someone who is trained and competent to do so.

8

The person who is trained and competent to mount abrasive wheels or cutting-off discs need not be the same person who is competent to operate the machines.

9

Using an abrasive wheel machine has the potential to cause occupational health problems and usually the wearing of appropriate PPE will be required.

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Abrasive wheels are potentially dangerous if not used correctly. Most accidents result from selecting the wrong type of wheel or from over-speeding. It is essential that the right abrasive wheel for the job is chosen; that it is correctly mounted by a competent person; that it is run at the correct speed and that guards and eye protection are used.

2

In most circumstances abrasive wheels rotate at very high speeds and contact with the revolving wheel can cause serious injury. When using a grinding wheel, a stream of hot abrasive particles is thrown off, which can cause injury, particularly to the eyes. Finally, there is always a risk of the wheel disintegrating or 'bursting' as it revolves. Fragments of the wheel can be projected a great distance, at high velocity, in every direction.

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1.4.1.3 Types of abrasive wheel An abrasive wheel is generally defined as a wheel, cylinder, disc or point having abrasive particles, and intended to be power driven. It may consist entirely of abrasive particles, or be of metal, wood, cloth, felt, rubber or paper, with a surface covered with abrasive material. It may also be formed of a ring or segments of abrasive materials. These types of abrasive wheels are used for shaping material via grinding operations.

2

Other types of abrasive wheel are those used for cutting rather than grinding operations. These are circular metal blades, usually with diamond impregnated tips, used for cutting through concrete, steel, etc.

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These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractors duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as it is reasonably practicable to do so.

3

The Contractor must provide employees with: (a)

comprehensible and relevant information on any risks that exist out of the work activity

QCS 2014

Section 11: Health and Safety Page 5 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) and of any control measures that are in place to reduce those risks

(b) 4

adequate training to enable employees to work safely.

The employee, in turn, has a duty under these Regulations to tell their Contractor of any work situation which presents a risk to their health and safety or to the health and safety of any other person who may be affected.

1.4.1.5 Personal Protective Equipment high-impact eye protection (possibly a full-face visor) to BS EN 166

(b)

hearing protection

(c)

possibly hand/forearm protection, depending upon the material that is being cut

(d)

possibly respiratory protection,

(e)

depending upon what is being cut and whether the machine is fitted with a particle collection/extraction system.

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Where risks to health and safety cannot be adequately controlled by other means, Contractors must: (a)


(b)


(c)

provide the users of the PPE with adequate instruction and training with regard to:

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PPE will include some or all of:

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(i) the risks that the PPE will protect against

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(ii) the purpose for which it has been issued and the manner in which it is to be used (iii) maintaining the PPE in good working order. The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

4

Employees for their part must: use any PPE that has been issued as instructed and in accordance with any training received

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1.4.1.6 Control of Vibration 1

The use of most types of abrasive wheel machine will involve the user either holding the material to be worked or the machine itself whilst the work activity is carried out. This has the potential of subjecting the person doing the job to hand/arm vibration.

2

These Regulations place various requirements on Contractors including: (a)

establishing if there is a risk from exposure to vibration

(b)

eliminating the risk at source or reducing it to as low as is reasonably practicable

(c)

implementing appropriate control measures if the exposure action value is reached

(d)

taking appropriate actions if the exposure limit value is reached

(e)

providing health surveillance to any employee when the risk assessment indicates that there is a risk to health

(f)

providing at-risk employees with adequate information, instruction and training.

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1.4.1.7 Choosing the correct wheel 1

BS 4481 Part 2:1983 includes a system of marking for abrasive wheels, which has been adopted by the UK Abrasives Industries Federation. This specifies the type and nature of the abrasive, grain size, grade and structure, as well as the nature of the bond.

2

Many types and grades of abrasive wheel are available, and the correct selection is important. As a general rule, soft grade wheels are most suitable for use on hard materials, and hard grade wheels on soft materials. Coarse grains are for the rapid removal of material, and fine grains for polishing.

3

The two common British markings in this class are: (a)

A.30.R.BF Suitable for general use on ferrous metals.

(b)

C.24.R.BF Suitable for general use on stone, brickwork, concrete, plastic and nonferrous metals.

The use of an unsuitable wheel may result in the wheel face becoming loaded as the pores are clogged by the material being removed. If the wheel is too hard or too fine it may become glazed or polished. The consequence, in both cases, may be that the operative will press too hard, in an attempt to get the work done, and cause the wheel to break.

5

It is important that only reinforced resin-bonded abrasive wheels should be used with portable grinding machines.

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British Standard system for the marking of abrasive wheels (BS 4481)

* Optional symbols The symbols 0 and 6 are the manufacturer's own

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1.4.1.8 Wheels 'bursting' 1

The two main causes of abrasive wheels bursting are: (a)

over-speeding

(b)

the incorrect mounting of wheels.

1.4.1.9 Over-speeding Abrasive wheels must not be run in excess of the maximum permissible speed recommended by the manufacturer. This should be clearly marked in rpm on all wheels over 55 mm in diameter.

2

For smaller wheels, a notice stating the maximum speed permissible should be displayed on or adjacent to where the machine is being operated. Any type of record may be kept, from computer database to a written record. The only restrictions are that a hard copy of the information must be available on request.

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1.4.1.10 Speed of spindle

Every power-driven machine for use with abrasive wheels should have a notice fixed to it, specifying the maximum and minimum spindle speeds.

2

Machines that are not marked with their spindle speed must not be used.

3

Sometimes these markings are very small. If this is the case, consideration should be given to painting or engraving the spindle speed clearly on the machine.

4

Always keep the markings clean and in good condition so that they are easy to read.

5

Care must be taken to see that the maximum speeds are never exceeded. Governors, or other devices to control or limit speed, must be properly maintained and in good working order.

6

The speeds of wheels may be checked using stroboscopic timing lights.

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1.4.1.11 Peripheral speeds

As an abrasive wheel wears down, its peripheral speed is reduced and this, in turn, reduces its efficiency.

2

A wheel operated at too low a speed will not cut properly and there will be a tendency to press the workpiece hard against the wheel. This may damage the wheel and cause it to burst.

3

Care must be taken to operate the wheel at the optimum speed recommended by the manufacturer.

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1.4.1.12 Mounting of wheels 1

In order to be able to demonstrate compliance with legislation, abrasive wheels should only be mounted by a trained and competent person appointed to this duty by the Contractor.

1.4.1.13 Maintenance 1

In addition to checks immediately before and after each use, every machine should be regularly and frequently serviced by a competent person in accordance with the

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manufacturer's instructions. A record of this maintenance should be kept. 2

It is good practice to record the type and serial number of all abrasive wheel machines in a maintenance log, together with the date each machine is due for service. When servicing has been carried out, ensure that details of any work done are entered in the log, together with the date that the next service is due.

3

All records should be kept up to date.

1.4.1.14 Appointment of a competent person It is strongly recommended that each appointment to mount abrasive wheels is recorded as a signed, dated entry in a register or by a certificate attached to that register. Records may be kept in an electronic format, providing a hard copy can be printed on request. Particulars of the class and description of the abrasive wheels for which the person is competent should be stated. A copy of the entry (or certificate) should be given to the person appointed.

2

Note: The suggested layout for a Register of Appointment is attached at Appendix 1. A copy of a suggested Certificate of Appointment is attached as Appendix 2.

3

A Contractor may revoke the appointment at any time, with a signed and dated entry in the register.

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1.4.1.15 Training

Training for the mounting of abrasive wheels must only be given by a competent person, which often involves attending an external course. It must cover the grades, types and marking of wheels; the use, hazards, speeds, storage, handling, inspection, testing, dressing, adjustments; and the functions of associated components such as flanges, blotters, bushes and locking nuts.

2

Employees who are being trained in the use of abrasive wheels must be provided with appropriate information, instruction and supervision.

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1.4.1.16 Mounting the wheel

The following procedure should be followed when mounting an abrasive wheel:

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Procedure

(a)

ensure the power to the tool is 'OFF'

(b)

clean the abrasive wheel with a brush and check for any signs of damage. In no circumstances should a damaged wheel be used

(c)

check that the spindle bearing is not worn

(d)

check that the maximum wheel speed is greater than the maximum spindle speed

(e)

check that the wheel fits easily and snugly onto the spindle. The correct brushes should be used if required

(f)

check that straight-sided wheels are mounted between the flanges, with a diameter of not less than one-third that of the wheel. The flanges should be recessed on the side which is next to the wheel, to ensure that the clamping pressure is not exerted near to the hole

(g)

ensure that the driving flange is secured to the spindle


(h)

check that washers or blotters of paper, or other compressible material, are fitted one either side (one only on a wheel with a depressed centre). Blotters ensure that the clamping pressure is distributed evenly over the wheel, and will reduce wear on the flanges

(i)

when tightening the nut on the spindle, use the correct size of spanner. Use hand pressure only. This will ensure that the flanges drive the wheel and prevent slip

(j)

use only the correct locking nuts.

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1.4.1.17 Diamond blades

As with bonded abrasive wheels, people working with diamond blades must be properly trained and competent. Most of the safe procedures and precautions for using bonded abrasive wheels on hand-held machines apply to diamond blades. Additional advice and information can be obtained from the suppliers and manufacturers.

2

Diamond blades are directional and must be mounted so that they rotate in the direction marked on the blade.

3

Diamond blades can be used on hand-held machines at peripheral speeds of up to 100 m/s, provided that the machine is designed for this speed and the marked maximum permissible operating speed of the blade is not exceeded.

4

Under no circumstances must the blade be allowed to overheat.

5

Periodically, it may be necessary to redress the blade by making cuts in a special dressing block or abrasive block.

6

These wheels can last a comparatively long time. Before use and with the power disconnected, make a special point of checking the condition of the spindle bearings as these can deteriorate considerably during the lifetime of a diamond-cutting wheel.

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1.4.1.18 In-use considerations Guards - fixed and hand-held machines 1

The guard should be so designed, and sufficiently robust, to contain any fragments in the event of the wheel bursting.

2

The guard must be securely attached to the body of the machine, properly adjusted and maintained.

3

The guard or shield supplied by the manufacturer must be adjusted to permit exposure of the minimum amount of wheel or disk to enable the job to be carried out. It must not be left off or altered in any way.

Employees are required to report any defects in work equipment, including abrasive wheels, guards or tool rests, to their Contractor.

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Defects

Rests should be secured and adjusted so that they are as close as practicable to the wheel, i.e. no more than 3 mm away. If the gap between the wheel and the rest is too great, the workpiece may become trapped and an accident may result.

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Tool rests

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It is good practice to continue to display cautionary notices concerning the dangers of abrasive wheels, wherever abrasive wheels are used or changed.

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Notices

1.4.1.19 Health considerations Protection of eyes 1

During cutting or grinding processes, a stream of dust or abrasive particles and hot sparks is thrown off. These can cause serious injury to the eyes.

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2


Because there is an obvious risk of eye injuries when an abrasive wheel is being used, eye protection should be provided in accordance with either goggles or a face shield or visor, to BS EN 166.

Respiratory protection 3

Depending upon what material is being cut, it is possible that the user of an abrasive wheel may be vulnerable to inhaling hazardous dust. With fixed machinery such as bench grinders or fixed concrete saws, it may be possible to reduce airborne dust to a safe level by such measures as: (a)

4

installing a fixed local exhaust ventilation system, for example in workshops

This would also serve as a useful reminder to employees of the training they have received. purchasing abrasive wheel machines which incorporate a facility for wet cutting or the attachment of a stand-alone dust extraction/collection unit

If such dust suppression measures are not practical, it will be for the Contractor, or the person to whom the responsibility is delegated, to assess the hazardous nature of the dust and provide suitable respiratory protective equipment (RPE), consulting a supplier of PPE if necessary to establish what is needed

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(a)

The very nature of carrying out grinding or cutting activities using abrasive wheels is likely to subject the person doing the job to a degree of hand-arm vibration. In extreme cases, handarm vibration can lead to permanent and disabling injuries. Contractors must assess the risk to employees who carry out such work and put preventative and protective measures in place to ensure that the health of employees who carry out this type of work is not adversely affected.

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Vibration

Grinding and cutting operations using abrasive wheel machines will inevitably result in an increased level of noise, both from the machine itself, for example a petrol-driven disc-cutter, and from contact between the cutting disc or grinding wheel and the material being worked upon. In many cases the level of noise generated will exceed the lower exposure action value, meaning that unless other control measures can be put in place, personal hearing protection must be made available and worn. Depending upon the level of noise and the proximity of other people, it may be necessary for them also to wear the hearing protection.

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Noise

1.4.1.20 Other safety considerations 1

The machine must have an efficient starting and stopping device that is easily accessible and which can be readily operated.

2

The floor area of the workplace must be kept in good condition, free of loose material, and should not be slippery.

3

Abrasive wheels should be properly stored, flat and preferably in their boxes and in accordance with the manufacturer's guidance. Care must be taken to see that any labels are retained, and not soiled or defaced so as to make them illegible.

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Construction Site Safety 1.4.1 Appendix 1 Specimen Sheet for a Register of Appointment Appointment of persons to mount abrasive wheels

Revocation

Date of revocation of appointment

.

Signature of occupier or his agent

Signature of occupier or his agent

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Class or Date of description of appointment abrasive wheels for which appointment is made

(2)

(3)

(4)

(5)

(6)

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(1)

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Name of person appointed

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Appointment

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Construction Site Safety 1.4.1 Appendix 2 Abrasive Wheels Certificate of Appointment to mount abrasive wheels Name Is hereby appointed to mount the following classes or descriptions of abrasive wheels _________________________________________________________________________________

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_________________________________________________________________________________

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_________________________________________________________________________________ _________________________________________________________________________________

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Signature of occupier or occupier's agent:

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The above is hereby revoked

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Date .............................................

Signature of occupier or occupier's agent:

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Date .............................................

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Construction Site Safety 1.4.1 Appendix 3 Abrasive wheels Safety checklist Who is responsible for the selection and the supervision of equipment using abrasive wheels; are they competent?

2

Have operatives received suitable instruction and training in the use of abrasive wheels equipment, and are they competent to use it?

3

Are the manufacturer's recommendations and company rules relating to the control and use of abrasive wheels being observed?

4

Are safety signs and notices displayed where cutting or grinding operations take place?

5

Are the abrasive wheels that are being used suitable for the type of work being carried out?

6

Have all abrasive wheels been mounted by a competent person?

7

Was the competent person appointed by the Contractor in writing, and has an entry been made in an appropriate register?

8

What types and classes of abrasive wheel or disc is the appointed person entitled to fit and mount?

9

Have two blotters been supplied with all flat wheels and discs? (Some wheels may not require blotters, therefore refer to the manufacturer's guidance for the specific wheel to be mounted.)

10

Are wheels of more than 55 mm in diameter marked with the maximum rotational speeds in rpm?

11

Are smaller wheels accompanied by details of their maximum rotational speed?

12

Is the maximum permissible spindle speed clearly marked on the machines in rpm?

13

Are checks made to ensure that abrasive wheels are not operated in excess of the maximum permissible speeds?

14

Are the correct flanges being used?

15

Is the guard fitted compatible with the machine?

16

Is the guard of the correct size, and not been exchanged or altered?

17

Are only reinforced discs used on portable hand-held machines?

18

Are the correct locking nuts used?

19

Are grinding machines complete with guards of the correct size and with tool rests?

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20 21

Angle grinder with cutting disc and adjustable guard and depth gauge

22

Are guards and tool rests correctly adjusted and secured?

23

Are machines properly maintained?

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Is local exhaust ventilation required and, if so, is it available?

25

Are other dust suppression measures necessary and, if so, have they been taken?

26

What facilities exist to have the spindle or wheel speed checked?

27

Has BS EN 166 eye and other necessary PPE protection been provided for the operator?

28

Is the PPE properly used?

29

Is RPE necessary and, if so, is it provided and used?

30

Have precautions been taken to safeguard other persons who may be affected by grinding operations?

31

What precautions are taken to ensure that the floor area is free from loose materials and maintained in a safe condition without risk?

32

Are the storage facilities for abrasive wheels and machines adequate?

33

To whom should operatives report defects?

34

Are all defects reported to the proper person?

35

What action is taken when defects are reported?

36

Has the problem of noise been considered?

37

Is a noise assessment necessary?

38

Are persons who are being trained, properly supervised?

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Portable Fixing Tools

1.4.2.1 Key points Portable fixing tools are used to drive fixing devices into a base material using either cartridges or a gas canister providing the propellant.

2

They can be extremely dangerous if used incorrectly. Operatives must be trained and competent and be of a sufficiently mature and responsible disposition.

3

Poor technique, or the use of incorrect equipment, will result in poor or defective fixing.

4

The tool, type of cartridge or fuel cell, type of fixing and the base material must all be compatible.

5

In most cases, items of additional PPE, in addition to helmet, boots and hi-viz, will have to be worn.

6

At the end of the job all unused cartridges must be accounted for.

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Portable fixing tools use the power of an explosive charge or a gas propellant to drive a fixing device into position. They are particularly useful if there is a large number of repetitive fixings to be made, where a portable fixing tool reduces the time and labour expended in this area. However, the resemblance of the tools to the shape and action of a gun can lead to their misuse, especially by young and inexperienced workers.

2

It should always be remembered that portable fixing tools are potentially lethal if they are used recklessly or incompetently.

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1.4.2.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractors duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3


4

These Regulations also require that the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risk to their health.

5

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any others who may be affected.

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1.4.2.4 The Provision and Use of Work Equipment These Regulations require that the Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

2


3

These Regulations require that where the use of any equipment involves a specific risk to the health and safety of employees, use must be restricted to competent and specified workers. This is of particular relevance to the user of portable fixing tools.

4


5

Proper training (which is offered by all tool manufacturers) and continual care in their issue and use is therefore essential.

6

Before portable fixing tools can be used, a risk assessment must be carried out.

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1.4.2.5 The Control of Vibration at Work

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The use of any percussive tool, such as one repeatedly operated by firing a cartridge or fuel cell, has the potential to subject the person doing the job to hand/arm vibration.

2

These Regulations place various requirements on Contractors including:

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establishing if there is a risk from exposure to vibration

(b)

eliminating the risk at source or reducing it to be as low as is reasonably practicable

(c)

implementing appropriate control measures if the exposure action value is reached

(d)

taking appropriate actions if the exposure limit value is reached

(e)

providing health surveillance to any employee when the risk assessment indicates that there is a risk to health

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(a)

providing at-risk employees with adequate information, instruction and training.

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2

PPE will be needed including: (a)

high-impact eye protection (possibly a full-face visor) to BS EN 166-B

(b)

hearing protection.

Where risks to health and safety cannot be adequately controlled by other means, Contractors must: (a)


(b)


(c)

provide the users of the PPE with adequate instruction and training with regard to: (i)

the risks that the PPE will protect against

(ii)

the purpose for which it has been issued and the manner in which it is to be used

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Section 11: Health and Safety Page 18 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) (iii)

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The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

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maintaining the PPE in good working order.

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4


Employees for their part must: (a)

use any PPE that has been issued as instructed and in accordance with any training received

(b)


(c)


1.4.2.7 The safe use of cartridge-operated tools

adequate information, instruction, training and supervision

(b)

competent and responsible users

(c)

the compatibility of the base material, the type of fixing and the cartridge strength

(d)

restricting access to the work area during fixing activities

(e)

the provision and use of appropriate PPE

(f)

carrying out activities in accordance with BS 4078-1, Code of practice for safe use

(g)

using cartridge-operated tools that comply with BS 4078-2.

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(a)

Note: Cartridge tools must not be used in areas where a flammable atmosphere or risk of dust explosion may exist.

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A cartridge-operated tool works by using a firing cap or cartridge to provide propellant to drive a fixing home. The primary factors which will ensure the proper and safe use of cartridge tools are:

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Don't 'fool about' with cartridge-operated tools

1.4.2.8 Types of tool 3

There are two main types of cartridge-operated tool. (a)

Indirect-acting. The driving force is transmitted to the fixing by means of the expanding explosive gas acting on a piston.

(b)

Direct-acting. The explosive force of the cartridge acts directly on the fixing, driving it along the barrel into the wall or material.

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1.4.2.9 Power level of tools Cartridge tools are generally classed as high power and low power.

2

Low power is defined as giving the pin a kinetic energy not greater than 3.5 m/kg/f and a velocity not greater than 98.5 m per sec.

3

High power applies to any values greater than those above. Using high power tools can result in dangerous through-shoots. This is where the fixing is fired right through the material.

4

Most of the commonly available tools are low power and indirect-acting. These are by far the safest. There are high power tools for special applications, and some old high power (directacting) tools are still in use.

5

Hammer-activated tools are nearly always low power.

6

Some modern tools have provision for varying the power level (within the low power range) by means of an adjustment which changes the size of the gas expansion chamber. There are also interchangeable pistons for different fixings or depths of penetration. Tools incorporating these features require a smaller range of cartridges.

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1.4.2.10 Safety devices

All tools should incorporate a contact pressure safety device, which prevents them being fired unless the muzzle is pressed hard against the workface. They should always incorporate a drop-firing safety device which prevents the tool from firing when it is dropped onto a hard surface.

2

In addition, some tools are equipped with an unintentional firing safety device. This prevents the tool from firing if the trigger is pulled before the tool is pressed against the work surface.

3

It should only be possible to fire the tool when it is correctly pressed against the work surface.

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1.4.2.11 Cartridges

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Cartridges are designed for specific brands or types of tool and are not interchangeable, even if they are of a similar type or appearance.

2

Cartridges are available in different strengths. It is preferable to start with a lower strength cartridge for a test fixing and then change to a more powerful cartridge if the depth of penetration is not sufficient.

3

BS 4078 requires the strength of the cartridges to be marked on the packaging and each cartridge to be colour-coded to indicate its strength.

4

The colour codes set out in BS 4078 are as follows:

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Cartridge strength Extra Low (XL) Low (L) Low/Medium (LM) Medium (M) Medium/High (MH) High (H) Extra High (XH)

Colour Brown Green Yellow Blue Red White Black

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5

It should be noted that the code is not universally followed, and that colour-coding alone must never be relied on as an indicator of the cartridge strength. Cartridges should be retained in the packaging (which identifies their strength) and not carried loose. Both cartridges and fixing nails are now available on plastic strips.

6

Proper controls must be put in place to account for all dispensed and unused cartridges.

7

Unused, or unserviceable cartridges which cannot be fired, are hazardous and in no circumstances should be exposed to fire or heat or be subject to mechanical impact.

8

The supplier should be contacted to discuss suitable arrangements for the return/disposal of any unused or unserviceable cartridges. Cartridges should be returned to their original packaging so that they can be properly identified.

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1.4.2.12 Fixings

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Fixings are generally either drive nails, eyelet nails or threaded studs. Designed to penetrate wood, steel and concrete, they have special characteristics of strength, hardness, shape and size which make them suitable for the purpose to which they are to be put. Ordinary nails and screws must never be used as substitutes.

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Attempting to fix into unsuitable materials with cartridge tools is dangerous. Before firing the first fixing, a simple test should be made by driving a fixing of the intended type into the base material with a hammer. The result will show whether the material is suitable. No attempt should be made to fix into unsuitable materials. The table below provides general guidance.

Conclusion

Plaster, plywood, lightweight blocks

Sinks in easily

Too soft

Marble, some rock, hardened steel, weld metal

Fixing blunted

Too hard

Glass, glazed tiles, slates, some cast-iron

Material cracks or shatters

Too brittle

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1.4.2.13 Suitability of base materials

Sound wood, concrete, Clear impression of mild steel fastener point

Suitable

1.4.2.14 Hazards in use 1

Hazards from the use of cartridge tools generally arise from one or more of the following three factors: (a)

lack of competence, knowledge or training

(b)

misuse, whether this be deliberate or due to ignorance of proper use

(c)

poor maintenance, rendering the equipment defective or unsafe.

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Two conditions which specially need to be guarded against are through penetration, where the fixing goes through the material emerging in free flight on the other side, and ricochet, possibly towards the operator, where the fixing is deflected after firing.

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1.4.2.15 Causes of through penetration: cartridge too undertaken

powerful

for

the

job

being

2

fixing into voids in the structure

3

the material being fixed into is too thin

4

changes in the type or consistency of the material being penetrated

5

not establishing the density of the material being fixed into.

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Penetration due to a change in the type of material

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To avoid these hazards:

check the suitability of the material for cartridge-fired fixing

7

if necessary, make a trial fixing using a low-powered cartridge

8

check the area behind the material or structure into which the fixing is being fired, and guard the area so as to prevent the access of unauthorised persons

9

use an indirect acting tool.

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1.4.2.16 Causes of ricochet:

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firing into a hole of a previously attempted fixing

2

attempting to fix into excessively hard materials, such as hardened steel or welded areas

3

cartridge tools not held square onto the work surface, causing the pin to strike at an angle and then be deflected

4

attempting to fix too near to an edge

5

hitting a reinforcing rod or dense aggregate hidden just under the surface

6

ricochet due to firing too near to edge

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To avoid ricochets: (a)

fixings should be at the recommended distance (or greater) from failed attempts

(b)

do not fix into unfamiliar materials without first checking their suitability for cartridge fixing

(c)

tools should be at right angles to the work surface. The whole rim of the splinter guard should be firmly placed against the workface so as to stabilise the tool and not leave gaps. (See diagrams below.)


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The risk of ricocheting is reduced by the use of low-powered, indirect-acting tools. If highpowered tools are used, there is a risk that the fixing can be deflected and come back towards the operator.

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1.4.2.17 Fixing into concrete

The advice of cartridge tool manufacturers should be sought before attempting to fix into concrete which is over two years old or any other special type of concrete.

2

Depth of material. Generally, concrete should be at least 100 mm thick or three times the depth of the fixing penetration, to avoid fixings breaking through the back surface.

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Fixing breaking through

Penetration. Concrete varies in hardness, and trial fixings may be necessary to establish the optimum penetration.

4

Spading in concrete is caused by the initial compressive impact of the tool and results in a crater being formed around the fixing. It may be due to the fixing being too large or through using a cartridge that is too powerful. Spalling can reduce holding strength of the fixing by up to 20%.

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Spalling of concrete

5

Edge failure is the result of attempting to fix too near to the edge of the material, causing it to break away. The minimum distances given below should be observed.

6

Fixing distances. Always leave at least 75 mm between the edge of the material and the nearest fixing, or from a failed attempt.

Minimum distances between fixings into concrete

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Fixing into masonry requires greater penetration. Fixings should not be made into mortar joints unless no other choice exists, and then only after seeking advice from the cartridge tool manufacturer.

1.4.2.18 Fixing into steel 1

Fixing distances. The minimum fixing distances are 12 mm from an edge of the material being fixed into and 25 mm from any other fixing or failed fixing, or 2.5 times the fixing shank diameter from an edge and 6 times the shank diameter from another fixing respectively (where this is greater than the distance detailed above).

The shank diameter of a fixing should always be less than the thickness of the steel being fired into.

1.4.2.19 General precautions

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Penetration. For maximum holding strength, fixings (whenever possible) should penetrate just through the steel being fixed into.

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Shank diameter less than thickness of steel

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Minimum distance between fixings into steel

Recoil of a cartridge tool can lead to loss of balance if working from an unstable workplace. In this instance, only low-power tools should be used. Operators not familiar with cartridge tools, or with the type of tool to be used, should test the tool for recoil before use. In all circumstances, an adequate and safe footing is a necessity. Makeshift platforms should not be used.

2

Misfires. In the event of a misfire, the cartridge tool should be kept pressed in position against the workface for at least 30 seconds, to allow for any delayed detonation. Following this time period, the cartridge must then be removed strictly in accordance with the manufacturer's instructions. Cartridges which have misfired should be stored in a metal box and returned to the supplier.

3

Note: Misfired cartridges should not be removed from the tool by levering under the rim. Some types are rim detonated and could be fired by this action. Only the proper extraction tool as supplied by the manufacturer should be used.

4

Loading of tools should be carried out immediately prior to use. Once the tool is loaded, it must never be pointed towards other people or at any part of the operator's body. Unused cartridges must be removed from the tool as soon as possible.

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1.4.2.20 Storage and issue of tools 1

Only responsible and competent persons should supervise and check the acquisition, issue, use, return and

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maintenance of cartridge-operated tools. 2

Cartridge-operated tools and cartridges should be stored in a place which is secure, dry and cool. The issue of such tools and cartridges should be strictly controlled, and licensed if necessary. Storage box

The following points should be clearly noted and understood: (a)

cartridge tools should only be stored in an unloaded state

(b)

different strengths of cartridge should be clearly identified and kept separate

(c)

the use of different makes of equipment on one site should be limited as far as possible

(d)

the manufacturer's instructions on the safe use of the cartridge tool should be available.

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Lighter duty gas powered tools can be used for the fixing of timber and other low density materials. These fixing tools are generally lighter in weight and use a battery and fuel cell, either propane or other gas, to act as a propellant rather than a cartridge. The fuel cell, typically a small aerosol canister, is mounted within the tool. The safety issues that need to be considered when using a gas powered tool are:

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1.4.2.21 Gas powered tools

operators must be trained. Usually this can be provided by the supplier of the equipment. Operators must also be in possession of the relevant equipment instructions with which they must be familiar

(b)

the tool and the fuel cells must not be exposed to extremes of heat nor used within a flammable atmosphere

(c)

during use, harmful fumes are expelled and therefore the tool should be used in a well ventilated area

(d)

when firing, the operator must be in a stable position and holding the tool at right angles to the work

(e)

firing must not take place when others are behind the work. As with cartridge tools, through-penetration can occur

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if a malfunction occurs, unlike when using a cartridge tool, the tool can usually be fired again. However, the manufacturer's instruction manual should be consulted

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(g)

because of the mode of operation and speed of use, the tool can become hot (reference should be made to warnings of hot areas on the tool).

1.4.2.22 Personal protective equipment 1

2

Personal protective equipment, complying with the relevant British Standards, should be used by operatives using cartridge-operated and gas-operated tools, as follows: (a)

eye protection to BS EN 166-B must be provided and worn at all times when handling cartridge-operated tools, their cartridges or gas-operated tools

(b)

noise levels will vary with the make of tool but all tools create a high intensity, short duration noise. Suitable hearing protection should be worn

(c)

safety helmets to BS EN 379 should be worn while cartridge tools are in use.

The safety of other persons in the vicinity of where cartridge-operated or gas-operated tools are being used, a factor which should have been covered in the risk assessment, must be considered and all necessary precautions taken.

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1.4.2.23 Selection, training and supervision

operatives should be properly and adequately trained and be competent in the use of the equipment and aware of the hazards which may arise

(b)

they should be tested for colour blindness (cartridge-operated tools only)

(c)

it is recommended that only persons over 18 years of age are allowed to use portable fixing tools

(d)

operatives selected to use these tools should be of a mature and responsible disposition

(e)

adequate close supervision must be provided where necessary, for example when the operator of a portable tool is inexperienced.

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Training can usually be sourced from the supplier or manufacturer of the equipment.

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The selection and training of personnel should take the following points into consideration:

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Construction Site Safety 1.4.2 Appendix Portable fixing tools Safety checklist Has a suitable and sufficient risk assessment been carried out?

2

Has adequate information, instruction, training and supervision been provided?

3

Is the activity carried out in accordance with BS 4078-1?

4

Does all cartridge-operated tool equipment comply with BS 4078-2, (BS EN 792 for gaspowered fasteners) including the provision of splinter guards?

5

Are the operatives selected for training in the use of portable fixing tools of a mature and responsible disposition?

6

Who is responsible for the maintenance, issue and return of equipment including any unused cartridges?

7

Are operatives properly trained and aware of hazards associated with portable fixing tools, especially penetration, ricochets, misfiring, and the misuse of tools?

8

Are safe systems of work in operation? Do they cover the above hazards?

9

Are checks made to ensure that procedures are being observed and especially to ensure that loaded tools are not left lying about?

10

Are all cartridges and fuel cells kept in a cool, dry place, under lock and key?

11

Are cartridges clearly marked to indicate their strength?

12

Is the correct PPE available as required and is it being worn correctly?

13

Is the place where the work with fixing tools is being carried out safe for the tool user and for any other people who may be in the vicinity?

14

Is there a need to create an 'exclusion zone' around the work area?

15

Where will cartridge-operated tools and their associated cartridges be securely stored on site?

16

Will fixing tools and their cartridges and fuel cells be stored in accordance with the manufacturer's instructions?

17

Is the tool correct and suitable for the job?

18

Are tools equipped with suitable safety devices?

19

Are operatives fully aware of cartridge colour codes?

20

Are operatives aware of the different types of fixings?

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Lifting Operations, Equipment and Accessories

1.4.3.1 Key points Many accidents occur during lifting operations because they were not properly thought through in advance.

2

All lifting operations must be carried out by, and under the control of, trained and competent persons.

3

The safe working load (SWL) of any item of lifting equipment or lifting accessory must never be exceeded.

4

All equipment and accessories used for lifting operations must be subjected to a schedule of inspections and thorough examinations.

5

In addition to the equipment and accessories used, attention must also be paid to site features such as overhead cables, unstable ground conditions and adjacent properties.

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Section 9, Part 7 of the QCS covers lifting equipment.

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Experience has shown that lifting operations can be hazardous work activities if not properly planned and carried out. Safe lifting operations will depend upon: The availability of suitable lifting equipment, that is properly maintained

(b)

the provision of adequate information, instruction, training or supervision for everyone involved

(c)

thorough pre-planning of each lifting operation

(d)

compliance with safe systems of work as detailed in risk assessments and method statements (lifting plan).

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Note: Section 1, Part 14.4 of the QCS covers the certification of lifting equipment and

These Regulations require that safe systems of work are developed, accidents that have occurred during lifting operations indicate that all too often these are not in place or not complied with if they are in place.

3

Unsafe working and accidents result from:

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(a)

a lack of training or knowledge of the equipment

(b)

poor maintenance of the equipment

(c)

the correct (or recommended) plant or equipment not being available

(d)

the misuse of plant and equipment

(e)

insufficient or inaccurate information on the load

(f)

insufficient or inaccurate information on underground hazards, such as buried services

(g)

unstable ground collapsing under the weight of the crane and its load

(h)

failure to take account of adverse weather conditions

(i)

poor slinging of the load

(j)

rushing to get the job done.

Note: BS 7121-1 General gives advice on the safe use of cranes but excludes manually-

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operated cranes and those mounted on waterborne vessels, except where a land-based crane is temporarily fixed to such a vessel. 5

It details safe systems of work and the control of lifting operations, which include site preparation, along with the rigging and de-rigging of cranes.

6

The Code of Practice to BS 7121 also introduces the term 'signaller' in place of 'banksman'. Throughout the following text any reference to a banksman has been replaced with signaller.

1.4.3.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other persons might encounter as a result of the work being carried out.

2


3


4

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected.

5

The Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

Before any lift is carried out, a suitable and sufficient risk assessment must be carried out under these Regulations, although where lifting activities are repetitive with broadly the same hazards and levels of risk, a single risk assessment to cover all the lifts might be satisfactory in some situations.

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1.4.3.4 Risk assessments

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1.4.3.5 Lifting Operations and Lifting Equipment 1

The main requirements are: (a)

lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

(b)


(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person, or the load otherwise becoming out of control

(d)


(e)

lifting equipment must be equipped with suitable devices to prevent any person falling down a shaft or hoistway

(f)


(g)

every lift must be properly planned by a competent person, properly supervised and

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Section 11: Health and Safety Page 31 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) carried out safely lifting equipment must be subjected to a programme of inspections and thorough examination as appropriate

(i)

reports of thorough examination must be made and retained, with all defects notified to the Contractor who must take appropriate actions.

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(h)

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1.4.3.6 The Provision and Use of Work Equipment All lifting equipment and accessories for lifting are classified as work equipment and must therefore also comply with these Regulations.

2

These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

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4


5

Dangerous parts of machinery must be adequately guarded, preferably by fixed guards that cannot be defeated or removed.

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The use of some lifting equipment, for example tower cranes, will inevitably involve employees having to work at height, the legal definition of which includes getting up to the high-level work place and getting down again. Even standing on the tracks of a crawler crane would be classified as working at height if a fall from that place could result in personal injury.

2

The key provisions of these Regulations are (briefly) that Contractors should:

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(b)

where such work cannot be avoided, to select the most appropriate work equipment for the work and to prevent falls

(c)


(d)

ensure that the work is properly planned, risk-assessment based and carried out safely by competent persons

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equipment used for working at height is appropriately selected and inspected as specified

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(f)

establish danger areas from which people must be excluded, when there is a danger of them falling or being struck by falling objects

(g)

measures are taken to prevent anyone being injured by falling objects.


CDM has implications for the way in which lifting operations are carried out: (a)

designers must ensure the health and safety of anyone engaged in lifting operations, for example by designing-in lifting points on components that will have to be craned into place

(b)

designers must provide sufficient information regarding their designs, such as notifying the weight of any component that has to be craned into place

(c)

there must be safe places of work, including getting to and from the place of work

(d)

traffic routes must be suitable for the vehicles that will have to pass over them, for example, mobile cranes must be used and moved in a way that pedestrians are not

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Section 11: Health and Safety Page 33 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) put at risk there must be suitable and sufficient lighting for every place of work and traffic route

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(e)

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1.4.3.9 Definitions Appointed person: A person who has the competence, adequate training, authority and experience to take overall responsibility and control of a lifting operation, having been appointed by the management of the organisation or organisations that require the load to be moved.

2

Competent person (for the purposes of inspection and examination): A person who has the practical and theoretical knowledge together with actual experience of what they are to examine so as to enable them to detect errors, defects, faults or weaknesses, which it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

3

Crane co-ordinator: A person who plans and directs the sequence of operations of cranes to ensure that they do not collide with other cranes, loads and other equipment (for example, concrete placing booms, telehandlers and piling rigs).

4

Crane supervisor: A person who controls the lifting operation and ensures that it is carried out in accordance with the appointed person's safe system of work.

5

Crane operator: A person who operates the crane for the purpose of moving and positioning loads or erection of the crane.

6

Lifting accessory: A lifting beam or frame, chain sling, rope sling or similar gear, a ring, link, hook, interlocks, plate clamp, shackle, swivel or eyebolt, and any loose equipment used with lifting gear.

7

Lifting equipment: A piece of work equipment for lifting or lowering loads including a crab, winch, pulley block or gin wheel (for raising or lowering), a hoist, crane, shearlegs, excavator, dragline, piling frame, aerial cable way, aerial ropeway or overhead runway, goods hoists, mobile elevated work platforms, scissor lifts, vehicle hoists, ropes used for access, forklift trucks, lorry loaders (hiabs) and passenger lifts.

8

Mobile crane: A crane capable of travelling under its own power, but does not include a crane that travels on a line of rails.

9

Plant and equipment: Any plant, equipment, gear, machinery, apparatus or appliance, or part thereof.

10

Safe working load (SWL): The maximum load that can be safely lifted by any item of lifting equipment, such as a crane or hoist, or any accessory for lifting.

11

Note 1: The safe working load includes the weight of the hook block and all the lifting gear. The weight of these should be deducted from the declared safe working load of the lifting equipment to obtain the net load that can be safely lifted.

12

Thorough examination: An examination by a competent person in such depth and detail as the competent person considers necessary to enable them to determine whether the equipment being examined is safe to continue in use.

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1.4.3.10 Safe systems of work 1

A safe system of work should be devised and effectively communicated to all those involved in a lifting operation. It must include: (a)

thorough planning of the operation, along with the selection, provision and use of suitable cranes and equipment

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Section 11: Health and Safety Page 35 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) any necessary preparation of the site and erection and dismantling of the crane(s)

(c)

ensuring that all equipment has been maintained, tested and examined as necessary

(d)

operation of all equipment by trained and competent people

(e)

supervision of the lift by trained and competent people, with the authority to progress or stop a job as necessary

(f)

safe slinging of the load by a trained and competent person

(g)

the provision of all test certificates and other documentation relevant to the equipment being used

(h)

the prevention of unauthorised use or movement of equipment, both by workers or members of the public who may be trespassing

(i)

an effective means of communication between all members of the team during lifting operations

(j)

the safety of all persons, both those involved in the lift as well as those not involved in the lift but who may be affected by the lifting operation.

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(b)

1.4.3.11 Construction and support

Every crane and item of lifting equipment must be properly made and strong enough to carry out the work for which it is intended.

2

Foundations, stages, scaffolds, derrick masts and anchorages that have to carry a load must be of good construction and adequate strength. All temporary support structures should be certified by a competent temporary works engineer and a 'Permit to Load' issued before any support is loaded.

3

Winch frames must be made of metal. Separate crane jibs must be clearly marked to identify which crane they are part of.

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1.4.3.12 Platforms

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Platforms for crane drivers and signallers must be large enough to allow the person to do their work properly, close boarded or plated and fitted with access ladders or steps.

2

Where a risk assessment indicates that there is a possibility of injury resulting from a person falling from the platform of a crane, suitable guard-rails and toe-boards should be provided to prevent such an occurrence. Guard-rails should be at least 950 mm above the working platform. The gap between the guard-rails and between the lower - guard-rail and toe-board must not exceed 470 mm. Guard-rails and toe-boards may be removed for temporary access.

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1.4.3.13 Cabin 1

Generally speaking, a crane should be provided with a cabin to give the driver protection from the weather. The cabin should afford an unrestricted view of the work in hand and permit access to any machinery contained within the cab, for maintenance, etc. Where practicable, it should be cooled in hot weather and heated in cool weather.

2

Cabins are not required, however, when the plant is indoors or otherwise protected (unless it is mobile) and will not lift more than 1 tonne or where, in the case of a hoist, it can be operated from a landing platform or inside the cage.

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1.4.3.14 Drums and pulleys 1

The size of a drum or pulley must match the size of the rope or chain being used. The rope or chain must be anchored to the drum and there should be never less than two 'dead' turns remaining on the drum.

1.4.3.15 Brakes, controls, etc. Cranes, winches, etc. must be fitted with brakes capable of holding and controlling the maximum load. Controls on all lifting devices must be clearly marked and designed so that they cannot be operated accidentally.

2

Cranes with derricking jibs

3

If the derricking motion of a crane is driven by the hoist motor through a clutch, and can only be controlled by the hoist brake, an interlock must be fitted to prevent dual operation.

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Ladders, platforms or handholds must be provided to give safe access to all parts of the crane or lifting appliance that need inspection or regular maintenance, and from which a person may fall from height.

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1.4.3.16 Access

1.4.3.17 Hired cranes

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Where a crane is hired, the responsibility for ensuring compliance with these Regulations lies with: the hire company to ensure work equipment is maintained, inspected and tested as appropriate, and to provide information to the hirer

(b)

the person hiring the crane to ensure they have selected suitable work equipment and that it complies with all relevant legislation.

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Where the hirer arranges for the crane hire company to carry out a 'contract lift', the crane hire company takes on the total responsibility for all aspects of the safety of the lifting operations.

3

The responsibilities for hired and contract lifts are clarified below:

4

Hired crane (hired and managed). The employing organisation should:

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(a)

carry out all work in accordance with BS 7121

(b)

supply the appointed person

(c)

plan the lift and operate a safe system of work

(d)

ensure that the crane hired is of a suitable type and capacity

(e)

check the credentials of the crane company and certification supplied.

The crane owner has a duty to: (a)

provide a crane that is properly maintained, tested and certified

(b)

provide a competent driver.

Contract lift (fully contracted). The employing organisation should specify: (a)

that all work is to be undertaken in accordance with BS 7121

(b)

that the lifting contractor is to supply the appointed person

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(c)

what information and/or services will be provided to the lifting contractor by the employing organisation.

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The lifting contractor is responsible for: (a)

supplying the appointed person

(b)

planning the lift, and operation of a safe system of work

(c)

organisation and control of the lifting operation.

1.4.3.18 Siting The site engineer, in consultation with the appointed person, usually decides on the siting of cranes or other lifting appliances. In the case of mobile cranes, the operator is responsible for ensuring that the movement and position of the crane are both safe and suitable under the direction of the crane supervisor and in accordance with the appointed person's safe system of work.

2

The crane operator should check that any ramps, slopes, gates, archways, buildings, trees or overhead lines do not present an obstacle or danger, and that refuelling or other service vehicles can gain access without causing a hazard.

3

A minimum 600 mm-wide clearance between travelling or slewing cranes and any fixed object (guard-rail, adjacent building, etc.) must be maintained. Where this is not practical, any place where a person might be trapped must be blocked by enclosing it with barriers.

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1.4.3.19 Overhead power cables 1

Particular care should be taken when siting cranes or other lifting appliances close to overhead power cables. The jib or boom does not need to touch a live power cable, a 'flashover' can occur over some distance depending on the voltage carried by the overhead cables and the level of moisture in the air.

2

The minimum recommended safe working distance away from overhead cables is the length of the jib of the crane, plus 9 metres if the cable is slung on wooden or metal poles and 15 metres if the cable is slung on pylons. This is measured with the jib pointing towards the cable, even when the crane will be working in the opposite direction.

3

If the minimum safe working distance cannot be maintained, the electricity supply company should be consulted to enable a safe system of work to be devised.


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The 'danger area' must be clearly marked off with stakes, flags, or similar indicators and, where it is necessary to pass below overhead power cables, 'goal posts' should be set up to indicate the maximum clearance height, as specified by the local electricity supply company.

5

Materials, including rubbish, should not be deposited in this area.

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1.4.3.20 Stability

A crane must have a stable and level base. The stability and load-bearing capacity of the ground must be sufficient to carry the most severe static and dynamic loads, taking into account such factors as the slewing torques, wind stresses and shock loading, as well as the weight of the crane and its load.

2

Care must be taken to see that the ground is firm and stable. Excavations which may not have been correctly filled in, as well as cellars, culverts, tunnels and shafts, may all reduce the stability of the ground and constitute a hazard to machinery and heavy loads.

3

It is also important to identify underground services and to carry out any temporary protection measures that may be required. The failure of a water main due to overloading, for example, can dramatically reduce the load bearing capacity of the ground.

4

The same principles apply when a crane is sited on a street or roadway for the purpose of working into a site.

5

Adverse weather, such as rain (producing soft ground) and strong winds, can rapidly affect the stability of a crane, and no crane should be used without these factors first being considered.

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1.4.3.21 Outriggers 1

The majority of mobile cranes are fitted with outriggers to increase the area of the supporting base. Outriggers are effective only if they are deployed correctly.

2

The safe rule is to use outriggers for all lifting duties (except where 'free on wheels' duties are required). ALL the outriggers must be extended

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fully and equally, on both sides. 3

If the stability of the ground is in any way suspect, suitable grillage must be used under each outrigger to reduce the ground area loading.

4

Where operating on a slight slope cannot be avoided, the operating area should be built up to give a level base (see diagram below). A slope of as little as 1 ° can significantly affect the stability and capacity of a crane, particularly where long jibs are in use.

1.4.3.22 Ballast, anchorage, etc. Cranes may need to be anchored to the ground or other foundations, or have counterweights or ballast to prevent them overturning. The anchorage or ballast should be checked each time the crane is erected, and after bad weather.

2

Before a crane is put to work, any new anchorage or ballast must be checked by applying a load 25% greater than the maximum rated load. If this test shows the crane cannot be worked safely with its normal load, it may still be used, if it is sufficiently derated. Such tests may only be carried out by a competent person. A modified loading diagram should then be fixed to the crane where it can be seen by the operator. Other lifting control documentation, such as the lift plan and method statement, should also be modified accordingly. A record of the test should be kept.

No crane or other lifting appliance may be erected unless under the supervision of a competent person, such as the operator or crane supervisor.

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1.4.3.23 Rigging and de-rigging

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De-rigging

The de-rigging of a crane must also be carried out under the supervision of a competent person, normally the crane operator, plus any other persons as recommended by the manufacturer.

3

Care must be taken to see that nobody stands under any jib section while the connecting pins are being withdrawn. People have been killed through doing so.

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1.4.3.24 Rated capacity indicators, etc. 1

Rated capacity indicators (previously known as automatic safe load indicators), radius load indicators and motion limit switches, together with their audio-visual warning systems, are fitted to cranes and other lifting appliances. Their purpose is to prevent any item of lifting equipment from operating outside its safe operating parameters. Under no circumstances should these devices be overridden or disabled.

2

During rigging (including the fitting of jib extensions and changes in reeving) it will be necessary to reset these warning indicators to take account of load conditions and operating radius. They must be tested by a competent person before use.

3

These requirements do not apply to guy derricks, small cranes (less than 1 tonne SWL), any

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hand-operated crane used in crane erection, and some hydraulic cranes. 4

They must be inspected by a competent person on a weekly basis, and inspections recorded.

1.4.3.25 Crane markings All cranes and other lifting appliances must be clearly marked with their maximum safe working load (SWL). If the lifting radius can be varied, an indicator must be fitted which shows the safe load at each operating radius.

2

All cranes or lifting appliances which are designed for lifting persons should be identified as such. Cranes and lifting equipment that are not designed for lifting persons, and might be used in error for this purpose, should also be clearly marked to this effect.

3

All cranes and other lifting appliances must carry clear identification marks.

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Lorry loader cranes must be fitted with an interlocking system (or equivalent engineering solution) to prevent cranes from operating without their stabilisers extended.

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1.4.3.26 Lorry loader cranes - interlocks

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1.4.3.27 Lifting operations

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Control of lifting operations

A person, other than the crane operator, should be appointed to take responsibility for the organisation and control of any lifting operations on behalf of the management.

2

They should be adequately trained and have the necessary experience to be deemed competent. The appointed person should be formally notified in writing of their appointment.

3

The appointed person must:

assess the proposed lift to identify the hazards and corresponding risks, provide for planning, selection of equipment, instruction and supervision to enable the work to be carried out safely ensure that all tests, inspections, examinations and maintenance have been carried out, and that there is a procedure for reporting defects and taking any necessary corrective action

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(c)

ensure that the crane supervisor is fully briefed on the relevant sections of the lift plan and contents of method statements

(d)

have the authority to carry out their duties and to stop the operations if they think there is a danger.

4

The appointed person's duties, but not their responsibilities, may be delegated to another competent person.

5

Drivers of cranes and other lifting appliances, and others involved in lifting operations, including signallers, must be adequately trained, experienced and of a mature disposition. The recommended age is 18 years or over, unless under the direct supervision of a competent person for the purpose of training.

1.4.3.28 Signals 1

If a driver cannot see the load during the whole lifting operation, they must have one or more

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trained signallers or some other signalling system (e.g. radio) to enable them to handle the load safely. 2

Signallers must be in a safe position, have a clear view of the path of the load and have effective communication with the driver. Signals must be clear and distinct. Mechanical or electrical signals should be kept in good order and safeguarded against accidental operation.

3

It is very important that clear and precise words of command are given so that there can be no misunderstandings.

4

A positive decision is needed on the use of words; for example, which word you would use: up or raise or lift or hoist

(b)

similarly,

(c)

lower or down or rest, etc.

The use of hand signals should be equally clear and everyone involved in the lift must be made aware of whether the hand signals specified in: (a)

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BS 7121 Safe use of cranes Part 1 (as shown in Appendix 7).

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1.4.3.29 Restriction on use

A hoisting mechanism should be used for - raising and lowering loads vertically and for no other purpose, unless it is designed to do so, competently supervised and can be done without overstressing the crane structure or mechanism or endangering its stability.

2

Crane jibs must not be worked at a radius greater than that specified on the test certificate.

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1.4.3.30 Safe working load

In no circumstances must the load on the lifting equipment exceed the safe working load (SWL), except when under test by an authorised competent person.

2

When lifting near to the SWL, the load should be raised a short distance only and the operation stopped to check stability and safety before continuing. Wind-loading will affect how near to the SWL a crane can operate. Care must also be taken when planning to lift loads out of water, as the load may suddenly increase beyond the SWL since the support previously given by the water no longer exists.

3

When two cranes or other lifting appliances have to be used for one load, each must work within its safe load, and must remain stable throughout the lift. Multiple lifts of this type must be supervised by a specially appointed competent person (see tandem lifts on the next page).

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1.4.3.31 Loads Slinging loads 1

Many accidents associated with lifting operations are caused by faulty slinging (for example, overloading, use of the wrong type of sling, unbalanced or insecure loads). This results in the load falling or tipping out of control with damage to plant, machinery and to the load.

2

The crane operator will often have to rely on the slinger or signaller, who should be trained, competent and aware of the possible hazards arising from the use of lifting accessories.

3

Loads must be correctly slung and made secure to prevent any part of them slipping and

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falling. The slinging of loads must only be carried out by someone who has been trained and is competent to do so. Many crane accidents feature loads that fall from height because they were not correctly slung.

5

Precautions must be taken to prevent the load striking, or becoming snagged on, any obstacle or causing other items to fall from height.

6

As far as possible, loose materials (bricks, slates, etc.) should ideally be banded and on pallets when being lifted. If not, they should be lifted in a properly constructed box or other container.

7

If loose materials are carried on a hoist, side pieces should be fitted to prevent anything falling. Wheelbarrows and trucks must be prevented from moving and should not be overfilled.

8

Loads should not be suspended or carried over areas occupied by persons. However, where this is not practicable, a safe system of work should be developed to minimise any risks to those below the load.

9

The safe system of work should include, for example, the prevention of access to the danger area below a suspended or moving load, by barriers or other means, ensuring the load is adequately secured and that the operator is in control of the movement at all times.

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Cranes are not designed to pull loads free from their attachment to their surroundings. The additional loading stress cannot be accurately determined and, when a load does break free, the sudden shock can result in damage to the boom or crane machinery, failure of the sling, failure of the wire, whiplash and other dangers.

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Anchored loads

In circumstances where the centre of gravity of a load is not known or where it is known to be off-centre, these factors must be allowed for when planning the lift. An example is the lifting of long columns from the vertical, where the load could become unstable and topple the crane. A written procedure setting out a safe system of work should be prepared to cover such operations.

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Unstable loads

1.4.3.32 Tandem lifts 1

Tandem lifts (lifting a load using two or more cranes simultaneously) is a specialist activity. This type of lift must only be planned and supervised by someone who has been trained and is competent in the techniques and calculations involved. The main factors to be considered when planning multiple lifts are the total weight and distribution of the load, its centre of gravity, the weight and capacity of any lifting accessories and synchronisation of the crane motions.

1.4.3.33 Demolition and dismantling work 1

Lifting loads from a place that is significantly above ground level demands the utmost care and, in particular, an accurate assessment of the weight of the load and its point of balance. By the time the load is 'on the hook' it may be too late to call a halt and start again. Loads should be raised about 150 mm and held, while the stability is assessed, before proceeding.

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1.4.3.34 Carriage of persons 1

Some items of lifting equipment, such as MEWPs or suspended cradles, are specifically designed for the lifting of persons and this type of equipment should be used wherever possible.

2

However, it is sometimes necessary to adapt equipment that is primarily designed for lifting materials to lift persons. An example of this is the fitting of a temporary working platform to the forks of a forklift truck. In such circumstances the working platform must:

conform to the requirements of working at height with regard to guard-rails and toeboards

(c)

be securely fixed to the forks so that it cannot become detached or otherwise unstable

(d)

prevent access to otherwise exposed dangerous parts of the forklift truck

(e)

be protected against overhead hazards.

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(b)

These Regulations require that all work equipment designed for carrying persons: be constructed to prevent a person using it from being crushed, trapped, or falling from the carrier, either whilst in transit or carrying out work from the carrier

(b)

be equipped with suitable devices to prevent the 'person carrier' falling

(c)

is such that a person trapped in a carrier is not exposed to danger and can be freed.

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Furthermore, if a 'man-riding' cradle suspended from a crane is being used, BS 7172 Part 1 advises that the cradle: (a)

is prevented from spinning or tipping

(b)

is controlled as described in the section on tower cranes.

1.4.3.35 Maintenance

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be fully compatible with the forklift truck to which it is fitted

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(a)

Contractors to ensure that work equipment (which includes lifting equipment and accessories) is maintained in an efficient state, in efficient working order and in good repair.

2

Therefore, lifting equipment and accessories for lifting must be properly maintained, although the frequency of maintaining work equipment is not specified.

3

As far as lifting equipment and lifting accessories are concerned, maintenance will normally be carried out in accordance with the manufacturer's instructions, using 'check-sheets, lubrication charts, etc. Maintenance must be carried out by a competent person who is familiar with the equipment and has the knowledge and experience to detect existing or potential faults.

4

The extent of the maintenance activities will vary between different types of lifting equipment depending upon its complexity. For example, maintaining a tower crane at one end of the scale and a gin-wheel at the other. Where the equipment has a maintenance log, it must be kept up to date.

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1.4.3.36 Thorough examination and inspection Thorough examination 1

These Regulations place a duty on Contractors to ensure that all lifting equipment and lifting accessories are subjected to a schedule of thorough examinations by a competent person at

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intervals not exceeding: (a)

six months for lifting equipment used for lifting persons and all lifting accessories

(b)

12 months for other lifting equipment.

The competent person might decide, for a variety of reasons, that a schedule of more frequent examinations is appropriate.

3

A thorough examination must also be carried out after any other event likely to have affected the safety of any lifting equipment or accessories or where the equipment has been out of use for a long period.

4

Furthermore, where the safety of lifting equipment depends upon the way it has been installed (as for the many items of temporary lifting equipment used on construction sites, such as tower cranes), it must be thoroughly examined after assembly and before being put into service at a new site or a new location on the same site.

5

The competent person must have sufficient practical and theoretical knowledge and experience of the lifting equipment to enable defects and weaknesses to be detected, and their importance in relation to the safety of the equipment to be assessed.

6

The competent person should also be sufficiently independent of the operation to ensure that there is no fear or favour in any recommendations made as a result of the thorough examination.

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1.4.3.37 Inspection

These Regulations also require that, where appropriate, as determined by a risk assessment, intermediate inspections of lifting equipment are carried out although the frequency of inspections is not specified. Depending upon the complexity of the equipment it might be appropriate to put in place two levels of inspection: daily and weekly.

2

Again, these inspections must be carried out by someone who is competent to do so although, in most cases, the same depth of technical knowledge will not be required as for thorough examinations. In some cases, for example carrying out a daily pre-use inspection of a mobile crane, it would be reasonable to expect the operator to be able to carry out the inspection.

3

Some factors that will determine the frequency and 'depth' of any inspection are; if the equipment is being used in a hostile environment

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(b)

if failure becomes more likely due to repeated use

(c)

the critical nature of some components, such as the 'rated capacity indicator'

(d)

the potential for the equipment to be tampered with, for example a mobile crane left overnight in a public place.

Some of the things covered by inspections include, but are not limited to: (a)

the soundness of materials, attachments, fittings, outriggers, jibs, ropes and hooks

(b)

the testing of the rated capacity indicator, the correct settings of cams, linkages and switches, and the correct working of audio-visual warning signals

(c)

the mechanical condition of the lifting equipment

(d)

routine maintenance (lubrication, tyre pressures and hydraulic fluid level).

In summary, any lifting equipment which is used in conditions commonly found in the building and construction industry should not be used unless it is:

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(a)

mechanically sound and free from any defects affecting its safe operation

(b)

properly maintained

(c)

regularly inspected, either weekly or to an agreed programme, when in use, usually by the operator, or other authorised person

(d)

thoroughly examined every 12 months (every six months when used for lifting people) by a competent person and after any exceptional circumstances likely to affect the safety of the lifting equipment

(e)

tested and thoroughly examined

Following any repairs or alterations which may affect the strength or stability of the lifting equipment.

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1.4.3.38 Reports These Regulations establish a regime of good maintenance and record keeping, whilst allowing the competent person to determine the schedule of inspections and thorough examinations.

2

An essential requirement, under these Regulations and good business practice, is to maintain records of maintenance and the results of inspections, thorough examinations and tests.

3

Evidence of inspections, thorough examinations and tests must accompany lifting equipment and accessories for lifting when they are hired, leased or loaned to other users.

4

Where thorough examinations or tests are carried out by the user during the period of hire, lease or loan, the owner of the lifting equipment or accessory must be informed of the results of each thorough examination or test.

5

The format in which the records of inspections, thorough examinations and tests are kept is not specified in these Regulations. However, records must be readily accessible, although they can be stored in an electronic format providing a hard copy can be produced on request.

6

Reports of thorough examinations should contain the information in Appendix 6 of this section.

7

Again, the records can be held in electronic form, but must be readily available to the user of the lifting equipment or accessory for lifting provided that the following safeguards are incorporated into the system.

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(a)

The records must be capable of being reproduced as hard copy when required.

(b)

The information must be secure against loss or unauthorised interference.

(c)

The information must be authenticated only by a person who is in a position to declare that the information is correct.

1.4.3.39 Tower cranes 1

Tower cranes can present particular safety considerations when used on site. (a)

Generally they are self-erecting and dismantling, or erected and dismantled using a large mobile crane for which provision has to be made in terms of space and stable ground conditions.

(b)

Portable tower cranes, often controlled remotely from the ground, need to be treated the same as a mobile crane.

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(c)

They require detailed attention to the foundation (static crane) or rails (mobile crane); manufacturers or suppliers should be consulted.

(d)

In many cases they have the capacity to over-sail adjacent properties and areas to which the public have access;

Arrangements will have to be made: (a)

Where the right to over-sail adjacent property is not given, it may be necessary and feasible to: (iv)

rearrange the siting of the tower crane(s)

(v)

review the type of crane required, for example a luffing-jib crane might be the only solution.

The required airspace must be confirmed with regard to the proximity of adjacent structures, overhead power lines or other obstructions.

(c)

The requirement for airspace may need to be discussed with any local airport to establish that there will be no intrusion into, or unacceptably near to, aircraft flight paths.

(d)

There may be a requirement for an aircraft warning light or beacon on the highest point of the crane; the colour intensity and whether it is on steady or flashes will depend upon the local rules for any flight path affected.

(e)

On sites where more than one tower crane is erected, there may be overlapping arcs of operation when slewing; anti clash devices should be fitted.

(f)

As a result of the above, the cranes should be erected with their jibs at different heights; crane slewing operations will have to be co-ordinated.

(g)

Electrically powered cranes will require a heavy duty power supply and the crane must be effectively earthed to protect against electrical faults and lightning strikes, including earthing of the appropriate rails.

(h)

High winds can temporarily stop tower crane operations; each crane should be fitted with an anemometer (wind-speed indicator).

(i)

In high winds, tower cranes must be left in 'free slew' with their hooks raised.

(j)

If used for lifting persons, a tower crane must:

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only be capable of lowering the load under power controlled conditions, i.e. not under 'free-fall'

(ii)

be equipped with an automatic braking system, e.g. a 'dead-man's' handle type of control.

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(i)

(k)

A rescue plan must be in place in the event of an accident or incident, for example, the operator becoming ill. The emergency services have no obligation to carry out such rescues and are often not able to assist because of the height of the rescue and because of restricted access for large vehicles such as fire service turntable ladders.

(l)

Tower cranes must be secured against unauthorised access, including climbing the tower and unauthorised use.

(m)

A lifting plan approved by an appointed person must be in place.

1.4.3.40 Excavators used as cranes 1

Excavators, loaders and combined excavator loaders may be used as cranes in connection with work directly associated with an excavation, and any other application where this type of equipment can be used.

2

All work is subject to a suitable and sufficient risk assessment, subsequent control measures

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and capabilities of the work equipment. The risk assessment should take account of the fact that when a machine is in the object handling mode (being used as a crane), it will be necessary for the slinger to approach the machine to hook the load on and off. This person will be in what is regarded as a hazardous area and much nearer to the machine than anyone would be in normal circumstances. The slinger is at risk of being struck by the load, bucket or excavator arm if the excavator moves or slews rapidly. Excavator operators and slingers must be made aware of these dangers; effective communication and constant vigilance are essential.

4

The risk assessment must also establish whether the machine is suitable for the proposed task. The weight of the bucket (if still fitted) plus the quick hitch must be added to the weight of the load to establish if the machine will be working within its safe working load. Ideally, unless there are good reasons for not doing so, the bucket will be removed to improve the machine operator's visibility.

5

The risk assessment must also address:

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the need for the lifting operation to be ideally segregated from other work activities taking place in the vicinity, particularly where it is necessary for the machine to travel with a raised load

(b)

the ground conditions, particularly where a tracked excavator will carry out the lifting operation. Such machines have no means of levelling themselves and are therefore dependent upon the ground being sufficiently level to track across it and carry out the lifting operation safely.

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(a)

The safe working load must be clearly marked on the machine and any lifting accessories, such as a quick hitch. A rated object handling capacity table must be available in the cab.

7

If the rated lifting capacity for an excavator (or the backhoe of a backhoe-loader) is greater than 1 tonne (or the overturning moment is greater than 40,000 Nm), the machine must be fitted with:

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a boom lowering control device on the raising boom cylinder(s) (a safety check valve), which meets the requirements of BS 6912:1, and

(b)

an acoustic or visual warning device, which indicates to the operator when the object handling capacity or corresponding load moment is reached.

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(a)

Chains or slings for lifting must not be placed around or on the teeth of the bucket. Accessories for lifting may only be attached to a purpose-made point on the machine.

9

Whilst BS 7121 may not specifically refer to excavators used as cranes, compliance with all the appropriate parts of BS 7121 would be required.

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1.4.3.41 Security when not in use 1

The manufacturer's handbook will contain recommendations for securing the crane when it is not in use, to minimise the chance of tampering, vandalism and damage.

2

The measures to be taken will vary for different types and makes of crane, and may also vary depending upon the length of time that a crane will be out of use.

3

However, in general: (a)

Do not leave loads suspended

(b)

Do remove operating keys

(c)

Do lock cabs and, where appropriate, prevent unauthorised access using other means.

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1.4.3.42 Strong wind conditions 1

Crane manufacturers' operating instructions will specify a maximum wind speed for safe operation.

2

This may be a single wind speed for all configurations of the crane or may vary, depending on the jib length, the radius, the load and other factors.

3

The manufacturers' instructions will also indicate the actions to be taken to leave the crane in a safe manner if the wind does exceed the maximum safe operating speed.

4

A copy of the Beaufort Scale, that outlines the visible signs of various wind strengths, is included in this section at Appendix 8.

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1.4.3.43 Accessories for lifting Ropes, chains, eye bolts and slings are all examples of accessories for lifting. They must be clearly marked with their safe working load.

2

All lifting accessories must also be: properly constructed and maintained

(b)

free of any defect or damage likely to affect their strength

(c)

regularly maintained and inspected

(d)

thoroughly examined

(e)

securely attached to the lifting equipment, for example the crane, and the load

(f)

used within their safe working load.

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Accessories used for lifting must be inspected and thoroughly examined, with records kept as specified in Appendix 5.

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1.4.3.44 Marking

Every rope, chain, etc. must be clearly marked with its SWL and carry an identifying mark. Where this is not possible then a coding system, such as a tag or colour code, should be used to allow the user to determine the safe working load. A lifting accessory may also be marked with its own weight which is a consideration when assessing the total load to be lifted.

2

Where the SWL depends on the configuration of a lifting accessory, such as a two leg chain, then the SWL for each configuration should be clearly marked on the equipment using a tag or by a chart available at the point of use.

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1.4.3.45 Overloading 1

Ropes, chains, etc. must never be overloaded except under test and as authorised by an experienced and competent person.

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1.4.3.46 Preventing damage 1

The edges and corners of a load should be packed to prevent sharp edges damaging lifting ropes, chains or slings.

1.4.3.47 Hooks All hooks used for lifting must be fitted with a safety catch, or should be moused, or so shaped as to prevent the sling eye or load coming off the hook

1.4.3.48 Slings

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Slings must be attached correctly to the lifting equipment by an approved method, either by securing the ring directly onto the hook if size permits, or by use of a suitable shackle, fitted with the pin of the shackle on the hook and the load suspended from the bow.

2

The correct method of slinging will vary with the types of load, the different materials or items lifted. It is essential to see that the load is secure. Care must be taken to see that slings are not damaged, and suspect or defective slings must be discarded.

3

Dog ropes or tag lines, securely attached to the end of the load, should be used when handling long or large loads, to direct the load into position and prevent it spinning. Tag lines should be as short as possible.

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1

See the slinger and signaller safety checklist in Appendix 4 to this section.

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Multiple slings (two-legged, three-legged, etc.) must be connected by a ring or shackle and the load properly distributed so that no leg is overloaded.

5

When in use, the angles between sling legs should be less than 90°. At angles greater than this, the strain on each leg increases very rapidly to a point where they may break because of overloading.

6

With a simple two-legged parallel sling, the load on each leg is half the total load. As the angle between sling legs increases, the load on each sling leg increases to approximately double at an angle of 120°.

7

With a sling angle of 90°, the SWL of the sling should be at least 43% greater than the nominal weight of

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How the load in each sling leg increases as the angle between the sling legs is increased

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1.4.3.49 Repaired ropes, chains, etc.

Any chain sling, etc. that has been altered or repaired by welding must be examined and retested, and an inspection or examination carried out before taking it back into use. The record should be kept until the next scheduled thorough examination.

2

Knotted ropes, chains or slings and those which have been shortened or joined by nuts and bolts through the links must not be used.

3

Any chain, sling or lifting equipment or accessory for lifting which is thought to have suffered a loss of strength or is otherwise defective should be withdrawn from use and quarantined. The equipment should be scrapped or re-examined by a competent person who will recommend that either it can be put back into service or must be disposed of.

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1.4.3.50 Construction of slings 1

Slings are available in a wide range of styles made from many different materials to suit particular purposes.

2

Chain slings are made from various grades of steel. They can stretch and the links, rings or hooks may become distorted and fracture if subject to excess stress.

3

Chain slings should only be shortened by using the correct shortening clutches. Chains must not be knotted or joined by nuts and bolts. Hooks must be of the 'C' type or fitted with a safety latch.

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Wire rope slings are made from drawn steel wire. Each leg of the sling will have an eye formed at either end. Wire rope slings may be damaged when 'kinked' sharply or if put under stress when twisted. Steel wire rope may be damaged by corrosion through poor care and storage.

5

Wire ropes should never be used if more than 5% (1 in 20) of the wires can be seen to be broken in any 10 x diameter, length.

6

Wire ropes should also not be used where they have been flattened such that there is a 10% reduction in rope diameter.

7

Wire rope slings must not be made up on site using bulldog grips.

8

Wire ropes and slings are of many different types of construction, each having properties related to usage. It is therefore important, when ordering an item, to specify the intended use.

9

Fibre rope slings might be made from natural fibres (manila, sisal, hemp) or synthetic fibres. Slings made from natural fibres can be prone to rotting. Only purpose-made slings, clearly marked with their SWL, should be used on site.

10

On no account should slings be fabricated from lengths of rope found laying around site. Fibre rope slings are more easily cut or damaged, and should be visually examined by a competent person every time before use to ensure they are serviceable. Natural fibre ropes should not be used for making up slings on site.

11

Synthetic fibre ropes do not rot but can be affected by some chemicals. Care should be taken to avoid contamination with alkalis or acids. Suspect or contaminated synthetic fibre ropes and slings must not be used.

12

Flat lifting slings are used where special lifting operations are required and afford a certain amount of protection to the load.

13

Flat and round slings may be made of woven synthetic materials (such as nylon, polyester, polypropylene and terylene) with 'eyes' sewn in, or plastic-coated wire mesh, or formed by a series of plaited wire ropes between two end fittings. These might also be covered with a plastic material. All woven materials are prone to damage and should be regularly checked for serviceability. Slings should be protected from sharp edges and placed evenly about the load, not twisted. Care must be taken to see that the SWL is not reduced by having a sling angle greater than 90°.

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1.4.3.51 Shackles 1

Two types of shackle are commonly used in lifting operations. They are the Bow type shackle and Dee type shackle, both of which are available with threaded or plain pins.

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2

Only bow type shackles may be used to suspend a load from a hook. The shackle must be positioned with the pin across the hook and the load suspended from the bow. If necessary, spacers should be fitted over the pin to centralise the shackle on the hook.

3

Overloading, out of balance loads and misuse can distort shackles; they should be checked regularly for shape and wear.

1.4.3.52 Eyebolts Eyebolts are made to screw into or through a load and may be plain (dynamo) or have collars, with or without links. The plain eyebolt is good only for vertical loading. Even when a collared eyebolt is used, the safe working load is reduced if the load to which it is attached initially lifted at an angle.

2

Collared eyebolts with links may be used providing the angle of load to the axis of eyebolt thread does not exceed 15°. Over 15°, safe working loads must be derated in accordance with BS 4278: Specification for eyebolts for lifting purposes.

3

When installed, the collar must be at right angles to the hole, should be in full contact with the surface, and be properly tightened.

4

The load should always be applied in the plane of the eye, never in the other direction. If necessary, washers or shims should be inserted below the collar to ensure that the eye is correctly aligned when tight.

5

Extreme care must be taken to ensure that metric threaded eyebolts are not inserted in imperial threaded holes. Although these might appear to match, it is an interference fit only, and the mechanical strength may be almost nothing.

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1.4.3.53 Bulldog grips (wire rope grips) Bulldog grips, if used properly to make an eye with a thimble, provide a simple and effective means of securing the ends of wire ropes instead of splicing or socketing. The final SWL will be about 75% of that of the wire. It is essential that the correct size and type of grip is used, that the wire is clean and that the correct torque is applied when tightening the grips.

2

Bulldog grips must be fitted with the 'U' bolt on the dead or tail end of the line (non loadbearing end). There must be no deviation from this practice.

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Correct method of fitting wire rope grips Note: The number of wire rope grips shown in the above illustration is insufficient. The figure is schematic only.

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Wire rope grips meeting the requirements of BS EN 13411 are efficient when correctly installed by a competent person. Generally, when using wire rope grips, the previous numbers of grips should be used and they should be tightened to the relevant torque. However, in all cases, the manufacturer's recommendations, in addition to the advice given in the standard, should be closely followed.

Maximum nominal rope diameter (mm)

Required number of wire rope grips

Tightening torque required (Nm)

5

3

2.0

6.5

3

3.5

8

4

10

4

12

4

14

4

16

4

19

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6.0

20.0 33.0

4

68.0

5

107.0

5

147.0

30

6

212.0

34

6

296.0

40

6

363.0

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4

The wire should be in good condition and all threads and nuts should be suitably greased.

5

The first bulldog grip should be fitted as close as possible to the thimble and, thereafter, at a spacing of no greater than six times the rope diameter.

6

Nuts must be tightened to the relevant torque:

7

(a)

when the rope is assembled

(b)

when taken into use

(c)

on the application of the load

(d)

at periodic intervals when in continuous use.

If the above criteria are not followed, then the strength of the eye and thimble will be considerably reduced. If the criteria are neglected for an extended period, the eye and thimble may fail.

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Wire rope grips must not be used to make lifting slings, long splices, or to join two wire ropes, other than with thimbles or eyes.

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For intermediate diameters of rope, the next larger size wire rope grip should be used, except as follows: (a)

the size 5 mm grip should only be used on a nominal 5 mm diameter rope

(b)

for 11 mm diameter rope, use four 10 mm rope grips tightened to a torque of 14 n/m.

1.4.3.54 Spreader and equaliser beams Spreader beams are used to support long or wide loads during lifts. They eliminate the hazard of a load tipping, as well as wide sling angles and any tendency of the sling to crush the load.

2

Equaliser beams are used to equalise the load in sling legs and to keep equal loads when making multiple leg lifts.

3

Both types of beam are normally manufactured to suit a particular purpose. Care should be taken to see that the correct beam is used.

4

The capacity of a beam with multiple attachments will be specified by the manufacturer. Generally, it will depend on the distance between the attachment points, for example, if the distance between attachment points is doubled, the lifting capacity is halved. Care must be taken not to exceed safe working loads at the various slinging points.

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Construction Site Safety 1.4.3 Appendix 1 General lifting operations Safety checklist Before starting work Ensure that adequately trained, competent persons are available to plan, carry out and supervise the lift.

2

Ensure that a suitable and sufficient risk assessment has been carried out, which considers all aspects of the lift including environmental factors such as the proximity of obstructions, underground services, overhead cables and structures.

3

Ensure that lift plans and method statements for the lifting operation are developed as appropriate.

4

Ensure that appropriate protection measures are put in place.

5

Ensure that all temporary works supporting lifting equipment, such as foundations, have been certified by a competent temporary works engineer and a 'permit to load issued'.

6

Ensure that a current thorough examination and/or test record has been issued and is available for each item of lifting equipment and accessory.

7

Ensure that the SWL of the lifting equipment and accessories is adequate for the weight of the load.

8

Ensure that all lifting accessories are clearly marked with their safe working load.

9

Ensure that correct and up-to-date copies of the Sling Chart and Safe Working Load tables are available, when using multi-leg slings.

10

Ensure that the method of communication is agreed and understood by everyone involved in the lift.

11

Ensure that a suitable rack is available for storing slings, etc. when they are not in use. Wire ropes should be stored in a dry atmosphere.

12

Ensure that the weights of loads to be lifted are known in advance, and that load weights are clearly marked.

13

Ensure that the ground conditions are sufficiently stable to take the weight of the lifting equipment and any load.

14

Ensure that a trained and competent slinger is available.

15

Ensure that a trained and competent signaller is available if required.

16

Ensure that all personnel involved in the lifting operation have been briefed and understand the risks, methods or work and the equipment to be used including emergency arrangements.

17

Ensure that the appropriate permissions have been gained if it is necessary to position any crane on the public highway (or other public place) to carry out lifting operations.

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Whilst work is in progress 18

Ensure that copies of the Sling Chart and Safe Working Load tables are being used where necessary.

19

Ensure that the correct techniques are being used for the attachment to the appliance and slinging.

20

Ensure, wherever possible, that the angles of slings are no more than 90°.

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Ensure that regular inspections, thorough examinations and tests of the equipment are carried out, as appropriate, and records maintained (see Appendix 5).

22

Limit the use of endless wire rope slings.

23

Ensure that slings are protected from sharp corners of loads by suitable packings.

24

Ensure that slingers understand that 'doubling up' slings does NOT 'double up' the safe working load; avoid this practice if possible.

25

Prevent strops, slings and ropes from being dragged along the ground.

26

Ensure that hooks used for lifting are NOT also carrying unused slings.

27

Ensure that any unused leg of a

28

multi-sling is correctly hooked back. The correct sling only should be used.

29

Ensure that unfit slings are removed from the site, and a responsible person informed.

30

Ensure that the crane hook is positioned above the load's centre of gravity.

31

Ensure that the load is free before lifting and that all legs have a direct load.

32

Ensure that 'snatch' loading does NOT take place.

33

Ensure that NO ONE rides on a load which has been slung and is being lifted.

34

Use tag lines to stabilise long or large loads.

35

Ensure that the load is landed onto battens to prevent any damage to slings, and to assist their easy removal.

36

Ensure that NO ONE is under a load which is being lifted.

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Construction Site Safety 1.4.3 Appendix 2 Mobile cranes Safety checklist

Before starting work Carry out the checks detailed in Appendix 1, plus: Consider whether a 'contract lift' is the best and safest option.

2

Check that the selected crane has been supplied. Check that the correct operating information and a competent operator have been supplied along with it.

3

Check that the ground is capable of taking the loads of the outriggers, crane, load or wind. If in doubt, get ADVICE from specialist companies.

4

Ensure that the approach and working areas are as level as possible.

5

Ensure that there is adequate protection from live electrical cables.

6

Ensure that the area is kept free of obstructions, and is adequately lit.

7

Ensure that the weights of the loads are known, and that the correct lifting gear has been ordered and is available.

8

Ensure that no 'crush zone' exists between the crane and any fixed object; if there is, erect barriers.

9

Check there are no restrictions on the access, i.e. check size(s) of vehicles.

10

Check that the company has provided enough information about the safe use of the crane.

11

Check that there is an up-to-date record and that inspections, thorough examinations and tests have been carried out as necessary.

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Whilst work is in progress

12 13 14

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Carry out the checks detailed in Appendix 1, plus: Check that daily and weekly inspections are being carried out. Ensure the crane is operating from planned and approved positions only in accordance with lift plans and method statements. Ensure that the signaller is available for each lift.

15

If outriggers are being used (blocked duties), ensure that they are fully extended, locked and adequately supported.

16

Check that tyres are at the correct pressure and in good, clean condition and that tracks are properly maintained.

17

Check that the crane is kept at a safe, predetermined distance from any open excavations or live overhead electricity cables.

18

Check, when travelling, that the load is secured and carried as near to the ground as possible and that tag lines are used.

19 20

Check that the rated capacity and radius indicators are in working order. Check that loads are not being slewed over any persons and that persons are not standing or walking under the load.

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21


Check, when travelling on sloping ground, that the driver changes the radius to accommodate the movement of the load.

Construction Site Safety 1.4.3 Appendix 3 Tower cranes Safety checklist Before starting work Carry out the checks detailed in Appendix 1, plus: Check that the appointed person has put in place a lift plan.

2

Check that the selected crane has been competent engineer supplied. Check that the correct operating information has been supplied along with it.

3

Ensure that the crane will be capable of lifting the required loads at the maximum required radius of operation.

4

Check that the ground is capable of taking the weight of the crane, the load and wind load. If in doubt, get ADVICE.

5

Ensure that any foundations have been designed and certified by a and a 'permit to load' issued.

6

Ensure that adequate ballast or counterweight units are in position and are correctly secured.

7

Check that a diagram or notice indicating the position and weight of removable ballast is prominently displayed.

8

Ensure that the approach and the base are as level as possible.

9

Check that the limit switch and other devices are installed to limit the travel of the bogie. Ensure that limit switches have also been installed to limit the crane travel on rails.

10

Ensure that the work area is kept free of obstructions, particularly where the crane operates on rails.

11

Ensure that there is an adequate power supply properly installed, earthed and tested. Where the crane operates on rails, ensure that they are also earthed.

12

Ensure that the weight of each load is known, and that the correct lifting accessories are available.

13

Ensure that a competent operator, who is sufficiently fit and has good eyesight, is available.

14

Ensure that a competent, trained signaller is available, and that the method of communication is understood by all involved in the lift.

15

Check that there are no restrictions on the access, i.e. check size(s) of vehicles for rigging/de-rigging.

16

Ensure that all necessary precautions with regards to live overhead electric cables have been taken.

17

Where necessary, ensure that all work areas are adequately lit.

18

Where appropriate check that any building or temporary works to which the crane is tied can support the loading.

19

What is the crane's free standing height? Check that the supplier has provided information with reference to the crane, etc.

20

Where appropriate, check that over-sailing and airspace rights have been agreed.

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21

Check that warning has been given of the slewing activities and that property has been protected, as necessary.

22

Check that there is an up-to-date record of inspection, thorough examination and test.

23

Check that there is a rescue plan in place and that it is acceptable in terms of practicality.

24

Check the competency, including training and qualifications, of the competent persons involved in lifting operations.

Whilst work is in progress Ensure that the works are being carried out in accordance with the lift plan.

26

Check that the daily and weekly inspections are being carried out and recorded.

27

Check that the rails, if used, are level, in line and being guarded.

28

Check the position and condition of the sleepers, etc. (Look for washouts.)

29

Check that the buffers are in place and that they are secure (if on rails).

30

Check that the bogie is blocked and chocked when not in use (if on rails).

31

Check that no nuts or bolts are missing or loose.

32

Check that crane ties, if used, are securely fixed in position.

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Check that the wind speed indicator is in working order. What wind speed is allowed for safe working?

34

Check that, when not in use, the crane jib is free to slew with the wind. Check that power supplies are off; loads lowered, hooks raised and doors locked.

35

Check the slewing movements in relation to people or adjacent property, etc.

36

Check that earth bonding strips are in place.

37

Where more than one tower crane is in operation with overlapping arcs of operation, ensure that crane activities are co-ordinated.

38

Ensure that the load rating chart is in place and being complied with.

39

Ensure that the rated capacity indicator is in working order.

40

Check that the SWL is plainly marked at different operating radii along the jib.

41

Ensure that all lifts are within the jib radius.

42

Ensure that operators know the weight of loads being lifted.

43

Ensure that loads are being lifted and not dragged, and that they are not swinging and creating a hazard.

44

Ensure that the operator is at the controls whenever a load is suspended.

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Construction Site Safety 1.4.3 Appendix 4 Slinger and signaller safety checklist Inspect to ensure that: 1

slings and other chains are not shortened by tying knots in them or by wrapping them round the crane hook fibre or rope slings are not damaged

3

chains are not joined by means of bolts or wire

4

wire ropes are not sharply bent or flattened at any point

5

wire ropes are never in contact with hot metal or acids that will damage them

6

wire ropes are never used singly when hooked by a spliced eye. (The cable is liable to untwist, allowing the splices to open and slip)

7

the proper pin is used in all shackles and the correct type of shackle is being used

8

all end links, rings or shackles ride freely on any hook on which they are used

9

the wind strength is safe for lifting operations to start.

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Reject:

any slings of insufficient length which create a wide angle between legs

11

extra long slings which seriously reduce the headroom

12

any wire ropes that have become damaged or rusty

13

any fibre or rope slings that are damaged or frayed.

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When loading

Ensure the slings are protected from sharp-edged loads by packing soft wood or other suitable material between the load and the sling. (Bricks are not suitable packaging material.)

15

Ensure the load is evenly distributed to avoid excessive stress on one side of the sling.

16

DO NOT let any load rest on a wire rope; it may crush the strands and render the rope unsafe.

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Before lifting 17

Ensure that the load is securely slung.

18

Always see that the crane hook is centrally placed over the load to prevent it swinging when the load is being raised, and that the load is in balance.

19

Position the hands well away from any chains or ropes before the crane takes the load.

20

Check that the load is free for lifting.

21

Give warning to all persons to keep clear of the load.

During lifting 22

Use only British Standard 7121 signals.

23

Always lift slightly, then pause to see that the load is safe and balanced.

24

Ensure signals are given by the person responsible for the lift, and nobody else.

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25

Ensure hooks and slings not in use are carried on the carrying hook, since they may cause the sling carrying the load to ride on the nose of the hook.

26

Never ride on a crane load, or allow any other person to do so.

27

Whenever possible, keep the load clear of people.

28

Ensure chains, slings, hooks or loads are never dragged along the ground.

When unloading 29

Make sure there is a firm foundation for the load, and make provision for the removal of all slings.

30

Stack

securely

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provide

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access

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subsequent

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Inspection and thorough examination

Thorough examination

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Inspection

Reports

Lifting equipment and accessories for lifting

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Lifting equipment and accessories for lifting

If appropriate and at suitable intervals between Before first use, unless a record Lifting equipment accompanies the lifting thorough examinations. equipment. Installation conditions (Suitable intervals, unless require assurance that it is safe otherwise laid down, would to use: be every week.) Carried  after installation out by a competent person.

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Lifting equipment



after assembly. When exposed to conditions causing deterioration:



lifting persons - every six months



other lifting equipment every 12 months.

User or owner

Follows the thorough examination. Report authenticated. Format - register or certificate, electronic form (easily retrievable). Provided to the user, and to the person from whom the equipment has been hired or leased in writing. Kept available for inspection. Kept available until next examination carried out or for two years, whichever is the longer.

In accordance with an examination scheme drawn up by a competent person. Carried out by a competent person. Accessory for lifting

If appropriate and at intervals Before first use. When exposed between thorough examinations. to conditions causing Carried out by a competent deterioration: person.

 every six months, in accordance with an examination scheme drawn up by a competent person. Carried out by a competent person.

Accessory for lifting

Report kept available until next inspection report made. Made in writing and provided to user. Thorough examination record for two years after report made.

Health and Safety Executive

Following thorough examination identifying an imminent risk of serious personal injury. Report in writing.

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Construction Site Safety 1.4.3 Appendix 6 SCHEDULE 1

INFORMATION TO BE CONTAINED IN A REPORT OF A THOROUGH EXAMINATION The name and address of the Contractor for whom the thorough examination was made.

2

The address of the premises at which the thorough examination was made.

3

Particulars sufficient to identify the lifting equipment including where known its date of manufacture.

4

The date of the last thorough examination.

5

The safe working load of the lifting equipment or (where its safe working load depends on the configuration of the lifting equipment) its safe working load for the last configuration in which it was thoroughly examined.

6

In relation to the first thorough examination of lifting equipment after installation or after assembly at a new site or in a new location-

(b)

(if such be the case) that it has been installed correctly and would be safe to operate.

whether it is a thorough examinationwithin an interval of 6 months

(ii)

within an interval of 12 months

(iii)

after the occurrence of exceptional circumstances.

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In relation to a thorough examination of lifting equipment other than a thorough examination to which paragraph 6 relates(a)

(if such be the case) that the lifting equipment would be safe to operate.

In relation to every thorough examination of lifting equipment(a)

identification of any part found to have a defect which is or could become a danger to persons, and a description of the defect; particulars of any repair, renewal or alteration required to remedy a defect found to be a danger to persons;

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(c)

in the case of a defect which is not yet but could become a danger to persons(i)

the time by which it could become such a danger;

(ii)

particulars of any repair, renewal or alteration required to remedy it;

(d)

the latest date by which the next thorough examination must be carried out;

(e)

where the thorough examination included testing, particulars of any test;

(f)

the date of the thorough examination.

9

The name, address and qualifications of the person making the report including the Contractor they are employed by.

10

The name and address of a person signing or authenticating the report on behalf of its author.

11

The date of the report.

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Construction Site Safety D3. Appendix 7 Recommended crane signals

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Reproduced from BS 7121 Safe Use of Cranes Part 1

Note: The signaller should stand in a secure position, where they can see the load and can be seen clearly by the crane driver, and they should face the crane driver if possible. Each signal should be distinct and clear.


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Construction Site Safety 1.4.3 Appendix 8 Wind strengths and effects (Beaufort Scale) Windforce number

Description of wind

Wind effect locally

Speed Km/h ≤1

Speed m/sec

0-1

0

Calm

Calm, smoke rises vertically.

1

Light air

Direction of wind shown by smoke drift, but 1.1-5.5 not by wind or weather vanes.

2

Light breeze

Wind felt on face. Leaves rustle. Wind or weather vanes move.

5.6-11

2-3

3

Gentle breeze

Leaves and small twigs in constant motion. 12-19 Wind extends light flags.

3-5

4

Moderate breeze Wind raises dust and loose paper. Small branches move.

5

Fresh breeze

6

Strong breeze

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5-8

Small trees in leaf begin to sway. Little crested wavelets form on inland waters.

29-38

8-11

Large branches in motion. Umbrellas used with some difficulty.

39-49

11-14

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Near gale

Whole trees in motion. Becoming difficult to 50-61 walk against the wind.

14-17

8

Gale

Twigs break off trees. Progress is generally 62-74 impeded.

17-21

9

Strong gale

Chimney pots, slates and tiles may be blown 75-88 off. Other slight structural damage may be caused.

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Mobile Elevating Work Platforms

1.4.4.1 Key points Mobile elevating work platforms (MEWPs) are a safe and convenient alternative to scaffolds when working at height, providing they are used correctly by trained and competent operators.

2

On some types of machine it will be necessary for the operator and any passengers to wear a safety harness and lanyard, the free end of which must be clipped to a strong point on the machine.

3

Operators and passengers must never clip the free end of the lanyard to the structure against which they are working.

4

Normally, MEWPs should only be operated from the controls in the basket or on the platform.

5

The ground level controls should only be used in an emergency such as the operator becoming incapacitated when the machine is elevated.

6

MEWPs are classified as 'work equipment' and 'lifting equipment for carrying people' and must therefore be subjected to an appropriate schedule of inspections and thorough examinations.

7

MEWPs must not be used to carry any load above the stated safe working load.

8

When calculating the total load carried, consideration must be given to any additional materials 'taken on board' when elevated, such as a quantity of removed roof tiles.

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The term mobile elevating work platform (MEWP) covers pedestrian-controlled, selfpropelled and power-operated mobile elevating work and access platforms.

2

MEWPs are designed to provide temporary working platforms that can be easily moved from one location to another. They are particularly suitable for tasks where the use of a ladder would be unsafe and the erection of a scaffolding platform too time-consuming or impracticable in relation to the job to be done. Some machines have specialised applications.

3

When using MEWPs (as with all other types of work equipment), the Contractor has a legal duty to provide, as far as is reasonably practicable, a safe place of work and the necessary information, instruction, training and supervision ' for operators..

4

The manufacturer or hire company who supplies any type of MEWP to a contractor must provide familiarisation training on the type of machine they are supplying. The Contractor of the machine operator, however, has a legal duty to ensure the operator's overall competence and assess the risks arising out of the work activity for which the machine is to be used. It is essential that no one should be allowed to use the equipment unless they have been instructed and trained by a competent person on the specific type of equipment to be used, and have themselves been judged competent to use it.

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2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3


4

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other person who may be affected.

1.4.4.4 The Provision and Use of Work Equipment All MEWPs are classified as 'work equipment' under these Regulations and Contractors must:

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ensure that the equipment is suitable for the intended task

(b)

maintain and keep the equipment in good working order (or ensure that it has been properly maintained if a hired-in machine)

(c)

ensure the equipment is subjected to a scheme of regular inspections (or has a valid certificate of thorough examination if a hired-in machine)

(d)

provide competent supervision.

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3

Dangerous parts of machinery must be adequately guarded, preferably by fixed guards that cannot be defeated or removed.

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All MEWPs are classified as 'lifting equipment' (for lifting people) under these Regulations. The main requirements of these Regulations are that: lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

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(b)


(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person or the load otherwise becoming out of control

(d)


(e)


(f)


(g)

lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate

(h)

reports of thorough examinations must be made and retained, with all defects notified to the Contractor who must take appropriate actions.

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1.4.4.6 Work at Height The fact that a MEWP is in use is indicative that someone is going to work at height. The key provisions of these Regulations are (briefly) that Contractors must: where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, make sure to select the most appropriate work equipment for the work and to prevent falls

(c)


(d)

ensure that the work is properly planned, risk-assessment based and that it is carried out safely by competent persons

(e)

establish danger areas from which people must be excluded, when there is a danger of them falling or being struck by falling objects

(f)


(g)

Employees who work at height, for example MEWP operators, must:

(h)

report to the Contractor any situation that they consider to be unsafe to themselves or to anyone else

(i)

use any work equipment, such as a MEWP, in accordance with the training and instructions provided.

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These Regulations require that, where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees. In essence, PPE may only be used as a last resort.

2

In the context of using MEWPs, PPE will include items of fall-arrest equipment, such as harnesses and lanyards, although consideration must also be given to the provision of PPE that protects against hot, cold and wet weather in the appropriate circumstances.

3

Whilst the Contractor must, as far is reasonably practicable, ensure that any PPE supplied is correctly used or worn, the employee, in turn, has a duty to properly use or wear the equipment, follow any information, instruction or training which they have been given, and know the procedures for reporting loss or defect to their Contractor.

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1.4.4.8 Types of MEWP 1

2

The basic types of mobile elevating work platform are: (a)

scissor lifts

(b)

telescopic booms or jibs

(c)

articulating and telescopic booms. All of these may be:

(d)

towable units

(e)

vehicle-mounted

(f)

self-propelled, or

(g)

pedestrian controlled.

The main functional differences between the three basic types of platform are described below.

Scissor lift: This type of appliance gives a vertical lift only. It may be fitted with outriggers, depending on its size and the height to which it extends.

4

Hydraulic extending boom (telescopic): This type gives both vertical height and outreach. The working platform may also be manoeuvrable.

5

All boom-type MEWPS are generally known as 'cherrypickers'.

6

Articulating and telescopic or multi-boom articulated: These types of equipment are usually vehicle mounted. They give a wide range of reach and height, with good platform mobility. They are nearly always equipped with outriggers. There are specialised types, for instance, machines that enable access to the underside of bridge arches from the roadway above.

7

Some units have a 'travel while elevated' ability and fourwheel drive. Rough terrain MEWPs have been specially developed for construction site work.

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1.4.4.9 Sizes 1

Sizes and capabilities vary considerably. Small, one-person platforms are available, with safe working loads of about 100 kg, and working heights of a few metres.

2

At the other end of the scale, platforms may be over 4 m x 2 m in size and have safe working loads in excess of 1,000 kg. Extending boom heights exceeding 60 m are obtainable and the outreach of some units can exceed 30 m.

3

The work activity which results in the use of MEWPs must, of course, have been subject to a risk assessment.

1.4.4.10 Causes of accidents MEWPs can provide safe access and safe working at heights, and are often safer than ladders or other access equipment. However, there have been a number of serious accidents in which operators have been thrown from MEWPs, particularly 'cherry pickers'. This can be caused by such events as the moving basket snagging an obstruction or the operator simply leaning too far beyond the guard-rail. In many cases, the wearing of a safety harness and short restraint lanyard, clipped to a strong point inside the basket, would have prevented the accident. This advice relates primarily to 'cherry pickers' but it is also relevant to scissor lifts if the operator is at risk of falling, for example, as a result of leaning too far over the guard-rail.

2

The typical 'cherry picker' consists of one or more pivoted arms. Movement from a single pivot causes the basket to move through an arc. To make the basket move in a straight line, for example up or down the face of a building, the operator must adjust more than one control either alternately or simultaneously. Accidents can occur when the operator is too 'heavy handed' with the controls, or the actual movement of the basket in relation to the degree of control movement is too coarse. This may cause the basket to move further and more rapidly than anticipated, or the operator may not be able to compensate quickly enough for the 'arc' movement. This may result in the basket striking, or being obstructed by, a nearby structure. If this occurs and power continues to be applied, the basket could become jammed and it is possible that a structural failure of part of the machine or a sudden movement of the basket could throw the operator out.

3

Other significant causes of accidents are: when a nearby vehicle or mobile plant strikes the MEWP, for example, if part of the boom encroaches into a traffic route or if road traffic skids into the machine on wet or icy roads

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(b)

entrapment of the operator below a fixed object whilst elevating the basket or platform

(c)

failure of the levelling system or a major component of the MEWP

(d)

an unexpected movement or overturning due to incorrect installation, or soft or uneven ground

(e)

falls from height whilst climbing from a MEWP onto a roof or other high level place. (MEWPs are intended for use as work platforms and not as a substitute for stairs to gain access to upper levels)

(f)

lack of information, instruction and training resulting in collisions whilst manoeuvring

(g)

where the nature of work being done from the basket may mean that operators are likely to lean out. This may happen, for example, when operators: (i)

inadvertently, or for reasons of speed and convenience, overreach or stretch from the basket and overbalance, or

(ii)

are handling awkward workpieces which may move unexpectedly

QCS 2014


(h)

where rapid movement of the machine is possible

(i)

where there are protruding features which could catch, impede or trap the basket.

4

Error of judgement by operators, or a lack of sufficient information, instruction, training and supervision can cause rapid movement of the basket and collision whilst manoeuvring. Whilst many incidents have been attributed to 'operator-error', these errors are foreseeable and should be considered as part of the Contractor's risk assessment.

5

The Contractor's risk assessment should, therefore, consider: information, instruction, training and supervision

(b)

competence and operator suitability

(c)

the degree of fine control that is necessary and available for the safe movement of a MEWP

(d)

the condition, suitability and maintenance of the MEWP

(e)

the need for, and use of, fall-arrest or fall restraint equipment.

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(a)

1.4.4.11 Controlling the risks

Having assessed the risks, Contractors and others responsible for the use of MEWPs must implement measures to control those risks.

2

The precautions for safe working from a MEWP include: ensuring that a MEWP is suitable for the job to be undertaken, as revealed by a risk assessment

(b)

ensuring guard-rails and toe-boards are fitted to the platform or the basket

(c)

ensuring the machine is never overloaded

(d)

using stability devices provided, i.e. outriggers, to make the machine stable

(e)

the provision of designated anchorage points for the attachment of lanyards

(f)

locking-out controls (other than those in the basket) to prevent unintentional operation

(g)

correct planning of the proposed task

(h)

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use of trained, competent and experienced operators

instructions when to enter or leave a basket, such as when it is fully lowered

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instructions for emergency procedures, such as rescue should the operator be incapacitated

(k)

use, as and where necessary, of suitable fall restraint equipment or, in high-risk situations, fall-arrest equipment.

1.4.4.12 Fall protection Work restraint system 1

Whereas fall-arrest equipment allows a person to fall but arrests the fall before the person hits the surface below, work restraint equipment prevents the fall from happening.

2

The main feature of work restraint equipment is that a shorter lanyard is used which restricts the operator's limit of travel to the confines of the basket or platform.

3

Lanyards should be carefully selected, taking into account the features of the machine on which they are to be used, to ensure that the user cannot get into a situation where a fall

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could occur. 4

BS EN 358 specifically states that such devices are not intended to arrest a fall.

Fall-arrest system 5

This passage of text refers predominantly to the use of 'cherry pickers', although in some circumstances parts could also be relevant to the use of scissor lifts.

6

Where a decision has been taken to rely on fall-arrest equipment as a means of preventing injury, it will be necessary for the operator to wear a full body harness and a lanyard equipped with an energy absorber. Vital considerations are: the height at which work is being carried out must be such that it allows the lanyard to arrest the fall and the energy absorber to deploy before the wearer hits the surface below. A minimum working height of 5 metres is recommended if fall-arrest is to operate successfully

(b)

the anchor point on the machine must have been designed to withstand the shockloading of arresting a fall. Many anchor points fitted to MEWPs are only rated for work restraint. If the anchor point is not marked with its rating, contact the manufacturer to find it out

(c)

users of harness and lanyard must have been trained in their use, inspection and care

(d)

in arresting a fall, a 'cherry picker' will flex, which could eject other occupants and materials out of the basket. This could also overturn the machine if it is operating towards the extent of its lateral operating-envelope

(e)

a check must be made that the structure has no projecting features that the falling person would strike during the fall

(f)

how the person who has fallen will be rescued after the fall has been arrested. This may be as simple as another operator gently lowering the boom of a 'cherry picker' using the ground level controls until the fallen person is at ground level.

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(a)

A safety harness must never be attached to anything outside the platform; operation of the controls in this situation could leave the user suspended in mid air (see illustration above).

8

An exception to wearing a harness whilst operating a mobile elevating work platform is when the machine is working over or near water. If a harness is being worn in such circumstances and the MEWP toppled into the water, the operator could be dragged under the water and drowned. The wearing of harnesses in such situations is not recommended, although operators should wear life jackets.

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1.4.4.13 Safe operation of MEWPs Safety helmets 1

Safety helmets must be worn if there are overhead obstructions in the area of operation or if there is a possibility of injury resulting from falling objects. On all building and construction sites, the wearing of safety helmets is mandatory. Chin straps should be worn to prevent the helmet slipping off and falling to a lower level and perhaps injuring someone.

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Safe working load 2

The safe working load (SWL) specified by the manufacturer must not be exceeded. The maximum number of persons permitted on the platform may also be given but, if it is not, 8590 kg of the SWL should be allowed for each person.

3

Care must be taken not to exceed the SWL with tools and equipment when work is being carried out from the platform.

4

Examples of how this can also be caused are:

(b)

the removal and lowering of fans, motors, pipework, window frames or other equipment from high level onto the platform prior to removing them for repair, maintenance or replacement

(c)

the temporary storage of removed materials, such as roof tiles

(d)

any form of shock loading.

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allowing an accumulation of plaster, cement, blasting grit or other loose materials

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(a)

It is usual for a single SWL to be specified for all conditions of height or reach.

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Height and reach

The figures given by manufacturers are the maximum possible; allowance has already been made for the physical height and reach of the operator.

7

If it becomes evident that the task requires a range of travel that is outside the reach of the machine, work must be stopped and the job reassessed. Steps, ladders, hop-ups or boxes must never be used on the platform or in the basket to gain extra height or reach.

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Operating envelope

All configurations of MEWPs have an operating area or envelope. With scissor lifts, the operating envelope will be determined by the maximum height and width of the platform; with articulated booms, it is a more complex shape.

9

As maximum height and maximum reach are not usually available at the same time, care is needed to ensure that the intended work area is within the machine's operating envelope (see diagram below).

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Ground conditions 10

MEWPs are often fitted with outriggers or stabilisers and these must always be fully deployed and used as recommended by the manufacturer. Attempting to operate the unit too close to a building or obstruction can make it impossible to fully extend the outriggers, and therefore unsafe to use.

11

Before deploying stabilisers or outriggers, check: (a)

that the machine is either level, or can be levelled up

(b)

that the ground is firm, without hidden voids and will support the loading with the use of adequate packing if necessary

(c)

that the machine will not have to pass over a cellar, basement, sewer, drain, manhole, old trench, uncompacted backfill or anything else that might collapse; consider the possible need for a ground survey.


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Travelling in operational mode

Travelling with the platform occupied or boom extended should only be undertaken when this mode of operation is within the machine's specified capabilities. Travel must never take place with outriggers or stabilisers extended, unless the machine is designed to function in this way.

13

Before travelling, a check should be made to ensure:

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no ramps, trenches, holes or other ground obstructions lie in the path of travel

(b)

no overhead electrical or other (communication) cables, building projections or other overhead hazards will be encountered

(c)

adequate warning has been given to people on the ground

(d)

a signaller or other responsible person is employed, if necessary

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nothing has been left unsecured and liable to fall off no trailing hoses, cables, wires on the unit or other snagging hazards are in the path of travel.

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Travelling up and down inclines and traversing slopes should only be undertaken within the limits laid down by the manufacturers.

15

Specially designed units, designated as 'rough terrain', can operate (usually without any stabilisers or outriggers) on construction and other sites where ground conditions may not permit a standard type vehicle to be used.

1.4.4.14 Tandem use 1

Under no circumstances should two platforms be linked together or bridged. However, in some circumstances, manufacturers can advise on the interlocking of platforms and controls so that one set of controls operates both platforms, allowing directional stability to be maintained at all times.

2

If a unit is being used in conjunction with a crane or some other appliance, a safe system of

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work must be planned and implemented; it should clearly define individual responsibilities and set out precise arrangements for communication. Wind and wind speeds 1

A MEWP must not be used in wind speeds exceeding those specified by the manufacturer. One commonly specified wind speed upper limit is that of 48.28 km/h (Beaufort Scale Force 6 -Strong Breeze) or about 12.5 m per second. This is also generally accepted as the maximum wind strength in which an operator can work without undue discomfort.

2

Other problems associated with operating in windy conditions include: the funnelling effects of winds between buildings, where actual wind speeds may be double that measured in the open

(b)

in the vicinity of large slab-sided buildings, high wind speeds and eddy currents may be created at the corners and on the side facing the wind

(c)

the effect of height - wind speed may be 50% greater at a height of 20 m than it is at ground level; modern machines are fitted with a wind-speed sensor which, if activated, only enables the working platform to be lowered

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(a)

(b)

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Percentage to be added to ground level windspeed to correct for working height.

(d)

Height above ground at which platform will be used.

wind chill factor. On a calm day 10°C is cool but not unpleasant, but with a wind of 32.19 km/h the temperature experienced on the face and hands is 0°C. If the day is cold, about freezing, the temperature experienced on the skin can be down to minus 15°C, making it almost impossible for the operator to work safely unless properly clothed and equipped for the circumstances.

3

Problems may also arise when handling sheet materials, panels and other materials light in weight in relation to their area. They can act like 'sails' and seriously affect the stability of a mobile elevating work platform due to the excess wind loading. If such materials are to be used, due allowance should be made, especially in gusty conditions.

4

Because of the difficulty in accurately estimating wind speeds by the observation of trees, windblown litter, smoke, etc., a hand-held anemometer should be used where necessary.

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Use on roads 5

People trained to operate a vehicle-mounted MEWP on site may not drive it on a public road, unless they hold the appropriate licence.

1.4.4.15 Prohibited uses MEWPs must not be used: (a)

as jacks, props, ties or supports

(b)

primarily for the transportation of goods or materials

(c)

as an alternative to passenger hoist (for example, transporting workers to a high level floor slab)

(d)

as a crane or lifting appliance.

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Such uses are either outside the designed use and safe working limits of the machine, or would bring it under other statutory provisions, such as those applicable to cranes and hoists.

3

Platforms must not be tied to buildings or other structures to gain additional support. The operation of the controls in such circumstances could cause an accident or create another hazard.

4

Extra height should not be gained by using ladders, stepladders or similar devices on the platform or in the basket of a MEWP. If the machine itself does not reach the required height, it is the wrong machine for the job. An alternative machine must be obtained or an alternative (safe) means of access devised.

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1.4.4.16 Operator requirements

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Physical fitness

People nominated or applying for training as operators should meet the following general requirements: must have full physical mobility

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(d)

must have good hearing in case warning signals are given

(e)

must have the correct colour vision for colour-coded controls (the Ishihara colour test may be relevant)

(f)

must have the ability to accurately judge space and distance

(g)

must have good eye-to-hand co-ordination, and sufficient dexterity to operate the controls

(h)

must have good eyesight, with glasses if necessary. The ability to read a car number plate at 25 m is usually satisfactory

(i)

must have a stable disposition.

must have sufficient agility to climb in and out of the platform must have a good head for heights, and not be subject to vertigo or acrophobia (fear of heights)

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Fainting or dizziness may render people unsuitable as operatives.

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Duties of operators 3

The main duties of operators are: (a)

to operate the machine safely and without risks to themselves or anyone else who may be affected by the works which are being carried out

(b)

to operate the machine in compliance with the manufacturer's instructions and any other training given, and to ensure that it remains safe and stable

(c)

not to abuse, ignore or override any safety device or equipment

(d)

to report all defects, faults or dangerous situations

(e)

to stop work and seek advice in any conditions that they consider could be unsafe to themselves or anyone else.

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Training No-one should be allowed to operate a MEWP unless they have demonstrated their competence on the machine and have had proper and adequate training, unless they are under the direct supervision of a competent person as a part of their training.

5

A wide range of MEWPs is now available, and operators should be trained specifically for the type of machine in use that they are required to use. For example, a person competent to operate a scissor lift would need separate and specific training and become competent before they could use an articulated boom unit ('cherry picker').

6

Both knowledge and skill should be tested during training to ensure that the operative has achieved a satisfactory standard of competence.

7

For all types of unit, three main stages of training can be identified:

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basic understanding of the operating principles, and the knowledge necessary for the day-to-day operation of the platform

(b)

task-specific training and practice on the type of machine concerned, if possible under all foreseeable operating conditions

(c)

properly supervised on-site familiarisation to gain experience and confidence.

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It is important to ensure that operatives fully understand the functions of limit switches and interlocks, and the serious dangers which can be caused by defeating or overriding them.

9

Most manufacturers provide some form of training or offer training courses.

10

When units are hired, it is important to ensure that the hire company provides adequate operative familiarisation training unless trained operators on that type of machine are already available.

11

The demonstration of equipment by a manufacturer's or hire company's representative should not in itself be regarded as sufficient training for those who are to operate it. In addition, the ability and experience of demonstrators and instructors should be verifiable, especially in respect of the user's proposed mode of use of the equipment.

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Other points 12

Operatives should only be permitted to use the type of unit they have been trained and authorised to use.

13

After training, an 'in-Contractor license' should be issued and adequate records kept of initial and any further training.

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The safety element of the training must include safety awareness and recognition of hazards.

1.4.4.17 Hazards 1

Some of the more common hazards associated with the use of MEWPs are outlined below. The list should not be regarded as exhaustive.

Work on or near a highway A collision with another vehicle. Always use barriers, lights, cones, notices, guards, or arrange traffic diversions.

3

The knuckle or elbow of an articulated boom encroaching into a traffic lane. Always ensure adequate space is available.

4

Standing and operating the platform in a traffic lane. Ensure that adequate safety provisions have been made.

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Overhead electrical cables

Electric shock from contact with, or electric arcing due to close approach to, overhead electric cables is often fatal.

6

Always maintain a safe distance from overhead electrical cables. The absolute minimum distance, measured from the furthest point of outreach to the ground level barrier or point directly beneath the nearest conductor, must be at least 6 m (when there is not work or passage under the lines), although most electricity companies recommend 9 m.

7

High winds can cause cables to sway and significantly reduce this distance.

8

No part of any machine should be closer than 15 m to any overhead line on steel pylons (9 m if on a wooden or steel pole) unless by arrangement with the electricity company.

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Falls of people or materials 9

Ensure that fall-arrest or work restraint equipment is worn at all times.

10

Do not allow any loose materials to accumulate on the platform.

11

If there is any danger of tools being dropped from the platform or basket by the operator then, where practical, the tools should be securely tethered to a point within the basket; alternatively, the area beneath the platform should be regarded as a danger area.

Entrapment of people 12

All moving parts and mechanisms should be properly and securely guarded.

13

All operators should be made aware of the hazards and procedures for avoiding entrapment between the platform and any fixed obstruction.

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Overturning Check for soft ground, drains and other unsuitable ground conditions before deploying the outriggers or stabilisers; check for the hazard before siting the machine.

15

Beware of overloading, especially if the platform or basket is being used at maximum outreach to remove fans, motors or other heavy loads. Always observe the safe working load.

16

Be careful when operating on a slope, even with the machine properly levelled by using the stabilisers or outriggers.

17

Always check that the machine is stable before operating.

18

Be careful when travelling with the platform raised, especially on poor ground conditions.

19

Unless the machine is specifically designed to travel while the outriggers or stabilisers are deployed, never attempt to travel in this manner.

20

Be careful not to collide with any obstruction or other vehicle.

21

Modern machines are fitted with a 'tilt sensor' which, if activated, only enables the working platform to be lowered.

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Restricted or enclosed spaces

Extra care is needed when working in, or maneuvering into, restricted or confined spaces to avoid collisions and or entrapment. A full and precise understanding of all controls is essential.

23

If the self-propelled unit has an internal combustion engine, remember that the exhaust fumes will cause a hazard in any confined or enclosed space.

24

Batteries for units should not be charged in enclosed spaces. There is a hazard of explosive hydrogen gases being given off.

25

LPG powered vehicles should not be refuelled in a confined space. Any spillage of fuel will quickly and dramatically expand into a large gas cloud. The gas will then accumulate at the lowest point and create an explosive hazard.

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Interference with vehicles in public places 26

Additional interlocks or guards may be necessary to prevent the operation of, or tampering with, ground level controls by unauthorised persons or children.

27

Care should be taken against the risk of entrapment as a result of inquisitive people, and especially children, getting too close or underneath. Scissor lifts are particularly hazardous.

Other hazards 28

Never attempt to use a unit which has a nearly flat battery. This could result in the operator being stranded aloft, in which case an emergency descent procedure would be required.

29

Avoid knuckles, joints and hoses becoming encrusted with paint, blasting grit, cement or plaster. This can be avoided by using gaiters which are usually supplied by the manufacturer.

30

Beware of the sideways thrust or torque from a drill or hand tools, or the recoil or thrust of

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cartridge tools. Whenever and wherever possible, the platform should be square onto the work. If it is sideways on, any thrust or recoil will push the platform away from the workface. Boom length will increase this effect.

1.4.4.18 Inspections and thorough examinations The maintenance of MEWPs is an essential feature in ensuring their safety when in use. These Regulations require a competent person to draw up a schedule for maintenance, taking into account the machine's mode of use, its frequency of use and the conditions under which it is used.

2

These Regulations require the minimum of a thorough examination before being used for the first time and, thereafter, every six months or when exposed to conditions that may cause deterioration.

3

Records of such inspections should be kept until the next thorough examination or for a period of two years.

4

However, the following inspections are recommended.

5

Daily inspections at start of work, usually carried out by the operator. They should check the following:

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tyre pressures and wheel nuts

(b)

brakes and steering

(c)

fuel, oil, water, hydraulic fluid and battery levels

(d)

lights, warning devices and communications

(e)

structure for visible defects

(f)

all operating controls

(g)

all hydraulic fluid lines for any leaks, however small.

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(a)

(a) (b)

a check of all items covered under the daily inspection an operational check of all functions of the machine a close visual examination of the chassis and structure.

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Weekly inspections by a competent maintenance fitter or operator after a specific number of hours of use. They should be:

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A record that these inspections have been carried out should be kept. .

8

At six-monthly intervals or after 1,000 operational hours, or as recommended by the manufacturer, a thorough examination should be made by a competent person and a written report issued. A similar examination is recommended after an accident, major repair or modification.

Maintenance work on scissor lifts 9

Special care is needed in the care and maintenance of this type of MEWP. No work or inspection should take place within the stack of a scissor lift unless scotches or chocks are used to prevent any entrapment hazard arising from mechanical or hydraulic failure leading to movement of the elevating/lowering mechanism.

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Construction Site Safety 1.4.4 Appendix

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Mobile Elevating Work Platforms

Safety checklist

Has a risk assessment for the work been carried out?

2

Has the daily inspection been completed?

3

Are lanyards always clipped to a strong point on the machine?

4

Ensure that the wind speed is not excessive.

5

Are the correct signs and barriers erected?

6

Is the operative competent, authorised and fully fit?

7

Does the operator have access to a copy of the manufacturer's operating instructions?

8

Ensure that the safe working load will not be exceeded.

9

Ensure that it is all clear overhead.

10

Ensure that the ground conditions are satisfactory.

11

Ensure a current record of the last thorough examination is available prior to use.

12

Are all outriggers and stabilisers safely deployed?

13

Make sure that the machine is level.

14

Ensure as far as possible that there are no cellars, drains or other voids beneath the area where the machine will be working.

15

Make sure that all tools and materials are secure.

16

Is a work restraint system or fall-arrest system necessary and, if so, is it available and used?

17

Make sure that the platform is not slippery or obstructed.

18

Ensure that all work is within the specified reach of the unit.

19

If movement of the machine is planned, ensure that the route is clear and safe.

20

Ensure that there are no restricted or confined space hazards.

21

Ensure that no part of the machine will encroach into a traffic route.

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Ensure that the machine operator is aware of the location of all fixed structures to avoid the risk of entrapment.

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Hoists and Hoist Towers

1.4.5.1 Key points Such equipment must only be designed (where appropriate), erected and operated by trained and competent persons.

2

Partially completed hoists used to move scaffolding during scaffold erection offer special challenges.

3

It is vital that the design of the hoist includes how the hoist will be supported or tied into existing or temporary structures.

4

Hoists that are designated for the carriage of goods only must not be used for carrying passengers.

5

Materials which are unhanded or otherwise loose must not be loaded onto inclined or other types of mobile hoist in such a way that they can fall off.

6

Under no circumstances should the safe working load of a hoist be exceeded.

7

The safe working load will be displayed on a notice attached to the hoist; this is usually expressed as a number of persons for passenger-carrying hoists.

8

Particular safety precautions apply to hoist towers to ensure the safety of passengers (where applicable) and others working nearby.

Note:

Section 9, Part 7 of the QCS covers lifting equipment.

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Hoists of various types are widely used on construction sites. These range from complicated goods and passenger (tower) hoists, mobile hoists and inclined hoists, and still include the humble gin wheel. As pressure increases to become more efficient and reduce manual handling, hoists are an increasingly vital part of many construction operations. The smooth and rapid movement of persons and materials assists in efficient management of projects. Even where other methods of moving materials around site are to be used, for example by a tower crane, it is not unusual to find a hoist used solely to assist the scaffold" erection process.

2

The number and type of powered hoists available for hire has increased significantly and their use may require a lifting plan to be drawn up by a competent person. This would need to consider possible exclusion zones under the hoist in the event of the load dropping, safe slinging methods, the appropriate lifting accessories, and so on. These are a different set of risks compared with, for example, loads being carried within the enclosed cage of a goods hoist.

3

Risks can arise from a late decision to use a hoist to solve a previously unforeseen problem during the construction phase, for example, if planning to use a hoist attached to a scaffold system that is already in place but which was not originally designed to take the additional loadings. There is a need for careful planning and possibly discussions with the scaffold designer before simply allowing a hoist to be hired and fixed to the scaffold.

4

The installation of hoists requires good planning and co-ordination and must be undertaken by competent individuals. All hoists must be supplied and, where appropriate, erected, altered and dismantled by people who are aware of these Regulations and the relevant British and International Standards. Special attention must be given to ground conditions to ensure adequate support for the hoist. The forces imposed on the structure by the hoist, its loads and inclement weather, particularly high winds, must also be taken into account. Hoist operators must be adequately trained, competent and authorised; and should be specifically

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responsible for ensuring that the hoist is not overloaded or otherwise misused. 5

Except for manually operated hoists and any that have an independent power supply, the requirement for a dedicated power supply to the hoist must also be considered. Power requirements may also mean the need for generators, which introduces potential noise and fuel storage and spillage issues.

1.4.5.3 Health and Safety at Work (Construction Sites) Contractors must provide and maintain plant and systems of work that are, so far as is reasonably practicable, safe and without risk to health.

2

Contractors have a duty to provide their employees with all necessary information, instruction, training and supervision which is necessary to ensure, so far as is reasonably practicable, the health and safety at work of the employees. This applies in respect of all systems of work and all work equipment. In the appropriate circumstances, this duty is also extended to cover subcontracted employees.

3

Employees have a duty to take reasonable care of their own health and safety and the health and safety of others who may be affected by what they do.

Where a hoist tower has to be attached to an existing structure, the client's biggest problem is likely to be the provision of information on the location and load-bearing capacity of secure anchorage points. Given the complexity, size and loading of many systems, this will mean providing detailed information on the existing structure, which may necessitate the commissioning of specialist reports. These would be passed on to the designers and contractors to form part of the pre-construction information. Hoists impact on designers in two ways:

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whoever designs the hoist installation must be a competent designer as defined within these Regulations and therefore will assume all of the designer's duties under CDM

(b)

if the design concept is that the materials movement would be by hoist then it must be feasible to erect one. What will the hoist tie to? Are there additional security aspects that need to be considered? Have the attendant logistics for deliveries been considered, for example, can a road closure be obtained?

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Whoever appoints a contractor to provide a hoist will have to consider their competence. CDM contains details of the type of questions to ask to verify organisational and individual competence.

3

When considering the competence of potential contractors, relevant points for consideration would be:

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(a)

to establish how they would check the installation has been designed and installed correctly

(b)

the extent of the training they provide to users

(c)

the handover and subsequent inspection arrangements.

Whilst many site managers are competent to carry out weekly inspections of, for example a simple scaffold hoist, more complex hoists will require additional expertise.


These Regulations formalise the need for risk assessments. Each assessment must be made by competent people and must consider all aspects of the work. A significant factor for

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consideration is where the works will be carried out on occupied premises and where there is the potential for interaction between the construction activities and other people such as the public or the occupier's employees.

1.4.5.6 The Provision and Use of Work Equipment These Regulations require that all work equipment supplied by the Contractor must be safe and without risk to health when properly used, is correct and suitable for the job, and maintained in good working order. In respect of this module, this applies to hoist towers, inclined and other types of mobile hoist, including hired machines and those purchased second-hand.

2

Contractors must provide employees with adequate and appropriate training so that they may use the work equipment safely and without risks to their health, and without risk to the health and safety of any other person who may be affected.

3

Generally, these Regulations require:

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work equipment to be suitable for the job

(b)

proper maintenance of work equipment

(c)

thorough examination after installation before first use and at further suitable intervals by competent persons

(d)

proper recording of inspection results

(e)

its use restricted to specified persons, where necessary

(f)

adequate information to employees concerning risks

(g)

suitable and adequate training on the work equipment

(h)

the guarding of all dangerous parts

(i)

protection against specific hazards

(j)

effective controls, stop controls and emergency controls

(k)

adequate lighting

(l)

appropriate warnings.

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1.4.5.7 Lifting Operations and Lifting Equipment By definition, all types of construction hoist are classified as lifting equipment under these Regulations. The main requirements of these Regulations are that:

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(a)

lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

(b)


(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person

(d)


(e)

lifting equipment must be equipped with suitable devices to prevent a person falling down a shaft or hoistway

(f)


(g)


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(h)

lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate.

2

Reports of thorough examination must be made and retained, with all defects notified to the Contractor who must take appropriate actions.


The use of any kind of hoist will inevitably involve either persons working at height or loads being raised to height. In almost all cases the erection, dismantling, servicing, loading or unloading of hoists will require that persons work at height.

2

The relevant requirements of these Regulations are: Contractors to ensure that work at height is planned, supervised and carried out in a safe manner by competent person

(b)

work at height is carried out using appropriate work equipment, particularly that which provides collective fall protection

(c)

suitable and sufficient steps are taken to prevent falling objects which are likely to cause injury to any person

(d)

where there is a risk of a person being struck by a falling object, steps are taken to prevent unauthorised access into that area.

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When it has been decided (possibly as early as the tender stage) that a construction (tower) hoist will be required on site, requirements must be quantified with regard to: consideration of the locations for siting the hoist

(b)

the loads to be carried in terms of weight and whether goods only or passengers are to be carried

(c)

the likely loading on the structure and whether any enabling work or structural changes are required

(d)

any constraints in the position where the hoist can be erected and whether other features such as scaffolds must be modified to accommodate the hoist

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the loading on the hoist's foundations

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1.4.5.9 Pre-planning (hoist towers)

2

At an appropriate point both the user of the hoist, for example the Contractor, and the supplier of the hoist should each assign an 'appointed person' who must liaise with each other to ensure that all aspects of the hoist selection, delivery, erection and use are carried out safely. The user's appointed person may need to rely upon the experience and competence of the supplier's appointed person in order to fulfil their responsibilities.

3

The detailed requirements of these roles, both of which require specific training and previous relevant experience, are considered to be outside the scope of this module. If necessary, readers should refer to BS 7212:2006.

4

A full and detailed risk assessment should be carried out before a hoist is positioned. A method statement can then be developed, which must then be agreed with the user.

1.4.5.10 Site survey 5

Prior to delivery of the hoist it will be necessary for both appointed persons to visit the site to establish the practicalities of installing it. During the site survey the supplier's appointed person will determine the appropriate type of hoist required, based upon criteria and

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information on the intended usage of hoist provided by the user's appointed person.

(a)

co-location with materials storage areas

(b)

avoidance of hazardous features such as overhead cables

(c)

the need for safe access at all levels

(d)

safe access to the cage or platform at ground level

(e)

the need for foundations and drainage.

In selecting the most appropriate hoist, the supplier's appointed person will have to take into account such factors as: the space constraints of the area

(b)

access implications relating to the size and weight of the hoist components

(c)

ground conditions

(d)

the proximity of site features such overhead power lines, railway tracks, adjacent public thoroughfares etc.

(e)

other work that will take place whilst the hoist is in place and how the site might change during this period

(f)

foreseeable extremes in weather conditions.

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The findings of the survey will determine the optimum position for the hoist, based upon such factors as:

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1.4.5.11 Erecting hoists

Hoists which rest on the ground must only be erected on a firm base, adequately supported and secured. All materials supporting the hoist must be strong enough to support the weight of the completed hoist structure and its maximum load, and be free from defects.

2

The erection of the hoist must be carried out in accordance with a method statement that has been discussed and approved by the user, as the proposed method and timing may impact upon other site activities.

3

In many ways, this is the most dangerous part of the work. Anyone not directly involved in erecting the hoist should keep clear of the area.

4

However, planning how the hoist will be erected and deciding 'who is responsible for what' is key to implementing a safe system of work. This is particularly important where the hoist will be built in conjunction with the erection of a scaffold. It is essential that the erection, and later modification and dismantling, of hoists are properly planned, adequately supervised and carried out in a safe manner by competent persons.

5

Where the hoist is attached to and supported by a scaffold, the scaffold must be designed to take account of the imposed loadings. This becomes more important where the use of a larger capacity hoist is being considered. These can lift weights of 1000 kg to heights of up to 60 m and can obviously exert significant loading on the hoist anchorages and scaffold ties.

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1.4.5.12 Use of part-erected hoists 1

It is common practice for scaffolders to build three or four lifts of scaffold, raising the components by hand, followed by the hoist company erecting the hoist to the height of the scaffold. Further erection of the part-completed hoist is co-ordinated with the scaffold contractors so that it can be used for hoisting scaffold components, as it follows the scaffold up. In such circumstances, normal safe working practices may not be practical. For example,

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the rules regarding the interlocking of landing gates cannot be applied when some of the gates have not been installed. Detailed guidance is available and it is strongly recommended that anyone faced with this situation on their site obtains and reads it. The guidance is published jointly by the UK National Access and Scaffolding Federation.

1.4.5.13 Safety of hoistways, platforms and cages Where necessary to prevent injury, hoistways and/or the hoisting machinery must be segregated by a substantial enclosure at ground level. Suitable barriers must be installed at all other access points, over the full height of travel, and wherever persons could be struck by any moving part, to prevent injury and/or falls.

2

Consideration must be given to the area around the base of the hoist with regard to loading and unloading materials, and whether a ramp or pit is required to facilitate access to the platform.

3

The area between the cage or platform and the host structure (the threshold) must be suitably protected to prevent any person or material falling through the gap at each landing.

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1.4.5.14 Landings

Where access to a hoist tower is required at several levels, consideration must be given to the space requirements at each landing with regard to loading and unloading the hoist. It is essential that each landing and threshold (the area between the platform and landing) can withstand the loads that will be imposed, with particular emphasis on items such as pallet trucks which can impose significant point-loading.

2

The mechanical or electrical features of the hoist should ensure that:

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the gates at any landing point cannot be opened unless the cage or platform is at that landing point

(b)

the cage or platform cannot be set in motion unless all of the landing gates are closed and latched.

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Winches for hoists must be constructed so that a brake is applied when the control lever or switch is not held in the operating position (the dead-man's handle concept), or if the power fails.

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1.4.5.15 Winches

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1.4.5.16 Handover 1

Once erected, the hoist will be subjected to a thorough examination, after which the supplier's appointed person should arrange to formally hand over the hoist to the user's appointed person.

2

The user's appointed person should arrange for all trained operators to be present at the handover of the hoist to receive:

3

(a)

familiarisation training on the use of the hoist in normal operations

(b)

instruction on what to do in emergency situations

(c)

instruction on how to carry out the daily pre-use inspections and weekly inspections.

A handover report, containing details of the instruction given, should be passed to the user's appointed person.

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1.4.5.17 Operation of hoists It is essential that only operators who have been trained in the use of the hoist are allowed to operate it. The operator should: (a)

know the rated load of the hoist

(b)

be able to accurately assess the weight and distribution of any load brought on to the hoist, and therefore identify if it is overloaded

(c)

have access to accurate wind-speed figures and be aware of any limitations placed on the hoist

(d)

be able to lower the hoist to the next landing in the event of a power failure (passenger carrying hoists only)

(e)

carry out daily pre-use checks and weekly inspections, and take the appropriate follow-up action as necessary. On some complex hoists, it will be necessary for the weekly inspection will be carried out by an employee of the hoist company.

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Each hoist should only be capable of being operated from one position at any one time. Where the operator is not carried on the platform or cage, they must have a clear view at all levels from the operating position or, if they have not, arrangements must be made for signals to be given to them at each level.

3

Whatever the system of signalling used, it must be distinct and clear to the person being signalled.

4

It is reasonable to expect that the hoist operator and the person(s) giving signals are at least 18 years of age. Irrespective of their age, hoist operators must be trained and competent unless under constant supervision by a competent person, for the purpose of training.

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The platform of a goods hoist must carry a notice stating: the safe working load

(b)

that passengers must not ride on the hoist.

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1.4.5.18 Safety notices

Cages for passenger hoists must carry a notice stating: the safe working load

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the maximum number of passengers that can be carried

1.4.5.19 Carriage of persons in hoists 1

No person should be carried by a hoist, unless it is a designated passenger lift and it is provided with: (a)

gates that shut to prevent persons falling out or being trapped between the cage and any other part

(b)

an efficient interlocking device which ensures that gates can only be operated when the cage is at the landing place, and that the cage cannot be moved until the gate is closed

(c)

an efficient automatic overrun device to ensure the cage will come to rest at its lowest point of travel.

2

The construction of the cage must be such as to protect passengers from falling objects.

3

No person should be allowed to travel in a hoist that is designated a 'goods only hoist'.

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1.4.5.20 Security of loads All loads must be secured to prevent any part slipping and falling.

2

Loose materials, for example, bricks and slates, must be lifted in a properly designed box, cage or other container. If loose materials are carried on the platform of a hoist, side boards must be fitted or other precautions taken to prevent anything falling. Wheelbarrows must be prevented from moving and must not be overfilled.

3

If hiring a powered scaffold hoist, consideration must be given as to how loads will be slung. Hoisting a wheelbarrow full of render using fabric slings is not likely to be considered as an acceptable or safe solution. Some of these now have a lifting capacity of 1000 kg and are far removed from simple powered gin wheels. The use of the proper lifting accessories, which can be hired-in with the hoist, is strongly recommended.

4

The slinging of loads may become an issue and whilst the suppliers may call the equipment a hoist, some are more akin to cranes, and users may, depending upon the nature of the load, need to be trained in safe slinging techniques.

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1.4.5.21 Inspection and thorough examination of hoists Inspection 1

These Regulations recommend that construction hoists are subjected to the following regime of checks and inspections, by a competent person who has been trained to the appropriate level. (a)

Daily pre-use checks, carried out by a person who has been trained to do it. This will often be the hoist operator who has been trained by the hire company.

(b)

A more thorough weekly inspection, which, depending upon the complexity of the hoist, may be carried out by the trained hoist operator. A greater degree of

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Section 11: Health and Safety Page 94 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) competence is required than for carrying out daily checks.

2

In either case, any defect discovered should be reported to the user of the hoist and, where necessary, the hoist put out of use until rectified.

3

In addition, passenger or goods hoists must be tested each time:

4

(a)

the height of the hoistway is altered or

(b)

gates or ties are added or removed to check for safe operation of the hoist.

Hoists which are not in regular use may need a special programme of checks, carried out by a competent person.

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All hoists must be thoroughly examined by a competent person: before first use on site

(b)

after substantial alteration, modification or repair

(c)

after any exceptional circumstance, such as accidental overloading, and

(d)

at least every six months if used for carrying passengers, or

(e)

at least every 12 months if used for carrying goods.

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Thorough examination

Accessories for lifting must be thoroughly examined at least every six months.

7

If, as a result of any thorough examination, a risk of imminent personal injury is identified, a copy of the report must be sent without delay to the Qatar Enforcing Authority.

8

Note: Where manufacturers recommend inspection at different intervals to the statutory periods, such recommendations should be followed and records kept.

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1.4.5.22 Keeping of reports, records, etc. These Regulations require that all testing, inspections and examinations are carried out by a competent person, and records kept by ways or means best suited to the needs of the Contractor concerned.

2

This enables the keeping of records in an electronic format provided that:

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(a)

the correct information is kept as is required by these Regulations

(b)

it is secure against loss or unauthorised interference

(c)

it is capable of being provided as a printed copy

(d)

it is authenticated by a competent person.

The reports or copies would normally be stored at the premises where the lifting equipment, in this case a hoist or hoists, is being used. Where this is not possible due to space constraints or for security reasons, then reports can be stored elsewhere, such as on a computer, provided that they are readily accessible.

1.4.5.23 Mobile hoists 1

Mobile hoists and conveyors are now commonly used throughout the construction industry. They can be easily transported to the site, are quickly erected and require little operating space. They may be fitted with buckets, skips, platforms or cages.

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Different models allow for basic height variations of between 8 metres and 30 metres, although much greater heights can be reached with extensions. Load capacity varies with the model but lifting capacity of 500 kg is not untypical.

1.4.5.24 Scaffold cranes or barrow hoists These are lifting appliances within the meaning of these Regulations

2

Care must be taken to see that they are not overloaded and are only attached to scaffolds in strict accordance with the manufacturer's recommendations and the scaffold design.

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1.4.5.25 Inclined hoists

These are lifting equipment within the meaning of these Regulations. They are particularly useful for trades such as bricklaying and traditional roofing, and indeed on a larger project they have the potential to eliminate a significant amount of manual handling.

2

Inclined hoists are also known as roof tile or brick carriers. New developments include telescopic and slewing functions. Load capacities go up to 200 kg and lateral extensions may be up to 35 metres.

3

Inclined hoists are specifically designed for use at angles between 10° and 85°, and they may also incorporate a hinged section to allow the hoist to follow the pitch of a roof.

4

They also provide flexible solutions to the problems of removing demolition waste in refurbishment situations. As they are in effect a conveyor belt system, care needs to be taken to ensure that the guards to the rollers are in place to ensure that fingers and/or clothing can not be dragged in. These are so called 'in running nips' and particularly where the motor driving the hoist is powerful the potential for serious injury is significant.

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1.4.5.26 Gin wheels

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In many cases provision has to be made to raise tools and light materials manually with a rope and gin wheel or single block. Whilst these are still in common use, modern variants are available, which incorporate an automatic locking mechanism to prevent the load from going into free-fall if the hoisting rope is accidentally released.

2

The following provisions and requirements apply to gin wheels connected to a scaffold:

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poles and hooks should be strong enough to take the load which is to be lifted and be properly secured to prevent movement

(b)

all ropes should comply with the relevant British or International Standard and fit the wheel correctly. They should be marked with a tag confirming their safe working load

(c)

preferably, the gin wheel should be suspended from a ring-type fitting passed over the end of the supporting tube and secured against lateral movement by scaffold fittings. If using a hook type, it

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Section 11: Health and Safety Page 96 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) should be properly lashed and moused (see diagram opposite)

(d)

any joints in standards should be made with sleeve couplers

(e)

gin wheels should be suspended not more than 750 mm from the outer support

(f)

hooks used for supporting materials should be safety hooks and spliced into the rope

(g)

the maximum loading should be no more than 50 kg at 750 mm from the outer support.

Inspection and thorough examination Whilst of simple construction, gin wheels are categorised as lifting equipment so must be thoroughly examined before use and then at least every 12 months, with a test certificate issued.

4

Similarly, the lifting accessories used -such as the rope, hook and shackles -must be thoroughly examined before use and then at least every six months.

5

Given the scope for the harsh treatment of this type of equipment, all parts of a gin wheel assembly should be thoroughly examined at least every six months.

6

The extent of any thorough examination should reflect the risks that would arise from its failure.

7

Where scaffolds are not available, other suitable anchorages must be provided if necessary by using counterweights.

8

If the appliance to be attached is a gin wheel, a safety factor of not less than three must be allowed when calculating the weight of the counterweight.

9

If the load to be lifted is G (in kilograms), twice G must be allowed because of the downward pull on the tail rope when raising the load; to this 0.5 G is added for friction.

10

To calculate the counterweight required, the following formula should be used: W = 3(2.5 x G x 0) T

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Where:

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W = Counterweight T = Tail length (metres) G = Greatest load to be lifted 0 = Overhang (metres) Reference BS 1261, BS EN 698, 699, 700 and 701

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Construction Site Safety 1.4.5 Appendix 1 Hoist towers safety checklist Pre-planning Have design calculations been obtained to ensure that the host structure can withstand the loads

2

Have the risks associated with having the hoist delivered, erected, used, modified and dismantled been assessed?

3

Have relevant other parties been informed of how these activities will affect the work that they have to do?

4

Has a method statement been agreed between the hoist company and the user?

5

Have the hoist company and the user each selected an 'appointed person'?

6

Has there been sufficient liaison between both appointed persons?

7

Have arrangements been made for the installation and testing of an adequate and safe electrical power supply?

8

If the hoist is not electric, have arrangements been made for the safe storage and decanting of petrol?

9

Is a foundation necessary and if so:

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is a design necessary?

(b)

is the extent of enabling work known?

(c)

must arrangements be made for drainage?

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Protection and access

Is the hoistway and any moving parts of its machinery protected by an enclosure?

2

Is the hoist tower completely enclosed on all four sides with wire mesh (except any landing)?

3

Have appropriate measures to taken to ensure safe access to the cage or platform at ground level?

4

Is it not possible to set the hoist in motion whilst any gate at ground level or at any landing is open?

5

Can the gates at any landing point only be opened if the cage is at that landing point?

6

Is any gap between the platform and tower (threshold) closely boarded?

7

Are landing stages kept free of plant or materials?

8

Is the hoist fitted with an overrun device at its highest point?

9

Is the hoist fitted with an efficient device capable of supporting the platform and load in the event of a failure of ropes or lifting gear?

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Loadings 1

Are loadings placed on a hoist tower as recommended by the manufacturer?

2

Are all loads evenly distributed?

3

Are loads prevented from displacement?

4

Are all wheelbarrows chocked?

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5

Is a safe working load notice displayed on the platform or cage and can it be clearly seen at all levels?

6

Is the safe working load strictly complied with?

7

Is the carriage of passengers on goods only hoists clearly prohibited and this communicated by appropriate signs?

8

Are special precautions put in place when the load will overhang the cage or platform?

Operation Is it clearly understood that the hoist must not be operated from inside the hoist enclosure?

2

Are the hoist controls so arranged that the hoist can only be operated from one position at any one time?

3

Is the operator's position safe and adequately guarded with hand-rails and toe-boards?

4

Is the operator provided with a clear view of the platform at all times?

5

Are all operators trained, competent, and not under 18 years of age (unless under constant supervision of a competent person)?

6

Are all signals connected with the operation of the hoist clear and distinct?

7

Is adequate lighting provided at all loading places?

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Testing and thorough examination

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Hoist

All hoists should be tested and thoroughly examined before use and after any substantial alteration or repair.

2

All material (goods) hoists should have been subjected to a thorough examination within the preceding 12 months.

3

It is good safety practice for all hoists to be inspected weekly by a competent person.

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Winch

All material (goods) hoist winches must be thoroughly examined every 12 months, or in accordance with an examination scheme of lesser intervals.

2

All hoist winches should be inspected weekly by a competent person.

3

All wire ropes used in conjunction with a material hoist winch must be thoroughly inspected every 12 months, or in accordance with an examination scheme of lesser intervals.

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Major defects 1

Any report relating to a thorough examination of a hoist showing that there is a defect involving an existing or imminent risk of serious personal injury must be sent to the Qatar Enforcing Authority.

2

Any such report must also be given immediately to the Contractor. The hoist must not be used before the defect is rectified.

Recording requirements Tests and examinations 1

Tests and examinations must be recorded before first use, after re-erection, alteration or repair and following alteration in height of travel.

2

The results of thorough examinations carried out before first use must be recorded in

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whatever manner the company requires and that record must be available for inspection.

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It is good practice to ensure that a weekly inspection is carried out and recorded in whatever manner the company requires and kept available for inspection.

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Plant and Work Equipment

1.4.6.1 Key points The term 'work equipment' is self-explanatory and very wide ranging; it refers to any item of equipment being 'used' to carry out work.

2

The word 'used' means any activity involving the work equipment, including: starting, stopping, repairing, modifying, maintaining, servicing or repairing.

3

Examples are an excavator, a hammer, a cement mixer and a hydraulic trench-support system.

4

Broadly speaking, the effort necessary to comply will depend upon the complexity of the equipment and its potential to cause harm; for example, a trowel will not require the same level of inspection as an electric goods hoist.

5

These Regulations also require anyone who uses an item of work equipment to be trained and competent to do so.

6

The effort and time needed to achieve the required level of competence will depend upon the complexity of the equipment and its potential to cause harm.

7

Work equipment must be inspected as necessary to ensure that it can continue to be used safely.

8

Certain work equipment must also be subjected to a schedule of thorough examinations.

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It is all referred to as 'work equipment' and includes all: toolbox tools, such as hammers and screwdrivers

(b)

powered tools, including electric and pneumatic (such as hand drills and circular saws)

(c)

testing and laboratory equipment, such as cube crushers

(d)

complex structures and machines made up of other components and equipment are also covered, such as scaffolds.

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Some types of powered hand tools, such as engine-powered cutting-off machines and chainsaws, have the potential to cause severe personal injury unless they are used by trained and competent persons in appropriate circumstances.

3

Another type of equipment commonly used in the construction industry that has the potential to cause harm if not properly used is mechanical equipment that operates through the application of leverage or torque. This includes jacks, winches and various cutting and bending tools that incorporate manually operated mechanisms.

4

Tools and equipment operated by air also cause significant injuries upon failure of the tools or the connections to the compressor.

5

All items of plant are classified as work equipment, including static and mobile equipment, pedestrian-controlled equipment, ride-on equipment and remote-controlled equipment.

6

Plant used in construction operations on site includes static plant used in the actual construction work, such as mixers and pumps.

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1.4.6.3 Health and Safety at Work (Construction Sites) These Regulations place general duty on all Contractors to provide safe plant and machinery for use at work. The self-employed worker is given similar duties regarding plant and machinery that they provide for their own use.

2

Additionally, these Regulations place a duty on Contractors to provide the information, instruction, training and supervision necessary for persons to be able to operate the plant and machinery safely. Employees, in turn, are required to use the equipment safely, in accordance with the training which they have been given.

3

A general duty is placed on any person who manufactures, designs, imports or supplies any article, materials or substance for use at work to ensure, so far as is reasonably practicable, that articles and substances are, by design and construction, safe and without risks to health when being used, set, cleaned or maintained by persons at work.

4

In addition, duties are placed on employees not to recklessly interfere or misuse anything provided for health and safety purposes. This could include the act of removing a guard or defeating a safety cut out switch.

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1.4.6.4 The Management of Health and Safety at Work

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2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place, to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, as far as is reasonably practicable.

3

The Contractor must, through the risk assessment process, establish any risks to the health and safety of any employee (or anyone else) arising out of the use of any item of work equipment. They must take the necessary steps to ensure that the equipment can be used safely.

4

This will involve:

providing employees with comprehensible and relevant information on any risks that exist with regard to the use of work equipment

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(b)

informing employees of any control measures that are in place to reduce those risks

(c)

taking into account the capabilities of employees who are required to use work equipment

(d)

providing adequate (health and safety) training in the use of potentially hazardous work equipment.

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation that presents a risk to the health and safety of themselves or of any other person who may be affected.

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These Regulations are fundamental to the health and safety aspects of how work equipment is selected, used and maintained.

2

These Regulations place legal duties on Contractors with regard to work equipment that they provide to employees and the self-employed for their own use, and those who otherwise have control of work equipment, such as those who hire in equipment.

3

These duties are to: only provide work equipment that is suitable for the job

(b)

ensure that work equipment is maintained in an efficient state and kept in good working order by persons who are trained to do so

(c)

ensure that maintenance logs are kept up to date where they exist

(d)

ensure that where the safety of work equipment depends on the way it is installed, it is inspected as necessary and records of inspections made

(e)

ensure that equipment subject to deterioration through exposed conditions, which could give rise to a dangerous situation, is maintained and inspected at appropriate intervals to allow remedy, or after each exceptional circumstance

(f)

ensure that where the use of work equipment involves a specific risk to the health and safety of employees, the use, maintenance, repair, modification and service of the equipment is restricted to competent and specified workers

(g)

provide employees with information, instruction and training in the use of work equipment, where necessary for their health and safety, including abnormal situations

(h)

ensure that work equipment has been designed and constructed in compliance with any European Safety or International Safety Directives?

(i)

ensure that dangerous parts of machinery are adequately guarded, where practical, by fixed guards that cannot be defeated or removed

(j)

take measures to protect the health and safety of any person from exposure to:

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anything falling from or being ejected from any item of work equipment

(ii)

rupture or disintegration of any parts of work equipment

(iii)

work equipment overheating or catching fire

(iv)

the unintended discharge of any article, dust or gas which is produced by or stored in the work equipment

(v)

the unintended explosion of any item of work equipment or any article or substance produced, used or stored in it

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(k)

ensure that users of work equipment are adequately protected from any part of the work equipment that exposes them to very high or low temperatures

(l)

ensure that all work equipment has adequate controls, emergency controls and, where necessary, a control system to enable it to be used safely

(m)

ensure that where stop controls are fitted, they bring the machine to a safe condition. This may include bringing the machine to a complete stop and/or isolating it from energy sources

(n)

ensure that where stop controls are provided, they are easily accessible and activated

(o)

ensure that all controls for use are easily identifiable and that where reasonably practicable, the operator is in a position of safety when operating them

(p)

ensure that failure of any equipment leads to a safe situation and that the function of

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Section 11: Health and Safety Page 104 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) stop controls are not affected, if reasonably practicable ensure that each item of work equipment can be effectively isolated from all sources of energy

(r)

ensure that work equipment is stable in use, if necessary by clamping

(s)

ensure that suitable and sufficient levels of light are available for the safe operation of work equipment

(t)

ensure where reasonably practicable, that servicing, maintaining and cleaning of equipment is carried out whilst it is shut down or with appropriate measures in place to safeguard employees

(u)

ensure, where appropriate, that warnings are incorporated. These can range from signs and notices, to alarms and beacons.

Specific conditions apply to mobile and self-propelled work equipment that has the potential to cause injury to employees and third parties. These require the Contractor to:

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(q)

ensure that no one is carried on mobile equipment unless provision is made for carrying passengers and provisions for their safety are made

(b)

ensure where there is a risk of an operator being injured from plant turning over, that sufficient steps are taken to prevent the machine from overturning or the provision of a roll over protection system (ROPS) (see below for further detail)

(c)

ensure that equipment has facilities to prevent unauthorised start-up, has appropriate controls, anti-collision measures (rail-mounted equipment) and, if required, has suitable lighting and adequate fire-fighting facilities

(d)

ensure that the operator of such plant and equipment has suitable vision in all directions, with visibility aids if direct vision is blocked, so far as reasonably practicable

(e)

ensure that remote controlled equipment stops automatically upon leaving its control range and incorporates anti crush and impact devices that are appropriate

(f)

ensure that measures are taken to prevent drive shaft seizures and systems for safeguarding drive shafts.

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These Regulations apply to all lifting equipment and accessories, such as cranes, shackles, hoists and slings that are used to carry out mechanical lifting operations.

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1.4.6.7 General requirements applicable to all work equipment Suitability for purpose 1

All equipment that is used to carry out a work activity must be suitable for the work to be carried out.

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Improvisation is dangerous and can lead to serious accidents occurring. A hand-held circular saw being used instead of a router to cut grooves or rebates in timber, or a dumper being used to transport persons, both have the potential to create dangerous situations.

3

All work equipment must be regularly maintained in an efficient state, in efficient working order and in good repair (as described in the following section).

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To be able to work as safely as possible, it is essential that work equipment is regularly maintained, again by a competent person. In practice, maintenance is usually divided into three types of activity: (a)

daily basic maintenance can be as simple as regularly checking the oil and water levels of a petrol-driven cement mixer, and is sometimes referred to as 'pre-use checks'

(b)

periodic maintenance of equipment involves more detailed checks than carried out under 'daily maintenance' and is usually carried out by a fitter as part of a pre-planned programme of regular inspections, for example the replacement of engine oil or hydraulic oil filters

(c)

detailed inspection and servicing, which may involve a degree of dismantling of the equipment in a workshop and entail, for example, the measurement of wear of moving parts or the integrity of hydraulic hoses and connections. This type of inspection is carried out at specific intervals according to the manufacturer's instructions and is often based on the 'running hours' of the equipment.

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Maintenance

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In conjunction with manufacturers' guidance, the competent person should draw up a programme of the frequency of maintenance to be applied to work equipment.

6

In drawing up the programme, there will be a need to take certain factors into consideration. (a)

The type, class and complexity of equipment.

(b)

Some types require weekly maintenance, others less frequent maintenance.

(c)

The frequency that a piece of work equipment is used.

(d)

Equipment in regular use will probably require more frequent maintenance than equipment used infrequently.

(e)

The equipment's potential to cause serious harm. Powered machinery with the potential to cause serious harm, for example a circular saw, will require more regular attention than a hammer.

(f)

The likely deterioration of work equipment when not in use.

(g)

The environment that the equipment is used in.

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There is no specific requirement to keep a maintenance log for work equipment, but where there is one, it must be kept up to date.

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Inspection

All work equipment must be inspected at suitable intervals and records of inspections made.

9

As with maintenance, a competent person must set up an inspection regime, in accordance with legal requirements and manufacturers' guidance. The frequency of inspection is not specified.

10

The level of inspection will depend on the complexity of the equipment and vary from a visual inspection to a comprehensive inspection that might include some dismantling and testing.

11

Usually inspection is undertaken as part of the maintenance activity as well, but inspection falls into two broad headings.

12

A visual check of low risk items before use will suffice for items such as hand tools, to check they are in good order. These inspections are not usually formally recorded inspections. In addition, equipment that poses a high risk, such as some plant, or is used in a high risk environment, such as a confined space, should undergo a visual check every time before use -usually an operator inspection, provided they are competent to do so.

13

More complex equipment and equipment used in higher risk areas should also undergo a formal inspection, after which the details of the inspection are recorded.

14

When deciding the frequency of inspections, the following points need to be considered:

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(a)

the type and class of the equipment

(b)

the frequency of use of the equipment

(c)

the potential of the equipment to cause serious harm if not maintained

(d)

the likely deterioration of the equipment whether in use or in store

(e)

the environment in which the equipment is being used.

15

Normal practice for most plant is to undergo a weekly formal inspection, in addition to the driver's daily inspection. The frequency of inspections may be adjusted after considering the above factors.

16

The following legislation also place duties on Contractors to ensure that specific work equipment and areas of work (which will also involve inspecting the associated work equipment) are inspected as highlighted below.

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Work at Height 17

These Regulations specifically require the inspection of work equipment used for working at height, such as scaffolds, and the recording of those inspections as detailed in these Regulations.

Construction (Design and Management) CDM 18

These Regulations require that: (a)

excavations which are supported are inspected at specific intervals

(b)

energy distribution systems are checked as necessary to prevent danger

both of which will involve the inspection of the associated work equipment.

20

Furthermore, these Regulations place duties on those people in charge of sites with regard to the safe use of vehicles on site.

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Records of inspection

These Regulations require that systems must be put in place for recording the results of inspections, Unlike in the past when prescribed registers had to be used, Contractors can produce their own records in paper form or electronically, providing that they can produce hard copy if requested.

22

Inspection records should include the following:

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information on the type and model of the equipment

(b)

any identification mark or number

(c)

its normal storage or use location

(d)

the date that the inspection was carried out

(e)

the name of the person who carried out the inspection

(f)

any faults found

(g)

any corrective action which was necessary

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to whom the faults were reported and details of the action taken the date when repairs or other necessary action were carried out and by whom.

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23

When hiring equipment, the records and results of the last inspection should be supplied, by the hire company, with the equipment.

24

There is no specified format for records of inspection, providing the necessary details are recorded.

Conformity with EU requirements or equivalent standards 25

Contractors should ensure that any work equipment that is in use or acquired, either new or second-hand, has a 'CE' or equivalent mark. This indicates that there is a relevant European product directive equipment and that it has been manufactured to known standards.

Training 26

Many accidents involving plant and equipment occur because the operator, through lack of training, is not competent. It is therefore essential that persons are adequately trained in the safe and correct use of the type of equipment they are required to operate.

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The level and complexity of the training required should be such that an operative can operate the plant or equipment safely, without risk to themselves or others who may be affected by their actions or omissions. In addition, adequate training should be given to supervisors and managers to allow them to understand the equipment and methods used.

Quick-hitches The operatives selected for training should be both physically and mentally able to cope with any situation the use of the item of plant or equipment demands. For example: (a)

a person with a fear of heights would not be suitable for training as a tower crane driver

(b)

a person who suffers from claustrophobia would be unsuitable as an operator of a tunnel-boring machine.

(c)

The intellect of the person to be trained should also be judged, to ensure that they can assimilate the information they will be expected to retain in order to carry out their tasks safely.

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1.4.6.8 Types of plant and equipment -specific requirements and risks

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Mobile work equipment

Mobile work equipment is any work equipment that carries out work while it is travelling, or which travels between different locations where it is used to carry out work. Mobile work equipment may be self-propelled, towed or remotely controlled, and may be fitted with attachments.

2

Examples of the types of equipment falling within these definitions include:

(b)

diggers

(c)

loaders

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site transport

(g)

remote controlled rollers etc.

(h)

trailers.

forklift trucks

compressors

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General considerations 3

The movement of mobile work equipment, whether over site roads or within specific areas, involves different and continually changing hazards. These have the potential to cause harm, such as: (a)

persons being struck or run over

(b)

persons being thrown from moving plant or equipment

(c)

persons being crushed by moving plant or equipment.

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Practical measures which should be considered to ensure that mobile plant and equipment can be used safely on site are: traffic routes should be planned in order to minimise congestion and risk of collision

(b)

these routes should be kept free of obstructions and properly maintained, with access points restricted and clearly marked

(c)

appropriate speed limits should be introduced

(d)

one-way traffic systems should be implemented if possible and appropriate parking places should be designated for delivery vehicles and those left temporarily on site

(e)

the operating area should be clear, as far as possible, on all sides

(f)

where excavation is taking place, operators must know the location of any overhead power lines, underground cables, sewers, ducts or services before digging operations commence

(g)

trenches and excavations should be fenced or otherwise guarded

(h)

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where equipment fitted with outriggers or stabilisers is used, the load-bearing capacity of the ground should be assessed so that the imposed loads do not exceed this capacity

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(i)

ground conditions should be stable and sufficiently level for the operations being carried out and the equipment used

(j)

where site vehicles are employed in tipping material into excavations, baulks of timber or other effective blocks should be provided to prevent the vehicle over-running the edge

(k)

excavations may have to be provided with extra support or shoring to prevent the weight of adjacent vehicles causing a collapse (surcharging).

5

Vehicles and plant designed for specific operations must only be used for those operations, and the design limitations and permitted modes of operation specified by the manufacturer must be complied with.

6

The overloading or overstressing of plant is particularly dangerous and must be prohibited. Manufacturers' and suppliers' instruction and information manuals should be made available for all who may need them.

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Forward-tipping dump trucks

(a)

overturning on slopes, rough ground and at the edges of excavations

(b)

travelling with a high-lift skip in the raised position

(c)

the driver failing to observe pedestrians who are then run over by the front wheels

(d)

the driver being thrown from the vehicle whilst travelling over rough ground

(e)

driver error due to lack of experience and training, including accidental operation of the controls.

.

Efforts to reduce dumper accidents must focus on: effective site management and control of how dumpers are operated generally

(b)

selecting the correct machine for the job

(c)

ensuring that machines are routinely inspected, serviced and withdrawn from use if unsafe

(d)

ensuring that only trained, competent drivers are allowed to operate dumpers, which includes removing the key when not in use

(e)

ensuring that site roads are suitable and safe for the use of dumpers.

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Amongst mobile plant, forward-tipping site dumpers are worthy of special note because they are involved in a disproportionately high number of plant-related accidents. This applies to both rigid-frame and articulated dumpers. The common causes of these accidents are:

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Material unloading and loading

Materials that are unloaded or tipped from plant should be deposited in planned locations where they will not cause an obstruction or hazard.

10

A signaller should assist the driver during any tipping operation to ensure that it is safe to tip and that there are no other hazards to be encountered during the operation.

11

Operatives must not remain on vehicles that are being loaded unless the vehicle is equipped with a reinforced cab or falling object protection system (FOPS).

12

Operatives working with plant or vehicles, or on sites where there are regular vehicle movements, should be provided with the appropriate personal protective equipment which should include high visibility clothing.

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Roll-over protection systems (ROPS) 13

Where there is the risk of mobile work equipment rolling over, Contractors have a duty to ensure that protective measures, such as reinforced cabs or a roll-cage, are fitted to stop mobile equipment doing anything more than falling onto its side, thereby minimising the risk of a person being crushed. The cabs or roll-cages should give adequate clearance for operatives to escape if the equipment does completely overturn.

14

Where there is a risk of an operator being thrown then crushed by equipment rolling over, a suitable restraining system (such as a seat belt) should be fitted.

15

This requirement may also apply to equipment fitted with a fully enclosed cab if there is a risk that a person being thrown from their seat could be injured by coming into contact with the inside of the cab's structure.

16

Restraining systems must be fixed to a strong anchorage point on the main structure of the equipment.

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In areas of limited access, ROPS may be removed only if a suitable and sufficient risk assessment has been carried out and there is no risk of overturning.

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There is no requirement for forklift trucks fitted with a vertical mast to be provided with specific roll-over protection where the mast acts as an anti-roll device. There is, however, no exemption from forklifts having to be fitted with restraining systems.

Where there is the risk to persons operating mobile work equipment of being struck by falling material, overhead protection or reinforced cabs must be fitted which stop any falling material striking the operator.

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Falling object protection system (FOPS)

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Roll-over of forklift trucks

Prevention of unauthorised start-up 20

It must not be possible for self-propelled mobile work equipment to be started by unauthorised persons when the vehicle is parked. Additionally, it must be possible to isolate the drive mechanism. This can be achieved by the removal of ignition keys or starting handles.

Lighting and warnings 21

When self-propelled mobile work equipment is used in the dark or in reduced visibility, lights must be fitted and used to enable the work area to be adequately illuminated. In addition, amber flashing beacons that give warning of the presence of the vehicle should be fitted and used. It is required that some types of construction vehicles be fitted with audible reversing

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warning devices or similar devices, such as CCTV. Ride-on plant Ride-on plant refers to equipment that is operated or used with persons 'riding on' the piece of plant as opposed to riding in it. Some trucks, excavators and planers are among the types of equipment within this category.

23

Plant that is not designed to carry passengers should be provided with a notice clearly stating 'No Passengers'.

24

People can only be carried if the vehicle has been designed for such a purpose. Passengers and drivers must not be carried unless proper seating, strongly and correctly connected to the main structure of the vehicle, is provided.

25

Where passengers are permitted to be carried, additional restraining devices must be provided.

26

Where on-board work activities have to be carried out, seating should be provided, if possible, with work platforms fitted with suitable barriers or guard-rails to stop operatives falling from the equipment whilst it is in motion.

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All-round visibility

To ensure safe operation of plant, a standard is being accepted whereby the operator of the plant or vehicle has all-round vision from the operating position. It is generally accepted that the operator should be able to see, at all times, an object positioned 1 metre above ground level and 1 metre away from the plant through 360° visibility.

28

This can usually be achieved by the use of additional mirrors, convex mirrors or by CCTV.

29

Where this is not possible, consideration should be given to providing a competent, qualified signaller working exclusively with the plant operator.

30

Contractors meeting the above criteria would be seen to be doing what is reasonably practicable to provide a safe place of work and a safe system of work in respect of that item of plant.

31

Every Contractor must ensure that the work equipment is so constructed or adapted as to be suitable for the purpose for which it was provided.

32

In selecting the work equipment, every Contractor shall take account of the working conditions and to the risks to the health and safety of persons who are in the vicinity of where the work equipment is to be used.

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1.4.6.9 Pedestrian-controlled work equipment 1

This type of equipment relies heavily on the experience and competence of the operative for its safe operation. Small pedestrian-operated rollers, vibrating or 'whacker' plates and surface grinders are among the types of equipment within this category.

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Common accidents involving pedestrian-controlled equipment occur when operators of small vibrating rollers are crushed between the machine and adjacent obstructions. This is one reason why these Regulations require efficient stop controls to be fitted.

3

It is also essential that operators be provided with, and wear, strong protective footwear to prevent their feet from being injured.

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1.4.6.10 Static work equipment

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This type of small plant should be sited on firm, level ground with the brakes applied and wheel chocks in position, as necessary.

2

Cement or concrete mixers, compressors and pumps are examples of static equipment.

3

Plant should be sited clear of personnel with allowance for safe access by authorised persons.

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The correct procedures for starting, operating and shutting down should be correct and strictly complied with.

5

All gauges, valves, connections and guards should be checked for tightness and proper attachment as a matter of routine.

6

Other points to be considered are:

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appropriate personal protective equipment must be provided by Contractors and used by operatives

(b)

access to all dangerous or moving parts of the equipment must be provided with guards which are securely fixed and in position

(c)

adequate ventilation is essential when using equipment in confined places, with harmful fumes being extracted to the open air

(d)

any air lines, spray guns or blasting nozzles, used as an accessory to the equipment, must never be pointed towards other persons or at any part of the body

(e)

hoses, pipes or cables should be kept clear of traffic and pedestrian routes. Simple ramps and barriers can be used to protect cables etc., and to provide safe access

(f)

air hoses should be fitted with whip-checks at every connection to prevent the hose connections from blowing apart

(g)

electrical and mechanical plant and equipment, unless specifically designed to eliminate the risk, must be switched off or stopped before adjustments are made and before any accessories are connected or disconnected.

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1.4.6.11 Manually operated hand-held plant and mechanical equipment 1

Selection of the correct equipment for the job in hand is vitally important. Choosing modern equipment that reduces the risk of injury or ill health is fundamental to creating safer working environments.

2

The environment in which the equipment is used also has a bearing on the safety of the

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operative. It may be safe to use a hand saw from a pair of builders' steps, but to use the modern electric equivalent from them could have fatal results.

Hand-held power tools, whether powered electrically, by internal combustion engine, hydraulically, by cartridge or compressed air, are covered by the definition.

4

As the use of these types of tool has increased, so has the potential for serious injury. Old type hand-operated smoothing planes could cause nasty cuts if wrongly used, but those injuries bear no comparison with the injuries that could occur when wrongly using their modern electrical equivalent.

5

Cutting chases in a wall using an older type cutting disc produces unacceptable amounts of dust. Modern equipment that is fitted with a dust suppression mechanism is safer and much healthier.

6

Also included within this category is the type of equipment that requires human effort in its operation, such as jacks, bar-bending machines, pipe-threaders and other machines where the principles of leverage or torque are utilised.

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Many jobs, such as nailing tiling battens on a roof, that traditionally would have been achieved by using a hammer, are now carried out by using nail guns powered by gas canisters. Equipment of this type is open to abuse, which can result in horrific consequences. It is possible to propel a nail in free flight from a nail gun giving it the lethal potential of a firearm.

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Included in this category are hand tools, ladders scaffolding, etc. Also included are huts and other temporary structures used for welfare accommodation or fuel and materials stores.

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1.4.6.12 Non-mechanical plant and equipment

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Hand tools

Unfortunately, many persons working in the construction industry do not appreciate that simple hand tools have the potential to cause serious harm.

3

In many cases where hand tools are used, persons react when things go wrong, instead of proactively checking to ensure that things do not go wrong in the first place.

4

Cold chisels with burred-over mushroom heads can result in a person losing an eye when a burr breaks off during use. A hammer head becoming detached from its shaft can cause a serious injury and not necessarily to the user.

5

In both examples, the potential to cause harm can be drastically reduced if a system of regular inspection and maintenance, as required by these Regulations, is in place.

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1.4.6.13 Access equipment Scaffolds 1

Scaffolds, if incorrectly erected or exposed to misuse, can also be the cause of accidents.

2

Such equipment must: (a)

comprise suitable components that have been inspected prior to use

(b)

be regularly inspected every 7 days or after alteration, damage or high winds, the

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Section 11: Health and Safety Page 117 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) results of the inspection recorded, and proactive maintenance regimes put into place

(c) 3

not be interfered with or altered by untrained individuals.

Many accidents have occurred due to installation of scaffold with damaged equipment such as split boards and bent tubes.

Ladders and other wooden access equipment Work equipment made from wood will not last for ever. It will deteriorate with age and use. Regular inspection of the equipment is essential for safety and will prolong its useful life, giving early indication of deterioration. It is commonplace for inspections of ladders and steps to be formally recorded, with each ladder or step being given a specific identifying number.

5

A key issue with wooden ladders and steps is that they must not be painted or treated with anything that would hide any faults or defects.

6

The regular inspection of wooden builders' steps must include the hinges that connect the support stays and the restraining rope that controls the opening of the steps as well as the condition of the timber.

7

Wooden extension ladders have ropes, pulley blocks, and clips that fit over rungs. These are vital to the safe use of these ladders and therefore must again be regularly inspected.

8

The simple wooden pole ladder must be checked to ensure that the wire ties beneath certain of the rungs are in place and tight. Rungs must be checked to ensure they are still firm and do not twist, and the stiles checked to ensure they are not split.

9

All work equipment has the potential to be the cause of accidents. Obviously, the potential and the consequences differ between types of equipment.

10

Management systems for the training and instruction of operators, and the inspection of equipment, must be in place and complied with.

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Construction Site Safety 1.4.6 Appendix 1 Plant and work equipment Safety checklist When was the plant or equipment last checked or tested?

2

Are statutory records being kept up to date?

3

Is the item of plant or work equipment the most suitable for the job in hand?

4

Is a risk assessment necessary to determine the most suitable item of plant or work equipment?

5

Have any faults developed through misuse or neglect?

6

Have faults or defects been correctly and promptly reported?

7

Are those faults reported being remedied promptly and effectively?

8

Does all plant or equipment comply with the relevant standards?

9

Are spot checks made on the condition of hand tools and other minor items of equipment?

10

Is there a procedure for the inspection of and repairing or replacing of such equipment and tools?

11

Are drivers and operators trained on specific plant or equipment aware of the hazards that are associated with its operation?

12

Is safety training included in any instruction which is given to operatives?

13

Is personal protective equipment available and issued to all who need it?

14

Have lists of authorised drivers and operators been kept up to date?

15

Is equipment issued to and used only by authorised persons?

16

What information is available in relation to specific items of plant? Where is it kept and by whom?

17

Do checks show that plant is being used safely?

18

Do operatives know the requirements of these Regulations and those which have a bearing on their activities, and are they aware of their own responsibilities?

19

Are rules observed by site vehicles?

20

Has any instance of overloading or over-stressing of plant come to light?

21

Are ROPS, FOPS and driver restraint systems fitted if appropriate?

22

Does the operator of mobile or self-propelled plant have adequate visibility in all directions and are all visibility aids in good order?

23

Are there any signs of the unplanned or dangerous location of any plant?

24

Are the locations of supply cables, pipes, services, etc. identified before any plant or other equipment is brought into the vicinity?

25

Where appropriate, are communications adequate between:

26

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(a)

the teams doing different work within the same area?

(b)

the different shifts using the same plant?

(c)

the workers engaged in a co-ordinated operation?

Has all work equipment been identified?

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Have inspection regimes appropriate to the equipment been instigated?

28

Are the records of the inspections and tests being kept up to date?


Woodworking Machines

1.4.7.1 Key points Woodworking machines are classified as 'work equipment' and must therefore comply with certain legal requirements.

2

Many items of woodworking equipment, with their partially exposed blades or cutters, have the potential to cause serious personal injury if they are not properly used and maintained.

3

Users of woodworking machinery must be trained on each type of machine that they are required to operate and be judged as competent by their Contractor.

4

Hand-held, bench-mounted and free-standing woodworking machines can all be found on sites; all types present particular hazards to the operator and, in some cases, other people.

5

The use of woodworking machines also has the potential to cause occupational health problems if appropriate preventative measures are not taken.

6

Section 18 of the QCS covers carpentery, joinery and ironmongery.

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Woodworking machine cutters can inflict very serious injuries and it is essential that these Regulations for guarding them are strictly observed. Neglect or ignorance of these Regulations governing the use of such machinery creates the conditions in which accidents occur.

2

Furthermore:

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the use of woodworking machines

(b)

contact with some hardwoods used

(c)

contact with the dust produced

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All have the potential to cause occupational health problems.

4

Within these Regulations, particular reference is made to circular saws and planing machines, since these are most commonly used on-site in the construction industry.

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Compliance with these Regulations mainly involves Contractors pro-actively managing:

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(a)

personal injury risks resulting from contact with moving blades and cutters

(b)

personal injury risks resulting from the maintenance of the machines

(c)

occupational health risks resulting from the use and maintenance of the machines.

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other person who may be affected.

1.4.7.4 Provision and Use of Work Equipment These Regulations stipulate the requirements for the safe operation and maintenance of all 'work equipment', which includes woodworking machines.

2

In the context of this section, the parts of these Regulations that are particularly relevant cover such factors as: work equipment being suitable for the job, and kept in good working order by persons who are trained to do so

(b)

the guarding of dangerous parts of machines and provisions relating to working space, floors, lighting, noise and temperature. They apply to all places where woodworking machinery is used

(c)

the requirements relating to the instruction and training of persons operating work equipment, including those employed in 'taking-off' and maintenance, and specify the duties of operatives

(d)

work equipment being fitted with suitable controls, emergency controls and where necessary, a control system, to enable it to be used safely

(e)

ensuring that each item of work equipment can be effectively isolated from all sources of energy

(f)

the requirements for maintenance and inspection.

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(a)

The parts of these Regulations that are particularly appropriate to the use of woodworking machinery are expanded throughout.

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1.4.7.5 Personal Protective Equipment These Regulations place duties on Contractors and employees with regard to the provision, use and care of personal protective equipment (PPE). Where the risks to health and safety cannot be controlled by other means, PPE may be issued and used; as a method of controlling risk it is the last resort.

2

However, when using woodworking machinery on site, PPE will often be the only practical method of controlling risk, particularly health risks

3

These Regulations place legal duties on Contractors to:

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(a)

provide suitable PPE for their employees and make sure that it is used properly

(b)

make sure that items of PPE are compatible when more than one item is worn at the same time. For example, if wearing safety spectacles, it is possible that the side-arms would interfere with the seal of a half-face respirator

(c)

make an assessment of the most suitable PPE to protect against the identified risks

(d)

make sure that PPE is properly maintained where this is necessary

(e)

replace PPE that is damaged or lost

(f)

provide suitable accommodation where necessary for PPE that is not in use

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(g)

4

Section 11: Health and Safety Page 122 Part 1.04: Safe Use of Plant Equipment (Regulatory Document) provide employees with adequate information, instruction and training on: (i)

the risks that the PPE will avoid or limit

(ii)

why the PPE has to be worn and how it should be used

(iii)

how to maintain the PPE in efficient working order and good repair.

These Regulations place legal duties on employees to: (a)

use any PPE provided in accordance with the instruction and training provided

(b)

report to the Contractor the loss of or defect in any PPE provided.

1.4.7.6 Construction (Design and Management) CDM In the context of this section, the relevant requirements are that the Contractor or person in control of the site must ensure:

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the competence of everyone who has to use or supervise the use of a woodworking machine

(b)

a safe place of work with safe access and egress and sufficient working space is provided

(c)

the prevention of risks of fire or explosion

(d)

the provision of adequate fire detection methods and fire-fighting equipment

(e)

adequate levels of lighting, taking into account the nature of the work being carried out

(f)

an acceptable level of site tidiness and cleanliness

(g)

suitable information, instruction and training where necessary for work to be carried out safely and without a risk to health.

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1.4.7.7 Types of machine

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The following list gives examples of different types of woodworking machine. It should not be taken as exhaustive. Circular saws

(b)

Sanding machines

(c)

Bandsaws

Routing machines

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(e)

Planing/thicknessing machines

(f)

Chainsaws

(g)

Mortising machines

(h)

Tenoning machines

(i)

Vertical spindle moulding machines, including high-speed routing machines

(j)

Multi-cutter moulding machines having two or more cutter spindles

(k)

Trenching machines

(l)

Boring machines

(m)

Automatic and semi-automatic lathes.

1.4.7.8 Training 1

No person should be required to operate any type of woodworking machine unless they have

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been trained and instructed in its operation. They must either be competent or under the direct supervision of someone who is. 2

Training should include instruction on all machines the person is likely to operate and the types of work to be undertaken on the completion of training. Instruction on the provisions of these Regulations and the methods of using guards, devices and appliances required by these Regulations must be included. Training should emphasise the dangers connected with the use of such machines.

3

Contractors will need to make sure that they do not employ young people in work situations where: the work is beyond their physical or psychological capacity

(b)

it involves harmful exposure to hazardous substances

(c)

it involves a risk of accidents which the young person, by reason of a lack of experience etc., would not recognise

(d)

there is extreme heat, cold, noise or vibration.

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1.4.7.9 Duties of employees

Employees using woodworking machines must use and keep properly adjusted all guards and other safety devices, and use push sticks, spikes, push blocks, jigs, holders, backstops, and any other safety devices provided.

2

They must report to responsible persons any defects in machinery, guards, devices or appliances and any damage or defects in the surface or ground around the machine.

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1.4.7.10 Occupational health Hearing protection

Woodworking machines can be particularly noisy when in use and the noise generated will be a significant hazard to health unless adequately controlled.

2

Ideally, the level of noise will be controlled by means other than issuing personal protective equipment (PPE), although in practice this will often not be possible on construction sites.

3

Where work activities are liable to expose employees to certain levels, Contractors to carry out an assessment of the risk and implement the necessary control actions, which will often translate into:

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(a)

identifying suitable hearing protection (PPE)

(b)

issuing it to those persons who are at risk

(c)

ensuring that it is worn in certain circumstances

(d)

providing adequate information, instruction and training on the risk to health arising from noise and the correct use of hearing protection.

There are three action levels at which particular actions should be taken; (a)

The lower exposure action value (80 dB(A)), at which an employee may request the provision of hearing protection from the Contractor, should he or she so wish.

(b)

The upper exposure action value (85 dB(A)) at which the Contractor is required to provide hearing protection for employees and ensure that it is worn by all employees who are at risk.

(c)

The exposure limit value (87 dB(A)) above which no employee may be exposed.

In work areas where the noise is at or above the upper exposure action value, the Contractor

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is required to create hearing protection zones, designated by appropriate signs, within which everyone must wear the hearing protection provided.

1.4.7.11 Vibration protection 1

Contractors are required to control the level of vibration experienced by employees whilst at work.

2

In the context of using woodworking machines, the predominant problem is considered to be hand-arm vibration. Whilst several manufacturers have produced 'anti-vibration' gloves, laboratory testing has shown these to be largely ineffective against vibration at the most damaging frequencies. In some circumstances, the fact that such gloves will keep the hands warm may offer limited benefit against hand-arm vibration. The control of hand-arm vibration will have to be achieved by other means.

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1.4.7.12 Respiratory protection

Contractors must control substances hazardous to health and to control occupational health risks arising out of the use of hazardous substances.

2

As noted earlier, hardwood dust is known to be a cause of nasal cancer. Ideally, airborne dust will be controlled by the fitting of effective extraction systems or dust-collection bags to woodworking machines and hand-held tools that generate either softwood or hardwood dust.

3

However, if for any reason the control of dust is not possible in this way, operators must be provided with, and wear, suitable respiratory protective equipment.

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Depending on the machine being used and the nature of the work being carried out, it may be necessary for machine operators (and possibly anyone assisting them) to wear eye protection, such as goggles or a full-face shield of a suitable impact-resistant grade.

It may be necessary to provide operatives with suitable gloves to protect against skin damage whilst handling timber, particularly unplaned timber. Furthermore, the skin of a small number of persons is adversely affected by the natural oils that occur in some woods, notably cedar.

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1.4.7.14 Skin protection

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1.4.7.13 Eye protection

1.4.7.15 Working environment 1

Sufficient clear and unobstructed space must be provided around machines to allow persons to work without the risk of injury.

2

Floors should be level, in good condition, free of loose material (wood chips, wood shavings and sawdust) and must not be slippery.

3

Where woodworking machines are being used on site, the temperature of any indoor workplace must be reasonable, having regard to the purpose for which the place is being used.

4

Where a reasonable temperature cannot be achieved or maintained, effective means of providing warmth for operatives should be introduced. If it is not a construction site, then a temperature of 16°C should be maintained but, where work is of a physically demanding nature, a temperature of 13°C is appropriate.

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Adequate natural or artificial lighting must be provided so that the work being carried out on each machine can be done safely. Artificial light must be positioned or shaded to prevent any glare affecting the operator.

1.4.7.16 Maintenance 1

Saw blades must not be cleaned while they are in motion or with the power supply to the machine switched on.

2

All machines must be of good construction, manufactured with sound material and properly maintained. Unless a machine is hand-held, it must be level, and fixed securely to a substantial structure which ensures its stability.

1.4.7.17 Controls

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Every machine must be fitted with start and stop controls which can be quickly and easily operated by the machinist.

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1.4.7.18 Braking

An essential safety feature of most woodworking machinery is the provision of an automatic brake.

2

This is to ensure that, if there is a risk of an employee coming into contact with tooling during the rundown period, the machine stops within 10 seconds or less, as defined by European Committee for Standardization (CEN) standards.

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1.4.7.19 Retrofitting of brakes

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All work equipment should be provided with the necessary controls which bring the equipment to a safe condition in a safe manner. To achieve this, a risk assessment should be carried out to determine whether the rundown time should be reduced and the retrofitting of brakes to a machine is necessary.

2

If the risk assessment shows that there would be no added safety benefit, then braking does not have to be provided.

3

Examples include machines fitted with interlocking guards that enclose the cutters and cannot be opened until the cutters have come to rest. Some machines might be totally enclosed by a noise hood, but the same interlocking requirements will apply.

4

In these situations, the machine rundown time is immaterial since an acceptable standard of safety has been achieved by guarding alone and subsequently there is no risk of contact in the rundown period.

5

Another example is where the blade, tool or cutter returns automatically to a safe position, such as a cross-cut saw fitted with a spring return which retracts the blade into a protective housing at the end of the cutting operation. However, if a risk assessment shows that the machine has a long rundown period and is in regular use by more than one person, consideration should be given to fitting a brake. This is because the machine could still be running down after use by one person when a second person pulls the saw carriage out of the protective housing, unaware that the blade is still rotating.

6

As well as enhanced safety, braking can improve productivity since more rapid stopping will allow quicker setting, adjustment and unjamming of a machine.

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1.4.7.20 Guarding cutters - general 'Cutters' include saw blades, chain cutters, knives, boring tools, detachable cutters and solid cutters. Cutters must be guarded to the greatest practicable extent, having regard to the work being done.

2

Guards must be of substantial construction, properly secured and adjusted, and maintained constantly in position while cutters are in motion.

3

Adjustments must not be made to any guard whilst the cutters are in motion, unless safe means (i.e. mechanical adjusters) are provided for those adjustments to be made.

4

The shape and size of guards may change as technology develops alternative safeguards, if these are at least as effective as before.

5

Every dangerous part of any woodworking machine must be securely fenced, unless it is in such a position or of such construction that it is as safe to every person on the site as it would be if it were fenced.

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1.4.7.21 Portable electrically-powered saws

Portable electrically-powered saws should always be disconnected from the electrical supply before any adjustments, repairs, cleaning or any type of maintenance is carried out.

2

Whenever possible, to reduce the risk from electric shock, all portable electric tools should operate from a 110 volt supply and be earthed or double insulated. The mains input to the 110 volt transformer should be protected by a residual current device (RCD), commonly known as a 'power breaker'.

3

Portable electrically-powered saws must never be carried by their supply cable. Furthermore:

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when operating, the supply cable must always be kept clear of the saw blade

(b)

the power plug must be examined each time, prior to use, for damage and security of the cable

(c)

all electrically-powered saws should be examined regularly by a competent electrician.

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(a)

Care should be taken to ensure that the spring-loaded, lower blade guard returns to cover the blade after every cut. This guard, also known as the swivel guard, is designed to uncover the saw teeth when material is being cut then automatically covers the saw teeth when the saw is withdrawn. This guard must never be wired in the open position.

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1.4.7.22 Riving knife (also called splitter or spreader) 1

The riving knife must be securely fixed below the table level, be of the correct radius, behind and in line with the saw blade.

2

It must be strong, rigid, smooth and easily adjustable.

3

The radius of the knife must not exceed the radius of the largest saw blade for which the machine has been designed.

4

It must be adjusted as close as practicable to the saw blade. Any gap between the riving knife and the blade must not exceed 8 mm at table level.

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5

In the case of a parallel plate saw blade, the knife must be thicker (usually about 10%) than the parallel plate of the saw blade to form a wedge in the saw cut, thereby preventing the timber 'ripping' the saw blade.

6

Where the diameter of the saw blade is less than 600 mm, the top of the knife should not be more than 25 mm below the top of the blade.

7

Where the diameter of the blade is 600 mm or more, the knife must extend at least 225 mm above the machine table.

1.4.7.23 Top guard (crown guard) The guard must be strong and easily adjustable.

2

It must be adjusted to extend from the top of the riving knife to a point as close as practicable to the surface of the material being cut; or to a point not more than 8 mm above the material being cut where squared stock is being hand fed.

3

The guard should have flanges on either side of the blade and be adjusted so that these extend beyond the roots of saw blade teeth. Where the guard has an adjustable front extension piece, it must be flanged on the side remote from the fence, and adjusted to extend beyond the roots of saw blade teeth above the saw table.

4

Note: Some saws have adjustable extensions to the front of the guard.

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The part of the blade below the table must be guarded to the greatest extent practicable.

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1.4.7.24 Bottom Guard

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1.4.7.25 Size of saw blade

Saw benches with a one-speed spindle must not use a saw blade less than 60% of the diameter of the largest saw blade which the bench is designed to use. In the case of saw benches with more than one spindle speed, the blade must not be less than 60% of the diameter of the largest blade which the machine is designed to use at the fastest spindle speed.

2

A notice should be displayed on the machine specifying the smallest diameter saw blade that may be used.

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1.4.7.26 Limitations on use 1

No circular saw may be used for cutting rebates, tenons, mouldings or grooves unless the cutter above the table is effectively guarded.

2

The saw blade teeth must project right through the upper surface of the timber at all times in any ripping operation.

3

A circular saw must not be used for crosscutting logs unless the material is firmly held by a gripping device, secured to a travelling table.

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1.4.7.27 Push sticks 1

Push sticks must be available for use on every table-mounted circular saw, and used to: (a)

keep hands away from the saw blade

(b)

feed material throughout any cut of 300 mm or less

(c)

feed material during the last 300 mm of any cut more than 300 mm in length

(d)

remove cut material from between the saw blade and the fence.

1.4.7.28 Removal of material Assistants employed to 'take-off' cut material may only stand at the delivery end of the machine.

2

Where this operation must be performed, the delivery end of the machine table must extend (over its whole width) at least 1.2 m from the up-running part of the saw blade.

3

This requirement is not applicable to machines which have a roller table, or a travelling table, or to portable machines with a maximum blade diameter of less than 450 mm.

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a suitable top guard, riving knife and ripping fence to be fitted

(b)

that the fixed guards should be of adequate strength and construction to withstand normal operational use

(c)

the fitting of a suitable switch attachment to enable the operator to control the saw at the bench.

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Mounting a hand-held circular saw onto a support for use as a bench circular saw, requires:

Note: Some manufacturers have designed a saw bench complete with a top guard, riving knife assembly and fence for use with their hand-held circular saws.

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1.4.7.29 Bench-mounted portable hand circular saws

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1.4.7.30 Narrow bandsaw

A narrow bandsaw is defined as a machine with a blade not exceeding 50 mm in width, running vertically.

2

The saw wheels and the whole of the blade, except the part which runs downward, between the top wheel and the machine table must be enclosed by guards.

3

The part of the blade between the top wheel and the friction disc or roller must be guarded by a front plate, as close as practicable to the blade, and having a flange at right angles to the plate extending behind the saw blade.

4

The friction disc or rollers must be adjusted as close to the surface of the machine table as practicable.

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1.4.7.31 Planing machines 1

(See illustration in Appendix 3)

1.4.7.32 Limitations on use A planing machine must not be used for cutting any rebate recess, tenon or mould unless the cutter is effectively guarded.

2

If the machine is not mechanically fed and is used for surfacing work, it must be fitted with a cylindrical cutter block.

3

Table gap

4

If the planer is hand fed, the gap between the cutter block and the front edge of the infeed or delivery table must not exceed 6 mm, measured radially from the centre of the cutter block.

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1.4.7.33 Bridge guard

Planing machines not mechanically fed must have a bridge guard over the cutter block, mounted approximately centrally and not liable to accidental displacement.

2

The guard must be strong, rigid and easily adjustable, vertically and horizontally, to allow work to be carried out without the risk of injury.

3

The guard must cover the full length and diameter of the cutter block, be mounted centrally over it and be securely fixed.

4

When 'flatting' squared stock:

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the gap between the end of the guard and the fence should not exceed 10 mm

(b)

the gap between the upper surface of the wood and the underside of the guard should not exceed 10 mm.

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When 'edging' (i.e. planing the narrow surface of a squared stock):

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(d)

the gap between the end of the guard and the surface of the wood should not exceed 10 mm

(e)

the gap between the underside of the guard and the surface of the feed table should not exceed 10 mm.

5

When 'flatting' and 'edging' are carried out successively, the clearances between the bridge guard and the material for each operation must be no greater than 10 mm.

6

When the planing of adjacent surfaces of stock of square cross-section is carried out as successive operations, the bridge guard must be adjusted so that the clearance between the material and the guard, or the fence and the guard, never exceeds 10 mm.

7

Where the above adjustment of the bridge guard is not practicable because of the shortness of the material, a suitable push block with handholds must be provided and used.

1.4.7.34 Cutter block guards 1

In addition to the bridge guard, hand-fed overhand planers must be provided with an

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effective, easily adjustable guard over the part of the cutter block which is behind the fence.

1.4.7.35 Combined machines used for thicknessing 1

The part of the cutter block exposed in the table gap must be effectively guarded.

1.4.7.36 General safety procedures The following general procedures should be observed to ensure the safety of operators and anyone else who may be affected by wood machining activities: knives, saws and cutters should be properly sharpened and correctly set

(b)

circular saw blades should be checked for cracks, particularly near the gullet at the root of the teeth. Defective items should not be used

(c)

before a machine is started, a check should be made to see that the cutters, saws or knives are of the correct type and are securely fixed; and that guards are properly adjusted and secure

(d)

the area around the machine should be cleared of waste material and there should be sufficient space to stack work safely before and after machining

(e)

the floor must be clean and free from oil, grease or anything else which might cause the operator to slip or trip

(f)

multi-speed machines must be started at their lowest speed

(g)

guards should be set to give the minimum clearance necessary for the material being worked. They must always be in position

(h)

the operator should not wear loose clothing, and should wear goggles, masks or ear protectors, if necessary

(i)

workplaces should have adequate heating and be well lit

(j)

adjustments must never be made to a machine while it is in motion, unless safe provision is made to do so

(k)

push sticks and jigs should be available and in use whenever necessary

(l)

offcuts, chips and sawdust should not be removed from the machine table with the hands while machine is in motion

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material should not be forced through the machine any fault should be promptly reported to responsible persons. If a fault develops, the machine must be switched off immediately

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machines must be switched off when left, even for a short period. They should also be switched off when the operator is speaking to somebody

(p)

operators should never allow their attention to be distracted while operating a machine, neither should anybody seek to distract them

(q)

at the end of a work operation, the machine must be switched off and isolated.

1.4.7.37 Operational safety - circular saws 1

Low peripheral speeds result in inefficient cutting as do dull, badly set or badly ground saw teeth. The extra effort applied to feed the wood increases the accident risk.

2

Deposits of sap, gum or resin on the blade tend to cause the saw to jam, or stall, or the timber to stick. Such deposits must never be cleaned whilst the blade is moving or with the power supply to the machine switched on. The saw should be stopped, electrically isolated and the proper tool used.

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1.4.7.38 Chainsaws Due to their high potential to cause injury, the use of chainsaws on building and construction sites is not generally recommended.

2

Where chainsaws are used on site, they must be used only by operatives who are fully competent, have received specific and nationally approved training, and who are certificated to carry out the intended operation.

3

A specific risk assessment should be carried out for the operation and a written method statement produced covering the operation, including the need for full personal protective equipment, safe working at heights and, if necessary, a workplace safely away from other workers,

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Construction Site Safety 1.4.7 Appendix 1 Safety checklist - general Operatives Is a list kept of operatives who are authorised and competent to operate woodworking machines?

8

Are operators only required to operate machines on which they have been trained and are competent?

9

Are operatives properly supervised, particularly those under 18?

10

Is adequate training given on the types of machine to be used and the kinds of work to be done?

11

Are operatives provided with all necessary personal protective equipment, including goggles, ear protectors, face masks and other protective equipment, where required?

12

Is the wearing of loose-fitting clothing prohibited at those machines where entanglement could be a problem?

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Is a programme of planned preventative maintenance in place for all woodworking machines?

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Machines and surrounding area

Are the start and stop controls so situated that they can be easily reached and operated?

15

Are all cutters guarded to the greatest extent practicable?

16

Are all machines level and securely fixed to ensure their stability?

17

Are all machines of sound construction and properly maintained?

18

Is sufficient space provided around a machine for safe working?

19

Are floors level, in good repair, free of loose material and not slippery?

20

Is adequate natural or artificial light provided in the workplace without glare being caused?

21

Is the temperature of the workplace satisfactory?

22

Is respiratory protection required?

23

Are noise levels reduced as far as practicable?

24

Is ear protection available where required?

25

Is eye protection required?

26

Is skin protection required?

27

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Is extraction equipment provided for chips and particles as is required on specified machines?

28

Has provision for the extraction of fumes been made where necessary?

29

Are fire extinguishers of the correct type immediately available?

30

Are suitable personnel fully trained in the use of fire-fighting equipment?

31

Do machines, as far as possible, run off a 110 volt supply with mains-powered equipment protected by a residual current device (RCD)?

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Construction Site Safety 1.4.7 Appendix 2 Circular Saw

Safety checklist Riving knife

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Is the riving knife secure, in a sound condition, and easily adjustable?

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Is the radius correct and in line with the saw blade?

3

Is the gap between the riving knife and the saw blade correct?

4

Is the riving knife of the correct thickness?

5

Is the height of the riving knife correct for the saw blade fitted?

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Saw blade

Is the saw blade in good condition -sharp with no cracks, and not less than the smallest diameter permitted?

7

Is a notice fixed to machines, specifying the smallest permitted blade diameter?

8

Does the saw blade project through the upper surface of the timber when ripping?

9

Is the saw blade above the table effectively guarded, when the machine is rebating, tenoning, moulding or grooving?

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Fence

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Is the fence correctly adjusted and secured?

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10

Top guard

Is the top guard sound and easily adjustable?

12

Is it adjusted correctly for the work being done?

13

Do the flanges at either side of the blade extend below the roots of the saw teeth?

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Front extension guard 14

Is the front extension guard adjusted to give maximum protection, and does it cover the saw teeth?

Bottom guard 15

Is the blade guarded below the table (open frame machines)?

Feeding work 16

Is a gripping device in use when cross-cutting?

17

Is there a push stick or are push blocks available and in use?

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Taking off 18

Does the delivery table extend at least 1.2 m from the up-running part of the saw blade?

19

Is the assistant, if present, correctly positioned?

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Safety checklist

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Table

Is the gap between the table and the cutter not more than 6 mm?

2

Is the table gap as small as possible?

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Bridge guard

Is the bridge guard rigid, strong, securely fixed and easily adjustable?

4

Is the bridge guard centrally mounted over the cutter block?

5

Does the bridge guard cover the full length and diameter of the cutter block?

6

Is the bridge guard adjusted to exclude the risk of injury, as far as is practicable?

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Cutter block 7

Is the cutter block guarded, on the side of the fence, remote from the bridge guard?

Limitations on use 8

Is the cutter effectively guarded when rebating, recessing, tenoning and moulding are taking place?

9

Is the machine fitted with a cylindrical cutter block if it is being used for surfacing?

10

Is the bridge guard correctly adjusted when 'flatting' or 'edging' is taking place?

11

Are push sticks available and in use?

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Combined machine used for thicknessing Is the cutter block exposed in the table gap effectively guarded?

13

When thicknessing, is an anti-kickback device fitted, or notice displayed specifying one piece only?

14

Is an extraction system provided to remove and collect any wood chips?

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Safety checklist

Are saw wheels and saw blades guarded correctly?

16

Is the saw blade between the top wheel and disc or roller guarded by a frontal plate as closely as possible, and does the flange extend behind the saw blade?

17

Are rollers or discs correctly adjusted?

18

Is the saw blade tension correct?

19

Is the saw blade in good condition and sharp?

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Safety checklist Operative

Is the operative suitably trained in the correct use of the machine?

2

Does the operative understand that there should be no loose clothing, ties or scarves, etc.?

3

Is the operative aware of the relevant Regulations?

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Prior to use

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Ensure the electrical power plug is removed from the supply socket before carrying out priorto-use checks. Are the machine and plug compatible with the electrical supply?

5

Are all leads, plugs and switches undamaged?

6

Does the on/off trigger and safety interlock operate freely?

7

Is the correct type of saw blade fitted for the work which is to be carried out?

8

Is the saw blade in good condition, sharp and not cracked?

9

Is the saw blade effectively guarded, above and below the soleplate?

10

Is the condition and the function of the spring-loaded bottom guard checked before use?

11

Does the spring-loaded bottom guard return to cover the saw blade after every cut?

12

Is the saw blade securely fitted to rotate in the correct direction? (Teeth should point upwards at the front end of the saw towards the soleplate.)

13

Has the fence (if used) been adjusted to the correct dimension?

14

Has the saw been adjusted to the correct depth and angle before use, with the teeth projecting just through the underside of the material?

15

Are all locking nuts and securing devices properly tightened and fastened?

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In use 16

Is the saw being held correctly with two hands using the main and front hand grips?

17

Is the material being cut adequately supported?

18

Is the fence or a straight edge being used as a guide as necessary?

19

Has a check been made to ensure that the clamps do not impede any movements of the saw? Is there sufficient free cable on the saw?

21

Is the correct stance being taken behind and in line with the saw?

22

Is the work area clear and free of obstructions?

23

Is the correct protective equipment in use?

24

Do all other personnel on site know that the operator must not be distracted whilst he or she is operating a saw?

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Operative

Is the operative competent, adequately and properly trained and supervised?

2

Is the operative familiar with the type of machine they are using and with the manufacturer's operating instructions?

3

Is the correct personal protective equipment being worn?

4

Is the operative aware that whilst using a chainsaw there must be no loose clothing, ties, belts, etc.?

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Prior to use 5

Is the ignition switched off?

6

Are new chains soaked in oil prior to use?

7

Is the chain sharp and in good condition?

8

Is the guide bar excessively worn? If so, it should be changed.

9

Does the chain brake function correctly?

10

Is the tension of the chain correct?

11

Is the lubrication reservoir functioning?

12

Are all handles and guards firm and secure?

13

Are all switches and controls effective?

14

Are wood or plastic wedges available to free the saw if it jams?

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In use Is the correct starting procedure (i.e. on the ground) undertaken?

16

Is the stance of the operator correct?

17

Does the operator keep both hands on the machine when it is in use?

18

Is there a safe system of work in place for cutting, avoiding kickback?

19

Is the chainsaw correctly adjusted so that the chain does not rotate when the engine is idling with the chain brake released?

20

Is the operator aware that the nose of the guide bar should not be used to cut?

21

Are all bystanders kept well clear of any cutting operations?

22

Do all other personnel on site know that the operator must not be distracted whilst he or she is operating a saw?

23

Is the work area kept clear and free from obstruction?

Are all parts checked for damage and soundness?

25

Are the cutting components protected from damage?

26

Are any defects found reported to the supervisor?

27

Is the chainsaw stored safely?

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After use

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15

Refueling

Is the correct type and grade of fuel used, from a properly marked, leak-proof, securely capped container?

29

Is all refueling carried out in a well-ventilated area outdoors?

30

Is there any leakage of fuel or spillage during refueling?

31

Are fuel and lubrication systems leak-free and functioning correctly?

32

Are fuel and lubrication system fluid levels correct?

33

Has clothing (which may have been contaminated during refueling) been changed prior to the saw being operated?

34

Is any spilt fuel removed from the saw or work area prior to saw operation?

35

Is the saw always started at least 3 metres away from the refueling area?

36

Is care taken to ensure that refueling is never carried out near to fires, sparks or other sources of ignition?

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Transportation 37

Is the chainsaw switched off when being transported, even if it is only a few paces?

38

Is the chainsaw always carried by the front handle?

39

Is the chainsaw always carried with the engine muffler away from the body, to prevent burns?

40

Has the chain guard (scabbard) been fitted?

41

If the chainsaw is being transported in a vehicle, has it been secured to prevent overturning and damage?

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Page 1 Part 1.05: Other hazardous Activities (Regulatory Document)

REGULATORY DOCUMENT .......................................................................... 1

1.5

OTHER HAZARDOUS ACTIVITIES ................................................................ 1

1.5.1

Working With or Near to Buried Services ...................................................... 4

1.5.2

Lone Working .............................................................................................. 19

1.5.3

Electrical Safety on Site............................................................................... 25

1.5.4

Working In and Around Excavations............................................................ 56

1.5.5

Working in Confined Spaces ....................................................................... 75

1.5.6

Safety in Demolition..................................................................................... 95

1.5.7

Safety in Piling ........................................................................................... 115

1.5.8

Safety in Formwork/Falsework .................................................................. 124

1.5.9

Explosives ................................................................................................. 126

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1

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FORWARD

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Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

9

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9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

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19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Working With or Near to Buried Services

1.5.1.1 Key points Many injuries and deaths have occurred because the location and exposure of buried services were not carried out in a safe manner.

2

Cable plans and charts cannot be depended upon to accurately identify the exact route of a buried service.

3

Safe digging procedures are essential; final exposure of buried services by hand-digging will be necessary.

4

Prior consultation with utility companies will be necessary in most circumstances.

5

There are now devices available for locating all types of underground service; operators must be trained and competent in their use, including the interpretation of survey results.

6

The exposure of buried marker tape or tiles whilst digging will indicate the presence of buried services below.

7

It should always be assumed that buried services are 'live' unless proved otherwise.

8

On certain sites old and abandoned metallic services or other metallic items can pick up signals from known services and distort survey results.

9

Accidental damage to any buried service must be reported immediately to the relevant authority.

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Section 8, Part 9 and Section 8, Part 10 of the QCS cover trenchless pipeline construction and pipeline cleaning and inspection, respectively.

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1

Buried services are, to a great extent, out of sight and out of mind until, perhaps, there is a fault or another reason to excavate. Every year people are injured and some killed due to accidental contacts with buried services, such as electricity cables and gas pipes. In every case, the damage and injury could have been avoided if the proper procedures had been followed.

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1.5.1.3 Legislative requirements The Management of Health and Safety 1

All work, including any work in relation to the location and exposure of buried services, must have been subject to a risk assessment.

2


3

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place to either eliminate the hazard or, where this is not possible, reduce the risk of injury as far as is reasonably practicable.

4

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and of any control measures that have been put in place to reduce those risks.

5

In the context of this module, some of the factors that the risk assessment must take into

QCS 2014


account are:

6

(a)

the equipment and work methods employed to safely identify, locate, expose and, if necessary, work on the services

(b)

the potential hazards posed by

(c)

accidental damage to the buried services

(d)

the competence of the persons who are to plan, supervise and carry out the work

(e)

satisfactory reinstatement of the disturbed ground.

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or of any other person who may be affected.

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The Provision and Use of Work Equipment All equipment used in conjunction with excavations or buried services is 'work equipment".

8

These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

9

It is essential that any work equipment used to locate buried services:

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is suitable and sufficient, for example, a cable avoidance tool that works by detecting electromagnetic fields will not detect a plastic gas pipe

(b)

is fully serviceable and calibrated where appropriate

(c)

is used by a trained and competent operator who has the knowledge and experience to interpret the results.

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Construction (Design and Management) CDM Under these Regulations, the client must provide the project-specific information needed to identify hazards which can be obtained by making sensible enquiries. This includes information from utility companies on the location of underground services.

11

By providing this information to the designer, the client creates an opportunity for hazards to be avoided by design.

12

Information on new services installed should be passed to the Engineer for inclusion in the health and safety file.

13

Contractors are required that energy distribution installations are located, checked and clearly marked to prevent danger.

14

Suitable and sufficient steps must be taken, so far as is reasonably practicable, to prevent risks to health and safety from construction work likely to damage or disturb underground services

15

Furthermore, under these Regulations the following requirements are particularly relevant to working with or near to buried services:

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(a)

no duty-holder may arrange for any person to carry out design or construction work unless they are competent to carry out the work they are required to do, or are under the supervision of a competent person

(b)

all duty-holders must co-operate with each other to ensure that each can fulfil their duties under these Regulations

QCS 2014


(c)

every person working on a project under the control of another person is required to report to that person anything which is likely to pose a risk to health or safety of any persons

(d)

duty-holders must co-ordinate their work activities to ensure, so far as is reasonably practicable, the health and safety of those people carrying out the construction work and any other person who might be affected by it

1.5.1.4 Types of buried services The most obvious examples of buried services are those used to carry gas, electricity, water and telecommunications. These may be found almost anywhere. However, drains and sewers are also buried services, the location of which must be identified before excavation starts.

2

There are many other types of buried services, the presence of which may not be known or detected unless a thorough investigation is carried out. They include services associated with cable television, hydraulics, process fluids, pneumatics, railway signalling, petroleum and fuel oils (large bore, deep pipelines linking major installations), private telecommunications, highway authorities, street lighting, civil aviation and military authorities.

3

Work in the vicinity of gas transmission pipelines, normally operating at above 7 bar (100 psi), often requires special measures to be taken and the local gas distribution company will be able to supply details of appropriate procedures.

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1.5.1.5 Risks and cost of damage

A significant risk of injury results from accidental contact with electricity cables. Buried electrical cables often carry high voltages, and accidental damage and contact has resulted in death or major burns. Most injuries are caused to people using pneumatic drills or jackhammers and involve 415 volt cables which were located within 0.5 metres of the surface.

2

Damage to gas pipes can cause a leak resulting in fire and an explosion.

3

In the event of a gas leak, suspected gas leaks or any other emergency relating to gas, immediately ring:

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Gas Emergency Service Number: 4

The consequences of damaging water pipes and telephone cables may be less immediately evident but are nonetheless serious, both in terms of disruption and cost. The interruption of services can create serious problems for places critically dependent upon them - for example, hospitals - and many people are likely to be put at risk or inconvenienced.

5

The cost of damage can be considerable. Fibre optic telecommunication cables are very expensive and a simple break may mean the replacement of a 2 kilometre length, at a cost measured in thousands of Riyals. Indirect costs, in some cases resulting from loss of production and disruption of business activities, will be borne by all affected, including those whose negligence caused the incident.

1.5.1.6 Checking for buried services 1

Before any digging takes place, a check must be made with all public and private utilities, such as gas, electricity, telecommunication and cable TV companies, and the owner or occupier of the land for the existence of services in the proposed work area.

2

The routes of known buried services should be clearly marked on the site plans

QCS 2014


When looking at plans, it should be borne in mind that reference points may have been moved, surfaces may have been regraded, services moved without authority or consent, and that not all service connections or private services are shown. Plans must be interpreted with care; the route shown may only be approximate. There may be other services present not shown on the plans.

4

It is not unknown on certain sites for old and abandoned services or other buried metallic items, such as tram lines or cast iron pipes, to pick up the electro-magnetic signals from known cables and distort the survey results.

5

Where appropriate, the route, when established, should be identified with paint, tape or markers but not steel spikes which might penetrate a cable or pipe.

6

A line on a plan does not necessarily mean a pipe or cable is located exactly in the position marked. It only indicates that it is roughly in that location. The exact position will only be known when the buried service is uncovered.

7

In many cases, there is no indication above the ground that a buried service exists. They may be found almost anywhere and at any depth from immediately beneath the surface to 1.5 metres or more below.

8

Indications that buried services do exist include the presence of lighting columns, illuminated traffic signs, telephone boxes, concrete or steel manhole covers, and hydrant and valve pit covers.

9

A change in the colour of the surface material may indicate the line of a trench where services have previously been installed.

10

Indicator posts, usually on the verge, or plaques on walls, are a clear sign that buried services are present. Indicator posts belonging to water and gas suppliers often give the size of the pipe and its distance from the post. The absence of posts or covers must not be taken as evidence that there are no buried services. Access covers can be as much as 1.5 km apart.

11

Cables or pipes may be laid loose in the ground, run in earthenware, concrete, metal, asbestos or plastic ducts, or be buried in cement-bound sand, loose sand, fine backfill or material dissimilar from the surrounding ground. Plastic marker tape, tracer wire, boards, tiles or slabs may have been laid above the service to indicate that there is something below. These may, however, have been removed or damaged in the past; they are also liable to be laterally displaced by ground water or movement and thus no longer indicate the true location of the service.

12

It is common practice for brightly coloured polythene tape (150 mm wide) or expanded plastic mesh, sometimes incorporating metallic tracer wire, to be placed in the backfill about 300 mm above the pipe or service. A text on the tape identifies the type of service below. When uncovered, these tapes indicate the presence of a pipe or cable before any damage is done. The absence of a tape should not be taken as evidence that there are no pipes or

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cables at the location; it may simply mean that no marker tape was used. Caution Never assume that services have been installed at the recommended depth, they are often shallower.

14

Never assume that when you have located a service that it is the only one, there may be others adjacent to, above or underneath it.

15

Beware of services encased in concrete bases, structures or in the concrete backing to kerbs.

16

Beware of services rising over obstructions, culverts, bridges etc. They are often much shallower in these locations.

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1.5.1.7 Use of cable and pipe locators

A wide range of instruments are available for the detection of buried services. Often they are just referred to as CATs (Cable Avoidance Tools). Several different principles may be applied in the task of detection and an instrument may incorporate more than one of these.

2

Note: Both CAT and Generator must be used together to give an effective search for services. Using the CAT alone will only give part of the picture.

3

Power detection. Virtually all electricity cables give off or radiate a magnetic field while current is actually flowing through them. This magnetic field or 'hum' is usually easy to detect by a CAT.

4

However, it should be noted that CATs may not be able to detect live cables:

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when there is no current flow because the cable has been disconnected from its load. (An example of this is a live pot-ended cable)

(b)

when the loading on a three-phase supply is evenly distributed across the three phases

(c)

when the current flow is so small that it is beyond the detection capability of the detection tool

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when there is no current flowing because the device is inactive, for example, street lighting during the daytime.

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Used in the power detection mode, CATs will occasionally detect metal, gas and water pipes, and telephone cables in proximity to electricity cables.

6

Radio frequency. Metal pipes and cables can act like radio aerials and re-broadcast low and very low frequency radio signals which can be detected. There are limitations due to geography and initial broadcast signal strength. If this method is used, other metallic objects may also radiate the signal, but it is a useful method and can sometimes detect electricity cables that have not been found by power detection. Not all CATs have this function.

7

Transmitter and receiver (inductive or conductive). This method is used when the service is not carrying electricity or there is no current flow in the service to be located.

8

A small portable transmitter or signal generator (Genny) is connected to an exposed part of the cable or pipe, or placed very close to it, so that the signal is fed into or induced in the pipe or cable. This signal is then detectable by a CAT. In order to use this method, the location of at least one section of the cable or pipe must be accessible, so that the transmitter can be positioned or attached.

9

It is important to continue to use the locator as the excavation progresses.

10

Metal detectors. Conventional metal detectors will usually locate flat metal covers, joint boxes, etc., but may well miss round cables or pipes. The deeper the object, the less the chance of detection. Reinforcing bars, metal deposits in the ground and discarded metal objects will usually also be registered by a signal. Some cable locators have a metal detector function.

11

Developments in 'moles', 'pigs', 'mouses' and 'sondes', which are detection devices put into pipes and services to trace their routes, mean that previously undetectable pipes and services can be followed and, in some instances, blockages and joints can be located.

12

Ground-penetrating radar. A portable radar transmitter is used to 'sweep' the area of land under which the buried services run. A display on the transmitter indicates variations in the density of the materials below the surface and can show where the land has previously been disturbed.

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The display will also show solid objects such as cables or pipes filled with air, gas or liquids, and indicate the depth at which they are buried. By marking all the spots on the ground where an underground service has been located, its route can be traced. Ideally, this method should be supported by existing service plans.

14

The proper training of operatives is essential. Interpretation of the radar display can be difficult for the untrained. A skilled and trained operative with the correct instrument can detect the majority of underground services.

15

In unskilled hands, the average locator will not reveal exactly what has been found, or exactly where and how deep it is.

16

One problem that can arise in the use of ground-penetrating radar is the detection of individual buried services where more than one service follows the same route. The majority of detectors cannot distinguish between cables or pipes running close together. Consequently, the uncovering of one cable or pipe does not mean there is not another close by.

17

Some of the detectors or detection modes are not omni-directional and it is therefore essential to cover or sweep the area twice to ensure a good chance of detecting a buried service. This is especially true in the case of electricity cables. The sweep must be made up and down, then from side to side.

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It is important that those using any type of cable locating equipment are given sufficient training and experience to be competent.

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Recording location of services 19

A record of the nature, co-ordinates, line and level of newly installed services as well as those exposed on site should be kept and passed to the Client. This will enable those in the future to locate underground services more accurately.

1.5.1.8 Colour-coding of buried services 1

A national agreement exists between the utilities groups for the colour-coding of buried services.

2

The colours used for ducts, pipes, cables and marker/warning tapes are listed in Appendix 1 of this module. The listing has been reproduced from the publication NJUG Guidelines on the Positioning and Colour Coding of Underground Utilities Apparatus (December 2007).

3

These colour-coded buried services should not be confused with the colour system contained in BS 1710 Specification for identification of pipelines and services, which

QCS 2014


generally applies to all above-ground building and process services. 4

It should be noted that both green and black plastic-covered cables have been laid for private telecommunications and television, some of these in earthenware ducts or previously used metal pipes.

5

Identification of colours in conditions of poor light or artificial lighting may be difficult.

6

The colour-codings in Appendix 1 apply to services being laid now. With the great variety of pipes and services laid over a period of years, there is a wide mixture of materials and colours. The principal ones, excluding cement, plastic, metallic or earthenware ducts, are summarised in the table below. This table also highlights the different services that may have similarly coloured pipes or cables. Service(s)

Cast iron

Gas, water

Steel

Gas, water

Braided steel

Electricity

Yellow steel

Gas

Copper

Water

Lead or lead covered

Electricity, water

Asbestos

Water

ov

Red PVC

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Blue PVC Grey PVC

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Hessian wrapped

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Pipe or cable

Electricity Electricity, water, telecoms Water Water, telecoms Electricity Gas

Natural PVC

Telecoms

o

Yellow PVC

The following points should be noted:

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All plastic, polythene and polyvinylchloride pipes are shown above as PVC.

(a)

black PVC must always be assumed to be live electricity until proved otherwise

(b)

all cast iron and steel must be assumed to be carrying gas until proved otherwise

(c)

ducts may well contain any one of the services, irrespective of type or colour of the duct.

1.5.1.9 Digging - mechanical or manual 1

Once the approximate location of a service has been identified using all available information (including plans, marker posts and other indicators and detectors), trial holes should be dug carefully by hand to establish the exact location and depth of the service.

2

Where two holes are dug at intervals, it should not be assumed that the service runs in a straight line between them, or that it runs at a consistent depth.

3

Mechanical excavators and power tools should not be used within 0.5 metres in any direction of the indicated line of a service, unless prior agreement on a safe system of work has been reached with the service owner. Power tools may be used to break paved surfaces, but great

QCS 2014


care must be taken to avoid over penetration, since a service may have been laid at an unusually shallow depth, especially in the vicinity of buildings or other services. Power tools must never be used directly over the indicated line of a cable unless it has been made dead or steps have been taken to prevent damage. 4

Buried services that cross the route of an excavation must be supported as necessary. It is also necessary to ensure that the method used to support the sides of an excavation allow for the protrusion of buried services through the excavation's sides.

5

Before and during excavation work: Check with all utilities and landowners before starting work.

(b)

Assume the presence of services when digging, even though nothing is shown on plans.

(c)

Use detection devices and keep a close watch for signs of buried services, such as marker tape or tiles.

(d)

Although there are recommended minimum depths for all services, they may be closer to the surface than normal, especially in the vicinity of works, structures, or other services.

(e)

Markers such as plastic tape, tiles, slabs or battens may have been displaced and will not indicate the exact location of the buried service.

(f)

Some electric cables and water pipes look alike, as do some gas pipes and water pipes. Ensure each pipe is properly identified before starting work on them.

(g)

Services could be easily damaged by a fork or a pickaxe forced into the ground, but careful use of spades and shovels enables services to be safely uncovered.

(h)

Carefully lever out rocks, stones and boulders.

(i)

Overpenetration of the ground or surface with hand-held power tools is a common cause of accidents.

(j)

If an excavator or digger is being used near any service, take extra care to prevent accidental damage. Where possible, no one should be near the digger bucket while it is digging.

(k)

Ensure the excavator operator and others excavating are informed of the presence of suspected services.

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If the service is embedded in concrete or paving material, the owner should deenergise it, otherwise make it safe or approve a safe system of work before it is broken out.

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(m)

Always assume closed, capped, sealed, loose or pot-ended services are live or charged, not dead or abandoned, until proved otherwise.

(n)

Follow the guidelines and advice issued by the electricity, gas, water and telecommunication industries.

1.5.1.10 Piling and drilling, etc. 1

Piling and drilling, thrust boring, bore holing and augering must not start until all the necessary steps and precautions have been taken and a safe system of work has been devised and implemented.

2

Services shown or thought to be nearby should be exposed by hand digging to establish their precise location.

QCS 2014


1.5.1.11 Exposure and protection 1

When a service is exposed in the bottom of a trench or excavation, it should be protected with suitable timber or other material to prevent it becoming damaged.

2

Services across a trench or along a trench above the bottom should be supported by slings or props, to avoid unnecessary stresses. In case of doubt, advice should be sought from the utilities or the owner.

3

Cables and services must never be used as jacking or anchorage points, or as footholds or climbing points. If a service pipe or cable needs to be moved to allow work to progress, the owner should be consulted and advice sought.

1.5.1.12 Reporting damage

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Any damage to buried services must be reported to the owners. Minor damage to the sheath of a cable or to a coating on a pipe can result in moisture penetration, corrosion and subsequent failure. A cable pulled and stretched may result in a conductor or core being broken, and a broken earthenware or concrete duct may prevent a service being routed through it.

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1

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If a gas pipe is fractured or starts leaking: evacuate all personnel from the area

3

enforce a ban on smoking and naked lights

4

prevent any approach by members of the public or vehicles

5

inform the gas company immediately.

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2

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If an electricity cable is damaged: avoid all contact with it

7

do not attempt to disentangle it from digger buckets, etc.

8

do not attempt to leave your cab. Stay put until you are told the cable has been made safe

9

inform the electricity company

10

keep everyone clear.

11

Note: Some cables are automatically re-energised by the local sub-station after a short time following the supply tripping out due to damage. Do not assume that a damaged cable will remain dead.

12

Beware of old pot-ended cables and pot joints; these are easily damaged if moved. Always consult the service provider before touching such apparatus.

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6

If any other service pipe or cable is broken: 13

leave well alone

14

inform the owner.

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Backfilling 15

Surplus concrete, hard core, rock, rubble and flint must never be tipped onto a service while backfilling a trench or hole, since it may result in damage.

16

Selected backfill material should be adequately settled and compacted, with care being taken to avoid mechanical shocks to the service pipe or cable. Warning tapes, tiles, etc. should be placed above the service at about 300 mm. When gas service pipes have been exposed, advice on backfill should be sought from the gas company.

Emergency works Emergency works and excavations usually mean that there is no time for planning or contacting each of the utilities.

18

However, work can be carried out safely if:

(b)

detectors are used correctly

(c)

trial holes are dug by hand

(d)

the practice of safe digging is followed.

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the area is marked out carefully

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(a)

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17

Permit to Work and Permit to Dig

Where it is appropriate, a formal Permit to Work system should be employed, with a Permit to Dig being issued, duly signed by a competent person. Those engaged on the work can then see exactly what has been done, what is expected of them and what precautions they must take. The permit also allows the person in control of the works to authorise excavation to proceed only when they are satisfied that the conditions of the permit have been met.

20

An example of a Permit to Dig is given in Appendix 2.

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Conclusion

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PLAN... LOCATE... DIG...

Plan the work to be done, including the risk assessment, using all available sources of information. Contact the utility companies and owners of services for information and advice on procedures and continue to liaise with them.

22

Locate the buried service before digging or excavation starts. Use all available information; look for indicators or markers and other signs; use detectors and locators, and dig trial holes.

23

Dig using a safe method of work (Permit to Work systems whenever possible); observe the rules in respect of the use of mechanical diggers and power tools. Ensure that all services are identified positively. Do not make assumptions about the number, type or exact location of services.

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21

QCS 2014


Construction Site Safety 1.5.1 Appendix 1 Colours of ducts, pipes, cables and marker/warning tapes 1

These guidelines, reflect utility practice in the UK. However, operators must not assume that any mains or services encountered will conform to the recommendations for positioning or colour coding detailed in this appendix.

Pipe/Duct Identification Issue 4, dated 8 January 2009 The pipe or duct may have the owning utility's name stamped upon it.

Duct

Pipe

Cable

Electricity HV (High Voltage)

Black or red tile

N/A

Black or red

Yellow with black legend

Electricity LV (Low Voltage)

Black or red

N/A

Black or red


Gas

Yellow

Yellow or yellow with N/A brown stripes that is removable to reveal white or black pipe

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Water non potable & Grey water

N/A

Black with green stripes

N/A

N/A

Water -Firefighting

N/A

Black with red stripes or bands

N/A

N/A

Oil / fuel pipelines

N/A

Black

N/A

Various surface markersMarker tape or tiles above red concrete

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Black

No distinguishing N/A colour/ material (e.g. Ductile Iron may be red; PVC may be brown)

N/A

Grey White Green Black Purple

N/A

Various

Water

Blue or grey

Blue polymer or blue N/A uncoated Iron / GRP. Blue polymer with brown stripe (removable skin revealing white or black pipe)

Blue or Blue/black

Water pipes for special purposes (e.g. contaminated ground)

N/A

Blue polymer with brown stripes (nonremovable skin)

Blue or blue/black

Telecoms

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Sewerage

Colour of Marker/ Warning Tape Where Used

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Colour of Duct/Pipe/Cable Buried in Ground

Black or light grey

N/A

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Duct

Pipe

Cable

Tape

Street lighting England and Black or orange Wales (consult the electricity company first)

N/A

Black

Yellow withblack legend

Street lighting Scotland

Purple

N/A

Purple

Yellow with purpleblacklegend or

Street lighting Northern Ireland

Orange

N/A

Black or orange

Various

Traffic control

Orange

N/A

Orange

Yellow withblacklegend

Street furniture

Black

N/A

Black


Telecoms

Purple/orange

N/A

Black

Communications

Purple

N/A

Grey

Communications power

Purple

N/A

Black

Road lighting

Orange

N/A

Black

Communications

Black or grey

N/A

Road lighting

Purple

N/A

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Highway Authority Services

Yellow withblacklegend Yellow withblacklegend Yellow withblacklegend

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Various

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Scotland

Black


Purple


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Construction Site Safety 1.5.1 Appendix 2 Example of a Permit to Dig Work must not start until Sections A, B & C of this permit have been completed and signed by authorised persons. Section A. Project details To be completed by project manager Company: .................................................................. Job/Contract ref: .............................................................. Contractor: .................................................................Location of works:...............................................................

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Start date: ..................................................................Completion date:.................................................................

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Brief description of works

Section B. Preliminary work

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To be completed by the Supervisor in change of the works

Yes

No

Comments

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Essential procedures

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1. Have contract drawings and details been issued by the client or otherwise obtained?

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2. Do drawings show the location, type and status of buried services?

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3. Have live services been made dead as far as it is possible or necessary to do so?

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4. Has the work area been surveyed by a competent person, using appropriate detection equipment to confirm the exact location of buried services?

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5. Has a method statement been written and submitted for comment and approval? 6. Has the method statement been explained to the operatives carrying out the work? 7. Is the person in charge of the excavation fully conversant with the principles of safe digging and/or avoidance of buried services? 8. Are all operatives familiar with safe excavation practices? 9. If plant is being used, is the operator competent and familiar with safe digging practices? I declare that the above safety precautions will be put into place before work commences or that an explanation given as to why some or all are not necessary:

Name:..................................

Signature:..................................

.Date:.....................

Time:....................

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Section C. Certification To be completed by the supervisor in charge of the works

I am satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely* I am NOT satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely and require the additional precautions / work outlined below to be undertaken before excavation work commences*

.

*Delete as appropriate

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Name:............................Signature:...................................Date:.....................Time:.................... Additional precautions / work necessary prior to commencement:

Section D. Completion of work

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To be completed by the supervisor in charge of the works I am satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely*

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*Delete as appropriate

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I am NOT satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely and require the additional precautions / work outlined below to be undertaken before excavation work commences*

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Name:............................Signature:...................................Date:.....................Time:.................... Additional work that is necessary to enable this permit to be cancelled:

Section E. Cancellation of permit To be completed by the supervisor in charge of the works I am satisfied that all work has been completed and this permit is now cancelled.

Name:............................Signature:...................................Date:.....................Time:....................

QCS 2014



Lone Working

1.5.2.1 Key points The implications of lone working must be thoroughly investigated, via a risk assessment, before anyone is allowed to work alone.

2

Lone working must be avoided whenever it may put the health or safety of any person at an unacceptable level of risk.

3

Anyone working alone, for example a single person working in a lift shaft, is a lone worker even if there are other people on site.

4

The suitability of the job and the person who will undertake the work must both be taken into account to establish whether lone working is advisable.

5

A suitable and effective system of checks to confirm the continued wellbeing of the lone worker must be put in place.

6

The risk assessment might indicate the need for a rescue plan.

7

Resist the urge to carry out unplanned lone working, for example the two members of a maintenance team separating so that one of them can fix an unexpected fault, unless it is proved safe to do so.

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Before lone working is permitted, the risks of a single worker carrying out the task must be assessed. The findings of the risk assessment must demonstrate that the person would not be at a greater level of risk than if accompanied.

2

Contractors have responsibilities for the health and safety of their employees and other people who might be affected by the Contractor’s work activities. Whilst legal duties are also placed upon employees, the Contractor still retains the legal duty to ensure the wellbeing of the employees.

3

Lone workers are people who work by themselves without any close or direct supervision.

4

As far as construction industry activities are concerned, they are likely to be people who:

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(a)

work on their own in a part of the site that is otherwise occupied by other people

(b)

have to work alone on the site outside of normal working hours

(c)

work alone in premises which are remote from the site, such as company offices or a builder's yard

(d)

work alone in domestic premises whilst the householder is not present.

1.5.2.3 Legislative requirements Duties of Contractors 1

A general duty on every Contractor is to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all their employees.

2

All of the requirements listed below could have implications when considering the need or advisability for someone to work alone.

3

So far as is reasonably practicable, Contractors must:

QCS 2014

protect the health, safety and welfare at work of all their employees

(b)

provide and maintain plant and systems of work that are safe and without risk to health

(c)

ensure safety and absence of risks in the use, handling, storage and transport of articles and substances

(d)

provide any necessary information, including information on legal requirements, to ensure the health and safety of their employees

(e)

provide adequate supervision and training, as is necessary, to ensure the health and safety of their employees

(f)

provide and maintain a safe and healthy place of work, with safe access and egress

(g)

provide and maintain a working environment that is safe and without risks to health and is adequate with regard to welfare facilities and arrangements for welfare at work.

.

(a)

Certain additional duties have been placed on the Contractor including:

to ensure, as far as is reasonably practicable, that the conduct of their activities does not endanger persons not in their employment who may be affected by operations under their control, for example, all contractors or the public.

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(a)

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General duties on employees:

to exercise reasonable care for the health and safety of themselves or others who may be affected by their acts or omissions at work

(b)

to co-operate with the Contractor, as far as may be necessary, to enable them (the Contractor) to carry out their legal duties in health and safety matters.

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Duties of employees

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These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

7

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

8


9

Employees, in turn, have a duty to tell their Contractor of any work situation which they believe presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

10

Also of importance with regard to lone working are the requirements on the Contractor to:

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(a)

establish contacts with external services, for example the emergency services

(b)

provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks

(c)

assess employees' capabilities when allocating work to individuals

(d)

provide adequate training for anyone involved in any aspect of lone working (including

QCS 2014

Section 11: Health and Safety Page 21 Part 1.05: Other hazardous Activities (Regulatory Document) rescue).

11

Arising out of the risk assessment for lone working the Contractor may decide that there is a need to: (a)

develop a method statement for each job

(b)

implement a Permit to Work system, encompassing or supplemented by a Permit to Enter.

1.5.2.4 Practical considerations 1

Before the job starts, the following factors must be considered as part of assessing the risks of carrying out lone working.

rw

Job factors that must be taken into account when considering whether the risks of lone working are acceptable include the following: Does the place of work and the job to be carried out present more unacceptable risks to the health and safety of a lone worker than it would for, say, a gang of two workers?

(b)

Can the lone worker enter and exit from the place of work safely, including exiting quickly and safely in an emergency?

(c)

Can all equipment, plant and substances used be safely handled by one person?

(d)

Are there barriers to effective communication with the lone worker?

(e)

If something goes wrong, is a prompt and effective rescue a realistic possibility?

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(a)

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The job

There may be circumstances in which unplanned lone working takes place when, for example, one person decides to separate from workmates to investigate a fault or sort out a problem. Depending on the working environment, these situations have the potential to put the health or safety of the 'lone worker' at significant risk. The findings of the risk assessment should indicate the potential risks arising from one member of a team becoming separated from workmates.

4

If such a situation could arise, managers and supervisors must ensure that clear instructions are given about the need for 'team members to stick together'.

5

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The person

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3

The suitability of the person who will undertake the work has to be considered when deciding whether lone working is safe. Questions to be asked and satisfactorily answered as part of the risk assessment include the following. (a)

Given that there will be no direct supervision, has the person who will carry out the job received adequate training and instruction to do it safely?

(b)

Does the person have sufficient experience to be able to recognise an unsafe situation developing which necessitates leaving the place of work?

(c)

Does the person know how to inform others, and who to inform if an unsafe situation develops?

(d)

Considering both routine work and a possible emergency situation, does the person have a medical condition that might make them unsuitable for lone working?

(e)

Does the person require and possess a particular level of physical fitness to carry out the work?

(f)

Is a young female or non-English speaking worker at a greater level of risk?

QCS 2014


The risks 6

A wide range of work activities can be classified as lone working, not all of which present unacceptable risks. For example, it could be argued that a lone worker travelling to an otherwise unoccupied part of a highway construction site, in a serviceable and suitable vehicle, is at far less risk than a lone worker entering an underground chamber after normal working hours.

7

The findings of a thorough assessment of the risks arising out of proposed lone working will indicate whether it is safe to proceed.

8

An assessment of the risks arising from carrying out work which involves the following common construction activities might indicate that lone working is not acceptable: working at height

(b)

working in any area which could become a confined space

(c)

working in narrow, deep excavations, whether classified as a confined space or not

(d)

working with, or close to, exposed live electrical cables or fittings

(e)

working with, or close to, other sources of other potentially hazardous energy

(f)

using any substance that could deplete the level of oxygen or otherwise result in reduced awareness or loss of consciousness

(g)

any hot-works

(h)

disturbance of sludge in any underground chamber, pipe etc.

(i)

entering ductwork

(j)

working over or near to water or other fluids in which a person could drown

(k)

the operation of any equipment such as power saws, misuse of which could lead to severe bleeding

(l)

the operation of any engine-driven equipment that emits toxic exhaust fumes

(m)

the operation of construction plant.

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(a)

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Note: The above list is not exhaustive.

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Control measures 9

The health and safety of anyone who is working alone should not be put at a higher level of risk than if working with other people.

10

This may require that extra risk-control measures are taken, for example: (a)

ensuring that the lone worker is competent to carry out the work

(b)

supplementing the risk assessment with: (i)

a permit to work which clearly defines the limits of the work allowed and the time within which it must be completed, and/or

(ii)

a method statement

(c)

providing the lone worker with a means of communication

(d)

implementing a 'check-in' system whereby either: (i)

the lone worker contacts another person at prearranged intervals, the frequency of checking-in depending upon the urgency of response if the lone worker fails to 'check-in'; or

QCS 2014

Section 11: Health and Safety Page 23 Part 1.05: Other hazardous Activities (Regulatory Document) (ii)

the reverse of the above system in which someone such as a supervisor periodically contacts the lone worker

(e)

supplying the lone worker with a manual alarm system or one which operates automatically by the absence of activity (see below)

(f)

providing the lone worker with a 'travelling' first-aid kit and possibly (if indicated by the findings of the risk assessment) first-aid training

(g)

establishing a trained rescue person or team and practising the rescue procedure.

Alarm systems Automatic alarms, also known as 'man down' alarms, have been in use in hazardous industries such as petrochemicals for some time. This equipment also has its uses for lone workers in the construction industry. Although the alarm can be triggered manually by a lone worker who is in distress or danger, depending on the type, they can be automatically triggered by: a lack of motion for a pre-set period of time

(b)

a tilt switch which typically operates after a short delay if the unit is tilted beyond 45° from the vertical.

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(a)

Of course, if such a system is in use, it is essential that:

the 'base station' where the alarm system is received is staffed continually whilst lone working is taking place

(b)

the exact location of the lone worker is known

(c)

a prompt rescue can be initiated by a trained rescue person or team, depending upon the circumstances.

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(a)

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12

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QCS 2014


Construction Site Safety 1.5.2 Appendix Lone working checklist 1

Have the risks of lone working been assessed?

2

Do the findings of the risk assessment show: (a)

that there are any particularly hazardous aspects of the job that might make it unsafe for lone working?

(b)

that lone working significantly increases the risks to the person doing the job?

(c)

that particular skills, knowledge, training or instruction are necessary?

Will the lone worker be able to cope with all the physical aspects of the Job without assistance?

4

Do the physical characteristics of the place of work make it suitable for lone working and emergency evacuation?

5

Are the levels of risk acceptable?

6

Is a permit to work necessary?

7

Is a method statement necessary?

8

Can the person selected for lone working follow a method statement when unsupervised?

9

Is the lone worker competent to work without direct supervision?

10

Will the lone worker be able to recognise an unsafe situation developing?

11

If so, will they know what to do?

12

Is a rescue plan necessary?

13

Has sufficient instruction and training been provided?

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(a)

Will an effective method of communication between the lone worker and a supervisor/manager be established?

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Is an automatic 'man down' alarm system necessary and if so: (a)

where will the base station be located? who will staff it whilst lone working is in progress?

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15

Is it necessary to establish a rescue plan and team?

16

Is a 'check-in' system required?

17

Does the lone worker have a medical condition that might increase the risks to their health or safety?

18

Does the lone worker require a 'travelling' first-aid kit and first-aid training?

19

Is there a need to isolate electrical supplies or other sources of energy?

QCS 2014



Electrical Safety on Site

1.5.3.1 Key points Electricity can be a killer; you cannot see it and may not know that an item of equipment is live until you touch it.

2

Buried cables, and those inside partition walls or other 'hidden places', are just waiting for the unwary to accidentally damage the cable and cause themselves serious injury or even death.

3

The electrical distribution systems found on site tend to operate in a harsh environment and must be treated with care and respect.

4

No-one other than a qualified electrician must alter the site distribution system.

5

Ideally, apart from mains-powered equipment in site offices, all other powered equipment such as electrical hand tools will run off a 110 volt supply.

6

The safest electrically powered tools and equipment are those that run off batteries.

7

Working on or near to live, exposed conductors poses obvious dangers. Competence is required and such work is usually carried out under a Permit to Work.

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Section 9 of the QCS covers mechanical/electrical equipment and Section 21 covers electrical works.

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Note:

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1

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Unlike most other hazards which can be seen, felt or heard there is no advance warning of danger from electricity; and electricity can kill.

2

Electricity and electrical installations on construction sites must always be treated with the utmost care and be under the control and supervision of experienced competent persons. Hazards arise through faulty installations, lack of maintenance and abuse of equipment.

3

Electric shock is a major hazard. The severity of the shock will depend on the level of electric current, and the duration of the contact.

4

At low levels of current, about 1 milliamp, the effect may be only an unpleasant tingle but enough to cause loss of balance or a fall. An electrical current of about 10 milliamps can cause muscular spasm and loss of control. Higher levels of electric current of 50 milliamps or above, for a period of about one second, can cause fibrillation of the heart which can be lethal.

5

Electric shock also causes burning of the skin at the points of contact.

6

1 milliamp is a one thousandth part of an amp.

7

Fuses cannot be regarded as adequate protection against electric shock. A fuse is intended only to protect equipment from damage. They are commonly rated at 3, 5, 10 or 13 amps for domestic and normal business use.

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1.5.3.3 Causes of electric shock 1

Contact between a live conductor and earth.

2

Contact between phase and neutral conductors (as the body is likely to have less electrical

QCS 2014


resistance than any load). 3

The majority of electrical accidents happen because people are working on or close to equipment which is either: (a)

assumed to be dead but is, in fact, live

(b)

known to be live, but workers have not received adequate training, lack adequate equipment or have not taken adequate precautions.

It cannot be emphasised too strongly that the installation, maintenance and repair of electrical services must only be carried out by a competent, qualified electrician.

5

Electric shock is not the only hazard. The very high temperature that results from electric arcing can produce severe and deep-seated burns. An electric arc also produces intense ultraviolet radiation which can damage the eyes (arc eye).

6

An electrical short circuit or the use of unstable or badly maintained equipment can ignite flammable materials, resulting in a fire or explosion.

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1.5.3.4 Legislative requirements

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2

Once those hazards have been identified, it is - then the Contractor’s duty to put control measures into place, to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and of any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or to any other person who may be affected.

5

In the context of this module, the risk assessment should include consideration of:

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(a)

the possibility of anyone coming into contact with live electrical equipment at a dangerous voltage

(b)

the control measures that must be put in place to ensure that no one is injured by coming into contact with live electrical equipment at a dangerous voltage, for example a Permit to Work system

(c)

the training and competence of any person who may have to work in the vicinity of live electrical supplies.

The Provision and Use of Work Equipment 6

These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

7


QCS 2014

Furthermore, these Regulations require that: all work equipment has adequate controls, emergency controls and where necessary, a control system, to enable it to be used safely

(b)

each item of work equipment can be effectively isolated from all sources of energy

(c)

the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work task safely and without risk to their health.

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Construction (Design and Management) CDM The hazard of exposure to live electrical conductors can in many cases be eliminated, or the residual risks reduced, by careful attention to design and planning aspects before construction work starts. Any residual risks must be controlled by good management and safe working practices during construction.

10

These Regulations place health and safety responsibilities on the client, designers, contractor and provide a framework for the management of risks, including electrical risks.

11

The client must ensure that all designers and all contractors appointed by the client, or likely to be, are promptly provided with all relevant information that the client has in relation to the health and safety risks arising from the project.

12

In the context of this section, this information could cover, for example, the existence of buried electrical services or live electrical circuits in a building that is about to undergo renovation.

13

The client must ensure that the Engineer promptly supplies the relevant information to the contractor and all designers.

14

Given the hazardous nature of electricity, it is difficult to see how identifying the location of live electrical services could be anything other than relevant.

15

These Regulations require that where there is a danger from electrical power cables they must be:

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9

suitably located (positioned) to prevent danger, periodically checked and clearly indicated by signs

(b)

directed away from the area of risk, or

(c)

made dead and where necessary earthed, or

(d)

where neither of the above two options are 'reasonably practicable', erect suitable warning notices and:

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barriers suitable to exclude work equipment which is not needed, or

(ii)

suspended protection if vehicles need to pass below the cable, or

(iii)

in either case other equally effective measures

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(i)

construction work that is liable to create a risk to health or safety from underground services must not commence unless all reasonably practicable steps have been taken to avoid damaging or disturbing them.

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(a)

Electricity at Work 16

These Regulations apply to all situations involving electricity, at any place of work, and place legal obligations on both Contractors and employees.

17

The main points of these Regulations are, briefly, as follows. (a)

All systems shall be of such a construction so as to prevent, so far as is reasonably practicable, any danger.

(b)

All work activity on or near a system, including operation, use or maintenance, shall be carried out, so far as it is reasonably practicable, so as not to give rise to any danger.

(c)

Any equipment provided to protect people while they are at work on, or near, any electrical equipment shall be suitable for use and properly maintained.

QCS 2014

Section 11: Health and Safety Page 29 Part 1.05: Other hazardous Activities (Regulatory Document) Notes: (i)

(i) 'System' includes every part of the system or installation, all conductors and electrical equipment, whether the system is electrically alive or dead.

(ii)

(ii) 'Electrical equipment' includes everything from overhead to underground cables with thousands of volts, right down to 6 volt circuits and even batterypowered hand lamps. The spark from the switch on a hand lamp could be a source of danger in an explosive atmosphere.

(iii)

(iii) 'Danger' is the risk of injury to any person.

(iv)

(iv) 'Injury' means death or any injury caused by electricity. This covers electric shock, electric burns, fires, arcing or explosions caused by electricity.

The strength and capability of electrical equipment must not be exceeded in such a way as may give rise to any danger.

19

All electrical equipment which may be exposed to the following must be constructed, or protected to prevent, so far as reasonably practicable, any danger arising from: mechanical damage

(b)

the effects of weather, temperature and so on

(c)

wet, dirty or corrosive conditions

(d)

flammable or explosive dusts or gases.

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(a)

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Note: 'Technical knowledge and experience' means that the person must be competent to do their job. To be considered competent a person needs: adequate knowledge of electricity

(f)

good experience of electrical work

(g)

an understanding of the system being worked on

(h)

practical experience of that type of system

(i)

knowledge of the hazards that might arise and the precautions that need to be taken

(j)

the ability to immediately recognise unsafe situations.

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(e)

Electricity supply

The supply of electricity on construction sites will normally be provided by one or both of the following:

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(a)

A public supply from the local electricity company.

(b)

A site generator, where public supply is not practicable or is uneconomic.

Public supply 21

A public supply of electricity being provided depends on the following: (a)

written application being made to the local electricity company, as soon as possible at the planning stage

(b)

the name, address, and telephone number of the main contractor and developer, giving the full site address and a location plan

(c)

details of the maximum demand load (in kilowatts) which is likely to be required during construction

(d)

details of the maximum final demand load (in kilowatts) which will be required when the job is complete

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(e)

dates when the supply is needed

(f)

a discussion with electricity company staff to determine the necessary precautions to avoid damage or hazards from any existing overhead or underground cables

(g)

the establishment of supply points (where incoming cables will terminate), switch gear, metering equipment and requirements for earthing.

Generators Generators (even if for stand-by purposes) may be required, and will be powered by petrol or diesel engines. Attention should be given to the siting of such equipment in order to minimise pollution caused by noise and fumes.

23

Any private generating plant must be installed in accordance with BS 7375. You are advised to seek advice from the local electricity company.

24

If the generator will produce over 55 volts AC, it must be effectively earthed. A competent person should test the effectiveness of the earth.

25

The principle of low voltages and their advantages should be considered further where portable generators are used on site.

26

Not all portable generators available for use on site have the 110 voltage output centre tapped to earth. This is particularly true of generators which have dual voltage selectable. This is important as the whole concept of using 110 volts on site is that by centre tapping to earth, the maximum voltage to which anyone is exposed is only 55 volts. Most people can survive a shock of 55 volts. If the supply is not centre tapped to earth, anyone receiving a shock will be exposed to the full 110 volts.

27

The metal framing of the generating set should be bonded to the metalwork of the site distribution system, where there is one.

28

The use of generators in excess of 10 kVA may require advice from a specialist electrical contractor.

29

Overhead power lines

30

Generally, electricity supplies above 33,000 volts are routed overhead. Supplies below this voltage may be either overhead or underground.

31

Overhead lines are normally uninsulated and can be lethal if contact, or near contact, is made. Electric arcs may jump a considerable distance. Care should be taken when dumping, tipping waste, regrading, landscaping, or when in planned or unplanned storage areas, not to reduce these minimum clearances.

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Working near overhead power lines 32

The local electricity company must be consulted before any work starts and a safe system of work must be devised and implemented.

33

Other suppliers may also need to be consulted, for example, Qatar General Electricity & Water Corporation and other electricity companies.

34

For some jobs, it may be necessary for the electricity supplier to isolate or re-route overhead cables to enable the work to proceed.

35

Practical steps that can be taken to prevent danger from any live electrical cable or apparatus include the placing of substantial and highly visible barriers.

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36

If access is only required from one side of a power line, then a barrier, on that side only, will suffice. If the overhead line crosses the site, barriers will be required on both sides of it. If there is a danger to people carrying metal scaffold poles, ladders or other conducting objects, the barrier should exclude both people and mobile plant.

37

Any ground level barriers should consist of either: a stout post and rail fence, or

(b)

a tension wire fence, earthed at both ends, with flags on the wire. The fence is earthed in consultation with the electricity company, or

(c)

large steel drums (for example 200-litre oil drums) filled with rubble or concrete, and placed at frequent intervals, or

(d)

an earth bank, not less than 1 m high and marked by posts to stop vehicles, or

(e)

substantial timber baulks, to act as wheel stops.

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(a)

Fences, posts and oil drums should be made as distinctive as possible by being painted with red and white stripes. As an alternative, red and white plastic warning flags or hazard bunting should be used on wire fences.

39

There should be a general rule prohibiting the storage of materials in the area between the overhead lines and the ground-level barriers. Precautions are necessary even though work in the vicinity of the line may be of short duration.

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38

Before doing any work on site, consult the local electricity company. They will normally arrange a site meeting and advise on heights, distances and other precautions.

(b)

It must be assumed that all overhead lines and cables are live unless advised otherwise by the electricity company.

(c)

All work should be carried out under the direct supervision of a responsible supervisor, appointed by the Contractor, who is familiar with the hazards likely to be encountered.

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If mobile cranes or excavators are used, the minimum distance from the ground level barrier to the line should be 9 m if on wood or metal poles, 15 m if on pylons PLUS the length of the jib or boom.

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Working near overhead power lines


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Ensure that safety precautions are developed and observed.

(b)

All plant, cranes and excavators may be modified with suitable physical restraints to limit their operations, where applicable.

(c)

Additional care may be needed as work proceeds because of reduced clearances.

(d)

Electronic proximity warning devices may be fitted on crane jibs.

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(a)

Where it is necessary to work beneath live overhead lines, additional precautions will be required to prevent the upward movement of ladders, scaffold poles, crane jibs or excavator buckets.

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Note: If any work takes place after dark, notices and crossbars should be illuminated. The height will be specified by the electricity company.

Working in proximity of underground cables 42

Damage to live underground cables during excavation work is the cause of a number of accidents resulting in injuries and disruption of supplies. There have been occasions when such accidents have been fatal. The electricity company should be consulted before the commencement of any work that may result in the exposure of or damage to, underground electricity cables.

43

Technology such as ground penetrating radar has improved cable identification significantly and there is now very little excuse for hitting underground cables.

44

It is essential that all those involved, particularly machine operators, are aware of the hazards.

45

Before any excavation work starts: (a)

ensure that employees have proper and safe work procedures and are working under

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Section 11: Health and Safety Page 33 Part 1.05: Other hazardous Activities (Regulatory Document) adequate supervision

(c)

obtain advice on the location and ownership of any underground electricity cables

(d)

check plans to establish cable routes, as well as their depth and voltage

(e)

use cable location devices where necessary and mark cable routes

(f)

users need to be trained to use cable avoidance tools (CAT) effectively

(g)

CAT will usually only locate energised cables and so a signal generator may have to be used in conjunction with the CAT to find the cable (CAT and genny as it is known).

During excavation: regard all buried cables as live. Do not assume that pot-ended cables are dead or disused

(b)

dig by hand when nearing the assumed line of the cable

(c)

do not use excavators and power tools within 0.5 m of the indicated line of the cable

(d)

if hand digging is not an option, the service must be isolated

(e)

ensure exposed cables are supported and protected against damage. They should not be used as hand and footholds

(f)

consult the local electricity company (Qatar General Electricity & Water Corporation) in all cases of doubt.

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(a)

Many incidents occur where people are asked to hand dig through concrete, tarmac and other compressed surfaces, and have to resort to using bars and picks. Consequently, cables are hit and penetrated. Alternatively, they persuade the excavator driver to dig a bit closer to the cable to reduce the amount of hand digging that they have to do. It is important to understand and be aware of situations where these so called 'human factors' may make an incident more likely.

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check with the electricity company that it is safe to start work

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(b)

Site distribution 48

As a first general guide, all wiring should conform to BS 7671: Requirements for Electrical

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Installation, even though much of it will be temporary. Makeshift arrangements cause accidents and must be prohibited. 49

All switch gear should be freely accessible and capable of being locked in the 'off position.

50

Wherever possible a reduced voltage system should be used.

51

Site offices and other accommodation should be a standard installation to the current BS 7671: Requirements for Electrical Installation.

Distribution equipment Electrical equipment must be manufactured to a standard which prevents, for example, the ingress of fingers, tools, dust or moisture as appropriate, depending upon the nature of the hazard. This is particularly important where electrical distribution equipment is to be sited outdoors, where the ingress of water and to a lesser extent, dust could be a problem.

53

Internationally, such equipment is assigned an IP (ingress protection) number. For example, equipment manufactured to:

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IP 32 - is protected against the ingress of solid objects over 2.5 mm, for example tools, and against the ingress of direct sprays of water up to 15° from the vertical

(b)

IP 54 - is protected against the ingress of dust (no harmful deposits) and low pressure jets of water (limited ingress).

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(a)

Electrical distribution equipment obtained from reputable suppliers or hire companies will conform to the necessary British or International standards.

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Site accommodation

Site offices and welfare facilities are the only locations where electrical equipment that runs off a 230 volt supply should be in use. The electrical supply panel for such facilities must incorporate a residual current device (RCD) in each circuit.

56

The correct operation of each RCD must be confirmed weekly by operating the 'TEST' button.

57

The incoming electrical supply to site accommodation must be properly designed and be installed and commissioned by competent electrical contractors.

58

All portable electrical equipment must be electrical safety (PAT tested) at appropriate intervals as decided by a competent person. This includes:

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(a)

common types of office equipment, such as fax machines and photocopiers

(b)

'kitchen-type equipment', such as kettles, microwave ovens, and so on.

(c)

small items, such as chargers for site radios and battery-powered tools.

59

All units for site use should comply with BS 4363 and installations with BS 7375. Plugs, sockets and couplers must conform to BS EN 60309-2.

60

BS 4363 recommends use of the following units:

Supply incoming unit (SIU) 61

Ratings up to 300 amps per phase. These units include main switch gear and metering equipment.

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Mains distribution unit (MDU) For the control and distribution of electricity on site. 415 volt three-phase, 230 volt singlephase AC.

63

A combined supply incoming and distribution unit (SIDU) may be used in some installations.

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Transformer units (TU)

TU 1 single-phase 230 volts - 110 volts TU 3 three-phase 415 volts - 110 volts

65

Transformer units are available with different outlet ratings, i.e. 16, 32 or 60 amps. Some units have socket outlets switched through miniature circuit-breakers for added protection.

66

Such transformer units can be used for portable tools and plant, and general floor lighting.

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(b)

16 or 32 amp

Outlet units (OU)

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110 volt socket outlet units

67

Such outlet units can be used for portable tools, floodlighting and extension outlets. They are not usually protected by circuit-breakers.

Extension outlet units (EOU)

68

(a)

110 volt socket outlet

(b)

16 amp

Such units can be used for portable tools, local lighting and hand lamps. They are not usually protected by circuit-breakers.

Markings 69

All supply, distribution and transformer units should be marked with the warning sign shown below from BS 5378 Safety signs and colours.

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A supplementary sign with the word DANGER, and indicating the highest voltage likely to be present, should be placed below the warning sign.

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70


Earthing

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All metal parts of the distribution systems and fixed appliances not carrying a current must be effectively earthed in accordance with BS 7430 Code of Practice for Earthing, to either: (a)

the metallic sheath and armouring of the incoming supply cable

(b)

the earthed terminal supplied by the supply authority

(c)

a separate earth electrode system.

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Periodic maintenance, inspection and testing is essential.

73

Earthing via water pipes or gas pipes is not permitted.

74

Monitored earthing systems are recommended for all transportable plant operating at any voltage above 110 volts and supplied with flexible cables. In these systems, a very low voltage current circulates continuously in the earthing circuit. If this circuit is broken or interrupted, the supply to the plant is automatically cut off until the earth path is made effective.

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Plugs, socket outlets and couplers Only components to BS EN 60309-2 should be used. This covers both single and threephase supplies and is intended to prevent plugs designed for one voltage being connected to sockets of another. This is achieved by different positions of the key-way in plug and socket.

Examples

76

Accessories should be marked with the maximum rated operating voltage and current.

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Colour coding may sometimes be used. Colour Operating voltage (AC) at 50/60 Hz Violet White Yellow Blue Red Black

25 50 110-130 220-230 318-415 500-750

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In all site offices, workshops, huts and similar premises, wiring, which is of permanent nature, should comply with BS 7671: Requirements for Electrical Installation.

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1.5.3.5 Cables

Changes to electrical wiring colours

In order to bring about a complete standardisation Internationally, changes to cable core colours were introduced and have been effective since 1 April 2004. These changes were introduced by an amendment to BS 7671: Requirements for Electrical Installation and will affect all single-and three-phase circuit cables.

3

The new core colours are:

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Neutral Blue (previously black) Earth will remain Green/Yellow Phase 1 Brown (previously red) Phase 2 Black (previously yellow) Phase 3 Grey (previously blue)

Many cables and flexes in the new colours are already in use, but this recent change further emphasises the need to use competent electricians for all cabling and wiring work, if electrical accidents are to be avoided.

5

More information on the changes can be found in a promotional leaflet that can be accessed at www.iee.org/publish/wireregs/cablecol.cfm

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Cables used for site distribution

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(a)

Cables that carry more than 65 volts (with respect to earth) should have a continuous armour or sheath, which is effectively earthed. (This requirement does not apply to arc welding processes.)

(b)

Where trailing cables are used, sheathing must be earthed in addition to the normal earth conductor.

All cables should have an overall protective sheathing. The three most common types in use are: (a)

tough rubber sheathing (TRS), resistant to wear and abrasion. Not used near solvents or oils

(b)

polyvinyl chloride (PVC). For site office and permanent work. Not suitable for outside work at low temperature

(c)

polychloroprene (PCP). This is the best all round type.

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Buried cables 7

All buried cables should be: (a)

at least 0.5 m below ground

(b)

protected with tiles or covers or placed in a duct

(c)

in a trench marked to indicate their route.

Cables on the ground The use of cables laid on the ground is dependent on the nature of work being carried out, and should be: (a)

only permitted for short periods

(b)

provided with additional protection, such as a reinforced sleeve

(c)

clearly marked, so as not to constitute a tripping hazard.

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Suspended cables are permissible on condition that: there is no tension or strain on connections

(b)

they are adequately marked for protection

(c)

they are supported on proper hooks, not nails

(d)

spans over 3 m are supported by catenary wires on poles

(e)

they are at a minimum height of 5.2 m above ground.

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Suspended cables

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1.5.3.6 Installations

Installations should be in accordance with plans drawn up by a competent person.

2

Any work or alterations to the installation may only be undertaken by a competent person.

3

The installation should conform with BS 7671: Requirements for Electrical Installation, and BS 7375 Code of Practice for the distribution of electricity on construction and building sites.

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All installations should comply with these Regulations as for permanent installations, with good workmanship and the use of correct materials.

Testing 5

Every installation should be tested in accordance with BS 7671: Requirements for Electrical Installation, before use on site, at three-monthly intervals or shorter periods if necessary. (a)

The record of any testing and inspections should be made by a responsible person on the appropriate certificates.

(b)

Testing and inspections must include: (i)

a visual inspection

(ii)

the continuity of final circuit conductors

(iii)

the continuity of protective conductors

(iv)

the earth electrode resistance

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Section 11: Health and Safety Page 39 Part 1.05: Other hazardous Activities (Regulatory Document) (v)

the insulation resistance

(vi)

polarity

(vii)

the earth fault loop impedance

(viii)

the correct operation of residual current devices and fault voltage operated protective devices.

6

Weekly inspections should be made of the whole system, including all portable electric tools. Records should also be kept of all these inspections.

7

Annual portable appliance testing of electrical equipment used in offices is recommended especially for items with heavy usage, for example, kettles, microwaves, photocopiers.

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Power requirements The calculation for power requirements should be left to an experienced person or to the electricity supply company.

9

To enable the total site requirements to be established, a site demand table listing items of plant, equipment and general site requirements should be completed. (See Appendix 4. This appendix also contains a guide to voltages required for typical plant.)

10

When calculating the demand, it is permissible to allow a diversity factor (assuming not all appliances will be in use at the same time), and a figure of not more than 50% is generally acceptable. Care should be taken to ensure that items such as lighting and heating remain at their full rated value, because heaters used in huts and drying rooms, or for water and cooking apparatus, tend to be left on.

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Work on site

The activities of contractors and others installing electrical equipment, lifts, heating, ventilation, and so on, must be carefully monitored to ensure that they do not jeopardise electrical safety or leave an installation in a dangerous condition.

12

Particular care is needed in respect of any alterations and extensions to existing installations, especially in the identification of circuits.

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Use of mains powered equipment 13

Wherever possible, battery-powered or 110 volt powered equipment should be used for reasons of electrical safety. However, on rare occasions, it may be necessary to use mains (230 volt) operated equipment on site, possibly because 110 volt variants are not available. Electrical equipment used in site offices will invariably be mains operated. As previously stated, the use of low voltage equipment is preferred due to the potentially deadly nature of 230 volt equipment in the event of a fault.

14

Where the use of mains powered equipment is inevitable, additional safety precautions must be taken. The supply must be protected by the use of a residual current device (RCD).

Residual current devices 15

Under fault conditions, these devices detect an imbalance in the current in the circuit and disconnect the supply before the person at risk can receive a potentially fatal electric shock.

16

There are two types of RCD: (a)

Those that are fitted as part of an electrical distribution system and, for example, are found within the supply panel for a site office. This type of RCD can only be installed

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Section 11: Health and Safety Page 40 Part 1.05: Other hazardous Activities (Regulatory Document) by a competent electrician.

(b)

Plug-in RCDs (commonly known as 'power-breakers') that are plugged into a mains supply socket and which have an in-built socket into which an individual mains powered electrical tool or other appliance is plugged.

17

Both types of RCD have a test button that simulates a fault and operates the device. The correct operation of the test button should be checked daily.

18

It should be noted that:

(b)

RCDs are delicate devices and should be treated with care. Advice on suitable RCDs for construction sites should be sought from manufacturers or suppliers

(c)

the use of a RCD does not give a 100% guarantee of safety

(d)

the device does not have a fail-safe feature and will not give an indication if it is faulty.

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RCDs do not reduce current flow or the voltage, only the time that the current flows (about 30 milliseconds), and thereby the severity of the shock

It cannot be stressed strongly enough that every attempt should be made to use battery powered tools or 110 volt powered tools where practical and possible. The use of mains powered equipment, apart from situations like site offices, should be avoided wherever possible.

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(a)

Portable and hand-held electric tools

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All portable and hand-held electric tools should be selected according to the principles of risk control. For example, where there is a very high risk of electric shock due to site conditions, the use of pneumatic equipment will eliminate the risk.

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A reduced low voltage system, i.e. virtually safe, which is recommended as the safest type of system for building and construction sites, is one where the phase to earth voltage does not exceed:

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Reduced voltage systems for use with portable and hand-held electric tools

55 volts to earth in the case of a single-phase centre tapped to earth supply

(b)

63.5 volts to earth in the case of a three-phase neutral point earthed supply.

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(a)

The maximum recommended voltage to earth for a reduced low voltage system is stated as 65 volts. Both of these systems will offer a phase to phase voltage of 110 volts for supplying power tools on site.

23

A reduced low voltage system will eliminate the risk of death from a phase to earth shock in the majority of situations. Other safer systems, for example, compressed air or battery power, should be considered when working in confined spaces or damp conditions.

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Outputs of 230 volts or 110 volts 24

110 volt systems that are not centre tapped or neutral point earthed can be just as lethal as a 230 volt system in phase to earth faults. In certain situations, even reduced low voltages are not safe.

25

The maximum voltage for portable and hand-held electric tools should be 110 volt centre tapped to earth. Flexible cables should be kept as short as possible, frequently checked for damage and properly repaired as necessary.

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1.5.3.7 Maintenance and testing 1

An appropriate maintenance schedule should be established for all portable electrical equipment and should include user checks, regular visual inspections, and combined inspection and electrical testing as necessary. It is recommended that 110 volt portable and hand-held tools should have the following inspection and testing facilities: (a)

User check Weekly

(b)

Visual inspection Monthly

(c)

Combined inspection and test before first use and thereafter three-monthly.

Insulating tape by itself is neither a legal nor satisfactory repair, either on conductors or the cable sheath.

3

Long leads which trail over the ground or floor and so create a tripping hazard must be avoided. Care must be taken in the use of cable drums or reels, as internal cable terminations may become loose. They can overheat and cause a fire. Drums and reels should be inspected regularly for signs of damage or wear.

4

All insulated or double-insulated tools manufactured in accordance with BS 2754, and with the recognised symbol attached, give extra protection against the danger of electric shock.

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1.5.3.8 Fuses

Fuses can blow through ageing as the internal fuse wire sags and eventually breaks. However, fuses usually blow for other reasons; usually due to a fault in a piece of equipment. The reason should be investigated and rectified before a fuse is replaced. If a second fuse blows immediately the power is switched on, the equipment is defective and no further attempt should be made to use it.

2

The equipment should be quarantined if it is repairable or otherwise safely disposed of and replaced.

3

Nails, screws, wire or silver paper must never be used to replace fuses.

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It is very dangerous.

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1.5.3.9 Lighting 1

Lighting is needed for safety, productivity and security.

2

The colour and nature of any artificial lighting must not adversely affect, or change the perception of the colour of any safety sign.

3

Where the failure of the primary artificial lighting would create a risk to health or safety of the person(s) at work, secondary lighting must be provided.

4

There are many different types of lighting, each with its own most suitable application. Advice should be sought in order to obtain the best light for a particular place, considering such factors as colour rendition, humidity, flammable or explosive atmosphere.

Handlamps 5

Handlamps must never be run from a 230 volt supply. They should be used on 110 volts or lower, and preferably from a safety extra low voltage (SELV) supply.

6

Lamps should all be insulated or double-insulated to BS EN 60598.

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7

The use of extra low voltage handlamps, even down to 12 volts, does not give any protection against fire or explosion in flammable or potentially explosive atmospheres if the bulb is broken. In such hazardous areas, only lamps to BS EN 60079-14 should be used.

8

Special care is needed in sumps and pits, where petrol, LPG fumes or other flammable gas might collect. All electrical equipment should be BASEEFA approved.

9

In confined spaces, boilers, tunnels, cramped locations or other hostile damp or humid atmospheres, lamps supplied should work at 25 volts.

Levels of illumination Illumination is measured in units of lumens or lux, which is the amount of light falling on one square metre.

11

Light meters are used to check levels of illumination. Illumination should be measured at the workplace, not at the light fitting.

12

There are certain factors which can affect the efficiency of lighting, such as:

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the amount of daylight available

(b)

the cleanliness and maintenance of light fittings and reflectors

(c)

reflection from walls and ceilings

(d)

the distance of the light source from the workplace

(e)

shadows thrown by equipment, materials, and so on.

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(a)

When considering the level of illumination required at a workplace, it should be remembered that if the distance from the light source to the workplace is doubled, the illumination level will be reduced to one quarter (inverse square law). For recommended levels for site lighting, see Appendix 2.

(a)

securely mounted at a height that will avoid damage to the lights whilst giving the required level of illumination positioned so as to prevent glare, dazzle or reflection

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Lighting should be:

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(c)

able to change position as work proceeds

(d)

adaptable, remembering that 50 to 100% more light is required for people over 40 years of age

(e)

increased if necessary, because more light will be required in hazardous situations and when goggles are worn

(f)

so positioned that it can be screened or shielded from reflective surfaces, on traffic routes, etc.

(g)

treated as a heat source, with the possibility of burns or fire hazards, particularly with halogen lighting units.

Site lighting 15

For area lighting with floor lights or beam floodlights: (a)

all areas should receive light from at least two directions

(b)

fittings should be mounted on poles; towers and high masts must be securely stayed

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(c)

fittings should usually be spaced at not more than two or three times the mounting height

(d)

230 volts is generally accepted for fixed floodlighting, mounted well above ground

(e)

installations must be to BS 7375, equipment to BS 4363

(f)

additional lighting should be provided in hazardous areas.

Dust and dirt on lights can absorb up to 20% of their output and cleaning is often costeffective in maintaining adequate levels of lighting for both working and safety. However, there may be access issues to overcome.

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This is usually of the tungsten filament type. It is used to supplement the general area lighting scheme.

(b)

Small sources of light tend to produce shadows; they should be used with a diffuser or be hung in rows.

(c)

Pendant fittings should be supported so as not to tension the supply cable. They should be of the festoon type only, with moulded-on lamp holders and protective guards.

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Local (task) lighting

(d)

The common type of lighting used by operatives should be 110 volts reduced voltage.

(e)

Care should be taken not to dazzle or cause a nuisance to anyone, including people outside the site boundary. For a guide to the characteristics and types of electric lamp, see Appendix 3.

Dispersive lighting 18

This is used over working areas, walkways, ladder access and stairs.

19

Types include dispersive, cargo cluster, fluorescent trough, wall glass unit, bulkhead unit

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tungsten or fluorescent. Fittings should be similar to the industrial indoor type but waterproof.

(b)

They should be mounted centrally, overhead where possible.

(c)

They should usually be spaced at one-and-a-half times mounted height, but the manufacturer's recommendations should be followed.

(d)

They should be mounted as high as possible to give an even spread of light.

(e)

Mains voltage (230 volts) should only be used where the installation is well protected and of a permanent nature. Reduced voltages should be used for regular sire work.

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1.5.3.10 Permit to Work

Permit to Work systems are essential to ensure safe working where high-voltage electrical supplies, cables and equipment exist, particularly in installation, maintenance or construction work.

2

A Permit to Work system should form part of that 'safe system'. In the case of construction sites, Permits to Work are more commonly used whilst the site electrical distribution system is itself being worked on.

3

Permits to Work must only be issued by an appointed authorised person, using duplicate and numbered printed forms as the example shown (see Appendix 5). They must be signed by an authorised person and by the competent person who is to carry out (or be responsible for) the work described on the permit.

4

Most systems contain provisions for the physical locking off of switches, and the retention or display of keys or permits.

5

One copy of the permit must be retained for the duration of the work by the person to whom it is issued. Before apparatus is made live again, the permit must be returned for cancellation. At cancellation, it must be countersigned by both the holder and the authorised person.

6

The authorised person should keep a record in the job file of the issued permits and their cancellation.

7

Before work starts, the authorised person should ensure that the Permit to Work will cover the making safe from all possible sources of supply.

8

If the work is handed over from one competent person to another, the permit is to be

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endorsed by the authorised person and transferred to the second operative.

1.5.3.11 Dealing with electric shock emergencies 1

On a construction site, a plan should be prepared for potential emergencies, including electric shock.

2

The plan should include: posting notices in appropriate and prominent places publicising the emergency procedures

(b)

training sufficient workers in the procedures to follow when treating an electric shock casualty, including first aid action

(c)

instructing workers in the action to take in the event of someone receiving an electric shock. For example, switching off the electrical supply and calling the emergency services.

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Construction Site Safety 1.5.3 Appendix 1 Safety checklist Permit to Work Are the instructions clear about who can grant permits and the time when a permit comes into operation or expires?

2

Who is the manager responsible for overseeing Permit to Work systems?

3

What is the procedure for co-ordinating the activities of different trades working on the same job?

4

What is the procedure for informing all contractors that a Permit to Work system exists?

5

Have all operatives been instructed and trained in safety procedures, such as Permit to Work systems, locking off and treatment for electric shock?

6

Have Permit to Work documents and procedures been checked and agreed by the Contractor and employee representatives to ensure all necessary safeguards have been provided?

7

Is the Permit to Work procedure regularly reviewed and updated?

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Cables

Have all necessary precautions been taken where overhead lines exist close to the site?

9

Are distribution cables so positioned that they do not cause a hazard at openings, passages, ladders, stairs, and so on?

10

Have precautions been taken to ensure that cables lying on the ground have been protected from physical damage or wet conditions?

11

Have the necessary precautions been taken to ensure that cables do not hang directly from nails, which may cause insulation damage?

12

Are cables protected from the edges of sharp objects?

13

Have all possible precautions been taken to ensure that suspended cables do not carry any weight? Are they supported by rods or catenary wires?

14

Are all cables visible, with, if necessary, yellow and black or red and white plastic bunting strips attached?

15

Is there an adequate supply of extension cable for use on the site?

16

Are all junctions and repairs properly carried out by a qualified electrician?

17

Are electrical circuits used for the correct purpose (for example, lighting circuits must not be used for power tools, especially where lighting festoons are fitted with trailing leads)?

18

Are buried cables correctly protected by a 450 mm cover and cover tiles? Is the line of the cable also clearly marked?

19

Are cables capable of carrying the load required and are they adequate for their purpose?

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Plugs 20

Are all industrial plugs to BS EN 60309-2, in good condition, not cracked or otherwise damaged?

21

Are splash-proof covers being used as necessary?

22

Are the correct plugs properly fitted to equipment?

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23

Are all plugs being used suitable for the site conditions prevailing?

24

Have any plugs been forced into the wrong sockets (for example, by the removal of keys)?

25

When plugs have been fitted, have the correct connections been made, with the wire being correctly colour coded in line with British and International Standards.

26

Are cable grips being used and is the earth cable fitted with some slack, so that it is the last to be pulled out?

27

Have all possible steps been taken to ensure that there are no improvised junctions, nails, matches or silver paper, being used in place of the correct equipment?

28

Is the correct type of fuse with the proper rating fitted?

29

Have all made-up leads or extension cables been correctly assembled by a competent electrician?

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Site accommodation

Has the incoming supply been installed by competent electrical contractors?

31

Is an RCD incorporated into each electrical circuit?

32

Is each RCD checked for correct operation on a weekly basis?

33

Is the use of 230 volt equipment restricted to office accommodation and welfare facilities?

34

Is a programme of PAT testing carried out on all portable 230 volt equipment?

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Power tools

Are all power tools used manufactured to BS EN 50144-1 or double-insulated to (BS 2754) and CE marked?

36

Is the plug undamaged?

37

Are cable clamps secure?

38

Have checks been made to ensure that trailing leads are not cut or frayed?

39

Is the cable protected from excessive flexing by a rubber sleeve where the cable enters the tool?

40

Are all screws in place and secure?

41

Have the tools or machines been checked to ensure that there are no cracks or missing pieces?

42

Have checks been made to ensure that the nameplate is secure with details of:

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Type

Serial number

Voltage

Volts AC/DC

Frequency

(normally 50 HZ)

Current

Amps

Speed

RPM

Checklist for operatives 43

Are all machines and hand tools disconnected before any adjustment or work is carried out on them?

44

Are all machines disconnected when not in use?

45

Is the tool fitted with the correct type and size of plug?

46

Have checks been carried out to ensure that any colour codings are correct?

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47

Are cables of an adequate rating for the tool that is being used?

48

Are checks carried out to ensure that no unofficial cables are being used?

49

Have instructions been issued to ensure that no makeshift repairs or maintenance are carried out?

50

Are all defects reported immediately to a competent person?

51

Is the machine kept clean and free from damp?

52

Are all connections correctly made, including waterproofing?

53

Are all operatives aware that they should never carry any tool or machine by its cable?

54

Have instructions been issued to ensure that no machine is started or stopped under load?

55

Do all portable tools have a current PAT test sticker?

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until the electricity company is consulted for advice

(b)

within 9 m of overhead power lines on wood, concrete or steel poles, or

(c)

within 15 m of overhead power lines on steel towers?

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(a)

Are all personnel working close to overhead power lines aware that the distances mentioned above are measured horizontally at ground level from directly below the outermost conductor?

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Is everyone working on site aware that no work should take place:

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Working near overhead power lines

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Note: Electricity companies have different rules for the lateral swing of conductors in high winds and the distance of barriers may vary between companies.

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Precautions near live overhead power lines

Has an essential ongoing system of liaison between Contractor or contractor and the electricity company been established?

59

Where overhead power lines have not been diverted or made dead and therefore remain live, have all practicable steps been taken to provide adequate barriers.

60

Have adequate arrangements been made for the passage of tall plant at specific times where overhead power lines have been made dead?

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Work beneath overhead power lines 61

On sites where work will take place below overhead power lines, have additional precautions, as necessary, been taken, as well as the provision of barriers with passageways?

62

Is all work carried out under the direct supervision of a responsible person, familiar with the hazards, after consultation with the local electricity company?

Passage beneath overhead power lines 63

If there is no work or passage of plant under overhead power lines, have barriers been positioned so as to prevent any close approach of any plant, equipment or personnel to within at least 9 m from the overhead power lines?

64

Does all plant passing under overhead lines use a defined passageway, protected by barriers?

Alterations to buildings 65

Have all electrical circuits been identified before any work is allowed to start?

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66


Is there a plan to remove old wiring and equipment which is no longer required, as early as possible?

Commissioning new parts of the electrical installation Has the Contractor prepared an agreed plant commissioning programme?

68

Are all the relevant contractors aware of this programme?

69

Is the programme regularly monitored?

70

Is each part of the installation that is being worked on securely isolated (lock, tag and try)?

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Construction Site Safety 1.5.3 Appendix 2 Recommended levels for site lighting

Applies to both indoor and outdoor activities and relates to the value on the ground, floor or horizontal working plane. They may require adjustment according to district brightness. Governing factors

Design value lux

Security

Depending on the degree of risk

5-30

Movement and handling

Movement of people, machines and vehicles, handling of materials, walkways and access routes

Stores and stockyards

For stored goods

Site entrances

General access, vehicle and pedestrian

General work area

General rough work, site clearance

Craft work

Reinforcing concreting, shuttering erection, bricklaying, scaffolding

100

Fine craft work

Joinery, all work with power tools and circular saws, plastering, painting, electrical, plumbing, shopfitting, brickwork

300

Special work

Retouching paint, French polishing

500

Site huts

Rest rooms, locker rooms, toilets

20

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Site offices

.

Purpose

30

30 50

150

On desks and reference tables, general lighting of drawing 500 office

Drawing offices on site

On drawing boards

750

Emergency lighting

For escape and standby purposes

5-70

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Tungsten halogen (T-H)

Mercury vapour (MBF)

Fluorescent tubular (MCF)

Sodium Sodium vapour vapour low high pressure pressure (SON) (SOX)

Wattage range

40/1500

300/2000

50/2000

6/85

35/180

250/1000

Voltage range

25/250

110/250

200/250

110/250

200/250

220/250

* Efficacy (Lumens Watt)

10-18

17-22

35-55

41-68

80-100

Colour rendering

Good

Good

Fair

Good

Resistance to vibration

Poor

Fair

Good

Normal life (hours)

1000

2000

Restrictions on use or on position

None

Horizontal 4 degrees

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Good

Good

Good

Good

5000/7500

6000

6000

None

None

For road lighting only

None

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Brief lamp characteristics

.

Tungsten filament (GLS)

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Construction Site Safety 1.5.3 Appendix 4 Electrical demand for construction sites

Plant 415 V3 phase

Type

Portable tools 110V 1/3 Site lighting 110V1 Temp accommodation phase phase 230 V 1 phase

kW No Total

Type

RW No

Total

Location

Type

kW

Requirement

Tower crane

Chasers

Lighting

Hoist

Hammers

Heating

Platform

Saw drills

Water heating Drying

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hoist

kW

Cooking

Pump 'A'

Vibrators

Pump 'B'

Air blowers

Saw bench

Dehumidifiers

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Compressor

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Batching plant

Power

Printing Fixed Floodlighting

Total load

Total load

Total load

Diversity factor

Diversity factor

Diversity factor

Diversity factor

Demand load

Demand load

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Total load

Demand load

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Demand load

For calculation purposes, check that only the formula: i x V = W is used i = current in amps

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where

V = voltage

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W = wattage

Volts

Phase 3

230

Derived from

Special provision

Application

Supply undertaking

Fixed and transportable equipment above 5 hp, e.g. crane, hoist, compressor, concrete mixer, and large scale personnel amenities

1

Supply undertaking

110

3

415V ' transformer Secondary winding phase to earth 64 V

Site offices, personnel amenities and fixed floodlighting Transportable equipment up to 5 hp, e.g. vibrators, pumps, site lighting other than fixed floodlighting, and hand tools

110

1

230V transformer

Secondary winding outers to earth 55 V

All portable and transportable tools up to 2.5 hp and site lighting

50

1

Transformer

Secondary winding outers to earth 25 V

Dangerous situations, tunnelling work, inside boilers, confined spaces

25

1

Transformer

Secondary winding outers to earth 12.5V

Dangerous situations, tunnelling work, inside boilers, confined spaces

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Typical electrical supplies used on construction sites

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Construction Site Safety 1.5.3 Appendix 5 Permit to Work on high voltage equipment

No. Issued to ........................................................................ Job ...............................................................................

.

I hereby declare that it is safe to work on the following H.V. apparatus which is dead, isolated from all live conductors and is connected to earth:

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……………………………………………………………………………………………………………………… ………… All other apparatus is dangerous

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SWITCHING AND ISOLATING. The apparatus is disconnected from all live conductors by the following operations:

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……………………………………………………………………………………………………………………… …………

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EARTHING. The equipment is earthed at the following points:

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……………………………………………………………………………………………………………………… …………

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DANGER NOTICES are posted at.....................................................................................................

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AUTOMATIC FIRE EXTINGUISHING CONTROL has been rendered inoperative at.................................... OTHER PRECAUTIONS..................................................................................................................

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Signed .................................................................. Date ........................................... Time ................................. (Authorised person) I hereby declare that I accept responsibility for carrying out work on the apparatus detailed on this permit and that no attempt will be made by me, nor by any person under my control, to carry out work on any other apparatus: Signed .................................................................. Date ........................................... Time ................................. Note: After signature for work to proceed, this receipt must be signed by, and the Permit to Work retained by, the person in charge of the work until work is suspended or completed and the clearance section has been signed. This is to certify that the work authorised above has been completed or stopped and that all workers under my charge have been withdrawn and warned that it is no longer safe to work on the apparatus specified on this Permit to Work and that gear, tools and additional earthing connections are all cleared. Automatic fire extinguishing control has been restored.

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Permit to Work is hereby cancelled

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Signed .................................................................. Date ........................................... Time ................................. (Authorised person)

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Construction Site Safety 1.5.3 Appendix 6 High voltage safety Identity of site................................................................................................................. THIS IS TO CERTIFY THAT ............................................................................................................... is the person responsible on this site for ensuring that the rules for the safe operation of H.V. systems and the Permit to Work system are complied with in every respect.

.

Signed .............................................................................. Date ..........................................................

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Status .............................................................................. Company...................................................

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The authorised person(s) for H.V. switching, isolation, testing and earthing is (are):

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………………………………………………………………………………………………………………………

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……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

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Working In and Around Excavations

1.5.4.1 Key points Many deaths and serious injuries have resulted from the collapse of unsupported excavations.

2

These accidents could have all been prevented if the sides had been supported.

3

The type of support system must be selected or designed by a competent person.

4

There is no minimum depth at which an excavation must be supported; it depends on the soil/sand.

5

The installation, modification and removal of any support system must be carried out:

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by persons who have been trained and are competent to do so

(b)

without putting the safety of these people at risk.

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(a)

Generally, the longer that an unsupported excavation is open the more chance there is of it collapsing; ground that was previously stable can become waterlogged or dry out.

7

In some cases it will be possible to detect at an early stage that the sides of an excavation are becoming unstable, for example during the inspections carried out by a competent person.

8

There are other hazards associated with working in excavations, for example the presence of underground services, contaminated land, etc.

9

Excavations can become confined spaces under certain circumstances, necessitating the management of additional health and safety hazards.


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Section 2 of the QCS covers ground investigation and Section 12 covers earthworks.

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Note:

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Almost all construction work involves some form of excavation, for foundations, drains, sewers, etc. These can vary greatly in depth and may be only a few centimetres deep or be very deep and very dangerous.

2

A relatively small collapse might involve about a cubic metre of soil, but a cubic metre of soil weighs over a tonne. A person at the bottom of a trench who is buried under this volume of material would be unable to breathe, due to the pressure on the chest, and could quickly suffocate and die.

3

Deep trenches look dangerous; however, trenches less than 2.5 metres deep are where most related deaths occur, in fact, most accidents occur in ground conditions with no visible defects; the trench sides seem clean and self-supporting.

4

Despite appearances, however, the removal of material causes pressure relief and introduces the conditions which lead to failure. Rainwater or hot, dry weather increase the chances of such failure. Surcharging the sides of an excavation also increases the likelihood of collapse.

5

Neither the shallowness of an excavation nor the appearance of the ground should be automatically taken as indications of safety.

6

An excavation may also be a 'confined space' and additional precautions will need to be taken.

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1.5.4.3 Legislative requirements The Management of Health and Safety at Work Before carrying out any work, including excavation work, a risk assessment of the work to be done is required under these Regulations.

2

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out. This includes other contractors and the public.

3


4


5

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

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With regard to excavations, these Regulations require that: all places of work are safe, with safe means of access and egress

(b)

steps are taken to ensure any structure that has become unstable due to any construction work, including excavation, does not collapse

(c)

steps are taken to prevent anyone being buried by a collapse of material

(d)

the sides of excavations are supported or battered back where necessary to prevent collapse or dislodgement and fall of material

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steps are taken to prevent people, materials, spoil, vehicles, equipment or plant falling into, or causing the collapse of, an excavation

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Construction (Design and Management) CDM

(f)

steps are taken to prevent danger from damage to underground and overhead services

(g)

excavations are inspected by a competent person and inspection reports prepared as specified

(h)

each excavation has sufficient fresh air

(i)

there is suitable lighting at places of work

(j)

anyone who has to carry out excavation work or work in an excavation is provided with appropriate training and is competent

Risk assessments 7

Before carrying out any work, including excavation work, a risk assessment of the work to be done is required.

8

The risk assessment must consider the potential for the sides of an excavation to collapse, the potential for someone to be injured and the possible need for a support system. The

QCS 2014


person assessing the risk of collapse must be competent to assess the soil stability. 9

The risk assessments should seek to eliminate or control the risk at source, for example by specifying trenchless techniques or ensuring the sides are 'battered' or 'stepped' (sometimes known as 'benched)' thus making a collapse impossible.

10

The risk assessment must include consideration of the following hazards: collapse of the sides

(b)

underground services

(c)

contaminated ground

(d)

fall of materials, persons, plant or equipment into the excavation

(e)

confined spaces - poisonous or explosive atmospheres or lack of oxygen

(f)

flooding

(g)

overhead services

(h)

moving plant - injury to persons

(i)

lifting operations

(j)

undermining adjacent structures or services

(k)

surcharging the sides of an excavation. Control measures should include:

(l)

protection of person(s) who are installing the support system

(m)

safe exposure and, if necessary, support of underground services

(n)

safe access and egress from the excavation

(o)

adequate ventilation of the workspace

(p)

dewatering the trench if necessary

(q)

the need for inspections of the excavation by a competent person

(r)

the stability of adjacent structures or land

(s)

guarding and lighting where necessary.

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Soil stability

.

(a)

Excavation involves the removal of soil and rock, in lesser or greater quantities. Water is almost always present, even if only as moisture in the soil. This presents an additional hazard that must be considered.

12

Soil varies in its nature. Some soil, like fine sand, flows easily. Other soils, like stiff clay, are more cohesive. No soil, whatever its structure, can be relied upon to support its own weight and, if a trench or excavation cannot be made safe by battering or stepping the sides, some form of support will be required. Loose and fractured rock will also need some support.

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Firm or stiff clay type ground Trenchless techniques 13

This module highlights the potential dangers associated with any form of excavation. Readers should also be aware of the work techniques available to eliminate, or at least partially eliminate, the need for excavations and thus their associated hazards.

14

Thrust boring, directional drilling and pipe jacking are examples of such techniques. Some of the trenchless methods that have been developed still require the excavation of pits at either end of the 'trenchless run' in order to launch and retrieve the boring equipment.

If battering the sides of an excavation, the angle at which the sides are cut will depend upon: the nature of the soil, which may be a mixture of materials

(b)

the water content of the soil, including any increase or decrease whilst the excavation is open.

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Battering or stepping excavations

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Refer to Appendix 4 - Angles of repose

1.5.4.4 Trench supports General requirements 1

The need for adequate support will depend on: (a)

the type of excavation

(b)

the nature of the ground

(c)

ground water conditions

(d)

surcharge of sides of excavation.


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Close boarded excavation

Generally speaking, timbering or shoring is not required for trenches or excavations where there is no danger whatsoever of any material falling or collapsing or where excavations are so shallow that such a fall would not result in any injury.

3

For all other excavations or trenches, a survey of the type of soil or other materials that will be excavated must be carried out by a trained and experienced person prior to excavation. This will usually provide sufficient information for a suitable method of excavation and support to be determined.

4

Where large, complex or extensive excavations are concerned, a specialist engineer should decide how to proceed.

5

An adequate supply of support materials must be available on site ready for use before the excavation commences.

6

They must be sound, free from defects, of adequate strength, of good construction and properly maintained. Supports must be fixed securely to prevent displacement.

7

All supports should be erected, altered and dismantled under the supervision of a competent person.

8

It is essential that work is organised so that the person(s) installing any type of support system can do so without their safety being put at risk.

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Types of support systems 9

All practical steps should be taken where necessary to prevent danger to any person from collapse of an excavation and from accidental fall or dislodgement of material from the side or roof or adjacent to any excavation.

10

Conventional timber shuttering or steel trench sheets and adjustable props should be used. The props may be mechanical (jacks or acrows) or hydraulic.

11

A temporary framework of supports, or a protective box or cage, may be needed to protect workers while they put in permanent timbering. A box or cage can be moved forward as timbering progresses.

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12


In addition to the traditional systems of supporting excavations, several proprietary support systems are available. These include shields (also known as drag boxes), trench-boxes and plate lining systems.

Shields 13

A shield consists of two vertical plates which are permanently braced apart to provide a safe working area between them. Shields are designed for providing temporary protection for workers in a trench, rather than for providing permanent support for the trench sides. Shields are designed to be dragged along the trench as work progresses, therefore only localised protection from falling materials is provided.

Trench-boxes The trench-box support system is modular and involves either lowering strutted, metal box sections into a pre-dug trench, or progressively digging the boxes in to provide continuous support as the depth of the trench increases.

15

The box sections are built up vertically and laterally to form a permanent support for the trench sides.

16

Boxes of this type can generally be extended in width and height to cater for various excavation dimensions.

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The principle of a plate lining system is that metal plates are slid into position between vertical soldier posts, which have been installed previously at pre-set intervals. The soldier posts are strutted apart to counteract inward pressure from the trench sides.

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Avoiding buried services

The use of any of these proprietary support methods can present problems when existing buried services cross the line of the trench being excavated.

19

A further method of supporting the sides of excavations, which combines proprietary and traditional technology, is the use of hydraulic waling frames. This system incorporates the lowering of a hydraulic frame into an excavation in which trench sheets have already been installed. The hydraulic frame is then jacked apart to provide support for the trench sheets. Each hydraulic frame, when in position, is disconnected from the hydraulic supply and left in the pressurised state. This method of support is better able than the other proprietary systems to cope with buried services that cross the trench because it leaves gaps between the trench sheets. Hydraulic frames that can be expanded in both length and width are available to cope with the excavation of manholes and pits.

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Inspection and maintenance of support systems 20

All excavation work requires careful monitoring, particularly when trenches are first opened and sides are unsupported. Even when support work has been installed, constant vigilance is essential.

21

Small movements of earth, resulting in movements in the supports or timbering of no more than 6-12 mm, are usually the only sign of the progressive weakening in cohesive soils.

22

Such movements can easily pass unnoticed but they are signs that something is wrong.

23

Movements can be detected from slight distortion in the timbering, bowing of poling boards and walings, or signs of local crushing.

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All timber must be regularly checked. Where timber remains in position for any length of time, it may dry out, shrink or rot.

25

The ground also may dry out and shrink, which loosens the timbering. Alternatively, it may absorb additional moisture, swell and displace the timbering. Soil may even leak into the excavation from behind the timbering, loosening it.

26

In close-boarded excavations, the support-work members must be kept tight against each other and against the soil face; wedges or telescopic struts holding them must always be kept tight. Raking, or angle, struts should all be regularly examined for signs of having been damaged or dislodged.

27

When loads are being moved into or out of the excavation by skip or bucket, care should be taken to avoid damage to struts or walls. Vertical boards, commonly known as rubbing boards, should be provided to avoid such damage.

28

During bad weather, spoil heaps tend to slump, and loose boulders or masonry may fall into the excavation. As a general rule, the distance between the edge of the trench and the bottom of the spoil heap must not be less than the depth of the trench.

29

Heavy vehicles should not be allowed near the edge of excavations unless the support work has been specially designed to permit it.

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Care must be taken to see that excavation work does not jeopardise the stability of any adjacent structure. Precautions to protect workers and others must be taken before and during any excavation work.

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1.5.4.5 Access

Safe means of getting into and out of an excavation must be provided. If a risk assessment identifies that ladders are a reasonable means of access or egress from an excavation, they must be suitable and of sufficient strength for the purpose.

2

They must be on a firm level base, sufficiently secured so as to prevent slipping and must, unless a suitable alternative handhold is provided, extend to a height above the landing place of at least 1 metre (about 5 rungs), so as to provide a safe handhold. Climbing into or out of an excavation using the walings, buried services and struts must be prohibited and specifically covered in the safe system of work and, if there is one, the method statement.

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1.5.4.6 Guarding excavations

Where necessary, suitable steps must be taken to prevent any person, vehicle, plant or equipment, or any accumulation of earth or other materials from falling into an excavation.

2

Barriers should also serve to keep materials, plant and equipment away from the edges of an excavation. Barriers may be removed to permit access of personnel, plant and equipment, but should be replaced as soon as possible.

3

During darkness, the edges of an excavation should be marked with lights, especially where they are close to public thoroughfares. Battery-operated traffic lamps placed at suitable intervals are usually sufficient.

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1.5.4.7 Vehicles and plant 1

Ideally, all vehicles and plant (except those which must approach an excavation, for example, for tipping or lifting activities) should be kept away from excavations. Traffic routes should be planned and set out accordingly.

2

When heavy loads (such as items of construction plant) are positioned close to excavations, additional pressure - known as surcharging - is placed on the excavation sides and on any form of support system that is in use. Where this cannot be avoided, it must be allowed for in

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the design of the excavation support system. Where vehicles are used for tipping materials into an excavation, safety measures, such as well anchored stop blocks, should be used to prevent the vehicle overrunning the edge. These must be placed at a sufficient distance from the edge of the excavation to avoid the danger of the edge breaking away under the weight of vehicles.

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1.5.4.8 Site lighting

There must be suitable and sufficient lighting at every workplace, the approaches to the workplace and on traffic routes. As far as possible, this should be natural lighting.

2

It is also good practice to ensure that attention is paid to the adequate lighting of access points, openings and lifting operations.

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1.5.4.9 Ventilation

Excavations must be kept clear of suffocating, toxic or explosive gases. These may be natural gases like hydrogen sulphide, methane and sulphur dioxide, exhaust gases from nearby plant, or leaks from nearby pipes or installations. These can seep through the soil and can accumulate at the bottom of an excavation, below ground level.

2

Leakage of propane and butane from LPG cylinders is potentially very dangerous; the gases will sink to the lowest point and form an explosive concentration that cannot disperse naturally. In a similar way, leaking oxygen in an excavation can lead to oxygen enrichment which can lead to fire or explosion. Gases which are heavier than air can leak into an excavation causing air to be displaced, leading to asphyxiation.

3

For the purpose of dealing with these hazards, the bottom of a deep excavation should be regarded as a confined space.

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Confined spaces 4

When an excavation is classified as a confined space, tests for toxic gas or oxygen depletion must be carried out before work starts, and continuously as work progresses. It is also recommended that the work should be subject to the issue of a Permit to Work certificate.

5

To ensure that every workplace or approach is safe and without risks to health, there must be a sufficient supply of purified air. The most common method of ventilation is to blow clean air into the excavation in sufficient volume to dissipate any gas and provide adequate breathable air.

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1.5.4.10 Underground cables and services 1

No excavation work should be carried out unless steps have been taken to identify and prevent any risk of injury arising from underground cables or other underground services.

1.5.4.11 Inspection and reports All excavations used to carry out construction work must be inspected by a competent person: (a)

at the start of every shift in which the work is to be carried out

(b)

after any event likely to have affected the strength or stability of the excavation or any part of it

(c)

after any accidental fall or dislodgement of any material.

.

1

The person who carried out the inspection must be satisfied that the work can be carried out safely and without risk to workers.

3

A report must be prepared by the person carrying out the inspection, giving the following information:

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the name and address of the person on whose behalf the inspection was carried out

(b)

the location of the place of work inspected

(c)

a description of the place of work or part of that place of work inspected, including plant and equipment or materials, if any

(d)

the date and time of the inspection

(e)

details of any matter identified that could give rise to a risk to the health or safety of any person

(f)

details of any action taken as a result of any matter identified above

(g)

details of any further action considered necessary

(h)

the name and position of the person making the report.

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(a)

The person who prepares the written report must write it before the end of the shift in which the inspection was carried out and provide a copy of the report within 24 hours to the person on whose behalf the inspection was carried out.

5

The report or a copy of it must be kept on the site until the work is completed and for a period of three months from the date of completion.

6

Not more than one written report in any period of seven days is required in respect of the inspection at the start of any shift. However, it is advised that a daily record of the inspection is kept, possibly in the site diary.

7

An example of an inspection report, which may be reproduced, can be found in Appendix 3 of this module.

8

Steps must be taken to protect workers from the fall of any material or object.

9

No material or object may be thrown or tipped from a height where injury may result. This includes scaffolding materials which should be lowered under control.

10

No timber or other materials are to be left with projecting nails.

11

Every workplace on a construction site must be kept in a reasonable state of tidiness and

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cleanliness. 12

Materials and equipment must be properly and securely stacked and stored.

13

Work equipment must be constructed or adapted so as to be suitable for the purpose for which it is used or provided. This includes any tools or items of equipment, for example, a shovel, podger or pile driving rig.

14

Contractors must avoid the need for employees to undertake any manual handling operations at work that will involve the risk of them being injured. Every client must ensure that the engineer and designer for any project carried out for the client is provided with any relevant information which the client holds, or could find out by making reasonable enquiries. For example, the client must provide details of underground services, ground conditions, etc, which could be found from making reasonable enquiries.

(b)

The designer has a duty to eliminate or reduce hazards by design. This might mean locating structures to avoid underground services, or specifying techniques that minimise deep excavations.

(c)

A health and safety plan must be prepared for every project and should include details of health and safety risks to any person carrying out construction work. This would include the risks from any excavation project.

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(a)

1.5.4.12 Excavators used as cranes

Excavators, loaders and combined excavator loaders may be used as cranes in connection with work directly associated with an excavation, and any other application where this type of equipment can be used.

2

All work is subject to a suitable and sufficient risk assessment, subsequent control measures and capabilities of the work equipment.

3

The risk assessment should take account of the fact that when a machine is in the object handling mode (being used as a crane), it will be necessary for the slinger to approach the machine to hook the load on and off. This person will be in what is regarded as a hazardous area and much hearer to the machine than anyone would be in normal circumstances. The slinger is at risk of being struck by the load, bucket or excavator arm if the excavator moves or slews rapidly.

4

Excavator operators and slingers must be made aware of these dangers; effective communication and constant vigilance are essential.

5

The risk assessment must also establish " whether the machine is suitable for the proposed task. The weight of the bucket (if still fitted) plus the quick hitch must be added to the weight of the load to establish if the machine will be working within its safe working load.

6

Ideally, unless there are good reasons for not doing so, the bucket will be removed to improve the machine operator's visibility.

7

The risk assessment must also address:

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(a)

the need for the lifting operation to be ideally segregated from other work activities taking place in the vicinity, particularly where it is necessary for the machine to travel with a raised load

(b)

the ground conditions, particularly where a tracked excavator will carry out the lifting operation. Such machines have no means of levelling themselves and are therefore dependent upon the ground being sufficiently level to track across it and carry out the lifting operation safely.

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8

The safe working load must be clearly marked on the machine and any lifting accessories, such as a quick hitch. A rated object handling capacity table, must be available in the cab.

9

If the rated lifting capacity for an excavator (or the backhoe of a backhoe-loader) is greater than 1 tonne (or the overturning moment is greater than 40,000 Nm), the machine must be fitted with: (a)

a boom lowering control device on the raising boom cylinder(s) (a safety check valve), which meets the requirements of ISO 8643, and

(b)

an acoustic or visual warning device, which indicates to the operator when the object handling capacity or corresponding load moment is reached.

Chains or slings for lifting must not be placed around or on the teeth of the bucket. Accessories for lifting may only be attached to a purpose-made point on the machine.

11

Whilst BS 7121 may not specifically refer to excavators used as cranes, compliance would assist in the provision of safe systems of work.

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Construction Site Safety 1.5.4 Appendix 1 Excavations Safety checklist Before starting excavation work Check that a site-specific risk assessment has been carried out.

2

For purposes of excavation, no ground should be considered good or safe until it has been investigated.

3

Prevent all access to the excavation by unauthorised persons, especially children. Backfill as soon as possible to reduce risks.

4

Check the soil types and decide which type of support work is required in consultation with a competent engineer or supervisor.

5

Check whether the excavation will affect adjoining roads, buildings or other structures, such as scaffolds.

6

Determine the positions of all public services, especially buried services, and ensure that they are adequately marked, supported or disconnected as necessary.

7

Always seek advice before excavating below existing foundations of adjacent or adjoining buildings. It may be necessary to provide shoring, i.e. raking or flying or both.

8

Provide an adequate supply of material for support work, along with barriers and correct traffic notices, before work starts.

9

Make provision for any side support system to stand proud of the existing ground levels. This prevents any loose material from falling into the excavation.

10

Check the need for, and provision of, adequate lighting.

11

Check that adequate and sufficient ladders have been provided for safe access to the excavation and that sufficient ropes for securing these items are to hand.

12

Determine the positions of bridges, temporary roads and spoil heaps.

13

Determine the methods of excavating before starting work, and the method by which it is intended to install and remove any support work.

14

Plan traffic routes to keep heavy plant and vehicles away from excavations, as far as is possible, except where they must approach the excavation for tipping and lifting activities.

15

Plan the safe backfilling of the excavation, using suitable materials.

16

Check that the excavator operator is competent.

17

Check that the excavator and equipment is in good repair and has been inspected.

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Construction Site Safety 1.5.4 Appendix 2 Excavations Safety checklist Whilst digging, working in, or reinstating an excavation Ensure that only sound support material is being used.

2

Ensure that approved and safe methods are adopted for the installation of support work in excavations. A competent person should be in attendance at all times.

3

Ensure that all working surfaces are safe.

4

Install supports as soon as the excavation sides are trimmed. This should be done from a work cage, from ground level, or from inside existing supports.

5

Ensure that all support work is secure and that props and wedges are tight and properly maintained.

6

Check for signs of overstress in support work, any damage that may have been caused by plant and, when timber is used, make long-term checks for disease and defects, i.e. dry rot, shakes, etc.

7

Check for any water or soil which may be seeping through support work.

8

Check for signs of the earth peeling or cracking at unsupported faces.

9

Check that there are adequate ladders, that they are maintained, secured and used correctly.

10

When pumping, ensure that there are adequate sumps and that soil is not being drawn from behind support work.

11

Check for hazardous atmospheres.

12

Ensure that spoil heaps and other materials are kept back from the edges of the excavation.

13

Ensure that there are adequate barriers, notices and warning lights.

14

Check that the edges of excavations are provided with top and mid guard-rails at all places where there is a danger of persons falling a distance likely to cause personal injury.

15

Check that any bridges and gangways are fitted with guard-rails and toe-boards.

16

Ensure that stops for dumpers, and tipping lorries are well anchored.

17

Ensure that all passing traffic is kept well back from the edge of the excavation.

18

Ensure that the correct method of withdrawing support work is used; if for any reason it is considered unsafe to remove it, leave it in.

19

Ensure there is adequate separation between working plant and people.

20

Dumper drivers should dismount while the dumper is being loaded.

21

Ensure that appropriate protective clothing and protective equipment are being used.

22

Ensure that persons are wearing suitable ear defenders when piling or other noisy activities are taking place.

23

Ensure that machine operators have the best possible vision of the work which is in progress.

24

Ensure that services are marked, protected and adequately supported when exposed in excavations.

25

Ensure that any backfilling is carried out correctly and in a planned sequence, and maintained.

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26


Ensure that each excavation is inspected by a competent person: (a)

before it is first entered

(b)

at the start of each shift

(c)

after any accidental fall of rock, earth or other material

(d)

after any event likely to have affected the strength or stability of the excavation.

Ensure that a proper record of all inspections is made and signed by a competent person.

28

Remember that records of inspections may be kept on computer or in another electronic form, so long as it is possible to immediately produce a hard copy on request.

29

Ensure that the written report, or a copy, is provided to the person on whose behalf the inspection was made within 24 hours.

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Section 11: Health and Safety Part 1.05: Other hazardous Activities (Regulatory Document)

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Report of inspection on *excavations, *cofferdams and caissons (*Delete as appropriate) Inspection carried out on behalf of (name and address)...................................................................................................................................................

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……………………………………………………………………………………………………………………………………………………………………………..

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Inspection carried out by (name) ...................................................(position) ....................................................................................................................

Description of place of work, or part inspected

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Location inspected

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Date and time of inspection

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Address of site ................................................................................................................................................................................................................... Details of any matter identified giving rise to a risk to the health and safety of any person

Details of any action taken Details of any further action as a result of any matter considered necessary identified

Page 72

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Construction Site Safety 1.5.4 Appendix 4 Angles of repose for different soil types The graph below shows the angle of repose at which various types of soil will slide if unsupported. They represent the maximum safe angle of batter.

2

This illustration shows typical maximum safe 'battering' or 'stepping' angles for certain types of soil. A competent person must be consulted on the safe angle for battering or stepping excavations. If in doubt, consult a geotechnical engineer.

3

Users of the above graph should be aware that:

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(a)

in many cases soil is a mixture of material and the above diagram must be interpreted with caution

(b)

an increase in water content will affect the ability of some types of soil to be selfsupporting. Bad weather, vibrations and other pressure could cause early failure

(c)

Slip planes can form in seemingly solid materials, even some types of rock.

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Construction Site Safety 1.5.4 Appendix 5 Requirements for excavators used as cranes Requirements on manufacturer at time of supply When object handling with When object handling with a rated lift capacity of more a rated lift capacity of less than 1 tonne than 1 tonne EC or Equivalent Certificate Yes Yes of Conformity Hose burst check valve on Yes Not required boom lift ram

Yes

Lift point with SWL marked

Yes

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Fixed safe working load (SWL) marked on the machine or displayed in the cab Acoustic or visual warning device

Not required

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Yes

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Yes

When not object handling Yes Not required Not required

Yes

Not required

Not required

Not required

Yes

Not required

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Rated object handling capacity table in cab

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Requirement

Machine maintenance required by owner Yes

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Weekly inspection of excavator

Not required

Yes

Yes

Not required

Yes

Yes

Yes

Yes

Yes

Yes

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Four-yearly test and thorough examination Twelve-monthly thorough examination

Yes

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Six-monthly thorough examination of lifting gear

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Records may be kept as a paper copy or by electronic means providing a hard copy is always easily accessible.

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Working in Confined Spaces

1.5.5.1 Key points Working in confined spaces has the potential to be very hazardous unless the appropriate controls are put in place.

2

Many people have died as a result of work in confined spaces not being adequately planned or organised, or safely carried out; many of them were would-be rescuers.

3

Ideally it will be possible to carry out the work without anyone having to enter a confined space.

4

Confined spaces are not just sewers and ducts; under these Regulations many other work areas could also be classified as confined spaces with issues including difficulty of access and egress, heat stress, etc. having to be considered.

5

A risk assessment must be carried out for all work in a confined space.

6

Where the findings of the risk assessment reveal there to be significant risks to health or safety, it may result in a method statement being written.

7

Any plan of the work must consider the method of rescuing the people in the confined space should the situation become unsafe.

8

Entry to a confined space should be controlled by a Permit to Work and, where considered necessary, a separate Permit to Enter.

9

Any training may need to be specific for the type of confined space - a sewer entry course may not be appropriate for someone who has to work in a hot roof space.

10

The use of respiratory protective equipment is common in confined space work and users must be face-fit tested and trained in its use, general care and maintenance.

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Every entry into a confined space is potentially hazardous.

2

Accidents are caused by a combination of factors arising from a lack of safety awareness, inadequate supervision and a lack of training. The situation is often made worse by heroic but ill-conceived rescue attempts, founded on insufficient planning and knowledge, which may lead to multiple fatalities. It is essential therefore, to be able to identify confined spaces and the hazards associated with entering and working in them.

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1.5.5.3 Meaning of 'confined space' 1

A "confined space' can be either: (a)

a place which is substantially, though not always entirely, enclosed or

(b)

a place where there is a reasonably foreseeable risk of serious injury from hazardous substances or conditions within the space or nearby.

2

Some confined spaces are easy to identify, such as closed tanks, vessels and sewers. Others are less obvious but may be equally dangerous, such as basement-level boiler rooms or toilets, as well as open-topped tanks, vats, silos or other structures that become confined spaces during their manufacture.

3

Some places may become a confined space only occasionally, perhaps due to the type of work to be undertaken, such as a room during paint spraying. A confined space may not necessarily be enclosed on all sides; some confined spaces (such as vats, silos or deep

QCS 2014


excavations) may have open tops. Places not usually considered to be confined spaces may become confined spaces because of a change in the condition inside or a change in the degree of enclosure or confinement. 4

The expression 'confined space' could also refer to the following examples: ducts, vessels, boreholes, building voids, and enclosures for the purpose of asbestos removal.

1.5.5.4 Legislative requirements The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2


3


4

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

5

Also of importance with regard to confined space working are the requirements on the Contractor to:

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provide health surveillance for at-risk employees

(b)

establish contacts with external services, for example the emergency services (rescue and medical services)

(c)

provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks assess employees' capabilities when allocating work to individuals

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(e)

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provide adequate training for anyone involved in any aspect of confined space working (including rescue).

Arising out of the risk assessment for confined space working will usually be a need for the Contractor to: (a)

develop a method statement for each job

(b)

implement a Permit to Work system, encompassing or supplemented by a Permit to Enter.

Confined Spaces 7

These Regulations require Contractors to plan work so that entry to confined spaces is avoided so far as is reasonably practicable, for example, by doing the work from outside. They also require a safe system of work to be developed and implemented if entry to a confined space is unavoidable, and adequate emergency arrangements, which will also safeguard rescuers, to be put in place before work starts.

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8


Duties to comply with these Regulations are placed on: (a)

Contractors in respect of work carried out by their own employees and work carried out by any person (for example, a contractor) insofar as that work is to any extent under the Contractor’s control.

9

The key duty is a complete prohibition of any person entering a confined space to carry out any work for any purpose whatsoever, where it is reasonably practicable to carry out the work by any other means.

10

If entry into a confined space is necessary then a risk assessment by a competent person must be undertaken. The outcome of the risk assessment will then provide the basis for the development of a full and effective safe system of work, including rescue arrangements.

Construction (Design and Management) CDM These Regulations place a legal duty on designers, when preparing their designs, to carry out design risk assessments and 'design out risk' so far as it is reasonably practicable to do so.

12

In the context of this section, designers should carry out their design work so that no-one has to enter a confined space during construction work, maintenance or cleaning of the structure or during its demolition.

13

Also, within the context of this section these Regulations place legal duties on contractors, including Contractors, with regard to:

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11

safe places of work

(b)

excavations

(c)

prevention of drowning

(d)

prevention of risk from fire, explosion, flooding and asphyxiation

(e)


(f)

fresh air.

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The Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

15

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to specified workers.

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Personal Protective Equipment 16

These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

17

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are found to be not reasonably practicable to implement. In practice, however, unless it is possible to carry out the work without entry into the confined space, the wearing of PPE will usually be necessary.

18

In deciding which type to issue, the Contractor must take into account the risk that the PPE

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is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely. Where the use of RPE is necessary, face-fit testing to establish the suitability of the RPE for the wearer, would be required. If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible and suitable for the task that is to be undertaken. Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable them to understand the risks being protected against, the purpose of the PPE and manner in which it is to be used.

20

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction and training that they have been given, and know the procedures for reporting loss or defect to their Contractor.

21

In addition to the more commonly used PPE, confined space working will often require the use of appropriate respiratory protective equipment (RPE) and rescue equipment such as a safety harness and line.

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Access to and egress from many confined spaces is made by lowering or raising a person vertically through the entry/exit point, including during practice or actual rescues.

2

In these circumstances:

as

safety harnesses and rescue lines must be regarded as lifting accessories

(b)

the tripod hoist or other type of winch must be regarded as lifting equipment used for lifting persons

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(a)

All such require inspection on a six monthly basis.

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1.5.5.6 Dangers in confined spaces

The air that we breathe contains around 21% oxygen and, at that level, people can work without difficulty. A falling level of oxygen will create an increasingly serious situation if breathing apparatus is not worn, or the level of oxygen otherwise restored. Generally, the following symptoms are experienced at the corresponding level of oxygen depletion:

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Oxygen deprivation and suffocation

(a)

19% tiredness (normal acceptable minimum level for working)

(b)

17% judgement (decision making) is affected

(c)

12% respiration is affected, fatigue experienced, flames are extinguished

(d)

10% light-headedness, increasingly difficult respiration

(e)

8% nausea, possible collapse

(f)

6% respiration stops, death in minutes.

Oxygen deprivation may be the result of: 2

the displacement of oxygen by gas leaking in from elsewhere, or the deliberate introduction of purge gas

3

the displacement of oxygen by a naturally occurring gas, such as methane

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4

oxidisation, rusting or bacterial growth using up the oxygen in air

5

oxygen being consumed by people working and breathing, or by any process of combustion

6

welding and other 'hot works'

7

the prior discharge of a fire extinguisher containing carbon dioxide or other asphyxiating gas.

Toxic atmospheres 8

However much oxygen is present in the atmosphere, if there is also a toxic gas present in sufficient quantity it will create a hazard.

9

Some of the many toxic gases which may be encountered include: hydrogen sulphide, usually from sewage or decaying vegetation

(b)

carbon monoxide from internal combustion engines, or any incomplete combustion, especially of liquefied petroleum gases (LPG)

(c)

carbon dioxide from any fermentation or being naturally evolved in soil and rocks, or coming from the combustion of LPG

(d)

fumes and vapours from chemicals such as ammonia, chlorine, sodium, and from petrol and solvents.

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(a)

Whenever a toxic gas (or any gas, fume or vapour that may be hazardous to health) is thought to be (or known to be) present, then an assessment of the risk to health must be made. Appropriate control measures must be put into place to eliminate the hazard or control the risks.

11

Petrol and diesel engines create carbon monoxide, which is an extremely toxic gas.

12

Liquid petroleum gas-powered engines create an excess of carbon dioxide, which is a suffocating hazard. The use of any form of internal combustion engine within a confined space must be prohibited, unless a specifically dedicated exhaust extraction system is operative.

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Some gases need only be present in very small quantities to create a hazard. A few of the major sources of explosive and flammable hazards are:

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Flammable atmospheres

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(a)

petrol or liquefied petroleum gas, propane, butane and acetylene. These are explosive in the range of 2% in air upwards. The hazard is normally created by a spillage or leakage

(b)

methane and hydrogen sulphide, which are naturally evolved from sewage or decaying organic matter. These are explosive in the range of 4% in air upwards

(c)

solvents, acetone, toluene, white spirit, alcohol, benzene, thinners, etc. These are explosive in the range of 2% in air upwards. The hazard generally results from process plants and/or spillage

(d)

hydrogen and other gases evolved from processes such as battery charging.

In an explosive or flammable atmosphere, a toxic or suffocating hazard may also exist.

Other causes of a hostile environment 15

Apart from the hazards dealt with above, other dangers may arise from the use of electrical and mechanical equipment, from chemicals, process gas and liquids, dust, paint fumes,

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welding and cutting fumes. Extremes of excess heat and cold can have adverse effects and may be intensified in a confined space. Consideration must be given to the timing of what would otherwise be considered 'standard' work. During hot weather, roof spaces and other types of confined spaces may reach temperatures which will lead to a dangerous increase in body temperature.

17

If work cannot be planned to avoid this, for example by starting early, then physical measures such as cooling and reducing the time spent working in the confined space must be introduced following an assessment by a competent person.

18

Further dangers exist in the sheer difficulty of getting into or out of, and working in a confined space. The potential hazard of an inrush of water, gas, sludge due to a failure of walls or barriers, or leakage from valves, flanges or blanks, must all be considered at the risk assessment stage.

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1.5.5.7 Information, instruction and training

The information, instruction and training given to employees must enable them to carry out work safely and without risks to their health. The extent of training needed will vary according to circumstances and the type of space being entered. An entry into a deep confined space using breathing apparatus would require a full breathing apparatus and rescue course. However, training to enter a bund around a large diesel tank where the risks are less significant, such as fumes and possible drowning in diesel, would not require such an intensive course, and indeed adopting the use of breathing apparatus in this instance may be entirely inappropriate.

2

Training should involve demonstrations and practical exercises. It is important that trainees are familiar with both equipment and procedures before working for the first time in confined spaces.

3

Practical refresher training should be organised and available. The frequency with which refresher training is provided will depend upon how long it is since the type of work was last done, or if there have been changes to methods of work, safety procedures or equipment.

4

No person should enter a confined space unless they are trained and competent to do so safely.

5

The training needs of each of the four categories of employee considered for confined space working should be considered. The categories are:

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(a)

supervisors

(b)

employees entering confined spaces

(c)

people employed as attendants outside confined spaces

(d)

rescue teams.

Some of the roles identified may be carried out by the same person.

1.5.5.8 Safe working 1

Safe working in a confined space can only be achieved by the use of a Permit to Work system in which each step is planned and all foreseeable hazards are taken into account. Such a system, backed up by adequate rescue facilities, should enable work to be carried out safely.

2

At the planning stage it will be necessary to determine;

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(a)

whether an entry into the confined space is required, or whether an alternative method of doing the work exists (see Checklist 1 at Appendix 1)

(b)

if an entry is necessary, whether it can be carried out without the use of breathing apparatus (see Checklist 2 at Appendix 1)

(c)

whether the entry must be made with the use of breathing apparatus (see Checklist 3 at Appendix 1).

In respect of (3) above, it should be emphasised that entry into a confined space using breathing apparatus should not be made routinely or undertaken as a matter of convenience, where the use of mechanical or forced ventilation would achieve a safe atmosphere.

4

If it is decided that the work can be done without anyone entering the confined space, provided that a safe system of work exists and the confined space has been isolated from potential sources of hazard, the work can proceed. It is important to avoid systems or plant being re-energised while work is proceeding and everyone involved should be advised accordingly.

5

Once it has been decided that people must enter a confined space, a preliminary meeting should be held with all concerned, and effective lines of authority and communication established in order to minimise any risk of subsequent misunderstanding.

6

The exact routine to be followed will vary, depending on the type of confined space to be entered. The provisions and precautions required for entry into a large empty surface water tank will obviously be different from those needed for entry into a narrow service duct containing pipes and valves, but the fundamental principle of a safe system of work applies to these and other cases. The risk assessment, as mentioned previously, will have identified many of the above points and should be used as the basis for developing the safe system of work.

7

It is stressed that all personal protective equipment in general, and respiratory protective equipment in particular, must have been specified by a competent person who is clearly aware of all of the circumstances surrounding its use.

8

If the fire and rescue service forms a part of the rescue plan, they must be given a warning that a confined space entry is to be made. This will give them the opportunity to assess the risks to their own staff and identify any equipment they might need.

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1.5.5.9 Isolation 1

The confined space must be isolated from all possible external sources of danger to persons entering it.

2

A full Permit to Work system should be used to record the location and types of isolation, and the hazards being guarded against.

3

Electrical isolation must never rely on a switch or fuse. The switch gear or fuse holder must be locked off and a warning notice applied.

4

Mechanical isolation of pipework should not rely on a single valve or on a non-return valve; these may let-by and create a hazard. Whenever possible, a section of pipe should be removed or a blank or spade should be put into a flange between the valve and the confined space and a warning notice displayed.

5

Paddles, stirrers or agitators, whether electrically or mechanically operated, should be physically disconnected by the removal of an operating arm, and a warning notice displayed.

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1.5.5.10 Cleaning There are a variety of methods of cleaning the inside of confined spaces to remove hazardous solids, liquids or gas. Cold water washing, hot water washing and steaming will remove many contaminants, while solvents or neutralising agents may be necessary for others. If hot water or steam is used, with or without a solvent, care must be taken to ensure that adequate ventilation exists for steam pressure and that condensation does not build up to unacceptable levels.

2

If steam is used or water is boiled in a confined space, account must be taken of the vacuum that can be created on cooling.

3

When steam or solvents are used, these may in themselves create a toxic, suffocating or flammable hazard. Even though a space has been well cleaned, it must not be entered until it has been monitored.

4

Great care must be taken if encountering any sludge or heavy deposits which may release toxic gases if disturbed.

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1.5.5.11 Purging and ventilation

Air purging and ventilation can be carried out by removing covers, opening inspection doors, etc. and allowing ordinary air circulation, or by the introduction of compressed air via an air line. However, higher rates of air exchange can be achieved by the use of air movers, induction fans or extractor fans.

2

It is especially important that when an inert gas (such as nitrogen) has been used to purge or render inert a flammable atmosphere, the inert gas itself is properly purged with air.

3

When air purging is taking place, the flow of air should be of a sufficient volume and velocity to ensure that no pockets or layers of gas remain undisturbed.

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Atmospheric monitoring

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Depending on the circumstances, as a result the risk assessment, continuous atmospheric monitoring may well be necessary when any work is to be done that would expose employees to any substance hazardous to health.

5

Before an entry is made into a confined space, tests must be carried out to establish the levels of oxygen, toxic gas or flammable gas in the atmosphere.

6

The external atmosphere around the opening should be monitored first and if the results are satisfactory, internal monitoring should be carried out by lowering a gas monitor into the confined space before it is occupied.

7

If entry into the confined space is necessary to carry out the tests, breathing apparatus or other respiratory protective equipment must be worn.

8

Suitably trained and competent personnel may use simple, reliable instruments to measure oxygen and flammable gas levels. The accuracy of the instruments must be assured by periodic calibration.

9

A satisfactory oxygen content must not in itself be relied on to indicate safety since flammable, explosive or toxic gas may exist alongside oxygen and need only be present in minute quantities to create a serious hazard.

10

The tests applied should take account of what the space is known to have contained, including any inert gas used to purge a flammable atmosphere which may itself produce

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toxic hazards or the risk of asphyxiation. Account must also be taken of hazards arising from other sources such as materials used for cleaning. Methane, hydrogen sulphide and carbon dioxide can all evolve naturally due to the decomposition of organic matter or, in some cases, by the effect of rainwater percolating through certain types of ground. It is necessary to test the atmosphere of a confined space at both high and low level as well as in any corners, etc. where pockets of gas may exist. Instances have occurred of carbon dioxide displacing oxygen at lower levels while a normal oxygen level continues to exist at higher levels of the same confined space. 11

The sense of smell must never be relied upon to detect gases. Some are odourless, and hydrogen sulphide, in particular, can paralyse the sense of smell to such an extent that even fatally high concentrations of the gas cannot be detected. In any case, the sense of smell varies from person to person and deteriorates with age.

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Providing that the specific contaminant is known, tests can be carried out by competent persons using the individual detector tubes available for the detection of specific toxic and asphyxiant flammable or explosive fumes or gases.

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Monitoring and testing equipment

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A wide range of portable gas detection equipment is available for flammable and toxic gases; some are specific to one gas (for example, hydrogen sulphide), while others can sample a range of different gases. Such instruments need to be properly calibrated.

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Continuous monitoring

The initial monitoring and testing must establish that the confined space is safe to enter. Monitoring should then be carried out at intervals to ensure the continued safety of personnel. Tests should be repeated after any breaks, such as lunch or overnight, or after the time limit set out in a Permit to Work has expired.

15

It may be necessary to issue individual monitors to people working in a confined space, so as to give them an instant warning of low oxygen, or toxic or flammable gas hazards.

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Competence of monitors 16

All atmospheric monitoring must be carried out by persons who are trained and competent to use the instruments and interpret the results. They must have sufficient practical and theoretical knowledge to enable them to make a valid judgement based on the results. They must be fully aware of their responsibilities in permitting an entry into a confined space.

Hazards of excess oxygen An oxygen-enriched atmosphere is, in itself, a major hazard. Organic materials, such as oil and wood, become highly combustible and ordinary materials, like paper and clothing, will burn with exceptional ferocity.

18

An increase of only 4% oxygen is sufficient to create a hazard and this may occur inadvertently. In oxyacetylene and oxypropane processes, sometimes not all of the oxygen supplied to a cutting torch is consumed. Some may be released, increasing the atmospheric oxygen above the normal 21%. The oxygen enrichment of the atmosphere in a confined space also results from the practice of using oxygen to sweeten or enrich the atmosphere when it has become oppressive, stale, hot, fume-filled or otherwise unpleasant. This is a very dangerous practice and must be prohibited.

19

Another way in which the atmosphere may become oxygen-enriched is through leakage from torches or hoses during meal breaks or overnight. For this reason, they should be removed at each breaktime. The deliberate kinking or nipping of an oxygen hose while changing a torch does not usually cut off the supply completely and can result in the release of substantial quantities of oxygen.

20

If excess oxygen is discovered, the space must be quickly evacuated and ventilated until normal levels of oxygen are regained.

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1.5.5.12 Selection of personnel

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Care is required in selecting the right people to work in confined spaces, since conditions can be difficult. They must be physically fit, agile and, most importantly, not be claustrophobic. People who suffer from asthma, bronchitis, or other respiratory conditions, or whose immune system has been suppressed, must be assessed by a medical practitioner as to their suitability to work in confined spaces.

2

Other health conditions which might indicate that a person is not suitable for working in a confined space, or that further checks need to be made before it is allowed, are:

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(a)

high blood pressure

(b)

partial or complete deafness

(c)

lack of mobility through joint problems

(d)

diabetes

(e)

depression or other mental illness

(f)

defective eyesight (which is not corrected by wearing glasses)

(g)

sensitivity of the skin to some substances

(h)

taking some types of medication.

3

Stamina is also required. The wearing of any form of respiratory protection tends to lead to an increase in respiration and a higher use of energy; the amount of work which can be done in confined spaces is less than that expected under normal conditions.

4

When respiratory protection is to be used, it should be remembered that facial hair and

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spectacles often prevent a respirator from fitting properly and thus achieving the assumed degree of protection. 5

Face-fit testing should be carried out to ensure that the chosen mask fits the wearer. This can be achieved quantitatively using a 'Portacount' for half or full face masks or qualitatively using bitter/sweet solutions for half or disposable masks.

1.5.5.13 Communications Adequate and effective communications must exist between those inside and those outside the confined space, so that, in the event of an incident, a warning can be given and the space evacuated or those inside rescued. The system needs to be 'fail safe', ensuring that if a reply is not received or a scheduled call not made, the procedure for rescue starts immediately.

2

When a confined space is relatively small, such that the person entering it cannot move far from the entry point and there are no other factors that could hinder effective communication, the method of communication may be relatively simple such as a pre-arranged system of tugs on the safety rope, which must be fully understood by all involved. However, if the nature of the confined space, the job to be carried out and other factors necessitates the 'entry person' travelling some distance from the entry point, a more elaborate communication system might be required.

3

Factors that could hinder effective communication and may need to be considered in the risk assessment are:

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the level of noise inside or outside the confined space, which may or may not be associated with the confined space work

(b)

the physical nature of the confined space or the presence of substances that could reduce visibility

(c)

the distance between the point of entry and the place of work

(d)

the presence of workers with little or no understanding of English, although it could easily be argued that such a situation should not arise in connection with working in confined spaces.

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Depending upon the findings of the risk assessment, prior communication with the emergency services regarding the location and nature of the work, might be considered necessary.

5

All types of respiratory protection affect verbal communication to some degree and, whatever method of communication is chosen, it should be tested and proved outside the confined space before entry is made.

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1.5.5.14 Work equipment 1

Due to the potential for a flammable or explosive atmosphere in confined spaces, selecting tools and other work equipment with which the work can be carried out safely is essential.

2

If there is any possibility of flammable gas existing in a confined space, all tools must be of a non-sparking material and all lighting and electrical equipment must carry BASEEFA* or equivalent approval. Smoking and naked lights must be strictly prohibited and care must be taken to avoid the generation of static electricity with the consequent risk of sparks. * British Approvals Service for Electrical Equipment in Flammable Atmospheres

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1.5.5.15 Fire safety 1

Hot works must not be carried out in a confined space unless atmospheric testing has confirmed that flammable or explosive gases are not present and the findings of a risk assessment show that it is otherwise safe to do so.

2

Where there is still a residual risk of fire, appropriate fire extinguishers may need to be kept in the confined space at the entry point.

3

Where 'hot works' are being carried out inside a confined space, the operative carrying out the work must also have a suitable and serviceable fire extinguisher at the place of work. In the event of a fire, the local fire service should be called in case the fire cannot be contained or extinguished.

Appropriate first-aid equipment and trained first aiders should be provided and available for emergencies and to provide first aid until professional medical help arrives.

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1.5.5.17 Rescue

The arrangements for the rescue of persons in the event of an emergency, both in terms of trained persons and equipment, need to be suitable and sufficient. The arrangements must be in place before any person enters or works in a confined space.

2

Where there are no qualified in-house emergency rescue services, the external emergency rescue services should be informed of the area and type of work taking place in a confined space.

3

Proper and effective rescue training is quite hard and arduous and is not to be undertaken lightly. Persons selected for such training need to be physically fit and able to adapt to situations as they arise during a rescue.

4

If a person is injured in a confined space which has been certified safe to enter without respiratory protection, an entry can be made to rescue and remove them straight away.

5

When a person collapses in a confined space and the cause is not known, irrespective of whether or not the confined space was certified fit for entry without respiratory protection, no one must enter unless they are wearing breathing apparatus. The collapse may have been due to a deterioration in the atmosphere within the confined space. The first duty of any rescuer is to ensure that they do not become a casualty themselves.

6

Each year, would-be rescuers who are insufficiently trained or equipped die by going into confined spaces where a person has collapsed.

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Rescue equipment 7

Every person entering a confined space wearing breathing apparatus must also wear a safety harness. The harness must be attached to a lifeline, attended by a person outside the confined space.

8

The harness must be one that is suitable for confined space rescue in that it must enable an unconscious person to remain in an upright position whilst being hoisted (see the following illustration). An unsuitable harness will allow the unconscious person to bend at the waist, making recovery through a narrow opening difficult or impossible.

9

This equipment forms part of a safe system of work for any entry into a confined space. Properly used, it may enable a rescue to be carried out successfully without the need for a

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rescuer to enter the confined space. Rescue equipment must include some means of lifting or pulling a person up from a confined space, since it is virtually impossible for the average person to achieve this solely by muscular effort. There are a variety of tripods, winches, blocks and tackles which, when used in conjunction with a safety harness, enable a person to be lifted quickly and safely out of a confined space.

11

This would mean testing and inspection in accordance with the schedule drawn up by the competent person. In practice, harness, lines and accessories such as carabiners should be subjected to a formal thorough examination, by a competent person, every six months and checked by the user weekly and before each use. Tripods, hoists and other lifting devices need to be load tested every six months in the same way that a scissor lift used for lifting people would.

12

Dependant on circumstances, rescue equipment may have to include first aid equipment, oxygen or resuscitation packs and rescue breathing apparatus. A secure line of communication to the emergency services may also be required.

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1.5.5.18 Respiratory protective equipment (RPE) Respiratory protective equipment must be selected by a competent person, be 'CE' marked and be suitable for the type of hazard against which it is to protect the wearer.

2

A wide range of types of respiratory protective equipment is available from various manufacturers. The equipment functions on the basis of two distinct principles outlined below.

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By purifying the air breathed 3

The air inhaled is drawn through a filter or medium that removes the harmful substance or pollutant. The nature of the filtering agent depends on the type of pollutant to be dealt with. These types are commonly called respirators.

4

The simplest form of respirator is the 'dust mask', a preformed cup made of filtering material

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which fits over the nose and mouth to filter out nuisance dust. These masks give no protection against harmful or toxic gases or fumes and the protection factor of the mask may not offer adequate protection against the level of airborne dust that can be experienced in a confined space. 5

More complex types have filter cartridges that may be general for various types of dust or fume, or specific to a particular substance.

By supplying clean air The air can be supplied straight through an air line via a pump or compressor or, alternatively, the person may carry compressed air in cylinders.

7

These types are known as breathing apparatus.

8

An alternative type of breathing equipment is the self-rescue set. This comprises a small compressed air bottle, the necessary hoses and valves and a face piece. Self-rescue sets can be carried by operatives who enter confined spaces in which the air is initially safe to breathe.

9

Should the air quality deteriorate, the face piece is placed over the nose and mouth and the air valve opened. The air bottle supplies fresh air to the operative whilst an escape from the confined space is made. The air bottle of a self-rescue set has a duration of typically 15-20 minutes.

10

The chart reproduced from BS 4275 at Appendix 2 details the different types of respiratory protective equipment and the system of classification. Whilst BS 4275 has now been withdrawn, it is considered that the chart still offers good guidance on general principles of selecting appropriate respiratory protective equipment.

11

Care must be taken to select the correct type of protection for the conditions. Respirators (as opposed to breathing apparatus) do not protect against oxygen deficient atmospheres and should not be used in any atmosphere dangerous to life. Respiratory protective equipment should not be used unless all other methods of control or protection have been examined and it is established that the use of RPE is the only reasonably practicable solution.

12

Respirators can only be used for protection against the gases or dusts for which they are specifically intended. It is important to note that dust masks and canister and cartridge respirators have a limited period of usage before becoming clogged with the contaminant. They may also have a limited shelf life, indicated by a use-by date.

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1.5.5.19 Permits Permit to Work Every entry into a confined space must be made under a Permit to Work, whereby a competent person must be satisfied that all necessary precautions have been taken and provisions made to secure the safety of those entering the confined space, before signing the Permit to Work. The signed Permit thus gives an assurance that work may safely take place.

2

Appendix 3 to this module shows an example of a Permit to Work. The content may be varied to meet individual requirements.

3

Permits should only be issued by named authorised persons, who must sign them. Such persons must be competent, have authority and possess sufficient practical and theoretical knowledge and actual experience of working conditions to enable them to judge whether everything necessary has been done to ensure the safety of personnel. It is quite common for several authorised persons to sign a Permit to Work, each certifying that they have taken the necessary actions with regard to their own area of responsibility, for example, electrical isolation, atmospheric testing. Where a Permit to Work system involves the use of padlocks and keys, for example for locking-off electrical isolators or other sources of energy, the keys must stay with an authorised person until such time as the Permit is returned for cancellation.

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Permit to Enter

Depending upon the nature of the confined space and the inherent risks of carrying out the work, some Contractors may choose to run a separate Permit to Enter system.

2

An example of when such a system might be used is where all preparatory work is carried out to meet the requirements of the Permit to Work and then the Permit to Enter is issued when final pre-entry checks of the atmosphere have been carried out.

3

Such a system would cover situations where:

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a single Permit to Work covers the duration of the whole job, but

(b)

successive shifts of workers are each authorised to enter the confined space under a newly raised Permit to Enter.

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1.5.5.20 Access and egress 1

Where it is practical, a safe way in and out of the confined space should be provided and, wherever possible, allow quick, unobstructed and ready access, such as a fixed, vertical ladder inside an underground chamber that terminates just below the entry/exit point at ground level.

2

The means of escape must be suitable for use by the individual who enters the confined space so that, ideally they can quickly escape in an emergency. However, it must be accepted that in many cases the entry/exit point will be of a restricted size that will not necessarily allow an easy escape route in an emergency, particularly if the person who is escaping is wearing a compressed air cylinder. The means of achieving a prompt escape or rescue must be considered in the risk assessment.

3

Suitable means to prevent access, for example a locked hatch, should also be in place when there is no need for access to the confined space. There should be a safety sign that is clear and conspicuous to prohibit unauthorised entry alongside openings that allow for safe access.

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1.5.5.21 Conclusion

poorly trained and equipped workers

(b)

the failure to put in place adequate emergency arrangements before work starts

(c)

the failure to carry out an initial check of air quality

(d)

the failure to set up a safe system of work, including continuous air monitoring, based around a Permit to Work system

(e)

the failure to follow an established safe system of work

(f)

the incorrect use of respiratory protective equipment

(g)

the use of the incorrect type of respiratory protective equipment

(h)

the failure to use safety harnesses and lifelines

(i)

ill-conceived and badly executed rescue attempts.

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(a)

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All such accidents are avoidable. If an accident does occur, it demonstrates that a breakdown has occurred in the supposed safe system of work.

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For work to be done safely in a confined space, great care has to be taken over the detail of each step of the procedure. Common causes of accidents are:

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Construction Site Safety 1.5.5 Appendix 1 Checklist 1 -Work in a confined space without entry of persons Ensure that entry into the space is totally prohibited.

2

Ensure that the isolation of services and processes is carried out as necessary.

3

Wash, clean, and purge the workplace, as appropriate, for work to be done.

4

Ensure that there is a safe system of work for the people concerned.

5

Ensure that other people know that work is going on.

6

Authorise work to start only on the issue of a Permit to Work.

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Checklist 2 - Entry into a confined space without breathing apparatus

.

1

Follow a safe system of work.

8

Put in place adequate emergency arrangements before work starts, which will also safeguard rescuers.

9

Initiate a Permit to Work which includes the requirements of a Permit to Enter unless separate permits are raised.

10

Withdraw the space from service.

11

Isolate the workplace from electrical, mechanical, chemical, heat and all other sources.

12

Check that no inward leakage of gas, fumes, steam or liquids is possible.

13

Clean, drain and purge the workplace as necessary for the type of work to be carried out and entry to be made.

14

Test the atmosphere for oxygen, flammable gas, toxic gas, etc.

15

Carefully check any sludge or deposit that may harbour gas, fumes or liquids.

16

Carry out a COSHH assessment, if necessary.

17

Arrange for any checking to be carried out remotely.

18

If necessary, clean, purge and ventilate the workplace again until the atmosphere is safe to enter.

19

Ensure that all tools and equipment are safe to use in the area.

20

Check the provision of protective clothing, harness, lifelines, rescue equipment and rescue personnel.

21

Ensure that rescue personnel are trained in the use of the equipment and capable of using it.

22

Ensure that the fire and rescue service is informed of the location and nature of the work, where appropriate.

23

If appropriate, ensure that the external emergency rescue services are informed of the location and type of work being carried out.

24

Brief all personnel on what is to be done and arrange communications.

25

Issue the Permit to Work which

26

authorises entry and fixes a timescale within which the work must be completed.

27

Constantly monitor the workspace and communications.

28

If the task is completed within the timescale, advise all concerned, cancel the Permit to Work and return the space to service.

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29


If the work is not completed in time, withdraw all staff, cancel the Permit to Work and consider how best to proceed.

Checklist 3 - Entry into a confined space with breathing apparatus Follow a safe system of work.

31

Put in place adequate emergency arrangements before work starts, which will also safeguard rescuers.

32

Initiate a Permit to Work.

33

Withdraw the space from service.

34

Isolate the workplace from electrical, mechanical, chemical, heat and all other sources.

35

Check that no inward leakage of gas, steam or liquids is possible.

36

Clean, drain and purge the workplace as necessary for the type of work and entry.

37

Test the atmosphere for flammable gas, toxic gas, oxygen, etc.

38

Decide which type of breathing apparatus is to be used.

39

Ensure that the personnel involved have a current valid certificate for the type and use of breathing apparatus.

40

Ensure that all tools and equipment are safe for use in the work area.

41

Check the provision of protective clothing, harness, lifelines, rescue equipment and rescue personnel.

42

Ensure that rescue personnel are adequately trained in the use of rescue equipment and are capable of using it correctly.

43

Ensure that the fire and rescue service is informed of the location and nature of the work, where appropriate.

44

If appropriate, ensure that the external emergency rescue services are informed of the location and type of work being carried out.

45

Brief personnel on what is to be done and arrange communications.

46

Issue the Permit to Work which authorises entry and fixes a timescale within which the work must be completed.

47

Constantly monitor the workspace and communications.

48

If the task is completed within the timescale, advise all concerned, cancel the Permit and return the space to service.

49

If the work is not completed in time, withdraw all staff, cancel the Permit to Work and consider how best to proceed.

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Construction Site Safety 1.5.5 Appendix 2 Classification of types of respiratory protective equipment

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Construction Site Safety 1.5.5 Appendix 3 Possible Layout for a Permit to Work Certificate

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PLANT DETAILS (Location, identifying number, etc.)

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The above plant has been removed from service and persons under my supervision have been informed

COMPLETION OF WORK

Signed Date Time The above plant has been isolated from all sources of ingress of dangerous fumes, etc. Signed The above plant has been isolated from all sources of electrical REQUEST FOR EXTENSION and mechanical power Signed The above plant has been isolated from all sources of heat Signed Date The above plant has been freed of dangerous materials EXTENSION

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ISOLATION

CLEANING AND PURGING

Material(s):

I have read and understood this certificate and will undertake to work in accordance with the conditions in it Signed

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WITHDRAWAL FROM SERVICE

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WORK TO BE DONE

ACCEPTANCE OF CERTIFICATE

Date

Time

The work has been completed and all persons under my supervision materials and equipment withdrawn Signed

Date

Time

The work has not been completed and permission to continue is requested Signed

Date

Time

I have re-examined the plant detailed above and confirm that the certificate may be extended to expire at

Method(s): Further precautions:

TESTING

Signed Contaminants tested

Date

Time Signed

Results

Signed Date Time I CERTIFY THAT 1 HAVE PERSONALLY EXAMINED THE PLANT DETAILED ABOVE AND SATISFIED MYSELF THAT THE ABOVE PARTICULARS ARE CORRECT *(1)THE PLANT IS SAFE FOR ENTRY WITHOUT BREATHING APPARATUS (2) BREATHING APPARATUS MUST BE WORN Other precautions necessary: Time of expiry of certificate: * Delete (1) or (2) Signed Date Time

Date

Time

THE PERMIT TO WORK IS NOW CANCELLED. A NEW PERMIT WILL BE REQUIRED IF WORK IS TO CONTINUE Signed RETURN TO SERVICE

Date

Time

I accept the above plant back into service Signed

Date

Time

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Safety in Demolition

1.5.6.1 Key points Demolition can be dangerous and should be left to competent persons. Almost all demolition projects will encounter asbestos.

2

Planning and supervision is vital to ensure a successful project.

3

Ensure the appropriate survey has been undertaken.

4

Ascertain if the structures are stable before starting and that instability can be avoided unless planned.

5

Ensure written risk assessments and method statements are developed, communicated and understood.

6

Salvage or soft stripping is hazardous and must be planned and controlled to avoid the risk of falling objects or collapse.

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Safe demolition is a very complex and technical skill. It is also potentially very dangerous if carried out by Contractors who are not fully competent in demolition techniques.

2

Information, planning, responsible implementation and controls are the essential elements for safe and successful demolition projects.

3

Whether demolition is required for a small building or for a complex factory site, you must be aware of the hazards and risks. These need to be identified, assessed and effectively controlled to reduce the potential for injury to persons and damage to property.

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1.5.6.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity. This is to identify any hazard that employees, or any other person who might be affected, may encounter during the work and to put control measures into place. These measures will aim to remove the hazards, or reduce the risks to health and safety arising out of those hazards, as far as is reasonably practicable.

2

The Contractor must provide comprehensive and relevant information on risks that exist in the workplace and on any control measures that are in place, ensuring these are fit for purpose and monitored for ongoing safety.

3

Employees have a duty to tell their Contractor of any work situation, including near misses, which presents a risk to the health and safety of themselves or of any other person who might be affected.

4

Where specific health hazards are identified, the Contractor must offer health surveillance to the at-risk employees. Given the nature of demolition and the potential hazardous substances that may be encountered, this duty could be particularly relevant to demolition contractors.

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1.5.6.4 The Provision and Use of Work Equipment These Regulations cover equipment used in demolition. They require that a Contractor supplies work equipment that is safe, correct and suitable for the job, and that the equipment is maintained.

2

Demolition has traditionally involved some work being carried out at height, which has in the past been the cause of deaths and injuries to demolition operatives. Due to advances in demolition techniques, and the increasing size and reach of the machines used, there is no longer such a need to work at height. However, where work at height is carried out, it must be done in a safe manner.

3

Under these Regulations, falling object protection is required for machinery. A demolition specification excavator must have a cab guard, as it is foreseeable when working overhead that material could fall onto the cab. The use of reinforcing bars as make-shift retaining pins for attachments would be contrary to these Regulations.

4

It is common to see mobile crushers used in the demolition process to process the demolition arisings for reuse as part of the next use of the site. These machines pose great risks to the untrained. Issues such as machinery guarding and clearing blockages, as well as noise and vibration, must be considered.


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These Regulations require Contractors to:

avoid the need to work at height where reasonably practicable

(b)

select the most appropriate work equipment when work at height cannot be avoided

(c)

(as far as is reasonably practicable) prevent falls

(d)

reduce the distance and consequences if there is a fall

(e)

where harnesses are being used, ensure emergency recovery arrangements are in place

(f)

ensure that all work at height is based upon a risk assessment and carried out safely.

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Where the use of work equipment involves a specific risk to health and safety, the use of the equipment must be restricted to competent, specified workers authorised to carry out the task.

3

The use of demolition machines, and in particular ultra high reach machines, is an important part of the strategy to reduce the need for employees to work at height during demolition activities.

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These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, the Contractor must provide and ensure that employees use suitable personal protective equipment.

2

In essence, personal protective equipment (PPE) may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are not practicable.

3

Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable the employees to

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understand the risks being protected against, the purpose of the PPE and the manner in which it is to be used. 4

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction, and training that they have been given, and know the procedures for reporting loss or defects to their Contractor.

5

These Regulations require that the Contractor provide employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

1.5.6.7 Construction (Design and Management) CDM CDM applies to all demolition and dismantling work, as defined in BS 6187, regardless of the project's size or duration.

2

Every contractor undertaking demolition operations must appoint one or more competent person(s) to plan and supervise the work. Under CDM it is a requirement that any dutyholder who puts 'another person' to work on a construction site, for example a contractor engaging the services of a demolition contractor, must ensure that the person is competent to do what is required of them.

3

The client has to ensure that there are adequate welfare arrangements. The demolition contractor is therefore expected to control and co-ordinate all aspects of health and safety regardless of the size of the project.

4

The National Federation of Demolition Contractors (NFDC) and the Institute of Demolition Engineers (IDE) can provide information regarding the competence required for particular projects.

5

CDM requires the following:

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The demolition or dismantling of a structure or part of a structure shall be planned and carried out to prevent danger so far as is reasonably practicable, or reduce the danger to as low a level as is reasonably practicable.

(b)

The arrangements for carrying out demolition or dismantling work shall be recorded in writing, prior to the commencement of the work.

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1.5.6.8 CDM duty-holders 1

The client is responsible for the provision of information such as Type 3 asbestos surveys/service information and must appoint various other duty-holders. The client must also ensure that adequate welfare facilities are provided, and not permit work to start until there is evidence of adequate health and safety management systems and planning.

2

The designer is responsible for making the client aware of the client's responsibilities under these Regulations as well as the design of the project. Many duty-holders can have designer responsibilities as outlined in CDM.

3

The Engineer is responsible for the co-ordination of health and safety design and planning aspects for projects, including: (a)

identifying and collecting pre-construction information

(b)

informing the client if there are gaps in the pre-construction information, which need to be addressed (for example additional surveys)

(c)

distributing relevant parts of the pre-construction information to contractors to enable

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Section 11: Health and Safety Page 98 Part 1.05: Other hazardous Activities (Regulatory Document) them to tender for, or prepare to carry out, the work

(d)

generally managing the flow of information between all parties

(e)

preparing the health and safety file

The Engineer is also to advise - the client on the competency and resourcing of contractors and to ensure that the Contractor's health and safety plan is adequately developed prior to the work starting on site.

5

The minimum lead times for the project must form part of the information pack. This is a very important development as, historically, the mobilisation period imposed by clients for this sector of the industry has been too short to allow for adequate planning. Engineers must themselves be competent; demolition and asbestos issues may be too specialist for many who normally perform the Engineers role and they should be prepared to take specialist advice.

6

The Contractor must ensure that the client is aware of their duties and is responsible for the overall construction phase, taking into account health and safety issues and the development of the health and safety plan.

7

Contractors and other workers must all work together as a team to achieve high standards in health, safety and welfare on site. The contractors, which normally include utility companies, must co-operate with the Contractor by obeying site rules, and so on.

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1.5.6.9 The health and safety plan and the health and safety file The health and safety plan provides a focus for the construction phase of a project.

2

Relevant pre-construction information, relating to the health and safety hazards associated with the work, should be provided by the client regardless of the size of the project.

3

In the context of this section, such information is likely to include:

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the location and physical state of any asbestos where its presence has been identified by a comprehensive invasive asbestos survey (Type 3 as defined in MDHS 100

(b)

the results of structural surveys

(c)

plans identifying the location of underground services

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the possible presence of contaminants, for example: (i)

poly chlorinated biphenyls (PCBs) in old electrical transformers

(ii)

the residual contents of tanks and pipelines

(iii)

the location and nature of contaminated ground

(iv)

other information which is required to ensure that the work can be planned safely.

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After being appointed by the client, the contractor must use the pre-construction information provided by the client to develop the construction phase plan to the satisfaction of the client, as advised by the Engineer.

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The health and safety plan must be:

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(a)

completed prior to any work commencing on site

(b)

reviewed and amended as often as is necessary for the duration of the project.

The health and safety file is a record of information for the client or end user of the premises. It tells those who might be responsible for the structure in future, of the risks that will have to

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be managed during any maintenance, repair or renovation. Generally, for demolition work the health and safety file will contain information such as details of: (a)

any services, which have been capped or discovered and worked around

(b)

the presence of any voids and details of any areas that may have been filled

(c)

the actions taken to remove or treat contaminated land

1.5.6.10 British Standard 1

BS 6187:2000 is the British Standard for Demolition. It recommends good practice methods for the demolition (both partial and whole), as well as decommissioning, of sites including buildings and structures. It takes into account safety, health and issues which affect protection of the environment.

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1.5.6.11 Definitions and terms used by the demolition industry Competent person in demolition: someone who has practical and theoretical knowledge, with actual experience, of the type of demolition which is taking place on the site. This person is generally accepted to be on site full time as the person responsible for the demolition activity.

2

Demolition; the deliberate pulling down, destruction or taking apart of a structure or a substantial part of a structure. It includes dismantling for re-erection or reuse.

3

Exclusion zone: an area where people are fully (sometimes partially) excluded during a demolition activity. This zone should be determined by a competent person, detailed in the health and safety plan, and may need to be defined by physical barriers on site.

4

Facade retention: where the outer wall of a building or structure is retained in its original position during the demolition phase. It is usually supported by a facade retention system, internal or external.

5

Fan: a protective screen fixed to scaffolding to contain falling debris during demolition. Any fan must be designed to withstand the intended load.

6

Felling: the deliberate collapse of a structure in such a way that the debris falls in a predetermined area.

7

Hot work: the application of heat (including the use of tools that can produce an incendiary spark). It generally uses oxygen and propane gas cutting equipment.

8

Propping and shoring: a system of temporary supports to prevent movement.

9

Safe working spaces: areas where demolition work is taking place, often protected by physical barriers (e.g. machines protected by ROPs, FOPs and MOPs as applicable).

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Machine-mounted attachments 10

Brock: a trade name for a range of remote control excavators, which can carry most demolition attachments.

11

Combination Cutter: a tool which can crush concrete and also cut steel reinforcing bar.

12

Demolition ball: a cast steel ball (drops or pendulum swings in line with the jib) used to demolish a structure (slew balling should be avoided; this technique is very rarely used now).

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Grapple: a powered claw for handling waste and recycled material.

14

Impact hammer: a large breaker, mounted on an excavator, and usually powered by hydraulics (occasionally by compressed air).

15

Pulveriser: hydraulically powered jaws for crushing concrete. It may be hand/machine/ crane mounted.

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Pusher arm: an extension to an excavator, which enables it to carry out high reach demolition.

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Shear: powered jaws for cutting metal.

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Rotator: an attachment fitted between the tool and the end of dipper arm of the excavator, which allows the tool to be turned. Essential for most work in restricted sites.

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Control of Asbestos: (a)

state that all asbestos containing materials should be removed prior to demolition so far as is reasonably practicable

(b)

require that the necessary planning actions and notifications are carried out.

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1.5.6.12 Asbestos considerations

The management process should be based upon the information from an Asbestos survey, carried out before contractors are invited to tender for the demolition. This should include a drawing of the building footprint (all floors) and a list of the approximate amounts and locations of asbestos-containing materials found.

3

From the survey, an inventory of asbestos containing materials should be made and ticked off when they are removed. This should prevent creating risk during soft strip and demolition.

4

There are many occasions when asbestos containing materials are only revealed during the demolition.

5

Machine drivers need to be trained in basic asbestos recognition so that they can stop work and take advice if they discover suspicious materials.

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1.5.6.13 Planning for demolition

It cannot be emphasised too strongly that demolition is dangerous and must be left to the experts.

Planning and supervision are of paramount importance.

1

Before any work starts, the implications of the demolition to be carried out must be determined, for example: (a)

What is the age of the building(s) and what was (were) the previous use(s)?

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Section 11: Health and Safety Page 101 Part 1.05: Other hazardous Activities (Regulatory Document) What was the type of construction and what were the materials used?

(c)

How much is to go?

(d)

Are floor slabs or piles involved?

(e)

Where are the separation points?

(f)

Are there any dangerous substances in, around or under the buildings which are to be demolished, e.g. asbestos, lead paints, flammable liquids, unidentified drums or packages, etc.?

(g)

Is the building on contaminated land?

(h)

Are there any site restrictions?

(i)

Are there people and adjacent properties that may be affected by the proposed working hours?

(j)

Will people be affected by noise or vibration emanating from the site?

(k)

You may need to carry out a dilapidation survey of the adjacent buildings and or highways.

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(b)

Once these things have been determined, decisions should be taken as to what are the acceptable or unacceptable methods to carry out the demolition.

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Two important final questions remain.

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How should the job and site be left safe?

(b)

What is the time scale for the job to be carried out and is it sufficient for the demolition to be carried out safely?

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1.5.6.14 The selection and appointment of a demolition contractor The Contractor, in selecting a demolition contractor, should satisfy themselves of the contractor's competence, knowledge, ability and resources to carry out the work safely.

2

Expertise is vital.

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Some or all of the following points may be covered in the risk assessment and method statement for the proposed job.

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1.5.6.15 Essential elements of a demolition health and safety plan

1.5.6.16 Project information 1

Names, addresses, contacts and telephone numbers should be detailed indicating the project managers, quantity surveyors, architects, structural engineers etc

1.5.6.17 Scope of work 1

An explicit and concise opening paragraph should be included, outlining the extent of work along with any other related activities, e.g. asbestos removal, facade retention, etc.

1.5.6.18 Existing environmental information and drawings available 1

Where available, construction drawings should have been supplied to the contractor, along with information on the former use of the site or buildings to be demolished. This information (if any) physical or chemical hazards are on the site or in the buildings, e.g. underground tanks and/or potential chemical or biological hazards or contaminated land.

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1.5.6.19 Risk assessment and special hazards 1

Having gathered all available information and visited the site to assess the work involved, along with identifying all known hazards and confined spaces, the contractor's appointed person on site should ensure that risk assessments, and assessments for asbestos, COSHH or noise are made. Method statements should then be drawn up.

2

Consideration must be given at an early stage to control the access for workers and any visitors, and ensure separate access and egress for vehicles, plant and machinery.

3

Finally, assess the impact that the site environment will have on any people who might be affected by the activity, such as neighbours or members of the public.

1.5.6.20 Programme The programme time allocated must be adequate to allow the demolition work to be carried out safely. This should detail the correct sequence of the works with any stop and review points.

2

Where the programme has unavoidable interfaces with other trades or contractors on site, this must be recognised as a potential area of risk. Good communications, planning and management are therefore essential to ensure high standards in health and safety.

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1.5.6.21 Services

Before any work starts, all utility companies should be contacted by the Contractor and sent a site plan, showing the footprint and extent of the planned demolition, and requesting the disconnection or isolation of the appropriate service (i.e. electricity, gas, water, telecommunications or other cables).

2

These requests should be made in good time and be acknowledged in writing by the relevant utility, with confirmation that the services have or will be isolated or disconnected.

3

Where such disconnection is not possible, any pipes or cables should be clearly identified, marked and protected to ensure that they are not disturbed during the works.

4

If overhead power lines are present, care needs to be taken, particularly where machines, cranes or excavators with high reach are to be used. Adequate control measures should be put in place (e.g. warning goalposts).

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1.5.6.22 Contractors 1

Competent contractors should be carefully selected and appointed. Their activities should be detailed in the health and safety method statement and incorporated into the health and safety plan.

2

All contractors must be adequately supervised, controlled and made aware of any site rules and emergency procedures.

1.5.6.23 Plant and equipment on site 1

Confirmation that personnel operating the machinery and equipment have been trained in their safe and proper use for the types of machine being operated) should also be kept readily available.

2

All plant, machinery and any associated equipment should be properly isolated and secured at the end of each shift.

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1.5.6.24 Site signage and security 1

The demolition area must be clearly defined by both physical barriers and adequate signage.

2

The demolition zone and exclusion areas may vary quite dramatically during the different activities which will take place on the site and must be properly maintained and controlled.

3

Typical signage on demolition sites includes the following text:

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Danger – demolition in progress - No unauthorised access

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Safety helmets must be worn at all times

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existing walls with adequate secured hoarding to a minimum of 1.8 (but preferably 2.4) metres high, sheeted in plywood or corrugated iron sheeting

(b)

an existing access scaffold with hoarding around the base as above

(c)

temporary ready fencing securely bolted together.

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Typical physical barriers may include the following:

Where there is the likelihood of trespassers or vandals, 24-hour security arrangements may have to be implemented.

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[Organisation’s contact details]


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1.5.6.25 Protection of people

The hierarchy of risk management must be applied, i.e. where possible avoid the risk, then reduce, manage and control to an acceptable level of protection.

2

Where demolition is being carried out above or unavoidably close to the public, adequate protection must be provided, e.g. fully sheeted scaffold with either 'Monarflex' or debris netting. If necessary, also provide scaffold fans and walkways.

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1.5.6.26 Access and egress

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Safe access and egress, both to the site and the workplace, must be clearly defined and maintained at all times for use by personnel, equipment, vehicles and emergency services.

2

Where practicable, pedestrians should be segregated from vehicles, plant and equipment movements.

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1.5.6.27 General site safety 1

Adequate procedures for action in the case of an emergency should be developed, implemented and communicated to all on site.

2

Adequate fire-fighting equipment must be available at all times, especially when any hot work is being undertaken.

3

A telephone or another form of communication must always be available on site to summon emergency services as necessary.

1.5.6.28 Welfare 1

The Contractor is responsible for ensuring that there are adequate and maintained welfare facilities.

1.5.6.29 First aid 1

An assessment should have been carried out by the demolition contractor.

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2

This will confirm the adequacy or otherwise of the company's arrangements for first aid. Any shortcoming identified by the assessment must be rectified.

3

On a demolition site it is envisaged that the minimum requirement will be a trained first aider or a number of trained emergency aiders, all with access to adequate first-aid facilities.

1.5.6.30 Scaffolding and access equipment platforms All access scaffolding or equipment must be fit for its purpose, properly designed, constructed of sound material and not so overloaded as to risk a collapse.

2

Scaffolding that is to be fitted with fans, debris netting or sheeting must be designed to take into account wind loadings and the changing conditions on site (e.g. the partial removal of structures which will affect the wind loading and ties). It is essential to ensure that the scaffold contractor fully understands the intended demolition method so that they can decide on the placement of scaffold ties.

3

Whenever scaffolding is provided as a means of access to the workplace, the contractor should ensure that the completed scaffolding has a handover certificate before allowing any of their personnel to work on it. Alterations to scaffolding must only be carried out by specialist competent persons.

4

It is the responsibility of the Contractor that scaffolding is inspected regularly and that suitable records of inspections are kept.

5

Mobile tower scaffolds should be erected in accordance with the manufacturer's instructions by trained personnel only.

6

In line with good practice, access should be by stair towers; however, ladders that are used for access to working platforms should be:

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free from defects and not painted

(b)

placed on a firm footing

(c)

used at an angle of approximately 75° (1 part out at the base to 4 parts up)

(d)

securely fixed at the top

(e)

extend at least five rungs (1 metre) above the working platform unless an adequate, separate handhold is provided.

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(a)

Where the demolition work requires that a progressive dismantling of the scaffolding takes place, attention must be paid to the remaining scaffold's stability, for example the adequacy of the remaining working platforms, ties and bracing.

8

After each time that the scaffold is modified and before it is next occupied, it must be inspected by a competent person to certify that it is still safe to work on, and a record of the inspection made

9

Where self-propelled mobile access platforms are used, Contractors must ensure that the operator is properly and adequately trained.

10

Additionally, care must be taken to ensure ground conditions are acceptable for these platforms.

11

Where the work requires employees to work from cradles (and/or suspended baskets) attached to a crane, a deadman's handle should be fitted with the ability to be power lowered only.

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1.5.6.31 Fall-arrest equipment Operatives must receive training in the inspection and safe use of safety harnesses, worn at all times when working in such equipment. These harnesses must be secured to an anchor point in the equipment. The harness and lanyard must be inspected each time they are worn. This is very important for anyone involved in hot works which could result in damage to a harness or lanyard.

2

With the progressive nature of demolition projects, harnesses are commonly used to prove a quick solution to a difficult access problem. It is vital that the following basic check is performed to avoid selecting an anchor point that is simply too close to the ground. The wearer needs to allow for: their height

(b)

the length of the lanyard

(c)

the extended length of any fall absorption device.

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In many instances this will mean that a minimum of a 5.5 m 'fall distance' is required to enable a fall to be safely arrested. This needs to be factored into the plan for working at height. It does not mean that harnesses may not be the safest way to do the work; just that restraint lanyards or work positioning harnesses, as opposed to fall-arrest equipment, are more appropriate in some circumstances.

4

There is significant concern regarding how long someone can survive if they do fall whilst wearing a harness and are suspended in it. Unless they are rescued immediately they are likely to suffer from a potentially serious medical condition known as 'suspension trauma'. Before work starts an effective rescue plan must be developed, which would ensure that someone who has fallen is rescued as soon as is practical and certainly within 10 minutes.

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in the design of a facade retention scheme

(b)

where there is doubt over the building's stability

(c)

where there is doubt about the proposed method of demolition

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(a)

where there is doubt about the capacity of the building to take loadings.

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The expertise of a structural engineer must be used in the following cases:

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1.5.6.32 Structural engineers

It is good practice to consult a structural engineer at the planning stage of demolition to avoid uncontrolled collapse.

1.5.6.33 Methods of demolition 1

This section gives an outline of the types of demolition techniques commonly employed.

Risk assessments, method statements and sequence 2

The key to a successful demolition is to ensure the appropriate risk assessments and method statements have been developed to identify the correct sequence of carrying out the work. These must be fit for purpose, clearly communicated and understood by the persons using them.

Partial demolition 3

Partial demolition is often carried out where refurbishment is being undertaken and can include facade retention. In any demolition, daily or, if required, more frequent checks should

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be carried out to confirm the stability of the remaining structure. 4

If at any time during the demolition the structure appears or becomes unsafe, all workers should be withdrawn until actions have been taken to remove any danger.

Complete progressive demolition Progressive demolition is generally carried out in the reverse order to construction, and often follows the soft strip-out phase.

6

This is the most commonly used method of demolishing structures and should be detailed in the health and safety plan.

7

In high-rise buildings where a floor-by-floor demolition is being carried out, danger points should be recognised such as:

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structural stability

(b)

on floor loadings

(c)

falling debris

(d)

maintaining clear access and egress

(e)

risk of fire hazards

(f)

the need for secure edge protection.

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Demolition by deliberate collapse

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(a)

Demolition by deliberate collapse can be achieved by pre-weakening the structure, followed by explosives, remote mechanical demolition or pulling, using a wire rope.

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When explosives are being considered, only fully qualified explosive engineers should be used.

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Manual demolition techniques

Manual demolition techniques are used when other methods of demolition are not suitable or possible.

11

Some of the types of tools or operations that can be used in manual demolition are:

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(a)

hand tools

(b)

breakers, compressors or hammers

(c)

concrete nibblers or hydraulic pulverisers

(d)

stitch drilling

(e)

drilling and hydraulic bursting

(f)

drilling and expansive pastes

(g)

oxygen and propane cutting equipment

(h)

diamond cutting and sawing

(i)

steeple jacking.

General precautions 12

For brick or concrete structures: (a)

identify any pre-stressed or post-tensioned concrete beams that may be present within

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Section 11: Health and Safety Page 108 Part 1.05: Other hazardous Activities (Regulatory Document) the structure and determine a safe method of demolition

(b)

wherever practicable, carry out demolition in the reverse order to construction

(c)

maintain tools in good condition, and use them safely

(d)

use compressed air or portable electric power tools, from a 110 volt supply

(e)

make operatives fully aware of the safe procedures

(f)

in addition to site induction, ensure task and tool box talks are prepared, delivered and understood at key stages of the work.

As far as is reasonably practicable, employees should not work above each other and care must be taken to ensure that debris does not drop into other working areas.

14

If lift shafts or other formed openings are used to drop debris down, the openings must be adequately protected by either suitable guard-rails and toe-boards (with no gap between guard-rails and toe-boards exceeding 470 mm) or by other substantial, effective barriers. It may not be possible to guard an opening where plant such as a 'bob cat' is being used to bulldoze arisings into a shaft or chute. In such cases a safe system of work must be developed which is sufficiently robust to:

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stop the item of plant falling into the chute or shaft

(b)

control when materials will be loaded and unloaded to stop materials being tipped onto someone below

(c)

protect other workers from falling down the shaft.

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(a)

It is still acceptable to use window openings as a means of removing debris from upper floors under certain conditions. The opening would need to be protected so that operatives cannot fall whilst throwing the debris out and the landing zone must be completely protected so that materials cannot fall on anyone. Typically the area will be fenced off with mobile fence panels and then the material loaded with an excavator into a hook bin container. If the structure has more than two storeys, consideration should be given to creating an enclosed drop zone within a scaffold chute.

16

With regard to falling materials and exposed edges, where necessary danger areas (exclusion zones) must be created.

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Oxy-propane cutting equipment:

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Oxy-propane cutting equipment

(a)

should be inspected and tested for leaks before use

(b)

cylinders should be secured in an upright position

(c)

hoses should be secured with crimped fittings not jubilee clips

(d)

flashback arresters should always be fitted between cylinder gauges and hoses

(e)

operatives must be trained in the safe use of the equipment and wear the appropriate PPE (e.g. goggles and gloves).

18

Whenever oxy-propane cutting equipment is used, the correct fire-fighting equipment should always be available. All operatives should be trained in the safe use of fire extinguishers.

19

Hot work should generally be stopped for an agreed period before leaving site, typically one hour before finishing, to avoid the potential of fire.

Mechanical demolition techniques 20

Machinery used should be fit for purpose, used in safe working spaces, adequately protected

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(e.g. by ROPs and/or FOPs) and operated by authorised competent persons. Remote control demolition 21

This utilises specialised equipment, often in hazardous or aggressive environments (e.g. nuclear installations). The use of 'Brock' type machines is becoming more common and they offer possible solutions to the difficulties of complying with the problems of noise and vibration experienced during hand demolition.

Using a 360° excavator with multi-functional attachments This type of demolition is commonly used to demolish low buildings, or is used after other height reduction techniques have been carried out.

23

To avoid physical injury from movement of the parts of the building being demolished, the machine should work in its own zone and be guided by a signaller. The signaller should always be in visual contact with the machine driver when positioned close to the machine.

24

Whilst the machine driver is isolated from noise and dust, the signaller is not and may need to wear PPE depending on the findings of the risk assessments for the work being done, for example if an impact hammer is being used.

25

The height of the wall or building to be demolished should not normally be greater than the attack (maximum) reach of the machine.

26

In some circumstances, it is possible to create a ramp for the machine to sit on to increase the reach using rubble from previous demolition. Care must be taken to ensure that there has been sufficient compaction to avoid the machine sitting on an unstable base.

27

If the ramp is being created within a building, it is very important to keep the ramp separated from the outside walls to avoid surcharging them. In some very limited circumstances, undermining or undercutting when the machine cannot reach the top of the building may be acceptable. Any contractor selecting this method must implement a safe system of work that ensures: the stability of the structure is maintained

(b)

the protection of the driver from falling material.

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(a)

With regard to the second bullet-point, it is likely that a combination of methods, such as preweakening, will be employed to ensure the direction that the material will fall is controlled.

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Super high reach 360° excavators 29

Typically these machines have a reach between 15 and 50 metres plus the length of the fitted attachments for crunching concrete or shearing steels. The recommended working height for this type of machine is 75% of the maximum reach.

30

These sophisticated machines are often fitted with variable width tracks, which usually make them much heavier, giving increased ground-bearing pressure and reduced working envelopes. It is vital that any voids and ducts located where the machine will track are discovered and adequately filled. In terms of ground conditions, these machines should be considered more as a crane or piling frame in terms of stability, rather than an excavator.

General precautions Before using the demolition equipment, steps must be taken to ensure that the building is completely empty and that all services are isolated.

32

Because of the danger of debris falling onto the excavator and its driver, the machine should have a fitted cab guard and, as an added precaution, should be fitted with shatterproof glass.

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Demolition ball

Demolition using a ball is extremely rare due to the advent of super high reach machines. When a ball is used, the crane equipment must be heavy duty and only drop or pendulum (e.g. in line with the jib) balling techniques should be employed.

34

When a ball is employed, regular (e.g. hourly) inspections of the equipment must take place, paying particular attention to the attachments and shackles.

The demolition of bridges, pylons, masts, etc. requires specialised planning and techniques.

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General precautions

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An assessment by a structural engineer should be undertaken to see if the structure could be safely broken down into small component lifts.

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A comprehensive safe working plan must be developed providing a safe means of access, using a competent crane hire company and experienced slingers and signallers.

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Environmental considerations 38

Noise, dust, fumes, vibration and fire control need to be properly addressed before and during the demolition operation. Consideration should be given to the following points.

Noise 39

The contractor must ensure that a noise assessment has been carried out and that, where possible, people are kept out of the danger area.

40

Any machinery which is to be used in the demolition process should, as far as possible, be fitted and used with soundproofing equipment (e.g. exhaust silencers).

41

Where it is necessary for people to work within the area of noisy operations, adequate hearing protection must be provided and used as necessary. If the upper exposure action value is exceeded, or likely to be exceeded, hearing protection must be worn and hearing

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protection zones clearly indicated. 42

Where the findings of a risk assessment indicate that the hearing of any employee is at risk due to noise exposure at work, health surveillance, including hearing checks, must be provided.

43

British Standard 5228 gives advice on the provisions for noise control on demolition sites.

Dust 44

Nearly all demolition activities create dust and many require a COSHH assessment.

45

Taking simple precautions, such as the following, ensures the dust nuisance can be reduced to a minimum. Implementing techniques that reduce dust generation.

(b)

The use of light water sprays both before and during demolition are very effective. However, consideration should be given to any potential run-off contaminants that may be produced and to the proximity of demolition work to electrical services and drains.

(c)

Where demolition is being carried out inside a building and water sprays are inappropriate, local ventilation, using air movers and filters, can help to alleviate dust levels.

(d)

Dust masks, as any other personal protective equipment, should be used only as a last resort. Where any mask is used, the wearer must be face-fit tested for the mask.

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(a)

A comprehensive ' invasive asbestos survey must be undertaken prior to the demolition being started and preferably before contractors are invited to tender for the demolition.

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Asbestos

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Fumes

A cutting torch, used on steelwork, may produce toxic gases such as nitrogen dioxide. If a phosphate coating is present, phosphine may be produced. If a chlorinated solvent has been used, sulphides may be formed which have no smell until high toxic levels are present. Additionally, toxic metal fumes may be given off.

48

Attention is drawn particularly to lead (lead painted steelwork), cadmium (cadmium bolt heads) and zinc.

49

Before any hot work cutting is allowed, available information or paint samples may be required for analysis, a COSHH assessment should be undertaken, and the necessary control measures implemented.

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Vibration transmission 50

Vibration from demolition operations can cause damage to adjacent property and injury to personnel working on site or, in extreme cases, to members of the public. Exposure to vibration must be controlled.

51

The following points should be given consideration. (a)

Attempts should be made to establish the presence of any existing sources of vibration and whether vibration monitors are needed in sensitive locations.

(b)

Where buildings adjoining those to be demolished are being retained, separation should be carried out using hand tools rather than machinery.

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(c)

Necessary precautions should be taken or alternative equipment considered to alleviate the risk of hand-arm vibration syndrome (HAVS), e.g. 'vibration white finger' from continued use of vibrating tools.

52

With regard to the last point, the exposure time for most demolition hand tools is extremely short, and the contractor will need a robust policy which includes health surveillance to carry out hand demolition using demolition picks.

Fire and explosion risks Where flammable liquids, gases or vapours have been used, or were released in a building which is under demolition, any equipment, tank or pipes, etc. which could have contained such substances must be purged and tested for explosive gases prior to work taking place. Any work should be done under a Permit to Work system.

54

General hot work, using oxygen and propane cutting equipment, should be carried out only by operatives trained in its safe and proper use, wearing the appropriate personal protective equipment, i.e. goggles, gloves, overalls.

55

If the occasional burning of debris, such as wood or paper, is allowed on site, the fire must be as small as possible, well away from buildings, roadways, fuel stores, and kept under constant supervision.

56

All fires must be completely extinguished at least one hour before work stops for the day and checked again, to ensure there are no glowing embers before operatives leave the site.

57

Adequate fire-fighting equipment must be available, with fire points containing extinguishers in prominent and well-marked areas adjacent to the demolition operations.

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Recycling

Demolition works should therefore be reviewed carefully to identify what wastes will be produced, what actions will be taken to deal with these wastes.

59

In addition to removing recoverable items from demolition operations, it is becoming increasingly common to crush the resultant brick and concrete into a sub-base material for future construction purposes. Crushing on site should only take place when environmental conditions permit such actions. Environmental emissions (noise, fumes and dust) are required to be recorded at least three times daily on a check sheet. Operations should cease if there are excessive emissions which cross the site boundary.

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(b)

All materials to be recycled should be checked for any contaminants and dealt with in the correct manner to the required specification e.g. 6F2.

(c)

Operatives working on the crushers must be properly trained (both general training on the use of crushers and specific training in respect of the equipment being used).

(d)

Serious consideration must be given to the need for machinery guarding on crushers. A daily check sheet should be completed by the operator, which confirms that all guards are in place and the emergency stops are working.

(e)

Robust safe systems of work are required to deal with blockages. These often happen because the operator loading the crusher simply feeds in lumps that are too big, or because during the demolition process the machine driver did not sort the materials well and large lumps of timber have entered the stockpile.

(f)

All crusher operators are likely to require hearing checks and monitoring as the noise levels are normally high.

(g)

Even with the dust suppression systems operational, it is unlikely that disposable

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Section 11: Health and Safety Page 113 Part 1.05: Other hazardous Activities (Regulatory Document) masks will offer a high enough level of protection. A risk assessment will be required to determine the type of RPE. Face-fit testing may be required following this.

(h)

In many circumstances the operator acts as a picker. On some machines it is an accepted practice that the operator wears a full body harness and is attached to a strong point by a restraint lanyard to avoid them being pulled into the machine and crushed.

Removal and disposal of materials Before any materials are removed from site, both vehicular access to, and egress from, the site must be agreed. Where applicable, bog mats and wheel washing facilities should be provided to ensure that debris is not carried onto the highway. Depending on the nature of the material, consideration should be given to covering lorries to prevent dust and debris.

61

Daily records must be kept of materials taken off site.

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Demolition is not an exact science and if the job does not look or sound right there may be a problem. If you have any doubts about the job, or how it can be safely carried out, request further clarification before proceeding.

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Common errors and assumptions

Provide daily briefings to the workforce on complex projects.

(b)

Check for continuing safe working practices.

(c)

Ensure access and egress routes are properly maintained.

(d)

Ensure the site is kept tidy.

(e)

Ensure the site is, as far as possible, free from any piles of combustible rubbish.

(f)

Ensure that sufficient signs are available and clearly visible to warn of hazardous areas and activities.

(g)

Check the contractor's operatives are continuing to wear suitable protective equipment.

(h)

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Daily inspection by the site supervisor and/or Contractor

Check that an approved safe system of work is being followed.

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(i)

Check the progress and sequence of the job to ensure that it is being carried out in compliance with the health and safety plan.

The key to a successful and safe demolition project is to plan, implement, monitor and maintain a safe system of work.

DEMOLITION IS DANGEROUS, TECHNICAL AND ONLY FOR THE

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EXPERTS

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PLANNING AND SUPERVISION ARE PARAMOUNT

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Safety in Piling

1.5.7.1 Safety in Piling 1

Piling operations can give rise to different hazards dependent upon the type of piling being undertaken. Certain hazards are, however, generally common on all types of piling and the following gives both the general precautions to be taken and the special precautions relating to the different types of piling. Section 4 of the QCS covers technical aspects of piling operations.

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1.5.7.2 General precautions

For all types of piling it is essential that a working surface designed to support the plant & equipment safely when working and moving, is provided. Failure of the Working Platform (piling mat) accounts for 30% of dangerous occurrences involving piling equipment. Any such failure is potentially fatal. It is important that the responsibility for design, construction and maintenance of the working platform is established and agreed, before work commences. Piling contractors will provide details of their equipment to assist contractors in constructing suitable access and working surface in the piling area. Piling contractors are to ensure that their access and work area remains suitable and in good order.

2

Prior to piling, all underground services in the area should be located and marked where they cannot be rendered safe. It is important to consult the services authority in the area on these matters. A check should also be carried out to ensure that there are no cellars, underground watercourses, ground conditions or made up or soft ground, etc., which could create hazards during the operation. Consideration must also be given to potential instability, which may be caused by the weather.

3

Where the site is contaminated, consideration must be given to the type of piling used and additional welfare facilities provided.

4

Piling contractors should be requested to provide an appropriate written method statement to the contractor. It is essential that induction training and information specific to the method statement is provided to piling and site operatives.

5

Particular attention should be given to planning activities concurrent with piling including identifying safe working distances and pedestrian and traffic access routes.

6

All persons working on piling operations must wear safety helmets and footwear. Ear and eye protection must be provided and worn where necessary.

7

When piling from a pontoon or adjacent to water, personnel should wear self-inflating life jackets. Rescue equipment (e.g. a safety boat and lifebuoys with lifelines attached) must be kept ready for immediate use and enough men must know how to use it.

8

Where fluid concrete is used provision for the washing out of static plant and delivery vehicles must be made, as you must protect watercourses against pollution.

9

Rated capacity indicators / limiters (RCI/L) are not required to be fitted on piling rigs when used for normal piling operations. Likewise, an RCI/L - is not required when a rig is being used to erect another rig,provided that the weight of components is accurately known and does not exceed 75% of the safe working load (SWL) of the rig. However, if a rig with a SWL

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of more than one tonne is used for general lifting operations, such as the loading and transport of materials on site, it must be fitted with an RCI/L. 10

Machine operators must be trained, competent, medically fit and authorised by the contractor to operate the machine.

11

Piling rigs are classed as lifting equipment and therefore require a thorough examination after assembly and before being put into service at a new site or in a new location and at least every 12 months. Inspections should also be carried out at suitable intervals. Accessories for lifting (lifting gear) require a thorough examination at least every 6 months.

12

Piling rigs and cranes should only travel on slopes at gradients approved by the machine manufacturer and "slew pins" must be used in these circumstances to reduce the risk of overturning.

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Guards must be fitted to the dangerous parts of the rig.

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1.5.7.3 Use of Cranes with piling It is important to differentiate between cranes and piling rigs.

2

Cranes are widely used conventionally for load handling in association with piling activities. Some techniques (e.g. sheet piling) also use cranes to install piles.

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Piling rigs are either purpose made machines or cranes specially adapted for piling by the fitting of masts / leaders and / or sub assemblies to power boring equipment.

(b)

Cranes must be selected and used in accordance with BS 7121 or equivalent international standard.

(c)

Cranes, which have been employed on piling duties, should be subjected to a thorough examination before being returned to general lifting operations.

(d)

Any crane used for raising or lowering people must be fitted with a dead man's handle and the descent must be effectively controlled; the latter is currently achieved by power lowering. Properly constructed man carrying cages, designed to prevent crushing and falls of people that are unable to spin or tip, must be used. The cages should be regularly and carefully inspected. Any item of lifting equipment used to carry persons must be thoroughly examined by a competent person at six monthly intervals.

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1.5.7.4 Materials handling 1

Piles and other materials should be stacked safely on ground of equal bearing ability, with safe access for subsequent removal and use in mind.

2

Circular objects should be chocked to prevent rolling.

3

Where there are marked lifting points they should be used. Never lift bundles by their security ties, use the correct sling.

4

Flat and bundled items (e.g. sheet piles, bundles of reinforcement) must be lifted with the correct lifting accessories and spacers placed between layers so that chains etc. can be safely removed after setting down.

5

Hand tag lines should be used for long or bulky items which are likely to spin, especially in windy conditions.

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1.5.7.5 Piling Techniques Driven piling - other than sheet piling Specialist piling rigs incorporating a leader or mast which guides the pile driving hammer and driving head are used. Piles are fitted to the driving head, pitched at the required position by the rig and driven to the required depth. No spoil is generated. Piles may be extended to meet technical criteria. All machinery should be in good condition and no lifting equipment should be used unless there are current records of thorough examination and where appropriate, testing of the equipment in existence.

(b)

All control levers on the piling rig should be clearly marked to indicate their purpose and mode of operation.

(c)

Persons not directly involved must stand well clear at all times when the rig is operating.

(d)

Hearing protection will be required.

(e)

When piles are extended by welding, full precautions for temporarily securing the additional length and welding must be observed.

(f)

When piles are extended using proprietary jointing systems the manufacturer's safety and technical procedures must be followed.

(g)

Where persons have to approach the rig mast and the raised hammer for alignment and, or maintenance purposes the hammer must be secured to prevent its unintentional release.

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Driven sheet piling 2

The Contractor must consider the following simple factors in connection with the sheet piling process: (a)

how the piles are held in position during driving, – how the piles are to be threaded,

(b)

how the first pile is secured whilst the second is threaded, the overall scheme to devise a system to prevent the falls of persons and materials.

(c)

Piles can either be held in position during driving using a special leader arrangement attached to the crane or piling plant or, alternatively, a gate system may be used.

Gate systems A supporting system should be chosen which is appropriate for the operation, e.g. where short runs of sheet piling are required and accuracy is not the main criteria', then a single gate system may be used.

4

A single gate system is made up of a simple frame of either timber or steel gates supported by block a suitable distance above ground level. A shallow guide trench is normally dug to assist with the location of the sheet piles.

5

The "gate support system" shown is a two-gate system, made up from timber H-frames, set in concrete

6

Kelly Blocks. These H-frames are then spanned by RSJs (gates). If the gates are over 2m high, or over any potentially dangerous area, they must not be used as working platforms unless fitted with toe boards which rise at least 150mm and main guardrails at least 950mm above the walkway. Additionally, intermediate guardrails, or other rigid barriers, must be fitted so that there is not an unprotected gap of more than 475mm in height in the means of protection against a fall. Where such protection cannot be provided, access to slinging points must be gained by ladder and NOT by means of the gates.

7

Permanent ladder access must be secure and extend above the gates sufficiently to provide a safe handhold. (A distance of 1.05m is recommended).

8

If using a cantilever system, a tie-back should be used where possible, as well as kentledge to provide safe anchorage and stability of the frame.

9

When piling is progressing and temporary piles are used to support the gate system, it is advisable to use purpose made brackets and bolt them to the piles. Any welding necessary should be carried out by competent welders.

10

When constructing Kelly Blocks, reinforcement should be placed in the concrete base. Vertical RSJs should have a good "key". Vertical timber should not be cast into the block but should be wedged and bolted. Where doubt exists over the stability of Kelly Blocks, guy lines should be used. Lifting eyes should be cast into the blocks.

11

When using Kelly Blocks, it is essential to ensure that these are temporarily landed on an adequate foundation to prevent subsidence and overturn during piling operations. This is particularly applicable during works in rivers, etc.

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Pitching sheet piles 12

If shackle holes have to be burned in the pile, sharp burrs should be removed to prevent damage to shackle pins.

13

Remote release shackles should be used where possible and the sheet pile must not be lifted vertically without first checking that the pin is properly engaged through the sheet. The

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length of the operating rope must be less than the length of the pile and the rope should be secured around the pile to prevent snagging, or being caught in the wind and becoming inaccessible. If piles are too heavy for a remote release shackle and work cannot safely be carried out from a ladder, a lifting cage should be provided to gain access for unscrewing the shackle.

15

If a special lifting eye is to be welded to the pile for angled pitching, the weld should have a factor of safety of at least 2.

16

Long sheet piles should be pitched with a pile threader following the manufacturer's guidance for use. Where this is not possible, a pile pitching cage should be used. The cage should hang from an adjacent pile, the operatives wearing safety harnesses hooked to the adjacent pile before the crane hook is removed from the cage.

17

When sheet piles are being pitched it is essential to take particular care to ensure the stability of the first few piles, but especially the first pile. This may be achieved by fixing the pile to the gate at two points so that it cannot move within the plane of the gate. This action will also ensure that the pile is stable if an effective toe-in is not achieved due to hard/stony ground conditions.

18

When feeding sheet piles through top and bottom gates, use wood blocks or a bent bar. Never use a straight pinch bar, as fingers can easily be trapped.

19

Additional precautions are required for work carried out from ladders, e.g. Clutching: the ladder must be placed in the valley of a previously placed pile; the ladder must be footed and, when at the top of the ladder and both hands are required for clutching, a safety harness must be worn and secured to the pile using a girder grip.

20

Wedging: the ladder must be placed against the RSJ and footed; wedges should be prepositioned on the RSJ A 4lb lump hammer should be used as this can be swung with one hand. If two hands are required, a safety harness must be worn, with the lanyard wrapped around the RSJ or connected to a girder grip.

21

The work method must not be changed without the approval of the contractor responsible for the piling operation. If windy conditions make the handling of the sheet piles difficult, work must stop until the responsible person has been consulted and a safe method of continuing the work has been devised.

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Piling Hammers 22

The recommendations of BS 5228 Pt. 4: Code of practice for noise control applicable to piling operations, should be closely followed.

23

Hammers, and in particular all clamping bolts, should be regularly inspected and a record kept.

24

Use guide rope when positioning a hammer.

25

Stand clear when starting and operating.

26

ALL personnel should be at ground level during pile driving.

27

Should the piston of a hammer jam, the trip-lever should be pulled to the open position before removing the hammer from the pile.

28

Damaged high-pressure airlines or high voltage cables, feeding the hammer, can present a

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serious hazard to persons working in the vicinity of the operation. 29

Therefore it is important to keep supply lines/cables under constant observation to avoid damage by trapping or from sharp objects.

Double acting air hammers 30

All hose couplings should be properly manufactured and matched. The joining of rubber pipes to brass spigots should be by clamp and not hose clips.

31

Ensure that the oil bottle/filter lid is secure.

.

Internal drop hammers Always place a swivel between the hammer and hoist rope.

33

Attachment of a hoist rope should always be done using a properly matched anchor and pear; the dead end of the rope should be secured to itself using a bulldog clip or other approved means.

34

Intermediate linking shackle pins should be secured.

35

Hoist ropes should be inspected regularly during piling operations and a record of inspections kept

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Helmets and inserts

Pile helmets or crowns must be well constructed, strong enough and free from defect. Should packing or spacers be needed, they should be drilled, tapped and screwed, to secure in place, and then be welded. Remember that any welds to a solid cast helmet will eventually crack.

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Pile extraction

Where pile extraction is necessary, due allowance should be made for the frictional forces occurring between the pile and ground, in order to determine the correct size of crane and extractor.

38

It is good practice to use a tag line between hook and adjacent pile to prevent the extractor swinging out of control should the pile snap.

39

Care should be taken when lowering extracted piles to ensure that the load on the crane hook is kept vertical.

40

Where a crane is used to extract piles it is common practice for the rated capacity indicator to be disconnected to prevent damage. This is a legal operation in that the crane is effectively a "piling rig" whilst this work is taking place. However, the competent person for lifting operations must ensure that the machine remains within its safe working capacity throughout the operation. The RCI/L must be promptly connected before any other lifting work is attempted.

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Rotary Bored piling 41

This technique involves specialist piling equipment that bores a hole which, depending on ground conditions may be lined (cased). Relatively short rotating boring tools are used which are withdrawn from the ground fully loaded with spoil. Once the tool is above the ground the

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rig is commonly slewed off the bore and the spoil is discharged. Reinforcement bars and concrete are placed in the hole and any temporary casing is extracted to complete the process. Personnel not directly involved with the activity should be kept clear at all times, particularly from the boring and spin off (spoil discharge) areas.

(b)

Fixed guarding to Rotary Bored Piling Augers is not practicable due to the nature of the equipment. A controlled zone must be identified at each pile location and can be defined as a zone at 2m radius from the centre of the auger. A banksman must be in attendance at all times while the piling rig is active and must be given authority and responsibility to ensure only authorised persons are permitted within the zone. No person is permitted within the zone while the auger is rotating (this precludes manual cleaning of the auger). Should any manual intervention be required the auger must be stopped. An excavator can be used within the zone for the purposes of clearing spoil but only under the banksman’s supervision.

(c)

To remove spoil from the auger the loaded auger should be carefully slewed off the pile position to the discharge point in a controlled manner. When the auger is being spun off it should be as close to the ground as possible to minimise the spread of spoil and the auger spin speed should be only sufficient to empty the tool so as to minimise the spread of spoil.

(d)

Spoil from bores should be kept clear of access to the borehole.

(e)

Open bores must be fitted with a cover or other suitable protection to prevent people falling into them. Common practices include leaving the casing 1m above working platform level and the auger or other boring tool in the borehole.

(f)

Freshly completed piles must be marked individually or in blocks to minimise trip hazards from reinforcement and soft concrete. They should be backfilled as soon as technically possible, remembering that soft spots must remain highlighted for the safety of people and plant stability.

(g)

In the majority of circumstances there is no need for a person to enter a pile bore/shaft and this should be avoided. Remote means of inspection and sampling the sides of shafts should be used wherever possible.

(h)

Where entry into a pile bore / shaft is unavoidable the recommendations of British Standard BS 8008 or equivalent must be followed.

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All persons entering the controlled zone must be properly informed and instructed on the risks associated with this operation. The banksman must be trained on slinger signalling matters. The banksman must be identified.

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The guard forms a “natural” resting position for the banksman, this position is away from the auger.

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Auger guarding and mechanised cleaning

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CFA (Continuous Flight Auger) Piling With this technique specialist piling rigs screw an auger into the ground the full depth of the pile bore. Concrete is then pumped through the hollow auger stem and spoil is removed as the auger is withdrawn. Reinforcement is placed in the bore after concreting.

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The majority of rigs used for this type of piling have a certain amount of guarding achieved by extending the gate (guide), which is used to maintain the position of the augers. However this gate does need to be opened to allow the piling rig to achieve its full depth and to facilitate the rigging of the augers and the gate will not allow work immediately adjacent to structures, especially in corners.

(b)

A controlled zone must be identified at each pile location and can be defined as a zone at 2m radius from the centre of the auger. A banksman must be in attendance at all times while the piling rig is active and must be given authority and responsibility to ensure only authorised persons are permitted within the zone. No person is permitted within the zone while the auger is rotating (this precludes manual cleaning of the auger). Should any manual intervention be required the auger must be stopped. An excavator can be used within the zone for the purposes of clearing spoil but only under the banksman’s supervision

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All persons entering the controlled zone must be properly informed and instructed on the risks associated with the CFA piling operation. The banksman must be trained on slinger signalling matters. The banksman must be identified. Providing this procedure is strictly adhered to then this may be adopted as an alternative approach to the guarding of CFA augers when mechanical means of guarding is not reasonably practicable. (a)

Mechanical or automatic auger cleaning devices should be used. All control levers on the piling rig should be clearly marked to indicate their purpose and mode of operation.

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(c)

When ropes are subject to heavy wear, they must be frequently inspected and changed as necessary.

(d)

Similarly, the auger section joints and their wedges must be inspected on a daily basis for excessive wear.

(e)

Freshly completed piles must be marked individually or in blocks to minimise trip hazards from reinforcement and soft concrete. They should be backfilled as soon as technically possible, remembering that soft spots must remain highlighted for the safety of people and plant stability.

Tripod bored piling 46

A tripod is set up over the pile position and various tools are used to advance boring. These are raised and dropped by a rope winch attached to the tripod. Casings are driven to line the bore, their depth varying with ground conditions. Spoil is removed as boring progresses. Reinforcement and concrete is placed before the casings are withdrawn.


(a)

Each tripod leg must be identity marked and every tripod and winch marked with its safe working load (SWL). Identity marks must correspond with the examination records.

(b)

Ropes should be secured with suitable fastenings, e.g. bulldog clips. Where appropriate, properly constructed saddles or hard eyes should be used.

(c)

Knots must not be tied in any rope used for lifting.

(d)

The tripod legs must not be overspread or overloaded. The base plates should be adequate and secured to prevent any accidental movement of the rig.

(e)

Only the correct pins should be used in the sheerlegs (tripod).

(f)

All parts of the winch should be effectively guarded, although it is acknowledged that access to the winch drum is required to enable the rope to be pushed across the drum during a gear change.

(g)

Constant attention must be paid to the condition of rope, which should be changed as soon as it becomes necessary.

(h)

When a rope/chain block is being used to extract the casings, the capacity of the block must not exceed the capacity of the rig.

(i)

Under no circumstances must there be less than 2 full turns of the rope on the winch drum at any time.

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Other techniques

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Safety in Formwork/Falsework

1.5.8.1 Formwork/Falsework and reinforced concrete structures 1

Falsework is any temporary structure used to support a permanent structure during its erection and until it becomes self-supporting. This definition applies not only to in-situ concrete construction, but also to precast concrete structures, structural steel erection, and even such items as brick arches, indeed, any construction method where the permanent structure may have a period of instability, requiring support in the erection process. Note: Section 5 of the QCS covers use and handling of concrete.

1.5.8.2 Standard solutions Falsework covers an extremely wide range of temporary support methods and BS 5975 recognises that, in simpler and more commonplace situations, e.g. support of floors and beams involving light loadings and low height support (within the range of standard props) standard solutions can most likely be used instead of individual designs.

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Standard solutions are given in B5 5975. However, unless the job falls within the limitations of the particular standard solution, further design will be required.

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1.5.8.3 Causes of failure

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Incorrect estimation of loads to be supported.

(b)

Design error, or loading programme changes after design completed.

(c)

Inadequate detailing and/or execution of points of load transference.

(d)

Inadequate horizontal lacing and diagonal bracing to resist lateral loads.

(e)

Inadequate foundations.

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Within the above scope, it must be recognised that failure often does not result from one specific error or inadequacy. More likely it will be due to an accumulation of errors, not in themselves critical, which combine to erode the factor of safety to the point where failure occurs.

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Whatever category the work falls into, it is generally accepted by competent international authorities that the causes of failure fall into a number of well-defined areas:

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1.5.8.4 Design

The design of temporary works such as falsework comes within the scope of these regulations. Whether the falsework design is provided by standard solutions or by individual design, the parameters on which the design is to be based need to be clearly established. In this respect, it must be recognised that the loads imposed on falsework do not only arise from the permanent structure. Many will occur as a result of method and plant decisions.

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BS 5975 covers with the preparation and contents of the design brief in detail.

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The main risks are:

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people falling during erection and striking of formwork and assembly of the steel frame collapse of the formwork

(b)

materials falling while striking the formwork

(c)

manual handling of shutters, reinforcing bars etc

(d)

being struck by the concrete skip

(e)

silica dust and hand-arm vibration from scabbling operations

(f)

awkward postures and working positions for steel fixers

(g)

dermatitis and cement burns from wet concrete.

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(a)

designers should consider the manual handling risks when detailing size and length of the reinforcing bar;

(b)

fixing reinforcement steel in prefabricated sections in factory conditions and craning it into position so that work can be done on benches to reduce the need for bending down. Alternatively, using long-handled tools can reduce the need to bend over

(c)

using formwork systems that have edge protection and access designed in

(d)

minimising the need for scabbling by using retarders; and

(e)

using concrete pumps instead of cranes and skips.

The Contractor is to ensure that: a method statement has been agreed before work starts, and that it is followed.

(b)

guard rails or other suitable barriers to prevent falls are put in place as work progresses.

(c)

workers have safe access to the work -- it is not safe to stand on primary or other open timbers.

(d)

a safe means of access is used. Many formwork systems have purpose-designed fittings to allow access platforms to be fitted and they should be used (see Figure 29).

(e)

climbing up vertical sections of reinforcement or up the outside of column formwork is not permitted. A tower scaffold can provide safe access to columns (see Figure 30).

(f)

equipment is in good order before use. Do not use substitutes for the manufacturer's pins in adjustable props.

(g)

the formwork, falsework and temporary supports are checked, properly tied, footed, braced and supported before loading, and before pouring walls or columns.

(h)

workers are protected from wet concrete (provide gloves and Wellington boots and proper washing facilities) and silica dust (provide respirators or avoid the need to scabble by using a retarder).

(i)

loads are spread as evenly as possible on the temporary structure. Do not place large loads of timber, reinforcing bars or wet concrete in a localised area -- spread loads evenly.

(j)

it is known when back-propping is required and how soon the new structure can be loaded; and there is a planned safe dismantling procedure.

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Many of these risks can be reduced or removed by design and careful planning:

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Figure 29: A formwork system with multipurpose fittings

Figure 30: A tower scaffold provides a safe means of access to the columns

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Explosives


This subsection aims to give general guidance to Site Managers on the acquisition, keeping, transfer, storage, transportation and use of explosives in the construction industry. In addition, it is anticipated that the information will enable Sub Contractor's method statements and risk assessments to be assessed. Further guidance on the use of explosives is provided in BS 5607:1998 "Code of Practice for safe use of explosives in the construction industry". Advice on the explosives used in cartridge operated fixing tools is given in BS 4078 Part 1.

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Note: Section 2, Part 1.5 of the QCS covers explosives.

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Before any work involving explosives is planned and carried out the person responsible for the site, for example the Principal Contractor, must appoint someone with sufficient knowledge and experience to oversee this work. Even when a sub contractor will carry out the blasting the appointed Supervisor must satisfy him or herself that the planning, documents and implementation are satisfactory as this is obviously a high-risk operation. Similarly, the business actually carrying out the work with explosives must ensure that Supervisors and Shot firers are competent to carry out their work. The competence and training of Shot firers is dealt with later in the section.

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1.5.9.3 Preliminary survey

Before any work involving the use of explosives is started, a detailed survey should be made of the site and its adjoining areas. Where earthworks, tunnelling or demolition are involved, relevant information may be obtained from British Standards 6031, 6164 and 6187 respectively.

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Special attention should be given to the character and structure of the geographical strata to ensure that they are not likely to transmit ground vibration to areas where it is likely to cause damage. The affect on utilities, including underground and over-ground services, should be carefully considered.

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Prior notice of the intention to use explosives should be given to all those who may be affected. For example, the water; gas, electricity and telephone authorities, the police and airports.

Documentation 4

Eplosives may be acquired, or stored only by persons who hold a valid Explosives Certificate. This is usually referred to as the "acquire and keep" certificate. An Explosives Certificate may be issued for both acquisition and storage of explosives or for acquisition only. Certificates permitting acquisitions only should be obtained where it is intended to use explosives on the day they are delivered to site. An Explosive Certificate is not required for the acquisition or storage of cartridge operated tool cartridges which carry the following UN numbers: 0275, 0276, 0323 or 0381.

5

In addition to the explosives certificate the person ordering or taking delivery of explosives must be competent to do so and have received the relevant approvals from the competent authorities.

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Storage Guidance on the methods of storing and types of construction required for a store for explosives may be ontained from the competent authority. In addition, advice may also be obtained from the manufacturer of the explosives which are to be used. The storage facilities will be inspected and therefore it is important that the guidance and advice is complied with.

7

The movement of explosives into and out of the store must be recorded, and there must be a formal procedure for accepting delivery of explosives and for checking that they conform to the contents of the advice note. It is essential to ensure that detonators are stored separately from other explosives. The loss of any explosives must be reported to the police. No person may transfer explosives to another person unless he is satisfied that the transferee has an Explosive Certificate certifying him to be a fit person to acquire explosives. This does not prohibit employers from giving explosives to their employees, but it does mean that a Principle Contractor must check that a Sub-contractor has an Explosives Certificate before providing the Sub-contractor with explosives.

8

Explosives stores must be kept clean and free from grit.

9

Rubber Overshoes must be kept in each store and worn by people who are not wearing rubber soled footwear and have to enter the store. No iron or steel implements should be taken into explosives stores and no naked lights or other means of ignition should be taken within 25m of them.

10

The issuing of explosives should be restricted to persons who have been authorised in writing by the Site Manager.

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Regarding the transport of explosives on public roads, various duties on operators of vehicles include: (a)

the requirement for vehicles to be suitable, having regard to the type of explosives and quantity of explosives carried; quantity limits for various types of explosives are also imposed,

(b)

restrictions on the carriage of loads of mixed explosives,

(c)

the requirement for the marking of vehicles and containers, except where small quantities of certain types of explosives are carried,

(d)

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(e)

the requirement to take all reasonable steps to ensure safe and secure carriage,

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the requirement for written, specified information about the load to be kept on the vehicle,

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Vehicle operators must ensure that drivers have received adequate instruction and training on dangers which may arise, action to be taken in an emergency and on their duties. Drivers must attend an approved course, on successful completion of which they will be awarded a Vocational Training Certificate. Drivers must carry these certificates.

13

Finally, where explosives are carried on the public roadway, the safe system of transport must be prepared by a person with training and knowledge of the health and safety implications of carrying explosives. This requirement will normally apply to the supplier who should be organised so that he delivers directly to the explosive store on the day when blasting is taking place.

14

Further transport of explosives on site must be in a vehicle provided solely for this purpose and be under the control of the shot firer. The vehicle should be clean internally and carry a red flag to indicate the presence of explosives. Detonators should be separated from explosives by at least 1m during carriage; explosives which have already been fitted with

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detonators must not be carried in any vehicle. Detonators should be kept in a suitable container, with no metal parts that will come into contact with the detonators; it should be kept locked until access is required. Explosives should be protected from the weather during transit. "No Smoking" restrictions and a ban on the use of CB radios and mobile telephones in the immediate vicinity must be strictly observed. When explosives are being transported on site, only sufficient explosives for the work in hand should be drawn from the explosives store, and the vehicle carrying the explosives should go directly to the shot holes.

16

When explosives are brought on to a site where there is no lawful storage facility, (as outlined under "Documentation"), liaison may be necessary between the explosives engineer making the delivery and site management on such matters as emergency arrangements and the provision of safe parking away from obvious sources of ignition and other dangerous goods.

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Before explosives mixtures are manufactured on site an application for an application for approval is required. In addition, a small amount of record keeping is required.

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The actual mixing process itself is very simple although the manufacturers advice should be sought as to the provision and use of suitable equipment and the appropriate mixing ratios. Some further guidance on this subject can be found in BS 5607:1998.

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Suitable and sufficient steps must be taken to ensure that nobody is exposed to risk of injury from the use of explosives in construction work. In addition, persons undertaking the drilling of shot holes must be protected from the dangers associated with work at edges from which there is a risk of falling, dust from the drilling process, unguarded dangerous parts of machinery and the rupture of large diameter compressed air hoses. These are normally chained at the coupling to prevent them snaking about in the event of a burst.

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Before any blasting takes place, both audible and visual signalling systems, giving warning of blasting operations, should be established. These must be explained and publicised through the site Induction Training, Site Rules and clearly visible Signs affixed at the entrances to the site. Audible warnings should consist of a series of readily recognisable signals, which have a distinctive sound. Visual signs should take the form of clearly painted notices posted on all access roads and sited outside the danger area. Sentries should be posted with clear instructions as to when they can stop access to the site and when they can allow access.

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1.5.9.4 Shotfiring Competence of shotfirers 1

BS 5607:1998 sets out the training requirements for Shot Firers, these must be adhered to if safety is to be achieved.

General precautions 2

Before explosives are used on any particular site, a written system of work, applicable specifically to that site, should be prepared. The responsibilities of persons with specific duties, such as the Supervisor, Shot firer and Sentries should be detailed in writing. When the system of work is being prepared, consideration should be given to the following matters:

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Section 11: Health and Safety Page 129 Part 1.05: Other hazardous Activities (Regulatory Document) The development of the Blasting Specification.

(b)

The preparation of written Explosives Rules that, that can be easily understood by the workforce.

(c)

The need to post sentries and visual warning signs around the areas likely to be affected by the blast.

(d)

The need to ensure that the danger area is clear of all personnel immediately before firing occurs.

(e)

The need to have an audible means of giving warning that a shot is about to be fired and to sound the all clear.

(f)

The need to notify the police, the general public, or occupiers of adjacent properties of shot firing times.

(g)

The system of work should always emphasise the following general precautions: -

(h)

The importance of the shot firer satisfying himself that the danger zone is clear before firing a round and that, after firing, a complete check is made to ensure that no misfires or other hazards exist.

(i)

The banning of cigarettes, matches and naked lights within a radius of 10m from explosives and detonators. This is a legal requirement in quarries.

(j)

The prohibition of drilling into old sockets, as these may contain explosives or detonators, which may be detonated by a drill.

(k)

The use of only wooden rods for charging and stemming shot holes.

(l)

Shot holes should be minimum of 3mm larger than the cartridge diameter for normal holes and 13mm for deep holes. Before charging, shot holes should be proved clear by inserting a stemming rod to the bottom.

(m)

Cartridges should be inserted into the holes one at a time, and stemming should be completed only with suitable material, e.g. sand, clay, gypsum, etc.

(n)

As high explosives are initiated by the application of a powerful localised shock, exposure to any deliberate, accidental or random compressive action must be prevented.

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Electrical detonation allows shot firing from a remote location and also controls the precise instant of firing, thus increasing the safety factor. In addition, the use of timing delay detonators in the firing circuit significantly reduces the levels of vibration. The method is generally used as a number of shot holes can be connected together and fired as a group.

4

The making up of primed charges should normally be undertaken by the shot firer immediately prior to charging. A non-ferrous pricker must be used for piercing the explosive, making it ready to receive the detonator. On no account must any other form of pricker be used. Detonators must be firmly secured to the primer cartridge in such a manner as to prevent the detonator or wire becoming detached or damaged. The ends of the detonator leads must remain twisted together until all holes have been charged.

5

Where it is not possible to achieve safe conditions at the charging place (e.g. in very wet conditions), it will be necessary for priming explosives to be transported to the charging place. Such procedures will require additional careful planning.

6

All rock surfaces, rails, metal objects, cables etc. must be considered as potential sources of stray current and great care must be taken to prevent detonator lead wires coming into contact with them.

7

Good connection of the detonator leads, connecting wire and shot firing cables is essential.

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Before attempting to fire a shot electrically, the shot firer must test the continuity of the circuit with a suitable instrument before he connects the firing cable to the exploder. This testing procedure must be carried out only after all persons have left the shot firing area and the shot firer himself is in the firing position. The removable handle of the exploder must be kept in the shot firer's possession at all times. The handle may be inserted into the exploder immediately prior to firing only and it must be withdrawn immediately after firing. After the shot has been fired, the appointed shot firer must inspect the area of the blast for misfires, or any other sort of danger, before allowing people to return to the area.

9

When detonating near overhead electrical cables, consultation should take place with the electricity supplier, who may be able to make the cables dead for a limited period. Advice should be sought on the minimum distance permissible between an explosive charge and an overhead electric cable. The following distances may be used for guidance: 11-70kV

20m

(b)

132-400kV

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Premature ignition of electric detonators by electromagnetic energy from radar, radio and television transmitters is a possibility which should always be considered and this is why CB radios and mobile telephones should be excluded from the shot-firing area.

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Beamed transmitters, such as navigational aids and military installations often operate at a high power and, if the station is in direct line of sight of blasting operations, adequate investigations should be made and suitable precautions taken. Commercial radio transmitters may be potentially dangerous as the wavelengths used are often similar to the overall length of the proposed blasting circuit.

12

Television transmitters are not generally a hazard as they transmit horizontal beams from a high mast, but portable walkie-talkie equipment and unmodified car transmitters up to 5W in output should not be taken within 10m of any blasting operation. Modified car transmitters and CB radio transmitters, which may have been illegally modified to increase their power, are potentially dangerous at much larger distances. Users of electric detonators are recommended to discuss this matter with the manufacturer or supplier of their detonators. In any event, the use of CB radios on sites should be banned by notices placed at all entry points.

13

Electrical means of detonations must not be used during storm conditions when there is thunder and lightning in the vicinity. The possibility of uncontrolled detonation should not necessarily prevent the use of this type of firing method. However, the manufacture/supplier must be consulted to ensure that the firing initiation system is appropriate for the circumstances.

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Detonating cord 14

Detonating cord is a very reliable initiator and its use for firing large groups of charges is free from some of the drawbacks of electrical shot firing such as current leakage problems. However, detonating cord must be protected from rain and ground water as moisture penetration can cause transmission failures. Covering the ends of the cord with waterproof tape may prove effective, but if conditions are very wet, the use of sealing compounds may be necessary. When laying out detonating cord, it is essential to ensure that branch lines do not cross over the main line, as on detonation a branch line may be severed, resulting in a misfire in the shot hole which it is serving. Detonating cord must not be kinked or knotted, otherwise transmission failure may occur. In use, detonating cord passes down the outside of explosive cartridges to the bottom of the shot hole, so care should be exercised when using a stemming rod otherwise the cord may be broken or damaged. Breakage of cord can also result from excessive tensioning, repeated stretching or the imposition of a sustained load. The power core of detonating fuse is liable to detonate, with the risk of serious injury if subjected to impact or shock. Detonating cord should always be protected from friction and

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heat. Shotfiring using safety fuse In surface blasting applications, the use of safety fuse is virtually restricted to single shotfiring operations such as the "popping" of large boulders. This is because accurate timing cannot be achieved and, if used in a group, an erratic timing sequence would result. However, safety fuse may be used where it is considered dangerous to use electrical detonation due to the presence of nearby electrical hazards.

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Safety fuse is used in conjunction with a plain detonator. The fuse is inserted into the open end of the detonator, which is secured by crimping on to the fuse. The correct crimping tool must be used. A primed charge is made up by inserting the detonator into a hole prepared in the primer cartridge.

17

The length of safety fuse must allow the shot firer and assistants ample time to walk to a place of safety after ignition. No single shots should be fired by fuse less than 1m in length, nor any shot in a round be fired by fuse less than 1.25m in length. A shot firer must not attempt to ignite more than six individual shots in a round. Only fuse lighters, specifically designed for the purpose, should be used.

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The following additional precautions are relevant to tunnelling and shaft sinking:

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Storage

Where it is necessary to store explosives in the tunnel between blasting operations, proper reserve stations should be excavated and fitted with steel doors. Reserve stations should not be nearer than 300m to the tunnel face. Reserve stations are not authorised storage places. Any explosives remaining in them at the end of a shift should be returned to the licensed explosives store or magazine.

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Explosives should be transported to the tunnel face in a clearly marked special mine car, lined with timber and having top or side lids fitted with padlocks. Explosives must not be carried on the driving locomotive itself.

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Drilling and charging 4

Drilling patterns should adhere to the agreed profile. All shot holes should terminate at the same vertical plane, except those drilled for cut shots and easers. If the presence of gas is suspected, tests should be made at the mouth of each shot hole, and within 9m of the face prior to charging. Plastic water stemming, water stemming under pressure, or water gel capsules reduce dust and toxic fumes. If possible, explosives with non-toxic characteristics should be used in tunnelling operations.

5

No explosives or blasting accessories should be conveyed to the face until all drilling operations for the round to be charged have been completed.

Sockets left after blasting 6

The most common cause of severe accidents with explosives in tunnelling results from drilling into sockets containing explosives which were not fired in the previous round. It is essential that drilling into such sockets be avoided.

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Electrical faults and hazards 7

Short-circuiting or current leakage from the circuit to earth is more likely to occur when conditions are wet. Ground water from rock fissures often contains mineral salts, which greatly increase its electrical conductivity. Bare wire connections should not be allowed to dangle in water, nor be allowed to hang against a wet rock face.

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The risk of premature explosion during electric storms is particularly high in tunnelling work. Dangerous static charges can also build up in compressed air equipment, and it is essential that such equipment should be positively earthed. Another hazard is from portable electric lighting cables; such lights should be removed to at least 9m from the face when preparing or charging blasts. Power to drilling and other equipment should also be switched off or completely isolated, when explosives and detonators are in the vicinity.

Serious shock and flash wave effects can be experienced in tunnel blasting work. In straight tunnel work, the minimum distance from the face to the firing point should be at least 300m. A shorter distance may be acceptable where a cross- tunnel or special refuge provides protection but, in such cases, the dangers from ricochets and fumes must be assessed. Before the all clear is given, the shot firer must ensure that all fume has been adequately diluted or has dispersed. This may initially require gas testing with a stain tube detector or some other suitable testing device to establish the timescale at which fume dilution is such that it is safe for the workforce to return to the face. This testing must be repeating as the work progresses and written records kept to ensure that the re-entry timescales are appropriate. Miners are likely to be working on a bonus system and therefore re-entry may require a strong level of control!

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All shot-firing operations are likely to leave fragments of loose material on the face. These can fall and have been known to cause injury and in some cases, where inclined, sloping rock beds in tunnelling are concerned, death. These must therefore be removed or stablised before any work involving an approach to the face, where there is a risk from falling material, can begin. A cherry picker will provide a useful platform for scaling down and the Shot firer should not allow anyone to approach a face until he is satisfied that the face has been inspected and loose material cleared.

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1.5.9.6 Misfires Electrical shotfiring misfires 1

If an electrically initiated charge fails to fire, the shot firer must follow the following procedure: (a)

Remove the handle from the shot firing apparatus.

(b)

Disconnect the cable from the shot firing apparatus.

(c)

After waiting 5 minutes, examine the shot firing cable and connections for any defect. If one is found, it must be remedied.

(d)

Return to the firing point and make a further attempt to fire the shot.

(e)

If this second attempt to fire is unsuccessful, the circuit should be split in half and each half should be tested in turn to locate the fault.

(f)

The faulty half should then be split in two and again each half should be tested separately by continuing this process, the fault can be located. All such tests must be affected from the firing shelter.

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(g)

Once the faulty detonator has been located, the remainder of the circuit should be connected in series, omitting the faulty detonator. The leading wires of the faulty detonator should be connected by string to a suitable marker to facilitate recovery of the primer cartridge after firing.

(h)

After re-testing, the modified circuit should be fired. Dislodged material should then be searched for any undetonated cartridges.

(i)

If material in the vicinity of the misfired hole is not dislodged by the blast, recovery of the misfired charge may be attempted by firing shot relieving holes at a distance of at least 300mm from the misfired charge. A similar procedure should be adopted if a misfire is found after a blast has been fired.

(j)

Where misfires are encountered after firing a round, the face or structure is likely to be fractured and weakened. Any dangerous conditions must be rectified before the shot firer deals with the misfire.

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In the event of a misfire, the shotfirer must adopt the following procedure:-

Ensure that no one approaches the shot firing area until at least 30 minutes have elapsed.

(b)

At the expiration of the 30-minute period, inspect the safety detonation fuse and, if the cause of the misfire is clearly evident, rectify the fault and make a second attempt to fire the round.

(c)

If this second attempt to fire is unsuccessful, the shot firer may adopt one of the following procedures: -

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(a)

Remove the stemming by compressed air, or water, using a non-ferrous or rubber blowpipe. Insert a primer cartridge into the hole, re-stem and fire, or

(ii)

Drill a relieving hole at least 300mm away from the misfired charge, taking care to ensure that this hole is drilled parallel to the misfired hole. Load and fire the relieving hole in the normal way.

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(i)

After either of these procedures has been followed, a most careful search must be made of the debris for detonators and unexploded explosives.

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Safety fuse misfires

Records of misfires

Records should be kept of any misfires.

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1.5.9.7 Disposal of Explosives 1

Extreme care must be taken in the disposal of unwanted, or apparently deteriorated explosives. In general, explosives should be returned to manufacturers or suppliers although substances such as gelignite can be burned Manufacturers guidance is essential in this respect and the persons involved should avoid the fumes as they produce severe headaches. Guidance is also contained in booklet HS (G) 36 Disposal of explosives waste and the decontamination of explosives plant.

2

All empty explosive boxes must be thoroughly examined by the shot firer, taken to a safe place, at least 50m from the store or magazine, and burned.

END OF DOCUMENT

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Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 1


1.6

HUMAN FACTORS ......................................................................................... 1

1.6.1

Accident Prevention and Control...................................................................... 4

1.6.2

Accident Reporting and Investigation (RIDDOR) ........................................... 22

1.6.3

Behavioural Safety ......................................................................................... 43

1.6.4

Drugs and Alcohol Misuse ............................................................................. 57

1.6.5

Safety Critical Communication ....................................................................... 72

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FORWARD

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Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

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19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Accident Prevention and Control

1.6.1.1 Key points The construction industry consistently accounts for a disproportionately high number of fatalities and major accidents.

2

Everyone on site has their part to play in accident prevention.

3

Accident prevention has to be actively managed; a good safety record will not 'just happen'.

4

Reported details of accidents show that in the vast majority of cases the accident could easily have been prevented by taking simple precautions.

5

You may have no influence over these decisions but find that you need to challenge the health and safety implications that arise as a consequence of them.

6

The true 'cost of an accident' encompasses many considerations and goes way beyond the financial implications.

7

Statistics show that new starters on site, and those at both ends of the age spectrum, are the most prone to accidents.

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1.6.1.2 Definitions

There are many interpretations of the words 'Accident/Hazard/Risk', but it is generally agreed that the following definitions apply:

2

Accident is an unplanned, unscheduled, unwanted event or 'occurrence', or any undesired circumstance which may result in injury to persons and damage to property. The injured person may not be an employee and property may not belong to a Contractor.

3

Hazard is the potential to cause harm, including ill health and injury; damage to property, plant machinery or environment; production losses or liabilities.

4

Risk is the likelihood that a specified undesired event will occur due to the realisation of a hazard by or during work activities or by products created by work activities.

5

An alternative word that is sometimes used for an accident is 'incident'. The main difference in the use of this word is that an incident is something that happened which may or may not have resulted in an injury or damage.

6

This diagram is a modified version of the Bird's triangle. Its aim is to simply demonstrate the approximate relationships between the different 'levels' of accident that occur. The triangle shows that for each fatality there will be several major injuries, a higher number of 'over-3-day' accidents and so on. In theory, if the number of minor accidents can be reduced, the base of the triangle will be shortened thereby having a beneficial effect at all levels with possibly no fatalities.

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The problem with this theory, and most of the other accident reduction models, is that frequently an incident can occur which results in no injury or even particular loss. However, the same incident under a slightly different set of circumstances could be a fatal accident. This makes accident prevention more difficult, particularly if the incidents go unreported.

1.6.1.3 The cost of accidents

(b)

loss of earnings

(c)

extra expense

(d)

continuing disability

(e)

incapacity for the same job

(f)

incapacity for activities outside the job

(g)

consequent effect on dependants and friends.

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Cost to people directly responsible:

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pain and suffering

worry and stress

(b)

recriminations, guilt

(c)

extra work, for example, reports, training and recruitment

(d)

loss of credibility.

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Cost to the Contractor:

working time lost by victim

(b)

time lost by other employees out of sympathy, curiosity, discussion

(c)

time lost by supervisors and others investigating the accident

(d)

possible damage to machines or materials

(e)

idle time (replan, repair and reinstate job)

(f)

rise in insurance costs prosecution under Qatar Law

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Cost to the victim:

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(h)

damage to reputation

(i)

possible failure to obtain work.

Cost to the working group: (a)

shock

(b)

personal grief

(c)

low morale

(d)

effects on production.

Cost to the State of Qatar: (a)

in social and economic terms, accidents are an unwanted expense

(b)

hundreds of thousands of person-day production lost each year

(c)

hundreds of hospital beds occupied

(d)

financial sums paid in death benefits

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(e)


Page 6

countless scores of lives changed for the worse.

6

Whilst there can be no complete end cost figure, the size of the problem can be seen to be huge. Therefore anything that helps to reduce the number of accidents must benefit both the nation and the individuals concerned.

7

The consequences of each accident are considered from different standpoints: vocational - future job prospects

(b)

financial - loss of earnings

(c)

social - standard-of-life issue

(d)

behavioural - reliance on medication, inability to concentrate, inability to sleep, illtemper, and so on

(e)

psychological - mood swings, loss of memory, emotional instability and guilt.

.

(a)

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1.6.1.4 Causes of accidents

Examining accident details will help to establish common factors and trends, revealing any weaknesses in a Contractors health and safety management system.

2

Accidents can be caused by the unsafe acts and attitudes of people at work, which result in unsafe conditions being created. They are also caused by a lack of foresight or planning, which may be a failure to set up a safe system of work, or failure to appreciate the results of risk assessments, COSHH assessments or other similar activities.

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Unsafe people create unsafe conditions which cause ACCIDENTS

It is impossible to list all the different types of unsafe acts and unsafe conditions which are found to exist in the Qatar construction industry. However, it is worth recording those which have been the most frequent known causes of accidents on construction sites:

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injury or damage

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and these accidents often result in

(a)

lack of planning

(b)

lack of management control and supervision

(c)

lack of knowledge of good safety techniques

(d)

lack of safety awareness

(e)

unsafe methods of working at height, including the use of working platforms, scaffolds, alloy towers, ladders and trestles

(f)

incorrect use of machinery, excavators, loaders, diggers, piling rigs, pneumatic drills

(g)

failure to segregate operating plant and pedestrians

(h)

failure to inspect and maintain all types of machinery, including ropes and hoists, lifting gear

(i)

incorrect use of tools and equipment, hand tools, power tools

(j)

use of faulty equipment with improvised repairs and modification of ladders, hand and power tools, trestles, ladders, fittings, fixings

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unsafe manual handling, lifting, loading, moving, stacking, storing

(l)

working at unsafe speeds on machines or with power tools, lifts, hoists

(m)

overloading of working places, scaffolds, false work, hoists, ropes, gin wheels, machines, vehicles, roofs

(n)

removal of guards from scaffolds, working platforms, machinery and excavations

(o)

failure to use protective safety

(p)

equipment, helmets, goggles, gloves, masks, clothing, footwear

(q)

unauthorised operation of tools, machinery, vehicles, equipment

(r)

ignoring or failure to use safety signals, signs and warning devices

(s)

ignoring established rules, safe procedures or work methods

(t)

throwing or accidentally dropping objects from heights

(u)

leaving nails or other objects protruding from timber

(v)

spillage of grease or oil

(w)

smoking, creating a naked flame or sparks in an area where flammable materials are stored or are in use

(x)

operating mechanical plant and vehicles at unsafe speeds, disregarding clearances necessary whilst manoeuvring

(y)

failing to adapt and adhere to established safe systems of work and procedures

(z)

illegal methods of access or egress to the workplace

(aa)

unauthorised interference with and misuse of plant and machinery

(bb)

carrying out work on moving parts with guards removed or safety devices inoperative

(cc)

riding on mechanical plant or vehicles in unauthorised and insecure places

(dd)

slippery or muddy conditions underfoot

(ee)

not obeying COSHH and risk assessments

(ff)

failure to warn others within the workplace

(gg)

failure to observe statutory or company or site requirements

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distracting people at work indulging in horseplay

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(jj)

failure to report faulty or unsafe equipment, or dangerous occurrences and incidents

(kk)

creating unstable structures.

1.6.1.5 Duties of the Contractors 1

The scope of Contractors responsibilities under this Regulatory Document is both wide and demanding. Some of these duties are detailed below.

1.6.1.6 The Health and Safety at Work 2

Contractor’s duties include: (a)

It shall be the duty of every Contractor to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees.

(b)

the provision and maintenance of plant and systems of work that are, so far as is reasonably practicable, safe and without risks to health;

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Page 8

arrangements for ensuring, so far as is reasonably practicable, safety and absence of risks to health in connection with the use, handling, storage and transport of articles and substances;

(d)

the provision of such information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of his employees;

(e)

so far as is reasonably practicable as regards any place of work under the Contractors control, the maintenance of it in a condition that is safe and without risks to health and the provision and maintenance of means of access to and egress from it that are safe and without such risks;

(f)

the provision and maintenance of a working environment for his employees that is, so far as is reasonably practicable, safe without risks to health, and adequate as regards facilities and arrangements for their welfare at work.

(g)

It shall be the duty of every Contractor to conduct his undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in his employment who may be affected are not thereby exposed to risks to their health or safety.

1.6.1.7 The Management of Health and Safety at Work

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(c)

These Regulations require that all Contractors carry out a risk assessment of all work operations and workplaces.

2

Furthermore, the Contractors must:

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put into operation whatever preventative and protective measures are necessary, and take effective steps to monitor these measures

(b)

provide information both to employees and those not employed by him as to the risks to health and safety generated by his operations

(c)

provide adequate training:

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upon recruitment

(ii)

when new processes are introduced

(iii)

when new work equipment is installed

(iv)

when new systems of work are introduced.

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Refresher training should be carried out during working hours.

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Every Contractor must: (a)

ensure that PPE is available, is compatible with and appropriate for the risk

(b)

carry out assessments for risks to health and safety

(c)

carry out periodic reviews of those assessments

(d)

ensure that any PPE is maintained and properly stored when not in use

(e)

give adequate training, information and instruction

(f)

take steps to ensure that any PPE supplied is properly used

(g)

provide any necessary PPE free of charge.


Contractors must ensure that:

QCS 2014


the work equipment provided is suitable for the purpose for which it is to be used

(b)

it is only used for the purpose it is intended

(c)

it is maintained in good working order

(d)

equipment logs are maintained, where necessary

(e)

the use of equipment is restricted to those so designated

(f)

repairs are only carried out by trained and competent personnel

(g)

any necessary maintenance or inspections recommended by the manufacturer are carried out

(h)

persons who are required to operate the equipment have received adequate information and training

(i)

safe systems of work are implemented and followed

(j)

maintenance can be done safely

(k)

controls are fitted to the machine.

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All Contractors must ensure that:

all lifting operations are properly planned by a competent person, are appropriately supervised and undertaken in a safe manner

(b)

each selected item of lifting equipment is suitable for the intended purpose, and is of adequate strength and stability for each load

(c)

the lifting equipment is positioned and installed to minimise the risk of:

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the equipment or load striking personnel

(ii)

the load drifting, falling or being unintentionally released

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(a)

an examination schedule is drawn up by a competent person and that all lifting equipment is thoroughly examined: before being used for the first time, following installation or assembly at a new location

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every six months for lifting accessories (abseil ropes/harnesses, chains, slings, and so on) and equipment used to lift people; or

(iii)

every 12 months for other lifting equipment

(iv)

after any activity or event liable to jeopardise its integrity

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suitable equipment is installed to prevent anyone falling down a hoistway or shaft.

If the equipment is to be used for lifting people, the Contractors must ensure that: (a)

people cannot be crushed, trapped, struck or fall from the carrier

(b)

the equipment has devices to prevent a carrier from falling

(c)

if a person becomes trapped in a carrier, they can be freed.


Every Contractor must: (a)

ensure that employees avoid risks to health and safety when manual handling

(b)

make an assessment of all lifting operations

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(c)

take steps to eliminate injuries

(d)

give information with regard to weights and centres of gravity of items to be handled.

1.6.1.12 Workplace Disability Awareness 1

Where people with a disability are employed on site, even, for example, administrative staff in site offices or staff in catering facilities, this is a part of the accident prevention process Contractors may have to consider the appropriate safety management steps to be taken to ensure the safety of employees who have a disability, based upon the findings of a risk assessment.

2

Examples of such steps might be: the provision of a disabled toilet

(b)

Providing assistance for employees with hearing difficulties who may not be aware of alarms

(c)

ensuring the effectiveness of site induction for those who have hearing problems or learning difficulties

(d)

considering the needs of people with physical disabilities with regard to access to site offices and other areas

(e)

the provision of appropriate evacuation equipment for evacuating people with physical disabilities from site offices and other areas

(f)

emergency escape routes that can be used by people with disabilities and, where appropriate, those assisting them.

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1.6.1.13 Duties of employees

Responsibilities of employees as follows.

2

It shall be the duty of every employee while at work:

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to take reasonable care for the health and safety of himself and of other persons who may be affected by his acts or omissions at work: and

(b)

as regards any duty or requirement imposed on his Contractors or any other person by or under any of the relevant statutory provisions, to co-operate with him so far as is necessary to enable that duty or requirement to be performed or complied with.

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No person shall intentionally or recklessly interfere with or misuse anything provided in the interests of health, safety or welfare in pursuance of any of the relevant statutory provisions.

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(a)


All employees must make full and safe use of systems of work implemented by their Contractors.


Employees must report any loss of, or any defect in, personal protective equipment.

1.6.1.16 Control of Substances Hazardous to Health 1

Employees must: (a)

make full and proper use of any control measure put in place to prevent harmful exposure to a substance hazard to health

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Page 11

report the fact to the Contractors if the control measure is thought to be defective.


Employees must: (a)

report to the Contractors (or supervisor) any work activity or defect which is thought could endanger the safety of anyone who is working at height

(b)

use any work equipment (including safety devices) provided for safe working at height in accordance with any training and instructions provided.

1.6.1.18 Planning for health and safety Despite the effort made by the majority to fulfil their legal, moral and social obligations, difficulties are often encountered in human behaviour which require time and tolerance before acceptable safety standards are achieved. It is essential that careful consideration is given to pre-planning, communication, training, supervision and the dissemination of information, if safe systems and places of work are to be developed and maintained.

2

All of the following measures can make a significant contribution towards the prevention of accidents through the implementation of safe systems of work and procedures:

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Allowing enough money and time to do the work safely.

(b)

Adequate protection and guarding of working places, platforms, machinery, tools, plant and equipment.

(c)

Implementation of an adequate system for the maintenance and repair of plant, equipment and tools.

(d)

Provision of appropriate training, instruction and information at all levels, including safety training.

(e)

Provision of adequate supervision and control.

(f)

Displaying the appropriate notices and warning signs.

(g)

Planning, siting and/or stacking materials and equipment to allow safe access or egress of site plant, vehicles and equipment.

(h)

Pre-planning and organisation of site layout which will provide maximum efficiency, safety and progression of the work sequences and operations.

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The provision of adequate resources and equipment to protect and maintain the health and welfare of all personnel.

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(a)

(j)

Producing, declaring, maintaining and supporting a safety policy, updating as appropriate to accommodate advancement and development.

(k)

Bringing about and maintaining an awareness of, and compliance with, all safety legislation and information relating to systems and procedures of work.

1.6.1.19 Factors likely to affect safety at work 1

Safety at work will be affected by: (a)

human and personal factors

(b)

job factors

(c)

environmental factors.

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1.6.1.20 Human and personal factors 1

Attitudes of people at work often play an important part in the prevention of accidents, and conversely, a wrong attitude can cause accidents to happen.

2

Attitudes differ depending on the person, for example their: age

(b)

general health

(c)

physique and ability

(d)

disabilities, if any

(e)

senses of smell, sight, hearing, touch and, sometimes, taste

(f)

natural dexterity, agility

(g)

education and qualifications

(h)

training and skills

(i)

home and social life

(j)

status at home and work

(k)

position in peer group.

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1.6.1.21 Job factors

Every work activity has a degree of inherent hazard. Building and construction sites can be particularly hazardous and demand the co-ordination of a large number of trades, skills and activities at any one time.

2

Particular attention should be given to: (a)

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(b)

adequacy, time and resources to do the job

(c)

provision of tools and equipment which are safe to use and properly maintained

(d)

implementation of safe systems of work

(e)

personnel who are unfamiliar with established safe systems of work and practices

(f)

personnel who are new to a specific worksite or unfamiliar with a new working environment

(g)

those lacking induction training and/or experience

(h)

the provision of adequate training, information and supervision

(i)

balanced workload

(j)

fatigue and boredom

(k)

the nature of the activity.

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the adequacy of time and resources to plan the job

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1.6.1.22 Environmental factors 1

The majority of people do not work in isolation. The attitudes of others in a working group, for example, managers, supervisors, safety advisors, may help to prevent accidents.

2

The following details should also be considered: the accident record of the firm, site and working group

(b)

the interrelationship of people within the group

(c)

information and communication processing methods

(d)

weather conditions - hot, cold, wet, windy

(e)

working at heights, in confined spaces or underground

(f)

working conditions - noise, dust, light, ventilation

(g)

health and welfare facilities.

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Types of hazard include: obvious dangers

(b)

potentially dangerous situations, often resulting from late changes to planned activities, forced by unforeseen circumstances

(c)

operational hazards, including high risk activities and operations creating health hazards or risk of injury.

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1.6.1.23 Hazards

Examples of dangerous conditions which may exist at the workplace include: failure to comply with safe systems of work

(b)

the presence of highly flammable material and other fire hazards

(c)

dangerous materials - acidic, radioactive, corrosive and gaseous

(d)

insecurely stacked, slung, lifted and transported loads

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unsafe machinery, equipment and tools

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1.6.1.24 Obvious dangers

(f)

unsafe working area due to weather conditions

(g)

unsafe electrical, dust and gaseous conditions.

1.6.1.25 Potentially dangerous situations 1

Examples of circumstances which might result in an accident: (a)

personnel entering a new workplace for the first time

(b)

personnel uninformed/unaware of emergency procedures

(c)

working with machinery or tools with guards or fences removed

(d)

unauthorised repair to plant and equipment

(e)

adopting incorrect methods of lifting and handling loads

(f)

use of incorrect type of plant, tools or equipment for the work involved

(g)

unauthorised removal of guard-rails, or failure to replace them following removal for access of plant or materials

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inadequate clearance around moving plant or equipment (minimum 500 mm)

(i)

transport of insecure or unstable loads

(j)

dropping tools and materials from a height

(k)

unauthorised improvisation

(l)

failure to wear PPE

(m)

spillage of oil, grease, paint, flammable and corrosive liquids

(n)

working in unstable excavations, without adequate supervision and control

(o)

untidy working places

(p)

congested walkways and areas -creating a tripping hazard

(q)

working at heights or over water without edge and/or personal protection

(r)

inadequate, incorrect or badly placed lighting

(s)

overhead carriage of materials

(t)

uncontrolled release of dangerous gases, steam, compressed air

(u)

unsafe electrical equipment

(v)

buried services and overhead cables.

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1.6.1.26 Operational risks

.

(h)

Examples of work that require competence, careful monitoring and/or close supervision are listed below.

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High risk activities:

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demolition

(b)

anything involving tower cranes

(c)

working at heights

(d)

work involving explosives

(e)

excavations

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piling

work in confined spaces

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(a)

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(h)

operating cranes, lifting equipment and other moving plant

(i)

steel erection or sheet material cladding

(j)

steeple jacking and other rope access activities

(k)

use of chemicals or other substances for which the manufacturer has advised strict control and usage

(l)

work associated with live traffic.

Operations creating health hazards or risk of injury: (a)

work with lasers

(b)

jobs with continual high exposure to noise or vibration

(c)

jobs with continuous elements of the same type of manual handling such as block laying, kerb laying

(d)

work with asbestos and other toxic dusts

(e)

work with hazardous substances

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(f)

work involving radiography

(g)

work involving exposure to extremes of hot or cold.

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Activities which are tedious, repetitive, carried out in extreme climatic conditions, demand long periods of concentration or are physically tiring may require: (a)

careful selection of personnel

(b)

consideration of medical history of personnel involved

(c)

pre-planning and sequence of operation

(d)

frequent shift changing

(e)

use of mechanical handling aids.

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1.6.1.27 The implications of inexperience

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Young persons

In accordance with Labor Law 14 Article (86), a child who has not attained the age of sixteen may not be employed in a workplace of whatsoever nature and shall not be permitted to enter into any place of work such as a construction site.

2

A 'young person', is any person who is between the age of sixteen but has not reached the age of eighteen.

3

Contractors are to ensure that ALL young persons they employ are protected at work from any risk to their health or safety.

4

Before employing a young person, the Contractor must assess the risks to the young person's health and safety arising from the work they are required to do, in accordance with these Regulations. This assessment must take account of a number of factors, such as: the inexperience and immaturity of young persons, and their lack of awareness of risks

(b)

the type of any work equipment involved and the way it is used

(c)

the potential for exposure to physical, biological and chemical agents

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(a)

(d)

any health and safety training that is required for young persons.

Having carried out this assessment, Contractors must then determine whether the level of risk has been reduced to as low as is reasonably practicable. There is particular importance placed on avoiding work that:

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(a)

is beyond the young person's physical or psychological capacity

(b)

involves harmful exposure to agents which are toxic or carcinogenic, cause heritable genetic damage or harm to the unborn child or which in any way chronically affect human health

(c)

involves harmful exposure to radiation

(d)

involves the risk of accident, which it may be reasonably assumed cannot be recognised by young people owing to their insufficient attention to safety or lack of experience or training

(e)

involves exposure to physical agents such as extreme cold or heat, noise and vibration.

Consideration to the level of acceptable risk may be given for young persons between the ages of sixteen and eighteen, where the work is necessary for their training, and where they are properly supervised

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New starters 7

New starters on a site and inexperienced persons, of whatever age, have similar problems to those of young workers.

8

They are subjected to a new environment, rules, methods and procedures; under different supervision; working with new colleagues using a variety of tools, equipment and manual effort to produce the work required. The start of their health and safety training is usually an induction into the company that should cover the following:

(b)

company safety policy

(c)

health, welfare facilities, pattern of work, movement of materials, direction of movement, and so on

(d)

warning signals and signs

(e)

special processes, materials, precautions and restrictions

(f)

fire procedures, drills, alarms, escape routes

(g)

reporting hazards

(h)

good housekeeping

(i)

first aid procedures and the reporting of accidents

(j)

safety equipment and clothing

(k)

machinery hazards

(l)

introduction to supervisor, trainer, colleagues

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The need for refresher and continuance training should be reviewed at intervals and carried out as necessary.

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Older workers

(a)

over familiarity with the job general slowing of reactions

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It should be noted that the number of incidents to older workers is typically higher than average. There are various reasons which have been suggested, such as:

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responsibility of management and supervision

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(c)

general loss of strength and flexibility

(d)

pre-existing damage to body and systems

(e)

age-related degeneration of hearing and eyesight

What is also noteworthy is that when an older person is injured, often the recovery time is longer, because the injury is more severe than it would be for a younger person. The classic example is a fall from height. A young person may well have the speed and strength to avoid the fall, and if they do fall they often seem to land better and do less damage. With the older person, the fall seems more inevitable, the landing harder and the recovery time longer.

1.6.1.28 Site security 12

Contractors must take all reasonable and practical steps to ensure that sites are secure, for example by: (a)

providing a perimeter fence not less than 2 metres high, either close-boarded or meshed (mesh not exceeding 30 mm)

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(b)

ensuring that the site access is gated and locked when the site is unoccupied

(c)

maintaining reasonable surveillance when the site is open

(d)

ensuring materials are not stacked dangerously near fences

(e)

displaying suitable warning notices

(f)

guarding or protect obvious hazards

(g)

regularly inspecting perimeter fencing, especially for holes near the bottom or other damage through which children might gain access.

Where complete fencing of the site is impractical: guard or cover all excavations and holes where there is a danger of any person or any materials falling in. And, if left open or unattended, fence at every accessible part with a barrier, preferably of chain link fencing, not less than 2 metres in height

(b)

effectively immobilise vehicles and plant

(c)

stack materials to prevent any possible displacement and use racking where possible. This particularly applies to manhole rings, large diameter concrete pipes and cable drums, all of which could roll and crush a child

(d)

lock off electricity supplies or switch off at isolators in locked enclosures or the building

(e)

isolate gas supplies, keep cylinders in a locked enclosure

(f)

keep all tools and harmful chemicals in a locked enclosure, when the site is unoccupied

(g)

for ladders to elevated positions; block off the first 2 metres and chain all loose ladders or lock them in enclosures.

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1.6.1.29 Accident prevention

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Supervision and control

The accident trend can be strongly influenced by providing adequate training and supervision to control the worker, the machine or the equipment and the working environment.

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Accident prevention is the control of these factors The worker 2

It is essential to ensure that the worker: (a)

is adequately trained and informed of the activities they are expected to do

(b)

is aware of all the hazards in any activity they are expected to do

(c)

is competent to do the work or is under adequate suitably qualified supervision

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(d)

adopts a safe system of work

(e)

uses the protection provided

(f)

is aware of accident and emergency procedures

(g)

is aware of the company's health and safety policy in addition to rules applicable to the work.

The working environment 3

This applies to all areas of the site including workshop, stores, offices, depot and welfare facilities.

4

Regular checks are essential to ensure: floors are clean and level, not slippery, and free from debris

(b)

stairs, gangways and working platforms are adequately guarded and maintained

(c)

openings, edges and holes are adequately protected

(d)

projecting objects or obstacles are protected and guarded

(e)

adequate lighting is provided at workplaces

(f)

materials and equipment are stacked or stored correctly

(g)

approved warning signs are displayed where required or where hazards exist

(h)

there is adequate ventilation, protection and control when working in confined spaces

(i)

there are established systems of waste disposal

(j)

passages and escape routes are clearly defined, and marked KEEP CLEAR

(k)

there is provision and maintenance of adequate welfare facilities

(l)

best possible standards in working conditions are provided

(m)

safe systems of work are maintained

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(a)

there is adequate fire-fighting equipment and extinguishers, which are properly sited



an adequate level of security is established and maintained to prevent unauthorised visitors.

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

Equipment and machines

Ensure the following procedures and practices are observed:

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(a)

regular inspections by trained, competent persons

(b)

no defective equipment is used

(c)

defects are properly rectified

(d)

adequate servicing and maintenance

(e)

records and reports maintained

(f)

all moving parts adequately guarded or protected

(g)

manufacturers' literature and instructions available for operatives

(h)

proper handling, lifting and slinging of equipment

(i)

equipment and machines adequately secured when in use and parked

(j)

hand tools inspected and maintained.

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Near-miss reporting 6

The importance of learning from experience cannot be overstated. It is an essential element of accident prevention. A near-miss is an incident which had the potential to result in personal injury and/or damage to the structure under construction, plant and equipment or the environment. Contractors will decide on their criteria for categorising an incident as a near miss.

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The details of all near misses must be accurately and honestly reported to enable the circumstances to be investigated and measures put in place to prevent a recurrence. In many cases, the only person able to give a full and accurate account of what happened will be the person who 'got it wrong'.

8

To achieve an effective reporting system, the workforce must: trust that management will treat the incident fairly and objectively

(b)

be sufficiently trained in risk awareness to appreciate that a near miss has occurred. Some near misses may not be so obvious as the side of an excavation collapsing seconds after it was evacuated be encouraged to report near misses with the assurance that individuals involved will not be disadvantaged by their honesty

(c)

have confidence that the issues raised will be addressed, or else 'why bother?'

(d)

be provided with the means of promptly recording the details of exactly what happened and offering their opinion as to why it occurred.

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(a)

Contractors may find it is beneficial to provide easily accessible near-miss reporting forms which can be completed in privacy and anonymously if that is the individual's choice. However, anonymous reporting does not provide the opportunity for follow-up discussions to establish more details, and it may encourage malicious reports to be submitted.

10

There could be a case for rewarding the honesty of individuals who made a mistake but had the courage to compile a near-miss report, which ultimately resulted in a safer system of work being developed. Theirs was the first step in the chain of improvement. Evidence shows that near-miss reporting linked to a reward scheme has the best chance of succeeding.

11

An example of a near-miss reporting form is given in the appendix to this module. This example; requires that the person involved outlines the circumstances of the event, then passes the form to their supervisor or manager as appropriate

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(b)

requires the supervisor or manager to assess the details of the event and declare what remedial actions have been, or will be, taken

(c)

incorporates a tear-off slip providing feedback on the investigation, which is returned to the person raising the issue as confirmation that the circumstances have been investigated.

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Construction Site Safety 1.6.1 Appendix Example of a minor event/near-miss report ANY CONTRACTOR: MINOR EVENT/NEAR-MISS REPORT (page 1) Please use this form to report:

Personnel safety - near misses (NM) Plant safety - minor events or near misses (ME/NM) Environment - minor events or near misses (ME/NM)

A report can be raised by ANY PERSON DATE/TIME OF OCCURRENCENE

Name:

LOCATION OF OCCURRENCE

.

PERSON INVOLVED

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Date:

Section:

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Time:

TYPE OF OCCURRENCE

People

Plant

Environment

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Please identify the plant/procedures/people involved and any relevant identified factors which can be used to improve safety

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DESCRIPTION OF OCCURRENCE

Thank you for completing this form. Please hand it to your supervisor immediately for completion of the second part. This portion to be detached and returned to sender after the investigation.  …………………………………………………………………………………………………………………. Please print your name and telephone number so that we can get back to you for more information if necessary and to let you know the outcome of our investigation. Name:

Section:

Please turn over to page 2 to complete the form

Tel:

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ANY CONTRACTOR: MINOR EVENT/NEAR-MISS REPORT (page 2) Potential for loss/severity STATE: minor/serious/ major

ASSESSMENT OF THE OCCURRENCE BY SUPERVISOR OR PERSON INVOLVED e.g. section head, manager NB: if major or frequent are appropriate, consider producing an event report instead

Possibility for recurrence STATE: seldom/occasional/ frequent

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Direct cause:

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Root cause:

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Corrective actions already undertaken: please give details of any immediate actions taken to prevent recurrence or make safe

Signature:

Date:

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Supervisor's name:

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Suggested corrective actions:

Thank you for completing this form. Please send it to:

Feedback on investigation:

Name:

Reference:

Tel:

Date:

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Accident Reporting and Investigation (RIDDOR)

1.6.2.1 Key points It is important that all workplace accidents, no matter how minor, are reported to the injured person's Contractors, site manager or supervisor as appropriate.

2

Certain types of accident, cases of occupational diseases (when connected with specific work activities) and some dangerous occurrences, must be reported to the Qatar Administrative Authority.

3

Each Contractor should have a procedure for investigating workplace accidents.

4

The investigation of accidents will enable trends to be established and preventative measures put in place.

5

The level of investigation should be proportionate to the seriousness of the accident.

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It may be said that there is no such thing as an 'accident'. An accident is always someone's fault and it is by no means always the fault of the injured person.

2

You have to report deaths, serious injuries and dangerous occurrences immediately, and less serious injuries within 10 days. Certain occupational ill-health issues and diseases also have to be reported.

3

Establishing the responsibility for investigation and enforcement will be carried out automatically after the accident report has been received.

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1.6.2.3 Accident records

Records can be stored in any medium, including electronic, providing that printable copies are readily available if required.

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Records must include details of:

date, time and place of accident

(b)

name and job of injured or ill person

(c)

details of injury/illness and what first aid was given

(d)

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(a)

what happened to the person immediately afterwards, e.g. went home, to hospital, back to work name and signature of the first aider or person dealing with the incident.

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Details of an accident should be recorded by the injured person, but can be completed by any employee.

1.6.2.4 The Reporting of Injuries, Diseases and Dangerous Occurrences 1

RIDDOR requires the following to be reported directly to the appropriate Qatar Administrative Authority: (a)

fatalities and major injuries

(b)

injuries resulting in incapacity for more than three days when linked to certain work activities

(c)

specified diseases

(d)

dangerous occurrences.

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Page 23

People covered by these Regulations include: (a)

employees including trainees

(b)

self-employed

(c)

other people who have been injured.

1.6.2.5 Reporting deaths, major injuries and dangerous occurrences These Regulations place a duty on the Contractor to make reports to the Administrative Authority. In the case of employees, the responsible person will be the Contractors. In the case of the self-employed or a member of the public, the responsible person will be the person in control of the site where the event occurred.

2

All subcontractors must notify both the Administrative Authority and the Contractor of any reportable accidents.

3

Where an accident, occupational disease or dangerous occurrence takes place that requires reporting under RIDDOR

4

Contractors can send reports by post to the competent authority:

5

The following must be reported immediately to the Administrative Authority by the quickest practical method (usually by telephone) and a report submitted on the approved form within 10 days:

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death of any person as a result of an accident at work

(b)

an accident to any person at work resulting in major injuries or serious conditions specified in these Regulations (see list below)

(c)

any one of the dangerous occurrences listed in these Regulations (see summary opposite).

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Note: A fatality cannot be registered without a properly completed death certificate.

(a)

Any fracture of any bone, other than to the fingers, thumbs or toes. Any amputation.

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1.6.2.6 Major injuries and serious conditions

(c)

Dislocation of the shoulder, hip, knee or spine

(d)

Loss of sight (whether temporary or permanent) or any other listed eye injury.

(e)

Electric shock or burn causing unconsciousness, or requiring resuscitation, or requiring admittance to hospital for more than 24 hours.

(f)

Any injury leading to hypothermia, heat induced illness or to unconsciousness requiring resuscitation or admittance to hospital for more than 24 hours.

(g)

Unconsciousness due to asphyxia or by exposure to a harmful substance or biological agent.

(h)

Acute illness or unconsciousness caused by any poisoning by any route.

(i)

Acute illness caused by exposure to infected material or a biological agent.

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1.6.2.7 Reportable dangerous occurrences Collapse, overturning or failure of any load-bearing part of any lift, hoist, crane, derrick, mobile powered access platform, access cradle, window cleaning cradle, excavator, piling rig or forklift truck.

(b)

Collapse or partial collapse of any scaffold over 5 metres in height or fall of any cradle.

(c)

Collapse of 5 tonnes or more of any building or structure, or any false work, or any wall or floor in any workplace.

(d)

Explosion, bursting or collapse of any closed vessel or boiler.

(e)

Contact with, or arcing from, any overhead electric cable caused by any plant or equipment.

(f)

Electrical short-circuit with fire or explosion, for example, from hitting an electrical service.

(g)

Explosion or fire caused by any material resulting in stoppage of work or plant for more than 24 hours.

(h)

Uncontrolled release of 100 kg or more of a flammable liquid, 10 kg or more of a flammable liquid above its normal boiling point or 10 g of a flammable gas inside a building, and 500 kg or more of such substances outside a building.

(i)

Uncontrolled release of any biological agents.

(j)

Accidental ignition of any explosive.

(k)

Failure of any load-bearing part of a freight container.

(l)

Bursting, explosion or collapse, or fire involving a pipeline.

(m)

Specific incidents involving road tankers.

(n)

Specific incidents involving dangerous substances being conveyed by road.

(o)

Escape of any substance in a quantity sufficient to cause death, injury or damage to health, for example, asbestos.

(p)

Malfunction of any breathing apparatus whilst in use or when being tested before use.

(q)

Contact with or arcing of any overhead power line.

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1.6.2.8 Other reportable injuries and deaths The following must be reported to the Administrative Authority within 10 days on an approved form (F100). A copy of the form is reproduced at Appendix 3.

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Any accident at work where, because of an injury, a person is incapacitated for work of their usual kind for more than three consecutive days, not counting the day of the accident, but counting rest days, weekends, and so on.

(b)

The death of an employee, if it occurs within one year of the date of the reportable injury, even though the injury has been previously reported.

(c)

Any injury caused by a work activity to someone who is not at work that results in them being taken to hospital by whatever means, e.g. a taxi, ambulance or private car, for treatment of that injury. This would include all members of the public.

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1.6.2.9 Keeping records 1

Records of all reportable deaths, injuries and dangerous occurrences must be kept for a period of three years. No precise method is prescribed, but a photocopy of the approved form is acceptable, as are electronic databanks and computer storage. If an 'in-house' accident form is designed to record the same details as the approved form, it is acceptable.

2

The minimum particulars that must be kept are: (a)

the date and time of the accident or dangerous occurrence

(b)

the injured person's details: full name and occupation

(ii)

nature of the injury

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in the event of an accident to a non-employee: (iii)

full name and status (for example passenger, customer, visitor or bystander)

(iv)

nature of the injury

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(c)

(i)

the place where the accident or dangerous occurrence happened

(e)

a brief description of the circumstances in which the accident or dangerous occurrence happened

(f)

the date on which the event was reported to the Administrative Authority

(g)

the method by which the event was reported.

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1.6.2.10 Reporting diseases

A disease must be reported where it has been diagnosed in a person doing a specified type of work. These Regulations list diseases against the type of work which makes them 'reportable'.

2

The report must be made when the disease has been diagnosed by a registered medical practitioner, who will notify the Contractors of it in writing.

3

Diseases have to be reported to the appropriate Administrative Authority on the approved form. (Form F100A) A copy of the form is reproduced at Appendix 4. Refer to the SAMAS SHE PROCEDURE 8

4

Reports must be kept in the same manner as for accidents and the minimum particulars that must be kept are:

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(a)

date of diagnosis of the disease

(b)

name of the person affected

(c)

occupation of the person affected

(d)

name or nature of the disease

(e)

the date on which the disease AuthorityAdministrative Authority

(f)

the method by which the disease was reported.

was

reported

to

the

Administrative

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Page 26

Diseases and work activities listed in these Regulations are:

Disease

Work activity

Chemical and metal poisoning

Any work activity

Chrome ulceration, acne, skin cancer, folliculitis

Work with chrome compounds, minerals, oil, tar, pitch, radiation

Occupational asthma

Work with epoxy resin, soldering flux, silica, sand, wood dust

Mesothelioma, lung cancer, asbestosis Leptospirosis

Work with asbestos

Hepatitis

Exposure to blood or human waste products

Nasal or sinus cancer

Working in a dusty building

Hand-arm vibration syndrome

Hand-held rotary or percussive tools, chainsaws and handheld circular saws

Pneumoconiosis

Work with silica, sand, grinding wheels, boiler descaling

Occupational dermatitis

Work with epoxy resin, oil, cement, solvents, hardwoods, plaster, concrete, bleach, acids, alkalis, wood preservatives and anything else which causes dermatitis

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Where there are rats, field mice, voles or other small mammals

1.6.2.11 Reportable or not reportable incidents under these regulations?

The following examples may provide some clarification:

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Note: For simplicity in the following passage of text, the word 'incident' is used to cover any reportable event such as injury, disease or dangerous occurrence.

1. A directly employed person breaks their arm at work. This must be reported by the Contractors, in their capacity as 'responsible person', as a major injury. 2. A self-employed subcontractor breaks their leg at work. The injury must be reported as a major injury by the Contractor acting in their capacity as 'the responsible person' who was in control of the premises. 3. An employee of a subcontractor on a project is informed by his doctor that he is suffering from work-related vibration white finger and subsequently informs his Contractors. The Contractors, in their capacity as 'responsible person', must report the incident as a reportable disease. 4. An employee inadvertently hits an underground electric cable whilst operating a road-breaker. There is minor damage to the external sheath, but the conductor is not exposed. This is not reportable as there was no electrical short circuit with fire and explosion. The incident, however, warrants significant internal investigation. 5. A member of the public is knocked down by a lorry entering the site as it crosses the pavement. They are taken to hospital by ambulance. This would be reportable as it involves a member of the

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public being taken to hospital. 6. A subcontractor employee burns his hand and is taken to the local hospital. He is back on site later that afternoon and continues to work as normal for the rest of the week. This would not be reportable. However, had the employee been admitted to hospital for 24 hours or more, the incident would be reportable. 7. An employed delivery driver twists his ankle on a Monday when he steps down from his cab. He receives first aid, insists he is fit to drive and later leaves the site. He subsequently takes the rest of the week off because of pain and swelling in his ankle. The incident should have been recorded in the site accident book, but it would seem unreasonable for the site to be aware of the consequence. The delivery driver's Contractors would have a responsibility to report this as an 'over-3-day' accident.

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8. An employee sustains a head injury as a result of falling over debris left on site. The accident occurred on a Thursday and because of the injury, the person is unable to return to work until the following Tuesday. Although only two actual working days have been lost, the accident must be reported as an 'over-3-day' accident because the Saturday and Sunday also count, as the injured person would have been unfit for work had these been working days.

From Contractors accident records and other statistics, it is possible to calculate the incidence and frequency rates for accidents at a particular place of work and for the types of injury, severity or duration.

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1.6.2.12 Calculating the incidence and frequency rates of accidents

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The incidence rate is based on the number of accidents, taken over a fixed period, per 100,000 employees.

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Accident incidence rate (AIR)

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Incidence rate =

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For example, if during a 12-month period there were six reportable accidents and during that year the company employed an average of 120 employees, the calculation would be: 6 x 100,000 = 5,000 120

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Number of reported injuries in a year x 100,000 Average number of employees in a year

4

The following formula is also used to calculate the incidence rate, particularly when the number of employees is small. Number of reported injuries in a year x 1,000 Average number of employees in a year

Accident frequency rate (AFR) 5

The accident frequency rate allows a calculation to be made that balances the number of reportable accidents that occur against the number of hours worked.

Frequency rate = Number of injuries in a period x 100,000 Number of hours worked in that period

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For example, if a company had five reportable injuries in a period during which its 260 workers worked a total of 125,000 hours, the accident frequency rate would be: 5 x 100,000 = 4 125,000

7

Therefore, when comparing the figures of different companies, care must be taken to ensure that the same multiplier is used.

1.6.2.13 Analysis and presentation of data To visualise trends more clearly, accident statistics are often displayed as bar charts, histograms and graphs.

2

The proper and effective reporting of accidents, along with their thorough investigation, can have major benefits for a Contractor. A Contractor might consider that they could:

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reduce costs by that the Contractor has a pro-active implementing change and preventing accidents

(b)

identify training needs which will also improve performance

(c)

show Qatar Administrative Authority, Workplace Inspectors their approach to safety

(d)

satisfy stakeholders that their workforce is properly trained and totally safety orientated

(e)

benefit from a possible reduction of insurance premiums following years of hard work to reduce accidents.

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be factual and without bias

(b)

clearly show the sequence of events leading to the accident or incident

(c)

identify the immediate cause

(d)

identify the underlying cause, e.g. unsafe acts or conditions

(e)

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An effective investigation will:

show the root cause, e.g. lack of supervision, training or monitoring.

By discovering all causes, especially root causes, you will be able to learn from accidents and incidents and then aim to prevent re-occurrences.

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1.6.2.14 Accident investigation

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1.6.2.15 Accident procedure 1

The procedure below is given as general guidance and outlines the steps that should be taken immediately after an accident: (a)

attend to the injured person, call for assistance if necessary and arrange for first aid, doctor, ambulance, hospital

(b)

isolate machine, tools or equipment

(c)

do not disturb or move anything unless to release an injured person

(d)

inform the manager, safety adviser, safety representative and other appropriate persons (such as the Workplace Inspectors, Fire Officers or Insurers)

(e)

ensure any remaining hazard is guarded against

(f)

take notice of anything significant and make general observations at the scene of the accident.

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1.6.2.16 Conducting an investigation It is not usually practical to investigate every minor accident, but those involving major or serious injuries to persons and major damage to plant or equipment should be thoroughly investigated so that immediate action can be taken to prevent a recurrence. The following headings may be useful as a guide to the steps to be taken: investigate promptly

(b)

record evidence

(c)

identify types of evidence, e.g. factual, corroborative

(d)

interview the injured person, if possible

(e)

question the person in charge and other supervisors

(f)

obtain details of the injured person's job and what they usually or normally do

(g)

interview witnesses

(h)

inspect plant for signs of misuse or defects

(i)

establish the full sequence of events

(j)

ascertain the nature and extent of the injury or damage

(k)

complete the accident report and the accident book

(l)

notify the appropriate authorities.

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1.6.2.17 Investigate promptly

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The sooner an investigation is started, the better - provided it is safe to do so.

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Engineers and supervisors will be anxious to find ways and means of repairing the damage to plant, machinery or buildings, but the first priority should be to establish the cause of the accident. Safety specialists, managers and safety representatives will be concerning themselves solely with the safety implications and preventing a recurrence.

3

It is important that the investigation is properly supervised and organised.

4

Where the Police, Fire or Workplace Inspectors wish to investigate, any other persons responsible for, or involved in investigating, the accident must take extreme care not to disturb possible evidence at the scene.

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1.6.2.18 Recording evidence 1

Statements from witnesses should contain such details as their age and occupation. The time, date and place of interview should be indicated at the end of the statement.

2

Witnesses' statements should always be written in their own words, even if these include slang or expletives.

3

The completed statement should be read to the witness and, ideally, signed by them and by the person who took the statement.

1.6.2.19 Identifying the types of evidence 1

Evidence will usually include: (a)

statement of witnesses and others given orally, or in writing. 'Others' may include experts who, for example, might have been called in to examine a machine or the state of a scaffold

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(b)

documentation of all kinds

(c)

material exhibits of all kinds.

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Factual evidence comprises the facts related by persons directly involved, and by witnesses who are able to say what they felt, saw, heard, or give an expert opinion. This type of evidence is primary, direct and positive and should be written in simple language, keeping to the facts and avoiding inferences, opinions and beliefs. The facts should be recorded clearly, accurately and in sequence.

3

The best witnesses are those persons directly involved who are able to: listen carefully to the questions

(b)

answer directly, fairly, impartially and truthfully

(c)

state clearly when they do not know the answer

(d)

remain calm when they are being asked questions.

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Material evidence includes, for example, equipment, machines, scaffolds,ladders or hand tools, where the use of or the state or condition of the item has a bearing on the accident.

5

Corroborative evidence tends to support the truthfulness and accuracy of the evidence which has already been given. The confirming evidence may take the form of site records, plant or maintenance records, warning notices, written procedures, reports made by safety officers etc.

6

People in the vicinity of an accident should be asked to give an opinion. In this way a full picture can be built up of the circumstances of the accident.

7

Experts, or specialists, who are familiar with the type of accident, or technical and other factors surrounding the accident, may be called upon to express their expert opinions.

8

When there is a lack of real or factual evidence, other forms of evidence such as circumstantial and corroborative evidence tend to become more valuable.

9

Photographs taken immediately after an accident record the state of the scene and often highlight conditions which existed at the time. Machines, equipment, tools and obstructions, and factors such as floor conditions, space and dimensions, may show up very well on photographs.

10

If possible, it is best to engage professional photographers and to obtain the largest possible prints. Time, date and place or subject photographed should be written on the back of the pictures.

11

Too many photographs are far better than too few, and it is a good idea to make drawings of the area where the incident happened.

12

Digital photography may not be accepted as primary evidence but may be suitable as supportive evidence.

13

Procedures should be in place to ensure that photographs have not been, or cannot be, computer-enhanced as this would destroy their value as evidence.

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1.6.2.20 Interviewing the injured person 1

Interviewing the injured person should be an early priority. Even the briefest description of the accident should suffice initially.

2

The physical and mental state of the injured person will need to be considered, and tact and

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patience required during the interview. The injured person should be fit to answer questions. 3

The injured person should be encouraged to talk about how the accident happened and it is important they have confidence and trust in the listener. It is important to stress that the purpose of the investigation is to find the cause so that preventive action can be taken. Blame should not be apportioned.

4

Questioning should not take the form of an interrogation. Someone well known to the injured person is probably the best person to do this. Safety officials are more likely to receive the co-operation of an injured person if they are able to demonstrate a genuine interest in their welfare and recovery. This may involve visiting the injured person, with the doctor's approval, in hospital or at home.

1.6.2.21 Questioning the person in charge Establish from the injured person, manager, supervisor or the person in charge, what the normal job and tasks of the injured person were. Did they include the activity which led up to the accident? Other questions which might be asked include:

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what task or type of job was being performed?

(b)

was it planned or part of a planned activity?

(c)

at what stage of the work did the accident occur?

(d)

was the person involved trained, and if so, when?

(e)

was the person authorised to carry out that type of work or use machinery in that location?

(f)

was the person authorised to be where the accident occurred?

(g)

what instructions had been given?

(h)

how many other persons were involved, or should have been involved, in the activity?

(i)

was the activity or task covered by any these Regulations?

(j)

were safe and correct procedures being observed?

(k)

did unsafe acts cause the accident? If so, were they those of the injured person, workmates, or others?

(l)

did any unsafe condition contribute to the accident?

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what safety equipment or personal protection was available and in use? were other contractors' employees or plant and machinery involved or at fault?

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had the injured person been involved in previous accidents?

(p)

who was supposed to be supervising the work activity?

1.6.2.22 Interviewing witnesses 1

Skill is required when interviewing. Witnesses should be interviewed one at a time. If they wish to say anything before notes are taken, they should be allowed to do so.

2

Interviewers should seek answers to the following basic questions: (a)

what did the witness actually see or hear?

(b)

what was the witness doing at the time?

(c)

what was the proximity of the witness to the accident or occurrence?

(d)

what actions did the witness take?

(e)

what actions did others take before and after the accident?

(f)

what was the condition of the workplace at the time?

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(g)

what hazards or unsafe conditions existed and what unsafe acts were performed?

(h)

what was the probable cause(s) of the accident or occurrence?

Skilled interviewers allow witnesses to tell things in their own way, intervening only to clear up specific points or answers where necessary. Questions should be impartial, and should be recorded together with the answers.

4

It is quite acceptable to go through an incident with a witness making rough notes and then to take a statement after that. That way, the witness often has more chance to remember and sometimes provides far more detail on the second run through.

5

Many witness statements are taken by the interviewer rather than written by the witness, and this would normally be agreed during the interview.

6

It is common for certain details to differ in witnesses' accounts, and it would be suspicious if they were identical, but there should be agreement about basic facts if the true cause of an accident or occurrence is to be determined.

7

The important witnesses are those persons involved. Their evidence will be more valuable than evidence from witnesses who saw or heard only from a distance, although they, too, should be interviewed. Corroborative evidence and information is often required, particularly when witnesses are few or are not reliable.

8

As much evidence and information as possible should be collected, since the action taken to prevent a recurrence will be based on what is learned.

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1.6.2.23 Inspection of plant for misuse or defects

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Inspection of plant, equipment, tools and machinery immediately after an accident may reveal signs of misuse, or defects, which may or may not have contributed to the accident. The scene should also be carefully examined to see if trip hazards, slippery floors, or some other defect contributed to, or caused, the accident.

2

Assistance from specialists and persons directly involved or familiar with the type of plant, equipment, or machinery in question can provide valuable information.

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1.6.2.24 Establish a sequence of events Evidence gained from interviews and from inspection of the scene, plant, equipment or machinery, should give an indication of the sequence of events leading up to the accident.

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1.6.2.25 Ascertain the extent of injury or damage It is not always possible to ascertain the full extent of injuries and damage resulting from an accident.

2

There may be complications or delayed effects from injuries. The total time off work will obviously not be known at the time of investigation.

3

Whilst it may be easy to identify the extent of the damage caused to plant, machinery, equipment, buildings and materials, it is far from easy to measure the overall effects of the accident in terms of lost time, lost production and, of course, the suffering of the injured person or persons.

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1.6.2.26 Completion of the accident book and an accident report form 1

Accident report details will vary, depending on who produces the report and whom the report is for. To help eliminate or reduce this variation, guidance in making reports and the use of a standard form is recommended.

2

As far as possible, reports should be concise, based upon fact rather than speculation, unbiased and should summarise the essential information obtained during the investigation.

3

Sample accident and damage report forms are included as Appendices 1 and 2 of this section.

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Construction Site Safety 1.6.2 Appendix 1 Personal Accident Report 1.

Name of Contractors ............................................................................................................................

2.

Site address ...................................................................................................................................... .......................................................................... Contact................................................................... Injured person’s name ......................................................................................................................

4.

Injured person's address ..................................................................................................................

5.

Age ...................................................................................................................................................

6.

Normal occupation ............................................................................................................................

7.

Occupation at time of accident .........................................................................................................

8.

Exact location of accident .................................................................................................................

9.

Date and time of accident .................................................................................................................

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10. Date and time of ceasing work .........................................................................................................

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11. State precise nature of injury ............................................................................................................

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(If eye or limb, state left or right)

12. To whom was the accident reported? ........................... Date ..................... Time ..........................

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13. Entry made in accident book on ....................................................................................................... 14. Qatar Administrative Authority informed :

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Date ..................... Time ................................................................................................................... 15. F100 report sent to Qatar Administrative Authority on.................................................................................... 16. Accident recorded in the official Contractors register? (If applicable) .............................................. 17. Was first aid given on site? ............................................................................................................... If treatment was received from a doctor, state name ....................................................................... 18. Did the injured person go to hospital? .............................................................................................. Give name of hospital ....................................................................................................................... 19. Was the injured person authorised to be at the place of the accident for the purpose of his/her work? 20. How was the accident caused? ........................................................................................................

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a) Give a full description of what happened ..................................................................................... b) State what the injured person was doing at the time ................................................................... c) If falls of persons from heights or into excavations or holes are involved, state distance of fall in metres 21. What action has been taken to prevent a recurrence? ..................................................................... 22. If machinery was involved a) Give name and number of machine or part causing the accident................................................

.

b) Was it working at the time of the accident? ..................................................................................

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23. Names and addresses of witnesses to the accident. Always obtain witnesses wherever possible.

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a) ....................................................................................................................................................,.

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b) ......................................................................................................................................................

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c) ...................................................................................................................................................... Attach signed statements from each witness whenever possible.

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24. Use the reverse of this form or a separate sheet of paper for a sketch plan of the scene.

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This form was completed by:

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Name .................................................. Signed ....................................... Date ................................

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TO BE COMPLETED BY HEAD OFFICE

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Further medical reports on injured person

Date ........................... Date ...........................

New address for injured person

.....................................................................................

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Injured person ceased employment

..................................................................................... .....................................................................................

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Construction Site Safety 1.6.2 Appendix 2 Damage Report Contact ..................................................................................................................................................... Address of site .......................................................................................................................................... ……………………………………………………………………………………………………………………... Plant or equipment affected ...................................................................................................................... ……………………………………………………………………………………………………………………...

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……………………………………………………………………………………………………………………...

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Serial numbers or identifying marks .........................................................................................................

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Full name and address of owner of the plant or equipment ......................................................................

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……………………………………………………………………………………………………………………... ……………………………………………………………………………………………………………………...

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Place, date and time of accident ...............................................................................................................

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……………………………………………………………………………………………………………………...

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Details of defects or damage ....................................................................................................................

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……………………………………………………………………………………………………………………...

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……………………………………………………………………………………………………………………...

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Names of operators concerned ................................................................................................................ ……………………………………………………………………………………………………………………...

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……………………………………………………………………………………………………………………... Cause of the accident ....;.......................................................................................................................... ……………………………………………………………………………………………………………………... Names of witnesses .................................................................................................................................. ……………………………………………………………………………………………………………………... ……………………………………………………………………………………………………………………... Agent or supervisor's signature ............................................ Date ...........................................................

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Appendix 3

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Form F100 Reporting of an injury or dangerous occurrence

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1.6.2 Appendix 4

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Form F100A Reporting of a disease

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Behavioural Safety

1.6.3.1 Key points Behavioural safety attempts to focus on why people act the way they do in relation to work activities and decision making. It is based on a process of observation, intervention and feedback, and aims to identify, in advance, any situations or conditions that may have an impact on completing tasks safely.

2

Situations or conditions may be influenced by an organisation, the individual or as a reaction to change by either.

3

Behavioural safety is proactive, trying to head-off potential problems rather than reacting to past accidents and mistakes.

4

For simplicity, this module and much of the text within it refers to 'behavioural safety; however, the principles apply equally to preventing incidences of occupational ill health.

5

To be effective, a behavioural based approach requires:

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clear and unambiguous leadership from the top down

(b)

'buy-in' at all levels to making the scheme work

(c)

an 'up-front' commitment in terms of time, effort and determination

(d)

scheme sponsors who believe in the value of making it work, who can be sympathetic to the reasons why some people behave in an unsafe manner and persuasive in convincing those people that they should not

(e)

effective communication on what the scheme is trying to achieve

(f)

a concerted effort to convince those affected that they will not be disadvantaged by the changes that will come about as a result of introducing the approach

(g)

effective engagement of everyone involved in the approach, not just those directly involved with the construction process.

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1.6.3.2 Why use a behavioral safety approach? Historically, improvements in health, safety and environmental performance have been achieved through improvements in engineering technology and enhancing safety management systems. In many ways, this methodology has reached its optimum performance and the related improvements in health and safety performance have begun to level off. Future performance gains will only be achieved by taking more account of the way people interact in every aspect of the workplace; and through integrating and understanding the human element of risk.

2

Trying to account for human performance in numerical ways is difficult. Many companies have tried to quantify human performance by using engineering methods.

3

For example, 'at risk' and 'safe' behaviors have been analysed to create a '% Safe' rating.

4

We all have our own perception of risk based on our individual experiences and it is not easy to make direct comparisons between different views and opinions. Despite this, most people have a genuine desire to work safely through adopting the 'best practice'.

5

This document defines behavioral safety as:

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'organisational, job and individual factors which influence behaviour at work in a way which can positively affect health and safety.'

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The practicalities of successfully implementing a behavioural approach involve: establishing an effective system of two-way communication to develop mutual trust between management and workforce

(b)

engaging the right people in the decision making

(c)

observing people at work

(d)

assessing their safe and unsafe behaviours (non-judgemental)

(e)

making timely interventions

(f)

establishing why unsafe behaviours take place

(g)

influencing those who behave unsafely not to do so in the future

(h)

recognising safe behaviours and if appropriate, rewarding

(i)

continuing assessment and research whilst looking for improvements in safety behaviour.

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The overall benefits are likely to be: more effective communication

(b)

a reduction in the number of workplace injuries

(c)

improvement in the standards of health and safety

(d)

reduced losses for the individual and the Contractors

(e)

the extension of safe working practices into the home life.

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There is a recognition that a behavioural approach attempts to: increase efficiency

(b)

achieve more flexibility and effectiveness

(c)

produce long-term changes.

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1.6.3.3 Developing a behavioural approach

The benefit for managers is to understand the motives behind why some people take risks and put themselves and others in danger, and thereby significantly reduce the potential for injuries and occupational ill health.

3

A behavioural safety approach is very effective in preventing workplace injuries and instances of occupational ill health. However, the approach does not reach its full potential until people start to share problems and issues with each other and with their supervisors.

4

Any success is dependent upon free and effective two-way communication and engagement. There must be mutual trust as to the motives of all parties. Such trust can only be built upon a just culture where employees at all levels can voice their mistakes knowing that the information will only be used to prevent the situation occurring again.

5

If a health and safety discussion is a positive experience, people will think about safety more positively and take steps to create the necessary safe working environment. Everyone has a right to carry out their work without being injured or becoming ill. Equally, nobody should have to tell somebody's family that their loved one has been killed or injured because the Contractor hasn't organised its health and safety arrangements effectively.

6

Behavioural safety has significantly contributed to improving the safety performance of Contractors that have committed resources and time to it.

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An effective behavioural approach must involve all levels of an organisation, not just those on the 'coal face'. However, when we look at why people do what they do, we often find that errors are rooted in the way that health and safety is organised. Unsafe situations found in the workplace reflect problems with the way the company is led and organised.

8

The principles of behavioural safety are well established but putting them into practice can be difficult. Low levels of trust, poor motivation, or management that is not visible and rarely visits the site mean that many organisations do not communicate effectively and do not obtain or sustain effective involvement from the workforce.

9

However, many workers are still sceptical about these processes because of their current working practices. For example, some people object to observing colleagues, while others feel that it is a judgemental process in disguise in which gathering information leads to allocation of blame. Others may just fill in the observation cards because they have a target to meet.

10

Furthermore, cultural issues such as poor leadership, completion bonuses, little or no worker engagement and not reporting accidents affect the ability to establish an open culture.

11

When not everyone is open about what is really taking place on site, there is the obvious potential for someone to be injured.

12

Organisations should provide a platform for productive debate, a chance to share best practice, air conflicting opinions that challenge existing working practices and provide an opportunity to learn more about the psychology of injury prevention.

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1.6.3.4 The psychology of behavioural safety

Behavioural safety applies tried and tested psychological principles in order to change the way people and organisations do things, particularly how people act or behave in respect of their own health and safety.

2

A behavioural approach takes into account:

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how people think

(b)

how people act and behave

(c)

how people respond to certain situations

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how their immediate surroundings can influence people's thoughts and actions.

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Thought processes 3

The conscious or alert state of mind can only process on average seven thoughts at once. If a distraction disturbs a person's thought processes, they may, for example, trip over a toolbox they have placed on some steps or fall into a hole they recently dug. Other thoughts have entered their conscious mind and the hazardous situation is momentarily forgotten.

4

Hence good workplace design and housekeeping practices, such as removing hazards immediately and always keeping walkways clear, are critical to prevent injury.

5

It is difficult to convert emotions and opinions into usable information that promotes safety improvements. Often the ability to increase safety awareness by the individual doing a 'Mental Risk Assessment' (i.e. asking 'what is going to put me at risk while I do this job?') is lost. Yet future performance gains will only be achieved by creating a process that is simple, positive and, most of all, resolves the issues as soon as practicable.

6

It is essential that employees feel that they are able to discuss the day-to-day aspects of their job, and it should be as natural as talking about their favourite sport. We should take

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into account the way people work alongside each other and try to work from a baseline of openness about what is going on. 7

By helping people to understand the implications knowledge, we will have identified a process that management system of the business, encouraging that resolves issues when they arise, rather than occurs.

of how they work and engaging their integrates human factors into the core positive, open and real communication keeping them hidden until an incident

Habits Habits are subconscious ways of thinking, both positive and negative. They are formed when a task and behaviour is repeated. The more repetitions, the stronger the habit, until no conscious thought is given to the job. An example of a negative habit is not wearing eye protection when using a disc cutter because the past is used to justify present actions - the worker has not been injured before so argues that they will not be injured now.

9

A positive habit can be formed by communicating the benefits, consciously ensuring eye protection is worn, perhaps by raising awareness via posters or stickers on the disc cutter, keeping eye protection with the disc cutter, or spoken reminders from work colleagues and supervisors. Eventually wearing eye protection becomes a habit and the norm.

Beliefs, expectations, attitude and behaviour

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We all have our own beliefs (attitudes) that underlie how we think and hence define the way we act. If managers and supervisors are not committed or do not really believe that health and safety is a priority, a powerful negative message will be sent to employees.

11

Low expectations and poor leadership from management can create negative attitudes from employees that result in poor methods of working that lead to poor health and safety performance.

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The challenge

It is increasingly being recognised that integrating a systematic, proactive process within the organisation's arrangements can add significantly more value by addressing behavioural aspects of health and safety at the same time as optimising efficiency and productivity.

13

Significant improvements can be made to performance through open communication and a reporting process based on what is really happening. This will enable better assessment of risks, bridges to be built, trust to be enhanced and the workforce to participate willingly as issues are resolved and solutions found.

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The barriers to progress 14

If management promotes a negative or passive message, making the workforce believe that it is collecting unnecessary data or that the information will never provide solutions, any potential gains will be lost.

15

Organisations that adopt a behavioural approach must fully understand that it is not a short term solution but a 'change in the way we do things round here' that will need an effective investment of resource and commitment.

The solution 16

A simple, fully integrated process that stimulates discussions on everything that is going on,

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whether safety or otherwise, is progressed through an action plan. Once people see that these positive discussions lead to a positive gain, even without the difficult observation process, even greater workforce involvement would occur.

1.6.3.5 Why observation processes can be difficult 1

People sometimes have major difficulties in carrying out a formal observation. To stand, observe, then to talk about what was seen in order to seek ways to improve work practices creates a challenging situation for many people.

2

Some of the issues are: people dislike being observed during any task

(b)

people will tend to change their behaviours whilst being observed, therefore defeating the purpose of the exercise

(c)

difficulty in interpreting the information to identify any trends

(d)

a focus on changing attitudes and behaviours means that training is likely to be via workshops and committees. This may be too expensive in terms of both available time and resources.

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Individuals vary in their perception of the level of risk associated with a particular situation. We all base this mental risk assessment on our own experiences and have a slightly different perspective on what is going on.

4

If a worker has not had an accident while carrying out a particular activity, they will often score the risk as zero in a personal risk assessment because they judge that it will not happen to them. For instance, an individual may work from an untied ladder, accepting there is a small risk of falling and not necessarily recognising the severity of the consequence if they did fall. However, they may observe a work colleague on the same ladder and can see the risk and potential consequence.

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People can cause or contribute to accidents, or mitigate the consequences, in a number of ways: A person can directly cause an accident by failing to carry out a job correctly. A person may hear but not listen and understand health and safety information that is associated with the task, thereby failing to work to expectations.

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1.6.3.6 Reducing human error and influencing behaviour

(c)

People tend not to make errors deliberately but they are often 'set up to fail' by the way the brain processes information. For example, errors may occur as a result of stress, fatigue, working long hours without sufficient rest, a lack of training, the poor design of equipment, weak procedures or because of the shortcomings in the culture of the organisation in which they work.

(d)

People can make disastrous decisions even when they are aware of the risks. A particular situation or the severity of its consequences can be misinterpreted and inappropriate action taken as a result. This poor assessment of the situation can lead to the escalation of an incident.

(e)

On the other hand, other people (such as workmates, supervisors and managers) can intervene to prevent potential accidents or mitigate their possible effects.

(f)

The severity of an accident can be reduced by the effectiveness of the emergency response. The effectiveness can be improved by planning and appropriate training.

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1.6.3.7 Active and latent failures 1

The consequences of human failure can be immediate or delayed. It is important to have an understanding of active and latent failures and how they impact on health and safety. (a)

Active failures have an immediate consequence and are usually made by front-line people such as drivers, operators or even the public. In a situation where there is no room for error, these active failures have an immediate impact on health and safety.

(b)

Latent failures are caused by people such as designers, decision makers and managers whose tasks are removed in time and space from operational activities. Latent failures are typically failures in the design, implementation or monitoring of health and safety management systems.

Latent failures provide as great, if not greater, potential danger to health and safety as active failures. These can be highlighted only through positive safety discussions that utilise the experience and knowledge of the workforce. Latent failures are hidden within an organisation until they are triggered by an event likely to have serious consequences.

3

Examples of latent failures are: Poor design of workplaces, plant and equipment

(b)

Gaps in supervision

(c)

Undetected manufacturing defects

(d)

Maintenance failures

(e)

Unworkable procedures

(f)

Clumsy automation

(g)

Ineffective competency assurance

(h)

Ineffective training

(i)

Ineffective communications

(j)

Uncertainties of role and responsibility

(k)

Ageing assets, plant, tools and equipment

(l)

Poor planning - insufficient people/time

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Poor intelligence on health and safety incidents.

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1.6.3.8 The management of change 1

Most people fail to plan for the human side of change and wonder why their plans rarely succeed. No single behavioural process fits into every company but some prescriptive processes may be a necessary step towards achieving open communication.

2

Any change creates 'people issues'. For example, there may be new leaders, changed roles, and the need to develop new skills and capabilities. Employees may be uncertain and resistant because they do not see the need for change or feel that they will be disadvantaged by it. Dealing with these issues on a reactive, case-by-case basis puts the progress of the job, workforce morale, and overall performance of the behavioural approach at risk.

3

Change is unsettling for people at all levels of an organisation. The team needs to work together and understand that individuals are going through stressful times and need support. Only after everyone aligns and commits to the change programme can the workforce deliver tangible results.

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Individuals (or teams of individuals) need to know what changes they will see as a result of a behavioural safety programme being - implemented, what is expected of them during and after the change programme, how they will be measured, and what success or failure will mean for them and those around them.

1.6.3.9 Lead by example The implementation of behavioural safety can pose particular problems with a fragmented and mobile workforce such as that found in the construction industry.

2

To be successfully implemented on site, it is fundamental that the principles of behavioural safety are embedded within the organisation's culture and understood by the workforce and management from the beginning. It cannot 'just be thrown in' as an initiative at a later stage.

3

The foundations, expectations and compliance processes must be made clear from the beginning. If employees and contractors receive the right induction, standards will be set for the future.

4

If people digress into non-compliance and break basic rules (such as not wearing hard hats or safety goggles), then subsequent batches of inductees will receive the message that safety is not taken seriously (they can get away without wearing their hats and goggles).

5

Similarly, when senior managers visit sites, they should receive the same induction and live by the same rules - body language and example can send a powerful message.

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1.6.3.10 Facilitation and coaching

Team leaders should be as honest and explicit as possible about what impacts on health and safety. People react to what they see and hear around them, and need to be involved in the change process.

2

Individual commitment, ownership and accountability for safety is vital to making change happen. Everyone must be willing to accept responsibility for change in the areas they influence or control. We do not expect machinery or plant to undergo alteration without appropriate engineering controls, why should we expect people to change without support.

3

Ownership is often encouraged by involving people in identifying problems and Grafting solutions. It is reinforced by coaching and facilitation, incentives and, sometimes, rewards.

4

These can be tangible (for example, financial compensation) or psychological (for example, camaraderie and a sense of shared involvement).

5

The best programmes reinforce the core messages of safety through regular, timely engagement and communication that is both inspirational and practicable. Communications are targeted to provide employees with the right information at the right time and to solicit their input and feedback.

6

Effective change requires continual review to ensure that new issues are identified and actioned.

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1.6.3.11 Staffing levels 1

Some companies operate with the lowest possible number of people required to achieve their commercial objectives. Margins are tight and contracts are won and lost on cost. This means that people can be stretched beyond acceptable limits, doing too much, working long hours and experiencing high levels of stress and fatigue - a recipe for disaster. Contractors should remember that if a job needs more people, then they should be provided, otherwise people get hurt.

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1.6.3.12 Training and competency 1

It is likely that if a workforce is: (a)

motivated and well trained

(b)

not under unreasonable time pressure

(c)

given the correct information and training

(d)

working with the right, well-maintained equipment

(e)

they will efficiently complete their tasks to a high standard.

Conversely, high workloads and tight timescales often result in training and competency assessments falling by the wayside, which can lead to ineffective decision making, poor working practices, out-of-date certification of plant, equipment and, of course, a negative effect on people's skills.

3

As part of managing change, it is essential that a training and competency assessment be carried out so that shortcomings are identified and addressed, and consequently people are not put at risk. Every Contractor is responsible to ensure that people are trained and competent to carry out their tasks. Greater production efficiencies are achieved through correct skill levels and further gains are made in completion times and work output.

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1.6.3.13 Fatigue

It has long been recognised that fatigue affects the mind and emotions as well as the body. The issue is important in any discussion regarding safety; operator fatigue has been implicated in many serious construction accidents.

2

The word 'fatigue' is, like 'stress', an umbrella term that encompasses many meanings. The phrase 'physical fatigue', for example, may refer to muscle aches and pains, shortage of oxygen, or a more systematic feeling of tiredness caused by sleep deprivation, illness or poor nutrition.

3

'Mental fatigue' is typically associated with tasks that demand intense concentration, rapid or complex information processing, and other high-level cognitive skills. Another form of fatigue is boredom, particularly when it results from repetitive or monotonous activity.

4

Symptoms of extreme fatigue would include obvious loss of concentration or difficulty in recalling information, poor decision-making, irritability, red eyes, uncontrollable yawning, and slow responses to questions.

5

A person suffering from mental fatigue may also spontaneously complain about being tired or having had too little sleep. Asking the person if they feel fit to start work may not result in a very reliable answer. Individuals may feel that they are under pressure to state they are fit for work, knowing that they are not.

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1.6.3.14 Shift work 1

Humans have evolved to be active during the day and to sleep at night. The timing of work, particularly shift work, can interfere with this pattern so the increasing demand for a 24/7 workplace has a serious impact on safety.

2

A disrupted sleep pattern can lead to fatigue and poor performance, which can increase risk. On a night shift, people are likely to be working when their bodies expect them to be asleep; they also then have to sleep during the day when they would otherwise be alert.

3

Other features of work schedules that affect levels of fatigue include the shift start time, the

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length of a shift, the number of shifts worked before a rest day, whether there is overtime, how much rest is taken between shifts, how much rest is taken during the shift, and whether the work schedule is regular and predictable. 4

Some shift patterns can result in a short daily rest interval of perhaps only 8 hours; this would be unfavourable for safety-critical workers.

1.6.3.15 Culture 1

Culture can be seen as 'the way we do things round here'.

2

Generally, people at work do unsafe things because:

(b)

it was a genuine slip or lapse-work patterns, working hours, fatigue and stress resulting from work or private issues etc. could be playing a part

(c)

a deliberate breaking of the rules - is the time allowed to do the job safely unrealistic? Is there a lack of management commitment to insisting on safe working? Peer pressure, particularly with regard to the young and inexperienced

(d)

management failure to devise and implement a safe working environment thus making unsafe working practices inevitable unless workers 'stand their ground'.

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they did not know that what they were doing, or the way they were doing it, was unsafe - an 'education' or 'training issue'

Safe working depends upon equal attention being given to: the conditions in which people are expected to work

(b)

safe systems of work being developed and implemented

(c)

safe behaviours being instilled in the people who have to do the work.

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(a)

The health and safety management system, as well as individual management practices, must support the desired culture. In fact, in the absence of a positive (or changing) culture, an observation and feedback process is unlikely to succeed.

5

Organisations rely on a number of processes and procedures to manage risk and thereby decrease the chance of incidents and injuries. Each of these processes has an important contribution to make, not only by improving workplace safety but also by influencing an organisation's culture.

6

These generally include systems such as:

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(a)

site rules and procedures

(b)

health and safety training

(c)

hazard identification and correction

(d)

discipline

(e)

incident reporting and investigation

(f)

health and safety communications

(g)

worker engagement

(h)

health and safety suggestions

(i)

rewards and recognition.

When the system is poorly designed or operating ineffectively, its ability to accomplish its primary purpose will be compromised. At worst, a poorly designed, badly implemented or illfunctioning system can also have a negative influence on an organisation's overall health

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and safety culture. 8

For example, the culture cannot improve when: (a)

incident investigations create an air of mistrust and blame

(b)

safety incentive programmes discourage injury reporting

(c)

accountability processes fail to recognise individuals for their accomplishments

(d)

performance evaluations only consider safety performance in terms of whether or not the individual was involved in an incident, i.e. the outcome of an incident and not the potential.

Poor features of one system can have negative influences on other systems. For example, when employee incentive programmes or supervisor performance evaluations are based primarily on reducing injury rates, is it reasonable to expect employees to embrace an open injury reporting and investigation system?

10

Similarly, when the incident investigation process is viewed as extremely blame-oriented, is it reasonable to expect employees to feel uncomfortable in having their safe and at-risk behaviours observed and recorded? The above factors will stifle open and honest communication and can impact upon each other.

11

Hazard identification and correction requires a climate that fosters:

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willing employee participation

(b)

sufficient training so that employees can recognise and correct hazards

(c)

open communication about the hazard and/or its suggested solution.

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1.6.3.16 Intervention

There are many recorded instances of people failing to intervene when they see an unsafe or illegal act, which is taking place in public. Whilst it is fully understandable that someone might not want to become involved in a violent confrontation in the street, in the context of work the personal risk to say, a supervisor who intervenes to prevent someone working unsafely, should not be so great.

2

However, the behaviour of supervisors and managers can directly affect the behaviour of operatives. The effect of failing to intervene in an unsafe situation is to condone that activity, practice or behaviour. This in turn sends a message to the operatives that the activity concerned is permitted and confuses the site teams. Therefore, intervention by managers and supervisors is critical in every case.

3

From the information available, the reasons for a failure to intervene appear to be split between a lack of knowledge that anything was wrong and a conscious decision not to take any action.

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1.6.3.17 Lack of knowledge 1

The situation in which there was a lack of knowledge is self-explanatory; the person in control of the activity had not received adequate training and was not sufficiently competent to appreciate that work was being carried out in an unsafe manner.

1.6.3.18 Conscious decision 1

The conscious decision not to intervene may possibly be based upon financial or time considerations, for example, a supervisor might ignore the unsafe use of a ladder because it saves the time and expense of hiring-in a MEWP.

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However, there may be other personal factors for not intervening: (a)

overload, the supervisor or manager is suffering from a heavy workload and is simply unable to identify the unsafe situation developing

(b)

actions of others, especially other managers or senior managers, can shape the decisions of the supervisor. Usually the fact that no one else involved in the operation is concerned is excuse enough for not getting involved

(c)

ownership of the situation where the supervisor or manager does not actually believe or understand their duties, or where they are not directly in charge of the operation and believe they have no jurisdiction

(d)

having the skills to resolve the issue is also important. Where a supervisor or manager lacks knowledge about the task or the important communication skills, then they are less likely to get involved

(e)

the risk of possibly entering into a situation where they may be required to make a difficult decision that could have a significant effect on the project. The support of senior managers is critical to allow junior managers and supervisors to become involved in safety issues and empowering them to take whatever action they deem necessary if an unsafe situation arises. At worst, this could even involve the cessation of work until the safety issue is investigated further.

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1.6.3.19 Risk and safety

Making assessments about risks and reaching an informed decision cannot be achieved without information - or at least that's what most management systems require.

2

The process of obtaining information begins with the recognition that the problem exists, and then raises questions to which answers are required. Deciding the level of accuracy and precision depends on the sampling and measurement methods.

3

In behavioural terms, this is done through identifying 'what' is happening during an observation and asking 'why'. The 'whats and whys' are collated, analysed and tabulated to identify trends, often by interpreting the data. Interpretation is based on the personal perception of what has been observed and so identifying trends can be difficult. Although risk can be quantified as abstract principles, health and safety cannot.

4

Whilst risk assessment is based on knowledge of the job and past experience, the corresponding judgement on safety is normative and can be 'political'. It may be possible to obtain group agreement on objective and rational measures of risk for various activities. However, there will often be . controversy over what are considered to be safe conditions.

5

Attempting to define acceptable levels of risk immediately raises the question of 'to whom' or 'on what terms' is the risk acceptable?

6

The distinction between risk and safety is more than a semantic one.

7

There are a number of factors to be considered in defining the acceptability of risk:

8

Cost: Safety is always compromised by available budget yet it costs far more to investigate and restore safe working conditions after an accident than it does to resolve the issues in the first place.

9

Controls: Who has control? Those at the place of work should have control over the safety requirements of the task. Ownership is critical for a safe working environment.

10

Customs: Many risks are taken because certain activities have always been done that way.

11

Conditions: Many people are put at risk because conditions have changed resulting in

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longer working hours, tight timescales, lack of resources, workload, fatigue, stress or an ageing workforce. This leads to errors, particularly in plant maintenance. 12

Consequences: Managers rarely evaluate in advance the consequences of something going wrong. Often the thought process seems to be 'if it hasn't happened yet, it won't happen at all'.

13

Benefit: What benefits does the individual get from taking a 'short cut' such as getting the Job done and an early finish.

1.6.3.20 Communication 'Actions speak louder than words'. For trust to be built an individual's behaviour and body language must reinforce what is being said -'walk the talk' as some people say.

2

Communication is at the heart of all that we do, both at work and in our own time. It takes place in many forms and can be transmitted via various media, e.g. face to face, radio, telephone, email or video conferencing. It is essential, especially within our working environment, that we get it right. Difficulties in achieving efficient communication may include background noise, the type of language used and sociocultural issues, so the potential for confusion and misinterpretation can be high.

3

It is vital to give the person receiving information the time and space to be able to think and formulate a response. In communication, it is the quality, not the quantity, which matters.

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what is said

(b)

how it is said

(c)

body language (conscious or not).

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Studies have shown that, generally, individuals assess what is being communicated to them by subconsciously attaching an 'importance value' to each of the above three factors in the following proportions: (a)

7% of the communication is by words that are said 38% is through the way we say it, and

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During a normal conversation, we usually transmit and receive in three ways:

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1.6.3.21 Verbal and non-verbal communication

(c) 3

55% by the use of our 'body language'.

During periods of high workload or stress, our body language goes largely unnoticed. This is when the words we use and the way in which we say them become more important. In addition, our listening capability reduces as our workload or stress increases. Key points are: (a)

communication involves both a listener and a receiver. What we say, how we say it and when we say it are very important

(b)

we need to watch out for overload - if the receiver is overloaded then there is no point in trying to communicate with them. If the message is important then we need to lessen the workload

(c)

ensure you have the receiver's attention - some, or all, of the message will be lost or misunderstood if the recipient is not paying attention.

1.6.3.22 Hearing and listening 1

There is a difference between hearing and listening. Hearing is a mechanical process

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involving the way sound waves are translated by our ear into sound. When listening, we actively engage the brain and apply logic and context to the sound. 2

We only listen to about one-third of what we hear and that is only if we are interested. The proportion is much less if we are not interested. A productive exchange would usually involve: (a)

Listening by actively engaging the mind

(b)

Evaluating by considering what is being said; asking ourselves if it makes sense, if it is in context; whether we wish to respond

(c)

Planning what we are going to say and waiting for an opportunity to respond.

1.6.3.23 Questioning skills The way in which questions are asked can control the discussion.

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There are several types of question and the most used are:

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Response

Closed

A fact or YES/NO

Open

Invites an extensive reply

Leading

Indicates the required answer

Limiting

Restricts options

Multiple

Many questions in one -confusion

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Type

We are always communicating. Even silence communicates something and may imply annoyance or criticism. Consider what effect your own personal style can have on others.

4

Some good practices in communication

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Control distractions.

(b)

Where possible make visual and eye contact.

(c)

Clearly identify the transmitter and receiver.

(d)

Be clear, precise and concise.

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(g)

Obtain verification from the receiver that the message is understood.

(h)

Acknowledge the verification (closed loop communication).

1.6.3.24 Nationality, language and culture 'Safety must be a common language' 1

Construction has become a globalised business, with Qatar worksites typically staffed by multinational as well as multilingual and multicultural crews. This trend has posed risks, in particular with respect to communication.

2

Areas for consideration when working with a multicultural team include their: (a)

capability in Arabic and/or English

(b)

work role expectations

(c)

leadership expectations

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(d)

attitudes to safety

(e)

mutual understanding.

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Cultural differences can be overcome by all parties, especially the leader, practising mutual respect and by taking the trouble to understand the differing cultures and getting to know the team members as individuals.

1.6.3.25 The benefits of health and safety discussions Discussion/Consultation/ Involvement/Feedback Improvements to working practices will reduce the potential for accidents, create a better system of work and raise awareness of issues and solutions.

2

One method of enhancing any safe system of work is through frequent and open discussions. The heart of any process is communication: everyone involved needs to share ideas and knowledge. This can have a massive influence on bottom line profits with everyone working more efficiently towards achieving a high quality product.

3

The Contractors image will also benefit if, by the actions exhibited, it is shown to be committed to a safe and healthy working environment where no one is injured or becomes ill as a result of coming to work.

4

One option is for site managers to have an informal 10-minute chat with their employees and/or contractors' supervisors at the start of every day. The manager should encourage them to tell each other where they will be working and how their activity could affect other people. This will help supervisors to plan their day as well as improving co-ordination, consultation, production and, ultimately, safety.

5

The aim of a behavioural safety discussion is to identify any difficulties in completing tasks safely and to aid the supervisor or manager in identifying problems to achieve a safe system of work. Participants in the discussion should:

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use open questions

(b)

smooth the way forward

(c)

be clear in what they are saying avoid any misunderstanding proactively resolve issues through positive actions rather than reactively observing unsafe actions.

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Those with more knowledge and experience can assist newer colleagues in understanding the hazards around them and stop people putting themselves at risk. Learning from a friendly, coaching manner is by far preferable to formal observations.

7

All employees should be involved in these discussions. Above all else, problems or issues should be resolved immediately with someone who has the authority to make the necessary changes.

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Drugs and Alcohol Misuse

1.6.4.1 Key points Managers and supervisors should know the signs and symptoms of taking drug and alcohol.

2

People who take drugs and alcohol and are still under the influence when they arrive at work are far more likely to suffer an accident and be a danger to others.

3

There is also likely to be an impact on productivity, sickness absence and morale generally.

4

If staff are under the influence of drug or alcohol misuse at work, firm decisive action must be taken by the Contractor; it is unlikely that the problem will just go away.

5

Contractors should have a written policy for dealing with employees who are unfit for work through drug and/or alcohol misuse.

6

Such a policy must be reflected in employees' contracts of employment to cover such eventualities as the 'right of search', random testing, suspension/dismissal from work.

7

Policies should be tailored to the specific needs of the company, be fully integrated with existing procedures and strike a balance between appropriate support and robust discipline.

8

Unless there is related misconduct, substance misuse should be seen as a treatable illness.

9

Anyone facing up to suffering from a drugs/alcohol misuse problem should be offered support and rehabilitation in strict confidence; there are many agencies who can offer professional advice and help.

10

Drugs testing is expensive and can introduce more problems than it solves, so the rationale for introducing a testing programme must be thoroughly thought out.

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The influence and use of alcoholic drinks and illegal drugs by employees on site is of growing concern to Contractors, given the risks to the health and safety of those employees and others who may be affected by the employees' actions or omissions.

2

Drug use poses a serious threat to the health, safety, well-being and livelihood of employees. Drugs may reduce perception, concentration and awareness, which can affect the safety and welfare of users and of others. The inability of a person to function competently and with reasonable care is a problem that must be addressed to prevent accidents occurring in the workplace.

3

It should also be appreciated that taking some prescription and over-the-counter drugs can result in a reduction in alertness, concentration and, therefore, safety performance. This is covered in greater detail later in this text.

4

Alcohol-related problems can be detrimental to the individual's state of health and their safety awareness.

5

This can affect the smooth operation of an Contractors business, and can result in waste and inefficiency. Both alcohol and drug problems can be effectively treated by a variety of means. The earlier the intervention, the higher the likelihood of a positive outcome.

6

Research findings show that drug and alcohol misusers are:

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3 times more likely to be absent from work for 7 consecutive days or more

(b)

at least 25% less effective overall

(c)

nearly 4 times more likely to be involved in workplace accidents.

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Drink driving 1

Driving on site under the influence of alcohol is equally, if not more dangerous than driving on a public road, and Contractors are required to develop a written policy on the matter. Contractors may also need to consider what their policy would be if an employee whose duties include driving (either on or off site) was convicted of drink driving.

Approximate detection times of alcohol and commonly used drugs in urine Approximate detection time

Alcohol Amphetamine

Dependent on amount consumed (approx. 1 unit per hour) 2-4 days

Barbiturates

2-10 days

Cannabis

2-30 days

Cocaine

12 hours - 4 days

Dihydrocodeine

1-2 days

Ecstasy

2-4 days

Heroin detected as morphine

1-2 days

Lysergide (LSD)

2-3 days

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1.6.4.3 Prescription and over-the-counter drugs

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In addition to the dangers which can be caused on site by the use of illegal drugs, some drugs prescribed by doctors or bought from pharmacies may also have unwanted sideeffects. On every drug packaging, there is a notice giving details of the correct dosage to be taken and at what intervals. This dosage must be strictly adhered to, as taking more than directed may have adverse effects. Similarly, there is often a warning on the packaging of over-the-counter drugs of the side-effects that they may have. This is suggested to be the case particularly with painkilling drugs and antihistamines. Some direction labels may also give a warning, for example:

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May cause drowsiness. If affected do not drive. Do not operate machinery 2

Such warnings should not be ignored - they are there for the guidance and safety of the person for whom the drugs are prescribed and should be strictly adhered to.

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If an employee is taking these forms of medication, a supervisor should be notified.

1.6.4.4 The scope of the problem 1

Problems at the workplace relate not just to consumption at or before work. Drugs or alcohol taken outside the workplace can affect performance long after the substance is consumed. The indirect effects of alcohol and drug problems on individuals' actions within the workplace can also be severe. When considering the scale of the drugs or alcohol problem within a company, the following must be taken into account.

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The risk of accidents due to under-performance caused by drugs or alcohol.

(b)

Inept and poor decision making.

(c)

Lower standards of work.

(d)

Low productivity caused by employees' inability to cope with workplace situations.

(e)

Disruptive actions by employees under the influence of substances, bringing about a breakdown in discipline.

(f)

The amount of time lost from the workplace due to absenteeism, lateness or habitual sick leave.

(g)

The general long-term health of the workforce.

(h)

Stress factors on employees due to home circumstances.

(i)

Stress factors on employees due to financial implications brought about by the need to feed a habit or addiction.

(j)

The adverse effect drugs or alcohol use could have on a Contractors image.

(k)

Security considerations.

(l)

The adverse effect on staff retention rates.

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Successfully tackling alcohol and drug misuse can benefit both your business and your employees. For example, you would save on the cost of recruiting and training new employees to replace those who left work because of untreated misuse.

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Offering support to those employees who declare a drug-related problem will also help to:

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reduce the risk of accidents caused by impaired judgement

(b)

create a more productive environment, and improve employee loyalty and morale

(c)

enhance public perception of your organisation as a responsible Contractor

(d)

contribute to Qatar society's efforts to combat alcohol and drug misuse.

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The misuse of alcohol or drugs (or solvents) by employees may come to light in a variety of ways. The following actions may indicate that a problem exists: (a)

absenteeism without notice poor time-keeping

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1.6.4.5 Identifying substance misuse

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(c)

high accident levels and a tendency to be clumsy

(d)

tendency to become confused and disorientated

(e)

poor performance of duties, a sloppy approach to work and poor presentation of the finished article

(f)

irritability or aggression, argumentative with superiors or work colleagues

(g)

misconduct

(h)

failure to remember, or failure to comply with, common instructions

(i)

a sudden need for increased supervision

(j)

leaving site either without permission or at lunch times to visit licensed premises

(k)

the finding of empty beer cans, bottles or drug-related paraphernalia.

Physical symptoms of substance misuse may include: (a)

rapid loss of weight

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(b)

gaunt appearance

(c)

tremors or sweating

(d)

constant tiredness

(e)

trackmarks, severe bruising or abscesses on arms

(f)

overdilated or very small pupils

(g)

cravings - ice cream, nicotine, sweet foodstuffs.

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(b)

severe mood swings

(c)

avoidance of authority or supervision

(d)

deteriorating relations with other staff

(e)

swings in morale

(f)

minimum involvement with other staff

(g)

obsessive or compulsive behaviour.

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Behavioural symptoms may include:

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The benefits of such identification need to be clear and, should a Contractor seek help, the Contractors may need to guarantee that the employee will not be disadvantaged.

5

Supervisors and managers may need training so as to be effective in identifying and addressing drug or alcohol misuse problems. The focus should be on specific examples of how work performance is being affected and not on direct confrontations or accusations of drug or alcohol related problems. Full training on effectively raising the issue with employees should be given. Contractor’s policy on the subject should be clear and specific.

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1.6.4.6 Developing a workplace policy The substance misuse policy that is adopted will need to take account of the particular needs of the Contractor and the practical situations, including those brought about by working on building and construction sites.

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However, there are a number of minimum requirements for such a policy, which should: contain a clear statement of the behaviour that is expected of employees

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(b)

apply equally to all employees, including managers and supervisors, at the workplace

(c)

be made known to all employees

(d)

be an integrated part of an overall health and safety policy

(e)

include clear statements on the roles and responsibilities of all employees in relation to the policy (e.g. site-based operatives, site based managers)

(f)

encourage those with a problem to come forward under a promise of strict confidentiality and future support

(g)

to the greatest possible degree, be non-punitive

(h)

state the conduct likely to result in action being taken under the policy

(i)

provide for appropriate treatment and rehabilitation for those with problems

(j)

be evaluated after implementation and amended, if necessary, in line with the outcome of the evaluation.

The policy is likely to be proportionate if:

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(a)

it is instituted to protect and promote employee safety

(b)

employees are aware of the policy

(c)

the process of collecting, transporting and testing samples can be proven to be independent and beyond reproach

(d)

employees will know what the Contractors will do with the test results

(e)

the Contractors has no other reasonable alternative way of obtaining the same result.

1.6.4.7 Implementing a substance misuse policy Implementing such a policy has four essential components: the education and information of all levels of management and employees and their representatives

(b)

the organisational support shown by the company

(c)

the addressing of issues in the work environment

(d)

the prevention and rehabilitation support offered by the Contractor to its employees.

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1

Information about a substance misuse policy, covering alcohol and drugs, must be provided to all employees, and be included as part of any induction training for new recruits. The policy must be supported by education about the harmful effects of alcohol and drugs

3

It is important that management demonstrates its full support for the policy by ensuring observance by all staff, at whatever level, and endorsing changes to the working environment to facilitate the full and proper implementation of the policy.

4

The provision of treatment and/or referral services is an important component of implementing the policy. If problems are detected early, before serious physical and social effects occur, a brief intervention may be all that is needed.

5

Confidentiality for employees undergoing treatment and rehabilitation must be guaranteed. Equally, employees should not be disadvantaged in terms of promotion or seniority because they have sought or are accepting help.

6

However, as with all workplace health and safety matters, consultation with employees and the provision of education and information at an early stage may prevent the onset of alcohol and drug problems at work.

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1.6.4.8 Misuse outside of the workplace 1

Generally, an employee's conduct outside of the workplace is not within the Contractors’ control. However, if drug or alcohol misuse during recreational times creates a risk to their health and safety, or to that of others who may be affected by the employee's actions during working hours, consideration must be given to the situation and to what action should or can be taken.

1.6.4.9 Alcohol or drug screening and testing 1

Introducing drug testing in the workplace is a difficult and potentially expensive initiative. It is essential to be completely clear on the reasons for doing so, or not. Testing is far from the whole answer and has inherent limitations.

2

Before any decision is taken by a Contractor to implement an alcohol or drug testing regime, care must be taken to ensure that an alcohol and drugs policy is fully established and communicated to all employees.

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Why test Drug testing might be introduced for a number of reasons. Other than where there is a clear clinical imperative (i.e. rehabilitation testing), the effectiveness of each approach has not been proven.

4

Recruitment screening usually refers to testing or assessing the health of potential employees during the recruitment process. Testing of this kind presents far fewer legal and logistical problems than introducing testing for existing employees.

5

Routine testing is done at specified times, and gives a clear message that it is not acceptable to be affected by alcohol when working. It might be used in situations where employees are in 'safety critical' posts, such as operating driving construction plant on a public road or operating machinery.

6

Random testing or unannounced testing is used as a deterrent to identify previously undetected drug or alcohol misusers. As with routine testing, any use in situations that are not safety critical may cause feelings of resentment amongst the workforce.

7

Reason or 'With Cause' testing might be used if a manager has reason to believe that an employee has been using drugs or drinking. This might be because of their behaviour or by physical signs, such as smelling of alcohol. It may also form a part of a post-incident or accident investigation.

8

Rehabilitation testing may be used where an employee has agreed to treatment and the treatment provider is testing to ensure compliance with a prescription (e.g. urine testing to ensure that an individual who has been prescribed methadone is not using heroin as well as the prescribed dose). Similarly, testing may be introduced as part of a return to work agreement between employee and Contractors.

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Is testing necessary?

Drug and alcohol testing is a controversial and complex issue which has scientific, ethical, legal, social, industrial and economic ramifications.

10

It is reasonable to expect employees to be unimpaired by drugs or alcohol whilst at work, but it could be argued that requiring an employee to undergo a test 'without cause' (randomly or without specific evidence that they are impaired) is unfair and intrusive.

11

Whether testing is appropriate or necessary should be carefully considered, as the damage to Contractors-employee relations can potentially outweigh the benefits.

12

Whether you decide to introduce testing or not, it must be emphasised that it is not an end in itself. Drug testing is no substitute for good management practice and should never be introduced without:

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(a)

full co-operation from employees

(b)

a programme of education for managers and employees

(c)

robust systems for referral to adequately trained health professionals.

Before considering the introduction of a testing programme, Contractors should be able to fully answer the following questions. (a)

Why do we want to test? (i.e. what do we hope to achieve by it?)

(b)

What substances will we test for?

(c)

Which employees will we test?

(d)

How will we select them?

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When will we test them? (e.g. routinely, randomly, pre-employment)

(f)

How often will we test?

(g)

How will we test (e.g. what method)?

(h)

Who is best placed to conduct the test? (e.g. independent company/laboratory, occupational health department)

(i)

What will we do with a positive result?

(j)

What training will be necessary and for whom?

(k)

What will be the financial costs?

(l)

What may be the other costs? (e.g. staff morale)

(m)

How will we involve the workforce and gain their consent?

(n)

What will be our safeguards? (i.e. how do we ensure that test results are accurate and legally defensible?)

The conclusions that are drawn from these questions should guide you to a well thought-out and rational decision.

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Methods of testing

There is a variety in both the methods used for employee testing and in the standards of service offered by drug testing companies. As yet there is no universally accepted accreditation scheme or quality standard.

16

It should also be clearly understood that there is a significant difference between testing for alcohol and testing for other drugs.

17

Alcohol testing indicates whether an individual is under the influence at that time. Drug testing - shows traces of drugs used in the past but does not necessarily confirm impairment at the time of testing.

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Alcohol use can be tested by: Breath testing - a 'breathalyser' measures the level of alcohol in the breath. This is convenient and inexpensive. Employees may be tested prior to commencing a shift, or immediately following an incident.

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Methods of testing for alcohol use

(b)

Blood testing is the most accurate measure of alcohol in the body although it is more invasive than a breath test. It is often inappropriate in a workplace setting due to lack of staff suitably trained to take samples.

Methods of testing for drug use 19

Drug use may involve the use of illegal drugs, or prescribed and over-the-counter medicines. These can be detected by gaining samples from: (a)

oral fluid: not as invasive as other methods but a relatively new technology so may be expensive or inaccurate

(b)

hair: not accurate for recent use, but depending on hair length the sample may reflect the individual's drug use pattern over a course of months

(c)

blood: very invasive, but can be more accurate than others

(d)

urine: potentially invasive, but well established science

(e)

sweat.

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1.6.4.10 Disciplinary procedures 1

The majority of Contractors will have a disciplinary procedure in place. It may be appropriate to ensure the procedure covers the consumption of alcohol or drugs in the workplace. You may also wish for the policy to contain a provision that possession, dealing or trafficking in drugs will be reported to the police.

2

For a drug and alcohol policy to be effective, it is essential that it is consistent with disciplinary procedure.

Taking disciplinary action Employees with a substance misuse problem or suspected of misusing drink or drugs should have the same rights to confidentiality and support as they would if they had any other medical condition

4

It can be very difficult for employees to discuss or openly admit to having a drink or drugs problem, because of the stigma or fear of reprisals, or the difficulty they have facing up to the issue.

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Construction Site Safety 1.6.4 Appendix 1 Example drink and drug misuse policy and procedure Any policy should reflect the requirements of the Contractor and must be implemented in practice. Introducing a policy that is not followed or is inappropriate to the business may be worse than not having a policy at all. The policy imposes obligations on you as a Contractor as well as your employees. If you have a policy you may, for example, have to agree to treatment for employees where you may otherwise have simply followed the disciplinary procedure.

2

Furthermore, if a policy is adopted it must be reviewed regularly to ensure that it is working and changed as necessary. You must also ensure the employees remain aware of the policy and its consequences.

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Policy

The company recognises the potential dangers of alcohol, drug and solvent misuse, known as substance misuse, to both the individual and the company.

4

The company aims to prevent, where possible, alcohol, drug and solvent misuse amongst employees and to detect at an early stage employees with problems.

5

The company aims to prevent misuse, where possible, and will offer assistance such as counselling or leave of absence from work if required for treatment. There may be, however, some instances when this offer may not be appropriate and managers must assess each case individually.

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Rules

Employees must not use, possess, conceal, transport, promote, or sell prohibited substances whilst on company premises, in company vehicles, on client premises or at the work site.

7

Employees must not report for work under the influence of alcohol or other drugs

8

Employees must not consume alcohol in the office or on site except on occasions approved by a senior manager.

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Establishing the problem 9

Managers should be aware that the misuse of drugs, alcohol or solvents by employees may come to light in various ways. The following characteristics, especially when arising in combinations, may indicate the presence of a substance problem.

Absenteeism 10

Instances of unauthorised leave.

11

Frequent Friday/Monday absences.

12

Leaving work early.

13

Lateness (especially on returning from lunch).

14

Excessive level of sickness absence.

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15

Strange and increasingly suspicious reasons for absence.

16

Unusually high level of sickness for colds, flu, and stomach upsets.

17

Unscheduled short-term absences, with or without explanation.

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High accident level 18

At work.

19

Elsewhere, for example driving, at home.

Work performance Difficulty in concentration.

21

Work requires increased effort.

22

Individual tasks take more time.

23

Problems with remembering instructions or own mistakes.

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Mood swings Irritability.

25

Depression.

26

General confusion.

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Self-referral 27

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In some instances, employees may come forward voluntarily and seek help themselves.

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Manager's responsibility

A manager is the individual responsible for a specific set of tasks and who has the power to issue orders, decisions and controls the resources and expenditures

29

A manager who suspects one of their employees of having a substance misuse problem must discuss the matter with the relevant manager/director before approaching the employee with their concern.

30

The manager will then discuss the matter with the employee and try to establish the cause of the problem (although it must be pointed out that individuals with a drugs or alcohol problem will often go to great lengths to conceal the situation).

31

The employee should be reminded or informed of the assistance the company is prepared to give employees who are trying to overcome an alcohol or drugs problem and should be informed of outside agencies where help can be obtained.

32

The employee should be informed that the company requires his or her performance to be improved to an acceptable and specifically outlined standard and that failure to achieve this will result in dismissal. The manager, having consulted with the director, should agree with the employee what follow-up action is to be taken. Where it is established that alcohol or drugs is or could be the problem, an appointment should be arranged with the company doctor or local drug and alcohol service provider.

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33

If the employee denies that either alcohol or drugs are the cause of the problem (whether believed or not), he should be treated as for any other disciplinary/capability problem, whichever is judged as appropriate by the manager and director.

34

However, if there are strong signs that the employee's unsatisfactory performance is drug or alcohol-related and he will not admit or acknowledge this, further encouragement should be given at all stages of the disciplinary/ capability procedure to face up to the problem.

Treatment and assistance Where employees acknowledge that they have a problem and are given support and treatment, this will be on the understanding that the company will give employees, assessed as having a substance misuse problem, all reasonable time off in accordance with the company's Absence Policy.

36

Every effort should be made to ensure that, on completion of the recovery programme, employees are able to return to the same or equivalent work.

37

However, where such a return would jeopardise either a satisfactory level of job performance or the employee's recovery, the appropriate director will review the full circumstances surrounding the case and agree a course of action to be taken. This may include the offer of suitable alternative employment, or the consideration of retirement on the grounds of ill health or dismissal. (Before a decision on dismissal is made, it should be discussed with the employee and an up-to-date medical opinion obtained.)

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35

Where an employee, having received treatment, suffers a relapse, the company will consider the case on its individual merits. Medical advice will be sought in an attempt to ascertain how much more treatment or rehabilitation time is likely to be required for a full recovery. At the company's entire discretion, more treatment or rehabilitation time may be given in order to help the employee to recover fully.

Recovery unlikely

o

If, after the employee has received treatment, recovery seems unlikely, the company may be unable to wait for the employee any longer. In such cases, dismissal may result but in most cases a clear warning will be given to the employee beforehand and a full medical investigation will have been undertaken.

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Relapse

Drug screening programme Procedure 40

Employees may be required to submit to a test to check for the presence of drugs or alcohol under the following circumstances. (a)

Following an accident or incident on company or client premises, at a work site or involving a Contractors vehicle.

(b)

Following the discovery of a prohibited substance on company premises.

(c)

Where there is reason to suspect that the employee may be under the influence of a prohibited substance.

(d)

Where it is suspected there has been a breach of the policy, for example high individual accident experience, excessive absenteeism, observed erratic behaviour and/or deteriorating job performance.

Refusal to take a drugs test

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If the employee refuses to take a drugs test, the employee will be subject to action under the company's disciplinary procedure up to and including dismissal.

Release of the test result 42

It is a condition of employment that all employees agree to the release of the results of screening for prohibited substances as required.

Right of search The Contractor reserves the right to search the person, his or her possessions and/or immediate work area, who works, visits or performs services on company premises. Where practical, in arranging for the search of the person to be carried out: the police will be contacted in the first instance

(b)

the person to be searched will be entitled to have a colleague present

(c)

the search will be carried out by someone of the same sex.

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Serious misconduct caused by alcohol, drugs or solvents

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If an employee is known to be, or is strongly suspected of being, intoxicated by alcohol, drugs or solvents during working hours, arrangements will be made for the employee to be escorted from the company premises immediately. The Contractors doctor may also be consulted on the incident. Disciplinary action will take place when the employee has had time to become sober.

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Intoxicated employees

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Consumption of alcohol on the premises

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Employees are expressly forbidden to consume alcohol when at work or to bring alcohol onto company premises under any circumstances. Any breach of this rule will result in disciplinary action being taken which is likely to result in summary dismissal.

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Education and training

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The Contractor will provide training for appropriate staff in recognising and responding to the early stages of alcohol or drugs problems amongst employees. The Contractor will provide health educational initiatives to raise awareness of the policy and the risks associated.

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How usually taken

Effects sought

Harmful effects include

Heroin(Smack, horse, gear, H, junk, brown, stag, scag, jack)

Injected, snorted or smoked

Drowsiness, sense of warmth and wellbeing

Physical dependence, tolerance, overdose can lead to coma and even death. Sharing injecting equipment brings risk of HIV or hepatitis infection

Snorted in powder form, injected

Sense of well-being, alertness and confidence

Dependence, restlessness, paranoia, depression, damage to nasal membranes

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Name (street or trade name)

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Commonly misused substances

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Cocaine(coke, charlie, snow, C)

Crack(freebase, rock, wash, stone)

As for cocaine but, because of the intensity of its effects, crack use can be extremely hard to control, damage to lungs

Ecstasy(E, XTC, doves, disco biscuits, echoes, scooby doos)Chemical name MDMA

Swallowed, usually in tablet form, occasionally snorted as a powder

Alertness and energy but with a calmness and sense of well-being towards others. Heightened sense of sound and colours

Possible nausea and panic, overheating and dehydration if dancing, which can be fatal. Use has been linked to liver and kidney problems. Long-term effects not clear but may include mental illness and depression

LSD(acid, trips, tabs, dots, blotters, microdots)

Swallowed on a tiny square of paper

Hallucinations, including distorted or mixed-up sense of vision, hearing and time. An LSD trip can last as long as 812 hours

There is no way of stopping a bad trip which may be a frightening experience. Increased risk of accidents can trigger off long-term mental health problems

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Smokable form of cocaine Similar to those of snorted cocaine but initial feelings are much more intense

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How usually taken

Magic mushrooms(shrooms, mushies)

Eaten raw or dried, Similar effects to those of LSD but the cooked in food or brewed trip is often milder and shorter in tea

As for LSD, with the additional risk of sickness and poisoning

Swallowed as tablets or capsules, injected ampoules

Dependence and tolerance, overdose can lead to coma or even death. Severe withdrawal symptoms

Effects sought

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Barbiturates(barbs, downers)

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Calm and relaxed state, larger doses taken to produce a drunken effect

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Amphetamines(speed, whizz, uppers, In powder form, dissolved Stimulation of the nervous system, billy, sulph) in drinks, injected, sniffed wakefulness, feeling of energy and or snorted confidence Rolled in tobacco into a Relaxed, talkative state, heightened spliff, joint or reefer and sense of sound and colour smoked; smoked in a pipe or eaten *Also smoked from a 'bong' waterpipe

Tranquillisers(brand names include Valium, Altivan, Mogadon (moggies), Temazapam (wobblies, mazzies, jellies))

Swallowed as tablets or capsules, or injected

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Cannabis(hash, dope, grass, blow, ganja, weed, shit, puff, marijuana, skunk*)


Insomnia, mood swings, irritability, panic. The comedown (hangover) can be severe and last for several days Impaired co-ordination and increased risk of accidents, paranoia, poor concentration, anxiety, depression, increased risk of respiratory diseases including lung cancer. Possible risk of developing mental health problems, especially schizophrenic conditions

Prescribed for the relief of anxiety and to Dependency and tolerance, increased risk of treat insomnia. High doses cause accidents, overdose can be fatal, severe drowsiness withdrawal symptoms

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How usually taken

Anabolic steroids(many trade names)

Injected or swallowed as tablets

Effects sought


With exercise can help to build up muscle. However, there is some debate about whether drug improves muscle power and athletic performance

For men: erection problems, risk of heart attack or liver problems For women: development of male characteristics Injecting equipment brings risk of HIV or hepatitis infection

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Poppers(alkyi nitrates, including arnyl Vapours from a small bottle Brief and intense head-rush caused by Nausea and headaches, fainting, loss of nitrate with trade names such as Ram, of liquid are breathed in sudden surge of blood through the balance, skin problems around the mouth and TNT, Thrust) through mouth or nose brain nose, particularly dangerous for those with glaucoma, anaemia, breathing or heart problems

Solvents(including gas lighter refills, aerosols, glues. Some paint thinners and correcting fluids)

Sniffed or breathed into the Short-lived effects similar to being lungs drunk and disoriented, possible hallucinations

Nausea, thick-headed, dizziness, blackouts, increased risk of accidents. Fatal heart problems can cause instant death

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Safety Critical Communication

1.6.5.1 Key points Good communication is essential for the management of health and safety on construction sites.

2

Contractors are legally required to provide information that is 'comprehensible', i.e. provided in a format that can be understood by the worker.

3

This requirement can result in problems where the recipients of the information have limited or no understanding of Arabic and/or English, particularly during site induction.

4

Communicating using images has the potential to overcome these problems, regardless of the mix of languages spoken on site.

5

A bank of images, each representing a hazard or a simple instruction has been developed.

6

It is likely that it will be necessary to hold separate training sessions to assess the understanding of safety critical words and phrases by those with Arabic and/or English language problems.

7

Confirming that the workers being assessed can associate each image with a spoken short phrase in plain Arabic and/or English, will give supervisors and managers confidence that the workers have an understanding of safety critical words in Arabic and/or English.

8

Due to their simplicity, these phrases aid translation into other languages, if needed.

9

Before using any images, workers' competence, training and language skills must be assessed. This will also indicate the level of supervision required generally.

10

The images can be used to support site inductions, tool box talks or other training, or superimposed on site plans to identify the location of welfare facilities, fire-fighting equipment, and so on.

11

The images also help to fill gaps in translation, as well as improving memory recall of site rules.

12

If appropriate, the images can enhance and complement existing procedures rather than replace them.

13

An understanding of the images should not be solely relied upon to ensure that work of a higher risk nature can be carried out safely.

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Good communication is essential for the management of health and safety on construction sites. The number of workers on sites, where Arabic and/or English is not their first language, has increased over recent years. Some of these workers have excellent skills in spoken and written Arabic and/or English, but there are others for whom understanding Arabic and/or English is a problem. This can be a barrier to effective communication of health and safety information.

1.6.5.3 Relevant health and safety legislation Health and Safety at Work 1

Contractors to provide employees with any necessary information and adequate training to ensure their health and safety at work.

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1.6.5.4 The Management of Health and Safety at Work The requirements of these Regulations: (a)

requires Contractors to provide 'comprehensible' information on the: (i)

risks identified in their risk assessment

(ii)

preventative and protective measures identified as necessary by risk assessments

(iii)

emergency procedures on site

(iv)

risks arising from the work of other contractors

(b)

duties on Contractors to provide 'comprehensible' information to subcontractors and the self-employed

(c)

duty on Contractors to take into account the capabilities of their employees. This includes their capability to understand instructions and training given in Arabic and/or English

(d)

places duties on Contractors regarding the employment of temporary workers or those supplied by a labour agency. Before starting work these workers need to be supplied with 'comprehensible' information on:

ta

any special occupational qualifications or skills required to enable the worker to work safely

(ii)

the requirement for any health surveillance arising out of the work to be carried out.

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(i)

The word 'comprehensible' can be taken to mean provided in a format that can be understood by the worker. The Contractor can provide information in a form which takes into account any language difficulties and suggests the use of symbols as one way of doing this.

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These Regulations place duties on the Contractors to ensure that workers are provided with instruction and training, with specific references made to induction training and site rules.

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1.6.5.6 Managing the situation 1

Contractors who engage workers who cannot speak or understand Arabic and/or English have a few options when deciding how to manage communications. These include hiring a bilingual supervisor who can give information, instruction and training to workers. Alternatively, Arabic and/or English speaking co-workers are often used on site to communicate with non-Arabic and/or English speaking workers. However, their competence (both technically in construction and as a translator) must be assessed first.

2

Another option is for training materials to be translated or to be represented in a pictorial form (images). The effectiveness of images to overcome language barriers has been confirmed through research.

1.6.5.7 Pre-start assessments 1

Before any worker starts on site certain facts must be established. These are the level of: (a)

the worker's competence and training

(b)

the worker's understanding of Arabic and/or English

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supervision required.

2

The type of work to be done by the worker will dictate the required level of competence and identify any training needed. Regardless of language issues foreign workers must meet the level of competence and training expected of any worker asked to do the task(s). Therefore, contractors should apply the same criteria for non/low-Arabic and/or English speaking workers as they do for Arabic and/or English speakers, which will require some form of competency assessment.

3

Failure to prove an acceptable level of competence will indicate that further training is required before considering the other pre-start factors.

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END OF DOCUMENT

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Section 11: Health and Safety Page 1 Part 1.07: Fire and Flammable Substances (Regulatory Document)


1.7

FIRE AND FLAMMABLE SUBSTANCES ........................................................ 1

1.7.1

Fire Prevention and Control in the Office....................................................... 4

1.7.2

Fire Prevention and Control in connection to construction .......................... 25

1.7.3

Dangerous Substances ............................................................................... 35

1.7.4

Liquefied Petroleum Gases ......................................................................... 50

1.7.5

Vehicle Fuels (including Petrol, Diesel and LPG) ........................................ 67

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1

QCS 2014


FORWARD

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QCS 2014


Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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Item Name

.

Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

9

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9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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1.7.1


Fire Prevention and Control in the Office 1.7.1.1 Key points Fires can and do kill, injure and cause serious human suffering and financial loss. The potential dangers are particularly severe on many construction sites, where construction activities such as hot work are frequently combined with circumstances where fires can spread quickly and escape may be difficult.

2

The rate of injury to people and damage to property and environment caused by fire in connection to construction is significant.

3

When construction activities are not adequately controlled, employees and members of the public can also be killed or injured, and property adjacent to construction sites be put at risk – for example, from a site fire large enough to spread off-site. Offices in particular site offices are vulnerable to fire risks and serious fire damage.

4

Particular attention is required regarding sites, premises, temporary accommodation brought onto site to provide offices, canteens and welfare facilities that are occupied by people at work on construction sites. They shall be subjected to a specific fire risk assessment.

5

Temporary accommodation on site must be used for their intended purpose. They shall not be used for storing dangerous substances.

6

These Regulations require a risk based approach for fire prevention and control and places legal obligations on the contractor to carry out a fire risk assessment and put in place appropriate control measures and maintaining them in accordance with any changes that occur.

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site-based offices and temporary site accommodation;

(b)

off-site company offices;

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(a)

(c)

any other place of work in connection to construction activities.

These Regulations require the contractor to ensure that:

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These Regulations places legal duties on contractors (thereafter referred to as ‘the contractor’) for fire prevention and control with regards to:

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(d)

construction sites, offices, premises and temporary accommodation or part of them are subjected to fire prevention and control measures;

(e)

fire risk assessments are carried out, recorded, reviewed and acted upon;

(f)

fire arrangements are in place for the offices, temporary accommodation and the construction site;

(g)

elimination and reduction of risks from dangerous substances are followed;

(h)

fire detection and fire systems are in place;

(i)

Procedures for serious and imminent danger and for danger areas;

(j)

emergency arrangements are in place including emergency routes and exits;

(k)

liaison is undertaken with the relevant governing body for fire.

1.7.1.3 The fire problem (l)

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1.7.1.4 Enforcement of fire safety legislation 1

The Fire safety legislation is enforced by the Civil Defence, Ministry of Interior, the State of Qatar.

1.7.1.5 Duty for fire prevention 1

These Regulations require the contractor to undertake a formal risk assessment in relation to: (a)

site-based offices and temporary site accommodation;

(b)

off-site company offices;

(c)

any other place of work in connection to construction activities and his undertakings;

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so as to determine the appropriate fire safety measures to be implemented.

These measures include a suitable means of escape, fire alarms, emergency lighting and fire-fighting equipment. Suitable records should be maintained.

3

The Contractor must:

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take such general fire precautions as will ensure, so far as is reasonably practicable, the safety of any of their employees; and

(b)

in relation to relevant persons who are not their employees, take such general fire precautions as may reasonably be required to ensure that the premises are safe.

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'General fire precautions' includes:

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(a)

reducing the risk of fire and the spread of fire on the premises

(b)

methods of escape

(c)

measures for securing that the means of escape can be safely and effectively used at all times

(d)

measures in relation to the means for detecting fire on the premises and giving warning in case of fire on the premises

(e)

arrangements for action to be taken in the event of fire, including measures relating to the instruction and training of employees, and measures to mitigate the effects of the fire.

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(a)

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(f) 5

measures in relation to the means for fighting fires on the premises


assess the risks to which relevant persons are exposed

(b)

consider the effects of dangerous substances

(c)

review the risk assessment regularly, particularly if there have been significant changes to the environment

(d)

not employ young persons without making a suitable and sufficient risk assessment of the risks to them.

6

The risk assessment must include the control measures which have been, or will be taken, to reduce the risk of fire and identify any group of persons identified by the assessment as being especially at risk.

7

No new work activity involving a dangerous substance may start unless the risk assessment has been made and the required measures have been implemented.

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Elimination or reduction of risks from dangerous substances 8

Where a dangerous substance is present, the Contractor must ensure that risks are either eliminated or reduced so far as is reasonably practicable.

Fire-fighting and fire detection 9

Where necessary, the contractor must ensure that the premises are equipped with appropriate fire-fighting equipment, fire detectors and alarms. Any non-automatic fire-fighting equipment must be easily accessible, simple to use and indicated by signs.

10

The Contractor must, where necessary: take measures for fire-fighting on and in the premises, adapting them to the nature of the activities carried out there and the size of the undertaking and of the premises concerned

(b)

nominate competent persons to implement those measures and ensure that the number of such persons, their training and the equipment available to them are adequate, taking into account the size of the premises concerned and any related hazards. This requirement does not apply to a self-employed person or a partnership where, in either case, there is sufficient knowledge and experience to enable adequate preventative and protective measures to be taken

(c)

arrange any necessary contacts with external emergency services, particularly regarding fire-fighting, rescue work, first aid and emergency medical care.

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(a)

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In order to safeguard the safety of relevant persons where necessary, the Contractor must ensure that routes to emergency exits from premises and the exits themselves are kept clear at all times. The following requirements must be complied with. Emergency routes and exits must lead as directly as possible to a place of safety.

(b)

People must be able to evacuate the premises quickly and safely.

(c)

The number, distribution and dimensions of emergency routes and exits must be adequate for the maximum number of persons who may be there at any one time.

(d)

Emergency doors must open in the direction of escape. Sliding or revolving doors must not be used for exits specifically intended as emergency exits. Emergency doors must not be locked or fastened in a way that stops them from being easily and immediately opened in an emergency.

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Emergency routes and exits

(e)

Emergency routes and exits must be indicated by signs. Emergency routes and exits requiring illumination must be provided with emergency lighting of adequate intensity in the case of failure of their normal lighting.

Procedures for serious and imminent danger and for danger areas 12

The Contractor must establish and put into effect appropriate procedures, including safety drills, and nominate a sufficient number of competent persons to implement those procedures. The Contractor must also ensure that nobody can access any area to which access has been restricted on grounds of safety, unless the person concerned has received adequate safety instruction.

Additional emergency measures in respect of dangerous substances 13

The Contractor must ensure that: (a)

information on emergency arrangements is available

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(b)

suitable warning and other communication systems are established to enable an appropriate response

(c)

where necessary, before any explosive conditions are reached, visual or audible warnings are given and relevant persons withdrawn

(d)

where the risk assessment indicates it is necessary, escape facilities are provided and maintained to ensure that, in the event of danger, relevant persons can leave endangered places promptly and safely.

14

The Contractor must ensure that the information required is made available to relevant accident and emergency services, and also displayed at the premises, unless the results of the risk assessment make this unnecessary.

Maintenance The Contractor must ensure that the premises and any facilities, equipment and devices provided are subject to a suitable system of maintenance and are maintained in an efficient state, in efficient working order and in good repair.

16

Where the premises form part of a building, the Contractor may make arrangements with other occupiers of the building to ensure that the above requirements are met.

17

Provision of information to employees, self-employed and Contractors from outside the undertaking

18

The Contractor must provide employees and relevant others with understandable and relevant information on the risks identified, the preventative and protective measures, the significant findings of the risk assessment and certain other matters. Such information will usually be communicated by way of safety signs, site induction, written procedures and similar means.

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(a)

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The Contractor must ensure that employees are provided with adequate safety training that includes suitable and sufficient instruction and training on the appropriate precautions and actions to be taken by employees in order to safeguard themselves and other relevant persons on the premises. It needs to take account of the fire risk assessment and the emergency procedures, and be easily understandable and repeated periodically. The training should cover: discovering a fire

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Training

(b)

how to raise the alarm

(c)

what to do on hearing the alarm

(d)

procedure for alerting visitors and all staff

(e)

calling the fire service

(f)

evacuation procedures, assembly points and fire drills

(g)

location and use of fire-fighting equipment

(h)

location of escape routes

(i)

how to open escape doors

(j)

importance of fire doors

(k)

how to stop equipment and isolate power

(l)

not using lifts

(m)

use and risks of highly flammable and explosive substances

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(n)

good housekeeping

(o)

smoking policy and smoking areas.

Co-operation and co-ordination 20

Where two or more Contractors share, or have duties at, premises, whether on a temporary or a permanent basis, they must co-operate as necessary to enable them to comply with the requirements of these Regulations.

General duties of employees at work

take reasonable care for the safety of themselves and of other relevant persons who may be affected by their work

(q)

co-operate with their employer (the contractor)

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(p)

The employee must inform their employer, or any other employee with specific responsibility for the safety of employees, of any work situation which they would reasonably consider to be a serious and immediate danger to safety. Employees should also report any matter which they consider to be a shortcoming in the employer’s protection arrangements for safety.

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Every employee must, while at work:

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1.7.1.6 The Management of Health and Safety

These Regulations require that risk assessments be carried out for all work activities. These include assessing and controlling the risk of fire on construction sites.

2

Furthermore, these Regulations require that all Contractors have access to competent health and safety advice, which again in the context of this module, includes having access to someone who is competent to:

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accurately assess the risks to the health and safety of any person from the outbreak of a fire, and

(b)

indicate to the Contractor what additional actions, if any, must be taken to adequately control those risks

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1.7.1.7 Construction (Design and Management) CDM In most cases, the requirements for fire and safety in on-site offices and other accommodation will be enforced under these Regulations and the requirements are: (a)

for measures to be taken to prevent the risk from fire, explosion or any substance likely to cause asphyxiation.

(b)

for measures to be taken to detect and fight fires in relation to work carried out on construction sites.

1.7.1.8 Fire risk assessments 1

The stages of a fire risk assessment are:

Identify potential fire hazards on site 2

What flammable materials are present?

3

What sources of ignition are present?

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4

Can anything be done to reduce either?

5

What must be done to keep flammable materials and sources of ignition apart?

Identify who might be harmed How many people are at risk?

7

Are any at an enhanced level of risk because of what they do or where they work?

8

Is the means of raising the alarm effective - can it be heard by all?

9

Are escape routes clearly signed and kept free of obstructions?

10

Does everyone know where their escape route is?

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Determine the level of risk

Having considered the fire hazards and who might be harmed, is the level of risk acceptable - are the existing fire prevention measures adequate?

12

To determine the answer to the above point consider:

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are sources of ignition under adequate control?

(b)

is a hot-works permit system in place and if not, is one necessary?

(c)

are the existing fire detection/warning systems effective?

(d)

is the means of escape (for everyone on site) adequate?

(e)

is the means of fighting fire (for example, portable fire extinguishers) adequate, appropriate for the likely type of fire and well maintained?

(f)

have sufficient site staff been trained in the use of fire extinguishers?

(g)

is it necessary to establish a network of Fire Wardens to oversee any evacuation of the site?

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(a)

Significant findings of the risk assessment, including details of any actions taken to reduce the fire risk, must be recorded in a manner that can be easily retrieved should it be necessary to do so.

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Record the significant findings

Review the fire risk assessment 14

It could be argued that this stage is more important on construction sites, due to the everchanging nature of the site, than it is in many other types of workplace.

15

For example, consider: (a)

what was an escape route last week might be a 'dead-end' today

(b)

the increasing complexity of escape routes as large structures are built

(c)

the start of a "hot-works' process

(d)

the start of a process that necessitates the storage of flammable substances, such as LPG and other gases, in bulk.

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1.7.1.9 The following is a list of some of the factors that should be considered when carrying out a fire risk assessment.

Abrasive cutters

(c)

Heaters

(d)

Heat-producing processes

(e)

Electrical apparatus

(f)

Machinery overheating

(g)

Discarded smoking materials

(h)

Arson or malicious fire-raising

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(b)

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Hot work

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Storage of combustible materials Flammable gases

(b)

Flammable liquids

(c)

Timber

(d)

Plastics

(e)

Paper, cardboard and similar materials

(f)

Cotton, wool and similar materials

(g)

Flammable waste material

Building features Access, egress

(b)

Floor openings

(c)

Flues

(d)

Doors, windows

(e) (f)

(g)

Floor construction

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(a)

Atria

Wall linings

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(a)

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Sources of possible ignition

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Maintenance (a)

Cleaning (use of flammable materials)

(b)

Plant maintenance

Fire detection (a)

Automatic detectors

(b)

Fire alarm call points

(c)

Alarm bells

Means of escape in case of fire (a)

Doors

(b)

Staircases

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(c)

Passageways

(d)

Assembly points

(Note that lifts are not recommended as a means of escape.)

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Fixed fire-fighting equipment

(b)

Hose reels, sprinklers

(c)

Extinguishers

(d)

Position of extinguishers

(e)

Site fire plan

Test regularly

(b)

Service after use

(c)

Maintain in correct position

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Maintenance of fire-fighting equipment

Staff training Raising the alarm

(b)


(c)

Appointment of fire wardens

(d)

Fire drills

(e)

Fire-fighting equipment

(f)

End-of-day fire checks

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Provision of fire-fighting equipment

An example fire risk assessment questionnaire is included at Appendix 2.

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1.7.1.10 On-site temporary buildings Temporary buildings on site include site offices, canteens, rest rooms, drying rooms and toilets. They are often of timber construction, although of fire-resisting surface materials. They may be found as a single building, or as a range of single-storey structures, or they may form a multi-floor 'administrative complex'. Ideally all temporary buildings would be easily accessible by the fire and rescue service, should the need arise.

2

Temporary buildings should be separated from the building under construction, other temporary buildings and storage compounds by a fire-break of at least 10 metres where possible. If it is not possible to achieve a 10-metre separation, ideally, the fire break will not be less than 6 metres.

3

Temporary buildings which are located inside the building under construction, or within 6 metres of it, must be equipped with fire-detection systems.

4

Temporary buildings should be designed and constructed:

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(a)

of materials that would not contribute significantly to the growth of a fire or the propagation of smoke or corrosive fumes

(b)

of fire-resisting material to BS 476 with regard to walls, roof, doors and windows, to achieve 30 minutes fire resistance

(c)

where stacked on top of each other, the floor and roof assembly, and members

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Section 11: Health and Safety Page 12 Part 1.07: Fire and Flammable Substances (Regulatory Document) supporting it, should have at least a 30-minute fire resistance.

5

Where temporary buildings do not sit flush on the floor, measures must be taken to prevent the accumulation of rubbish in the space beneath the floor, whilst still allowing under-floor ventilation.

6

Consideration should be given to fitting automatic fire detection systems and intruder alarms to temporary buildings in which flammable substances are stored.

7

Automatic fire detection systems must be fitted in temporary buildings in which cooking is carried out.

1.7.1.11 The conditions for fire In order to take the measures required to prevent fires starting, it is first necessary to understand the conditions that must be present to enable a fire to start.

2

Three factors are necessary for fires to burn:

3

Fuel or combustible material. Any material or substance, whether liquid, solid or gas, which will burn given sufficient amounts of heat and a supporter of combustion such as air or oxygen.

4

Heat or ignition source. Every fuel has an ignition temperature. All solids and liquids give off vapour when heated, and it is this vapour that ignites.

5

Air (or other supporter of combustion such as oxygen) which is always there to sustain fire, providing the other factors are present.

6

Once a fire has started, if any one of these factors is isolated or removed, the fire will be extinguished. There are three basic ways of achieving this:

7

Removal of the fuel or combustible material, leaving nothing to burn.

8

Removal of the heat by the application of water to cool the burning material.

9

Reduction or exclusion of the air/oxygen by smothering the burning material. Foam, dry powder, carbon dioxide (CO2) and fire blankets are all smothering agents.

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1.7.1.12 How fires can be spread 1

Fire can be spread in four ways: (a)

conduction

(b)

convection

(c)

radiation

(d)

direct burning.

2

Conduction is where heat is transmitted from one place to another along or through solid material, such as along a metal pipe or through a door or wall. The conduction of heat therefore has the potential to start a fire in a location that is remote from the original source of heat.

3

Convection occurs where superheated gases or heat rising from a fire ignites other combustible material or when particles of burning material in the circulating air are deposited

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in another place, causing another fire. 4

Radiation is the transfer of radiated heat from the fire, through the air directly to other flammable materials nearby, which will cause those materials to be raised to their ignition temperature and then burn.

5

Direct burning is a combination of conduction, convection and radiation and is where the fire spreads and reaches other combustible materials and ignites them, adding further fuel to the fire.

1.7.1.13 Classes of fire All fires can be placed into one of the following six categories.

2

Class A - Carbonaceous material, such as paper, cloth, wood, rubber, often referred to as 'solid fuel fires'.

3

Class B - Flammable liquids or liquefiable solids, such as oil, fat, paint and fuel. These can be subdivided into:

4

B1 - Fires involving liquids that are soluble in water, such as methanol. They can be extinguished by carbon dioxide, dry powder and water spray.

5

B2 - Fires involving liquids that are not soluble in water, such as petrol and oil. They can be extinguished using foam, carbon dioxide and dry powder.

6

Class C - Flammable gases or liquefied gases, such as propane, butane, hydrogen or acetylene.

7

Class D - Combustible metals, such as magnesium, sodium and phosphorus.

8

Class E - Electrical fires - Any fire involving electrical apparatus or equipment.

9

Class F - High temperature cooking oils or fats, such as those used in deep fat fryers in large catering establishments or restaurants.

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On the majority of building or construction sites, the following carbonaceous items are freely available sources of fuel:

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Class A - carbonaceous material

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(a)

cardboard, paper and cloth

(b)

wood

(c)

dirty rags, oily rags and clothes

(d)

packaging materials.

If a fire occurs involving carbonaceous material, a hose-reel or a water extinguisher should be used. The jet of water should be aimed at the base of the fire first, and then moved progressively over the whole of the burning area. Always remove the material from the source of heat if possible, but without endangering the person involved or starting a fire in another location.

Class B - flammable liquids or liquefiable solids 12

Fires involving flammable liquids, such as: (a)

petrol or diesel

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(b)

oil

(c)

paraffin

(d)

paint

(e)

resin and adhesive.

This type of fire should be dealt with using foam or dry powder extinguishers, depending on whether the fire is contained or flowing.

14

If the fire is contained, use a foam extinguisher with the jet of foam directed at the back of the container.

15

This allows a blanket of foam to build up and spread across the surface of the burning liquid.

16

If the fire is flowing, a dry powder extinguisher should be directed at the front edge of the fire, in an attempt to separate the flames from the fuel.

17

The aim of using extinguishers in such a way is for the fire to be covered with a blanket of either foam or dry powder. This will cut off the supply of air, and thus the oxygen, to the fire.

18

Once the blanket has been laid, do not disturb it until the liquid has cooled. Any reintroduction of air may cause the fire to re-ignite.

19

NEVER use a water extinguisher or a hose-reel on a fire involving any flammable liquid. The water will react violently with the burning liquid and cause an explosion.

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Class C - flammable gases or liquefied gases

Extreme caution is necessary when dealing with fires involving liquefied gases as there will always be the danger of an explosion.

21

LPG expands to a ratio of 274:1 so a leak of just 1 litre of liquid would produce a cloud of gas, if diluted in air to the right concentration, large enough to fill a room 3m x 2m x 2m. This would cause an explosive atmosphere.

22

If a fire occurs in which a compressed gas cylinder is directly involved: (a)

call the Qatar Administrative Authority and tell them of the location of the cylinders and type of gas involved attempt to turn the gas off at the cylinder, if it is safe to do so

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(c)

attempt to turn off any gas appliances if it is safe to do so

(d)

activate the emergency evacuation procedure and clear the site.

23

Do not try to fight a fire in which a compressed gas cylinder is directly involved; leave it to the Qatar Administrative Authority as an overheated cylinder can explode.

24

If a fire involves other combustible materials, for example timber, that might cause the fire to spread to the location of the cylinders, a decision based upon personal safety will have to be taken upon whether to attempt to fight the fire to prevent an escalation of the situation.

25

Class C fires are best dealt with by the use of dry powder extinguishers.

Class D - combustible metals 26

Fires of this type involve magnesium, sodium, phosphorus, and similar metals, and should only be dealt with by trained fire fighters.

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27

NEVER APPLY WATER TO ANY BURNING METAL FIRE OR A FIRE INVOLVING POWDERED METAL. It would cause an immediate explosive reaction.

28

Specially formulated powders are available for use in controlling fire in metals but, as a last resort, if no proprietary powder is available, dry sand or earth may be applied to smother the burning area.

29

The proprietary powder should be carefully placed and not thrown onto the burning metal. Throwing the powder will cause the burning material to be spread.

30

Be sure either to wear darkened safety glasses whilst attempting to cover the fire, or to look away from the extreme brightness. Failure to take these precautions could damage the eyes.

1.7.1.14 Electrical fires Fires involving electrical equipment can be dealt with using carbon dioxide (CO2) or dry powder.

2

In staff training, the following simple rules for safety should be emphasised:

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do not use water on any fire involving electrical equipment. You may be electrocuted

(b)

switch off the electricity supply, if possible, before fighting the fire. It is then just an ordinary fire

(c)

do not approach closer than 1 metre to any fire where the electrical supply has not been switched off

(d)

carbon dioxide (CO2) is the best extinguishing medium if the concentration of gas can be confined, for example within an electrical distribution cupboard

(e)

in extinguishing electrical fires, direct the discharge from the extinguisher to one edge of the fire and, with a sweeping movement, pass to the far edge until the fire has been extinguished.

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(a)

Electrical equipment used on building and construction or demolition sites sometimes incorporates devices to protect against overheating and fire.

4

Most fires in electrical equipment are due to misuse or neglect, where appliances have not been properly maintained, or are being used for a purpose, or in a manner, for which they were not designed.

5

A fuse larger than the appliance rating will negate the purpose of the fuse and render the appliance potentially unsafe.

6

All employees should be properly trained so that they do not misuse equipment, and ensure that damaged or defective equipment is reported, taken out of use and professionally repaired.

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1.7.1.15 Other types of fire Flammable adhesives and flammable liquid stores 1

Use dry powder or foam.

2

Extreme care must be taken if the adhesive is petroleum- or spirit-based as explosive vapours will be given off.

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Cooking ranges (site canteens) 3

Use foam, dry powder, carbon dioxide (CO2) or a fire blanket. Never move a cooking container, the contents may splash and cause serious burns.

Hot working with cutting or welding equipment, bitumen boilers 4

Use foam, dry powder or carbon dioxide (CO2). Turn off the heater.

5

The correct types of fire extinguisher must be provided and kept close at hand, with a careful watch being maintained for fire breaking out whilst work is in progress.

1.7.1.16 Dealing with fire In the event of a fire, the most important consideration is the safety of occupants such as site visitors and staff.

2

Effective control measures, such as periodically practising emergency evacuations and the routine maintenance and/or testing of fire detection and fire-fighting equipment, can save lives. Everyone must know what they have to do if there is a fire or during a rehearsal of emergency evacuation procedures (a fire drill).

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1.7.1.17 Emergency procedures

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In the event of a fire occurring, it is essential that the alarm is raised as quickly as possible so that workers can quickly and safely reach a place of safety.

2

This can only be achieved by considering the following steps.

3

A means of detecting and warning of fire must be provided in all offices. Hand bells, klaxons, manually or electrically operated sounders may be suitable so long as they are clearly audible above background noise in all areas and can be readily identified as being a fire alarm. Flashing lights or vibrating pagers may be required in certain circumstances.

4

Legible written emergency procedures must be displayed in prominent locations within offices and should include: the location of the notice to enable the location of the fire to be pinpointed, e.g. firstfloor photocopier room

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(b)

instructions for raising the alarm

(c)

instructions for calling the fire and rescue service

(d)

instructions to report to the nearest assembly point

(e)

clear information as to the whereabouts of the assembly point

(f)

a clear instruction not to leave the assembly point until a roll-call has been taken

(g)

an indication of the locations of fire escape routes

(h)

an instruction not to re-enter the building or site until it has been declared safe to do so by someone in authority.

1.7.1.18 Calling the fire and rescue service 1

If a fire is discovered, everyone on site must be made aware of it. The fire and rescue service must be called. Where there is a switchboard, it is usual for the switchboard operator to be nominated as the person who always calls the Civil Defence (Fire Department).

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2

On hearing the alarm, anyone calling the fire and rescue service should give the full postal address of the site, any prominent nearby landmark, and any instruction for entering the site where there is more than one option.

3

If you have a fire alarm which is automatically connected to the Civil Defence (Fire Department) via an alarm company, the Civil Defence (Fire Department) must still be called to confirm that the automatic call has been received.

Location of occupants It will be necessary to appoint fire wardens whose job it is to ensure that offices and other accommodation are completely evacuated in the event of the fire alarm sounding (including practice drills) and to conduct a roll-call at the assembly point.

5

The fire wardens must be trained in their duties and have a clear understanding of the area of the offices for which they are responsible. The number of fire wardens required will depend on several factors, including the area and layout of the office complex and the number of levels on which it is sited.

6

The location of permanent staff can be easily identified by the use of IN/OUT boards that can be removed from their normal location, taken to the assembly point and used for the roll-call.

7

Arrangements must be made for visitors to be logged into and out of offices so that, in the case of an emergency, they can be located quickly and taken to a safe place.

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Means of escape

Adequate means of escape must be provided to enable all visitors and employees to reach a place of safety if a fire occurs. If a fire occurs in the open air, it will usually be obvious to all site staff where the danger lies and the direction they must go to remain safe.

9

Means of escape must have regard and consider individuals with disabilities.

10

They should also consider the following points: As part of emergency planning, dedicated escape routes should be decided on, clearly signed and adequately lit.

(b)

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Such signs should be positioned where the escape route changes direction or level. The signs must indicate the final exit to a place of safety.

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(c)

All directional signs should be clearly visible and kept unobstructed and should conform to BS 5499.

(d)

11

To ensure that all site employees are aware of these escape routes, periodic fire drills should be carried out and should include the full evacuation of all visitors and staff from the building. Records should be kept of all drills and evacuations.

Where construction site offices are located in a multiple-occupancy building, the safety of other occupiers, as well as their visitors and members of the public, must be a consideration. For example, emergency exit routes from the premises may have to be maintained or provided for other occupiers through the construction area or other provisions made for them.

1.7.1.19 Emergency lighting 1

The provision of emergency lighting should always be considered when assessing the fire safety requirements for satisfactory means of escape.

2

This is particularly important where work is dependent on artificial lighting because natural

QCS 2014


light is not available or practical. 3

If the lighting circuits fail, any standby emergency lighting system must switch on automatically and clearly illuminate: (a)

exits and directional signs

(b)

corridors and associated exits

(c)

circulation areas

(d)

changes in levels

(e)

any projections and protrusions, such as temporary partitioning, office equipment and storage

(f)

internal and external staircases.

Emergency lighting, whether by battery or standby generator or a combination of both, should be tested on a regular basis by a competent person in accordance with BS 5266.

5

Records of tests of the emergency lighting equipment should be kept and must be available for inspection when required.

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Automatic or manual fire alarms should be tested weekly, with a different call point being used on each occasion where these are a feature of the system.

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1.7.1.20 Fire alarms

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1.7.1.21 Fire drills

Fire drills in site offices and on site should be held on a regular basis, at not more than sixmonthly intervals. They should take the form of a rehearsal of the evacuation procedures to ensure that everyone knows how to leave the site quickly and safely if a fire occurs.

2

Records of fire alarms, equipment tests and fire drills should be kept.

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1.7.1.22 Fire-fighting equipment

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Portable fire extinguishers

Fire extinguishers do not prevent fires.

2

Fire extinguishers can be used by trained employees in an attempt to minimise loss and damage after a fire has started. However, preventing the fire in the first place is a far better option.

3

Where there is a realistic possibility that staff will have to use a fire extinguisher, they should be trained in their use.

4

In line with the risks identified in a fire risk assessment, adequate numbers of suitable types of portable fire extinguisher must be provided and kept available throughout the premises.

5

Extinguishers must be located in conspicuous positions near exits on each floor. They should be fixed to the wall with their carrying handles approximately 1 metre above the floor level. Where this is not possible, they should be fixed in position (for example, using base plates or stands) at floor level.

6

In the open, they should be situated in red painted boxes which are either sitting on the floor or raised 500 mm above ground level, with a 'FIRE POINT' sign at a height readily seen

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above any obstructions. Care must be taken during winter months to ensure that extinguisher contents do not freeze. To protect electrical distribution panels and items of electrical equipment, appropriate extinguishers (usually carbon dioxide) must be provided near but not dangerously close to the equipment concerned.

8

For large or costly items of equipment, such as computer suites, the installation of automatic fire detection and extinguishing systems should be considered.

9

Fire-fighting equipment should be inspected monthly and maintained and tested at least once a year by a competent person. The maintenance and tests should be carried out in accordance with the manufacturer's instructions.

10

All fire-fighting equipment must be maintained and inspected regularly, and all such inspections recorded in the appropriate register.

11

Extinguishers should be tested by discharge at intervals specified in BS 5306, and should always be recharged immediately after any use.

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Colour of fire extinguishers All fire extinguishers should conform to BS EN 3.

13

Colour-coding by agent or medium (see below) enables a trained person to rapidly identify the type of extinguisher needed in an emergency. Colour of panel

Water Foam

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Red

Cream Blue Black Yellow

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Wet chemical

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Carbon dioxide

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Powder (all types)

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Extinguishing medium

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Other information concerning its use may also be displayed on the body of the extinguisher.

Toxic vapours from fire extinguishers 15

The discharge of a carbon dioxide (CO2) extinguisher in any small, enclosed or confined space will reduce the percentage of oxygen in the air. The dust cloud from a dry powder extinguisher may, in a confined space, produce local and temporary breathing difficulties and poor visibility.

16

Once an extinguisher has been discharged in such circumstances, the user should leave the area immediately. When it is safe to do so, the area should be thoroughly ventilated before allowing anyone to re-enter. If there is a need to re-enter before the air has cleared, suitable breathing apparatus will have to be worn.

Staff training in the use of fire extinguishers 17

The contractor is to ensure that all employees are familiar with fire procedures, and that an appropriate number of them are trained in the use of fire-fighting equipment.

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18

Training in the selection and use of portable extinguishers is essential if they are to be used effectively in fighting small fires.

19

It is also very important that the right type of extinguisher is used on certain types of fire. Details of which one to use with which type of fire are contained in Appendix 2 of this section.

20

Attention should be given to the physical strength of persons who may have to use extinguishers. Some extinguishers weigh up to 20 kg.

21

During staff training on the use of extinguishers, the following points also need to be emphasised:

(b)

only use an extinguisher if it is safe for you to do so

(c)

do not let the fire come between you and your escape route. You may become trapped if the fire develops

(d)

always stay between the fire and your escape route

(e)

if the extinguisher does not appear to be working or is ineffective on the fire, get out immediately

(f)

if the fire starts to increase or gets out of control, get out immediately.

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think of evacuation first

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During induction training or ongoing staff training, the following points should be made to all staff: do not use a fire extinguisher unless you have been trained to do so

(b)

do not misuse fire extinguishers, for example, when messing around or as a joke

(c)

do not move fire extinguishers from their allocated positions

(d)

do not use fire extinguishers as door stops

(e)

immediately report any fire extinguishers that appear to have been used, misused or damaged.

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1.7.1.23 Hose-reels Hose-reels linked to a constant water supply may sometimes be available, and can be an effective means of fire-fighting.

2

Hose-reels work:

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(a)

either, by the user opening a valve adjacent to the hose-reel drum before unreeling the hose and turning on the nozzle

(b)

or, by automatically turning on the supply as the hose-reel is unwound.

3

Training employees in the correct use of hose-reels is essential if fire-fighting is to be effective. Staff need to be fully aware of how the hose-reels work before they use them in an emergency.

4

A HOSE-REEL SHOULD NOT BE USED:

5

(a)

on live electrical apparatus

(b)

on any fire involving fat, oil, paint or other flammable liquids

(c)

on any fire involving burning metal or metal powder.

To do so could lead to electrocution, or a violent explosion of burning liquid or metal.

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1.7.1.24 Fire blankets These are usually sufficient to deal with small, contained fires involving frying pans, teamaking facilities and so on.

2

Before attempting to extinguish such fires, always turn off the gas or electricity supply.

3

Pull the blanket from its container and wrap the corners of the blanket around your hands, making sure that your hands and forearms are completely covered. Hold the blanket at chest level and gently place it over the burning container to exclude the air from the fire. DO NOT THROW the blanket as you may miss the burning container or cause it to spill.

4

Leave the blanket in place until the container has cooled down. Do not lift one corner to check if the fire is out as this may allow enough air in to re-ignite the fire. Do not move the container before it is cold.

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Section 11: Health and Safety Part 1.07: Fire and Flammable Substances (Regulatory Document)

Page 22

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Types of portable fire extinguisher and what to use them on Make yourself aware of the instructions on the fire extinguisher before using it. Water (red)

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Class Substances, materials, etc.

Foam (cream)

Carbon dioxide (CO2) (black)

Dry powder (blue)

Wet chemical (yellow)

YES Difficult to use o For small fires

YES outdoors in windy conditions only YES, but not if no water available ideal

Carbonaceous and organic materials, wood, paper, rag, textile, cardboard, common plastics, laminates, foam

YES Excellent YES

B

Flammable liquids, petrol, oil, fats, adhesives, paint, varnish

NO

YES If liquid is YES, but not ideal YES not flowing

YES, but not ideal

C

Flammable gas: LPG, butane, propane, methane, acetylene

YES Will cool the area and put out secondary fires

YES If in liquid YES form

YES

NO

D

Metal, molten metal, reactive metal powder

NO

NO

NO

YES Trained person - if no explosive NO risk Special powders are available, but DRY sand or earth may be used

NO

NO

YES

YES, but not ideal Or switch off NO electricity and deal with as an ordinary fire. Be aware that equipment may retain an electrical charge.

NO See Note

NO

NO

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Electri Electrical installations, computers, cal electric typewriters, VDUs, photocopiers, televisions, etc.

F

Commercial deep fat fryers or oil fryers NO

Notes: Dry powder may not penetrate spaces or behind equipment Light water foam (AFFF) may be used instead of water or foam Extinguishers used to control Class B fires will not work on Class F fires because of the high temperatures generated

YES

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Construction Site Safety 1.7.1 Appendix 2 Fire safety questionnaire 1

This questionnaire has been worded so that the desirable answer is YES. If you answer NO, you may wish to give more thought to the problem.

General Has a fire risk assessment been carried out?

3

Have any shortcomings highlighted by the risk assessment been rectified?

4

Have employees been made aware of the significant findings of the fire risk assessment?

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Flammable materials

Are flammable materials, especially flammable waste materials, cleared away on a daily basis?

6

Is there proper storage for highly flammable liquids?

7

Are LPG bottles being stored properly?

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Smoking materials Is there a non-smoking policy?

9

Are ashtrays provided in places where smoking is permitted?

10

Are there adequate and clear 'No Smoking' signs in areas where smoking is not permitted?

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Heating appliances

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Are heating appliances correctly sited, installed and maintained?

12

Are fuel supplies, such as propane and butane, kept outside and piped into the building?

13

Are combustible materials being kept well away from heaters and stoves?

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Electrical appliances 14

Is all electrical work or repairs carried out by competent electricians?

15

Are the correct fuses fitted to electrical appliances?

16

Is only one appliance being used from each socket?

17

Are all electrical appliances being inspected and tested regularly?

Staff training 18

Is everyone on site trained in fire prevention?

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19

Are all staff being properly trained in procedures to be followed in case of fire?

20

Are all staff being trained in the use of fire-fighting equipment?

21

Have fire marshals been appointed and trained?

22

Is the location of the fire assembly point known to everybody?

Fire extinguishers Are all fire extinguishers serviced regularly, checked and recharged as necessary?

24

Are all fire extinguishers of the appropriate type?

25

Are all fire extinguishers clearly identified and easily accessible?

26

Is there an up-to-date fire plan, showing the location of each fire extinguisher and its type, for the premises?

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Fire alarm Is the fire alarm tested weekly?

28

Is a different call point used for each test?

29

Can the fire alarm be heard clearly in all parts of the premises?

30

Is someone nominated to call the fire and rescue service in case of fire?

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Fire drills and records

Are fire drills held on a regular basis?

32

Are records kept of all drills and tests of equipment?

33

Are the records readily available for inspection?

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Fire Prevention and Control in connection to construction 1.7.2.1 Key points The risk of fire is greater during the construction- including refurbishment and demolition works.

2

This set of regulations is about preventing fires from starting and ensuring people’s safety if they do.

3

It applies to all construction works, small and large, and aimed at all with a role in developing, managing and applying fire safety prevention and development of standards and arrangements on site.

4

It is essential that fire safety are considered in the planning for construction and implemented effectively during the construction phase. Precautions must be considered at the design stage and before work starts.

5

It needs to address the risks both to the site personnel and neighbouring environment. This may mean rejecting proposals for particular methods and materials in a specific location, based on the potential for serious consequences from any fire during the construction stage, or planning additional, sometimes expensive or difficult, mitigation methods if a specific design or method is not to be changed.

6

Materials, methods of construction and site processes must be selected to minimise fire risk and work planned in an order that is practical but also minimises risk. For example, alternative specifications for materials which are fixed together using mechanical rather than hot means can reduce risk.

7

Sites involving higher risk materials and processes will need higher standards of general fire precautions. Reducing the risks is particularly important when there are constraints which cannot be removed such as location of site and space available.

8

There are specific duties for the responsible person to carry out fire risk assessments for construction and construction related activities. A detailed fire risk assessment and required controls need to be developed from the outset identifying the stages and activities which give rise to critical risk points and which, therefore, will need highest levels of control.

9

Fire risk assessments need to be carried out by a competent person. Projects that are more complex will probably need to be assessed by a person who has had comprehensive training or experience in fire risk assessments.

10

A high degree of communication and co-operation is required between all parties, including main and sub-contractors, to ensure adequate controls are in place at all times. Where construction work takes place in occupied or part-occupied buildings or premises, the responsible person needs to take account of the implications for occupiers including staff. Effective liaison between contractors and occupiers is essential.

11

Coordination with the Civil defence for works, including demolition shall be part of planning of works. The Civil Defence (Fire Department) may wish to be involved in advising on the management of on-site fire risks.

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It should be noted that the Civil Defence (Fire Department) can gain access to site at any time to conduct their fire fighting/prevention duties. Fire extinguishers, emergency lighting, fire alarms and fire signs must comply with current Civil Defence

1.7.2.2 Interpretation 1

“Construction work” means the carrying out of any temporary or permanent building, civil engineering or engineering construction and includes:


(a)

the construction, alteration, conversion, fitting out, commissioning, renovation, repair, upkeep, redecoration or other maintenance, (including the use of corrosive, flammable or toxic substances), de-commissioning, demolition or dismantling of a structure;

(b)

the preparation for an intended structure, including site clearance, exploration, investigation and excavation, and the clearance or preparation of the site or structure for use or occupation at its conclusion;

(c)

the assembly on site of prefabricated elements to form a structure or the disassembly on site of prefabricated elements which, immediately before such disassembly, formed a structure;

(d)

the removal of a structure or of any product or waste resulting from demolition or dismantling of a structure or from disassembly of prefabricated elements which immediately before such disassembly formed such a structure; and

(e)

the installation, commissioning, maintenance, repair or removal of mechanical, electrical, gas, compressed air, hydraulic, telecommunications, electronic or similar services which are normally fixed within or to a structure.

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“Dangerous substance” means:

a substance or preparation which meets the labeling guide for classification as a substance or preparation which is explosive, oxidising, extremely flammable, highly flammable or flammable;

(b)

a substance or preparation which because of its physico-chemical or chemical properties and the way it is used or is present in or on site or premises creates a risk; and

(c)

any dust, whether in the form of solid particles or fibrous materials or otherwise, which can form an explosive mixture with air or an explosive atmosphere;

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“Explosive atmosphere” means a mixture, under atmospheric conditions, of air and one or more dangerous substances in the form of gases, vapours, mists or dusts in which, after ignition has occurred, combustion spreads to the entire unburned mixture;

4

“General fire precautions” has the following meaning: measures to reduce the risk of fire on the construction sites and premises and the risk of the spread of fire on them

(e)

measures in relation to the means of escape from the construction sites and premises;

(f)

measures for securing that, at all times, the means of escape can be safely and effectively used; measures in relation to the means for fighting fires on construction sites and premises;

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(h)

measures in relation to the means for detecting fire on the premises and giving warning in case of fire on the construction sites and premises; and

(i)

measures in relation to the arrangements for action to be taken in the event of fire on the construction sites and premises, including— (i) measures relating to the instruction and training of employees; and (ii) measures to mitigate the effects of the fire.

5

“Responsible person” means: (a)

in relation to construction site, the party (normally the contractor) responsible for the site;

(b)

in relation to workplaces other than the above (such as an office building), the owner, if the workplace is under his control;

(c)

in relation to any place of work not falling within (a) or (b) (e.g. site compounds or premises) -

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Section 11: Health and Safety Page 27 Part 1.07: Fire and Flammable Substances (Regulatory Document) (i) the party who has control of the place of work; or (ii) the owner where the party in control of the place of work does not have control in connection with the construction works.

6

“Workplace” means any construction sites, site compounds, site premises or building provided on a permanent or temporary basis in connection with construction used or provided as a place of work and includes: (a)

temporary accommodation units brought onto site to provide offices, canteens and welfare facilities or a part of them;

(b)

any place within the sites or premises to which such employee has access while at work; and

(c)

any room, lobby, corridor, staircase, road, or other place— (i) used as a means of access to or egress from that place of work; or

“Substance” means any natural or artificial substance whether in solid or liquid form or in the form of a gas or vapour;

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(ii) where facilities are provided for use in connection with that place of work.

The responsible person shall:

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1.7.2.3 Duty for general fire precautions

(a) take general fire precautions to ensure, so far as is reasonably practicable, the safety of his employees; and

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(b) in relation to relevant persons who are not his employees, take general fire precautions, as may reasonably be required to ensure their safety and that of the construction site.

1.7.2.4 Duty for prevention of risk from fire form construction works

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The responsible person shall take suitable and sufficient steps to prevent, so far as is reasonably practicable, the risk of injury to any person during the carrying out of construction work arising from fire or explosion

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1.7.2.5 Duty for fire risk assessment The responsible person shall make a suitable and sufficient assessment of the risks to which relevant persons are exposed for the purpose of identifying the general fire precautions he needs to take to comply with the requirements of the Regulatory Document.

4

Any such assessment must be reviewed by the responsible person regularly so as to keep it up to date and particularly if:

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(a) there is reason to suspect that it is no longer valid; or (b) there has been a significant change in the matters to which it relates including when the site, special, technical and organisational measures, or organisation of the work undergo significant changes, change in scope or extensions; or 5

Where changes to an assessment are required as a result of any such review, the responsible person must make them.

6

The responsible person must not employ a young person unless he has, in relation to risks to young persons, made or reviewed an assessment in accordance with the above duties.

7

As soon as practicable after the assessment is made or reviewed, the responsible person must record the following: (a) the significant findings of the assessment, including the measures which have been or will be taken by the responsible person; and (b) any persons or group of persons identified by the assessment as being especially at risk.

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8


No new work activity involving a dangerous substance may commence unless: (a) the risk assessment has been made; and (b) the measures required have been implemented

1.7.2.6 Duty for Fire Safety arrangement 9

The responsible person must make and give effect to such arrangements as are appropriate, having regard to the size of his undertaking and the nature of its activities, for the effective planning, organisation, control, monitoring and review of the preventive and protective measures.

1.7.2.7 Duty for elimination and reduction of risks from dangerous substances Where a dangerous substance is or is liable to be present in or on site and premises, the responsible person shall ensure that risk to relevant persons related to the presence of the substance is either eliminated or reduced so far as is reasonably practicable:

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(a) replace a dangerous substance, or the use of a dangerous substance, with a substance or process which either eliminates or reduces the risk to relevant persons.

(c) mitigate the detrimental effects of a fire. The responsible person must:

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(b) Where it is not reasonably practicable to eliminate risk, apply control measures consistent with the risk assessment and appropriate to the nature of the activity or operation

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(a) arrange for the safe handling, storage and transport of dangerous substances and waste containing dangerous substances; and

Temporary accommodation on site must be used for their intended purpose. They shall not be used for storing dangerous substances.

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(b) ensure that any conditions necessary for ensuring the elimination or reduction of risk are maintained.

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1.7.2.8 Duty for fire detection and fire fighting In order to safeguard the safety of relevant persons, the responsible person must ensure that:

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(a) the site is, to the extent that it is appropriate, equipped with appropriate firefighting equipment and with fire detectors and alarms; and (b) any non-automatic fire-fighting equipment so provided is easily accessible, simple to use and indicated by signs. 14

For the purposes of the above, what is ‘appropriate’ is to be determined having regard to: (a) the dimensions; (b) Use of the site and work activities; (c) the equipment contained on the site; (d) the physical and chemical properties of the substances likely to be present; and (e) the maximum number of persons who may be present at any one time.

15

The responsible person must, where necessary: (a) take measures for fire-fighting in the site, adapted to the nature of the activities carried on there and the size of the undertaking and of the environment concerned; (b) nominate competent persons to undertaken and implement those duties and measures

QCS 2014

Section 11: Health and Safety Page 29 Part 1.07: Fire and Flammable Substances (Regulatory Document) respectively, and ensure that the number of such persons, their training and the equipment available to them are adequate, taking into account the size of, and the specific hazards involved in, the environment concerned; and

(c) arrange any necessary contacts with external emergency services, particularly as regards fire-fighting, rescue work, first-aid and emergency medical care. (d) A person is to be regarded as competent for the purposes of the above shall have sufficient training, experience and knowledge and other qualities to enable him properly to undertake the duties in relation to Fire prevention and control.

1.7.2.9 Emergency procedures Where necessary in order to safeguard the safety of any person on a construction site, the responsible person shall prepare and implemented suitable and sufficient arrangements for dealing with emergency, including procedures for any necessary evacuation.

17

The procedures shall take account of:

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(a) the type of work for which the construction site is being used;

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(b) the characteristics and size of the construction site and the number and location of places of work on that site;

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(c) the work equipment being used;

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(d) the number of persons likely to be present on the site at any one time; and (e) the physical and chemical properties of any substances or materials on or likely to be on the site.

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(f) The procedures shall ensure that steps are taken to ensure that every person to whom the procedures extend is familiar with its arrangements and that they are tested and put in effect at suitable intervals.

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1.7.2.10 Emergency routes and exits Where necessary in order to safeguard the safety of relevant persons, the responsible person must ensure that routes to emergency exits from premises and the exits themselves are kept clear at all times.

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The following requirements must be complied with in respect of sites where necessary (whether due to the features of the site, the activity carried on there, any hazard present or any other relevant circumstances) in order to safeguard the safety of relevant persons—

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(a) emergency routes and exits must lead as directly as possible to a place of safety; (b) in the event of danger, it must be possible for persons to evacuate the site as quickly and as safely as possible; (c) the number, distribution and dimensions of emergency routes and exits must be adequate having regard to the use, equipment and dimensions of the premises and the maximum number of persons who may be present there at any one time; (d) emergency doors must open in the direction of escape; (e) sliding or revolving doors must not be used for exits specifically intended as emergency exits; (f) emergency doors must not be so locked or fastened that they cannot be easily and immediately opened by any person who may require to use them in an emergency; (g) emergency routes and exits must be indicated by signs; and (h) emergency routes and exits requiring illumination must be provided with emergency lighting of adequate intensity in the case of failure of their normal lighting.

QCS 2014


1.7.2.11 Liaison with the emergency services

access for emergency service vehicles

(b)

fire-fighting shafts

(c)

fire lifts and temporary hoist facilities

(d)

dedicated emergency escape routes and staircases

(e)

sprinkler installations

(f)

floor-load limitations

(g)

positions of dry riser inlets and wet risers

(h)

fire points

(i)

temporary buildings and accommodation

(j)

hazardous items such as gas cylinders, gas mains, electrical risers, temporary holes in floor slabs etc.

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(a)

Liaison with the local fire and rescue service should also include the arranging of site inspections and familiarisation tours for fire and rescue service crews.

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Liaison with the emergency services is essential. In particular, on large or complex developments, the fire and rescue service should be provided with site plans detailing the following:

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1.7.2.12 Fire protection during construction

Construction works should be designed and planned to allow the earliest possible installation of fixed fire protection features. These will aid the protection of the building and improve the means of escape of those working within the structure.

37

Such measures include:

fire-protective materials on structural steelwork

(b)

automatic fire detection systems

(c)

automatic sprinklers and other fixed fire-fighting installations

(d) (e) (f)

fire doors

(g)

fire stopping to lift shafts, service ducts and voids.

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fire escape staircases

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compartment walls

38

Wet or dry rising mains, where planned, should be progressively commissioned as the project progresses.

1.7.2.13 Water supplies for fire fighting 39

Adequate water for fire fighting must always be available. Whether this is achieved by utilising the fire hydrants fixed to existing street mains or by providing a fixed dam, the amount of water likely to be required should be discussed with the fire authority as part of the liaison process.

40

All fire hydrants must be clear of obstructions and suitably marked. Particular care should be taken to ensure that site plant, delivery lorries or workers' cars are not parked close to or over hydrants.


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Construction Site Safety 1.7.2 Appendix Safety questionnaire 1

This questionnaire has been worded so that the correct answer is YES. If you answer NO, you may wish to give more thought to the problem.

Assessing fire risk Has a suitable and sufficient fire risk assessment been carried out?

3

Have any shortcomings highlighted by the risk assessment been rectified?

4

Have employees been made aware of the significant findings of the fire risk assessment?

5

Has a competent person been appointed to continually assess the fire risk and to develop and update the fire safety plan?

6

Is it necessary to appoint Fire Wardens to oversee any site evacuation?

7

If so, have they been appointed and their duties and areas of responsibility made clear?

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Flammable materials

Are flammable materials, especially flammable waste materials, cleared away on a daily basis?

9

Is there safe, secure storage for highly flammable liquids?

10

Are LPG bottles securely stored in a facility which enables any leakage of gas to safely disperse?

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Bonfires

If bonfires are allowed on site and are really necessary, are they properly supervised?

12

Are bonfires lit during working hours?

13

Are bonfires properly extinguished well before the end of the working day?

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Smoking 14

Is smoking prohibited in all site accommodation and enclosed work areas?

15

Is there a non-smoking policy on site?

16

Is a means of safely disposing of smoking materials provided in places where smoking is permitted?

17

Are there adequate and clear official 'No Smoking' signs at each entrance to all site accommodation and in other areas where smoking is not permitted?

18

Is any total or partial smoking ban actively enforced?

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Hot work 19

Where required, has a Hot Work Permit been issued?

20

If so, does it specify that hot work must cease a specified period (e.g. 1 hour) before the end of the working day?

21

When hot work takes place is the correct type of fire extinguisher provided?

22

Are the correct precautions being taken where flame-cutting and welding takes place?

23

Are checks being made at the end of work to see that nothing is left smouldering?

24

Are cavities, eaves and other voids checked at the end of work?

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Heating appliances Are heating appliances correctly sited, installed and maintained?

26

Are fuel supplies, such as propane and butane, kept outside and piped into the building?

27

Are combustible materials being kept well away from heaters and stoves?

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Electrical appliances

Are all electrical work or repairs carried out by competent electricians?

29

Are the correct fuses fitted to electrical appliances?

30

Is only one appliance being used from each socket?

31

Are all electrical appliances being inspected and tested regularly?

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Staff training

Is everyone on site trained in fire prevention?

33

Are all staff properly trained in the procedures to be followed in case of fire?

34

Are all (or sufficient) staff trained in the selection and use of fire-fighting equipment?

35

Have fire marshals been appointed and trained?

36

Is the location of the fire assembly point known to everybody?

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Fire extinguishers 37

Are all fire extinguishers serviced regularly, checked and recharged as necessary?

38

Are all fire extinguishers of the appropriate type?

39

Are all fire extinguishers clearly identified and easily accessible?

40

Is there an up-to-date fire plan for the site?

41

Is the fire plan updated as necessary?

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Fire alarm 42

Is the fire alarm tested weekly?

43

Is a different call point used for each test?

44

Can the fire alarm be heard clearly in all parts of the premises?

45

Is someone nominated to call the fire and rescue service in case of fire?

Fire drills and records Are fire drills held on a regular basis?

47

Are records kept of all drills and tests of equipment?

48

Are the records readily available for inspection?

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Dangerous Substances 1.7.3.1 Key points A risk assessment must be carried out before dangerous substances are stored, transported or used. In some cases, a method statement and/or a Permit To Work will also be required.

2

These Regulations cover the flammable or explosive properties of dangerous substances used in the workplace.

3

People who use dangerous substances must be fully aware of their hazardous properties, adopt methods of controlling the risks and be trained in the use of portable fire extinguishers.

4

Electrical apparatus and naked flames should not be used near dangerous substances, particularly if they are being sprayed.

5

Good ventilation is essential wherever dangerous substances are used or stored.

6

Smoking policies and waste disposal policies must be established and diligently monitored.

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Dangerous substances are widely used on building and construction sites. The main hazards are fire and explosion, and everything possible must be done to lessen the risks.

2

Safety is divided into three areas:

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the storage of substances

(b)

the safe handling and transport of substances

(c)

the uses to which substances are put.

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1.7.3.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

If an identified hazard requires health surveillance, the Contractor must make it available to employees. The surveillance must be appropriate, taking into account the risks to their health and safety that have been identified.

4

The Contractor must provide employees with clear and relevant information on any risks that exist in the workplace and of control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or of any other person.

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1.7.3.4 Dangerous Substances and Explosive Atmospheres 1

Contractors must control the risks to safety from fire and explosions. These Regulations apply at all places of work where: (a)

a dangerous substance is present (or is liable to be present) at the workplace

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(b)

the dangerous substance could be a risk to the safety of people as a result of fires, explosions or similar energetic events.

2

A definition of a 'dangerous substance' is:

3

'any substance or mixture of substances that can put people's health or safety at risk from fire and explosion.'

4

Dangerous substances are: (a)

any substance or mixture of substances that is classified as explosive, oxidising, extremely flammable, highly flammable or flammable

(b)

any dust, whether in the form of solid particles or fibrous materials, which can form an explosive mixture in air.

A definition of 'explosive atmosphere' is:

6

'a mixture of air and one or more hazardous substances in the form of a gas, vapour, mist or dust, which will explode after ignition has occurred.'

7

In the construction industry, many dangerous substances are used, or created by, work activities, for example:

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the storage and use of solvents, adhesives and paints

(b)

the storage and use of flammable gases such as oxygen and acetylene during cutting and welding

(c)

the storage and use of LPG for work processes, heating or cooking

(d)

the creation of large quantities of airborne dust, for example as a result of woodmachining or sanding, and the handling and storage of bulk waste dust

(e)

the storage and decanting of vehicle fuels and lubricants

(f)

the storage and handling of liquid flammable wastes such as fuel oils

(g)

many 'hot work' activities such as the hot-cutting of tanks and drums that have contained flammable materials.

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1.7.3.5 Contractors' duties Contractors must assess and eliminate or reduce risks from dangerous substances.

2

Complying involves:

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Assessing risks 3

4

Before work is carried out, Contractors must assess the fire and explosion risks that may be caused by dangerous substances. This should be an identification and careful examination of: (a)

dangerous substances in the workplace

(b)

work activities involving those substances

(c)

ways in which those substances and work activities could harm people.

The purpose is to help Contractors to decide what they need to do to eliminate or reduce the risks from dangerous substances. If there is no risk to safety from fires and explosions, or the risk is low, no further action is needed. If there are risks then Contractors must consider what else needs to be done.

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Preventing or controlling risks Contractors must put control measures in place to eliminate risks from dangerous substances, or reduce them as far as is reasonably practicable. Where it is not possible to eliminate the risk completely Contractors must take measures to control risks and reduce the severity of the effects of fire or explosion.

6

The best solution is to eliminate the risk by replacing the dangerous substance with another substance, or using a different work process.

7

This is called substitution.

8

In practice, this may be difficult to achieve. However, it may be possible to reduce the risk by using a less dangerous substance, e.g. by replacing a low flashpoint liquid with a high flashpoint one. In other situations, it may not be possible to replace the dangerous substance. For example, it would not be practical to replace petrol with another substance at a filling station.

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(b)

avoid or minimise releases of dangerous substances

(c)

control releases of dangerous substances at source

(d)

prevent the formation of a dangerous atmosphere

(e)

collect, contain and remove any releases to a safe place (for example, through ventilation)

(f)

avoid ignition sources

(g)

avoid adverse conditions, e.g. exceeding the limits of temperature or control settings, that could lead to danger

(h)

keep incompatible substances apart.

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These control measures should be proportionate to the degree of risk as highlighted in the risk assessment and be appropriate to the nature of the activity or operation.

Mitigation 11

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reduce the quantity of dangerous substances to a minimum

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Where the risk cannot be eliminated, these Regulations require control measures to be applied in the following priority order:

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Control measures

In addition to control measures, Contractors must subsequently put in place mitigation measures. These measures should be consistent with the risk assessment and appropriate to the nature of the activity or operation, and include: (a)

reducing the number of employees exposed to the risk

(b)

providing explosion-resistant plant

(c)

providing explosion suppression or explosion relief equipment

(d)

taking measures to control or minimise the spread of fires or explosions

(e)

providing suitable personal protective equipment.

Preparing emergency plans and procedures 12

Arrangements must be made to deal with emergencies. These plans and procedures should cover safety drills and suitable communication and warning systems, and should be in

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proportion to the risks. If an emergency occurs, workers tasked with carrying out repairs or other necessary work must be provided with the appropriate equipment to allow them to carry out this work safely. 13

The information in the emergency plans and procedures must be made available to the emergency services to allow them to develop their own plans if necessary.

Providing information, instruction and training for employees 14

Employees must be provided with relevant information, instructions and training.

15

This includes: the dangerous substances present in the workplace and the risks they present, including access to any relevant safety data sheets and information that applies to the dangerous substance

(b)

the findings of the risk assessment and the control measures put in place as a result (including their purpose and how to follow and use them)

(c)

emergency procedures.

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(a)

Information, instruction and training need only be provided to other people (non-employees) where it is required to ensure their safety. It should be in proportion to the level and type of risk.

17

The contents of pipes and containers must be identifiable to alert employees and others to the presence of dangerous substances.

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In relation to construction site activities, this could include bottled gas/petrol storage areas. These duties include: identifying and classifying (zoning) areas where potentially explosive atmospheres may occur

(b)

avoiding ignition sources in zoned areas, in particular those from electrical and mechanical equipment

(c)

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Places where explosive atmospheres may occur

providing appropriate anti-static clothing for employees

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(d)

where necessary, identifying the entrances to zoned areas by the display of signs

(e)

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before they come into operation, verifying the overall explosion-protection safety of areas where explosive atmospheres may occur.

Decisions on the zoning of areas and the appropriate actions to take must be made by someone who has been trained and is competent to do so.


These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means that are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by employees. In essence, personal protective equipment (PPE) may only be used as a last resort. In deciding which type of PPE to issue, the Contractor must take into account the risk that the PPE is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely.

2

If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible so that each item does not adversely affect the performance of

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another. 3

Whilst the Contractor must, as far as possible, ensure that any personal protective equipment supplied must be worn, the employee in turn must ensure that they wear the equipment provided and know the procedures for reporting loss or defect to the Contractor.

4

Dangerous substances and explosive atmospheres require the prevention of: (a)

inhalation of fumes and vapour given off by dangerous substances

(b)

skin contact with dangerous substances

(c)

eye injuries resulting from splashes of dangerous substances.

1.7.3.7 Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, it must be restricted to competent specified workers.

3

In the context of this module, these Regulations apply to the provision and use of work equipment that allows dangerous substances to be handled (including decanting), transported, used and disposed of in a safe manner.

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The Control of Substances Hazardous to Health does not apply to dangerous substances by virtue of their explosive or flammable nature. However, they may apply if these substances also possess certain other hazardous properties. This would be identified as part of the COSHH assessment carried out on the substance.

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1.7.3.8 Control of Substances Hazardous to Health

1.7.3.9 Construction (Design and Management) CDM These Regulations specify the measures to be taken to prevent the risk from fire, explosion or any substance likely to cause asphyxiation.

2

These Regulations specify the measures to be taken to detect and fight fires in relation to work carried out on construction sites.

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1.7.3.10 Competence and training 1

In most cases it will be necessary for the Contractor to provide employees with adequate information, instruction, training and supervision to enable them to carry out any work task safely and without risk to their health.

1.7.3.11 Storage of dangerous substances 1

2

On most building or construction sites, dangerous substances will be used at some time during the construction phase. Depending upon the nature of the work to be undertaken it may be necessary to store bulk quantities of dangerous substances, either: (a)

in an external, secure, purpose-built compound, where site conditions allow

(b)

in a suitable, secure internal storeroom if, because of the nature of the site, external storage is not possible.

Alternatively, small quantities, from, say, 200 ml containers upwards will often be taken to

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the place of work by the person doing the job. Where small quantities of dangerous substances for daily use are required in the workplace, metal lockable bins may be used.

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on a concrete sloping pad with a sump to catch any leaks or spillage

(b)

with a low sill all around, sufficient to contain the contents of the largest can or drum stored + 10%, i.e. bunded

(c)

surrounded by a 1.8 metre high wire fence

(d)

so that it is protected against direct sunlight

(e)

at least 2 metres away from nearby buildings or boundaries, except that, where the boundary of the store forms part of a solid wall, cans or drums may be stacked up against that wall up to 1 metre from the top.

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(a)

Cans or drums should be stored: (a)

so that their contents can be easily identified and removed in the event of any leak or damage on their sides and chocked to prevent movement.

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Where it is necessary to store dangerous substances in bulk, a store should be built:

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Storage in the open air

6

Stores or bins must be kept locked and only sufficient amounts for each day's requirements should be removed, as and when needed.

7

They may be marked with suitable signs such as 'Flammable Liquid' or 'Flammable Gas'.

8

Additionally, if an assessment shows that an explosive atmosphere may be present in a particular area, appropriate numbers of the sign below must be displayed.

9

The sign comprises a yellow background and black graphics. Signs must conform to BS 5499 Safety signs and colours.

10

Naked flames, smoking, matches or lighters must not be allowed in the area of the store, and proper prohibition signs must be clearly displayed as well as other signs already indicated.

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Any lighting within a store must be flameproof to the appropriate standard, and under no circumstances should electrical sockets be permitted.

12

Where there is a need for electrical apparatus (other than lighting) within a store, the supply must be permanently wired in using intrinsically safe equipment.

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Other points to be noted.

Stores should not be built below ground level, because the vapours from spillages and leaks will not be able to disperse.

14

Adequate cross-ventilation at both high and low level is necessary.

15

The store should always be kept locked when unattended.

16

A door sill of approximately 150 mm in height should be provided to catch any leaks or spillages in order to retain the liquids inside the building.

17

A quantity of absorbent material, to soak up any spilt liquids, and a suitable container for the collection and safe disposal of the contaminated absorbent, should be provided at the store.

18

The use of mobile phones in or immediately adjacent to the store should be prohibited. Notices to this effect should be provided and prominently displayed.

19

Any shelves or racking in the store should be of a non-ferrous metal or other noncombustible construction.

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Storage inside a building 20

A separate building should be provided, if possible, solely for the storage of dangerous substances where protection from the weather or security is required. Ideally, it will be constructed from fire-resisting materials and it should be at least 2 metres away from other buildings or boundaries.

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21

A risk assessment should be carried out to determine whether the risks of storing dangerous substances in such a location are acceptable. If not, either additional control measures must be put in place or alternative arrangements made for storing the substances.

22

Where a separate building cannot be provided, and the store forms part of an existing structure, the surrounding walls and roof of the store must be fire-resisting and the door should be of the fire-resisting type and open outwards.

23

It is recommended that the maximum quantities that may be stored in cabinets and bins are no more than 50 litres for highly flammable liquids (and flammable liquids with a flashpoint below the maximum ambient temperature of the workroom/working area) and no more than 250 litres for other flammable liquids with a higher flashpoint of up to 55°C.

Other points to be noted. Stores should not be built below ground level, because the vapours from spillages and leaks will not be able to disperse.

25

Adequate cross-ventilation at both high and low level is necessary.

26

The store should always be kept locked when unattended.

27

When not in use, containers of flammable liquids needed for current work activities should be kept closed and stored in suitable cabinets or bins of fire-resisting construction and which are designed to retain spills (110% volume of the largest vessel normally stored in it).

28

A quantity of absorbent material, to soak up any spilt liquids, and a suitable container for the collection and safe disposal of the contaminated absorbent should be provided at the store.

29

Signs should be positioned on or near the store stating, for example 'Highly Flammable' or 'Flashpoint below 32°C'. All signs should conform to BS 5499 Safety signs and colours.

30

Naked flames, smoking, matches or lighters must not be allowed in the store, and signs stating this must be clearly displayed.

31

The use of mobile phones in or adjacent to the store should be prohibited. Notices to this effect should be provided and prominently displayed.

32

Any lighting or other electrical apparatus must conform to BS EN 60079-14.

33

Any shelves or racking in the store should be of a non-ferrous metal or other noncombustible construction.

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1.7.3.12 Handling and use of dangerous substances likely to cause an explosive atmosphere 1

The use of any dangerous substance, including decanting small quantities for daily use from bulk containers, must be the subject of a risk assessment.

2

The findings of the risk assessment will indicate the maximum quantity of the dangerous substance that can be taken to the place of work and the safe working practices to be observed once it is there and being used.

3

Generally, only enough of the dangerous substance to enable the work-in-hand to be carried out should be taken to the place where it is to be used. Clearly, actual quantities will depend on the work activity and also the organisational arrangements for controlling the fire risks in the workroom/ working area.

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Decanting, mixing or sampling should not be carried out in a store. It should be done in the open air or in a separate room constructed of fire-resisting materials.

5

Funnels should be used to prevent spillage whilst decanting is taking place and drip trays should be used to catch any spillage that may inadvertently occur.

6

Any spillage should be soaked up using proprietary absorbents, dry earth or dry sand.

7

Metal bins with lids should be provided for any used absorbents to be placed in and these should be emptied regularly and carefully.

8

Consideration must be given to the disposal of any waste as it may well be classified as hazardous waste.

9

In general, where work involves the use of a dangerous substance that has the potential to create an explosive atmosphere inside a room, all electrical power should be turned off unless all electrical fittings are intrinsically safe by design. If space heating is needed, it should be flameproof and incapable of causing the ignition of any vapours present in the atmosphere.

10

The build-up of concentrations of vapours must be avoided and dispersed, if necessary, by natural or mechanical ventilation. If mechanical ventilation is necessary, a flameproof motor, not in the ventilation trunking, should be used.

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Other points to be considered

Naked flames, welding and heating torches, and smoking materials should be prohibited in any area where an explosive atmosphere may be present.

12

Metal bins with lids must be provided for offcuts, waste or rags. They should be emptied regularly.

13

A suitable container with a lid should be used for any brushes or scrapers which require soaking, to remove residues of dangerous substances. This should be placed in a safe area well away from any possible source of ignition.

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1.7.3.13 Spraying of dangerous substances New covering materials, such as paints, varnishes and lacquers, and the techniques for applying them, have been developed and extensive use of spray painting equipment can now be seen on construction sites,

2

Using a spray gun for spraying dangerous substances is most likely to introduce an airborne explosive mist into the workplace, creating a hazard both to the user and to other workers in the area. Such work must only be undertaken by fully trained and competent employees and in a situation where all appropriate precautionary measures are in place. A risk assessment must be carried out and other controls such as 'permits to work' and 'permits to enter' (for those people involved in the job, by implication, excluding all others), implemented as necessary.

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Points to be noted 3

Identify the material carefully and always follow the manufacturer's instructions on preparation, use and application.

4

Always use the correct type of spraying equipment. Never make do, just because the proper equipment is not immediately to hand.

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If alternative control measures are not available or adequate, protective clothing and respiratory protective equipment must be used.

6

Always use the hygiene and washing facilities provided.

7

Do not introduce ignition sources into the working area.

8

Do not smoke or use naked flames in the working area.

9

Always place warning signs in approaches to the area where the work is being carried out, and at entrance points to areas in which dangerous substances are being used. Use physical barriers, if necessary, to stop unauthorised persons entering the area.

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1.7.3.14 Empty tanks and containers Bulk tanks and drums Do not cut or heat any empty tanks, containers or drums unless they have been certificated as being free of flammable vapours that could explode. Current opinion recommends reducing the length of time that such certification is valid for. Under most circumstances, the cutting work should be planned to start immediately the 'gas-free' certificate is issued.

2

Special care is necessary when demolishing or dismantling disused bulk-tanks. By disturbing the tank or heating the residues left inside, you may cause an explosive concentration of vapours.

3

Entry into any disused tank or vessel that may be regarded as a confined space should be avoided by doing the work from outside, if possible. Often, there will be a need to clean residues and if entry to a confined space is unavoidable, a safe system of work must be followed and the work carried out under a Permit to Work system.

4

There are a number of factors to consider when the work involves large tanks. The first would be what the contents were. Oil storage tanks may have held so called 'heavy fuel oil' and these will undoubtedly have been insulated. It is quite likely that the insulation system will have been asbestos. If the tanks once held petrol, it may have been leaded fuel. This means that the exposure to lead fumes during cutting should be considered.

5

It is normal for large tanks, whether above or below ground, to be emptied and cleaned by a specialist contractor before dismantling. The contents are generally removed by a large vacuum tanker and then the inside of the tank is steam cleaned. Most of this work can be carried out from the outside and it is only to carry out the final clean that entry is required. Operatives carrying out this final clean must be trained in confined space working and provided with all the normal gas detector, rescue equipment and PPE that would be expected for confined space working.

6

Having been cleaned, the tank is tested and a 'gas-free' certificate issued. It should then be cut up as soon as possible. The implication of not doing so is that it is practically impossible to completely clean a tank, particularly where its construction incorporates internal ribs, welds and other internal features which could harbour residue of the content. These may well become fume and if the concentration becomes high enough then the atmosphere inside the tank may become explosive if ignited.

7

It is important to be aware that even so called cold cutting techniques such as hydraulic shears may cause sparks and so leaving the cutting even until the next day is simply not an option.

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1.7.3.15 Fire 1

Fires involving flammable liquids usually fall into one of two categories: (a)

flowing liquid fires

(b)

contained liquid fires.

2

Powder extinguishers are the most suitable type for tackling a flowing liquid fire. The use of foam or carbon dioxide extinguishers may be effective on a small, flowing liquid fire.

3

Foam extinguishers are the most suitable type for use on contained liquid fires. Powder or carbon dioxide extinguishers may also be used, but operators should be aware of the short duration of small carbon dioxide extinguishers and the possibility of reignition of any residual vapours being given off when an ignition source is still present.

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4

DO NOT USE A WATER EXTINGUISHER FOR ANY FIRE INVOLVING HIGHLY FLAMMABLE LIQUIDS, BECAUSE THE WATER WILL CAUSE A VIOLENT REACTION AND MAKE THE LIQUID OVERFLOW.

5

Suitable portable fire extinguishers should, wherever possible, be sited in pairs (so as to minimise the risk of failure) and in strategic positions adjacent to the store.

Colour of fire extinguishers 6

Colour-coding by agent or medium (see below) enables a trained person to rapidly identify the type of extinguisher needed in an emergency. Colour of panel

Water

Red

Foam

Cream

Powder (all types)

Blue

Carbon dioxide

Black

Wet chemical

Yellow

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Extinguishing medium

Other information concerning its use may also be displayed on the body of the extinguisher.

8

Training in the correct type of extinguisher to use and the safe way to operate fire-fighting equipment is essential and should be undertaken by all staff who work with dangerous substances. The use of the wrong extinguisher in the wrong way would have serious consequences.

9

Advice on training can be obtained from extinguisher manufacturers or the local fire station.

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Construction Site Safety 1.7.3 Appendix 1 Safety questionnaire 1

This questionnaire has been worded so that all the correct answers are YES. If you answer 'NO' to any question perhaps you need to give the matter more attention.

Dangerous substances General Has a risk assessment been carried out?

3

Does it indicate that other methods of managing the situation are required, such as a method statement or Permit to Work system?

4

Have employees been made aware of the significant findings of the risk assessment?

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Storage in the open air Is the base of the store built of concrete and sloped?

6

Is there a low level sill surrounding the base?

7

Is there a ramp for access to the store over the sill?

8

Is a sump provided to catch any leakages or spillages and is the capacity large enough to contain any leakages or spillages?

9

Is there a roof or cover over the store to protect the contents from direct sunlight?

10

Is there an adequate separation distance between the store and adjacent buildings or boundaries?

11

Are appropriate signs displayed, for example 'Highly Flammable' or 'Flashpoint Below 32°C'?

12

Are the correct fire extinguishers provided and positioned adjacent to the store?

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Storage in buildings 13

Is the storage building used exclusively for the storage of dangerous substances?

14

If the store is part of a multi-purpose building, is there adequate fire separation from the rest of the building?

15

Are appropriate signs displayed, for example 'Highly Flammable' or 'Flashpoint Below 32°C'?

16

Is there a sill across the doorway to prevent leakages or spillages reaching the open air and is the capacity large enough to contain any leakages or spillages?

17

Is there adequate cross-ventilation at both high and low level?

18

Is there the required separation distance between the store and adjacent buildings or boundaries?

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Storage at the place of work 19

Is there a lockable metal cabinet available to store small quantities for daily use?

20

Is it marked with appropriate safety signs?

Decanting Is decanting done only in the open air or in a fire-resisting building?

22

Is the decanting located away from any source of heat or ignition?

23

Are dangerous substances only decanted into small, correctly marked containers with effective closures?

24

Are funnels correctly used to assist decanting?

25

Are drip trays positioned to catch any leakages or spillages?

26

Are suitable absorbents or spill kits available to contain any spillage?

27

Are metal bins available for used absorbents to be placed in?

28

Are these bins emptied regularly?

29

Is contaminated absorbent safely, carefully and properly disposed of?

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21

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Use of dangerous substances

Where dangerous substances are used, is adequate ventilation provided?

31

If there is a need for mechanical extraction, is the electric motor out of the line of discharge of the fumes?

32

Are there signs stating 'No Smoking' or 'Naked Lights'?

33

Are metal waste bins with lids provided for dangerous substances that are no longer required?

34

Are the correct warning notices provided?

35

Are serviceable fire extinguishers of the correct type provided and positioned adjacent to the workplace?

36

Are containers with lids provided for cleaning brushes?

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Spraying 37

Have the materials in use been clearly identified?

38

Are the correct precautions in relation to use and storage being observed?

39

Is the correct spraying equipment being used?

40

Is the correct protective clothing and equipment, including RPE, being worn?

41

Are the necessary precautions being taken to avoid all ignition risks?

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42

Are warning notices correctly displayed?

43

Are barriers in use if necessary?

44

Are serviceable fire extinguishers of the correct type provided and positioned adjacent to the workplace?

Empty tanks and containers Are the necessary precautions being taken against the risk of explosion in storage tanks awaiting demolition or dismantling?

46

Has an explosive gas-free certificate been obtained prior to any hot work? (NB Check how long the certificate is valid for.)

47

Is a Permit to Work system used when work is being carried out on disused or redundant tanks?

48

Are authorising Permits to Work to deal with all the confined space issues being obtained before any entry into a tank is made?

49

Has thought been given to the possibility of contamination around the tank from leakage or spillage?

50

Has advice been sought from a competent person before work begins?

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Fire

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Are the correct types of fire extinguisher provided and suitably positioned adjacent to the store or workplace?

52

Have the staff been correctly trained to use them?

53

Are there procedures to call the fire and rescue service?

54

Is there a telephone available to call the fire and rescue service?

55

Is the address of the site displayed on prominent notices conveniently located in offices and near telephones?

56

Are suitable absorbents or spill kits available to contain any spillage?

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Liquefied Petroleum Gases 1.7.4.1 Key points A risk assessment must be carried out before dangerous substances are stored, transported or used. In some cases a method statement and/or a permit to work will also be required.

2

Liquefied petroleum gases (LPG) are normally found as compressed liquids, usually of commercial butane or propane.

3

LPG is a colourless odourless liquid that floats on water but vaporises to form a gas which is heavier than air. A stenching agent is normally added.

4

A release or spillage of LPG can form a large vapour cloud of flammable gas capable of ignition from some distance.

5

LPG is stored on site in fixed tanks, refillable cylinders or non-refillable disposable cylinders (cartridges).

6

Storage should be in secure, non-combustible, well ventilated areas away from other risks and sources of ignition.

7

All LPG cylinders and regulators for use with fixed heaters, cookers and lighting in site huts must be kept outside and piped in using rigid copper piping.

8

Staff who work with LPG must be suitably trained in the hazards and use of LPG, such as not rolling cylinders. .

9

In the event of a leak, do not attempt to operate electrical apparatus or switches.

10

If a fire breaks out that involves LPG cylinders:

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immediately inform the fire and rescue service of the whereabouts of all cylinders on site, including details of whether they are full or empty

(b)

if in any doubt as to the safety of the overall situation, evacuate the site and put a security cordon in place.

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LPG is a mixture of hydrocarbons that are a gas or vapour under normal conditions of temperature and pressure, but can be turned into a liquid by either the application of pressure or the reduction of temperature.

2

LPG can be found in numerous locations, in various sizes of cylinder and can be put to a variety of uses on building and construction sites. Uses range from the heating of bitumen boilers, site huts and offices to providing a fuel for hand tools and cutting equipment.

3

If used properly and safely, LPG is a convenient and valuable source of energy. Misuse or carelessness can cause serious accidents.

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Legislative requirements

1.7.4.3 Dangerous Substances and Explosive Atmospheres 1

The nature of LPG, particularly in its gaseous form, will result in areas where it is used or stored coming within the requirements of these Regulations.


All work activities must be the subject of a risk assessment, including those that involve the

QCS 2014


use of LPG and other flammable substances. These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out. 2

Once those hazards have been identified, it is the Contractor's duty to put control measures into place in order to remove or reduce those hazards as far as is reasonably practicable.

1.7.4.5 Construction (Design and Management) CDM These Regulations specify the measures to be taken to prevent the risks of fire, explosion or exposure to any substance likely to cause asphyxiation on construction sites.

2

These Regulations specify the measures to be taken to detect and fight fires in relation to work carried out on construction sites.

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1.7.4.6 Provision and Use of Work Equipment

Any equipment used in conjunction with the use, handling or storage of LPG is classified as work equipment under these Regulations. Every Contractor must ensure that all persons who work with or supervise others in the use of LPG or LPG equipment have available to them adequate health and safety information and, where appropriate, written instructions regarding the use of that equipment.

2

Equipment that is used in conjunction with LPG which is hired-in or purchased second-hand must also comply with the requirements of the Regulations.

3

Every Contractor must ensure that all persons who work with, or supervise others in the use of LPG equipment, have received adequate training for the purposes of health and safety, and be aware of any risks in the use and precautions to be taken in the case of an accident.

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1.7.4.7 Personal Protective Equipment These Regulations require that, where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by employees. In essence, personal protective equipment (PPE) may only be used as a last resort. In deciding which type of PPE to issue, the Contractor must take into account the risk that the PPE is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely.

2

If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible so that each item does not adversely affect the performance of another.

3

While the Contractor must, as far as reasonably practicable, ensure that any personal protective equipment supplied is worn, employees must ensure that they wear the equipment provided and know the procedures for reporting loss or defects to the Contractor.

4

In the context of these Regulations they are preventing:

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(a)

skin contact with LPG in its liquid form

(b)

jets of gaseous LPG entering the eyes or impacting on the skin

(c)

the inhalation of gaseous LPG when a released cloud of LPG is confined. Entry into such areas should only be undertaken by trained persons when absolutely necessary.

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Every Contractor should, as far as is reasonably practicable, avoid the need for employees to undertake any manual handling operations at work which may involve a risk of injury.

1.7.4.9 The Control of Substances Hazardous to Health 1

These Regulations do not apply to LPG by virtue of its flammable nature, but they will apply by virtue of its other hazardous properties.

Definitions Liquefied petroleum gas means any commercial butane, commercial propane or a mixture of the two.

.

2

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Commercial butane

This is usually stored in blue cylinders and is generally known as Camping Gaz or Calor Gas.

4

It consists mainly of butane and butane isomers. The remaining components are predominantly propane and propane isomers, pentane and pentane isomers.

5

Because of the low vapour pressure, butane cylinders are not generally used outside.

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Commercial propane

This is usually stored in vessels or in red cylinders.

7

It consists mainly of propane and propane isomers. The remaining components are predominantly butane and butane isomers, ethane and ethane isomers.

LPG properties

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LPG is a colourless, odourless liquid or gas which normally has a smell or 'stench' added before distribution.

9

As a liquid, it is lighter than water and will float before evaporating.

10

As a gas, it is approximately twice as heavy as air and will sink and flow into sumps and underground excavations or workings. It will also sink into drains but, because its density is approximately half that of water, it will not flow through drains which are water trapped.

11

It is capable of ignition at some distance from the original leak. The resulting flame can travel back to the source of the leak.

12

Any release of liquid under pressure to the atmosphere results in its rapid conversion to gas. This gas has a volume of about 230 (butane) and 270 (propane) times that of the liquid.

13

The expansion during a rapid release of pressure results in a rapid drop of temperature, which for propane can approach its boiling point of 45°C. Leakage of liquid LPG will result in the release of large volumes of highly flammable gases.

14

For example, 1 litre of liquid propane spilt in a workplace will evaporate to make approximately 270 litres of gas. If it is diluted with air to 2%, this will give 13,750 cubic litres of an explosive gas/air mixture - enough to fill a room 3 m x 2.3 m x 2 m.

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Properties of liquefied petroleum gases

Property

Commercial butane 0.57

Commercial propane 0.5

2

1.5

Litres per tonne

1745

1995

Boiling point

-2°C

-45°C

1.5 bar

7.0 bar

1:230

1:270

1.9%-8.5%

2.0%-10.9%

Density in comparison to water Density in comparison to air

Pressure at 15°C Expansion ratio Levels of flammability

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.

The use of LPG equipment in confined spaces, and small, poorly ventilated spaces (such as basement and sub-basement boiler houses, toilets and kitchens) can give rise to a highly flammable or explosive atmosphere, if the equipment should leak.

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Flammability

Following mechanical failure of LPG equipment, or any other event which causes the release of LPG, the resulting gas will form a flammable mixture with air at gas concentrations between approximately 2% and 10%.

17

Ignition of released LPG, where the concentration exceeds 2%, can result in fire or, if confined, an explosion. If a leak does not ignite immediately, and the LPG and air mixture drifts from the point of release, it will gradually become more diluted.

18

However, should the concentration still exceed 2% and ignition occur, this could cause a flash or cloud fire-back to the point of release.

19

A leak of LPG may be noticed either by the smell or the noise of the gas escaping. There may also be condensation or frosting on the outside of the cylinder.

20

Leaks must not be traced with a lighted match or naked flame as this would almost certainly cause an explosion. Only soapy water or a proprietary leak-finding fluid should be used.

21

If it is suspected that LPG has leaked inside a building, no attempt should be made to touch any electrical apparatus.

22

DO NOT turn light switches or sockets or any other electrical appliance either ON or OFF.

23

Open all doors and windows, if it is safe to do so, and leave immediately. Do not re-enter the building until advice has been sought and you are told it is safe to do so.

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Workplace exposure limits 24

25

The maximum levels of exposure for LPG, are: (a)

1,000 ppm (0.1 %) for long-term exposure (reference period: 8 hours)

(b)

1,250 ppm (0.125%) for short-term exposure (reference period: 15 minutes).

During any maintenance work involving release of pressure, especially in confined spaces, care must be taken that these exposure limits are not exceeded.

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Inhalation 26

LPG gas is not toxic, but at concentration levels above about 10,000 ppm (1%) in air, propane becomes a slight narcotic. At higher levels, it becomes an asphyxiant by displacing oxygen.

27

In a sufficiently high concentration, a person will suffocate and die.

Cold burns The release of liquid propane onto unprotected skin will cause cold burns. This is due to the rapid vaporisation of the liquid, withdrawing heat from the affected area of the body.

29

The release of liquid, or significant amounts of gas at vessel pressure, can also cause the adjacent fittings to cool. This may be sufficient to cause cold burns if the fittings are subsequently touched by unprotected hands.

30

Suitable skin and eye protection must be worn whenever there is the possibility of a release of liquid LPG.

31

In the event of a cold burn, treat as for a bum from a hot object. Flush with copious amounts of cold water and seek medical help.

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Environmental hazards

A small unignited release of LPG would not pose a serious danger to the environment.

33

The gas, being heavier than air, will 'roll' and sink to the lowest point, such as basements or excavations. This may result, if in the flammable range, in a fire or explosion, even if a naked source of flame is a considerable distance from the original leak.

34

A fire and explosion would be instantaneous on ignition and would be limited to immediate damage. The fire might devour only escaping LPG and then the danger will have passed with no lasting environmental damage.

35

The fire will bum fast and the explosion will be intense, but both may be over very quickly.

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1.7.4.10 Storage

LPG can be stored on construction sites in one of three ways:

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(a)

in fixed storage tanks

(b)

in refillable cylinders

(c)

in non-refillable cylinders (i.e. disposable cylinders).

Fixed storage tanks 2

Whilst most LPG used on construction sites can be found in cylinders, on some larger sites there may be a need for bulk storage. In view of the large capacity, it is essential that the positioning of any storage tank is carefully planned and discussed with the local Fire Prevention Officer.

3

LPG tanks should be positioned on a level concrete base to provide a stable foundation. For short-term installations it may be satisfactory to stand the tank on concrete slabs, but advice must be sought from the tank or gas suppliers.

4

Tanks should not be sited close to any ditches, cellars or drains, and delivery and

QCS 2014


emergency vehicles must easily reach them. 5

All access roads must be clear of obstruction and the entire area kept free from weeds and other vegetation.

6

Tanks over 2,250 litres liquid capacity should be electrically bonded and earthed.

7

All bulk storage tanks must have good all-round ventilation. On non-secure sites, tanks should be protected against vandalism by a chain link fence at least 2 m high.

8

Motorway type crash barriers should surround the installation to minimise damage by motor vehicles. Installations must be clearly labelled:

HIGHLY FLAMMABLE LPG: NO SMOKING OR NAKED LIGHTS

.

Signs must conform to BS 5499 Safety Signs and Colours.

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Separation

Adequate separation must be maintained between bulk storage tanks and adjacent buildings or boundaries.

11

As a guide, the distances detailed in the table should be followed:

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Separation distances of bulk LPG tanks Gas capacity

litres

gallons

metres

450

99

2.5

451-2,250

100-495

3

2,251-9,000

496-1,980

7.5

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0.2-1

Minimum distance*

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Water capacity

tonnes Under 0.2

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"Minimum distance from boundaries, buildings or sources of ignition Where possible, LPG storage areas should not be positioned under power cables.

13

Where this is unavoidable, the minimum distances between the extremity of the vessel or cylinders to the nearest cable should be:

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12

(a)

up to 1 kV - 1.5 m

(b)

1 kV or above- 10 m.

1.7.4.11 Cylinders Handling 1

Care must be taken when moving cylinders around the site, especially by hand or on rough ground. A full 47 kg cylinder has a total mass of about 90 kg and, before moving by hand, requires a manual handling assessment. Cylinders must not be rolled, even when empty.

2

Cylinders should be handled with care and, wherever reasonably practicable, moved using suitable equipment. They should not be moved unprotected in dumper trucks or on forklift trucks. The valve on a cylinder should not be used for lifting or to lever the cylinder into position. Damage to the valve can result in a non-controllable release of LPG under high

QCS 2014


pressure. Throwing cylinders from any height or dropping them is prohibited, as in such circumstances damage to the valve, shroud and cylinders is even more likely. Damaged cylinders Before use, cylinders should be examined. Any damaged or faulty cylinder should not be used. The cylinder should be labelled and put in a safe place for return to the supplier.

4

If a cylinder is found to be leaking (usually from the valve) and the leak cannot be stopped, the cylinder should be carefully removed to a well-ventilated open space free from sources of ignition. It should be left with the leak uppermost, marked faulty, and notices displayed prohibiting smoking or other naked lights. General access should be prevented by barriers or otherwise. The supplier of the cylinder and, if necessary, the fire and rescue service, should be informed immediately.

5

Under no circumstances should attempts be made to dismantle or repair defective cylinders.

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Refillable cylinders

A level base of compacted earth, concrete or paving slabs should be provided and surrounded by a secure chain link fence at least 2 m high. A hard standing should be provided for the delivery and dispatch of cylinders. The area should be kept weed and vegetation free. If the compound is more than 12 m square, two exits should be provided in opposite corners of the compound. If less than 12 m square, one gate will suffice. Gates should open outwards and always be left unlocked when someone is in the compound. There should be sufficient shelter to prevent cylinders from being exposed to extremes of weather.

7

Signs must be clearly displayed indicating the presence of LPG, and prohibiting smoking and the use of any naked flame in the area of the store.

8

LPG cylinders must be stored with their valves uppermost. They must be stored away from oxygen, highly flammable liquids, oxidisers, toxic or corrosive gases or substances. A distance of at least 3 m must be kept between LPG cylinders and other such substances, although they may be kept in the same compound.

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Separation 9

Any store for refillable LPG cylinders must be located away from boundaries, buildings, fixed sources of ignition or electrical equipment by at least the distances detailed in the table below. LPG storage (including empties) Separation from building/boundary under 1,000kg

3m

10

1,001-4,000 kg 4m The store must be sited at least 3 m away from any cellars, drains or other excavations into which a leak of gas would collect.

11

No cylinder should be stored within 1.5 m of any compound fencing.

12

If only a small compound is used, 3 m x 3 m for example, cylinders may be stored against

QCS 2014


the inside of the compound fencing, providing this fence is not within 3 m of any boundary. 13

Empty cylinders must be stored with their valves securely closed to prevent any residue of gas escaping, or air being drawn into the cylinder.

14

Stocks should be grouped in batches of not more than 1000 kg and batches separated by a minimum 1.5 m gangway.

15

Where lighting is necessary, it should be mounted well above ground level and not less than 2 m above the cylinders.

16

Any equipment not in use, such as portable hand equipment, should be isolated so as not to be accessible to trespassers. Any cylinders not required should be returned to the storage compound or other secure position.

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Non-refillable cylinders

Non-refillable LPG cylinders for use with small portable equipment such as blowlamps may be stored in a lockable metal container.

18

Care should be taken when changing cylinders to ensure that connections are correctly made and that there are no leaks.

19

Always dispose of empty containers safely and in accordance with the manufacturer's recommendations. Do not, under any circumstances, puncture or throw 'empty' cylinders onto a fire.

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Additional storage details for small LPG containers

These are often non-refillable (e.g. cartridges) but small refillable cylinders (e.g. Primus) should also be stored in the same way.

21

Although only containing small quantities of gas, they must not be stored in occupied site huts.

22

They should be kept in a secure, non-combustible, well-ventilated external enclosure. The store should have warning signs: 'Highly Flammable - LPG' and prohibition signs: 'No smoking/naked lights'.

23

The disposal of cartridges after use requires care as they still contain gas. Under no circumstances should cartridges be thrown on fires. Small numbers of empty cartridges may be disposed of by including them in normal refuse.

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General transportation of LPG cylinders 24

When loaded onto vehicles, cylinders must be kept upright and secured. Vehicles must be equipped with a dry powder extinguisher and a first-aid kit. They must also display warning notices.

25

Do not overload the vehicle and, if using a closed vehicle, ensure that any cylinders are removed from the vehicle at the end of each journey.

26

If a cylinder leaks during a journey, close the valve immediately. If this is not possible, move the vehicle to open ground away from buildings and people, and inform the emergency services.

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Use of LPG in cylinders 27

Everyone with any responsibility for the storage and transportation of LPG must understand the characteristics and hazards of the LPG product they are using.

28

They should understand the fundamentals of fire fighting and control of leakages. They should also have knowledge of the procedures for dealing with emergencies.

29

It is not possible to cover all aspects of the use and application of LPG, but the following checklist gives the main points for its safe use and handling. Please note that this list should not be regarded as exhaustive. Never use or store a gas cylinder on its side, unless it is a special cylinder for use on LPG-fuelled plant and vehicles. Liquefied gas may escape, causing concentrations of gas, and operatives may suffer frostbite because of the very low temperature of the escaping liquid.

(b)

Propane cylinders must never be stored indoors because any leak will lead to large concentrations of explosive mixtures.

(c)

Only hoses suitable for use with LPG installations or appliances should be used and these should be inspected frequently for wear.

(d)

Cylinders must not be dropped during handling, nor brought into violent contact with other cylinders or adjacent objects.

(e)

Before and after use, valve protection caps and plastic thread caps or plugs should be fitted to prevent accidental leakage.

(f)

LPG cylinders should not be used below ground level as any leakage of gas will collect at the lowest point and will not disperse.

(g)

Regulators must be handled with care. Damaged regulators should not be used, but should be replaced or sent for specialist repair.

(h)

Hoses and fittings should be examined before use. Damaged items must be replaced.

(i)

LPG cylinders are fitted with a left-hand thread or push-on connection. Union nuts and couplers have grooves on the outside corners of the nuts confirming this. Always use the correct size spanner to tighten or loosen connections. Hand tight connections will permit leaks.

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(a)

m

Left-hand threaded nut showing grooves on face corners

30

Over-tightening will damage threads and cause leaks. Checks for leaks should be carried out using soapy water or other proprietary detector.

31

NEVER USE A MATCH OR OTHER NAKED FLAME.

32

Before connecting any cylinder of LPG to equipment, it is essential that all fires, flames or other potential sources of ignition, including any smoking materials, are extinguished. Where it is reasonably practicable to do so, cylinders should be changed in the open air.

33

If a leak is found, the gas supply must be turned off at the cylinder immediately.

34

Flexible hoses should be in good condition and be protected or steel braided if they are likely to be subjected to damage by abrasion. Hoses must conform to BS 3212 (Specification for

QCS 2014


flexible rubber tubing, rubber hose and rubber hose assemblies for use in LPG vapour phase and LPG air installations). 35

Before use, inspections should be carried out on all LPG appliances and equipment. The inspection should cover testing for leaks, cleaning, adjusting, checking hoses, hose clips and ferrules.

36

Empty cylinders should always be treated as new ones and returned to a properly designated central storage area for collection. Under no circumstances should an LPG cylinder, either full or empty, be left around the site or buried during site operations.

Regulators LPG regulators should be suitable for the equipment with which they are to be used. They should be suitable for either propane or butane and be set to the correct pressure. They should be capable of passing the correct flow capacity.

38

It is dangerous to use regulators set at the incorrect pressure.

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1.7.4.12 Bitumen boilers and cauldrons

The majority of, if not all, bitumen boilers or cauldrons are fuelled by LPG to melt the block bitumen. Such a boiler or cauldron must be sited on a level non-flammable base, away from areas where site traffic may damage hoses or gas cylinders.

2

Ensure that any LPG cylinder is at least 3 m away from the boiler or cauldron to which it is attached.

3

Full cylinders, not attached, should be kept at least 6 m away from the boiler or cauldron and protected from heat.

4

Supply hoses should be checked for crushing, damage to the metal braiding or impregnation with bitumen. Any unserviceable hose must be replaced.

5

The sequence for lighting is as follows:

(b)

Have the source of ignition ready before turning on the gas. Light the burner, ensuring that the gas is turned on slowly.

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(c)

Remove the burner from the boiler or cauldron.

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(a)

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(d)

Replace the burner beneath the boiler or cauldron.

6

If frost forms on the outside of the cylinder, the gas flow rate is too high. Either use a smaller burner or couple two or more cylinders together by means of a manifold.

7

Never leave a bitumen boiler or cauldron unattended when the burner is alight.

8

Never move a bitumen boiler or cauldron with the burner alight.

9

If a bitumen boiler or cauldron is overfilled, overflows or boils over, the LPG cylinder valves must be turned off immediately. Any spillage should be contained using dry sand or earth and then left until cool. No attempt should be made to remove or recover any spillage of hot bitumen.

10

A dry powder extinguisher, of a minimum 4.5 kg in size, should be provided whenever a bitumen boiler or cauldron is used.

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1.7.4.13 Gas-operated hand tools 1

(a)

disposable

(b)

refillable.

These cylinders come in various shapes, sizes and colours, depending on the manufacturer. They range in size from the very small (0.5 kg) to the very large (47 kg).

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2

There are two types of LPG cylinder available for use with portable tools:

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Range of LPG cylinder sizes

All LPG cylinders used with portable equipment should be positioned upright and secured (if possible). Cylinders used with cutting equipment should always be placed on purpose-made trolleys.

4

Before changing a cylinder, always make sure that all valves are closed.

5

Hoses must never be kinked to try to shut off gas when changing torches. It does not work and can lead to a gas escape.

6

Always replace valve protection caps and plastic thread caps.

7

Flames from portable tools must not be allowed to play on LPG cylinders.

8

When work has been completed, turn off the cylinder valves and allow the flame from the portable torch to burn out.

9

Closure of torch valves rather than cylinder valves will retain gas in hoses which, if damaged, will allow gas to escape.

10

Hoses and torches must never be put into site toolboxes while still attached to the cylinder.

11

Manufacturers' operating pressures must be strictly observed and must NEVER be exceeded.

12

Do not interfere with preset pressure regulators.

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1.7.4.14 LPG for use in site huts and other small buildings 1

All LPG cylinders and regulators for use with fixed heaters, cookers and lighting within site

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huts, must be kept outside and the gas supply piped in using rigid copper piping. The use of flexible hosing is permitted only between the cylinders and change-over valves or manifolds, and for the final connection to appliances, but this must be kept as short as possible. All pipework should be exposed and easily accessible for inspection, but located to prevent accidental damage. Any work on LPG pipework or other parts of a fixed installation, including testing, must only be carried out by appropriately trained persons.

3

Ventilation for heaters and cookers must be permanent and adequate. It should be divided equally between vents at high and low level.

4

A two-burner cooker in a site hut needs approximately 150 mm x 150 mm ventilation. A 3 kW convector heater needs approximately 225 mm x 225 mm ventilation.

5

Inspections of all appliances must be carried out before use. If soot forms or smells occur, do not use or allow the appliance to be used. Find out the reasons for the problem and have it put right.

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Enclosed spaces

Before using LPG equipment in an enclosed space, it is essential to carry out a risk assessment. It is essential to ensure that there is adequate ventilation, which may have to be forced. This is necessary to ensure full combustion and also to make certain that the products of combustion, other fumes and excess oxygen from any cutting apparatus are removed. Proper safety precautions and atmospheric monitoring should be considered.

7

Wherever practicable, cylinders used with operations in confined spaces should be located in a safe area, preferably in the open air. The supply pressure should be reduced to the lowest practicable level on leaving the source of supply.

8

Where cylinders are used below ground level, the number must be kept as small as possible. All cylinders and hoses should be removed as soon as work has finished or if it is interrupted for a substantial period, e.g. overnight.

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Fire

Instructions for dealing with incidents involving LPG will vary for each situation. The most important thing is to avoid endangering anyone's life. The following actions should be taken by anyone discovering a fire.

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Action in an emergency

(a)

In case of fire, no matter how small, call the Civil Defence (Fire Department).

(b)

Whilst waiting for the fire and rescue service to arrive (if it can be done safely), turn off all cylinder valves to cut off the fuel supply and remove the cylinders from the area.

(c)

If the actions in 2 above cannot be completed safely, and thereby starve the fire of further LPG, evacuate the site and impose a cordon to stop anyone inadvertently entering the area.

(d)

Never attempt to use a water extinguisher to put out an LPG fire. Dry powder extinguishers are the most suitable type to use. The use of the wrong extinguisher in the wrong way could have serious consequences.

(e)

Training in the correct type of fire-fighting equipment to use, and the safe way to operate it, should be undertaken by all staff who work with LPG. These staff must be trained to recognise when the situation is getting out of control and they should also evacuate the area.

(f)

When the fire and rescue service arrives, inform the Fire Officer of the situation

QCS 2014

Section 11: Health and Safety Page 62 Part 1.07: Fire and Flammable Substances (Regulatory Document) including: (i)

the location and contents of all the cylinders

(i)

details of any security cordon that you have implemented

(ii)

confirmation that all people who were known to be in the area have been accounted for or details of anyone that is unaccounted for, and

(iii)

if possible and required, offer them the data information sheet relating to the cylinder(s) involved.

Remember that cylinders fitted with pressure relief valves can produce gas jets which will extend a considerable distance.

(h)

if cylinders are exposed to a severe fire or are engulfed in flames, no attempt should be made to fight the fire. Evacuate everyone from the area.

(i)

where a flame from a leaking gas cylinder is extinguished but the valve is still open, gas will continue to escape and there will be a danger of a gas cloud forming and the risk of an explosion.

(j)

any cylinder involved in a fire should be clearly labeled that it has been involved in a fire and removed from the area to a safe place. Contact the suppliers -they will give advice and arrange for the cylinder(s) to be collected,

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(g)

Instructions concerning emergency procedures should be clearly displayed and all employees should be made aware of them.

11

Data information sheets are available from product manufacturers giving advice in case of an accident involving LPG cylinders. A copy of each sheet should be available for inspection and those sheets relating to the cylinders involved should be given to upon request the Civil Defence (Fire Department).

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1.7.4.15 Fire-fighting equipment Selected and suitable employees should be trained in the use of fire-fighting equipment.

2

Advice on the training of staff can be obtained from the LPG supplier or fire and rescue service.

3

Portable fire extinguishers, sited in pairs to minimise the risk of failure, should be positioned at strategic points wherever LPG is stored or used. As a general guide, no fewer than two 4.5 kg dry powder extinguishers or equivalent should be provided for every 20 large cylinders (47 kg) stored.

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1.7.4.16 Training 1

Most accidents involving LPG are due to ignorance of basic safety precautions.

2

All persons using LPG cylinders, tools or equipment should be suitably instructed in the hazards associated with LPG, and the precautions to be taken in its use.

3

An LPG safety questionnaire is attached at Appendix 1.

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Construction Site Safety 1.7.4 Appendix 1 LPG safety questionnaire 1

This questionnaire has been worded so that all the correct answers are YES. If you answer 'NO' to any question you may need to give the matter more attention.

Storage Has a risk assessment been carried out?

3

Has specialist advice been sought prior to the location of fixed or moveable storage tanks?

4

Is there the required separation distance between the storage tanks and adjacent buildings or boundaries?

5

Is the base supporting the tanks level?

6

Is the base paved or concrete?

7

Is there a chain link fence surrounding the tank?

8

Are there barriers to prevent collision?

9

Are the correct warning signs displayed?

10

Are there outward opening exits from the cylinder storage compound?

11

Are the exits non-self locking?

12

Is the area kept weed free?

13

Are all access areas being kept clear?

14

Are the correct type of fire extinguishers provided?

15

Are all cylinders stored upright?

16

Are the LPG cylinders 3 m from cylinders containing any other products?

17

Are cylinders being handled safely?

18

Is the LPG being grouped in not more than 1,000kg?

19

Are there 1.5 m wide gangways?

20

Is lighting provided?

21

Is lighting at least 2 m above the tallest stack?

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Transportation 22

Have drivers received adequate training?

23

Are cylinders transported upright and secured?

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24

Is the vehicle equipped with the correct type of fire extinguisher?

25

Is the vehicle equipped with a first-aid kit?

26

Does the vehicle carry suitable warning notices?

27

If using a closed van, are all gas cylinders offloaded at the end of each journey?

Use of LPG cylinders and appliances Are valve caps and protectors replaced after every use?

29

Are regulators being handled carefully?

30

Is the correct size of spanner being used to tighten connections?

31

Is all equipment, such as hoses and clips, being inspected regularly for leaks?

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Bitumen boilers and cauldrons

Is there a fire extinguisher of the correct type readily available?

33

Is the boiler or cauldron standing on a non-flammable level base?

34

Is the cylinder in use with the bitumen boiler or cauldron, a minimum of 3 m away?

35

Are any cylinders not in use a minimum of 6 m away?

36

Are hoses inspected regularly for damage or bitumen impregnation?

37

Are cylinders ice-free when the boiler or cauldron is alight?

38

Should manifolds coupling two or more cylinders be used?

39

Are bitumen boilers always attended when alight?

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Hand tools

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Are cylinders being used in the upright position?

41

Are purpose-made trolleys being used for cylinders used in conjunction with cutting equipment?

42

Are hand tools being used at the manufacturer's recommended operating pressures?

43

Are connecting hoses being regularly checked for wear and damage?

44

Are cylinder valves being turned off on the completion of work?

45


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Site huts and other buildings 46

Are LPG cylinders, supplying heaters and other appliances, fixed outside the building?

47

Is the gas fed into the building by the provision of fixed copper piping?

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48

Are fixed installations only installed, modified and by competent engineer?

49

Is the final, short flexible hose as short as possible?

50

Are all pipes in use readily accessible for inspection?

51

Is there plenty of ventilation at high and low levels?

52

Are weekly inspections being carried out on all appliances?

53


Fire precautions Are written procedures provided and displayed prominently?

55

Is there a telephone available to summon the fire and rescue service?

56

Are the correct types of fire extinguishers provided?

57

Are your staff trained in the use of fire extinguishers?

58

Are your staff and visitors aware of the site emergency evacuation alarm and procedure?

59

Are personnel aware of pressure relief valves?

60

Are product data sheets available?

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Construction Site Safety 1.7.4 Appendix 2 Retrieval of orphaned compressed gas cylinders The cylinder retrieval arrangements in place for the major national companies are listed below. Collection company

Contact numbers

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Notes

If a cylinder is no longer needed, it should be returned to the local dealer of the company owning the cylinder.

2

Until such time as they are collected, 'orphaned' cylinders should be stored in a safe and secure manner.

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Vehicle Fuels (including Petrol, Diesel and LPG) 1.7.5.1 Key points A risk assessment must be carried out before dangerous substances are stored transported or used; in some cases a method statement and/or a permit to work will also be required.

2

Petrol is a flammable liquid that can be used for equipment such as generators and stored on site in small quantities in containers designed for the purpose. It has a flashpoint below 21 °C.

3

Diesel is a heavy mineral oil with a flashpoint much higher than that of petrol and is normally used as fuel for large commercial vehicles and construction plant.

4

Liquefied petroleum gas (LPG) is a compressed liquid, usually propane or butane, stored in cylinders. It is commonly used for heating, cooking or powering small vehicles such as dumper trucks or forklifts. It is heavier than air and has a flashpoint much lower than that of petrol.

5

Sources and safe storage of fuels should be recorded and carefully monitored.

6

Staff who work with flammable fuels must receive training in their safe handling and use prior to beginning work and must receive regular training in the use of fire extinguishers. Water must not be used on any liquid fuel fires.

7

The disposal of waste fuel is likely to be hazardous waste and should be managed accordingly.

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Vehicle fuels are classified as 'dangerous substances'. As such, there will be a risk of fire involved in their transportation, storage and use.

2

Wherever flammable liquids are stored or used a list of the substances present should be maintained, along with details of their quantities and location, which should be readily available for use by the fire and rescue service.

3

When used correctly and safely, petrol, diesel and LPG are useful fuels for the engines of vehicles and plant. When abused, they can cause explosions which can severely burn or even kill.

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1.7.5.3 Legislative requirements 1

Contractors are strongly advised to familiarise themselves with the content of Sections G1, G3 and G4 with regard to: (a)

the practical aspects of safe transportation, storage and use of dangerous substances (diesel and petrol) and LPG in the workplace

(b)

general advice on fire fighting, including the selection and use of hand-held fire extinguishers.

1.7.5.4 Petrol 1

Whilst the majority of construction plant will run on diesel oil, some small items of plant will have petrol-fuelled engines, for example: (a)

chainsaws

(b)

small portable generators

QCS 2014


(c)

disc cutters.

(d)

there will, therefore, be a need on occasions for petrol to be stored on site. This assumes that only small quantities of petrol will be stored on site.

Petrol, like many other flammable liquids, can give off large volumes of flammable vapours at room temperature. These vapours, when mixed with air, can ignite with violent and devastating consequences. Spilled petrol, if not contained, can flow to a source of ignition and then flash back to the source of the spillage. It is a dangerous substance to have on site unless adequate controls are implemented.

3

Petrol should ideally be stored outdoors to permit the dispersal of fumes from leakage. However, it is acknowledged that in some circumstances, for example the refurbishment of a city-centre building which has no open land, it may be necessary to store small quantities of petrol inside the building.

4

Petrol should be stored in suitable containers that enable the safe filling of petrol-powered machinery without spillage. Where necessary a funnel should be made available.

5

Containers must be robust, have tight fitting lids to prevent the leakage of liquid and vapour and be otherwise suitable for the purpose. Ideally containers will be of metal construction as these are more resistant to fire. These are usually of 5 litres capacity and the convention is that green containers are used for unleaded petrol.

6

All containers should be clearly labeled "Petroleum Spirit' or 'Highly Flammable' so that people on site are aware of the contents and any precautions that they must take.

7

Containers should, where reasonably practicable, be stored in the open air at ground level (singularly or in stacks). This enables leaks to be quickly seen and any vapours to be easily dispersed. They should not be stored on the roof of a building.

8

Where the best option of storing containers outside is not reasonably practicable they may be kept in suitable storerooms, preferably separate buildings, specifically designed for the purpose.

9

Other activities, including filling and emptying containers, must not be carried out in the designated storage area. This is to prevent other activities that are a higher risk causing a fire, which then spreads to involve the larger quantities in storage.

10

Any lighting equipment in any installation must conform to BS EN 60079-14 Explosive atmospheres - electrical installation design, selection and erection.

11

Electrical socket outlets are not permitted within any store where petrol or other flammable materials are stored.

12

Suitable fire-fighting equipment, such as a foam or dry powder extinguisher conforming to BS EN 3, must be positioned in close proximity to the store.

13

The store should not be sited under a staircase or other means of escape. A sill should be provided (not less than 150 mm in height) across the doorway of the store to prevent any leakage of petrol flowing out, along with measures to prevent any leakage of petrol into the drains or sewers.

14

The height of the sill should be adequate to contain a spillage of 110% of the volume of the largest container in the store or 25% of the aggregate capacity, whichever is the greater.

15

All reasonable precautions must be taken to prevent fire or means of ignition being brought close to any container.

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Outdoor storage 16

Petrol must be stored away from other storage areas and processes. There must be a minimum distance of 2 metres between a petrol storage area and any: (a)

occupied building

(b)

site boundary

(c)

process area

(d)

fixed sources of ignition

(e)

flammable liquid storage tanks.

Where higher risk activities (processes) are taking place, such as oxyacetylene cutting, the safety distance should be increased to a minimum of 4 metres.

18

The above distances may be reduced if fire walls to specific dimensions and standards of fire resistance are built.

19

Any outdoor petrol storage area should be secure both during working hours and at night. It might be considered that the normal site security arrangements are sufficient or that a dedicated secure store is required, in which case a welded mesh, palisade or chain-link fence of 1.8 metres high is the minimum requirement.

20

The features of any petrol storage area should not limit the means of escape in a fire.

21

Storage areas and a space of 1 metre around them will be classified as a Zone 2 hazard area and as such:

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any electrical fittings must be of the appropriate standard

(b)

there must be no sources of ignition

(c)

there must be no accumulation of combustible materials such as rubbish or vegetation.

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Where petrol is stored indoors at a place of work, a maximum of 50 litres may be stored. A risk assessment must be carried out and measures implemented to ensure that so far as is reasonably practicable, storage is carried out so as to:

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(a)

minimise the risks of fire and explosion

(b)

mitigate the effects of any fire and explosion that may occur.

In doing so, the risk assessment must consider the storage area with respect to: (a)

the absence of any sources of ignition

(b)

effective ventilation

(c)

adequate security

(d)

prohibition of filling equipment inside the storage area

(e)

avoiding spills and dealing with any spills that do occur

(f)

keeping containers closed when not in use.


Where significant amounts of petrol will be stored indoors a specially designed storage building must be constructed. However, given the small quantities of petrol that will be stored indoors on most construction sites, it is not envisaged that such a structure will be required.

Bulk petrol storage tanks

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Demolition or rebuilding work on a site may involve the removal of old petrol storage tanks. Before any work can be started to demolish or remove any tanks, they must be certified gasfree and cleaned. This is a hazardous operation and should only be done by skilled specialist contractors.

26

No attempt must be made by anyone other than a specialist contractor to enter a disused petrol tank.

27

Note; Lead which has settled into any remaining sludge can be a major health hazard in old petrol tanks. It may also be present in rust and scale.

28

Where any tank is to be left in temporary disuse, it must be sealed below the pump by disconnection, and then by stopping the suction pipe. The vent pipe should be left open to the air.

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Vehicle petrol tanks 29

No welding, soldering or brazing operations should be performed on any vehicle fuel tank until it has been properly freed from gas or the contents made inert. This prohibition applies whether the tank is on or off the vehicle. A competent person should then authorise 'hot work' on the tank, preferably under a Permit to Work system.

QCS 2014


1.7.5.5 Diesel oil General requirements 1

The tank must have sufficient strength so that in normal circumstances it will not leak.

2

Appropriately designed and constructed supports for the tank must be used.

3

The tank must be so positioned to minimise the risk of impact damage by other vehicles and should not be placed within 10 metres of a watercourse or within 50 metres of a spring, well or borehole. The tank should also be positioned with consideration for future maintenance.

4

The tank must be situated within a secondary containment system (bund wall) which: has a capacity of 110% or more of the tank's capacity - or, if more than one container is stored, 110% of the largest container's storage capacity or 25% of the aggregate capacity, whichever is the greater

(b)

is so constructed that its base and walls are impermeable to oil and water

(c)

is strong enough to withstand being filled with either water or oil

(d)

has walls which cannot be penetrated in any form by tank drainage

(e)

if penetrated by a fill pipe or draw-off pipe, is adequately sealed to prevent leakage

(f)

has valves, sight gauges and vents sited within it.

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(a)

External fill pipes and draw-off pipes to the tank(s) should be positioned to minimise impact damage and, if above ground, should be properly supported. If underground, they should have no mechanical joints except where accessible.

6

They should be laid in a duct or sleeve to protect them from physical damage, and be protected against corrosion.

7

The whole system should have a leak detection system which should be tested regularly.

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Fill pipes

All fill pipes should be fitted with an automatic overfill prevention device if filling takes place where the tank cannot be kept under constant observation.

9

All fittings should either be screw type or other fixed type coupling.

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Where fuel oil is to be dispensed into containers or vehicles, the outlet must be fitted with a valve or nozzle which closes automatically when not in use, and which cannot be fixed in the open position unless an automatic cut-off nozzle is used on the end of the hose.

11

The hose and nozzle should be housed in an enclosed secure cabinet with a drip tray when not in use, or have a lockable valve where the feed leaves the tank. Hoses should be kept locked or kept within the bund when not in use.

12

Any permanent valve or tap which opens directly from the tank must: (a)

be located within the secondary containment system (bund wall)

(b)

discharge vertically downwards

(c)

be locked off when not in use.

QCS 2014

13


Finally, no vent must discharge outside of the bund in the event of an overfill.

Bulk diesel storage tanks The following points should be noted: the storage tank should be of mild steel

(b)

all bulk storage tanks should be placed on concrete or brick cradles

(c)

storage tanks should be protected from impact damage by delivery vehicles or site traffic

(d)

the tank should be in the open air, on level ground well clear of any openings, windows or doors

(e)

the tank should be vented at the top

(f)

protective gloves should always be worn when handling diesel oil. Skin contact may cause irritation leading to dermatitis and infection

(g)

metal storage cans should be kept in a lockable store, which has a sill to prevent any spillage flowing out. Appropriate warning labels should be displayed prominently on the store

(h)

a minimum distance of 750 mm between the tank and walls and 600 mm from the base is recommended to facilitate inspection

(i)

the tank should be marked with its capacity and the type of material stored within it

(j)

ensure that surfaces where deliveries are to be made and oil dispensed are protected by a surface impermeable to the oil stored and isolated from any drainage system

(k)

protective gloves should always be worn to protect any exposed skin. Contact can lead to irritation and dermatitis

(l)

metal storage cans should be kept in a lockable store with a sill to prevent spillage flowing out.

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(a)

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Any mobile bowser should be fitted with a lock to any tap, valve or pipe through which oil is discharged and all pipes and valves should be locked shut within the bunded area of the bowser when not in use.

16

Where the oil is delivered through a permanently attached flexible pipe:

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(a)

the pipe must be fitted with a hand pump or with a valve at the end which closes automatically when not in use

(b)

the pump or valve must be fitted with a lock and locked shut when not in use

(c)

the pipe must be fitted with a lockable valve at the end where it is connected to the bowser and kept locked shut when not in use

(d)

any sight gauge must be fitted with a lockable valve which is locked shut when not in use.

1.7.5.6 Liquefied petroleum gas (LPG) 1

Every Contractor must ensure that all persons who work with or supervise others in the use of LPG equipment have available to them adequate health and safety information and, where appropriate, written instructions relating to the use of that equipment.

2

Containers of LPG are liable to explode if involved in a fire; pieces of the container may be projected over considerable distances.

QCS 2014


Every Contractor must ensure that all persons who work with, or supervise others in the use of, LPG equipment, have received adequate training for the purposes of health and safety, and be aware of any risks in the use and precautions to be taken in the case of an accident.

4

LPG is used in the building and construction industry as a fuel for small plant vehicles, such as dumper trucks and forklift trucks.

5

Only the correct type of cylinder should be used as these are of special construction and designed specifically to be laid on their side for fitting to the truck and for operation.

6

The following safety points should be strictly observed: make sure you have the correct type of cylinder

(b)

make certain it is correctly connected using the correct size of spanner to tighten the connection

(c) (d) (e)

never interfere with preset reducing valves

(f)

manufacturers' recommended operating pressures should never be exceeded

(g)

store additional cylinders safely

(h)

only keep on site the minimum quantity of LPG that is needed for effective operations.

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if you suspect a leak, do not use a lighted match or other naked flame. Only use soapy water or other proprietary leak detection fluid

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make sure all cylinder valves are turned off before you attempt to change the cylinder

7

LPG cylinders are fitted with a left-hand thread or push-on connection. Union nuts and couplers have grooves on the outside corners of the nuts confirming this. Always use the correct size spanner to tighten or loosen connections. Hand-tight connections will permit leaks.

QCS 2014


Left-hand threaded nut showing grooves on corners

Storage of LPG cylinders All LPG cylinders not in use, empty cylinders awaiting return to the supplier and spare cylinders should be kept securely.

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LPG cylinders should be stored above ground level well away from drains and other low lying areas.

(b)

Stores in the open air should be sited as far from buildings as possible.

(c)

LPG stores in buildings should be accessible directly from the outside and be well ventilated.

(d)

LPG cylinder stores should not be used for the storage of petrol or other fuels (including acetylene).

(e)

Full cylinders should be stored separately from empty cylinders; all cylinders being stored with their valves uppermost.

(f)

Cylinders should be protected from direct sunlight.

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Fire fighting

Fires involving petrol and other vehicle fuels are usually severe, may cause explosions and are generally best left to the fire and rescue service. Knowledge of what to do in the event of a fire is essential if injuries and deaths are to be avoided.

10

In most cases where vehicle fuels are involved in a fire, or are being heated by it, a rapid evacuation of the site and a call to the fire and rescue service will be the only sensible and safe courses of action.

11

However, where other, less hazardous materials such as timber are involved in a fire, which could spread to a fuel storage area or an area where construction plant is located, a decision based upon the risks to personal safety will have to be taken as to whether or not to attempt to fight the fire to prevent the situation escalating.

12

Generally, the fire and rescue service will not enter any structure that is on fire in which LPG cylinders are known to be present. They are more likely to create an exclusion zone around the structure. It is of great assistance to them if the location of any LPG storage area is such that it can be cooled by a water spray from a distance.

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Disposal of Fuels 13

Other materials contaminated by fuels such as PPE, rags, used spill kit materials, etc. should also be regarded as hazardous waste and should be segregated from other non-hazardous wastes.

14

LPG cylinders that are no longer required should be returned to a local dealer of the company owning the cylinder. Under no circumstances should the LPG cylinder be disposed of in a waste skip or metal recycling skip. END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 1


1.8

MISCELLANEOUS .......................................................................................... 1

1.8.1

Sources of Health and Safety Information ....................................................... 4

1.8.2

Safety Signs .................................................................................................. 12

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Page 2

FORWARD

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Page 3

Sr. No


Part No.

Part Name

1

1

7

Submittals

8

7.5.2


2

1

7

Submittals

9

7.6.1


3

1

10

Health and Safety

All

All

All

4

1

11


10

11.4.6


5

1

14


3

14.4


6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1


7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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Item Name

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Page No. Item No.



Temporary Fencing

15

7.8.13

Safety Requirements


4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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1

17

8

8


6

8.1.9

Safety

18

8

9


7

9.2.5

Safety Requirements

19

8

10


4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16


1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1


7&8

1.1.11


25

21

1


14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5


28

29

3


4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4


32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Page 4


Sources of Health and Safety Information

British Standards Institute (BSI) BSI publications, including all British, European and ISO standards and other reference material, can be obtained direct from: British Standards Institution

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Customer Services 389 Chiswick High Road London W4 4AL Tel: 020 8996 9001 Fax: 020 8996 7001 Email: [email protected] Alternatively, they can be ordered: online from www.bsonline.bsi-global.com



from most branches of good quality bookshops; details on the above website.

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Construction Standards British and European Standards

Sections British and European Standards 1.1

1.3

1.4

1.6

1.7

X

BS 1139-3 Metal scaffolding. Specification for prefabricated mobile access and working

X

.

X

BS 1129 Specifications for portable timber ladders, steps, trestles and lightweight staging

BS 1377 Methods of test for soils for civil engineering purposes

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X

BS 1710 Specification for identification of pipelines and services

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X

BS 2037 Specification for portable aluminium ladders, steps, trestles and lightweight stagings BS 2482:2009 Specification for timber scaffold boards

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BS 2830 Specification for suspended access equipment for use in the building, engineering construction, steeplejack and cleaning industries

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BS 3212 Specification for flexible rubber tubing, rubber hose and rubber hose assemblies for use in LPG vapour phase and LPG air installations

1.5

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BS 598 Sampling and examination of bituminous mixtures for roads and other paved areas

1.2

X

BS 4078-2 Powder actuated fixing systems. Specification for tools

X

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BS 4078-1 Powder actuated fixing systems. Code of practice for safe use

X

BS 4250 Commercial butane and propane X

BS 4363 Specification for distribution assemblies for reduced low voltage electricity supplies for construction and building sites

X

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BS 4293 Specification for residual current operated circuit breakers

BS 4465 Specification for design and construction of electric hoists for both passengers and materials

X

BS 4481 Part 2 Bonded abrasive products

X

BS 5228:2009-1 CoP for noise and vibration control on construction and open sites - Noise

X

BS 5228:2009-2 CoP for noise and vibration control on construction and open sites - Vibration

X

BS 5266 Part 1 Emergency lighting

X

BS 5266-10 Guide to design and provision of emergency lighting

X

BS 5306 Fire extinguishing installations and equipment on premises

X

1.8

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Page 6


1.2

1.3

1.4

1.5

1.6

BS 5306-3 CoP for maintenance of portable fire extinguishers

X

BS 5499 Fire safety signs, notices and graphic symbols

X

BS 5531 CoP for safety in erecting structural frames

X

BS 5534 CoP for slating and tiling

X

X

BS 5588 Fire precautions in the design, construction and use of buildings

X

BS 5607 CoP for safe use of explosives in the construction industry

.

X

BS 5972 Specification for photoelectric control units for road lighting

X

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X

BS 5975 CoP for Falsework

X

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BS 6187 CoP for demolition (under review)

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BS 7071 Specification for portable residual current devices BS 7121-1 Code of Practice for safe use of cranes. General

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BS 7121-2 Inspecting, testing and examination

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BS 7121-3 Mobile cranes

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X X X X

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BS 7121-4 Lorry loaders

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BS 7212 CoP for safe use of construction hoists

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X

BS 5974 CoP for temporarily installed suspended scaffolds and access equipment

BS 7121-5 Tower cranes

BS 7273 CoP for the operation of fire protection measures

X

BS 7375 CoP for the distribution of electricity on construction and building sites

X

BS 7430 CoP for earthing

X

BS 7671 2008 IEE wiring regulations 17th edition

X

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BS 7288 Specifications for socket outlets incorporating residual current devices (SRCDs)

BS 7863 Recommendations for colour coding to indicate the extinguishing media contained in portable fire extinguishers

X

BS 7883 CoP and use of anchor devices conforming to BS EN 795

X

BS 8411 Code of practice in the use of safety nets on construction sites and other works

X

BS 8454 Code of practice for the delivery of training and education for work at height and rescue

X

BS 8476 Code of practice for the safe use of concrete pumps BS 8800 Guide to occupational health and safety management systems

1.7

X X

1.8

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Page 7

Sections British and European Standards 1.1 BS 18004 Guide to achieving effective occupational health and safety performance

1.2

BS EN 143 Respiratory protective devices. Particle filters. Requirements, testing, marking

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BS EN 166 Personal eye protection. Specifications BS EN 169 Personal eye protection. Filters for welding and similar operations BS EN 170 Personal eye protection. Ultraviolet filters BS EN 171 Personal eye protection. Infrared filters BS EN 172 Personal eye protection. Sunglare filters for industrial use BS EN 175 Equipment for eye and face protection during welding and allied processes BS EN 280 Mobile elevating work platforms. Design calculations. Stability criteria. Construction. Safety. Examinations and tests BS EN 340 Protective clothing. General requirements BS EN 341 Personal protective equipment against falls from a height. Descender devices BS EN 352-1 Hearing protection. Safety requirements and testing. Ear muffs BS EN 352-2 Hearing protection. Safety requirements and testing. Ear plugs

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BS EN 149 Respiratory protective devices. Filtering half masks to protect against particles. Requirements, testing, marking

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BS EN 140 Respiratory protective devices. Half masks and quarter masks. Requirements, testing, marking

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X

.

X

BS EN 138 Respiratory protective devices. Specification for fresh air hose breathing apparatus for use with full face mask, half mask or mouth piece assembly

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1.5

1.7

1.8

X

,

X

BS EN 137 Specification for respiratory protective devices: self-contained opencircuit compressed air breathing apparatus

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X

BS 31100 Code of practice for risk management BS EN 3 Portable fire extinguishers Parts 3, 6 and 7 BS EN 131-3 Ladders - user instructions BS EN 136 Respiratory protective devices. Full face masks. Requirements, testing, marking

BS EN 165 Personal eye protection. Vocabulary

1.3

X

X X

X

X X X X X

X

X

X X X X

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1.2

1.3

1.4

BS EN 353-1 Personal protective equipment against falls from a height. Guided type fall-arresters including a rigid anchor line

X

BS EN 353-2 Personal protective equipment against falls from a height. Guided type fall-arresters including a flexible anchor line

X

BS EN 354 Personal protective equipment against falls from a height. Lanyards

X

X

X

X

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BS EN 393 Lifejackets and personal buoyancy aids. Buoyancy aid 50 BS EN 397 Specification for industrial safety helmets BS EN 420 Protective gloves. General requirements BS EN 474 Earth moving machinery. Safety BS EN 529 RPE - Recommendations for selection, use, care and maintenance BS EN 671 Fixed fire fighting systems. Hose systems BS EN 752 Drain and sewer systems outside buildings BS EN 792-13 Hand-held non-electric power tools. Safety requirements. Fastener driving tools BS EN 795 Protection against falls from a height. Anchor devices. Requirements and testing BS EN 1146 Respiratory protective devices Self-contained open-circuit compressed air breathing apparatus incorporating a hood for escape

1.8

X

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BS EN 365 Personal protective equipment against falls from a height. General requirements for instructions for use, maintenance, periodic examination, repair, marking and packaging BS EN 388 Protective gloves against mechanical risks

X

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X

BS EN 362 Personal protective equipment against falls from a height. Connectors

BS EN 364 Personal protective equipment against falls from a height. Test methods

1.7

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BS EN 360 Personal protective equipment against falls from a height. Retractable type fall-arresters BS EN 361 Personal protective equipment against falls from a height. Full body harness

BS EN 363 Personal protective equipment against falls from a height. Fall-arrest systems

1.6

.

BS EN 355 Personal protective equipment against falls from a height. Energy absorbers BS EN 358 Personal protective equipment against falls from a height. Belts for work positioning systems and restraint and work positioning lanyards

1.5

X

X

X

X X X

X

X X X

X X

X

X

X

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Page 9


1.2

BS EN 1261 Fibre ropes for general service. Hemp BS EN 1263-1 Safety nets. Safety requirements, test methods BS EN 1263-2 Safety nets. Safety requirements for the positioning limits

1.3

1.4

X

X

BS EN 1492-4 Textile slings. Safety. Lifting slings for general service made from natural and man-made fibre ropes

X

X

BS EN 1827 Respiratory protective devices. Half masks without inhalation valves with separable filters for gases and particles. Requirements, testing, marking

X

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BS EN 1869 Fire Blankets

X X

X

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BS EN 1870 Safety at woodworking machines - circular saws and vertical panel saws

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BS EN 1498 Personal fall protection equipment - rescue loops

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X

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BS EN 1496 Personal fall protection equipment - rescue lifting devices

X X

BS EN 12158-2: Builders hoists for goods. Part 2: Inclined hoists with non-accessible load carrying devices

X

BS EN 12159: Builders hoists for persons and materials with vertical guided cages

X

BS EN 12385-2 Steel wire ropes. Safety. Definitions, designation and classification

X

BS EN 12385-4 Steel wire ropes. Safety. Stranded ropes for general lifting applications

X

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BS EN 12158-1: Builders hoists for goods Part 1: Hoists with accessible platforms

BS EN 12810-2 Facade scaffolds made of prefabricated components. Particulars of structural design

X

BS EN 12811-1 Temporary works equipment. Part I Scaffolds. Performance requirements and general design

X

BS EN 12811-2 Temporary works equipment. Information on materials

X

BS EN 12841 Personal fall protection equipment - rope access - rope adjustment devices

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BS EN 1492-2:2000 Textile slings. Safety. Roundslings, made of man-made fibres, for general purpose use

BS EN 12899-1: Fixed, vertical road traffic signs. Fixed signs

1.7

X

X

BS EN ISO 6103 Bonded adhesive products. Permissible unbalances of grinding wheels as delivered. Testing

1.6

X

BS EN 1492-1:2000 Textile slings. Safety. Flat woven webbing slings, made of manmade fibres, for general purpose use

BS EN ISO 5349-1 Mechanical vibration. Measurement and assessment of human exposure to hand transmitted vibration

1.5

1.8

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Page 10

Sections British and European Standards 1.1 BS EN 13794 Respiratory protective devices. Self-contained close-circuit breathing apparatus for escape

1.2

1.3

X

1.5

1.6

1.7

X

BS EN 13411-5 Terminations for steel wire rope. Safety. U-bolt wire rope grips

X

BS EN 14439 Cranes - safety - tower cranes

X

BS EN 14502-1 Cranes - equipment for lifting persons - suspended baskets BS EN 14593-1 Respiratory protective devices. Compressed air line breathing apparatus with demand valve. Apparatus with a full mask. Requirements, testing, marking BS EN 14593-2 Respiratory protective devices. Compressed air line breathing apparatus with demand valve. Apparatus with a half mask at positive pressure. Requirements, testing, marking BS BS EN 14686 Fibre ropes of polyester/polyolefin dual fibres BS EN 50144-1 Safety of hand-held electric motor operated tools. General requirements BS EN 60079-14:2008 Explosive atmospheres - electrical installations design, selection and erection BS EN 60309 Plugs, socket-outlets and couplers for industrial purposes BS EN 60825 Safety of laser products

X

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BS EN 61557 Electrical safety in low voltage distribution systems

1.4

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BS EN ISO 12402-2:2006 Personal flotation devices. Lifejackets, performance level 275. Safety requirements

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BS EN ISO 12402-3 Personal flotation devices. Lifejackets, performance level 150. Safety requirements BS EN ISO 12402-4 Personal flotation devices. Lifejackets, performance level 100. Safety requirements BS EN ISO 12402-5 Personal flotation devices. Buoyancy aids (level 50). Safety requirements BS EN ISO 12402-8 Personal flotation devices. Accessories. Safety requirements and test methods BS EN ISO 14001:2004 Environmental management systems. Requirements with guidance for use BS ISO 525 Bonded abrasive products. General requirements. Pt1: Specification for general features of abrasive wheels, segments, bricks and sticks BS OHSAS 18001 Occupational health and safety management systems. Requirements BS OHSAS 18002 Occupational health and safety management systems -guidelines for the implementation of OHSAS 18001:2007

X

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X

X

X

X

X

1.8

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1.2

1.3

1.4

PD 2754-2: IEC 60536-2:1992 Classification of electrical and electronic equipment with regard to protection against electric shock. Guide to requirements for protection against electric shock

1.5

1.6

X

X

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PD 5304 Safe use of machinery

1.7

1.8

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Safety Signs


The colours used and their meanings are outlined on the following pages, together with example signs.

1.8.1.2 Prohibition signs

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These signs are red and white with a black image. The signs inform people of things they must not do, for example 'No pedestrians' or 'No smoking'.

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No pedestrians

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No smoking

Children must not play

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1.8.1.3 Mandatory signs

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These signs are blue with a white image and inform people of things that they must do, for example 'Wear ear protection' or 'Use crawling boards'.

Wear a respirator

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Wear a hard hat

Wear eye protection

Wear safety gloves

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Wear ear protection

Wear work boots


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Ear protection zone

Use crawling boards

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These signs are either yellow or amber with a black image and warn people of potentially dangerous situations, for example 'Forklift trucks operating' or 'Fragile roof.

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1.8.1.4 Warning signs/signs on hazardous substances

General warning

Flammable

Corrosive

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Radioactive

Page 15

Toxic

Explosive

Danger of electrocution

Laser beams

Highly flammable

Forklift trucks operating

Harmful

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Fragile roof

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Irritant

Falling objects

Hazardous to the environment

Suspended loads

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1.8.1.5 Safe condition signs

Emergency eye wash

First aid

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Assembly point

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These signs are green with a white image and inform people of features of the site that are associated with a safe condition, for example 'First aid' or 'Fire exit'.

Emergency shower

Wash hands

Drinking water

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Line-throwing appliance

Lifebuoy with line

Stretcher location

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Page 17

Fire exit

1.8.1.6 Fire safety These signs are also red and white, but predominantly red with a white image. They indicate the location of facilities associated with fire safety such as 'Call point' or 'Fire point'.

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Call point

Fire point

an 'Unauthorised access strictly prohibited' sign - red and white = must not do

(b)

an 'All visitors must report to the site office' sign - blue and white = must do a 'Beware open excavations' sign - yellow and black = beware of danger an 'Assembly point' sign - green and white = safe condition.

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Often 'mixed signs' will be displayed, which are a combination of the four main types of sign. For example, a sign at the site entrance might include:

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1.8.1.7 Mixed signs

Hose reel

Similar signs that indicate, for example, the location of a dangerous substance storage area will also usually comprise a combination of signs, such as a 'Flammable' (warning) sign, a 'No smoking' (prohibition) sign, and additional appropriate wording.

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Page 1 Part 2.1.01: Safety, Health and Environment Management System

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..........................................................1

2.1

SAFETY, HEALTH AND ENVIRONMENT (SHE) MANAGEMENT SYSTEM .1

2.1.1 Amendment Schedule .................................................................................................. 3 2.1.2 Safety, Health and Environmental (SHE) Management Framework ............................. 4

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2.1.3 Statement of Intent ......................................................................................................10 2.1.4 Policy and Responsibilities - Example .........................................................................12

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2.1.5 Organisation Charts ....................................................................................................22

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2.1.6 Index of Key Process ..................................................................................................22

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2.1.7 Author .........................................................................................................................22

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2.1.8 Approvals ....................................................................................................................22

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Purpose 1

The purpose of this document is to provide guidance for development of a clear policy, responsibilities and an example of a management framework that reflects the COMPANY commitment, core values, standards and expectations for both the organisation and those working with COMPANY.

Scope This policy covers all COMPANY operating areas, projects and activities.

2

This policy is intended to assist appointed consultants, sub-contractor and suppliers etc., to meet legislative and other requirements not intended to replace these. The policy should always be read in conjunction with QCS Part 1 (RD) requirements and any other legislative requirements as advised and may be introduced.

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QCS 2014

2.1.1


Amendment Schedule Details of change

Date

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Revision No.

QCS 2014

2.1.2


Safety, Health and Environmental (SHE) Management Framework


This document sets out a framework for the management of Safety, Health and Environmental (SHE) issues across COMPANY’s operations, projects and activities.

2.1.2.2 SHE Management System The management system, and this framework, is based on recognised standards i.e. ISO 9001 ‘Quality Systems’, BSI OHSAS 18001 ‘Occupational Health and Safety Management Systems’ and ISO 14001 ‘Environmental Management Systems’.

2

In summary, the key requirements of the system are:

Procedures for hazard identification, risk assessment, control and management of change.

(c)

Documented, measurable SHE objectives and plans.

(d)

Clear management responsibilities.

(e)

Competence assurance identification and delivery.

(f)

Arrangements for communication, consultation and engagement with the appropriate stakeholders.

(g)

Operating procedures and processes.

(h)

Arrangements for SHE document control and retention.

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Consistent SHE policy statements throughout COMPANY’s operations.

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training

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(k)

Systems for capturing learning events and best practice.

(l)

An audit and monitoring system.

(m)

Regular management reports on SHE performance, including improvement reports.

(n)

Regular management reviews.

Active performance indicators. System for notification, investigation and recording of accidents, learning events and environmental incidents including standardised statistics.

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In order to achieve the consistency desired, along with compliance, with the OHSAS 18001 and ISO 14001 standards, these management system elements are mandatory.

2.1.2.3 Background 1

To ensure core values and expected behaviors set out in the SHE policy namely, commitments to: (a)

Continuously improve SHE performance towards our overall goal of protecting both people and the environment.

QCS 2014


(b)

Ensure that business decisions take proper account of SHE matters and their implications.

(c)

Comply with all legislative requirements pertaining to SHE as the minimum standard.

2

Our overall goal is to protect both people and the environment. Our principles require us to have an effective SHE management system that will deliver consistency in approach and good management information on performance throughout our operations.

3

Good corporate governance also requires SHE performance to be properly reviewed and in addition COMPANY is committed to review and publish this information.

2.1.2.4 Purpose The purpose of this document is to set out an enabling framework for the management of Safety, Health and Environmental (SHE) issues across COMPANY’s operations wherever they are carried out. It deals with the management systems to be adopted, and does not prescribe actual systems of work which it is recognised will be affected by stakeholder, legislative, cultural and working practice requirements.

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2.1.2.5 Scope GENERAL

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Throughout this document reference is made to ‘COMPANY’. This term means any region, operational area or project wherever it is based and wherever it carries out work.

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Continuously improve SHE performance towards our overall goal of protecting both people and the environment.

(b)

Ensure that business decisions take proper account of SHE matters and their implications.

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(a)

Comply with all legislative requirements pertaining to SHE as the minimum standard.

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Joint shall ensure that the SHE management system is consistent with the international best practice principles set out within QCS commitments to:

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JOINT VENTURES (JV’S) AND PARTNERING AGREEMENTS

When entering into a Joint Venture or partnering arrangement the business concerned will ensure that: (a)

A clear and unambiguous policy is developed, put in place and communicated.

(b)

The relevant parties will agree/develop a SHE Management System that takes cognizance of best practice and standards.

(c)

Key processes put in place include planning, competence, operational control, emergency preparedness, change management, performance measuring and monitoring, accident and incident investigation and review.

(d)

Arrangements must also be in place for reporting on SHE performance to relevant parties (including incident reporting), SHE management review by the board and if appropriate the formation of an independent SHE board to provide advice etc

(e)

Within the policy and defined roles and responsibilities, a board member must be identified who has specific responsibility for SHE matters.

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2.1.2.6 Policy POLICY STATEMENTS 1

The COMPANY SHE policy statement and responsibilities applies to all COMPANY’s operations wherever they are carried out. They are included in Section 3 and Section 4 of this document.

2

A template format for the SHE policy statement is included in Section 3 of this document. All Joint Ventures or partnering agreements must use this template as a basis for developing any specific policy. COMMUNICATION

.

The developed policy, including personal responsibilities and those of direct reports, must be communicated to each employee. Examples of those responsibilities are outlined within this section.

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3

The policy statement will be reviewed at least annually.

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REVIEW

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2.1.2.7 Planning

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PLANNING FOR HAZARDS, ENVIRONMENTAL IMPACT IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL COMPANY will have and maintain procedures for the identification of hazards, environmental impacts, the assessment of risks, and the implementation of necessary control measures. Procedures must include the provision of suitable management and operational levels to ensure work is carried out safely and with consideration of the environment.

2

The procedures will address the activities of: COMPANY employees

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(b)

COMPANY contractors (including any further sub-contractors)

(c)

Other contractors performing work under COMPANY’s control

(d)

Other persons affected by COMPANY’s undertakings, i.e. members of the public

In respect of environmental impact the procedures will also address the supply of goods and materials for use by the COMPANY business. LEGAL AND OTHER REQUIREMENTS

4

Establish and maintain a procedure for identifying and accessing the legal SHE requirements that apply and have an impact on our activities. Impact may also include the effect of any material change that may be brought about by organizational re-structure or senior management appointments. Information on any relevant new SHE requirements that must be communicated to employees and other interested parties as appropriate.

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OBJECTIVE 5

6

COMPANY will set documented, measurable, annual SHE objectives and targets. The objectives must be consistent with the SHE policy and the commitment to continuous improvement. A management programme will be produced for achieving the objectives setting out: (a)

The designated responsibility for achievement of the objectives

(b)

The means and time-scale by which the objectives are to be achieved

(c)

Any appropriate improvement targets and associated improvement plans

The programme will be reviewed at regular intervals to ensure it is up to date and that it addresses any changes that may have occurred in COMPANY.

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2.1.2.8 Implementation and Operation STRUCTURE AND RESPONSIBILITIES

This document recognises that SHE is everybody’s responsibility and will be managed through the organisation in a systematic and structured manner.

2

Regional businesses must develop an effective management structure, including individual responsibilities in SHE matters at all levels. The structure will recognise line management responsibility and allow for access to competent advice on SHE matters.

3

Statements of individual and collective responsibilities are included in Section 4 of this document.

4

A SHE organisational structure chart for the COMPANY business is included in Section 5 of this document. The chart shows operational and functional responsibilities for SHE and visible to all, for example displayed on site.

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COMPETENCE AND TRAINING COMPANY will have processes in place to ensure that those working for, or on behalf of, COMPANY are competent to perform any tasks they are given that may have an impact on SHE performance.

6

COMPANY will also identify the training necessary to meet our SHE policy commitments at each level and function within the business.

7

Plans will be developed to deliver the required training.

8

Training records will be kept and achievement of the required training will be monitored.

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COMMUNICATION AND INVOLVEMENT 9

COMPANY will establish and maintain appropriate arrangements and strategies for: (a)

The communication

(b)

The communication of relevant SHE information to employees and those working on our behalf.

(c)

Consultation with and engagement of employees, those working on our behalf and those affected by the activities of the business.

QCS 2014

(d)

Section 11: Health and Safety Page 8 Part 2.1.01: Safety, Health and Environment Management System Receiving and responding to relevant communication from external interested parties.

OPERATIONAL CONTROL

Project Management Plans

(c)

SHE Management Plans

(d)

Method/Task Statements

(e)

Permit Controls

(f)

Work Instructions

(g)

SHE Performance Reports

.

(b)

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Risk Assessments

In addition, establish arrangements for the control of SHE documentation and data. The arrangements will ensure that documentation and data is: Retrievable

(b)

Current

(c)

Appropriately authorised, and where necessary

(d)

Periodically reviewed

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(a)

Records retention schedule will be prepared, which will identify all SHE records and their associated retention periods. These records will be stored appropriately such that they are readily retrievable and protected against damage, deterioration or loss throughout the retention period.

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(a)

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Prepare operating procedures and plans for the planning and control of activities associated with identified risks. These may include provision for:

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EMERGENCY PREPAREDNESS

COMPANY will assess the potential for emergency situations and, where appropriate, establish emergency preparedness and response arrangements.

14

There arrangements will be periodically reviewed and tested and, where necessary, revised. Reviews will be undertaken to a pre-determined programme and after the occurrence of accidents or emergency situations.

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2.1.2.9 Checking and Corrective Action PERFORMANCE MEASUREMENT AND MONITORING 1

COMPANY will establish and maintain procedures to monitor and measure SHE performance on a regular basis. This will include: (a)

Active systems which monitor the achievement of objectives and compliance with standards.

(b)

Reactive systems which monitor accidents, ill-health and incidents.

ACTIVE PERFORMANCE INDICATORS 2

Active performance indicators will at least include:

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(a)

Performance results against our short, medium and long term SHE strategy

(b)

Achievement of objectives

(c)

SHE training achievement

(d)

Audit results and surveys

(e)

Assessment against SHE performance standards

(f)

Statistical analysis

(g)

Cases of good working practices

(h)

Learning event reports

ACCIDENTS, INCIDENTS AND CASES OF ILL HEALTH

COMPANY employees

(b)

Employees of sub-contractors where

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COMPANY will establish procedures for notification, investigation and recording of accidents, incidents, cases of ill health, learning events (near misses) and environmental incidents involving:

COMPANY has direct sub-contractors (and any further sub-contractors) performing work under its control, or

(ii)

Has general supervisory authority over the worksite

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(i)

Others affected by COMPANY work such as visitors or members of the public

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Accident and cases of ill health statistics will be compiled and included in management reports. The standard statistics to be used across COMPANY are based on RIDDOR record keeping guidelines for occupational injuries and illnesses. In particular, accident frequency rates, accident incident rates, lost time incident frequency rate and total recordable case frequency rate will be used.

5

Investigation procedures will ensure that incidents that have, or could have, led to serious harm to the individual or the environment are investigated and reported on. Investigations will establish what happened, any corrective or preventive actions required and allocate responsibility for taking such action.

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ENFORCEMENT ACTION Details of any enforcement action taken by the Administrative Authority in the form of prosecutions, enforcement notices, orders, etc will be recorded and included in management reports and communicated as soon as is reasonably practicable, to the senior management team. AUDIT 7

COMPANY Regional businesses will undertake regular audits to monitor the operation of the SHE management system and measure its adequacy and performance.

8

Significant findings of the audits must be acted upon. Close-out reports detailing the action taken will be produced.

9

Details of audits undertaken and their results will be included in management reports.

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2.1.2.10 Management Review MANAGEMENT REPORTS ON SHE PERFORMANCE 1

Prepare regular reports on SHE performance for review by its senior management board. These reports should be prepared at least monthly.

2

Management reports on SHE performance will be produced at corporate, operational area and project levels. A consistent structure will ensure that the key information contained in the reports can be meaningfully compiled and used at a higher level.

3

Report on SHE performance on a monthly basis.

Executive summary

(b)

SHE performance

(c)

Site visit feedback (by exception)

(d)

Learning Events

(e)

Occupational Health

(f)

Environmental

(g)

Stakeholder involvement

(h)

Training

(i)

Best Practice

(j)

Progress against action plans

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Senior management teams of each COMPANY Regional businesses must regularly review SHE performance. Review of SHE performance should be a standard agenda item for management team meetings, and should be high on the agenda. The review should at least consist of presentation and consideration of the relevant SHE report. Headings within the report include:

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MANAGEMENT REVIEW MEETINGS

Actions arising from the review should be documented, responsibility clearly allocated with appropriate timescales.

2.1.3

Statement of Intent

1

COMPANY, (The Contractor) will comply with its legal duties in order to provide a safe and healthy working environment for its employees and others affected by its activities. It will take positive action to ensure that other contractors' employees, occupiers of premises, and members of the public do not have their health and safety adversely affected by the work operations of the company. The only acceptable standard of health and safety, and for welfare facilities, will be full and proper compliance with the requirements of legislation. Where it is possible and practical to do so, the company will exceed the minimum requirements of the Qatar Regulatory Document (Construction).

2

The company will seek to ensure that each company with whom it contracts or subcontracts aspires to a similar high standard of health and safety management.

3

In recognition of the importance that this company places on the engagement and wellbeing of its employees, the company will:

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(a)

consult, on health and safety matters, with its employees and others who may work under its control to ensure that the arrangements for health and safety management are practical to implement and effective

(b)

as far as is reasonably practicable, fully and effectively control the health and safety risks arising from its work activities, in co-operation with employees, other contractors, clients and other relevant parties

(c)

ensure that accident and ill health prevention is provided the highest priority, commensurate with business objectives, within all company operations

(d)

investigate lapses in health and/or safety performance and implement remedial actions to prevent, so far as is reasonably practicable, their recurrence

(e)

provide and ensure that all plant and equipment owned, used or hired by the company is appropriate, safe to use and properly maintained, inspected and tested

(f)

ensure that all equipment, materials and substances used by the company are appropriate for their intended use and used, handled and stored safely

(g)

ensure that all employees are provided with adequate supervisory training, information and instructions to competently carry out their work activities

(h)

ensure that all working places are maintained in a safe and healthy condition

(i)

provide adequate resources, including sufficient finance, and access to competent health and safety advice, to achieve the aims of this policy

(j)

review and revise this policy statement at regular intervals and also where necessary due to changes in the company activities.

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Signed:........................................................ Designation: ............................................

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Date: .......................................................... Review Date: ...........................................

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2.1.4


Policy and Responsibilities - Example

2.1.4.1 Senior Management Board Collective responsibilities in safety, health and environmental (SHE) matters Provide positive individual and collective leadership on SHE issues.

(b)

Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Ensure a SHE management system is implemented within their sphere of responsibilities. Monitor and review its effectiveness and take necessary improvement action.

(d)

Monitor that personnel under their control comply with their individual responsibilities in SHE matters.

(e)

Challenges areas or instances of performance.

(f)

Ensure that disciplinary processes are in place to address breaches of the SHE policy or management system.

(g)

Establish a framework for the management of SHE.

(h)

Monitor and review the overall SHE performance and where appropriate take necessary actions to minimize and negate.

(i)

Ensure board discussions and decisions take proper account of SHE policy commitments.

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2.1.4.2 Managing Director

(b) (c)

Provide positive leadership on SHE issues for COMPANY

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Individual responsibilities in safety, health and environmental (SHE) matters

Set a clear vision and values for SHE expectations for COMPANY. Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

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(d)

Ensure that business decisions take proper account of SHE policy commitments.

(e)

Keep abreast of developments in SHE legislation and industry standards.

(f)

Ensure the implementation of an appropriate SHE management system, in compliance with a developed SHE Management Framework, within the business(es) for which responsibility is held. .

(g)

Appoint a responsible person for SHE responsibility.

(h)

Review SHE performance at management team meetings and take appropriate improvement action.

(i)

Monitor that members of the management team comply with their individual responsibilities in SHE matters.

(k)

Consult regarding on decisions affecting SHE management.

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(m)

Ensure that arrangements are in place to ensure everyone is aware of their own individual responsibilities under SHE policies and those of any personnel under their control.

(n)

Ensure appropriate action is taken to address breaches of the SHE policy

2.1.4.3 Directors/Members of the Senior Management Team Individual responsibilities in safety, health and environmental (SHE) matters Provide positive leadership on SHE issues.

(b)

Promote a SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Keep abreast of developments in all Qatar SHE legislation and industry standards.

(d)

Ensure that the SHE management system is implemented within their sphere of responsibility. Monitor and review its effectiveness and take necessary improvement action.

(e)


(f)

Ensure appropriate action is taken to address breaches of the SHE policy.

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Provide positive leadership of SHE issues and promote the adoption of SHE best practice.

(b)

Promote an positive SHE culture of that engages all employees.

(c)

Monitor and report on the implementation of the COMPANY SHE Management Framework and progress against the COMPANY SHE Performance Standards.

(d)

Lead and provide functional management for the SHE personnel within COMPANY.

(e) (f)

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Provide assistance and advice to ensure compliance. Develop and recommend annual SHE objectives and targets. Monitor and report against these.

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2.1.4.4 SHE Director

(g)

Produce reports monthly and annually on SHE performance in COMPANY.

(h)

Involved and lead in investigations to ensure that they are adequately reported.

(i)

Review reports of accident and incident investigations identify any trends and ensure that there is an appropriate response to prevent future recurrence.

(j)

Regularly meet with all SHE personnel in COMPANY to monitor and review management of the function as well as development.

(k)

Keep abreast of developments in SHE legislation.

(l)

Represent COMPANY through involvement with appropriate external SHE forums, networks, industry and regulatory bodies.

(m)

Develop and monitor the implementation of processes for the development of SHE personnel in COMPANY.

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2.1.4.5 SHE Managers/Advisers* Individual responsibilities in safety, health and environmental (SHE) matters (a)

Provide positive leadership within your area of operation and promote the adoption of best practice.

(b)


(c)

Keep abreast of developments in SHE legislation and industry standards.

(d)

Monitor and report on the effectiveness of the SHE management system and progress against the COMPANY SHE Performance Standards. Make recommendations for improvement as appropriate.

(e)

Monitor and report on operational SHE performance and make recommendations for improvement. Monitor to ensure that effective action is taken.

(f)

Lead and provide functional management for any SHE personnel under their control.

(g)

Assist with the identification of SHE training needs, and monitor delivery and recording.

(h)

Monitor and report on the implementation of the approved SHE objectives.

(i)

Produce SHE performance reports as required.

(j)

Promptly alert line and functional management to significant accidents and incidents. Where appropriate be involved in the investigation and ensure that the findings are reported.

(k)

Review accident and incident reports and investigation reports, identify any trends and ensure that there is an appropriate response to prevent future recurrence.

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* The term “SHE Adviser” includes dedicated health and safety or environmental advisers .

Individual responsibilities in safety, health and environmental (SHE) matters. In so far as they are applicable to the role

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2.1.4.6 Managers at all levels*

(a)

Provide positive leadership on SHE issues within your area of operation.

(b)


(c)

Implement the business unit SHE management system. In particular: (i)

Identify SHE training needs and have the necessary training arranged. When arranged, release those who require training;

(ii)

Make arrangements for SHE induction training for all new starters at the workplace under their control

(iii)

Implement operating procedures, including risk assessment procedures, for the planning and control of activities associated with identified risks;

(iv)

Ensure that written method statements, risk assessments and/or SHE rules are brought to the attention of those affected;

(v)

Appoint appropriate personnel to undertake SHE duties;

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Section 11: Health and Safety Page 15 Part 2.1.01: Safety, Health and Environment Management System (vi)

Ensure that suitable arrangements are in place for the effective control of changes to planned methods of work.

(d)

Keep abreast of developments in Qatar SHE legislation and industry standards.

(e)

Monitor and review the effectiveness of the SHE management system and report deficiencies.

(f)


(g

Give personnel under their control, including contractors, clear instructions as to their responsibilities to ensure correct working methods.

(h)

Make adequate provision for dealing with safety, health or environmental emergencies.

(i)

Promptly alert line and SHE management to Significant injury to employees or those working under our control;

(ii)

Reportable dangerous occurrences and learning events;

(iii)

Incidents that could lead to enforcement action;

(iv)

Enforcement notices served;

(v)

Injury to a member of the public or a visitor;

(vi)

Serious environmental incidents.

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(i)

Where appropriate, be involved in the investigation and ensure that the findings are reported.

(k)

Report visits by members of relevant administrative authorities e.g. Civil Defence (Fire Department)

(l)

Ensure that the SHE manager/adviser is accompanied on workplace inspections. Following such inspections take action agreed as necessary. Thereafter report as requested on the action taken.

(m)

Act immediately on any breach of SHE rules or procedures, unsafe situation or potential threat to the environment that comes to their attention and, where necessary, report such breaches.

(n)

Ensure that the disciplinary process to address breaches of the SHE policy or management system is applied where necessary.

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(j)

*Managers people in the organisation at any level above supervisor and below director

2.1.4.7 Supervisors* 1

Individual responsibilities in safety, health and environmental (SHE) matters (a)

Provide positive leadership on SHE issues for the members of the work team for which they are responsible.

(b)

Promote a positive attitude in the workforce and encourage behaviours that protect both people and the environment.

(c)

Organise work to be carried out in accordance with relevant SHE risk assessments/ method statements.

(d)


(e)

Give personnel under their control, including contractors, clear instructions about the required methods of work.

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Section 11: Health and Safety Page 16 Part 2.1.01: Safety, Health and Environment Management System Ensure that all relevant personnel are involved in SHE risk assessments prior to any work activity commencing, and, where appropriate, that method statements are available, understood and that any identified control measures are implemented.

(g)

Where appropriate assess and implement any additional SHE controls required to address the needs of new employees, young persons, non-English speaking workers, disabled persons, pregnant women, etc.

(h)

Monitor that risk assessments/method statements accurately reflect the SHE hazards present and ensure that any required changes are agreed and implemented in accordance with the arrangements for control of changes to planned methods of work.

(i)

Ensure appropriate arrangements are in place for two-way communication and where appropriate deliver tool box talks to the work teams.

(j)

Identify any SHE training requirements of personnel under their control and advise appropriate management accordingly.

(k)

See that accidents and incidents are reported immediately to the relevant manager.

(l)

Ensure that personal protective clothing and equipment is used where identified as required and is properly maintained and stored.

(m)

Ensure that the plant and equipment supplied is appropriate for the work and has any necessary certification. Ensure that plant and equipment is immediately put out of use if unsafe or presents a potential threat to the environment.

(n)

Ensure that only authorised persons operate plant and equipment.

(o)

See that unattended plant, materials and premises are left in a condition that does not present a risk to persons or the environment.

(p)

Ensure that the disciplinary process for breaches of SHE procedures and rules is applied where necessary.

(q)

Develop fire safety procedures, communicate with staff and carry out the necessary training and fire drills with a frequency that is appropriate for the size of the site and the duration of the construction operations.

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*Supervisors people at the first level in the organisation that have responsibilities over the work of others;

Individual responsibilities in safety, health and environmental (SHE) matters. In so far as they are applicable to the role (a)

Set a good personal example on SHE issues within your area of operation.

(b)

Take care of your own health and safety whilst at work; ensure your activities do not adversely affect the health and safety of others or damage the environment.

(c)

Co-operate with the company in all matters of health, safety and environmental protection and make your contribution to reducing accidents and conserving natural resources.

(d)

Ensure you have been fully briefed on, and have a good understanding of, the task at hand. Always work in accordance with the instructions given and any written SHE risk assessments/method statements. Report any conflict.

(e)

Never deviate from an agreed method of working unless the supervisor or relevant manager has been notified and authorisation has been obtained.

(f)

Ensure that you have and use the correct access, tools, equipment and personal protective equipment for the work.


(g)

Never undertake hazardous operations nor operate any items of plant or equipment unless trained and authorised to do so.

(h)

Maintain a tidy workplace with an appropriate level of cleanliness.

(i)

Report to immediate supervisor any defects in plant or equipment or unsafe methods of work and ensure that plant, equipment and premises are left in a safe and secure state and place when unattended. Do not operate any item of plant or equipment that has become defective.

(j)

Report to your immediate supervisor all potential hazards and incidents that have or could have resulted in personal injury or environmental damage.

(k)

Report any work-related personal injury or disease to your immediate supervisor and ensure that an entry is made in the accident book at your place of work.

(l)

If you are asked to undertake a task that you feel is unsafe or for which you feel you do not have the appropriate knowledge or training, report this to your immediate supervisor.

(m)

Ensure you have been fully briefed on the fire safety drill and that you understand your roles and responsibilities. Actively participate in all health and safety drills.

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Ensure that arrangements exist to deliver the following: (i)

Orders to suppliers for materials, plant and equipment etc. include relevant SHE requirements notified by the specifier;

(ii)

Suppliers of materials, plant and equipment etc. are requested to provide all necessary information and operating instructions so that their products can be used safely without risk to persons or the environment;

(iii)

Where such information is received by the procurer that it is passed on to the persons who will use the materials, plant and equipment etc;

(iv)

Orders to suppliers for personnel include sufficient detail to adequately describe the work for which they are required;

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(vi)

Contractors and Labour Agencies are assessed as competent and adequately resourced for the work before contracts are placed; Tendering contractors have been provided with the Standard Rules for SubContractors on Safety, Health and the Environment and that compliance with them is a condition of contract;

(b)

No undertakings, either verbal or written, are given to any supplier relieving it of its SHE responsibility.

(c)

Monitor that the above arrangements are effectively implemented.

* Notes 1.

Procurement Managers includes those individuals managing the procurement of personnel.

2.

These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document.

3.

Procurement Managers where they are responsible for placing contracts with suppliers of products and services.

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2.1.4.10 Design, Engineering and Planning Managers* Individual responsibilities in safety, health and environmental (SHE) matters (a)

(i)

Designs which recognise, include and apply safe practice during preparation, construction and subsequent operational use and maintenance, and which consider lifecycle environmental impact including decommissioning and disposal;

(ii)

Design/engineering/planning interfaces are co-ordinated to ensure that the project can be carried out with minimum risk to persons and environment.


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Ensure that arrangements exist to deliver the following:

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Ensure that arrangements exist to deliver the following: All plant and equipment is in a safe condition on leaving its depot or store and that relevant, current inspection/thorough examination certificates and licences are carried with that item of plant or equipment;

(ii)

Plant and equipment hired in is from an approved supplier and has current inspection/thorough examination certificates available with it;

(iii)

Inspection, planned preventative maintenance and periodic tests and thorough examinations are carried out and that results are recorded;

(iv)

Repairs and maintenance work are carried out in a proper manner by competent personnel;

(v)

Sufficient information is available regarding the use of all plant, equipment and materials and this information accompanies the item when leaving the depot or store;

(vi)

All plant and equipment defects notified are remedied and plant and equipment is immediately put out of service if it is unsafe or a risk to the environment.

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2.1.4.11 Plant/depot/works/stores manager*

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* These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document

(b)


* These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document

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2.1.4.12 Site Engineers/Foremen Individual responsibilities in Safety, Health and Environmental (SHE) matters (a)

Appreciate the responsibility allocated to individuals within the operative and management structure.

(b)

Set a good example and leadership by working safely on the site and wearing the appropriate personal protective equipment.

(c)

Ensure safety arrangements, including fire safety drills, are implemented.

(d)

Ensure that only trained and authorised workers use plant and equipment and that persons undergoing training do not operate plant and equipment unless closely supervised by a competent person.

(d)

Ensure that employees under their control attend induction training before working on the site and that they are correctly supervised at all times.

(e)

Ensure that plant and equipment under their control or brought to site by the subcontractor has any necessary certificates of test, inspection and examination and is safe to use.

(f)

Ensure that clear instruction and information is give to persons under their control.

(g)

Carry out recorded safety inspections of site conditions.

(h)

Ensure that persons under their control wear and use any personal protective equipment correctly, to manufacturer’s instructions and to statutory and company requirements.

(i)

Ensure that employees under their control are given appropriate safety information as required and that details of control measures from risk assessments are fully explained.

(j)

Ensure that any accident/incident is reported and that all accidents are entered in the accident register.

(k)

Ensure that access/egress routes are kept clear from obstruction, particularly escape routes and ensure that good housekeeping is observed at all times.

(l)

Ensure that any plant/equipment for use by employees under their control is checked to ensure any necessary guards or safety devices are checked and fit for use by competent persons prior to use.

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Attend any meeting on safety issues as required and as applicable, co-operate with all personnel on matters of Safety, Health and the Environment.

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2.1.4.13 Office Staff 1

Individual responsibilities in Safety, Health and Environmental (SHE) matters (a)

(b)

Ensure personnel are fully aware of the procedures in the event of an emergency, including: (i)

Any accident, incident or emergency procedure

(ii)

Positions of the fire exits, layout out of escape routes and assembly point location/s

(iii)

Position of the first aid equipment and the identity of the trained first aid personnel

Report any defects in plant or equipment immediately to your supervisor. Ensure plant, equipment and premises are left in a safe and secure state and place when unattended


(c)

Observe good housekeeping at all times and keep corridors, doorways and floor spaces clear and free from obstruction.

(d)

Do not attempt to lift or move articles as heavy as likely to cause injury.

(e)

Do not over-reach for items on high shelves, use the equipment provided.

(f)

Do not misuse or interfere with equipment provided for the safety of you and others.

(g)

Do not try to use, repair or maintain any equipment for which you have received no training or instruction.

(h)

Report any work related personal injury or disease to your immediate supervisor and ensure that an entry is made in the accident book at your place of work.

(i)

Report all potential hazards and incidents that have or could have resulted in personal injury or environmental damage to your immediate supervisor.

(j)

Report any unsafe situation or task you may feel is unsafe and for which you do not have the appropriate knowledge or training, to your supervisor.

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2.1.4.14 Responsibility Matrix

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A responsibility matrix that links the roles in the organisation to the responsibilities under the COMPANY policy is shown on the following page.

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Section 11: Health and Safety Part 2.1.01: Safety, Health and Environment Management System

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Responsibility Matrix Directors/Managers at all levels a

b

Senior Management Board



    

Managing Director



            

Directors/Members of the Senior Management Team



    



           

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SHE Director

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         

Managers at all Levels



           



              

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SHE Managers/Advisers

Supervisors

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d

All employees

          

All Employees HR Managers





Procurement Managers and Buyers Design Engineering & Planning Managers Plant/Depot/Works/ Stores Manager













Engineers/Foremen



             

Office Staff



        



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2.1.5


Organisation Charts COMPANY plc

TBA

Index of Key Process

1

SHE Mandatory Policy, responsibilities and management framework

2

Safety, Health and Environmental Risk Management

3

COSHH (Control of Substances Hazardous to Health)

4

Guidance on Safe Working in the Vicinity of Buried and Overhead Services

5

Electricity at Work

6

Authorisation of Plant/Equipment Operators

7

Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, Promotees and Subcontractors

8

Contractors Check List for Initial Safety, Health and Environmental Meeting

9

The Reporting of Accidents/Incidents, Diseases and Dangerous Occurrences (RIDDOR), Learning Events and Environmental Incidents

10

Personal Protective Equipment (PPE)

11

The Safe Use of Cranes and Other Lifting Appliances (Excavators, Tele Handlers and Lorry Loaders)

12

Permit to Work Systems

13

Control of Scaffolding and Working at Heights

14

Fire Precautions During Construction Works in Building

15

Asbestos

16

Procedures for Environmental Protection

17

Associated forms for the above.

18

Standards and Guidance

2.1.7

Author

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2.1.6

SECTION

NAME

POSITION IN COMPANY

CONTACT DETAILS

SHE Manager

2.1.8

Approvals NAME

Approved by:

POSITION IN COMPANY

SHEQ Director END OF DOCUMENT

SIGNATURE & DATE

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS).............................................................. 1

2.2

SAFETY, HEALTH AND ENVIRONMENT PROCEDURAL AUDIT CHECKLISTS…..……………………………………………………….. ................... 1

2.2.1 EXAMPLE SHE-PRO-002- COSHH.................................................................. 2 2.2.2 EXAMPLE SHE-PRO-003- Safe Working in the Vicinity of Buried and Overhead Services............................................................................................ 5

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2.2.3 EXAMPLE SHE-PRO-004- Electricity at Work .................................................. 9

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2.2.6 EXAMPLE SHE-PRO-008- The Report and Investigation of Accidents and Incidents.......................................................................................................... 18 2.2.7 EXAMPLE SHE-PRO-011- Permit to Work Systems ...................................... 22

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2.2.8 EXAMPLE SHE-PRO-013- Fire Precautions During Construction Works in Buildings ......................................................................................................... 23

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2.2.9 SHE-PRO-014- Asbestos................................................................................ 24

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2.2.1 EXAMPLE SHE-PRO-002- COSHH

as

qa

The Project /Site Manger must Ensure the procedure is established and reviewed for effectiveness. Appoints a COSHH Coordinator for the project.

ta

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QCS 2014

Project Manager

3.i

se

Has the Project Manager appointed a COSHH Coordinator for the project?

1.ii

3.ii

3.ii

et

Has a register of hazardous substances been produced?

m

COSHH Coordinat or

ito

ov

er

If a substance is supplied or created by COMPANY, the COSHH Coordinator is responsible for ensuring a COSHH assessment has been undertaken. The COSHH Coordinator should ensure that a register of all hazardous substances is maintained, and that each has a valid COSHH assessment, and where applicable a MSDS.

COSHH Have all substances on the register had an Coordinat assessment done? or If a substance is supplied or created by a sub-contractor, it is their responsibility to provide the COSHH assessment along with all other risk assessments submitted for acceptance. These assessments are likely to accompany a method statement, and should be read as part of the method statement acceptance process. Project/Site Managers must ensure that assessments and method statements have been agreed, and monitor work to ensure it is undertaken in line with the method statement. The COSHH Coordinator should ensure that all hazardous substances present on a project have a valid COSHH assessment. For a supplied substance the COSHH assessment should be accompanied by the manufacturers/suppliers MSDS.

3.ii

3.ii

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If there are sub-contractor supplied hazardous materials do they have a valid COSHH assessment?

Project Manager Competent Person Supervisor

Is there evidence that where an activity has changed after the initial Risk Assessment/ Method Statement was carried out, a review has taken place and the documents updated in line with the change?

been

3.ii

3.ii

3.iv

ito

ov

er

se

as

Have the COSHH assessments reviewed and agreed?

qa

Contractor s / COSHH Coordinat or Project/Sit e Manager

rw


ta

QCS 2014

3.iv

m

et

Where an assessment identifies the likelihood of an adverse health condition or identifiable disease being contracted, then health surveillance may be required. Project Manager / Contractor

Where the health of an individual has been identified as a risk, has health surveillance been arranged?

All activities undertaken under the Risk Assessment (and controls therein) shall be monitored to ensure that the assessment is both suitable and sufficient and is being worked to correctly. Project manager / Supervisor

Is the work being carried out in accordance with the agreed Risk Assessment / Method Statement?

3.iv

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Has a briefing been given to the workforce based on the content of the risk assessment / method statement?

m

et

ito

ov

er

se

Supervisor

as

qa

Dependant on the nature of the Risk Assessment and Method Statement, give a briefing to ensure that the detail is communicated to all relevant Operatives and carry out a reality check to confirm understanding of key aspects.

ta

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QCS 2014

Total Awarded Total Achievable % Score

12

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ta

2.2.2 EXAMPLE SHE-PRO-003- Safe Working in the Vicinity of Buried and Overhead Services

qa

Project/Site Manager

3.i

ov

er

Has the Project manager identified the excavations required to carry out the contract works?

ito

Has the Project manager Appointed a Services Coordinator?

et

Are suitable service location equipment available and a competent operator identified / trained?

m

Project Manager

se

as

Evaluate Project Program and the works drawings to identify the requirements for excavation. Appoint a Services Co-ordinator or retain the Services Coordinator’s duties himself. Ensure the availability of suitable service location equipment and a competent operator. Where overhead electrical supply cables are present ensure that controls are in place before authorising any activities on site Agree with Services Co-ordinator the site colour-coding scheme for surface marking of services.

Where overhead electrical supply cables are present have controls been put in place before authorising any activities on site? Is a site colour-coding scheme for surface marking of services in place and communicated?

Services Co-ordinator

3.ii

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Page 6

m

et

ito

ov

er

se

as

qa

ta

Seek out and retain copies of all statutory authority and service drawings relevant to the project’s scope of work. Have transposed onto a master drawing(s), the details of all relevant services. Have recorded on the master drawing(s) the location and depths of services installed during site establishment. Confirm with the Supervisor/Engineer in control of an activity requiring a Permit to Excavate the full extent of the intended activity. Check the activity drawings against the master drawing(s). Produce an activity specific location drawing for reference by the locator of services that includes current landmarks, using SHE-FRM-3-02. Request the locator of services undertake a thorough survey of the area where the activity is to take place with an appropriate service locator, even if it has been established from drawings that there are no recorded services present. Provide an activity specific, location drawing (including any updates identified in the survey) for reference by the Supervisor/Engineer in control of the activity. Update master drawing(s) following receipt of survey information. Ensure information on master drawing(s) is transferred to ‘as-built’ drawings for inclusion in the H&S file. Before any activities start on a site where overhead services are present or adjacent, contact the SHE Adviser for advice. Where overhead electrical supply cables are present the local Electricity Company shall also be contacted for advice on re-routing or clearance and insulation. Have copies of all statutory authority and service drawings relevant to the project’s scope of work been obtained. And details Services transposed onto a Master services Coordinat drawing? or

Has an activity specific location drawing been produced for all activities requiring excavations, that include current landmarks, using SHE-FRM-3-02? Has a thorough survey of the area where the activity is to take place been undertaken with an appropriate service locator, even if it has been established from drawings that there are no recorded services present? Has the master drawing(s) been updated following receipt of survey information or installed services?

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3.iii

ov

er

se

as

qa

Has the information on the master drawing been transferred to ‘as-built’ drawings for inclusion in the H&S file? Where overhead services are present or adjacent to the works has the local SHE Adviser been contacted for advice? Where overhead electrical supply cables are present has the local Electricity Company been contacted for advice on rerouting or clearance and insulation? Locator of Services

rw


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QCS 2014

Has the position of services been physically and clearly marked on the ground in accordance with the services marking scheme?

m

Locator of Services

et

ito

Physically and clearly mark the position of services on the ground in accordance with the services marking scheme. Update the activity specific location drawing provided for reference to you by the Services Co-ordinator. .

Have updates been made to the activity specific location drawing?

Supervisors/Engineers

3.iv

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Page 8

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QCS 2014

as



excavation or penetration of the ground (using the information in the guidance); any activity beneath or in the vicinity of overhead electrical supply cables or pipework containing a hazardous substance where there is any possibility, however remote, of plant, equipment, materials or people encroaching into a safety zone; any activity beneath or in the vicinity of any other overhead service where there is a possibility of damage.

se

 

qa

Prepare or arrange for the Sub/Work Package Contractor to prepare for agreement/approval by the Project/Site Manager a specific method statement for activities involving: -

ov

er

Ensure persons under their control fully understand they do not commence excavation or penetration of the ground in an area unless the whereabouts of services has been established and a Permit to Excavate has been prepared and approved by the Service Coordinator and obtained, SHE-FRM-3-02.

Has a specific method statement for activities involving: - excavations or work under or near overhead services been prepared?

m

Supervisor s /Engineers

et

ito

Ensure all personnel involved in the activities are instructed in the method statement and Permit to Excavate and sign to confirm their understanding.

Has a Permit to Excavate been prepared and approved by the Service Coordinator? Have all personnel involved in the activities been instructed in the method statement and Permit to Excavate and signed to confirm their understanding?


17

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QCS 2014

ta

2.2.3 EXAMPLE SHE-PRO-004- Electricity at Work

qa

Managing Director

3.i

se

Has The MD for the Company / Region shall appoint in writing an Electrical Duty Holder for their area of responsibility?

er

Managing Director

as

The MD for the Company / Region shall appoint in writing an Electrical Duty Holder for their area of responsibility

3.ii

Electrical Duty Holder

et

ito

The Electrical Duty Holder shall Assess and approve all temporary Electrical contractors prior to their appointment In conjunction with the Site / Project Manager appointed coordinator and Authorised Person for each location. Take reasonable steps to ensure that the site electrical coordinator has the competency to undertake the role. Ensure that all projects and appropriate contractors have a copy of the latest Rules for Electrical Safety Undertake independent inspection/audit of site electrical installation / equipment under COMPANY control.

m

    

ov


Have all temporary Electrical contractors been Assessed and approve prior to their appointment? Has an authorised person been appointed to for the location? Has the site electrical coordinator been assessed to ensure he has the competency to undertake the role? Is there a copy of the latest Rules for Electrical Safety available on the project? Do the electrical contractors working on the project have a copy of the latest Rules for Electrical Safety? Have inspections / audits been undertaken by the Electrical Duty Holder?

Page 9

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ta

rw

QCS 2014

The Site Electrical Coordinator shall     

3.iii

qa

Site Electrical Coordinator

ov

Has the coordinator checked to ensure work is being carried out in accordance with the RES?

ito

Site Electrical Coordinat or

er

se

as

Ensure All work is carried out in accordance with the COMPANY Rules for Electrical Safety. After consultation with the EDH, appoint in writing a competent person for the location he is responsible for. Display the appointment of the site electrical coordinator and competent person on the location notice board and electrical switch gear. Keeps an up to date drawing showing the electrical circuits for the location’s temporary electrical system. Ensure schedule tests are carried out on installations and equipment

m

et

Has a competent person been appointed for the project, and the appointment displayed? Is there an up to date drawing of the temporary site electrical circuits? Has the required tests for the electrical system been scheduled? Have the required tests for the electrical system been carried out as scheduled?

Authorised Person

3.iv

The Authorised Person shall control the permit to work system and issue permits as required. Authorise d Person

Is the Authorised person issuing electrical permits as required?

Site / Project Manager

3.v

Page 10

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ta

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QCS 2014

ito

ov

er

se

Has the Site /Project Manager appointed in writing a permanent works electrical duty holder? Has the specification for the temporary site electrics been communicated to the temporary electrical contractor?

et

Site / project Manager

as

After consultation with the EDH appoint in writing a permanent works Electrical Duty Holder. Ensure that the specification for the temporary site electrics is communicated to the temporary electrical contractor.

m

 

qa

The Site / Project Manager shall


15

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QCS 2014

ta

2.2.4 EXAMPLE SHE-PRO-005- SafetyAuthorisation of Plant/Equipment Operators

qa


3.i

se

as

Identify the plant requirements for the project and produce a plant schedule. This should identify COMPANY’s plant requirements. The schedule should be reviewed and revised as the project progresses. Where appropriate appoint a Plant Coordinator or retain the duties. Project Manager

ov

er

Has a plant schedule been developed to record the plant requirement of both COMPANY & contractors?

ito

Has a plant schedule been developed reviewed and where necessary revised?

m

et

Has a plant Co-ordinator been appointed in writing? Plant Co-ordinator

3.ii

Assess the plant schedule and ensure the plant required is available in line with the contract programme. Advise the Project/Site Manager of any revisions/additions needed to complete the works..

Plant Coordinator

Is the required plant available to carry out the work in accordance with the plant schedule and contract program?

Plant Co-ordinator/Supervisor

3.iii

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ta

rw

QCS 2014

se

Are copies of the plant operator certificates available in the site register?

er

Plant Coordinat or Supervisor

as

qa

Obtain copies of Plant Operator certificates; forward a copy of the COMPANY direct employed operators certificate to the Regional Training Coordinator. A copy of all Plant Operator certificates should be held on site in the Site Register. Check the operator’s certification for the plant to be operated (see section 4.i and 4.ii) and only allow the use of plant where the certification corresponds to the exact type of plant to be used. Where defects are reported / noted on item of plant, ensure the plant is put out of service and replacement/repair is arranged.

ito

ov

Are plant operators in possession of the correct certificate for the plant they are using?

m

et

Have any defects been noted in the site register and if necessary has the plant with the defect been put out of service?


7

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2.2.5 EXAMPLE SHE-PRO-006- Safety, Health and Environmental Training

qa

SHE training strategy

3.i

se

as

. The SHE Department will be responsible for producing and reviewing a SHE training strategy for the whole business. The training strategy and associated training matrix will be available on the intranet*. Line managers are responsible for ensuring that their staff have had the necessary training, or ensuring that appropriate arrangements are made to cover any shortfalls. Requests for SHE training are to be made to the relevant Training Coordinator Has a SHE Training Strategy been produced and is it available to the projects?

Manager

Has a local schedule been produced to identify training requirements for the location in line with the training matrix?

et

m

Inductions

ito

ov

er

SHE Department

3.ii

All newly assigned employees will receive a SHE induction. In addition a location specific induction will be required to ensure all necessary SHE information is provided. Project inductions will not be given to any person who cannot provide evidence of competency relevant to their role. Projects will provide a full SHE induction for everyone who will be on site. This induction must be provided before an individual is allowed to go onto the site. Project Managers are responsible for ensuring that a site specific induction is in place and provided as required. Visitors to sites, and other locations such as offices, must receive a tailored SHE induction if the full induction is not provided. Visitors must be accompanied by a suitable person who has attended a full site induction. Site inductions will include a short evaluation. Location Have all persons received a SHE induction. Manager / including a location specific induction? Supervisor Are all persons working on the project in possession of relevant qualifications to their role? Where there are Visitors on site have they received a visitor’s induction and are they being accompanied around site?

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qa

ta

Have all persons on site undertaken an induction evaluation questionnaire specific to the projects?

Page 15

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QCS 2014

3.iii

as

Supervisors’ inductions

ov

Have all supervisors received a specific supervisor SHE induction?

ito

Location Manager / Supervisor

er

se

Any person on a site who will act in a supervisory capacity must undergo a top up induction. This will identify what COMPANY will expect of them as a supervisor or manager. In particular it will cover expected standards of behaviour on site, and dealing with instances of unsafe behaviour

3.iv

et

Newly assigned COMPANY staff:

 

m

staff shall not commence their duties until they have: received a copy of the SHE policy statement and their SHE responsibilities. If the role involves managing or supervising others they must also receive a copy of the responsibilities of those grades they will be managing or supervising. Responsibilities should be explained to them by their line manager; received general advice and been informed of any significant findings of risk assessments for the work they will undertake;

Location Manager / Supervisor

Have all staff received a copy of their specific SHE Responsibilities, and have they been explained to them by their line manager?

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Page 16

ta

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QCS 2014

er

se

as

qa

Have all staff been informed of the significant findings contained within the risk assessments for the work they will undertake.

3.v

ov

Agency staff

ito

When requesting staff or labour the COMPANY Manager is required to specify to an employment agency:

Project Manager

m

et

 any special occupational qualifications or skills required to do the job, including any specific evidence of competence  specific features of the job that may effect health and safety (e.g. work at heights, heavy manual handling operations, etc). If agency staff are being employed on the project have any specific requirement, with regards to skills, qualifications etc and special features of the job which may effect h & s, been notified to the agency?

SHE training arrangements

3.viii

SHE training will be arranged by the relevant Training Coordinator, who will also maintain SHE training records. The only exception to this will be project specific site Inductions which will be arranged and delivered by site personnel, with records maintained on site. Training Coordinator

Are the SHE training records up to date and available to Managers

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et

ito

ov

er

se

as

qa

ta

Are the SHE Induction records up to date and available on site

m

Project / Site Manager


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QCS 2014


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2.2.6 EXAMPLE SHE-PRO-008- The Report and Investigation of Accidents and Incidents

as



3.

Investigate cause of accident, record physical evidence and take steps to prevent recurrence. Inform the SHE Department of such incidents. Record and report the accident on the accident book form and send a copy to the SHE Department together with any supporting evidence/documentation Complete the accident book entry report. (Accident Investigation Report Part 1, AIR SHE-FRM-8-02/2)

se

  

qa

For All Accidents on Site

Have all accidents recorded had an element of investigation and steps taken to prevent re-occurrence?

Project / Site Manager Project / Site Manager

Has the SHE Department been informed of all accidents recorded on the project?

ito

ov

er

Project / Site Manager

m

et

For all accidents reported to COMPANY has the Accident Book been completed?

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QCS 2014

qa

For All > 3 Day RIDDOR Reportable Accidents

Inform the SHE Department and Contracts Manager as soon as the accident becomes a possible “over 3 day reportable”. Obtain from any contractor a copy of the F100. In the case of an COMPANY emplyee, provide the SHE Adviser / Manager with all relevant detail to allow MIT / SHE to complete the F100. Where appropriate to the potential outcome of the accident / incident, in conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form). Ensure the investigation is undertaken and the report Produced within an appropriate time frame as per QCS requirement.

as

 



er

se



For any RIDDOR Accidents has an F100 been completed and sent to the Enforcing Authority?

Project / Site Manager Project Manager / SHE Advisor

For appropriate accidents / incidents has a First Alert been completed?

et

ito

ov

Project Manager / Supervisor

m

Has an investigation been carried out and a report been completed?

Reporting and Investigating a Major Accident/Incident (Fatal Accident or Major Injury)

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ta

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QCS 2014

qa

 Contact your SHE Adviser / Manager. The SHE Adviser / Manager will inform the MIT and prior to commencing the investigation and following consultation with the SHE Manager / Director, will advise our legal representatives.

as

 In conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form).

se

 SHE Advisor to ensure that the Labor Ministry has been informed. Where applicable ensure that the Police has also been informed.  SHE Advisor to Inform SHE Director / SHE Manager.

er

 SHE Advisor to carry out an immediate investigation of the accident in conjunction with MIT.

ito

ov

 SHE Advisor to ensure that a copy of the form F100 is completed and sent to the Enforcing Authority within 10 days of the accident, or in the case of a non COMPANY employee, obtain a copy from their employee and ensure that a copy is forwarded to the COMPANY Insurer.

Project Manager

m

et

Was contact made immediately to the SHE Advisor?

Project Manager / SHE Advisor Project Manager / SHE Advisor SHE Advisor

Has a First Alert been completed?

Were the Enforcing Authority has been informed and an F100 been completed and sent to the Enforcing Authority & other relevant parties? Has an investigation been carried out and a report been completed?

Accident Book/Register

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qa

as



Site management shall control and verify entries made in the COMPANY accident book and ensure that copies are forwarded as soon as possible after they are made to the SHE Department. All notified accidents shall be entered in the COMPANY accident book including all employees, contractors, visitors to site and accidents to members of the public.

Project manager Project Manager

er

se

Is the Accident book available and under secure control? Have all accident book entries been sent to the SHE Department?

The Project / Site Manager is responsible for the completion of the SHE Return and this shall be sent to the SHE Department as soon as possible after the month end but no later than the second working day of the following month.

m

et



ito

Monthly SHE Returns

ov



ta

rw

QCS 2014

Project Manager / Contractor

Have the monthly returns been completed and sent to the SHE department each month within the time scales set?


13

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QCS 2014

qa

ta

2.2.7 EXAMPLE SHE-PRO-011- Permit to Work Systems

1.ii

2.ii 1.iii 3.iii

3iii

et

ito

ov

er

se

as

Project/Site Manager to ensure this procedure is established and proper application of a permit to work system affecting COMPANY, or employees of sub contractors. Project Has an authorized person been appointed Manager for the implementation of this procedure? Have responsibility for the overall co-ordination and signature for the permit to work system. Authorized Have they co-ordinated the permit to work Person system relating to complexity and detail of the project? Have they satisfied themselves that the precautions required by the permit to work are in place before work commences?

m

Sub contractors to work in accordance with this procedure. Sub Worked in accordance with the permit and contractor associated document?

1.vi 1.vi


4

Page 22

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been

qa

Has a fire safety coordinator appointed for the project?

ta

EXAMPLE SHE-PRO-013- Fire Precautions During Construction Works in Buildings

Have fire wardens been appointed for the project? Have the appointed duty holders received suitable training? Does the site specific induction include details about fire risks on site and site specific emergency arrangements? Has a fire risk assessment been completed for the project and integrated into a site emergency plan? Have fire emergency drills been completed / planned? Have the requirements of the fire plan been fully implemented on site?

3.iv

3.iv

m

et

ito

ov

er

se

Project Manager / Site Manager

as

2.2.8


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QCS 2014

3.iv

3.iv 3.iv 3.iv


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SHE-PRO-014- Asbestos

qa

2.2.9

ta

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QCS 2014

1.ii

4.ii

5.i

6.i

5.xiii

m

et

ito

ov

er

se

as

Project/Site Manager to ensure the procedure is established and that the identification and removal of asbestos containing materials (ACMs), is carried out in accordance with this procedure and relevant information is communicated to interested parties. Project Has a suitable asbestos survey relevant to Manager the works & project been completed and is the report available on site? Have the relevant control measures been implemented and being monitored from the asbestos removal plan/risk assessment? Has the asbestos removal plan/risk assessment/method statement been reviewed and accepted? Does the site specific induction include reference about the Asbestos Containing Materials (ACM’s) on site? Person’s undertaking the work activities are required to carry out the task in accordance with this procedure.

1.vi Competent Person/ Contractor

Has a suitable risk assessment been undertaken for any work which may expose persons to asbestos fibers? Have the findings of the risk assessment been incorporated into planned works? Has a competent supervisor been identified within the planned works? Although COMPANY appoints a specialist contractor for the removal of Asbestos, Project/Site Manager should ensure that they work in line with current legislation and do not put others at risk from their operations.

5.v 5.v 1.iv

5.vi

Page 24

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rw

Is the asbestos removal contractor sufficiently dealing with waste produced during any works. Double bagged with separate disposal as special waste?

ta

Project Manager Competent Person Supervisor


qa

QCS 2014

5.viii 5.ix

8

8

m

et

ito

ov

er

se

as

Are viewing panels or CCTV viewing aids incorporate into the enclosure? Are air clearance certificates available for areas reoccupied further to asbestos removal? An effective Management System/ Asbestos Management Plan should be in place to protect staff, operatives and the public when working within a building which contains asbestos Project Are ACM’s clearly labeled with suitable Manager/ warning signs? Site Manager

5.vii


11

END OF DOCUMENT

Page 25

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ........................... 1

2.3.1

Risk Identification and Management ............................................................... 6

2.3.1.1 Responsibilities ............................................................................................... 6

.l. l

.

2.3.1.2 Definitions ....................................................................................................... 7

rw

2.3.1.3 Action Required To Implement This Procedure ............................................ 10

ta

2.3.1.4 Guidance To This Procedure ........................................................................ 12

qa

2.3.1.5 Appendices ................................................................................................... 14

as

2.3.1.6 Reference Documents .................................................................................. 14 2.3.1.7 Author ........................................................................................................... 15

m

et it

o

ov

er

se

2.3.1.8 Approvals ...................................................................................................... 15

QCS 2014


Page 2

PROCESS MAP – COMPANY DIRECT WORK Project/Site Manager

Estimator

Competent Person

Operative

SHE Team

HR

Review tender information for SHE Risk 3.1

3.1

3.2

3.2

Stop work and inform competent person if works significantly change from the agreed RA/MS with agreed RA/MS

3.5

as

Circulate RA/MS for review 3.

se

Review completed RAMS prior to issue

.

Where identified prepare MS

Provide advice and monitor works against RA/MS

.l. l

Appoint a project competent person to produce Company Risk Assessment and Method Statement 3.2

Undertake activity in line with agreed RA/MS

rw

Allow for measures to control the Identified risk

Prepare RA in line with RA Schedule

ta

3.1

Review Risk Register and produce a SHE Risk Assessment Schedule 3.2

qa

Include SHE risk on project Risk Register

Issue Agreed RAMS to relevant supervisor/operat ive

ov

er

3.2

o

3.2

Brief supervisor/operat ive on content of RA/MS

3.2

3.2

m

et it

Monitor works against agreed RA/MS

Maintain up to date Risk Assessment/Method Statement records

Monitor works against issued RA/MS 3.2

3.2 Review and revise RA/MS if circumstances change

Provide advice where works involve young person or expectant mothers 3.2

3.2

Key

Activity Guidance

QCS 2014


PROCESS MAP – SUBCONTRACT WORKS Estimator

Contractors Responsible Person


Contractors Operatives

Review tender information for SHE Risk

Provide advice and monitor works against RA/MS

3.1 Review Risk Register and update with changes identified by Contractors 3.3

Prepare RA for all activities in the scope of Works 3.3

.

3.5

.l. l

Include SHE risk on project Risk Register

o

ov

as

er

se

When satisfied the RA/MS is sufficient, return to the S/C for issue 3.3

Brief the Operatives of the content and controls in the agreed RA/MS

Undertake the activity in line with the RA/MS

3.3

Monitor works against agreed RA/MS

Monitor the works against agreed RA/MS

3.5

3.5

m

et it

ta

3.3 3.3

qa

Where identified prepare a Method Statement

Review the RA/MS using Check Sheet System

rw

3.1

Allow for measured to control the Identified risk 3.1

SHE Team

Stop work and inform the relevant person if works significantly change from the agreed RA/MS 3.3

Maintain up to date Risk Assessment/Method Statement records 3.5

Key

Activity Guidance

Review and revise RA/MS if circumstances change 3.3

Page 3

QCS 2014


PROCESS MAP – FACILITIES SERVICES AND CUSTOMER ACTIVITIES Area Manager/Customer Care Manager

COMPANY Operative/Tradesman

Line Manager/Customer Care Manager

Produce a Schedule of regular activities undertaken in Property Services and Customer Care operations 3.1

.l. l

.

Complete a full Method Statement where the Risk cannot be controlled by a TRICS form

rw

Undertake a general Risk Assessment to determine whether the activities require a Method Statement

3.2

qa

ta

3.1

as

Complete task Risk Identification and Control Statement (TRICS) for the activity

Carry out the works in accordance with the completed form

m

et it

o

ov

er

se

3.2

Complete task Risk Identification and Control Statement (TRICS) for the activity 3.2

Produce a Schedule of regular activities undertaken in property Services and Customer Care operations 3.

Key

Activity Guidance

Page 4

QCS 2014


Page 5

PURPOSE 1

The purpose of this procedure is to assign responsibilities and provide a consistent approach to the planning, development and production of suitable and sufficient Risk Assessments and the control of Method Statements for all activities.

SCOPE

et it

o

ov

er

se

as

qa

ta

rw

.l. l

.

This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site

m

1

QCS 2014

2.3.1


Page 6

Risk Identification and Management

2.3.1.1 Responsibilities SHE DIRECTOR 1

Authorises and reviews this procedure.

PROJECT/SITE MANAGER Ensures the procedure is established and used and that Risk Assessments are carried out and, where appropriate, Method Statements are produced.

3

Unless delegated to others, in writing, retain responsibility for monitoring of the works against the relevant control documents.

ta

rw

.l. l

.

2

Prepare Risk Assessments taking account of the task being undertaken and the specific layout and restrictions of the place the work is to be carried out and where identified produce a written Method Statement incorporating a safe system of work.

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4

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COMPETENT PERSON

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Either supervises the work activities or the sub/work package contractor undertaking those work activities in line with relevant control documents required by this procedure. Provide support to the review process for the Risk Assessment and Method Statement, to ensure acceptability SHE-FRM-1-03.

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5

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SUPERVISORS

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SHE MANAGER/ADVISER 6

Provides advice and support in the application of this procedure and monitors effectiveness of the relevant control documents.

7

If the nature of the work is deemed ‘safety critical’, the SHE Manager/Adviser may provide appropriate support for the production of the control documents and the communication to all relevant Operatives.

OPERATIVE/CONTRACTOR EMPLOYEE 8

Carry out the work in accordance with the relevant control documents.

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SUB/WORK PACKAGE CONTRACTOR 9

Prepare Risk Assessments taking account of the work being undertaken and the specific layout and restrictions of the place the works is to be carried out.

HUMAN RESOURCES 10

Provide assistance in cases of new or expectant mothers, young persons or children.

2.3.1.2 Definitions

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Written documents used to manage the risk associated with the work activity including: Risk Assessment

(b)

Method Statement

(c)

Permits

(d)

Plan of Work

(e)

Certification

(f)

Licence

(g)

Skill Card

(h)

or any other supporting documentation

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(a)

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1

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CONTROL DOCUMENTS

RISK ASSESSMENT The process of hazard, aspect, impact, identification, assessment of the risk, and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity and the protection of the environment from harm. In undertaking the Risk Assessment the Qatar Regulatory Document (Construction) principles of prevention must be considered, which are:

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(a)

Eliminate

(b)

Control - In controlling the hazard the following should be considered in order: (i)

Substitution – use a less risky method/material

(ii)

Guarding – place guards, barriers and /or signage to isolate or warn of the hazard

(iii)

PPE – provide personal protection to individuals

(iv)

Decontamination – clear/clean up after exposure

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RISK ASSESSMENT GUIDES 3

Refer to SAMAS 2.4.

METHOD STATEMENT A hazard control measure in the form of a written safe system of work describing the proposed working method and addressing the output from the Risk Assessment process, providing instruction and guidance for those individuals’ carrying out the activities. The purpose of this document is to ensure the proper planning of an element of the works and to detail the overall methodology and associated controls SHE-FRM-1-03. The document must be issued/briefed to management/supervision.

5

For work carried out by COMPANY Facility Services or Customer Care activities, the Method Statement may be substituted with Task Risk Identification and Control Statement (TRICS) SHE-FRM-1-05.

6

Sub/Work Package Contractors are to be encouraged to follow the COMPANY structure as mentioned above. Suggestion to adopt COMPANY safe system will require an element of instruction/training. For guidance contact the SHE Team.

7

Alternatively Risk Assessment and Method Statements prepared by Sub/Work Package Contractors may be prepared as a single document, providing the content is equivalent to that of the RA/MS above.

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This document is specific to Property Services Work and Customer Care activities and eliminates the need to produce a detailed Method Statement in the format described above. It must only be used when the Supervisor has carried out a Risk Assessment which concludes that a Method statement is not required. The Job/Task RA/MS is completed by the operative / supervisor using form SHE-FRM-1-02.

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TASK RISK IDENTIFICATION AND CONTROL STATEMENT (TRICS)

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COMPETENT PERSON 9

Is a person who has sufficient training, experience and knowledge to enable them to properly undertake the task in question or carry out the Risk Assessment.

TECHNICAL ADVISER 10

Dependant on the type of work the Method Statement is being prepared for, the Technical Adviser can be any combination of individuals (i.e. Designer, Materials Engineer, Temporary Works Co-ordinator, etc.)

11

The Technical Adviser provides, where required, support to the review process to ensure suitability of the content of the Risk Assessment/Method Statement. SHE-FRM-1-03.

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YOUNG PERSON 12

Any person between the age of 16-18 years old.

CHILD

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Any person under 16 years old.

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2.3.1.3 Action Required To Implement This Procedure GENERAL At Tender stage the Estimator will review the Pre-Tender Safety Information provided and instigate the production of a Project Specific Risk Register, which will identify Risk including safety risks associated with the proposed works.

2

Details of the risks identified and any measures included on the risk register will be included in the enquiry documents produced for contractor’s works.

3

Allowances should be made in the settled tender for arrangements to control these risks during the Construction Phase of the project.

4

At the start of the Construction Phase, the Project/Site Manager will review the risk register and project program and produce a schedule of activities which will be used as a basis for ensuring that all elements of the construction process are identified and considered for Risk Assessment.

5

Using the schedule the Project/Site Manager will ensure a suitable Risk Assessment is produced which will identify whether a Method Statement is required as part of the control measures.

6

For Facility Service or Customer Care works the Area Manager or Customer Care Manager will produce a schedule of activities undertaken on a regular basis by operatives working on this type of work. A Risk Assessment will be undertaken and where it is identified that the hazards can be controlled without the need of a full Method Statement he will indicate that the operation be subject to a Risk Identification and Control Statement (TRICS) and the procedure in 3.4 will be followed.

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ACTIVITIES UNDERTAKEN BY COMPANY Before carrying out any activity undertaken by direct COMPANY employees, the Project/Area/Site Manager for the workplace/operation/ design concerned shall first produce/review the Risks Assessment Schedule with the intention of identifying where hazard and risk could arise. This should include discussion with the people undertaking the work, if appropriate. It should be remembered that a risk could be seen as minimal but by further work processes could become significant. Such as painting outside to painting in a confined space.

8

Following this review a specific Risk Assessment using SHE-FRM-1-02 shall be undertaken by a Competent Person appointed by the Project/Area/Site Manager.

9

Where young persons or expectant mothers are involved in the activity, additional concerns may be required. Advice should be sought from the HR Team.

10

Where identified in the Risk Assessment the Competent Person in conjunction with any other relevant person will:

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(a)

prepare a Method Statement taking account of the following:

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(i)

The controls identified in the Risk Assessment.

(ii)

All relevant Safety, Health, Environmental (SHE) matters.

(iii)

The headings, as a minimum, indicated in SHE-FRM-1-03 & 1-04.

(iv)

Circulate the Method Statement utilising the tracking and content sheet SHEFRM-1-04.

Take account of comments received from other parties and re-circulate Risk Assessment and Method Statement to those people to ensure issues raised have been dealt with adequately.

(c)

Following agreement of the suitability of the Risk Assessment and Method Statement by the Project/Site Manager, ensure it is issued to relevant management/supervision.

(d)

Monitor performance against the Risk Assessment and Method Statement and identify and make any necessary changes The Risk Assessments produced shall be used, where appropriate, as the basis for COMPANY personnel checking the contents of sub or work package contractors’ safety method statements.

(e)

The Risk Assessment and Method Statement shall be briefed to ensure that the detail is communicated to all relevant Operatives and carry out a reality check to confirm understanding of key aspects.

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(b)

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ACTIVITIES UNDERTAKEN BY CONTRACTORS The Project/Site Manager must ensure contractors have been procured via COMPANY Contractor Assessment procedure.

12

Before carrying out any activity undertaken by sub-contract employees the Contractors Responsible Person shall first undertake a risk assessment taking into account the hazards associated with the work this should include, if appropriate, discussion with the people undertaking the work, and COMPANY Management.

13

The Risk Assessments produced shall be used, where appropriate, as the basis for COMPANY personnel checking the contents of sub or work package contractors’ safety method statements.

14

Where identified in the Risk Assessment the Contractors Responsible Person will prepare a Method Statement taking account of the following:

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(a)

The controls identified in the Risk Assessment.

(b)

All relevant Safety, Health, Environmental (SHE) matters.

(c)

The headings, as a minimum, indicated in SHE-FRM-1-03 & 1-04 (Note: the use of the COMPANY format Risk Assessment and Method Statement templates may be suggested to the Sub-Work Package Contractor for work carried out on projects and locations under COMPANY control).

15

The Project/Site Manager will review the Risk Assessment and Method Statement produced using the tracking and content sheet SHE-FRM-1-04. Circulating to relevant parties as required. Following the review he will take account of comments received from

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Page 12

other parties and re-circulate Risk Assessment and Method Statement to those people to ensure issues raised have been dealt with adequately. Following agreement of the suitability of the Risk Assessment and Method Statement, the Project/Site Manager will issue it to relevant COMPANY Management/Supervisor who will then ensure that the contractor’s supervisor gives a briefing of the Risk Assessment and Method Statement so that the detail is communicated to all relevant operatives.

17

The Project/Site Manager or Supervisor will monitor performance against the Risk Assessment and Method Statement and identify and communicate any suggested changes. In cases where any significant changes to the system of work are necessary, activities must be stopped so that the changes to be made are re-assessed and approved. Where appropriate, following any revision, the checking process should be repeated.

.

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TASK RISK IDENTIFICATION AND CONTROL STATEMENT (TRICS)

The TRICS SHE-FRM-1-05 should be completed prior to commencement of works by the Appropriate Line Manager. Where this is not possible or practicable, the individual tradesman undertaking the task should complete the task assessment. The TRICS format is only to be used after an assessment has been made by the relevant Manager and the need to produce a Method Statement for the works has been eliminated.

19

Should the initial TRICS being completed by the tradesman reveal that other assessments (e.g. Manual Handling/Noise) are required the risk assessment guides should be used to develop a safe system of work. Should the safety requirements of the job still not be met then the individual Line Manager shall be contacted immediately.

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RECORDS AND MONITORING OF THE RISK ASSESSMENT The Project/Site Manager should maintain up to date current Risk Assessment records so that any significant change to a activity requiring the Risk Assessment to be re-evaluated can be controlled. The need for review will depend upon the level of risk and the significance of the change.

21

Where appropriate to the activity the SHE Advisor for the project will monitor performance and identify any necessary changes by inspection and/or audit.

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2.3.1.4 Guidance To This Procedure RISK ASSESSMENTS 1

All Contractors and self-employed persons are required to make suitable and sufficient Risk Assessment of work activities to be undertaken. A record of the significant findings of Risk Assessments must be kept. This record shall state the hazards and risks and the controls needed to reduce the risks to an acceptable level. The controls shall then be implemented by management to protect health and safety and the environment.

2

Where Risk Assessments are required to be carried out under particular sections of the Qatar Regulatory Document (Construction), COSHH, Noise, Asbestos and Lead etc. a repeat assessment is not required unless other elements of the work demand assessment in

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their own right (e.g. painting at height may require a COSHH Assessment for the paint as well as an assessment of the risk of working at height or damage to a watercourse due to spillage). 3

Where an assessment identifies the likelihood of an adverse health condition or identifiable disease being contracted, then health surveillance may be required. In all such cases the advice of the SHE Team shall be sought.

4

On completion of a Risk Assessment the record shall then be used to supply the following information to the relevant persons at risk: Hazard/risk/impacts

(b)

Preventative and protective measures

(c)


(d)

Name of emergency wardens or incident controllers

(e)

Instruction and training to carry out the work safely

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(a)

All activities undertaken under the Risk Assessment (and controls therein) shall be monitored to ensure that the assessment is both suitable and sufficient and is being worked to.

6

Any changes in work must be notified to the competent person who has developed the Risk Assessment and must result in a review of the assessment and if necessary a revised assessment produced.

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5

Refer to SAMAS 2.4

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METHOD STATEMENTS

8

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USE OF RISK ASSESSMENT GUIDES Refer to SAMAS 2.4

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2.3.1.5 Appendices

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FORMS

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2.3.1.6 Reference Documents

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Appendix 1 – Risk Assessment Process

S,H&E Risk Assessment Form (SHE-FRM-1-01)

2

Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02)

3

Tracking and Content Sheet (SHE-FRM-1-04)

4

Task Risk Identification and Control Statement (TRICS) (SHE-FRM-1-05)

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REFERENCE DOCUMENTS 5

Qatar Regulatory Document (Construction) RD1.1.7

6

Risk Assessment Methodology SAMAS 2.4

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2.3.1.7 Author

SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

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2.3.1.8 Approvals

POSITION IN COMPANY

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NAME

Approved by:

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SHEQ Director

SIGNATURE & DATE

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PUBLIC/VISITORS :

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OTHER WORKERS :

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PERSONS EXPOSED

EMPLOYEES :

Almost no probability A small probability A high probability Almost Certain

Disabled :

YOUNG PERSONS :

Acceptable Risk Level

Action

Insignificant

No action required and no documentary records need to be kept

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Estimated Total No. of Persons at Risk :

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HAZARDS (WHAT MIGHT CAUSE HARM?)

Acceptable

S

H

Unacceptable

Others :

ito

New or Expectant Mothers :

Date :

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Person Supervising Work :

Date :

Fatality, building loss, catastrophic environment impact

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Person Conducting Assessment :

Risk Quantifying

Major injury, damage or environment impact

Location :

qa

Activity :

No injury, damage or environment impact

Risk Assessment No :

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Site & Contract No :

Minor injury, damage or environment impact

RISK FACTOR

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SHE-FRM-1-01 - SAFETY, HEALTH & ENVIRONMENTAL RISK ASSESSMENT

E

S

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Unacceptable

E

No further preventative action. Consideration shall be given to more costeffective solutions or improvements that impose no additional cost burden. Monitoring required to ensure that controls in place are properly maintained. Work shall not be started or continued until the risk level has been reduced to an acceptable risk level. While the control measures selected shall be cost-effective, legally there is an absolute duty to reduce the risk, this means that if it is not possible to reduce the risk even with unlimited resources, then the work shall not be started or shall remain prohibited.

NOTES

1

Adverse Weather Conditions

17

Loading/Unloading

2

Cold\Hot

18

Materials

3

Electricity

19

Moving Parts of Machinery

4

Excavation

20

New or Expectant Mothers

5

Fire/Flammable Atmosphere

21

Proximity to Water

6

Floor/Ground Conditions

22

Scaffold

7

Flying Particle/Dust

23

Sharp Objects

8

Hand or Power Tool

24

Stairs/Steps

9

Hazardous Substance

25

Static Equipment/Machinery

10

Heat/Hot Work

26

Structure

11

Lack of Experience

27

Temporary Works

12

Lack of Training

28

Vehicle/Mobile Equipment

13

Lack of/too much Oxygen

29

Working Hours/Fatigue

14

Ladder

30

Workstation Design

15

Lifting Equipment Appliances

31

Young Persons

16

Lighting

32

Other

1.

Physical Hazards are the nature of issues that may cause harm. Tick box for hazard.

2.

Preventative / Control Measures are the actions that will stop it going wrong.

3.

Control measures are to ensure that residual risks are reduced to a minimum. Where controls fail to reduce the risk to a acceptable level then refer assessment to your line manager.

4.

If the operations are likely to affect the public or the safe operation of a public infrastructure or transport system, the control measures must reduce the likelihood of significant harm to the level that existed before our work commenced.

5.

Where young persons or expectant mothers are involved in the activity, ensure that any additional controls are put in place in accordance with local procedures.

6.

In addition to the above, consideration must be given to other individuals’ susceptibility due to pre-existing health conditions, e.g. bad back, poor hearing. Additional ‘human factors’ such as ergonomics, workplace design, etc. should also be considered.

7.

Where a hazard is identified that is not listed in the Physical Hazards list, enter the hazard description followed by Other in brackets i.e. (Other).

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Risk Before Controls U/A

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Nature of Risk What Might Go Wrong?

Control Measures Implemented By (Name)

Perceptive /Control Measures How do you Stop it Going Wrong?

Risk After Controls U/A

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HAZARD No.

Name Person Completing the Assessment Person Reviewing the Assessment

Signature

Date

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(SHE-FRM-1-02) Job/Task Risk Assessment/Method Statement Section 1 - Job / Task Allocation To be completed by person taking works order/organising task: o

Job / Contract N .: Client:

Contact Name:

Date:

Job / Task Location:

Description of work:

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Proposed work method:

(additional sheets if required)

Signature:

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Completed By (Name):

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Section 2 - Risk Assessment

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To be completed by operative / person undertaking the work/task

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Upon arrival at the work location complete this Risk Assessment before starting work. If the responses mean you cannot complete the job/task safely, discuss your concerns with your Manager. *Delete as required

Yes / No

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Is the proposed work method (above) acceptable? (If No following this risk assessment a method statement must be produced) Are there any client controls e.g. Permits / clearances certificates etc?

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SAFE SYSTEM

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Are barriers and signs needed to separate the work area? Do you know the location emergency procedures / fire exits / muster points / First Aid etc? Do power supplies / fire detection systems need isolating

/ / / /

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SAFETY & SECURITY

Yes No Yes No Yes No Yes No

HEALTH HAZARDS

What personal protective equipment is needed (tick relevant boxes)? Safety Footwear Safety Helmet Hi-Visibility Vests Gloves Eye Protection Hearing Protection Dust Masks Other(state): ……………………………………………. List any items of plant / tools required: (Include drills, saws, compactors, breakers etc…) Are you competent and have you received the training to use them? Yes / No Are all the plant / tools suitable for use, tested and inspected? Yes / No Confirm plant / tools will be visibly inspected by the user prior to use? Yes / No Check labels on materials and substances. If hazardous, has a COSHH Yes / No / NA Assessment been carried out?

EXCAVATION

Have all underground services been located and clearly marked? Are shoring materials on site before starting work?

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SAFETY EQUIPMENT

PLANT & EQUIPMENT

Yes / No / NA Yes / No / NA

Which is the most appropriate for access (circle as appropriate) Ladder WORK AT HEIGHT

Access Tower

MEWP

Scaffolding If Mobile Elevated Work Platform are you trained and competent to operate? If scaffold / access tower has this been erected by competent person? Will this be inspected by the user prior to use?

Yes / No / NA Yes / No / NA Yes / No / NA

QCS 2014

MANUAL HANDLING SITE TIDINESS ENVIRONMEN T

Completed by (Name):


Page 20

Can heavy/awkward items be moved and stacked securely? Is lifting apparatus required? Is a separate Manual Handling assessment required? Are materials in safe area and stacked securely? Are all materials segregated from building users and members of the public? Are there facilities for the disposal of spent materials or packaging? Do any consents to discharge trade effluent apply or are any required? Are there any risks to trees or other ecology – contact SHE adviser for advise where required Has consideration been given to prevention of nuisance from dust/noise to neighbours

Yes / No / NA Yes / No Yes / No Yes / No Yes / No

Signature:

Date:

Yes / No / NA Yes / No / NA Yes / No / NA Yes / No / NA

Section 3 – Task Statement

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To be completed by operative / person undertaking the work/task if the ‘proposed work method’ does not accurately describe the method of work required, complete the following to explain the safe method of working that will be adopted:

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(Explain how the work is going to be done, include things such as plant, materials, access to the work area, manual handling, sequence of work, any limitations, protection to building users, members of public etc.)

Insert names of all members of the work gang and confirm the work method has been explained. Name and position:

Signature

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Risk Assessment/ Method Statement – Tracking and Content Sheet (SHE-FRM-1-04) Project :

Contractor :

METHOD STATEMENT TITLE :

DATE :

Review Project/Site Manager SHE Function

1st review date

Status*

Name (print)

2nd review date

Status*

Name (print)

1st review date

Status*

Name (print)

2nd review date

Status*

Name (print)

1st review date

Status*

Name (print)

2ndreview date

Status*

Name (print)

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As Required Status

Signature and date:

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Name:

Prompt List

A – Work can proceed as described B – Work can proceed when comments are incorporated C – Re-submit and review before work can proceed

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NB: Use the ‘Prompt List’ below to give a status code, as follows: *Status

Signed off by COMPANY as current working document

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Technical Advisor

Fully describes the works/individual tasks/the sequence, method and process in place to identify change requirements?

2

Names and titles of key personnel/supervisors responsible?

3

Details resources required eg equipment, plant, men and materials?

4

Programme of works and working hours identified?

5

Interfaces/security of the client/public/other contractors identified?

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Are all the hazards identified? Have all the risks been evaluated? (See item 7) Are there arrangements in place for reviewing control measures due to changing circumstances?

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Specific Risk Assessment / attached and satisfactory? 6

.

As Required

7

High risk or safety critical activities identified/controls specified?

8

Access/scaffolding requirements (including ancillary arrangements such as anchor points) fully detailed and described?

9

Certificates of competence or qualification of operatives provided?

10

Certificates for plant/equipment inspection/examination provided?

11

COSHH, noise, manual-handling issues dealt with?

12

Personal protective equipment specified?

13

Permit requirements identified?

14

Monitoring (checks and inspections) identified?

15

Any builder’s work in connection identified/adequate notice given?

16

Temporary protection/support identified (eg fire, traffic, services)?

Yes

No

In Part

N/A


17

Environmental controls/waste disposal identified?

18

Cranage/lifting equipment - certificates/checklist/lifting plan in place?

19

Emergency arrangements/first aid/special welfare/?

Prompt List

Yes

Details of toolbox talks to be provided?

21

Details of temporary works schemes identified, including drawings, calculations and checks?

22

Workplace environment, design, layout and specific limitations identified, have human factors been taken into consideration, ie experience, fatigue, communication, methods, etc?

23

Conformation of briefing of method statement to operatives.

24

Any other (specify)?

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Comment/Observation (if appropriate)

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No

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In Part

N/A

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(SHE-FRM-1-05) Task Risk Identification and Control Statement (TRICS) Section 1 - Task Allocation To be completed by person organising task: o

Job / Contract N .:

Date:

Client:

Contact Name:

Location:

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Description of work:

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Are there any client controls e.g. Permits / clearances certificates etc required? Is there a requirement to isolate fixed plant or equipment? Will there be a requirement for Lone Working? Will there be a need to enter a confined space? Are there materials / substances used by the client which could be hazardous to the person carrying out the work Do any consents to discharge trade effluent apply or are any required?

/ / / /

No No No No

Yes / No Yes / No

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LOCATION INFORMATION

Yes Yes Yes Yes

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If the answer to any of the above is YES, consideration should be given to producing a detailed Method Statement

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The need for a Method Statement has been considered and the issue of this TRICS is acceptable for this work

Signature:

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Completed By (Name):

Yes / No

Contact Details

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Review Date

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Section 2 - Risk Assessment To be completed by the person undertaking the work/task

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Upon arrival at the work location complete this Risk Assessment before starting work. If the responses mean you cannot complete the job/task safely, discuss your concerns with the person signing above. Completed By (Name):

Signature:

Contact Details

EMERGENCY & SECURITY

SAFETY EQUIPMENT

Are barriers and signs needed to separate the work area? Do you know the location emergency procedures / fire exits / muster points / First Aid etc? Do power supplies / fire detection systems need isolating The following PPE is mandatory for COMPANY Employees. Safety Footwear Safety Helmet Gloves Eye Protection Indicate if it is available for use

Yes / No Yes / No Yes / No

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What additional personal protective equipment is needed (tick relevant boxes)? Dust Masks Hi-Visibility Vests Hearing Protection Other (state): …………………………………………….

Check labels on materials and substances. If hazardous, has a COSHH Assessment been carried out? If yes attached to this TRICS

HEALTH HAZARDS

Yes / No / NA

List any items of plant / tools required: (Include drills, saws, compactors, breakers etc…)

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PLANT & EQUIPMENT

qa

Have all underground services been located and clearly marked? Is there a drawing available for the support work? Are sufficient shoring materials, as identified on the drawing, on site before starting work?

as

EXCAVATIO N

ta

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Are you experienced in their use or received the training to use them? Are all the plant / tools suitable for use, tested and inspected? Plant / tools have been visibly inspected by the user prior to use and no defects apparent

Yes / No Yes / No Yes / No


Which is the most appropriate means of access (circle as appropriate) MEWP

Scaffolding

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Access Tower

If Mobile Elevated Work Platform are you trained and competent to operate? If scaffold / access tower has this been erected by competent person? Confirm this has been inspected by the user prior to use?

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WORK AT HEIGHT

If non of the above is practical is a ladder the proposed means of access

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o

Specify the type of ladder Indicate the height / no of rungs needed to provide safe access

SITE TIDINESS WORK AREA

ENVIRONME NT

Yes / No / NA Type………… … Rungs……

Are there any heavy or awkward items be moved or stacked? If lifting equipment is required is it available? Is a separate Manual Handling assessment required?

Yes / No / NA Yes / No Yes / No

Is there space in the work area to stack / store materials safely and allow access? Are all materials segregated from building users and members of the public? Are there any object / vehicles materials belonging to the client which may be a hazard? Is the area suitably lit to carry out the task safely? Are the ground / floor conditions suitable for the work to be carried out?

Yes Yes Yes Yes Yes

Are there facilities for the disposal of spent materials or packaging? Are there any risks to trees or other ecology – contact SHE adviser for advise where required Has consideration been given to prevention of nuisance from dust/noise to neighbours

Yes / No / NA

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MANUAL HANDLING


/ / / / /

No No No No No

Yes / No / NA Yes / No / NA

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Page 25

Section 3 – Task Statement To be completed by the person undertaking the task. Accurately describe the safe method of working that will be adopted:

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(Explain how the work is going to be done, include things such as plant, materials, access to the work area, manual handling, sequence of work, any limitations, protection to building users, members of public etc.)

Signature:

Date:

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Completed by (Name):

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o

I confirm that the above statement identifies the hazards and risks associated with the works to be carried out and the control measures identified are in place.

Insert names of all members of the work gang and confirm the work method has been explained. Name and position:

Signature

QCS 2014

2

Section 11: Health and Safety Page 1 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

SAFETY AND ACCIDENT PREVENTION ADMINISTRATION SYSTEM (SAMAS)

MANAGEMENT

/ 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES

1

2.3.2

COSHH (CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH)

1

2.3.2.1 Responsibilities .................................................................................................. 4

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2.3.2.2 Definitions of terms ............................................................................................ 5

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2.3.2.3 Appointment of COSHH Co-ordinator ................................................................ 5 2.3.2.4 Appendices .......................................................................................................11 2.3.2.5 Reference Documents ......................................................................................13

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2.3.2.6 Author ...............................................................................................................13

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2.3.2.7 Approvals ..........................................................................................................13

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Process Map COSHH Co-ordinator

Project Manager

Ensure procedures are in place and COSHH Co-ordinator is appointed 1.2, 3.1

Procurement

C/S Manager/ Works Package Manager

1.7, 3.8 Control exposure to hazardous substances used or created by 1.4, 3.11 Company

Request MSDS for all substances ordered by Company 1.5, 3.12

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Ensure all appropriate information is obtained/passed over at initial SHE meetings with sub contractors

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Attend initial SHE meeting. Identify hazardous substances to be used 1.6, 3.2

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Ensure hazardous substances used or created by sub contractor has valid assessments and 3.2, 3.5 MSDS

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Agrees and monitors against method statements

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Request MSDS for all substances ordered by Company 1.5, 3.12

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When required ensure face fit tests have been carried out and records maintained 3.6

Ensure arrangements are in place for disposal of hazardous substances and containers 3.7

Key: Activity Guidance

Ensure monitoring and health surveillance is carried out where identified in COSHH assessments 3.8, 3.9

Undertake COSHH assessments for all hazardous substances and submit for approval 3.2

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1.4, 3.2

Maintain Register and file containing assessments and MSDS and advise First Aiders of location

SHE Provides support as necessary

Understand duties. Attend training if necessary 1.3, 3.5

Undertake COSHH assessments for all hazardous substances used and/or created by Company 3.3

Review arrangements at regular intervals to ensure continued effectiveness 3.2, 3.5

Sub Contractors

Control exposure in line with COSHH assessments 1.6, 3.4

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PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a system for the control of substances hazardous to health.

SCOPE This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Governmental responsibilities regarding COSHH rest with Civil Defense & Environment Ministry.

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COMPETENT AUTHORITIES

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Authorises this procedure. PROJECT/MANAGER

2

Ensures the procedure is established and reviewed for effectiveness. Appoints a COSHH Co-ordinator for the project.

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COSHH CO-ORDINATOR Carries out duties as defined in the procedure.

CONSTRUCTION/SITE MANAGER OR WORKS PACKAGE MANAGER

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Is aware of COSHH assessment controls along with other risk assessments and method statement. Monitors work to ensure it is done in line with method statement.

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Requests Material Safety Data Sheet (MSDS) for all substances ordered by COMPANY

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PROCUREMENT

Provide COSHH assessments and MSDS for all substances. Control exposure in line with COSHH assessment and method statement.

Make themselves aware of location of COSHH assessments and MSDS in case needed in an emergency.

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FIRST AIDERS

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SUB-CONTRACTORS

SHE MANAGER/ADVISER 8

Provides advice and support in the application of this procedure and monitors effectiveness of control measures.

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2.3.2.2 Definitions of terms HAZARDOUS SUBSTANCE ‘Substance’ means a natural or artificial substance whether in solid or liquid form or in the form of a gas or vapour (including micro-organisms).

2

A ’substance hazardous to health’ is one which, because of the way it is made, stored, transported, used or disposed of, presents a risk to health in the workplace. The definition of a hazardous substance is comprehensive. All supplied substances which are classified as hazardous must by be labelled correctly. Substances will be labelled as Very Toxic, Toxic, Harmful, Corrosive or Irritant. However, some hazardous substances can be created during processes, and these are also covered by the Qatar Regulatory Document (Construction), for example dusts of any kind in specified concentrations.

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QATAR WORKPLACE EXPOSURE LIMITS (WEL) (BASED ON UK HSE STANDARDS) This is the exposure limit approved by the UK Health and Safety Commission for a substance in relation to the specified reference period of either 15 minutes or 8 hours. A list of WEL’s is available in the HSE Publication “EH/40 Workplace Exposure Limits”, which is updated annually. The majority of WELs listed in EH40 are for single compounds or for substances containing a common element or radical, for example, 'isocyanates'. A few of the WELs relate to substances commonly encountered as complex mixtures or compounds, for example 'rubber fume'. If the Safety Data Sheet lists a substance with a WEL, the employer should ensure that the WEL is not exceeded.

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Is a dust of any kind present in the air at concentrations equal to or greater than 10 mg/m 3 over an 8 hour period if inhalable (i.e. can be breathed in) or 4 mg/m over an 8 hour period if respirable (i.e. small enough to reach to the very base of the lungs).

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HAZARDOUS DUST

The Project Manager is responsible for appointing a COSHH Co-ordinator

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2.3.2.3 Appointment of COSHH Co-ordinator

ASSESSMENT OF RISK 2

Under COSHH the risk presented by any hazardous substance used, stored, transported, created or disposed of in the workplace must be assessed.

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If a substance is supplied or created by COMPANY, the COSHH Co-ordinator is responsible for ensuring a COSHH assessment has been undertaken. The COSHH Co-ordinator should ensure that a register of all hazardous substances is maintained, and that each has a valid COSHH assessment, and where applicable a MSDS.

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If the substance is supplied or created by a sub-contractor, it is their responsibility to provide the COSHH assessment along with all other risk assessments submitted for acceptance. These assessments are likely to accompany a method statement, and should be read as part of the method statement acceptance process as covered by procedure SHE-PRO-001. Construction/Site Managers and Works Package

5

Managers must ensure that assessments and method statements have been agreed and must monitor work to ensure it is undertaken in line with the method statement. The COSHH

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Co-ordinator should ensure that all hazardous substances present on a project have a valid COSHH assessment. For a supplied substance the COSHH assessment should be accompanied by the manufacturers/suppliers MSDS. 6

NB - a MSDS alone does not constitute a COSHH assessment.

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In all cases risks to persons other than those using a substance must also be considered (e.g. those working in adjacent areas). The COSHH Co-ordinator should ensure this is done, and that suitable measures are taken. These measures may include provision of information and training to personnel other than those who will use the substance. COSHH ASSESSMENT PROCEDURE To enable COMPANY to comply with the requirements of COSHH, an assessment is required. This is in two parts:

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Firstly, COMPANY must not carry out any work that is liable to expose employees to any substance hazardous to health, unless a suitable and sufficient assessment of the risks created by the work has been made.

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Secondly, if the first step indicates that substances hazardous to health will be used or created, COMPANY must identify the actions to be taken to comply with COSHH.

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The procedure itself is fairly simple but does take time and effort. It involves:

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identifying jobs, working processes and procedures that involve the use or generation of substances that are hazardous to health

(b)

identifying all the hazardous substances in use in the workplace, very toxic, toxic, harmful, corrosive or irritant

(c)

identifying how the hazardous substances are stored and used. This means how they are used, not how they should be used

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(a)

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Very toxic or toxic: Substances that, in low quantities, cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin.

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Harmful: Substances that may cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin.

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Corrosive: Substances that may, on contact with living tissues, destroy them.

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Irritant: Non-corrosive substances that through immediate, prolonged or repeated contact with the skin or mucous membrane may cause inflammation.

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Identifying how these hazardous substances might enter the body. Normally these methods are classed as:

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inhalation into the lungs, when the substance is in the form of a gas, vapour, fume, mist, aerosol or dust

(b)

absorption through the skin or eyes by contact with a substance that can penetrate unbroken skin, or is absorbed through unprotected cuts or grazes

(c)

injection by contact with contaminated sharp objects or high-pressure equipment, e.g. water jetting

(d)

ingestion by swallowing particles of a hazardous substance resulting from handto-mouth transfer identifying the amount of exposure. This involves knowing how much of the substance will be used, how people will be exposed to it and if there are is a workplace exposure limit investigating the possible health effects of such exposure

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(a)

identifying who is at risk, for example the persons using it or anyone who enters the area within the following 24 hours

(ii)

considering the effectiveness of the control measures already in place, for example whether the concentration of vapour is likely to be above the WEL

(iii)

identifying the risk to workers if control measures deteriorate or fail or if an emergency occurs, for example if a volatile solvent is accidentally spilt resulting in a high concentration of hazardous vapour in the workplace

(iv)

finally, from the above considerations, making a decision upon whether a substance represents a health risk or not. If the answer is 'no', the findings should be recorded. If 'yes', action will be necessary to either prevent or control exposure.

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(i)

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Completed assessments must be made available to the person who is going to carry out the work so that they are aware of the health hazards present and the control measures that they must use, record COSHH Assessments on SHE-FRM-2-01.

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CONTROL OF EXPOSURE TO HAZARDOUS SUBSTANCES The measures which need to be taken to comply with COSHH should be detailed on the COSHH assessment. The overriding duty is to prevent exposure to hazardous substances. This may be achieved by using a different process, design or technique which does not require or create the hazardous substance, or substituting the hazardous substance for a non-hazardous one. Where it is not possible or practicable to prevent exposure completely, exposure should be reduced by using an alternative less hazardous substance or version (e.g. more dilute concentration), using a different form (e.g. pellets instead of powders) or changing the process (e.g. to use less).

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If it is not reasonably practicable to prevent exposure, then exposure must be controlled. This must be achieved as far as possible by controlling the substance at source by engineering controls. Other measures may also be needed such as provision of information and instruction, and hygiene facilities. Personal Protective Equipment (PPE) can only be used as a last resort where adequate control cannot be achieved by other means.

20

Where a substance has been assigned a WEL, this must not be exceeded.

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Additional requirements may be necessary if substances have been identified as carcinogens, mutagens, asthmagens or are biological agents. These substances may be identified by the risk phrases R42, R42/43, R45, R46 or R49. Consult the SHE Advisor for further information if required.

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Control measures should be monitored to ensure that they are effective. Where they prove ineffective the assessment should be reviewed, and measures modified so far as is reasonably practicable.

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DUTIES OF THE COSHH CO-ORDINATOR The COSHH Co-ordinator should ensure that first aiders know where to access information on hazardous substances used on the project. This could be achieved by maintaining a file of all MSDS and assessments which is easily accessible by first aiders.

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COSHH Co-ordinators should liaise with Safety Co-ordinator / SHE Adviser / Managers / Environmental Adviser / First Aiders / Emergency Co-ordinators for further advice if necessary.

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RESPIRATORY PROTECTIVE EQUIPMENT (RPE) – FIT TESTING 25

COSHH requires fit testing of RPE. Where sub-contractors provide RPE for their workers they should also provide evidence that a suitable fit test has been carried out for each worker required to wear RPE. The COSHH Co-ordinator should ensure that fit tests have been carried and records are available.

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Where COMPANY employees are required to wear RPE, COMPANY will be responsible for ensuring fit tests have been carried out. The SHE Department can undertake fit tests, or it is possible to have a member of the project staff trained to undertake the tests. Training can be provided by the SHE Department and takes half a day. Records of training should be kept on site as well as centrally.

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Fit testing of individuals must be carried out using the appropriate RPE for the task identified in the risk assessment, and the results recorded on the Qualitative Fit Test Proforma – SHEFRM-2-02.

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Records of fit testing must be kept on the users personnel file for 5 years. If there are any changes in the wearer, such as significant weight change or dentistry that may affect the size or shape of the face, then a new fit test should be carried out.

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Further information on RPE can be found in SHE-PRO-010 – Personal Protective Equipment (PPE). USE AND DISPOSAL OF HAZARDOUS SUBSTANCES Hazardous must only be used by persons who have received instruction and training, and must only be issued in quantities sufficient to complete the task. Hazardous substances are often harmful to the environment, and half empty containers can pose a risk to persons in the future. Therefore, all containers must be disposed of as hazardous waste, including empty containers.

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The COSHH assessment will identify when exposure monitoring is required. Typically this will be required if any of the following apply: If it is possible that the failure of any control measures could result in a serious health effect;

(e)

If a substance has a WEL

(f)

If there is doubt whether exposure monitoring should be carried out, consult the SHE Dept who will advise on appropriate protocols and details of record keeping.

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Responsibility for health surveillance lies with COMPANY. Many of the tasks carried out in the construction environment will not require health surveillance to be carried out. However, if all three of the following conditions apply, then health surveillance is required: An identifiable disease or adverse health effect may be related to exposure.

(b)

There is a reasonable likelihood that the disease or effect may occur under particular conditions of work. There are valid techniques for detecting indications of the disease or the effect.

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HEALTH SURVEILLANCE

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EXPOSURE MONITORING

ARRANGEMENTS TO DEAL WITH ACCIDENTS, INCIDENTS AND EMERGENCIES 33

Arrangements to deal with emergency situations (e.g. spillages, accidental release or over exposure) should be detailed in the appropriate method statement. Emergency arrangements which cover the project as a whole should also be detailed in the construction phase plan. INITIAL SHE MEETING

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At the initial SHE meeting (see procedure SHE-PRO-007) COMPANY will advise subcontractors of any substances used by others which could affect their employees. In addition sub-contractors will be required to advise COMPANY of all hazardous substances they will use.

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PROCUREMENT

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All orders and requisitions shall clearly identify the product being ordered and shall contain a requirement to comply with COSHH and to provide the MSDS. The COSHH Co-ordinator shall ensure MSDS from the supplier are delivered with the product.

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2.3.2.4 Appendices APPENDIX 1 – EXAMPLE OF COSHH RISK ASSESSMENT

Auto diesel

Substance hazard classification:

Flammable, harmful/irritant

Trade name(s):

Any auto fuel production company

Substance used for:

Motive power for plant and other diesel powered vehicles

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Name of hazardous substance:

Safety precautions

Inhalation: can lead to nausea and headaches.

Avoid inhaling vapour or mist; ensure good ventilation. Remove the victim from exposure.

Skin contact: can be irritating and have a defatting effect.

Avoid prolonged/repeated contact. Wear PVC gloves. Do not use as a cleaning agent.

Eye contact: will cause irritation.

Wear eye protection if splashing can Rinse immediately with plenty of occur. water until irritation subsides. Seek medical advice.

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Remove contaminated clothing. Wash skin thoroughly with soap and warm water.

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Remove to fresh air. Seek medical attention if conditions severe.

Do not eat, drink or smoke during use.

Do not induce vomiting. Wash mouth with water. Seek immediate medical attention.

Fire: products of combustion are toxic. Vapour/air mixture is explosive.

Do not smoke during use. Avoid heat sources and open flames.

Clear the area. Do not inhale vapours, smoke etc.

Spillage: fumes/vapour likely to collect in low areas.

Do not allow to enter drains. Eliminate ignition sources. Ensure good ventilation.

Contain with sand or granules. Remove into a container. Dispose of as hazardous waste.

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Ingestion: will irritate mouth, throat etc.


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Potential hazards

Additional information: Environmentally damaging. Assessment date Approved for use by (print name and position)

Next review date

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Signature

APPENDIX 2 - COSHH RELATED RECORD KEEPING REQUIREMENTS

Maintenance Records Examination and where appropriate test records. Maintenance records.

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PPE (various items) Respiratory Protective Equipment (RPE) e.g. cartridge type Local Exhaust Ventilation (LEV)

Archive Period None specified, recommended minimum 3 years Minimum 5 years Minimum 5 years

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COSHH Related Record Keeping Requirements Summary Issue Document Personal Protective Equipment COMPANY Register entries

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Examination and test records Minimum 5 years (including repairs)1 Exposure Monitoring (Personal) Monitoring results or a suitable Minimum 40 years summary2 Exposure Monitoring (Not Monitoring results or a suitable Minimum 5 years Personal) summary Health Surveillance Health record containing particulars 40 years from date approved by the HSE. of last entry Disposable RPE Project specific records Minimum 5 years Breathing Apparatus Maintenance, examination and test Minimum 5 years records. Maintenance log. Fit Test Report RPE Qualitative Fit Test Records Minimum 5 years 1 All LEV systems must be examined/tested every 12 months. 2 All personal monitoring results must be treated as confidential information and consultation must be carried out through the SHE Department.

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2.3.2.5 Reference Documents FORMS 1

COSHH Assessment Form – (SHE-FRM-2-01)

2

COSHH RPE Qualitative Fit Test Report (SHE-FRM-2-02)

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COSHH Training Record (SHE-FRM-2-03)

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UK Workplace Exposure Limits (EH40)

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REFERENCE DOCUMENTS

2.3.2.6 Author

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

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2.3.2.7 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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COSHH ASSESSMENT

Name of hazardous substance: Substance hazard classification: Trade name(s):

Safety precautions


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Potential hazards

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Substance used for:

Additional information: Assessment date NEXT REVIEW DATE Approved for use by (print name and position) Signature

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Name:

Worker No:

Report Number:

Employer: Date of Test:

Name of tester:

RPE Model Number: Size of RPE Tested: Sensitivity Test Complete? Y/N

Solution Dose? 10 - 20 - 30 (circle)

Please circle test solution used. Bitter

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User Seal Test carried out successfully? Y/N Exercise (Duration is 1 minute for each). Normal Breathing.

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Deep breathing through mouth

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Turn Head side to side – breathe in as head looks at shoulder. Look up and down – breathe in looking at ceiling.

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Talking for 1 minute.

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Jog on the spot OR bend down and then up.

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Breathe normally.

Note - 1

The performance of RPE with a tight fitting facepiece (filtering facepieces, half and full face masks) depends on good contact between the wearer’s skin and the face seal of the mask. A good face seal can only be achieved if the wearer is clean- in the region of the seal and the facepiece is of the correct size and shape to fit the wearers’ face. Spectacles with side arms and other items of PPE must not interfere with the correct fitting of the facepiece or the face seal Dosage for Fit test – Initially, same dosage as determined in Sensitivity Test when hood is in place. Then introduce a ½ dose every 30 seconds during exercises If at any time during the test, the subject tastes the particulate then the test is failed. Wait 15 minutes before re-testing. If the retest is failed then test using a different sized mask.

Fail

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Note –3

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Note - 2

Pass

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Exercise 1

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Notes: (To be used by the employee, Manager, Occupational Hygienist and/or SHE Advisor. )

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I certify that I have carried out the Fit Testing of Respiratory Protective Equipment as required under the COSHH Regulations

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Signature of tester……………………………………… Date ………………….

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I certify that I have received Fit Testing for Respiratory Protective Equipment as required under the COSHH Regulations

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Signature of employee……………………………………… Date ………………….

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THIS DOCUMENT TO BE RETAINED ON FILE FOR 5 YEARS.

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Section 11: Health and Safety Part 2.3.02: Control of Substances Hazardous to Health (COSHH) Assessment Sheet No:

Substance:

Activity No:

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Contract:

Page 17

Date

Position Held

Signature

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I declare that I am in receipt of training in the precautions required for the safe use of substances list above.

Instructor's Signature: Copy to:

Site Register

Date:

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Section 11: Health and Safety Page 1 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services


2.3

SAFETY , HEALTH AND ENVIRONMENT PROCEDURES .......................... 1

2.3.3

SAFE WORKING IN THE VICINITY OF BURIED AND OVERHEAD SERVICES ...................................................................................................... 1

.

2

Responsibilities .......................................................................................... 4

2.3.3.2

Definitions .................................................................................................. 4

2.3.3.3

Action Required To Implement This Procedure .......................................... 5

2.3.3.4

Guidance to This Procedure....................................................................... 7

2.3.3.5

Reference Documents................................................................................ 7

2.3.3.6

Author......................................................................................................... 8

2.3.3.7

Approvals ................................................................................................... 8

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2.3.3.1

is appointed

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Process Map

PLANNING LOCATION

Ensure evaluation of programme & works drawings, identify requirement for excavations & equipment is available 3.1

Locator of Service

Supervisor/Electrical Engineer

SHE Advisor

Contact all relevant stat. authorities, Engineer & obtain information on all u/g and overhead services. Produce ‘Master’ drawing where practicable 3.2, 3.5

Produce activity specific service location drawing 3.2

Carry out cable/pipe/service detection survey

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Ensure this procedure is established. Appoint Services Co-ordinator 1.2

Services Coordinator

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Project Manager

Mark location of services on ground/identify overhead services

Update activity specific service location drawing 3.3

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Undertake service plans and maintain master copy

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Ensure timed circuits are identified or isolations 3.2

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Ensure services to be removed are made DEAD or SPIKED by authorised person 3.2

Input to Method Statement as appropriate

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Identify trial holes required to establish exact location and type of service 3.2, 3.3

Agree Method Statement

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Re-assessed by competent person

OPERATIONAL CONTROLS

Approve and monitor Permit to break ground & confirm duration 3.2

Ensure service plans are updated & maintain master copy 3.2

Ensure updated plans are forwarded to H&S file

Re-assessed by competent person Key

Activity Guidance

HOLD POINT Instruct personnel in contents of Permit and Method Statement 3.4

Proceed in accordance with Permit & Method Statement and monitor. Notify Service Cocoordinator of any 3.5 change and need to review RAMS

Monitor operations & permit. Investigate any learning events or strikes 1.6 Insp. Report

HOLD POINT

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PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work for activities carried out where buried services may exist or overhead services are present.

SCOPE This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Qatar General Electrical and Water Corporation (KAHRAMMA) is the responsible for the distribution network cables and wire, not the Qatar General Electricity and Water Company

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Authorises this procedure PROJECT/SITE MANAGER

2

Ensures that works are carried out in accordance with this procedure and appoints the Services Co-ordinator.

Ensures that necessary information regarding services is available and undertakes the duties specified in this procedure.

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SERVICES CO-ORDINATOR

Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures preparation of the necessary control documents required by this procedure.

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SUPERVISOR/ELECTRICAL ENGINEER

LOCATOR OF SERVICES

SHE ADVISER

Provides advice and support in the application of this procedure and monitors others’ effectiveness to manage the activities.

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Undertakes the physical check and survey, in line with their training, to determine the location of both identified/unrecorded services.

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2.3.3.2 Definitions SERVICES 1

Any cable or pipe, either buried in the ground or supported overhead, providing telecommunications, electricity, gas, water, drainage or other service. ANY CABLE RISK ASSESSMENT

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The process of hazard identification, assessment of the risk, and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity.

3

Refer to SHE-PRO-001 (

).

METHOD STATEMENT

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4

A statement describing the proposed working method that addresses the output from the risk assessment process and provides instruction and guidance for those individuals carrying out the activity.

5

Refer to (SHE-PRO-001). PERMIT TO BREAK GROUND

6

Control document – (SHE-FRM-3-02 ) Permit to Break Ground, to ensure that potential hazards from services during excavation or penetration of the ground are identified and risks are controlled and maintained.

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2.3.3.3 Action Required To Implement This Procedure

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PROJECT/SITE MANAGER

Ensure the evaluation of tender information, Project Programme and the works drawings to identify the requirements for breaking ground or location of overhead services.

2

Appoint a Services Co-ordinator or retain the Services Co-ordinator’s duties in 3.2.

3

Ensure the availability of suitable service location equipment and a competent operator who is appropriately trained in the use of detection equipment.

4

Agree with Services Co-ordinator the site colour-coding scheme for surface marking of services.

5

Check that the controls in this procedure are implemented.

6

Agree method statements and associated risk assessments.

7

In case of a service strike, a specific site investigation must be undertaken in conjunction with the SHE Team (SHE-FRM-8-06).

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SERVICES CO-ORDINATOR Seek out and retain copies of all statutory authority and service drawings (including client’s where applicable) relevant to the project’s scope of work.

9

Have transposed onto a master drawing(s), the details of all relevant services.

10

Have recorded on the master drawing(s) the location and depths of services installed during site establishment.

11

Confirm with the Supervisor/Electrical Engineer in control of an activity requiring a Permit to Break Ground the full extent of the intended activity. Check the activity drawings against the master drawing(s).

12

Produce an activity specific location drawing for reference by the locator of services that includes current landmarks, (SHE-FRM-3-02).

13

Request the appointed Locator of Services to undertake a thorough survey of the area where the activity is to take place with an appropriate service locator (and ‘Genny’ where circuits on timers are likely), and none energised services, e.g. gas and water, even if it has been established from drawings that there are no recorded services present.

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In conjunction with the Locator of Services, specify where and when trial holes are dug to establish the exact location and type of service identified. Provide an activity specific, location drawing (including any updates identified in the survey) for reference by the Supervisor/Electrical Engineer in control of the activity.

15

Update master drawing(s) following receipt of survey information.

16

Ensure information on master drawing(s) is transferred to ‘as-built’ drawings for inclusion in the projects Health and Safety File.

17

Ensure secure isolation of any service or purging of any pipe-work before it is worked upon or removed and be aware of any presence and effect of timed circuits.

18

Before any activities start on a site where overhead services are present or adjacent, contact the SHE Adviser for advice. Where overhead electrical supply cables are present, Qatar General Electricity & Water Company shall also be contacted for advice on re-routing or clearance and insulation. Review Method Statement/Risk Assessment before final approval by Project Manager.

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LOCATOR OF SERVICES

Physically and clearly mark the position of services on the ground in accordance with the services marking scheme.

20

Assist in establishing the exact location and type of service identified when trial holes are being dug.

21

Update the activity specific location drawing provided for reference to you by the Services Co-ordinator.

22

Advise the Services Co-ordinator of any deviations from records

23

Seek advice from the Services Co-ordinator where doubt about a signal or lack of one exists.

24

Continue to use the service locator and genny, whilst the work proceeds, to establish the presence of any services missed/not located during the initial sweep, frequency as determined by the Service Co-ordinator.

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SUPERVISORS/ELECTRICAL ENGINEER 25

Prepare or arrange for the Sub/Work Package Contractor to prepare for agreement by the Project/Site Manager a specific method statement SHE-PRO-001 for activities involving: (

26

)

(a)

excavation or penetration of the ground;

(b)

any activity beneath or in the vicinity of overhead electrical supply cables or pipework containing a hazardous substance where there is any possibility, however remote, of plant, equipment, materials or people encroaching into a safety zone;

(c)

any activity beneath or in the vicinity of any other overhead service where there is a possibility of damage.

Ensure persons under their control fully understand they do not commence excavation or penetration of the ground in an area unless the whereabouts of services has been established and a Permit to Break Ground has been prepared and approved by the Service Co-ordinator and obtained (SHE-FRM-3-02).

QCS 2014


Ensure all personnel involved in the activities are instructed in the method statement and Permit to Break Ground and sign to confirm their understanding, including the requirement to stop work immediately in cases where a service is damaged so that the situation can be reassessed by a competent person.

28

Ensure persons under their control fully understand they may not in any way interfere with a service or remove any service cover, warning tile or other protection unless specifically authorised by their Supervisor.

29

In the event of a service being damaged, work must be stopped immediately and cordoned off so that a re-assessment can be undertaken by a competent person before work recommences.

30

Establish in conjunction with the Services Co-ordinator the need for additional surveys as the activity progresses where the location of services may have been missed.

31

Where overhead electrical supply cables are present, that persons under their control fully understand these are not insulated, therefore if contact or near contact is made with them by a conducting object, there is a risk of death or serious injury to any person in the immediate vicinity.

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2.3.3.4 Guidance to This Procedure

The Risk Assessment/Method Statement (SHE-PRO-001) shall reference the activity specific location drawing provided by the Services Co-ordinator.

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RISK ASSESSMENT/METHOD STATEMENT

Any delay between the services survey and the activities to be performed shall be minimised and a limit specified on the Permit to Break Ground, SHE-FRM-3-02 This limit for the Permit(s) must be agreed with the Service Co-ordinator. (

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PERMIT TO BREAK GROUND

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REFERENCING

The Risk Assessment/Method Statement shall be referenced on the Permit to Break Ground.

4

If a sub or work package contractor is undertaking the works, the contractor’s supervisor shall confirm that the items on the Permit have been undertaken before any ground is broken (see also 3.4 stop work requirements).

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2.3.3.5 Reference Documents PROCEDURES 1

Safety, Health and Environmental Risk Management and Written Safe Systems of Work – (SHE-PRO-001)

2

Permit to Work Systems – (SHE-PRO-011) FORMS

3

Permit to Break Ground – (SHE-FRM-3-02)

QCS 2014

4


Site Investigations of Underground Strikes (SHE-FRM-8-06) FURTHER REFERENCE Qatar Regulatory Document (Construction) , Section 1.5

6

Statutory Authorities/Client’s Plans & Drawings

7

Works Programme & Drawings

8

Site Service Plan

9

Risk Assessment/Method Statement or Task Statement

10

Site Investigation

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5

POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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2.3.3.6 Author

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SHE Manager

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2.3.3.7 Approvals

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NAME

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Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014


Section 1

Permit Number

2

Prepared By

3

Start – Date/Time

Date

(To be noted on the RA+MS)

Requested By

Duration Specific Location Activity Plant To Be Used (As Part Of The Safe Systems Of Work) Yes

No

Safety Pin Required

Yes

No

The services itemised below exist at the above location & on the attached sheets Service Drawing Exist Service Drawing Exist Number Yes/N Number Yes/N o o Electricity Drainage Underground Ducts Overhead CCTV Street Lighting Temporary Services Gas Others (i.e. ordinance) Telecom Approval To Remove Fibre Optics Redundant Water Mains Services Sewers Restrictions 1 Permit valid from ...................................... to ............ 2 Excavate trial holes by hand every ....................................... metres 3 Expose services along full length in works areas Yes No 4 Confirm a risk assessment and method statement have been prepared Yes Risk assessment/s and method statement/s ID Number ................................................................ 5 Service locator/survey carried out Yes by whom ...................................... Is the equipment calibration up to date Yes Date of Calibration ............................................... 6 Has ground radar survey been carried out Yes (If Yes attach appropriate drawings) No Any other comments/ restrictions identified

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7

Approved By: (COMPANY Authorised Person/Service Co-ordinator) Print Name .................................................... Signature ................................. Position ......................................................... Date ....................................... Acknowledgement of COMPANY/*Contractors Supervisor I understand the hazards involved in this work and that in the event of a service strike the area will be cordoned off and only re-entered following advice from the utility provider. All personnel involved will have this fully explained to them by me and sign section 9 of this permit to confirm this is the case. Print Name ................................................... Signature ...................................................Position .................................... Print Name ................................................... Signature ...................................................Position ...................................

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Quick Hitch Fitted

8

Date ............................... Confirmation of Completion of Works Print Name ............................................................... Signature ...................................... Position ................................................................... Date .............................................

9

Confirmation that personnel have been advised of Section 7 (Sign and Print Name) Date ................................

*If relevant Distribution:

White copy – Workplace recipient Pink copy – Distribute as required Blue copy – Retain in book (file copy)

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 1

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ------------------------------------------- 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ---------------------- 1

2.3.4

ELECTRICITY AT WORK ------------------------------------------------------------------ 1

2.3.4.1 2.3.4.2 2.3.4.3 2.3.4.4 2.3.4.5 2.3.4.6 2.3.4.7

Responsibilities ........................................................................................................... 4 Definitions ................................................................................................................... 4 Actions Required to implement This Procedure .......................................................... 5 Appendices ................................................................................................................. 7 Reference documents............................................................................................... 10 Author ....................................................................................................................... 10 Approvals ................................................................................................................. 10

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is appointed

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Process Map - Control of Electrical Operations Services Coordinator

Locator of Service

Appoint an Electrical Duty Holder for the Company/Region

Issue current version of RES to Project Managements/Electric al Contractors

3.1

3.2

Supervisor/Engineer

Appoint an Authorised Person for electrical works for the location 3.3

Appoint an Authorised person for the Permanent and Temporary Works

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Obtain and update a drawing showing the locations Temporary Electrical System 3.3

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Appoint a Permanent Works Electrical Duty Holder 3.5

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Audit the electrical installation/equipme nt 3.2

Key:

Activity Guidance

Control the Permit of Work System and issue the appropriate permits 3.2

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3.2

Display the appointment on the location notice Board 3.3

SHE Advisor

.

Project Manager

Ensure the Schedule tests are carried out 3.3

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PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work in relation to the design, installation, maintenance, and examination and testing of electrical systems/equipment.

SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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The SHE Director shall approve this procedure MANAGING DIRECTOR

2

The Managing Director shall appoint in writing an Electrical Duty Holder (EDH) for the Company/Region who shall be a qualified Electrical Engineer or appoint an Electrical Consultant to manage the EDH duties

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Ensure any applicable sections of this procedure are established, and complied with.

4

The responsibility for electrical safety of the permanent works under construction shall remain with the operational line management.

5

The appointment of a Permanent Works Electrical Duty Holder shall be the responsibility of Site Manager with reference to the EDH.

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ELECTRICAL DUTY HOLDER (EDH)

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3

It is the responsibility of the EDH to implement this procedure and monitor that all portable electrical appliances provided by COMPANY for use by COMPANY personnel or others comply with it.

7

The EDH shall be responsible for electrical safety with respect to the whole or defined parts of the Company’s electrical systems and/or equipment, ensuring compliance with the Rules for Electrical Safety and, with regard to installations, planned preventative maintenance.

8

The vetting/approval of temporary electrical sub-contractors shall be the responsibility of the EDH or the Operational/Area Director following consultation with his/her SHE Adviser in circumstances where the EDH duties are delegated to an approved electrical contractor.

9

It is acknowledged that different arrangements exist in respect of site set ups, some being under the control of the client/external partners. In circumstances where deemed necessary the EDH shall endeavour to influence the client/external partners to adopt COMPANY standards.

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2.3.4.2 Definitions 1

A full set of definitions are contained in the COMPANY Rules for Electrical Safety. DESIGNATED PERSONS ELECTRICAL DUTY HOLDER

2

An Electrical Engineer appointed by the Managing Director in writing to be responsible for ensuring electrical safety with respect to the whole or defined parts of the Company's electrical system and/or equipment.

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Page 5

AUTHORISED PERSON 3

An electrical contractor or electrically qualified Engineer or Technician appointed by the Electrical Duty Holder in writing, to carry out specified duties on the electrical system or equipment and to take control of any danger that is to be avoided and who is competent to accept such responsibility. SUB CONTRACTOR'S AUTHORISED PERSON

4

An electrically qualified Engineer or Technician appointed by the by the Sub-Contractor in writing, to carry out specified duties on the electrical system or equipment and to take control of any danger that is to be avoided and who is competent to accept such responsibility.

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The Site/Location Manager will be the Site Electrical Co-ordinator for the site/location under that person's control, unless the position is otherwise delegated in, writing and that person is approved by the Electrical Duty Holder in writing.

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SITE ELECTRICAL CO-ORDINATOR

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2.3.4.3 Actions Required to implement This Procedure

The MD for the Company/Region shall appoint in writing an Electrical Duty Holder for their area of responsibility.

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MANAGING DIRECTOR

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The Electrical Duty Holder shall :

Ensure ALL work is carried out in accordance with the COMPANY Rules for Electrical Safety.

(b)

Assess and approve all temporary electrical contractors prior to their appointment.

(c)

In conjunction with the Site/Project Manager appoint in writing an Authorised Person for each location.

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(a)

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ELECTRICAL DUTY HOLDER

3

(d)

Take reasonable steps to ensure that the Site Electrical Co-ordinator has the competency to undertake the role.

(e)

Ensure that all projects and appropriate contractors have a copy of the latest Rules for Electrical Safety.

(f)

Undertake independent inspection/audit of site electrical installation/equipment under COMPANY UK control.

(g)

During inspection/audit of the temporary electrical installation shall also consider the electrical safety controls in place for the permanent works.

The minimum frequency of inspection/audits shall be carried out at a frequency as deemed necessary by the EDH in agreement with the Area Director responsible for the site. SITE ELECTRICAL CO-ORDINATOR

4

The Site Electrical Co-ordinator shall :

QCS 2014


Page 6

(a)


(b)

After consultation with the EDH, appoint in writing an Authorised person for the location he is responsible for.

(c)

Display the appointment of the Site Electrical Co-ordinator and Authorised Person on the location notice board and electrical switch gear.

(d)

Keep an up-to-date drawing showing the electrical circuits for the location’s temporary electrical system.

(e)

Ensure schedule tests are carried out on installations and equipment.

AUTHORISED PERSON

Control the permit to work system and issue permits as required.

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(a)

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The Authorised Person shall :

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SITE/PROJECT MANAGER

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The Site/Project Manager shall :


(b)

After consultation with the EDH appoint in writing a permanent works Electrical Duty Holder.

(c)

Ensure that the specification for the temporary site electrics is communicated to the temporary electrical contractor.

(d)

Undertake the duties of the Site Electrical Co-ordinator or appoint appropriate person to undertake those duties.

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(a)

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2.3.4.4 Appendices

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APPENDIX 1 – SUGGESTED INSPECTION AND TEST FREQUENCIES FOR ELECTRICAL EQUIPMENT Formal Visual Inspection No

No

No

No

Information technology: e.g. desktop computers, VDU screens

Yes, 2-4 years

No if double insulated – otherwise up to 5 years

Photocopiers, fax machines: NOT hand-held Rarely moved

Yes, 2-4 years

No if double insulated – otherwise up to 5 years

Double insulated equipment: NOT hand-held. Moved occasionally, e.g. fans, table lamps, slide projectors

Yes, 2-4 years

No

Double insulated equipment: HAND-HELD e.g. some floor cleaners

Yes, 6 months – 1 year

No

Earthed equipment (Class 1): e.g. electric kettles, some floor cleaners

Yes, 6 months – 1 year

Yes, 1-2 years

Cables (leads) and plugs connected to the above. Extension leads (mains voltage)

Yes, 6 months – 4 years depending on the type of equipment it is connected to

Yes, 1-5 years depending on the type of equipment it is connected to

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Battery operated: (less than 20 volts)

Combined Inspection and Testing

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Equipment/Environment

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Extra low voltage: (less than 50 volts AC) e.g. telephone equipment, low voltage desk lights

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QCS 2014

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OFFICES AND OTHER LOW RISK ENVIRONMENTS ONLY CONSTRUCTION SITES

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Battery operated power tools and torches

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25V portable hand lamps (confined or damp situations) 50V portable hand lamps

Formal Visual Inspection

Combined Inspection and Test

Less than 25 volts

No

No

25 volt secondary winding from transformer

No

No

Secondary winding centre tapped to earth (25 volt)

No

Yearly

qa

Equipment/Application

Voltage

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ito

110V portable and hand-held tools, extension leads, Secondary winding centre tapped to earth site lighting, moveable wiring systems and associated (55 volt) switchgear

Monthly

Before first use on site and then 3 monthly

230 volt mains supply through 30mA RCD

Weekly

Before first use on site and then monthly

230V equipment such as lifts, hoists and fixed floodlighting

230V supply fuses or MCBs

Monthly

Before first use on site and then 3 monthly

Weekly

*Before first use on site and then 3 monthly

6 monthly

Before first use on site and then yearly

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230V portable and hand-held tools extension leads and portable floodlighting

RCDs

Fixed**

Equipment in site offices

230 volt office equipment

*Note: RCDs need a different range of tests to other portable equipment, and equipment designed to carry out appropriate tests on RCDs will need to be used. ** It is recommended that portable RCDs are tested monthly.

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QCS 2014

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APPENDIX 2 - VISUAL INSPECTION OF ELECTRICAL EQUIPMENT CHECKLIST THIS IS A SIMPLE INSPECTION REQUIRING THE MINIMUM OF TRAINING. THE FOLLOWING CHECKLIST COVERS THE REQUIREMENTS.

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Plug

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General

N.B.

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Appliance Casing

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Cable

No damage, cracks or bent pins, cable sheath secured. Inspection of the inside of the plug to check correct fusing/wiring in place can also be part of the visual inspection.

No damage, significant abrasions, cuts, taped joints

No damage, loose parts or screws missing No evidence of overheating (discoloured/hot areas), air intakes not choked, appliance is dry (where appropriate) appliance is dry (where appropriate) appliance is within its test period (check tag) Use the right tool for the job in the right place – don’t improvise. UNPLUG APPLIANCES WHILST INSPECTING. IF APPLIANCE IS DEFECTIVE DON’T USE IT – REPORT IT!

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Page 10

2.3.4.5 Reference documents 1

Qatar Regulatory Document (Construction) RD1.5

2

COMPANY Rules for Electrical Safety (RES) (Qatar General Electricity & Water Company to Supply)

POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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2.3.4.6 Author

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SHE Manager

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POSITION IN COMPANY

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NAME

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2.3.4.7 Approvals

SHEQ Director

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Approved by:

END OF DOCUMENT

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONEMNT PROCEDURES..............................1

2.3.5

POWERED WORK EQUIPMENT PROCEDURE ..............................................1

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2.3.5.1 Responsibilities ..................................................................................................4 2.3.5.2 Definitions ..........................................................................................................5

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2.3.5.3 Action Required to Implement this Procedure ...................................................6 2.3.5.4 Guidance To This Procedure .............................................................................8

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2.3.5.5 Appendices ......................................................................................................11

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2.3.5.6 Reference Documents .....................................................................................13 2.3.5.7 Author ..............................................................................................................13

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2.3.5.8 Approvals .........................................................................................................13

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Page 2

PROCESS MAP Plant Coordinator

Supervisors

Procurement Quantity Surveyor

Identify PWE requirements and produce PWE schedule

Provide proof of competence Review PWE schedule and maintain during the project

3.7

3.2

Regional Training Coordinator

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Operate, inspect and maintain plant

3.2

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3.3

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Ensure relevant Certification is available for PWE on site 3.3

Key: Activity Guidance

Monitor use, inspection and maintenance f PWE 3.3

Advise Subcontracto r Management of PWE requirement at pre-start

Report defects as identified

3.5, 3.6

3.7

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Report defects as identified 34

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3.7

Develop and revise PW Schedule

SHE Team

Assist and advise on plant requirements use and maintain as 3.8

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Monitor use of PWE including inspection and 3.4

Appoint a plant Co-ordinator

Contractor

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3.1

Operator

.

Project Site Manager

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Estimator/ Bid Manager

Identify PWE equipment and provide a copy to COMPANY Plant Co3.8

Arrange training as requested by Project Team 3.9

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Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a system for the control and safe use of powered work equipment.

SCOPE

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Page 4


Authorises this procedure ESTIMATOR/TENDER TEAM

2

Ensures that information provided by designers is utilised at tender stage for inclusion of resource to allow compliance by others with this procedure.

Ensures this procedure is established on Projects under his control. For the purposes of this procedure, Project/Site Manager may also mean Office Manager.

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PLANT CO-ORDINATOR Applies the requirements of this procedure.

5

Note: The person appointed must be site based and competent to carry out their duties. PROCUREMENT/BUYER/QS

Supports the Plant Co-ordinator in the application of this procedure.

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Supports the plant co-ordinator in the application of this procedure. OPERATOR

Operates Plant in accordance with the requirements of this procedure.

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SUPERVISOR 7

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9

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SHE ADVISER Provides advice and guidance in support of this procedure and monitors the effectiveness of its application. CONTRACTOR 10

Ensures only competent personnel are dedicated/owned/hired plant and equipment.

authorised

11

Ensures maintenance is completed and recorded as appropriate.

to

REGIONAL TRAINING CO-ORDINATOR 12

Processes formal training requests from the Project/Site Manager.

operate

specifically

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Page 5

2.3.5.2 Definitions POWER 1

The Provision and Use of Work Equipment. POWERED WORK EQUIPMENT (PWE)

2

Powered Work Equipment as referred to in PUWER.

3

NB. The Requirements for the use of Lifting Equipment are contained in SHEPRO-010

Defines the equipment as fit for its intended use within its design and operational parameters.

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SUITABILITY OF PWE

For the purposes of this procedure, ‘use’ includes all activities involving PWE such as starting, operating and stopping the equipment, plus any setting, repair, modification, maintenance, servicing, transportation and cleaning.

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USE

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‘Contractor’ means any work package contractor or their sub-contractor and include any PWE supplier.

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CONTRACTOR

The individual’s demonstrated capacity to perform, i.e., the possession of knowledge, experience, training, skills and personal characteristics needed to satisfy the special demands or requirements of a particular situation.

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COMPETENCE

A control/management document displayed within the project office to be updated regularly by the Plant Co-ordinator. SHE-FRM-5-001.

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PWE SCHEDULE

PWE CHECKLIST 9

An aide memoir and control document to be completed by the Plant Coordinator (COMPANY and Contractor) or nominated person for any equipment received onto site and filed within the SHE Register. SHE-FRM-5-02. PLANNED PREVENTIVE MAINTENANCE (PPM)

10

Involves replacing parts and consumables or making necessary adjustments at preset intervals so that risks do not occur as a result of the deterioration or failure of the equipment.

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Page 6

CONDITION-BASED MAINTENANCE 11

Involves monitoring the condition of safety-critical parts and carrying out maintenance whenever necessary to avoid hazards which could otherwise occur. BREAKDOWN MAINTENANCE

12

Involves carrying out maintenance only after faults or failures have occurred. It is appropriate only if the failure does not present an immediate risk and can be corrected before risk occurs, It is unlikely that this system of maintenance would be acceptable for the PWE covered by this procedure.

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Identify the PWE requirements for the project and complete the initial PWE schedule (Appendix 1) Allow resource for any equipment in the bid and include details and information relative to the same in the handover process between the pre-construction and construction teams.

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ESTIMATOR/TENDER TEAM

.

2.3.5.3 Action Required to Implement this Procedure

as


Review the initial PWE schedule (Appendix 1) and amend / maintain as required throughout the Project duration.

3

Where appropriate, appoint a Plant Co-ordinator or retain the duties of that appointment.

4

Arrange training for Directly employed persons through the Regional Training Co-ordinator as necessary to ensure the competence of appointees.

5

Monitor PWE use on site to ensure the effectiveness of controls.

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2

7

Take control of, review and develop the PWE Schedule as the project progresses.

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PLANT CO-ORDINATOR

Enter all details of PWE received on site into the PWE Schedule (SHE-FRM-5-01).

8

Act as the focal point for all PWE used on site and assist other management/supervision in the selection and control of the PWE used.

9

Must ensure either a certificate of thorough inspection not more than 12 months old (6 Months where lifting persons) for any lifting equipment received on site is attached to the site register and the next inspection date is logged on the PWE Schedule (SHE-FRM-5-001).

10

Arrange/Complete all pre-use checks as detailed on SHE-FRM-5-002.

11

Record operators/users of each PWE on the PWE Schedule.

12

Complete or ensure the completion of all regular inspections and maintenance of PWE in the appropriate Project SHE Register or the equivalent subcontractor control document.

QCS 2014


Page 7

13

Ensure arrangements are made for the safe-keeping and issue of all ignition and security keys and for smaller PWE for its safe storage and controlled issue.

14

Confirm a system of PPM or Condition Based Maintenance is applied by all sub-contractors on any PWE used on site.

15

Implement a system of PPM or Condition Based Maintenance on any PWE purchased for use on site based on manufacturers guidelines and completed by competent people (externally contracted as necessary). SUPERVISORS Complete all duties as appointed and authorised by the Plant Co-ordinator.

17

Monitor PWE use on site to ensure the effectiveness of controls, maintenance and servicing.

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16

PROCUREMENT/BUYERS

Advise sub-contractor management at pre-start of requirements regarding PWE (see ‘Contractor’ actions below).

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18

QS

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Advise sub-contractor management at pre-start of requirements regarding PWE (see ‘Contractor’ actions below) and issue copy of Appendices 1 & 2 where no sub-contractor internal control documents/system exists.

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19

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OPERATOR

Provides proof of competence.

21

Operates plant and equipment when authorised to do so, in approved areas, subject to site or ordered limitations and in compliance with training and manufacturer’s guidelines.

22

Ensures maintenance is completed in accordance with training, employers Risk Assessment and manufacturer’s guidance.

23

Ensures defects are promptly reported to the plant co-ordinator and where necessary secures unsafe equipment in a safe location/state.

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20

CONTRACTOR 24

Identify the PWE requirements for the project and complete an initial PWE schedule (Appendix 1) or similar ‘in-house’ control document. Provide copy to COMPANY Project Manager/Plant Co-ordinator.

25

Monitor PWE use on site to ensure the effectiveness of controls, maintenance and servicing. REGIONAL TRAINING CO-ORDINATOR

26

Deliver or arrange to be delivered any training formally requested by the Project Team to ensure the competence of Directly employed appointees.

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Page 8

SHE ADVISER 27

2.3.5.4

Assist pre-construction and construction teams as requested in application of this procedure.

Guidance To This Procedure

1

This procedure and guidance is intended to ensure compliance with statutory requirements for all COMPANY projects regarding PWE.

2

Although POWER covers all ‘work equipment’, this procedure and guidance is only intended to provide direction on the control of Powered Work Equipment (PWE) which would include but is not limited to the following: Drills - cable fed, hydraulic and petrol driven (it is not intended that sites include low risk battery drills etc within the scheduled part of this procedure however this does not remove the needs to monitor the use of such equipment to ensure it is fit for purpose and used correctly).

(b)

Saws – circular, reciprocating, bench and rip

(c)

Breakers/Hammers/Chisels/Tampers – All

(d)

Electric/petrol/diesel/gas Powered Plant – All

(e)

Self Propelled Work Equipment – Dumpers, Dozers, Rollers, Excavators etc

(f)

Cartridge Operated Fixing Tools - All

(g)

Lifting Equipment - FLTs, Hoists, HIABs, MEWPs

(h)

n.b. Other than inclusion on the PWE Schedule, all Crane Lifting Operations controls and requirements are covered in SHE-PRO-010.

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RISK ASSESSMENT

Where the specific controls required for the use of PWE have not been considered under the general Risk Assessment for work, a specific Risk Assessment is required prior to its use. The Plant Co-ordinator or Contractor (in the case of sub-contractor equipment) is responsible for its completion. See SHE-PRO-001.

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3

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(a)

4

5

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SELECTION AND SUITABILITY The equipment ordered must be suitable to the work intended and the operating environment, e.g. (a)

Telehandler – consider: loads, reach, site height/width/ground restrictions, operator competence/ability and delivery restrictions etc.

(b)

Breaker – consider: Individual capability, material to be broken, access, technological developments (noise/vibration suppression), tool outputs etc.

Experience coupled with Risk Assessment should allow the selection of the correct equipment, however, if doubt exists consult your local SHE Adviser. PRE-USE/RECEIPT INSPECTION

6

To ensure serviceability, all equipment received on site (COMPANY and Sub-contractor) must be subject to a pre-use inspection using either the COMPANY PWE Checklist (SHEFRM-5-002) or manufacturers guidance as appropriate.

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Page 9

REGISTRATION AND AUTHORISATION 7

To assist in ensuring only competent and authorised personnel use PWE on site, all operators shall be recorded on the PWE Schedule (SHE-FRM-5-001). COMPETENCE Where a recognised industry standard exists i.e. certificate of training achievement, to show competence for the operation of particular equipment, the operator shall possess that appropriate certification, the details of which shall be entered on the PWE Schedule.

9

Where there is no recognised industry standard/certificate of training achievement, the operator shall possess evidence of training on that particular equipment or his employer shall provide written confirmation of training on that particular equipment.

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8

REGULAR INSPECTION

The purpose of an inspection is to identify whether the equipment can be operated, adjusted and maintained safely and that any deterioration (for example defect, damage, wear) can be detected and remedied before it results in unacceptable risks. Inspection should include, where appropriate, visual checks, functional checks and testing. Regular inspections in this context should be completed by the nominated competent person (usually the operator) and conform to the requirements of the Risk Assessment taking into account, training requirements, manufacturers guidelines and equipment specifications.

11

All PWE in use on COMPANY sites will subject to a regime of regular recorded inspection. The maximum period between inspections shall be 7 days and these inspections shall be recorded in the site SHE Register.

12

The above does not include any pre-use checks required of the operator, the occurrence of which should be included in the monitoring checks.

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10

In line with current statutory requirements, all lifting equipment must be subject to thorough inspection: Before being put into service for the first time unless either ;

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(a)

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THOROUGH INSPECTION (LIFTING EQUIPMENT)

(i)

the lifting equipment has not been used before; and

(ii)

in the case of lifting equipment, the employer has received such a declaration made not more than 12 months before the lifting equipment is put into service or if it is obtained from the undertaking of another person, it is accompanied by physical evidence of thorough inspection

(iii)

Where the safety of the lifting equipment is dependent on the installation conditions

14

Where it is exposed to conditions causing deterioration which is liable to result in dangerous situations

15

As a maximum the thorough inspection should be completed at 12 monthly intervals, where the equipment is used for the lifting of persons, the period is reduced to 6 months.

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Page 10

MAINTENANCE 16

It should be remembered that different maintenance management techniques have different benefits:

17

Where safety-critical parts could fail and cause the equipment, guards or other protection devices to fail and lead to immediate or hidden potential risks, a formal system of PPM or Conditioned Based Maintenance is likely to be required. RECORDS The following records shall be maintained throughout the use of any PWE on site: PWE Schedule - Completed on receipt of any PWE and maintained with all relevant detail until the PWE is removed from site. Any PWE merely ‘Off-Hired’ shall be subject to the same controls as other ‘in-use’ equipment.

(b)

Maintenance – A record of all maintenance completed shall be kept in the site SHE Register.

(c)

Regular Inspection – All regular inspections shall be recorded in the site SHE Register.

(d)

Thorough Inspection – A record of all thorough inspections completed prior to or during the PWE time on site shall be maintained in the site SHE Register.

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(a)

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18

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APPENDIX 1 – PWE SCHEDULE

as

Registration/ Date Checklist Equipment Fleet/ Received Completed Type Serial on By Number Site

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COMPANY

Works Package/ Subcontractor

.

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2.3.5.5 Appendices

Owner

Page 11

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QCS 2014

Date of Last Thorough Inspection

Date of Next Thorough Inspection

Authorised User(s) By Name

Competence Details

Risk Assessment Completed and Communicated By

Competent Inspector

Date Removed From Site

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Appendix 2 – PWE Checklist PLANT/WORK EQUIPMENT DETAILS Contract:

Location:

Type of plant/Equipment: Equipment Fleet or Serial No: Order No:

Received by:

Date:

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Supplier:

User (COMPANY or Sub-Contractor):

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CHECKLIST

Yes

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WORK EQUIPMENT

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1. Is the item of plant/work equipment as ordered or a suitable alternative?

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2. Is the item of plant/work equipment in good condition? Are there any noticeable defects i.e. oil leaks, damaged panels, tyres, guards missing, etc? 3. Has plant/equipment been supplied with the necessary; • Operating instructions • Manufacturer’s Handbook • Completed maintenance Checklist (PPM/Service Record) • Warning Notices/Signs/Safety Equipment (locking bars/pins etc.) attached • Appropriate Drip Trays/Spill Response Kit • Is all information in English 4. Has a current certificate of thorough examination (or EU Declaration of Conformity) been supplied/provided with the equipment (Lifting Equipment only) 5. Where equipment has been assembled on site, has a written confirmation been provided as to its fitness for use? Defects/Comments/Actions:

Signature:

Date:

Notes: 1: Where a suitable alternative has been provided, the person completing the checklist must revisit the Risk Assessment and amend controls as necessary. 2: Where lifting equipment is supplied for the lifting of persons, the thorough inspection/EU Declaration must be within 6 months of issue date.

COMPLETED FORM TO BE FILED IN PROJECT SHE REGISTER

No

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2.3.5.6 Reference Documents PROCEDURES 1

SHE PRO 001 – SHE Risk Management and Written Safe Systems of Work

2

SHE PRO 010 – The Safe Use of Cranes and other Lifting Appliances REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.4

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3

NAME

POSITION IN COMPANY

CONTACT DETAILS

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SECTION

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2.3.5.7 Author

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SHE Manager

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2.3.5.8 Approvals

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Approved by:

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NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Page 14

PLANT/WORK EQUIPMENT DETAILS Contract:

Location:

Type of plant/Equipment: Equipment Fleet or Serial No: Supplier:

Order No:

Received by:

Date:

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User (COMPANY or Sub-Contractor): CHECKLIST

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WORK EQUIPMENT

Yes

No

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1. Is the item of plant/work equipment as ordered or a suitable alternative?

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as

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2. Is the item of plant/work equipment in good condition? Are there any noticeable defects i.e. oil leaks, damaged panels, tyres, guards missing, etc? 3. Has plant/equipment been supplied with the necessary; • Operating instructions • Manufacturer’s Handbook • Completed maintenance Checklist (PPM/Service Record) • Warning Notices/Signs/Safety Equipment (locking bars/pins etc.) attached • Appropriate Drip Trays/Spill Response Kit • Is all information in English 4. Has a current certificate of thorough examination (or EU Declaration of Conformity) been supplied/provided with the equipment (Lifting Equipment only) 5. Where equipment has been assembled on site, has a written confirmation been provided as to its fitness for use? Defects/Comments/Actions:

Signature:

Date:

Notes: 1: Where a suitable alternative has been provided, the person completing the checklist must revisit the Risk Assessment and amend controls as necessary. 2: Where lifting equipment is supplied for the lifting of persons, the thorough inspection/EU Declaration must be within 6 months of issue date.

COMPLETED FORM TO BE FILED IN PROJECT SHE REGISTER

QCS 2014



Y

N

Page 15

Y

SPECIFIC REQUIREMENTS 1 Satisfactory guards provided for dangerous parts of machinery?

1 Suitable for its purpose 2 Suitable for its location

2 Other hazards minimised? 3 In a good order a) Ejection/falling of anything 4 Restricted to use by authorised personnel (if necessary)

b) Disintegration/collapse of equipment

5 Provided with instruction for use and maintenance (in Arabic & English)

c) Fire or overheating

6 Have operators been trained?

e) Hot/cold surfaces

7 Have supervisors been trained?

3 Controls satisfactory?

8 Is a maintenance log kept (plant and machinery only)

a) Stop/start

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d) Explosion of equipment or contents

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b) Emergency (over-rides others) 9 Is log kept up to date (plant and machinery only

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c) Run controls

d) Audible/visual warnings

10 Are maintenance arrangement satisfactory

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e) Clearly indicated, visible, safely positioned f) “Fail safe” g) Isolation arrangements 4 Is equipment stable? 5 Is lighting adequate? 6 Have the safety of maintenance personnel been considered? 7 Is safety information marked on the equipment 8 Are necessary warnings/warning devices on equipment? 9 If warnings not marked and necessary is there a written system of work/permit?

N

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 1


2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES..............................1

2.3.6

SAFETY, HEALTH AND ENVIRONMENTAL TRAINING FOR ALL EMPLOYEES, NEWLY ASSIGNED EMPLOYEES, PROMOTEES AND SUBCONTRACTOR PERSONNEL ...........................................................................1

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2

2.3.6.1 Responsibilities ...................................................................................................5

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2.3.6.2 Definitions ...........................................................................................................6

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2.3.6.3 Action Required To Implement This Procedure .................................................7 2.3.6.4 Guidance To This Procedure ..............................................................................9

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2.3.6.5 Reference Documents ......................................................................................10

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2.3.6.6 Author ...............................................................................................................11

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2.3.6.7 Approvals ..........................................................................................................11

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PROCESS MAP - INDUCTION FLOWCHART

Ensure project specific inductions are developed and delivered (including supervisors) 1.3, 3.2, 3.3 Attend all inductions and complete any questionnaires for project specific inductions

Ensure all their employees receive SHE Inductions, provide support to employees if i d 1.2, 3.1, 3.4

Contracts Managers and Supervisors

Contractors Employees & Site Visitors

SHE Team

Advise on content of inductions. Use Company standards as the baseline 1.4

Attend project inductions and additional; supervisors induction. Ensure evaluation of understanding 1.7, 3.2, 3.3

.

Employees

3.6, 5.2, 5.4

Attend project induction and complete questionnaire (if required) 1.7, 3.2, 3.6

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Ensure all their employees and subcontract employees attend project induction 1.4, 3.2

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Project and Site Manager

Line Manager

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3.8, 3.10

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Check training and competency certification where required

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Check understanding of content with individual(s). Take suitable action if i d 3.2,

Maintain induction, training and competence records

Monitor inductions are taking place and that required standards are being achieved 1.4

1.3, 3.8, 3.10

Provide assistance to project teams 1.4

Key:

Activity Guidance

QCS 2014


PROCESS MAP - TRAINING FLOWCHART Line Manager

Project and Site Manager

Training Co-ordinators

Employees

SHE Team

Develop and review SHE training strategy and matrix

Arrange training to meet line managers 1.5, 3.8

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Ensure all Employees have had training as defined by SHE training Strategy Matrix. Make arrangements for additional training to fill short falls (ie sickness absence)

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1.4, 3.1

ta

Attend all training within required timescales

1.2, 1.3, 3.1, 3.7, 3.9

1.6, 3.7, 3.9

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3.8, 3.9, 3.10

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Maintain training records

Key:

Activity Guidance

Monitor training is being provided in line with strategy and matrix 1.

Page 3

QCS 2014


Page 4

PURPOSE 1

The purpose of this procedure is to outline measures to be taken to ensure the provision of consistent levels of Safety, Health and Environmental inductions and training throughout all managerial levels and operations across the business, thereby ensuring that each employee receives appropriate training in safety, health and environmental matters which reflect their operational needs. None of the processes described in this procedure are intended to replace external schemes. SCOPE

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This procedure covers all COMPANY projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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1

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Page 5


Authorises this procedure LINE MANAGERS Line managers are responsible for ensuring that all staff for whom they are responsible have received the training and inductions, and that necessary standards have been attained. Should any staff for whom they are responsible fail to achieve required standards, line managers must provide appropriate support to assist employees.

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2

In addition to the above, Project and Site Managers must ensure that a suitable site specific induction programme is in place, and that necessary records are kept on site.

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3

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PROJECT/SITE MANAGERS

Safety, Health and Environmental Advisors will provide advice on the content of Safety, Health and Environmental inductions, and they will also monitor that inductions are being provided as necessary, and that standards are being achieved.

Training Co-ordinators are responsible for the co-ordination and standards of training required by this procedure. EMPLOYEES

ito

Will attend all training (including inductions) they are required to do to ensure compliance with the safety, health and environmental training strategy. Where there is a problem attending courses, this will need to be raised at the earliest opportunity, with appropriate authorisations obtained from their Line Manager and or Director.

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5

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TRAINING CO-ORDINATORS

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4

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SAFETY, HEALTH AND ENVIRONMENTAL TEAM

CONTRACTORS

7

Attend all site inductions, and ensure all sub-contract staff also attend. Only where authorised to do so, deliver COMPANY site inductions and ensure records are kept.

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Page 6

2.3.6.2 Definitions EMPLOYEES 1

For the purposes of this procedure, any person carrying out work activities for or on behalf of COMPANY, this will include agency personnel and labour, but not contractors. NEWLY ASSIGNED EMPLOYEES

2

Any employee who is new to a site/location, or new to their role.

The person within a business unit given the responsibility of co-ordinating delivery and recording of training provided to employees and, where Contractors appropriate, within the business unit.

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3

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TRAINING CO-ORDINATORS

qa

Any person who is not carrying out work activities for or on behalf of COMPANY but is visiting the project for other reasons, i.e. Client staff, Trade representatives.

Workers with the adequate:

Knowledge – Mentor or classroom gained.

(b)

Ability – Competence based assessment.

(c)

Technical Training – International Certification i.e. NEBOSH, CITB, OSHA.

(d)

Experience – Site hazard and operations awareness.

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(a)

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5

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COMPETENT OPERATIVES

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4

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VISITOR

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2.3.6.3 Action Required To Implement This Procedure 1

Refer to the Induction flowchart to ascertain who is assigned the actions required to implement this procedure. SAFETY HEALTH AND ENVIRONMENTAL TRAINING STRATEGY The Safety, Health and Environmental Team will be responsible for producing and reviewing a safety, health and environmental training strategy for the whole business. The training strategy and associated training matrix will be available on the COMPANY intranet*. This will ensure that the latest version is always available. The Safety, Health and Environmental training strategy will identify which training is to be provided to whom, and at which stage of their employment.

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THE INDUCTIONS

All newly assigned employees will receive a Safety, Health and Environmental induction. The induction format can be found on the COMPANY intranet*. In addition a location specific induction will be required to ensure all necessary safety, health and environmental information is provided.

4

Project inductions will not be given to any person who cannot provide evidence of competency relevant to their role.

5

Projects will provide a full Safety, Health and Environmental induction for everyone who will be on site, except accompanied visitors – see below. This induction must be provided before an individual is allowed to go onto the site. A standard format will be used for site inductions. This format is available on the COMPANY Intranet. Project Managers are responsible for ensuring that a site specific induction is in place and provided as required.

6

Visitors to sites, and other locations such as offices, must receive a tailored Safety, Health and Environmental induction if the full induction is not provided. This will cover important arrangements such as access and egress (including emergencies), muster point, location of first aid, etc. Visitors must be accompanied by a suitable person who has attended a full site induction. This will usually be a member of the site or contractor’s management team, but could be other designated persons by agreement with the Project or Site Manager. The induction formats are available on the COMPANY Intranet*.

7

All inductions should be interactive, and seen as an opportunity for two way communication. Where aids such as video/DVD are used these must not be used as the sole means of delivering the induction.

8

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3

Site inductions will include a short evaluation. There are two example formats one on the reverse of the Induction Record sheet (SHE-FRM-6-02 and a separate question set and * guidance which may be used is available on the COMPANY Intranet . Local project management will need to determine what action to take should any individual fail to demonstrate a good level of understanding of the project requirements, including safety critical items. This should begin with taking reasonable steps to provide some assistance which may include further explanation, assistance with language difficulties, or assistance with reading and/or writing. )

SUPERVISORS’ INDUCTIONS 9

Any person on a site who will act in a supervisory capacity must undergo a top up induction. This will identify what COMPANY will expect of them as a supervisor or manager. In particular it will cover expected standards of behaviour on site, and dealing with

QCS 2014


Page 8

instances of unsafe behaviour. A format for the supervisors’ induction is available on the COMPANY Intranet*. NEWLY ASSIGNED COMPANY EMPLOYEES Newly assigned COMPANY staff shall not commence their duties until they have: (a)

Received a copy of the Safety Health and Environmental Policy Statement and their Safety, Health and Environmental Responsibilities. If the role involves managing or supervising others they must also receive a copy of the responsibilities of those grades they will be managing or supervising. Responsibilities should be explained to them by their Line Manager.

(b)

Been informed where they can access a copy of the Safety Health and Environmental procedures, and the name of the person they should contact to explain those procedures (usually their local Safety Health and Environmental Advisor).

(c)

Received general advice

(d)

Been informed of any significant findings of risk assessments for the work they will undertake.

(e)

Received inductions as required by this procedure.

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If site based, they will also need to be informed of the Safety Health and Environmental Standards and Guidance, requirements for daily briefings and communication of safety, health and environmental matters.

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11

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10

AGENCY STAFF & DIRECT LABOUR

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Any special occupational qualifications or skills required to do the job, including any specific accredited training or evidence of competence.

(b)

Specific features of the job that may effect health and safety (e.g. work at heights, heavy manual handling operations, etc).

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(a)

Before starting work the line manager of agency staff or labour is required to check that they hold the necessary qualifications, and that they have been informed of any features identified to the agency as above.

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13

When requesting staff or labour COMPANY is required to specify to an employment agency:

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12

14

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PROVISION OF INDUCTIONS BY CONTRACTORS’ PERSONNEL

(To be read in conjunction with guidance in Section 4)

15

Only in exceptional circumstances will contractors be allowed to undertake COMPANY site induction training. Agreement of the appropriate Project Manager and Safety, Health and Environmental Team will be required.

16

Where a contractor delivers this training COMPANY will provide contractors with sufficient site specific details to enable the training to be properly conducted. The same records will be maintained as would be if COMPANY were undertaking the training, including any test results.

17

In addition to the COMPANY Induction contractors may undertake their own induction training to their own staff or sub-contractors.

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Page 9

TEMPORARY COVER 18

Whenever temporary cover is provided for a post, particularly posts with key safety, health and environmental responsibilities, the immediate Line Manager shall ensure that the person undertaking the temporary cover is fully conversant with, and inducted in, the safety, health and environmental responsibilities of their temporary position. The responsibility to ensure this training has been delivered to the temporary post holder remains with the Line Manager, even if the delivery is delegated to the outgoing post holder or another. SAFETY, HEALTH AND ENVIRONMENTAL TRAINING ARRANGEMENT Safety, health and environmental training will be arranged by the relevant Training Coordinator, who will also maintain safety, health and environmental training records. The only exception to this will be project specific site inductions which will be arranged and delivered by site personnel, with records maintained on site.

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19

See SHE-PRO-005

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20

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PLANT AND MACHINERY

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RECORDS

Records of training, including all inductions, will be maintained to provide proof of inductions and training, also these records will allow accurate planning for future training needs. Records will include evidence such as copies of certificates or tests (where they have been used) and will be maintained on site and where appropriate forwarded to the Training Co-ordinator.

22

Project Introduction to Health & Safety at Work SHE-FRM-6-02. (

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21

2.3.6.4 Guidance To This Procedure This procedure and the roles and responsibilities highlighted within it aim to ensure that a consistent and relevant level of safety, health and environmental inductions and training is provided across the business.

2

One vital element required to achieve this aim is in the delivery of the inductions, this is often one of the first contacts with personnel working on COMPANY projects/sites and as such is the opportunity to engage with people and to set out the culture required to achieve a safe environment.

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1

3

Delivery of inductions may not be an easy task for individuals to perform and to aid with this process the Safety Health and Environmental Team has produced a short training session for personnel who may be required to undertake this operation, it is then envisaged that only these personnel should carry out the inductions as far as possible. This process will then produce a standardised, consistent and comprehensive approach to inductions throughout COMPANY

4

Evaluation of understanding of the induction is useful in gauging retention of information and to highlight any areas of confusion or further clarification, an example of a format that may be utilised is form SHE-FRM-6-02 (

5

).

Clarification of understanding may also be obtained via the use of questions and answers amongst the participants both during and at the completion of an induction. For further

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Page 10

advice and clarification on the type and circumstances of use of evaluation contact the Safety, Health and Environmental Team. Following a number of incidents it has become necessary to ascertain if inductees working under the control of COMPANY have any health issues that may affect their work, such issues can include for example :

(b)

Taking medication that makes you feel drowsy

(c)

Diabetes

(d)

Epilepsy

(e)

Lone working restrictions

(f)

Issues First Aiders need to know about, etc

On the induction record sheet SHE-FRM-6-02 there is a space for this information. The completed sheet must be kept in a secure, locked location on the project and regularly reviewed so that data that is no longer relevant can be appropriately destroyed. (

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6

(a)

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2.3.6.5 Reference Documents FORMS

Project Introduction to Health & Safety at Work and Induction Evaluation SHE-FRM-6-02

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1

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DOCUMENTS

Qatar Regulatory Document (Construction) All Sections

3

Safety Health and Environmental Policy Statement & SHE Responsibilities

4

Safety Health and Environmental Standards & Guidance

5

Safety Health and Environmental Training Strategy and Matrix

6

Visitors Induction Format & Guidance

7

Site Specific Induction Format & Guidance

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2

Active Behavioural Change Induction & Guidance

9

Supervisors Induction & Guidance

10

Office Induction Format

QCS 2014


2.3.6.6 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

POSITION IN COMPANY

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SHEQ Director

SIGNATURE & DATE

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NAME

Approved by:

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2.3.6.7 Approvals

Page 11

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Page 12

Accurate completion of this form will enable us to make the necessary provisions without delay (PLEASE GIVE SITE/MOBILE CONTACT NUMBER)

Name:

Site/Dept:

Job Title:

Staff/Hourly Paid:

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Please state why the person requires training.

qa

If a specific course is required give full details below.

Fee:

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Course Title

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Course organiser

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Location of course

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Preferred dates

Signed by Trainee

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Signed by Nominating Manager

Send copies of arrangements to: Authorisation for Booking and Cheque for £

made payable to:

Approved/not approved

Date Director

.

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QCS 2014

ta

RECORD OF INDUCTION ATTENDANCE

CARRIED OUT BY(print:name)………………………………………

qa

DATE OF INDUCTION: …………………………………………

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NAME of attendee: (capitals) Mr. Mrs. Ms ……………………………………… HOME POSTCODE (First 3 digits) …………………… EMPLOYED BY (company name); : …………………………………………………………………………………………………………………………….

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OCCUPATION; ……………………………………………………………………… NUMBER OF YEARS IN OCCUPATION:………….

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EVIDENCE OF COMPETENCY HELD:…………………………………………………………………………………………………………………….

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NUMBER AND EXPIRY DATE : ……………………………………………………………………………………………………………………………..

ito

Is attendee a SUPERVISOR OR OPERATIVE (state which)……………………………………………………………………………………………………

et

Please detail below any medical condition(s) that may affect your normal day to day activity or require specialist attention or medication during your working day.

m

For example:, Taking prescribed medication may make you feel drowsy; and expose you to potential danger. If you have Diabetes or Epilepsy this may require us to implement, for example Lone Working Restrictions in case of a potential seizure. …………………………………………………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………………………………………………… SIGNATURE of attendee

……………………………………………………………………Date……………………………………………. Please be assured that any medical information you provide will be treated as confidential, securely stored and disposed of when no longer required, in accordance Company procedures. It is requested solely for the purpose of assisting COMPANY to maintain its duty of care obligations to all individuals working on our sites and will enable us to provide appropriate support as required. Induction Evaluation (please tick appropriate answer)*

.


Who can operate mobile plant on COMPANY sites?

1.

The nearest person to it when it needs to be moved

2.

Anyone with a car driving licence

3.

Page 14

Q5

What is needed to achieve Perfect Delivery?

1.

Four cornerstones completed

2.

Three out of the four cornerstones completed

Only suitably trained, certificated and appointed drivers

3.

Two out of Four as long as plan is in place to complete

4.

Anyone with 30 years experience on a building site

4.

What event the client allows

Q2

If you have any doubt about your task you should?

Q6

Who could potentially be affected if you had an accident

1

Use your best guess and carry on.

1.

Yourself

2

Don’t start work, stop and ask.

2.

Yourself and your colleagues

3

Follow what everyone else is doing.

3.

Yourself, colleagues, family, friends & anyone else connected

Q3

What mandatory P.P.E must be worn on this site?

Q7

Where should re-fuelling of plant take place

1.

Hard hat and Safety footwear

1.

Anywhere

2.

Hard hat, safety boots, hi – viz jacket, eye protection and gloves

2.

Where directed and in designated area

3.

Hard hat, ear protection and safety boots

3.

In parking area for plant

4.

Hard hat, eye protection and gloves

Q8

The COMPANY LIFE programme asks for your help by

Q4

Which of the following should be reported immediately?

1.

Being responsible for you and your workmates

1.

Accidents

2.

Challenging unsafe behaviours

2.

Environmental incidents (spills etc)

3.

Believing we can achieve an incident free environment

3.

Learning events (near misses)

4.

Going home from work in the same condition you arrived in

4.

All the above

5.

Everything mentioned above

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Answer

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Answer

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Page 15

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Q9.

As a supervisor you must

Answer

Communication is vital in helping build a good safety culture and incident free environment, should you?

1.

Ensure that job is completed at all costs

1.

Select pieces of information that apply only to your work

2.

Ensure that there are site specific risk assessments and method statements in place before job commences

2.

Communicate with all parties anything that will impact on the operation of the site

3.

Ensure that only your own personnel are working safely

3.

Not give feedback to people raising issues

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Q10.

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Additional questions to be completed by supervisors only

Answer

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*It is appreciated this type of evaluation by testing will not fit all circumstances and arrangements, ie special works or property services but some form of evaluation must take place via discussions or interactive sessions.

QCS 2014

Section 11: Health and Safety Page 1 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES............................... 1

2.3.7

CONTRACTORS INITIAL SAFETY, HEALTH AND ENVIRONMENTAL MEETING 1

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2

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2.3.7.1 Responsibilities.............................................................................................. 4 2.3.7.2 Definitions ...................................................................................................... 4

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2.3.7.3 Actions Required to Implement This Procedure ........................................... 5

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2.3.7.4 Reference Documents ................................................................................... 6

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2.3.7.5 Author ............................................................................................................ 6

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2.3.7.6 Approvals ....................................................................................................... 6

QCS 2014


Process Map Project/Site Manager

Contractor

Supervisors

SHE advisor

.

Evaluate each Contractor Scope of Works to assess Risk Rating SHE FRM 7 02 3.1

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Where the Activity Risk Rating is high, notify the SHE Advisor

Attend Contractor SHE Meeting when required

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3.1

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Arrange for Contractors and others to attend the pre-start SHE meeting

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Review the Contractors Pre-start Agenda in line with the “Creating a Safe Environment” document and record the outcome of discussions

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3.1

Monitor the site performance against the agreed record

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3.1

Address any non-compliance noted during monitoring 3.1

Key

Activity Guidance

3.1

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PURPOSE 1

The purpose of this procedure is to provide appropriate SHE information to sub-contractors and ensure a clear and common understanding in respect of contractor’s activities, obligations, responsibilities and expectations in relation to SHE matters.

SCOPE

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Authorises this procedure

PROJECT/SITE MANAGER Ensures that any initial safety meeting, as defined in the procedure, is carried out in accordance with this procedure and relevant information is communicated to interested parties.

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2

Provides advice and support in the application of this procedure.

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SHE MANAGER/ADVISER

SUPERVISOR/CONTRACTORS CO-ORDINATOR#

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To monitor any identified arrangements are adhered to and report any non-compliance to Contractor/Project Manager.

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Where they are responsible for the procurement of the contractor, they are to ensure that a copy of the Safe Delivery Document is included in the enquiry/tender documentation and that the contractor acknowledges receipt.

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QUANTITY SURVEYOR/ESTIMATOR/BUYER

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2.3.7.2 Definitions

CONTRACTOR

1

The organisation undertaking the activity or arranging for the activity to be undertaken.

HIGH RISK ACTIVITIES 2

Any work evaluated as High Risk on form SHE-FRM-7-02

ANY WORK INTERESTED PARTY 3

Any person/s who will benefit and/or need to know the information or arrangements that are defined in the outputs/actions from the initial safety meeting, detailed in this procedure.

QCS 2014


2.3.7.3 Actions Required to Implement This Procedure SCOPE OF WORK 1

TheProject/Site Manager will evaluate each contractor’s scope of work to assess the Risk rating, using form SHE-FRM-7-02.

HIGH RISK ACTIVITY The Project/Site Manager will notify SHE Adviser of any meeting taking place, for High Risk activities.

3

The SHE Advisor will attend any meeting for High Risk activities when requested to by the Project Manager.

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2

The Project/Site Manager shall ensure the Contractor is aware of site arrangements for Safety, Health and Environmental issues by holding an initial SHE meeting prior to the Contractor commencing work on site.

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SITE ARRANGEMENTS

In conjunction with the COMPANY Safe Delivery Document each item in the checklist at SHE-FRM-7-01 – Checklist for Contractor’s Initial SHE Meeting shall be covered or deleted/struck through where not applicable, and where appropriate a record of the discussion taken.

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RECORDS

On completion of the checklist it shall be stored for record purposes and distributed to all interested parties who have duties identified within the checklist detail. This, for example, could include the Contractors Site Manager, Supervisor and Safety Manager, who needs to be informed in relation to any of the arrangements/agreements.

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RECORD STORAGE

PERFORMANCE MONITORING 7

The Project Manager / Supervisor(s) / Co-ordinator(s), shall monitor the performance of the contractor against the agreements made to ensure compliance, and report on any nonconformance.

NON COMPLIANCE 8

The Project Manager will act on any Reports to ensure the non- compliance is addressed.

QCS 2014



Checklist for Contractor’s Initial SHE Meeting – (SHE-FRM-7-01)

2

Risk Evaluation form – (SHE-FRM-7-02)

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DOCUMENTS Qatar Regulatory Document (Construction) RD1.1.4 and RD1.1.8

4

Standard SHE Rules for Subcontractors

5

Contract Documents

6

CDM Evaluation Information

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2.3.7.5 Author NAME

POSITION IN COMPANY

CONTACT DETAILS

SHE Manager

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SECTION

2.3.7.6 Approvals

NAME

Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Section 11: Health and Safety Page 7 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section A

Contract:

Contract Nr.:

Venue:

Meeting Date:

Tel. Nr.

Tel. Nr.

Mobile Nr.:

Mob. Nr.:

Fax Nr.:

Fax Nr.:

e-mail:

.

Contract Address:

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Trading Address:

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Trade:

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Subcontractor Name:

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Subject to Contract The matters agreed at the pre-contract meeting, as recorded in these minutes, are not binding on the parties unless and until the issue by . …………of a Letter of Intent or Sub-Contract order. Once a Letter of Intent or Sub-Contract order is issued by …………….. the matters set out in these minutes shall be incorporated as terms and conditions of the Letter of Intent and / or Sub-Contract, as appropriate.

e-mail:

Company Representatives Present

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Subcontractor's Representatives Present Job Title

Name

Job Title

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Name

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By signing below, the Sub-Contractor’s representative is deemed to have the authority to agree to the following and hereby confirms that these minutes are a true and accurate record

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Name:

Signature:

Date

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Signature:

Name:

Is the Sub-Contractor approved within the COMPANY Pre Qualification System?:

YES

NO

Date

If NO refer to COMPANY Regional Commercial Director before proceeding with this meeting or any works

Subcontractor Staff Responsible

COMPANY Staff Responsible

Director / Principal:

Project Manager:

Manager / Supervisor:

Contract Manager

Foreman:

Foreman:

Safety Advisor

SHE Advisor:

First Aider:

First Aider:

The Sub-Contractor proposes to Sub Let the following works The prior written consent of COMPANY is a condition precedent to any sub letting or assignment of the Sub-Contract works or any part thereof. Item to be Sub Let

Company Details

QCS 2014

Section 11: Health and Safety Page 8 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section B SCHEDULE OF ATTENDANCE

CONTRACT…………………………………………..CONTRACTOR………………………………………….. Item

N/A

Provided by ………..

Contractor

Maintained By …………

Contractor

Records & Inspections By ………….. Contractor

Mechanical Plant Small tools and tackle Access Scaffold Cradles/Suspended Access Equipment Mobile Elevated Work Platforms

.

Public Protection / Fans etc

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Bandstands, hop-ups etc Safety Scaffold

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Roof edge protection

N/A

N/A

N/A

N/A

Distribution of materials

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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Unloading

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Hoist Piling mat Crane facility

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Lifting gear Offices, stores etc

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Space for offices, stores etc 1st Aid equipment

N/A

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First aid room

N/A

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Water Supply Electrical Power 110v

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Leads, spiders etc Safety Lighting

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Task Lighting Set out grid lines and levels

N/A

N/A

Clear rubbish to centre point

N/A

N/A

N/A

N/A

Clear away rubbish on a daily basis

N/A

N/A

N/A

N/A

Skips

N/A

N/A

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Set out from grid lines and levels

N/A

N/A

Protection of work in progress

N/A

N/A

Protection of work on completion Remove temporary protection (from other trades) and make good

N/A

N/A

Holes and chases (mark/cut) Signed for COMPANY

Signed for Contractor

Date:

Date:

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

QCS 2014

Section 11: Health and Safety Page 9 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section C

Scope & Definitions The purpose of the meeting is to ensure that there is a clear and common understanding as to the package contents, respective obligations, responsibilities and expectations. The term “Contractor” throughout these minutes shall mean the prospective Sub-Contractor named above, and subject to the requirements of section A the agreements reached shall apply to ALL sub-sub-contractors appointed by the sub-contractor to carry out works on his behalf. All Reference to numbered rules in this document are the rules contained ………………. Creating a Safe Environment Document, which has been issued to the subcontractor and forms part of the Sub-contract and Suppliers conditions. Matters for Discussion (Delete Where Not Applicable)

Manager / Supervisor

(b)

Forman / Foremen

(c)

Site Safety Supervisor

(d)

Temporary Works Co-ordinator

First Aiders

(g)

Emergency/Fire Marshall

(h)

Waste Controller

(i)

Scaffold Inspector

(j)


(k)

Safety Advisor / Supervisor

(l)

Services Co-ordinator

(m)

Plant Co-ordinator

(n)

Appointed Person for Cranes

(o)

Crane Supervisor/s

(p)

Induction Presenter

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(f)

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COSHH Co-ordinator

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Temporary Works Supervisor (e)

Contractor

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(a)

COMPANY

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Appointed Persons & Duty Holders The following persons were identified as carrying out the specified roles for the Contractor on this project.

.

Notes / Actions (Agreement Reached or N/A)

Where these names are not known at this time they are to be advised to ……………….. in writing not less the 2 weeks prior to commencement of the Contractors Works. Failure by the Contractor to notify by this time may delay the start of the contractors works.

QCS 2014

Section 11: Health and Safety Page 10 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section D

1

General

…………… to provide the Contractor with a copy of the Project’s Construction Phase Plan and/or specify where available on site.

Copy provided / Available in …………. site office

Health & Safety File / Operational & Maintenance Manuals / As installed Drawings The Contractor is to supply the following to be included in the CDM Safety File

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Details to be added as appropriate to the project

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All information is to be Delivered to ……………….. as specified by the Project manager and in any case within 14 days of the completion of the contractor's works, or 7 days before the practical completion date of the project which ever is the sooner. OR*

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………………… confirmed that these are not required.

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The contractor will be issued with a copy of the COMPANY Document “Creating a Safe Environment” which contains reference in the form of Rules to the topics listed below.

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The COMPANY Manager and the representative of the Contractor at this meeting will review the Creating a Safe Environment Rules and indicate:-

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1. Whether the rule applies to the contractors works , and

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2. The contractors understanding and agreement to those applicable rules.

In addition to these rules some of the topics require further site specific details to be agreed, these specifics are contained in Section E of this document and where applicable the attendees must discuss these items and reach agreement or detail the actions to be taken in the relevant sections, in order for the works to be carried out in a controlled and safe manner. Where agreement cannot be reached then the work must not proceed until persons of appropriate seniority have discussed and assigned actions to enable the works to be carried out safely and without risk.

QCS 2014

Section 11: Health and Safety Page 11 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Applicable Yes / No

Item / Rule Entry to site

Yes / No

3.0

Site Safety, Health and Environmental supervision and visits (see additional information in section E)

Yes / No

4.0

Safety, Health and Environmental training, instruction and competence (see additional information in section E)

Yes / No

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Housekeeping (see additional information in section E) Fire precautions (see additional information in section E) Personal Protective Equipment (see additional information in section E) Hazardous substances (see additional information in section E) Environmental impact Waste management (see additional information in section E) Work at height (see additional information in section E) Scaffolding and safe means of access Mobile Plant Other plant and equipment (see additional information in section E)

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

.

First aid and welfare facilities Pre-agreement as to safe work procedures (see additional information in sectio E) Permits to work (see additional information in section E)

Lifting operations and lifting equipment (including Piling)(see additional information in section E)

Yes / No

19.0

Excavations and confined spaces

Yes / No

20.0

Electrical work (see additional information in section E)

Yes / No

21.0

Noise at work

Yes / No

22.0

Asbestos

23.0

Explosives and sources of ionising radiation

Yes / No

24.0

Services and operating processes

Yes / No

25.0

Substance abuse

Yes / No

26.0

Reporting of accidents and dangerous occurrences

Yes / No

27.0

Statutory improvement, prohibition and other notices

Yes / No

28.0

Safety representatives, safety committees and worker engagement

Yes / No

29.0

Non-English speaking personnel

Yes / No

30.0

Temporary works/false work/formwork (see additional information in section E)

Yes / No

31.0

Manual Handling

Yes / No

32.0

Demolition (see additional information in section E)

Yes / No

33.0

Vehicle drivers including delivery drivers

Yes / No

34.0

Installation and commissioning of lifts

Yes / No

35.0

Working in occupied premises

Yes / No

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5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0

Yes / No

Agreement & Understanding Confirmed (9)

QCS 2014


Section E Additional Topics to be discussed in Detail and agreement reached

INSPECTIONS & AUDITS

Yes /No

THE CONTRACTOR AGREED TO UNDERTAKE REGULAR SITE SHE INSPECTIONS AT A FREQUENCY AGREED BY COMPANY.

The Contractor indicated that he would be undertaking Senior Manager SHE inspections / audits.

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The following requirements were confirmed to the Contractor

Yes / No

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The contractor will be encouraged to participate in the COMPANY VOICE consultation process and COMPANY Behavioural Change Programme which will be / is running on this project.

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The contractor and COMPANY agreed a schedule for the submission of SHE Method Statements prior to commencement of the work activity (attach schedule to these minutes)

Yes / No

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PRE-AGREEMENT AS TO SAFE WORK PROCEDURES RISK ASSESSMENT/SAFETY METHOD STATEMENT

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The following requirements were confirmed to the Contractor

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The attached Method statement review form will be used to assess the completeness of the Contractors Method statements, the contractor should ensure that all the relevant points noted on the review sheet are addressed.

7

Permit to Work

7a

The following permits will operate on this project:-

QCS 2014


8

Housekeeping & Clearance of Rubbish

8a

The storage area for the Contractors materials was agreed as.

9

Liquefied Petroleum Gases / Welding and Cutting

Yes / No

.

The contractor will be bringing LPG to site

Yes / No

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The contractor indicated he would be carrying out welding / cutting operations

Flammable Liquids and Compounds

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9b

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The location of the storage for gas bottles was agreed with COMPANY site management as

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If Yes the contractor is to provide detail

Yes / No

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Are any types of flammable liquids or compounds e.g. petrol, diesel, Solvents, mastics etc. to be brought to site by the contractor

Personal Protective Equipment

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The location of the storage for flammable liquids etc was agreed with COMPANY site management as

COMPANY will provide PPE to the contractor as a last resort but will charge the contractor at the following rates; Safety Helmets Hi Viz Vest Standard Gloves Standard Light Eye Protection Ear Protection (Muffs) Safety Boots Other (Specify)

Hazardous Substances 11

Does work involve the use of any substances that can give rise to hazards in use?

Yes / No

QCS 2014


If Yes the contractor is to provide detail 11a

11b

COMPANY provided a list of substances to Contractor that may affect his employees on site, including land contamination or biological hazards. List to be attached to this document

12

Environmental Impact

12a

Yes / No

Yes / No

Are any substances being used that may harm the environment

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If Yes Details are to attached to this document

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Are there any contaminants which may affect the Contractor’s working area? 12b

Yes / No

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If yes COMPANY are to supply details and a list is to be attached to this document

Waste Management

13a

The Contractor was informed of the locations of disposal skips & the recycling arrangements which will be adopted & the arrangements for temporary storage.

Yes / No

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Work At Height

14a

Specify any access equipment e.g. elevating platforms, MEWPS or facilities for safe working places e.g. scaffolding, edge protection to be used by the Contractor’s.

18

Piling Operation

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The Contractor supplied details and specification of the Piling Mat

Yes / No

If yes a copy is to be attached to this document

20

Electrical Work A Copy of The COMPANY Rules for Electrical Safety (RES) has been issued to the contractors as the works they are undertaking involve the provision of or connection to electrical systems or equipment

Yes / No

QCS 2014

22


Asbestos It has been identified that this project / building contains Asbestos Containing Materials (ACMs). If yes the contractor was made aware of the requirement for ALL persons who work on this Project to have suitable asbestos awarness training. NB any person not able to provide evidence will not be admitted to site.

Temporary Works / Falsework / formwork Yes / No

The contractor confirmed that he will be designing the Temporary Works and therefore will have additional duties under CDM.

Yes / No

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The Contractor confirmed that his work will require elements of temporary works.

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The contractor confirmed his appointed Temporary Works Supervisor for his works is:

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TEMPORARY WORKS DESIGN

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If the contractor has indicated that temporary works design will be included in their scope of works the following information should be provided for the design staff to be employed on this project (direct and agency) and the breakdown of relevant qualifications and experience. Employer

Discipline

Qualifications / Experience

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Yes / No

The following requirements were confirmed to the Contractor A Temporary Works Co-ordinator has been / will be appointed. The Contractor’s full co-operation is required in helping to ensure that his duties can adequately be fulfilled.

QCS 2014

Section 11: Health and Safety Page 1 Part 2.3.08: The Report and Investigation of Accidents and Incidents

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES............................... 1

2.3.8

THE REPORT AND INVESTIGATION OF ACCIDENTS AND INCIDENTS ...... 1

.

2

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2.3.8.2 Definitions ...................................................................................................... 4

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2.3.8.3 Action to Be Taken To Implement This Procedure ....................................... 5

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2.3.8.4 Appendices .................................................................................................. 12 2.3.8.5 Reference Documents ................................................................................. 20

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2.3.8.6 Author .......................................................................................................... 20

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2.3.8.7 Approvals ..................................................................................................... 20

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PROCESS MAP Project/Site Manager

Contract Manager/Director

SHE Manager/Adviser/Dept

Client/Regulatory Bodies

Human Resources

MIT

Insurers

Incident Control

Determine type and nature of incident/occurrence

1.3, 3.12

. Receive First Alert

Contact Regulators as required

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Contact Regulators as required

Tie in with any contractual reporting requirements

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Receive First Alert

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Inform all relevant parties by first alert (within 24 hours)

Provide support, as circumstances dictate

Investigation of Anon emergency procedures including consider use of company emergency telephone number and informing Company Media Representative

If appropriate obtain a copy of the F100 and distribute to relevant parties

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3.1, 3.2, 3.3

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Receive copy of F100/A

3.1, 3.2, 3.3

Receive copy of Accident Register/Book

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If appropriate, complete and forward accident book form to Regional Office

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Involvement of Comapny SHE Director, as circumstances dictates

Agree requirement for investigation and report based on outcome and/or potential 3.1, 3.2, 3.3, 3.4, 3.5

Carry out investigation, prepare report action plan and distribute as required. (Interim report to be issued within 7 days of incident)

Provide detail, if required

Provide detail, if required

3.1, 3.2, 3.3, 3.4, 3.5 Produce Monthly Returns form and send to SHE Department 3.8

Key

Activity Guidance

Log into data base

Receive information for processing

Receive copy of F100/A and Investigation Report

QCS 2014


PURPOSE 1

The purpose of this procedure is to focus on the potential of incidents, NOT just the outcome, and to assign responsibilities and establish a system for the reporting and investigation of Safety, Health or Environmental accidents/incidents, diseases, dangerous occurrences and learning events as required by both Qatar Legislation (RIDDOR) and COMPANY and client requirements.

SCOPE

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Note: Qatar Civil Defence and the Environment Ministry have responsibilities and authority in relation to the reporting of fires and environmental impacts, respectively.

QCS 2014



Authorises this procedure and decides whether an incident review is necessary. He may also delegate responsibility for chairing this review.

CONTRACTS DIRECTOR / MANAGER Provides support in the application of this procedure, assists the Major Incidents Team (MIT) in the investigation process and the production of reports.

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2

Ensures that any reporting and investigation of an incident is carried out in accordance with this procedure (and any associated client procedures), and that appropriate contact is made with the SHE Department and other interested parties

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3

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Provides advice and support in the application of this procedure, assists the Project/Site Manager and the Major Incidents Team (MIT) in the investigation process and the production of reports.

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4

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SHE ADVISER / MANAGER

To report all accidents, incidents, diseases, dangerous occurrences and learning events to the appropriate person.

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EMPLOYEE / CONTRACTOR EMPLOYEE

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2.3.8.2 Definitions

CONTRACTS MANAGER

1

Project or Office based Manager overseeing a number of projects.

PROJECT / SITE MANAGER 2

For the purposes of this procedure, Project / Site Manager may also mean Depot Manager or Office Manager.

MAJOR INCIDENT TEAM (MIT) 3

A team appointed by the Regional Managing Director to investigate all major incidents in line with the matrix in Appendix 5.

QCS 2014


RIDDOR 4

Qatar Regulatory Document (Construction) Report of Injuries, Diseases and Dangerous Occurrences

LEGAL REPRESENTATION 5

A firm of Solicitors, approved by the Company.

LEGAL PRIVILEGES

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ACCIDENT / INJURY CLASSIFICATION

ta

Classification of accidents and injuries are detailed in Appendix 2.

qa

7

.

Any report formed under request from legal representation.

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2.3.8.3 Action to Be Taken To Implement This Procedure

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REPORTING AND INVESTIGATING A MAJOR ACCIDENT/INCIDENT (FATAL ACCIDENT OR MAJOR INJURY) – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

2

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential.

3

Ensure that the scene of the accident is not interfered with. Cordon off area wherever possible (instruct line supervision accordingly).

4

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1

Contact your SHE Adviser / Manager. The SHE Adviser / Manager will inform the MIT and prior to commencing the investigation and following consultation with the SHE Manager / Director, will advise our legal representatives.

5

If an COMPANY employee is involved, notify HR Department who will arrange for notification of relatives of the person concerned as soon as possible and preferably by personal visit by someone who knows the family etc.

6

Obtain photographs of the area. (Any digital prints may be verified by date and signature.)

7

In conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form).

8

Complete the accident book entry report. (Accident Investigation Report Part 1, AIR SHEFRM-8-03)

QCS 2014

9


If appropriate : (a)

Consider also any specific client requirements.

(b)

Contact the COMPANY Emergency Media Telephone Number.

REPORTING AND INVESTIGATING A FATAL ACCIDENT OR MAJOR INJURY – SHE MANAGER /ADVISER Ensure that the Qatar Labor Ministry, Workplace Inspector has been informed. applicable ensure that the Police have been informed.

Where

11

Inform SHE Director / SHE Manager.

12

Carry out an immediate investigation of the accident in conjunction with MIT.

13

Ensure that a copy of the form F100 is completed and sent to the Labor Ministry within 10 days of the accident, or in the case of a non COMPANY employee, obtain a copy from their employee and ensure that a copy is forwarded to the COMPANY Insurer.

14

Ensure copies of any relevant reports and forms are forwarded to the SHE Department.

15

Complete an AIR Part 1 SHE-FRM-8-02 and 2 SHE-FRM-8-03 and agree distribution with the Business SHE Manager.

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10

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REPORTING AND INVESTIGATING AN OVER 3 DAY INJURY – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

17

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential.

18

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16

Investigate cause of accident, record physical evidence, and take steps to prevent recurrences.

19

Inform the SHE Department and Contracts Manager as soon as the accident becomes a possible “over 3 day reportable”.

20

In conjunction with the SHE Manager / Advisor complete Accident/Incident First Alert report form and distribute.

21

Obtain from any sub-contractor a copy of the F100.

22

Report the accident in the accident book and send a copy to the SHE Department and Insurance Broker.

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23


Agree with the SHE Manager / Adviser who will produce the investigation report and the timing of this, including any interim report if necessary.

REPORTING AND INVESTIGATING A NON RIDDOR REPORTABLE ACCIDENT (‘LOST TIME INJURY’ AND ANY OTHER PERSONAL ACCIDENT) – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

25

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential

26

Investigate cause of accident, record physical evidence and take steps to prevent recurrence.

27

Inform the SHE Department of such incidents.

28

Record and report the accident on the accident book form and send a copy to the SHE Department together with any supporting evidence/documentation.

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REPORTING AND INVESTIGATION OF AN INCIDENT/NEAR MISS/LEARNING EVENT – PROJECT / SITE MANAGER / SHE ADVISER / MANAGER Where a near miss, learning event is observed, the process detailed in SHE-PRO-016 should be followed.

30

If appropriate to the circumstances the Project / Site Manager / SHE Adviser / Manager will complete First Alert report and circulate as appropriate.

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PROCEDURES– CONTRACTORS (SUB/WORK PACKAGE), THIRD PARTIES, ETC Procedures above apply.

32

These contractors are expected to carry out their own reporting and investigation procedures but we must ensure that it is done. Where the contractor is obliged to report accidents, they shall be requested for a copy of the report to COMPANY site management who will forward to the SHE Department.

33

According to the severity or potential of the injury or the level of environmental damage the contractor may be requested to carry out a joint investigation. This will be decided in discussion with the Contractor.

34

Reporting/Investigating of Accidents to the General Public/Third Parties

35

Follow the procedure as Section 3.i to 3.iv above as appropriate to the category and ascertain the type of injury and hospital details, etc.

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ACCIDENT BOOK/REGISTER Site management shall control and verify entries made in the COMPANY accident book and ensure that copies are forwarded as soon as possible after they are made to the SHE Department.

37

All notified accidents shall be entered in the COMPANY accident book including all employees, contractors, visitors to site and accidents to members of the public.

38

Remember, some accidents, which seem minor at the time, may be important long after the particular contract is finished and hence full information becomes essential.

39

Accident books must be retained for at least three years from the date of the last entry in the book.

40

The accident book must be sent to archive at the end of the contract with the rest of the contract documents.

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The Project / Site Manager is responsible for the completion of the SHE Return and this shall be sent to the SHE Department as soon as possible after the month end but no later than the second working day of the following month.

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MONTHLY SHE RETURNS

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In the event of a reportable disease being advised by a Doctor, the Project / Site Manager must: Ensure that the SHE Department is notified.

(b)

After consultation with the SHE Adviser / Manager carry out an immediate investigation and prepare a written report with emphasis on preventing recurrence of the problem with a copy to the SHE Department.

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42

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DISEASES - PROCEDURES

(c)

After completing above, arrange with the SHE Adviser to complete and forward form F100A to the appropriate Labor Ministry Department with a copy to the SHE Department within 10 days. In the case of COMPANY employees, forward a copy to the Insurance Broker.

(d)

A disease needs to be reported only when a written statement prepared by a Registered Medical Practitioner diagnosing the disease is in line with the Qatar Regulatory Document (Construction) RIDDOR Section.

DANGEROUS OCCURRENCES (SPECIFIED BY RIDDOR) - PROCEDURES 43

If injury to person is also involved, carry out procedure under Section 3.1 to 3.4 as appropriate.

44

For all events, consult with the SHE Manager / Adviser for the full list of specified Reportable Dangerous Occurrences.

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45


All Dangerous Occurrences shall be investigated by the Site / Project Manager in conjunction with the SHE Department :

ALL DANGEROUS OCCURRENCES Do not interfere with the scene of the accident.

47

Notify the Contract Manager and SHE Department immediately and discuss whether reportable.

48

If appropriate contact the COMPANY Emergency Media Telephone Number.

49

Obtain written statements for witnesses where possible.

50

Obtain photographs of the area and record physical evidence.

51

Report accident on the form from the accident book with a copy to the Insurer.

52

Reportable Dangerous occurrences shall be reported by the SHE Department will inform the Qatar Administrative Authority. The Administrative Authority, Workplace Inspector will advise whether and when you can resume work in the area.

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In addition to the above:

The Manager, in consultation with the SHE Manager / Adviser, shall report the occurrence on First Alert report form and distribute as appropriate.

(b)

The Manager, in consultation with the SHE Manager / Adviser, to complete Form F100 and send to the Qatar Administrative Authority within 10 days.

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(a)

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DANGEROUS OCCURRENCES REPORTABLE UNDER RIDDOR

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REPORTING & INVESTIGATING ENVIRONMENTAL INCIDENTS - PROCEDURE To assist the reporting process, environmental incidents have been categorised and examples of each type of category are listed in Appendix 1 (guidance document).

55

For all environmental incidents, consult with the SHE Manager/Environmental Adviser for advice.

56

Following an environmental incident, complete the reporting requirements as detailed below : (a)

If it is a significant/serious incident then completes a First Alert form as per section 3.12 (note examples of types of environmental incidents requiring First Alert).

(b)

In addition, less serious incidents must also be recorded and reported monthly as per section 6.8, to enable COMPANY to monitor and measure environmental performance.

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(c)

Where deemed necessary, a formal Investigation report shall be completed as per section 3.13 and 3.5 in cases of Learning Events

FIRST ALERT PROCEDURES 57

COMPANY operates a ‘First Alert’ system to ensure that serious incidents are notified quickly to the relevant personnel.

58

A First Alert form should be completed for the following circumstances: Fatal accidents;

(b)

Major Injury accidents;

(c)

Over 3 Day Injury;

(d)

Dangerous Occurrences;

(e)

Following receipt of enforcement notices from any enforcing authority either by the Company or its sub-contractors;

(f)

All accidents and incidents, including those resulting in significant damage to the environment, where prosecution is likely or where substantial loss has occurred or where public attention is likely.

(g)

Significant Learning events (near misses).

(h)

Visits by a Regulatory Authority

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(a)

If however, doubt exists whether or not to send a First Alert then it should be sent. It is the responsibility of the Regional SHE Adviser / Managers to ensure the First Alert is circulated to respective COMPANY post holders. Further circulation will be agreed with the relevant SHE Managers.

60

All First Alerts shall also be copied to the COMPANY SHE Director.

61

First Alerts shall be sent as soon as possible after the accident/incident has become known to the Company and in any case WITHIN 24 HOURS.

62

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The Project/Site Manager shall contact the SHE Manager/Adviser for their site to provide support on the information required for the First Alert.

ACCIDENT/INCIDENT INVESTIGATION REPORTS 63

It is important that accidents/incidents are properly investigated by the Project Management Team to determine what has happened and any actions needed to improve performance.

64

It is of the utmost importance that actions arising from an investigation are fully closed out. This is the responsibility of the Project / Site Manager to produce a written report in conjunction with the local SHE Manager / Advisor.

65

Formal investigations will be necessary:

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(a)

for accidents/incidents reportable under RIDDOR;

(b)

where prosecution or other formal enforcement action is being taken/is considered likely;

(c)

where, although not reportable, there was potential for more serious consequences or there are wider lessons to be learned (such as near miss/learning event incidents)

(d)

Significant pollution/damage to the environment has been caused

The decision on whether to conduct a formal investigation should be taken in conjunction with the relevant SHE Manager / Advisor.

67

Reports on accident/incident investigations should be written in the format set out on the Accident/Incident Investigation Report form. (Notes for guidance for completing the AIR are also included with this form). In cases where witness reports are taken to support the investigation, these should also be included.

68

For any incident and subsequent investigation, a completed or interim report shall be issued within 7 days from the date of the incident.

69

Distribution of completed accident/incident investigation reports must include the COMPANY SHE Director. Any distribution outside COMPANY should be agreed with the SHE Director who will provide the necessary direction

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Section 11: Health and Safety Part 2.3.08: The Report and Investigation of Accidents and Incidents

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2.3.8.4 Appendices

ENVIRONMENTAL INCIDENT TYPE

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EXAMPLE

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APPENDIX 1 – GUIDANCE ON CATEGORIES OF ENVIRONMENTAL INCIDENTS

Any Spillage of Fuel / Oil / Chemicals / Soap Oil etc. <10 liters

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SPILLAGES

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Significant or major spillage which has entered a watercourse or drain Any formal investigation into complaints of nuisance

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NUISANCE I.E. NOISE, DUST, VIBRATION, ODOUR ETC.

OTHER

Category for Sustainability Reporting (SHE Dept Use Only) Non-notifiable Pollution Incident

YES YES

YES

Notifiable Pollution Incident

YES

YES


YES


Any waste materials causing a nuisance

YES


Any visible oil/silt/chemicals in controlled waters as a result of COMPANY activities

YES

Discharging to Controlled Waters or Drains without discharge consent/approval from Regulator.

YES

Any Breaches of Discharge Consent Parameters

YES

YES

Non-notifiable Pollution Incident

YES

YES


YES

YES

Notfiable Pollution Incident

YES

Environmental Managers discretion

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ECOLOGY & BUILT HERITAGE

First Alert Required?

Any letters/correspondence received from in relation to nuisance complaints/investigation

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CONTROLLED WATERS

Report in Monthly returns?

River/stream bank collapse as a result of COMPANY operations. Damage to any plant, animal (or their habitat), or building/structure that is protected under Qatar law such as Damage to any listed buildings, Scheduled & Ancient Monuments etc. Any other incident leading to damage to the environment, breach of regulation etc.

YES

YES

Non-notifiable Pollution Incident (Environmental Managers Discretion) Non-notifiable Pollution Incident (Environmental Managers Discretion)

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Appendix 2 – Accident / Injury Report Form Classifications

NO TREATMENT 1

Any incident, which results in a minor injury but requires none of the treatments noted in any other of the above categories.

FIRST AID CASE Injury that is given First Aid treatment by a First Aider, site medical centre or hospital.

3

First Aid treatment means the following:

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Cleaning, flushing or soaking wounds on the surface of the skin.

(b)

Using wound coverings such as bandages, Band-Aids, gauze pads, etc.; or using butterfly bandages or Steri-Strips, (other wound closing devices such as sutures, staples, etc., are considered medical treatment);

(c)

Using any non-rigid means of support, such as elastic bandages, wraps, non-rigid back belts, etc. (devices with rigid stays or other systems designed to immobilise parts of the body are considered medical treatment)

(d)

Using temporary immobilisation devices while transporting an accident victim (e.g., splints, slings, neck collars, back boards, etc.).

(e)

Drilling of a fingernail or toenail to relieve pressure, or draining fluid from a blister;

(f)

Using eye patches;

(g)

Removing foreign bodies from the eye using only irrigation or a cotton swab;

(h)

Removing splinters or foreign material from areas other than the eye by irrigation, tweezers, cotton swabs or other simple means;

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(a)

(i)

Using finger guards.

(j)

Administering tetanus immunisations.

MEDICAL TREATMENT CASE 4

Injury that results in a person being taken to hospital or given medical treatment by a Doctor or other Health Care Professional.

5

Medical Treatment means the management and care of a patient to combat disease or disorder including; (a)

Closing wounds using sutures or staples,

(b)

Immobilisation of parts of the body using rigid stays plaster casts etc.

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6


Medical Treatment does not include; (a)

Visits to a doctor or health care professional solely for observation or counselling;

(b)

The conducting of diagnostic procedures such as x-rays and blood tests, including the administration of prescription medications used solely for diagnostic purposes (e.g., eye drops to dilate pupils); or

(c)

“First-Aid Treatment” as defined above.

LOST TIME INCIDENT (LTI) /RESTRICTED WORK CASE Injury that results in a person missing between one and three workdays (not counting the day of the accident) from work, or injury that results in a person remaining at work but being unable to discharge their normal duties for one to three days.

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Injury not being a major injury that results in a person either missing 4 or more consecutive days from work (not counting the day of the accident) or being unable to fulfil his/her normal duties for 4 or more consecutive days, including non-working days i.e.- weekends.

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OVER 3-DAY LT OR RESTRICTED / MODIFIED CASE

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Defined injury, which requires immediate notification to Enforcing Authority under the Reporting of Injuries, Disease or Dangerous Occurrence (RIDDOR). Specifically: Any fracture, other than to the finger, thumb or toe

(b)

Any amputation

(c)

Dislocation of the shoulder, hip, knee, or spine

(d)

Loss of sight (whether temporary or permanent)

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(e)

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(a)

A chemical or hot metal burn to the eye or penetrating injury to the eye

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MAJOR INJURY

(f)

Any injury resulting from an electric shock or electric burn, leading to unconsciousness or requiring resuscitation, or admittance to hospital for more than 24 hours

(g)

Any other injury (i)

Leading to hypothermia, heat induced illness or to unconsciousness

(ii)

Requiring resuscitation

(iii)

Requiring admittance to hospital for more than 24 hours

(iv)

Loss of consciousness caused by asphyxia or by exposure to a harmful substance or biological agent

(v)

Acute illness or loss of consciousness resulting from the absorption of any substance by inhalation, ingestion or through the skin

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Section 11: Health and Safety Page 15 Part 2.3.08: The Report and Investigation of Accidents and Incidents (vi)

Acute illness which requires medical treatment where there is reason to believe that this resulted from exposure to a biological agent or its toxins or infected material.

FATALITY 10

The death of any person, whether or not they are at work, if it results from an accident arising out of or in connection with work.

LOSS OF CONSCIOUSNESS Caused by asphyxia or by exposure to a harmful substance or biological agent.

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Any injury to person who is not at work if it results from an accident arising out of or in connection with work and results in them being taken from the place where the accident happened to a hospital by whatever means.

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3RD PARTY HOSPITAL

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LEARNING EVENT

Near miss/learning events are a near miss or significant incident which could have resulted in injury or damage to property or harm to the environment.

14

Site management should openly encourage near miss/learning event reporting which is vital in creating a climate which sustains communication and co-operation to rectify unsafe situations or conditions and therefore preventing the situation or condition eventually causing harm.

15

SHE Learning Event cards have been introduced to improve the frequency of reporting and providing a feedback mechanism at the operational zone.

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DANGEROUS OCCURRENCE (DO) An occurrence, which arises out of or in connection with work and contained in RIDDOR, specifically for construction works, this would include: (a)

The collapse of overturning of, or the failure of any load bearing part of any lift, hoist, crane, derrick, MEWP, access cradle, excavator, pile-driving frame or rig (over 7m in height) or fork lift truck.

(b)

Any unintentional incident in which plant or equipment comes into contact with or causes an electrical discharge by coming into near proximity of an overhead electrical line exceeding 200 volts

(c)

Electrical short circuit or overload attended by fire or explosion and stops the plant for more than 24 hours or has the potential for death.

(d)

Collapse of: (i)

Scaffolding over 5m in height

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Section 11: Health and Safety Page 16 Part 2.3.08: The Report and Investigation of Accidents and Incidents (ii)

Scaffolding erected near to water, which could have resulted in a drowning incident

(iii)

The suspension arrangements of any slung scaffold

(e)

Incidents involving pipelines or pipeline works including unintentional escapes, damage, etc.

(f)

Collapse of: A building or structure under construction, alteration, demolition etc that involves the fall of more than 5 tonnes of material.

(ii)

Any floor or wall of a building used as a work place

(iii)

Any false work

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(i)

The escape of flammable substances, including specific quantities of liquids or gas

(h)

The escape of any substances in sufficient quantities to death or major injury or damage to health.

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(g)

Where any person suffers from any of the occupational diseases specified in RIDDOR and their work involves one of the activities noted. All instances where it is suspected that it may be necessary to report an Occupational Disease should be referred to the SHE dept.

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REPORTABLE ILL HEALTH

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ENVIRONMENTAL INCIDENT

Any unplanned event that may result in damage to the environment, enforcement action from regulators, or likely to affect or attract public attention. A number of examples of environmental incidents are included in Appendix 2.

19

Where there is any doubt as to which category the injury / occurrence should be recorded contact your local SHE department or Advisor

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Appendix 3 – Accident/Incident Reporting Matrix

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Any Accident Involving a Member of the Public

Incident Involving Verbal or Physical Abuse at the Workplace

Dangerous Occurrence or Disease

Significant Pollution Incident

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SIGNIFICANT Level 2

Accident Requiring First Aid Treatment

Minor Pollution Incident

Learning Event

MINOR Level 1

Inform SM/PM as soon as practicable.

Inform SM/PM immediately.







Inform SHE and CM immediately. Isolate/secure the scene.

Inform SHE and CM immediately.

Inform SHE and CM immediately.

Inform CM, SHE and SHEM as soon as practicable.

Inform CM and SHE as soon as practicable.

Inform CM and SHE as soon as practicable.

SM to complete all sections of Accident Register/ Book.


SM to complete First Alert report form. Limited circulation.

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Inform SM/PM immediately. Leave the accident scene untouched.

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MAJOR INCIDENT Level 3 Inform SM/PM immediately. Leave the accident scene untouched. Inform SHE and CM immediately. Isolate/secure the scene.

Pollution Incident

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MAJOR INCIDENT Level 4 Inform SM/PM immediately. Leave the accident scene untouched. Inform SHE and CM immediately. Isolate/secure the scene.

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Initial Contact

Major Injury

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LEVEL

Fatal

Accident Resulting in 3-Days or More Absence

Inform MIT immediately, RMD, EA and SHEM as soon as possible.



Inform RMD and SHEM as soon as possible by First Alert.

Inform RMD and SHEM as soon as possible by First Alert.

Inform SHE and SHEM as soon as possible.

Inform RMD and SHEM as soon as possible.

Inform RMD and SHEM as soon as possible.

Inform RMD and SHEM as part of monthly report.



Accident Register/ Book

CM/SM/PM to complete First Alert as soon as practicable.






SM to complete Dangerous Occurrence form.




SM to complete Learning Event report form.

First Alert

CM/SM/PM to complete First Alert as soon as practicable.

SM to complete all sections of Accident Register/ Book. SHE and SM

SM to complete all sections of Accident Register/ Book. Full



Full

Full

SM to complete all sections of Accident Register/ Book. SM to

SM to complete all sections of Accident Register/ Book. SM to

SM to complete Learning Event report form.

Full



Investigation


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SHE Advisor/ Manager

Review of

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investigation by MIT, EA, and Police. Prevent witness collusion.

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SHE to obtain copy from contractor or complete if COMPANY employee.

Incident Involving Verbal or Physical Abuse at the Workplace

Dangerous Occurrence or Disease

Significant Pollution Incident

SIGNIFICANT Level 2


Accident Requiring First Aid Treatment

Minor Pollution Incident

Learning Event

MINOR Level 1

to complete as detailed in Investigation Requirements. Prevent witness collusion.

investigation by SM and SHE.

investigation by SM and SHE as necessary.



inform SHE.

inform SHE.

incident by SM and SHE


SHE to complete and forward to EA as RIDDOR.




No requirement

No requirement.

No requirement.

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SHE Adviser/ Manager to obtain copy from contractor or complete if COMPANY employee.

Any Accident Involving a Member of the Public

Notes : EA 1

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F100 Report Form

MAJOR INCIDENT Level 3 investigation by MIT, EA, and Police. Prevent witness collusion.

Pollution Incident

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Requirement

MAJOR INCIDENT Level 4 investigation by MIT, EA Inspector and Police. Prevent witness collusion.

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LEVEL

Major Injury

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Fatal

Accident Resulting in 3-Days or More Absence

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= Enforcing Authority, SM = Site Management, CM = Contract Management, RMD = Regional Managing Director, MIT = Major Incidents Team, SHEM = Safety, Health & Environmental Manager

2

It is the duty of the SM to ensure that all accidents, incidents or near misses are reported as detailed above.

3

Only the Health and Safety Support Team are to complete the F100 for COMPANY employees.

4

In the event of a fatality, every assistance is to be given to the visiting authorities; however no statement should be given under caution without legal representation.

5

Any enquiries by the media should be directed to head office.

6

The level of investigation and responsible persons noted are the minimum required in some cases for significant and minor categories a higher level of the management structure may need to produce the required reports.

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APPENDIX 4 – INCIDENT POTENTIAL MATRIX AND INVESTIGATION LEVELS

Investigation Levels

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When using this matrix consider the potential outcome of the incident not the actual outcome, and use this to help decide the appropriate investigation and reporting levels. Guidance on the Environmental categories is given overleaf.

Report

Approval

Supervisor or equivalent

AIR Pt 1 only for each IP

Project Manager or SHE Adviser

N/A

SHE Adviser + Supervisor

AIR Pt 1 for each IP + AIR Pt 2

Project Manager

N/A

(MIT) SHE Manager + SHE Adviser + Project Manager or equivalent


Senior Manager, e.g. Ops Director

MD + SHE Director + Ops Director + Head of SHE

(MIT) Ops Director + SHE Director + Head of SHE


Senior Manager, e.g. Ops Director

MD + SHE Director + Ops Director + Head of SHE

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Investigation Team

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Level 2

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Level 1

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Level 3 Level 4

Incident Review Panel

NB The Managing Director will decide whether a Level 3 Incident Review is necessary and may delegate responsibility for chairing it. COMPANYS Head of SHE should be notified of all Incident Reviews and should be invited to attend at Level 4.

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2.3.8.5 Reference Documents FORMS First Alert (SHE-FRM-8-01)

2

Accident/Incident Investigation Report (AIR) Parts 1 SHE-FRM-8-02 (Accident Book) and 2 (SHE-FRM-8-03)

3

Statement of Injured Person/Witness Report Form (SHE-FRM-8-04)

4

Monthly Data Collection Form (SHE-FRM-8-05)

5

Site Investigation – Avoidance of Underground Services – (SHE-FRM-8-06)

6

Learning Event (SHE-FRM-16-01)

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REFERENCE DOCUMENTS

Qatar Regulatory Document (Construction) RD1.1.6.

8

F100

9

F100/A

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2.3.8.6 Author

NAME

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SECTION

POSITION IN COMPANY

CONTACT DETAILS

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SHE Manager

2.3.8.7 Approvals NAME

Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Information should be communicated immediately by telephone to the project SHE Advisor. The first alert to be completed by the Project Management in conjunction with SHE Dept and circulated by e-mail/letter within 24 HOURS to person identified in section 8. The information communicated should only be based on fact and not on hearsay at this initial stage of notification. Project Name

Contract Number

Project Manager

Region

Originator

Date (Please print name/title in block capitals)

INCIDENT TYPE

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1.0

Lost time Incident

Major Injury

Dangerous Occurrence

Over 3 day Injury

Enforcing Authority Visits

Improvement/Prohibition Notice

Significant Environmental Incident

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Fatal

INCIDENT DETAILS

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2.0

Significant Learning event (near miss)

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Injury to member of the public or Third Party

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Date of Incident

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Time of Incident Site Address

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Name of any injured

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Occupation of injured

Age

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Male/Female

Address of any injured

COMPANY Employee

3.0

Contractor (please specify)

Other (please specify)

FULL DETAILS OF INCIDENT (HOW IT HAPPENED) / RESULT OF ENFORCING AUTHORITY VISIT

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Section 11: Health and Safety Page 22 Part 2.3.08: The Report and Investigation of Accidents and Incidents NATURE OF INJURY / DAMAGE / LOSS / ENFORCEMENT ACTION

5.0

DETAILS OF PLANT AND OWNER / HIRER (IF RELEVANT)

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ACTION TAKEN (AS A RESULT OF THE INJURY / DAMAGE / LOSS / ENFORCEMENT ACTION)

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6.0

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4.0

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DISTRIBUTION PLEASE NOTE THE FOLLOWING REQUIREMENTS

• •

DISTRIBUTION TO PERSONNEL IN TABLE 1 IS A MANDATORY REQUIREMENT. WHERE THE INCIDENT IS A FATALITY, MAJOR INJURY, DANGEROUS OCCURENCE, OVER 3 DAY OR ENFORCEMENT NOTICE THE DISTRIBUTION MUST ALSO INCLUDE THE RELEVENT PERSONNEL IN TABLE 2. TABLE 3 SHOULD BE COMPLETED AS APPROPRIATE TO THE LEVEL OF INCIDENT AND/OR MEDIA INTEREST.

Distribution as appropriate:

Name:

.

•

TICK THE BOXES ON THE RIGHT HAND SIDE OF THE DISTRIBUTION LIST TO IDENTIFY THE ACTUAL CIRCULATION DETAILS.

Telephone

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TABLE 1 – SHE DEPARTMENT – Mandatory Distribution

E-mail

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SHE Director

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SHE Manager(s)

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SHE Team Leads

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SHE Support Team

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Head of Environment and Sustainability, if appropriate

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SHE Adviser (relevant to the project)

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TABLE 2 – SENIOR MANAGEMENT TEAM

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Managing Director

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Regional MD/ Area Director/BD Director for Retail or Airports

TABLE 3 – OTHERS HR Director/ Regional Delivery Centre HR Manager (serious accident to COMPANY/ employee only) Business Development & PR (E=MC) Others as required Insurance Department to be notified by SHE Director

Dist. 9

9 9 9 3 9

9

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Part 1(page 1 of 2)

For Office Use Only o INCIDENT N .

Instructions for use 1. This form is to be used for ALL accidents (however minor), dangerous occurrences and cases of ill health arising from work which occur at Company premises or involve Company employees, or the public 2. For detailed guidance see relevant business unit guidance 3. Use applicable parts of this form to report significant dangerous occurrences 4. ALL parts to be completed legibly and the original forward to the SHE Department IMMEDIATELY

rd

O Minor 0‐8 hours lost time

O Fatality 3 Party Hospital

O Between 1‐3 days lost time or restricted work

O Reportable Dangerous Occurrence

O More than 3 days lost time or restricted work

O Reportable Ill Health

O Major Accident

O Environmental

Incident Date: ……………………….. Incident Time: (24 hour clock)……………. Assign Shift:

Day

Night

General Location of Accident Construction Sites

Public Highway

Delivery/Storage Area

Residential Dwelling

Unloading/Loading Area

Site Perimeter/Off Site

Vehicle

Office

Welfare Area

.

Other

Car Parks

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Where on the premises did the accident occur?

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Project/Contract Name: …………………………………………………………… Project/Contract Number: …………………

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Address: ………………………………………………………………………………………………………………………………………………………………………… Site Telephone No: ……………………………………………………….. Site Fax No: ………………………………………….

qa

Description of incident: Give a brief description of what happened and details of any injuries sustained including the side

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of the body (left or right)

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Name and telephone number of hospital (where applicable): ……………………………………………………………………………………………………..

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Initial treatment received: None required

Onsite First Aid Paramedic/Ambulance Hospital A&E visit

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Date/time IP ceased work: Date: …………… Time: …… Time lost by IP as a result of the incident: ……… hours Time: ……………………….

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Date/time IP returned to work: Date: ………………………….

Details of Injured Casualty (IP) Surname: ……………………………… Forename(s): ………..……………………DOB: …………………… Sex: Male Status Contractor Employee Sub‐Contractor Employee Client Rep Member of Public

Female Other

Name of employer: …………………………………………………………… Occupation: ………………………………………………………….. Address: …………………………………………………………………………………………………………………………………………………………………………. Postcode: ………………………………………………………Contact Telephone Number: ……………………………………………………… Witnesses Name

Occupation

Employer

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Part 1(page 2 of 2) Injury nature – Select ONE only Immediate Cause Immediate Causes continued Asphyxiation/gassing Animal/Insect bite or sting Struck by falling object Asphyxiation Amputation Structural collapse Burn/Scald Contact with electricity/lighting Trapped/caught in machinery Concussion Contact with heat/cold Using non‐powered hand tools Confusion/Bruising Contact/exposure biological hazards Using powered hand tools Crush/Trap injury (specify in box) Contact with/exposure to air/water Pressure Dislocation Driving at work Existing conditions/natural causes Electric Shock Injury location – Select ONE only Explosion Effects of weather/exposure Exposure to extreme heat/cold/explosion Foreign body in nose/ear/throat Abdomen Exposure to mental stress factors Foreign of vertebral column Ankle Fractures (excl vertebral column) Exposure to noise/vibration Arm/Shoulder Ill Health Exposure to radiation (e.g. UV/nuclear) Back Ingestion Face collapse/Cave in or rock slide Chest Internal e.g. .chest/abdominal/pelvis Fall while ascending/descending Digestive System Jolt/Jar injury Falls from height Eye Falls on same level incl. trips/slips Loss of sight Face/neck Fire Finger (specify in box) Multiple injuries Hit by moving/flying objects Nerves/Spinal cord (excl bone injury) Foot Hitting/stepping on structure/object Not yet known Hand Manual handing lifting Open wound/Laceration Head Manual handling push/pull/carry Other Leg/Hip Other /not known (Specify in box) Poisoning/Toxic substance Multiple Physical assault/bullying Shock/Trauma Other (Please State) Plant/vehicle component failure Sprains/strains Respiratory System PPE Failure Superficial cuts/Abrasions Wrist Repetitive movement injury Unconscious Source of Hazard – Select ONE only Biological Agent Flying Particle Lifting Equipment Radiation Vehicle/mobile equipment Cold/Heat Hand Tool Materials Scaffold Working Surface Stairs/Steps Workstation layout Dust Hazardous Substance Moving parts of machinery Electrical Equipment Heat/Hot Work Other Static equipment/machinery Excavation Lack of Oxygen Power Tool Structure Floor/ground condition Ladder Proximity to water Temporary Works Action taken (or suggested) to prevent recurrence and to communicate lessons learnt from the incident Details of person completing the form

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Name: ………………………………………………………… Position: …………………………………………………………. Date: ………………………….

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Part 2 This form must only be used in conjunction with the accident/dangerous occurrence/case of ill health Part 1

Project: Name of Injured Person:

Date: Safety

Health

Environment

Property

To check a box above, right click on the box, click on Properties and then click onto Default Value, Checked. Click OK to finish.

Supporting Information Available 6.

8.

Insurance Report

4.

Method Statement

9.

F100/A

5.

Photographs *

10.

Construction Drawings

Occurrence/Case of ill health form

Injured Person’s Statement

12.

Witness Statement

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3.

7.

11.

13.

Other Specify

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2.

Site Sketch Accident/Dangerous

.

Risk Assessment Competency Checks Maintenance Checks (PPM)

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1.

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Previous Experience/Training Relevant Training Details

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Other, specify

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Date of Induction

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Procedures applicable to accident/incident

Date of last relevant awareness talk(s)

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Incident Details (use continuation sheet if necessary)

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(in addition to the information on the Accident/Dangerous Occurrence/Case of Ill Health form)

Immediate Causes (see A-Z of Accident Causes)

Category

Description

Category

Description

* Digital photographs must have the correct level of validation i.e. date, independent witness etc.

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Part 2 Root Causes (see A-Z of Accident Causes)

Category

Description

Category

Description

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Remedial Action (use continuation sheet if necessary)

Learning Opportunities and Responsibilities

Target Date

Close Out Date

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Action

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Person Responsible

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Toolbox Talks Safety Briefing

Review of RA Other Specify

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First Alert Safety Bulletin Safety Reminder

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Communication of Learning

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.

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Investigation Team Name

Position

Signed

Investigation Approval Name:

Position:

Signed:

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Distribution PLEASE NOTE THE FOLLOWING REQUIREMENTS

•

•

DISTRIBUTION TO PERSONNEL IN TABLE 1 IS A MANDATORY REQUIREMENT. WHERE THE INCIDENT IS A FATALITY, MAJOR INJURY, DANGEROUS OCCURENCE, OVER 3 DAY OR ENFORCEMENT NOTICE THE DISTRIBUTION MUST ALSO INCLUDE THE RELEVENT PERSONNEL IN TABLE 2. TABLE 3 SHOULD BE COMPLETED AS APPROPRIATE TO THE LEVEL OF INCIDENT AND/OR MEDIA INTEREST.

Distribution as appropriate:

Name:

.

•

TICK THE BOXES ON THE RIGHT HAND SIDE OF THE DISTRIBUTION LIST TO IDENTIFY THE ACTUAL CIRCULATION DETAILS.

Telephone

E-mail

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TABLE 1 – SHE DEPARTMENT – Mandatory Distribution

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SHE Director

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SHE Manager(s)

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SHE Team Leads

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SHE Support Team

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Head of Environment and Sustainability, if appropriate

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SHE Adviser (relevant to the project)

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TABLE 2 – SENIOR MANAGEMENT TEAM

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Managing Director

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Regional MD/ Area Director/BD Director for Retail or Airports

TABLE 3 – OTHERS HR Director/ Regional Delivery Centre HR Manager (serious accident to COMPANY/ employee only) Business Development & PR (E=MC) Others as required ( Insurance Department to be notified by SHE Director

Dist. 9

9 9 9 3 9

9

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3

Statement Witness DOB or Age: Address:

of

Name:

DD/MM/YY

Post Code:

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Employer: Occupation: Length of Employment: Relating to Accident/Incident at Date & Time:

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STATEMENT:

I confirm that the above statement is true. Signed:

Witnessed:

Name:

Name:

Date:

Date:

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Project : ……………………………………… Project No : ………………… Month : ………………. Completed By : ……………………………………... Date : ………………… AIR 1 sent ;

No of Accident Book Entries

Minor

Lost Time

>3Day

Major

COMPANY Sub-Contractor / Other Hours/Employees Av. No. Direct Employees – DAY SHIFT

Contractor Employees Hours Worked – DAY SHIFT

Av. No. Contractor Employees – DAY SHIFT

Direct Employees Hours Worked – NIGHT SHIFT

Av. No. Direct Employees – NIGHT SHIFT

Contractor Employees Hours Worked – NIGHT SHIFT

Av. No. Contractor Employees – NIGHT SHIFT

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Direct Employees Hours Worked – DAY SHIFT

Training/Inductions

No. of Persons with Skill Cards – Direct Employees

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No. of Inductions – Direct Employees

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No. of Inductions – Contractors/Others No. of Supervisors Inductions – Direct Employees

No. of Toolbox Talk Attendees – Contractors/Others

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Proactive Indicators

Yes

No

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Do you hold Employee Safety Meetings

Total No. of Toolbox Talks Undertaken No. of Toolbox Talk Attendees – Direct Employees

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No. of Supervisors Inductions – Contractors/Others

No. of Persons with Skill Cards – Contractors/Others

No. of Employee Safety Meeting

No. of Representatives

No. SHE Advisor Inspections Undertaken – Sub-Contractors

No. of Issues Raised

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No. of SHE Advisor Inspections Undertaken – COMPANY

No. of Issues Closed Out

No. of Leadership Assessments Undertaken

No. of SHE Procedural Audits Carried Out

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No. of Project SHE Inspections Undertaken (Managers/Supervisors)

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SHE Procedure Ref. No.

Environmental Indicators Electricity (Kilowatt Hours)

Fuel Oil (Litres)

Waste Generated

Gas (Kilowatt Hours)

Water (Cubic Metres)

Construction

Demolition

Excavation

Construction

Demolition

Excavation

Project Waste Generated – Inert (tonnes) Project Waste Generated – Non Hazardous (tonnes) Project Waste Generated – Hazardous (tonnes) Waste Management Project Waste to Landfill (tonnes) Project Waste Recycled Off Site (tonnes) Material Re-Used Directly on the Project (tonnes)

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To be completed by Manager/Supervisors for damages to underground services Contract Location :

Manager :

Date of Incident:

Time of Incident:

1.

Type of damage (9)

2.

Where was the damage? (9)

Electric

Gas

Telecom

Water

Service

Main

Other (please state)


State type (e.g. PE, Ductile Iron, Steel, Lead, etc) :

For electric cables / telecom / fibre optic cable (if known) Street Lighting

State voltage of electric cable (if known) (9)

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5.

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4.

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For gas/water/drainage What diameter was the main or service? 3.

Was the cable in a duct?

No

No

Power Mode

Radio Mode

Genny Mode

7.

What mode did the team use? (9)

8.

Locator No:

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Was a cable locator used prior to excavation?

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Yes

6.

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415v

Yes

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If yes, please state number of ducts…

240v

Calibration Expiry:

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What is the number of the locator and is it in calibration? Genny No: Calibration Expiry:

Yes

No

et

9.

Were trial holes dug?

Yes

No

The services had been marked i.e. crayon / spray paint / other

Yes

b)

Plans were issued

Yes

Plans were accurate and they cover the working area

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c)

10.

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Was there evidence to show :a)

No No

metres

If yes, at what depth were they dug?

Was the service … 11.

12.

13.

a)

Encased in concrete

Yes

b)

Under concrete

Yes

c)

Under tarmac

Yes

d)

Unmade ground (verge)

Yes

No No No No

What was the depth of the underground service damaged? Were there any visible features above or below ground to assist in location of service e.g. covers/boxes, etc If yes, what were they?

metres

Yes

No

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Was assistance required from utilities before excavating? 14.

Yes

No

If yes, please give details … Name Address Telephone No. Contact Name

15.

16.

What caused the damage? (9)

Mechanical Plant

Power Hand Tools

Non-Powered Hand Tools


State type (i.e. JCB 12” – Bucket, Breaker – Chisel, Shovel – Grafter, Fork, etc) :

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If the excavation was open at the time of the damage, state what measures had been taken to protect the damaged service:

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17.

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Give a brief description of how the damage occurred and sketch layout of site. (Show

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dimensions of excavation, position of damaged utility and location of relevant valve covers, boxes, manholes, metres, street lights, etc)

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18.

Was a Sub-contractor responsible?

Please detail an assessment of repair costs (i.e. time taken on job, etc)

No

£

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20.

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Yes

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19.

If yes, please give details … Name Telephone No. Address

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21.

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What steps have you taken to prevent re-occurrence? (use additional sheet if required)

Supervisors Name (Print)

Signature

Street Works Qual

Date

Project Manager’s Close Out Are you satisfied that a full investigation has been completed?

Yes

No

Yes

No

State additional actions where necessary …

Is the action to prevent reoccurrence appropriate? State additional actions where necessary …

Where appropriate state what management action has been taken.

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Manager’s Name

Signature

Street Works Qual

Date

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(Print)

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REPORT OF AN INJURY OR DANGEROUS OCCURRENCE Form F100 Filling in this form This form must be filled in by a Contractor or other responsible person.

Part A

Part C

About you 1 What is your full name?

About the injured person

2 What is your job title?

1 What is their full name?

3 What is your telephone number? postcode?

2 What is their address and

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If you are reporting a dangerous occurrence, go to Part F to describe the incident.. If more than one person was injured in the same incident, please attach the details asked for in Part C and Part D for each injured person

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About your organisation

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4 What is the name of your organisation?

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3 What is their home phone number?

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5 What is its address?

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Part B

Female? 6 What is their job title

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About the incident

4 How old are they? 5 Are they Male?

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1 On what date did the incident happen?

7 Was the injured person (tick only

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one box)

2 At what time did the incident happen?

one of your employees?

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(Please use the 24-hour clock eg 0600)

on a training scheme?

Give details:

3 Did the incident happen at the above address? Yes No

Go to question 4

on work experience?

Where did the incident happen?

Employed by someone else? Give details of the employer:

Elsewhere in your organisation – give the name, address and postcode At someone else’s premises – give the name, address and postcode In a public place – give details of Where it happened

self employed and at work? a member of the public?

Part D About the injury

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If you do not know the postcode, what is the name of the Construction Site? 1 What was the injury? (eg fracture, laceration)

4 In which department, or where on the premises, did the incident happen?

2 What part of the body was injured?

Part F

3 Was the injury (tick one box that applies) a fatality?

Describing what happened

a major injury or condition?

Give as much detail as you can: For instance

(see accompanying notes)

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remain in hospital for more than 24 hours? none of the above

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Part E

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About the kind of accident Please tick the one box that best describes what happened, then go to Part G.

ito

Contact with moving machinery or material being machined

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Hit by moving, flying or falling object

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Hit by moving vehicle Hit something fixed or stationary Injured while handling, lifting or carrying Slipped, tripped or fell on the same level Fell from height How high was the fall? Trapped by something collapsing Drowned or asphyxiated Exposed to, or in contact with, a harmful substance Exposed to fire Exposed to an explosion

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• the part played by any people

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need resuscitation?

• the events that led to the incident

qa

4 Did the injured person (tick all the boxes that apply) become unconscious?

• the name and type of any machine involved

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an injury to a member of the public which meant they had to be taken from the scene of the accident to a hospital for treatment?

• the name of any substance involved

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an injury to an employee or self-employed person which prevented them doing their normal work for more than 3 days?

metres

If it was a personal injury, give details of what the person was doing. Describe any action that has since been taken to prevent a similar incident. Use a separate piece of paper if you need to.

QCS 2014

Section 11: Health and Safety Page 37 Part 2.3.08: The Report and Investigation of Accidents and Incidents Contact with electricity or an electrical discharge

Part G Your signature

Injured by an animal Physically assaulted by a person Date

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Another kind of accident (describe it in Part F)

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Please continue on this page if necessary

QCS 2014


REPORT OF A CASE OF DISEASE Form F100A Filling in this form This form must be filled in by an employer or other responsible person.

Part B

About you

About the affected person

1 What is your full name?

1 What is their full name?

2 What is your job title?

2 What is their date of birth?

3 What is your telephone number?

3 What is their job title?

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Part A

4 Are they

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4 What is the name of your organisation?

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About your organisation

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5 What is its address?

female?

5 Is the affected person (tick one box) one of your employees? on a training scheme? Give

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details:

male?

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6 Does the affected person usually work at this address? Yes No

Go to question 7 Where do they normally work?

on work experience? employed by someone else?

Give details:

was the injury? (eg fracture, laceration)

7 What type of work does the organisation do? other? Give Details:


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Part C

Continue your description here

The disease you are reporting 1 Please give: • the name of the disease and the type of work 7

it is associated with; or

8

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• the name and number of the disease

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2 What is the date of the statement of the doctor who first diagnosed or confirmed the disease?

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3 What is the name and address of the doctor

Part E Part D Describing the work that led to the disease

Your signature Signature

Please describe any work done by the affected person which might have led to them getting the disease. If the disease is thought to have been caused by exposure to an agent at work (eg specific chemical) please say what that agent is. Give any other information which is relevant. Give your description here

Date

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Please continue on this page if necessary

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 1

2


2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES .......................... 1

2.3.9

PERSONAL PROTECTIVE EQUIPMENT (PPE) ........................................... 1

2.3.9.1 Responsibilities................................................................................................ 4

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2.3.9.2 Definitions ........................................................................................................ 4 2.3.9.3 Actions Required to Implement This Procedure ............................................. 5

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2.3.9.5 Author ............................................................................................................ 12

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2.3.9.6 Approvals ....................................................................................................... 12

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Page 2

PROCESS MAP – COMPANY DIRECT WORK Project Manager

Buyer

COSHH Co‐ordinator

SHE Dept/Competent Person

Supervisor

Operatives

Ensure PPE procedure is established 1.3

Hold until specific PPE identified by Risk Assessment 3.2

Assist in assessing suitability or any need for specialist PPE, BA equipment to be ordered

rw

Specify and order PPE in accordance with Appendix 1

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Note Light Eye protection is not suitable for all operations

3.2, 3.4

qa

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3.2, 3.4

Ensure stock is adequate and maintained

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3.5

3.16 Review this procedure and improve if appropriate

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Ensure an adequate issue and return system is implemented

et

Ensure adequate instruction ion use, replacement and maintenance of PPE

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3.16

Issue PPE and record 3.16

Monitor effectiveness of procedure. Review if required or feedback to S.H&E Dept 1.3

Use/wear PPE as detailed by Risk Assessment/Method Statement. Provide feedback on effectiveness Monitor compliance of working practices of operatives against procedure 1.5, 1.6

1.8

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Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish an adequate system is in place for the selection, storage, issue and maintenance of Personal Protective Equipment (PPE).

SCOPE

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This procedure covers all COMPANY projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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1

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Page 4


Authorises this procedure. MANAGING DIRECTOR

2

Agrees and communicates PPE requirements for their area of responsibility and sets the appropriate delegated authority to allow sign off of ‘exceptional’ risk assessments for any deviation of the mandatory PPE requirements set out in this procedure.

Ensures that works are carried out in accordance with this procedure and arrangements are monitored.

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3

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Ensures that PPE is ordered in accordance with the specifications set out in this procedure.

qa

4

ta

BUYER

SUPERVISOR

as

Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures the controls are in place that are required by this procedure.

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5


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6

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SHE ADVISER

Person identified as being competent to undertake a risk assessment in relation to the activity being undertaken.

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COMPETENT PERSON

OPERATIVE/CONTRACTORS EMPLOYEES

8

To comply and co-operate with COMPANY/Employer in respect of this and any associated procedure and requirements therein.

2.3.9.2 Definitions PERSONAL PROTECTIVE EQUIPMENT 1

“Personal Protective equipment” (PPE) means all equipment which is intended to be worn or held by a person at work and which protects them against one or more risks to their health and safety, and any addition or accessory designed to meet that objective. Items such as fluorescent yellow waistcoats, safety harnesses etc are PPE as defined. Ordinary working clothes and uniform not specifically provided to protect the wearer’s health and safety are not PPE.

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Page 5

SUITABLE 2

“Suitable” means it is appropriate for the risk, user friendly, correctly fitted, effective and complies with design and manufacturing standards. OVERLAPPING REQUIREMENTS

3

N/A RESUME OF THE REQUIREMENTS

(b)

The PPE is suitable.

(c)

If two different types of PPE are worn, they do not adversely affect each other’s performance against the risk (i.e. they are compatible).

(d)

PPE is maintained (including replaced or cleaned), in efficient working order and in good repair.

(e)

Appropriate storage and accommodation is provided for PPE when not in use.

(f)

Employees are provided with adequate information, instruction and training about the use of the PPE, its limitations, the risk(s) it guards against and how to maintain it in efficient working order. Such information should be easily understood.

(g)

That PPE is properly used.

se

The required employees are to:-

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PPE is provided but only as a “LAST RESORT” for employees exposed to a risk of health or safety whilst at work.

(a)

Use the PPE provided to them in accordance with any training and instruction given

(b)

Return the PPE to any accommodation provided for it after use

Report any loss of or obvious defect in the PPE to their employer.

ito

6

(a)

er

5

The required employers to ensure that:

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2.3.9.3 Actions Required to Implement This Procedure

1

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PERSONAL PROTECTIVE EQUIPMENT

Places responsibilities on employers to provide suitable personal protective equipment to their employees whilst at work. There is a similar duty for the self employed. RISK ASSESSMENT

2

Prior to the selection of any Personal Protective Equipment (PPE) a risk assessment shall be carried out to identify the relevant PPE, proportionate to the risk involved. Any assessment should also take into consideration any overlapping requirements.

3

Refer to SHE-PRO-001 to assist with this process. The risk assessment shall also consider the requirements for specialist PPE, such as Breathing Apparatus. Further advice in this area can be sought from your local SHE Dept.

4

A guide to the standards required for common PPE is in Appendix 1.

5

The List at Appendix 1 covers:(a)

Type of protection

QCS 2014


(b)

Potential Health and Safety effects if not worn

(c)

Typical hazards

(d)

Relevant BS/EN

Page 6

CONTINUOUS ASSESSMENT COMPANY promotes the continual assessment of PPE in terms of fit for purpose and suitability and the users feedback on its effectiveness, comfort and compatibility should be encouraged by the relevant project management.

7

Any feedback on its effectiveness should then be reported to the SHE Department. This could then allow for items/types of PPE to be added to the approved list. Purchase of such unlisted PPE should initially not take place until there has been consultation with the SHE Department.

.

6

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When considering the type of PPE, ie gloves, respirators, foot protection etc. further information is available on the MSDS sheets as detailed in SHE-PRO-02. Information can be obtained through the COSHH Co-ordinator.

ta

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CONSIDERING TYPE OF PPE

A stock of the appropriate PPE shall be available on site. This will be dependent on the contractual requirements (i.e. stipulated by clients) or as a result of risk assessment.

as

9

qa

STOCK OF PPE

er

The main types of protection that are in regular use with COMPANY are: Eye protection

(b)

Head protection

(c)

Hearing protection

(d)

Respiratory protection

(e)

Foot protection

(f)

Hand protection

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(a)

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TYPES OF PPE

MANDATORY PPE

11

COMPANY has a requirement in place for the mandatory wearing of the following items of PPE on all its projects: (a)

Head protection

(b)

Foot protection

(c)

Hand protection

(d)

Eye Protection

12

In addition where there are plant movements, Hi-Vis clothing must be worn in areas designated by the Project/Site Manager.

13

Mandatory requirements will be included in the Site Rules and communicated at Induction.

14

In exceptional circumstances an approved risk assessment may be undertaken to allow for deviation from the mandated PPE requirements. This would be at Director level.

QCS 2014


Page 7

EYE PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS) 15

Particular operations may require the use of either glasses, goggles or full face masks etc. The SHE Department shall be contacted and will advise on the type required.

16

It is also critical that suitable and sufficient risk assessments identify the correct type of eye protection to ensure that Light Eye Protection (LEP) is not used in place of the eye protection that may be required, e.g. grinding or cutting operations where goggles would be required and not LEP.

17

It is COMPANY policy to issue prescription safety glasses to COMPANY employees when applicable. Anyone who considers they need prescription safety glasses should contact the local SHE Manager/Advisor who will advise on the process to be followed.

.

HEAD PROTECTION (SEE ALSO 3.7 – MANDATORY REQUIREMENTS) Safety helmets are only designed to last for 3 years and this figure may reduce dependent on the use, environment, storage arrangements etc., for example helmets must not be stored in direct sunlight as the sun rays degrade the plastic (e.g. if stored on the rear shelf of a car). Safety Helmets should be subject to regular inspection by the user, to determine their suitability for use up to the 3 year maximum.

19

To identify the “age” of a helmet there is identification on the underside of a helmet (usually under the peak), it is usually a stamped circular disc containing a number surrounded by 4 or 12 segments. The number represents the year of the helmet shell moulding and each segment containing a dot defines the month of the year. A shell marked with six dots surrounding a number 98 would represent a shell that was moulded in June of 1998. Some manufactures use different methods, reference should be made to the manufacturer’s guidance

20

Markings on the Helmet

21

Every helmet claimed to comply with the requirements of European Standard BS EN 397, shall carry a moulded or impressed marking giving the following information :

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number of European Standard BS EN 397

(b)

name or identification mark of the manufacturer

(c)

year and quarter of manufacture

(d)

type of helmet (manufacturer’s designation). This shall be marked on

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both the shell and the harness

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(e)

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(a)

(f)

size or size range (in centimetres). This shall be marked on both the shell

(g)

and the harness

(h)

abbreviation for the material of the shell in accordance with ISO 472 (eg ABS, PC, HDPE etc)

HEARING PROTECTION 22

There are two basic types of ear defender used in construction; they are ear plugs and ear muffs. It is also possible to purchase more specialist type such as ear muffs with in built communication systems.

23

Both plugs and muffs give good attenuation and comfort, although ear muffs give better protection at frequency ranges HZ 1000-8000 e.g. high impact noise, hilti, piling hammers.

24

In some extreme cases it may be required to give double protection, ie muffs and plugs. In all cases the requirement is for assessment of noise and the selection of the most suitable

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type of defender. Consultation with the SHE Department will help you choose the most suitable type. 25

There may also be operational constraints on the type of protection, for example plugs should not be the automatic choice if working with contaminated land and should definitely not be used when working in compressed air.

26

If there are medical reasons why a person cannot use certain types of protection then this should only be agreed to after a letter has been received from a doctor. RESPIRATORY PROTECTION Respiratory Protective Equipment (RPE), as with any other form of PPE, should be considered as a method of last resort in preventing or reducing exposure.

28

Before ordering RPE there must be prior consultation with the SHE Department who will assist you in assessing the risks and advise on the type of RPE to purchase/use.

29

RPE includes a very wide range of devices, from disposable filtration masks to self contained Breathing Apparatus (BA). Therefore choosing the right type of RPE is essential. Please refer to COSHH procedure for information on face fitting or RPE.

30

In the case of BA, please refer to your local SHE Department for advice.

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FOOT PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS) The type of foot protection will depend on the particular circumstances and the identified types produced by means of assessing the risk. This includes the frequency of exposure and the likely severity of the injury.

32

The type and style is detailed at Appendix 1 and it should be recognised that in some circumstances personnel may be eligible for more than one type, e.g. when working in both dry and wet conditions.

33

As a minimum the protection afforded should be steel toe cap and mid sole protection.

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Gloves must be carefully selected so as to be fit for purpose, taking into account use, comfort, dexterity, temperature protection and grip.

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HAND PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS)

The general requirements of any glove must include:

(a)

Fit for purposes

(b)

Construction

(c)

Sizing

(d)

Storage requirements

(e)

Breakthrough properties

36

For whatever glove is being used on site, both product and technical information should be available.

37

Consultation with the SHE Department will provide further advice on type/selection. Where gloves are required to prevent a health risk, they will be selected as part of the COSHH assessment.

38

NB:

For further details on all the above protection see Appendix 1.

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MINIMUM DRESS STANDARDS 39

The minimum acceptable dress on site when working is: (a)

Long Trousers (Waist to ankle. Shorts & ¾ length are not permitted)

(b)

Shirt, T Shirt, Polo Shirt, wearing of short sleeves may also have restrictions in terms of COSHH assessment requirements such as protection against irritants etc – Long sleeves preferred ( Vest, singlets are not permitted

(c)

Safety helmet

(d)

Safety footwear

CE MARKING All PPE manufactured and imported from the European Union should have CE marking indicating its conformity with the PPE directive. Items referred to within this document conform to the CE standard marking and site management will check compliance.

41

NB: NUISANCE DUST MASKS (mask or gauze pad) do not conform to the European Standard EN149 and are not CE marked. Therefore they are not classified as protective equipment and SHALL NOT be used on site.

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ISSUE AND USE

The COMPANY Personal Record/Issue Card logs shall be completed for the issue of protective equipment/clothing to confirm receipt by employees.

43

All PPE issued to COMPANY employees is issued/replaced free of charge .

44

Abuse or non use of PPE supplied is a disciplinary offence.

45

In addition to the issue of equipment the project manager shall ensure that there are procedures in place for the replacement, maintenance, means of reporting defects, storage and, if appropriate, return of PPE when not in use.

46

Where relevant adequate information, instruction and training proportionate to the risk shall be provided. This may range from instruction on how to fit and fit test RPE through to the mandatory legal requirement for training in the use of BA.

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47

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SUPPLIERS

Suppliers quoted within these procedures have no prior arrangements or contractual agreements and all purchases shall be made in accordance with COMPANY Procurement Procedures. CONTRACTORS, VISITORS AND LABOUR AGENCY PERSONNEL CONTRACTORS

48

It is a condition of contract that all contractors provide PPE to the appropriate BS/EN as required, and also be of the type identified by the Project or the contractors’ risk assessment.

49

The type identified for the Project will, where appropriate, be discussed at the initial safety meeting.

50

If the contractors do not supply the relevant PPE then COMPANY will supply the PPE and charge the contractor at cost, plus handling fee.

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LABOUR AGENCY PERSONNEL

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Labour agencies are required by COMPANY contract conditions to ensure the personnel they supply to COMPANY possess the relevant PPE. Visitors shall comply with the directions of the Project Manager.

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APPENDIX 1 - PPE PURCHASE LIST Type of Protection

Relevant BS/EN

Typical Hazards • • • • • • • • •

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BS 2092 BS EN 166 349B

• • • •

Falling objects Striking objects Sunlight UVA & B Restricted view

• • • • •

High noise levels Low frequency noise levels Mid frequency noise levels High frequency noise levels High impact noise levels

EN 352-1 EN 352-2 EN 352-3

• • • • • • • • • • •

Harmful dusts Inhalable dusts Respirable dusts Toxic dusts Gases Liquids or solids Micro biological Vapours Fumes Mists Oxygen deficiency

EN149 Pr EN 140 En 405

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EN 397

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Respiratory Protection Potential Health & Safety effects if protection not worn:• Upper tract respiratory problems ie rhinitis • Lower tract respiratory problems ie asthma, bronchitis • Toxic poisoning (various health effects) • Viral infections • Asphyxiation

Chemicals Liquids Gases Molten metal Hot solids Short circuit electrical Direct sunlight Laser beams Airbourne dust (large and small particles) Flying particles (high and low velocities)

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Eye Protection Potential Health & Safety effects if protection not worn:• Blindness • Eye injuries (various) • Cataracts • Headaches • Restricted vision • Eye strain • Arc eye Head Protection Potential Health & Safety effects if protection not worn:• Head injuries • Sunburn • Cuts, bruises • Fractures • Concussion • Unconsciousness Hearing Protection Potential Health & Safety effects if protection not worn. • Hearing damage • Noise induced hearing loss • Tinnitus • Increased stress levels • Communication problems

• • • • • • • • •

Falling objects Sharp objects Piercing objects Cements Oils Contaminated land Chemicals Water/mud Uneven ground

BS EN 345 and 346

Hand Protection Potential Health & Safety effects if protection not worn:• Hand injuries general • Cuts/lacerations • Dermatitis • Burns • Poor dexterity and grip (i.e. due to cold weather)

• • • • • • • • • •

Sharp objects Abrasives Chemicals Oils Cement Wood Lack of dexterity Cold/ Heat Weather Water

EN 420

High Visibility Clothing Potential Health & Safety effects if protection not worn:• Bruising • Fractures • Concussion • Unconsciousness • Death

• • •

Cars Mobile Equipment Heavy Equipment

EN 471 Class 3

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Foot Protection Potential Health & Safety effects if protection not worn:• Foot injuries/amputation • Burns • Dermatitis • Biological infection • Blood poisoning • Sprains & strains • Fractures • Bruising • Cuts

Notes: 1) 2)

This list must be read in conjunction with any relevant company procedure. When in doubt the SHE Department must be consulted to assist in any assessment or alternative PPE.

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N/A

REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.3 and RD 1.4

3

Safety, Health and Environmental Risk Management and Written Safe Systems of Work – (SHE-PRO-001)

4

COSHH - (SHE-PRO-002)

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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2.3.9.5 Author

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SHE Manager

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2.3.9.6 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ......................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ..................................1

2.3.10 THE SAFE USE OF CRANES & OTHER LIFTING APPLIANCES (EXCAVATORS, TELE HANDLERS AND LORRY LOADERS) ...........................1

.

2.3.10.1 Responsibilities .............................................................................................. 4

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2.3.10.2 Definitions ....................................................................................................... 5

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2.3.10.3 Action Required To Implement This Procedure ............................................. 6 2.3.10.4 Application of Procedures to Cranes under the Control of Contractors ........ 8

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2.3.10.5 Guidance To This Procedure ......................................................................... 9

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2.3.10.6 Reference Documents ................................................................................. 13 2.3.10.7 Author ........................................................................................................... 14

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2.3.10.8 Approvals ..................................................................................................... 14

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Process Map Project Manager/Contractor

Ensure all those involved in planning, recording, permitting and carrying out lifting operations are competent. Ensure adequate arrangements are put in place, including for 1.2, 3.2, 3.8

Appointed Person

Specialist Contractor/Crane Supplier

Lift Supervisor

Ensure lifting equipment and accessories are suitable for the task and have adequate strength and stable in use 3.1, 3.9, Appendices 1 & 2

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All crane lifts must have an appropriate Lift Plan prepared by a qualified

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1.3, 3.3, 3.7, 3.9, Appendix 1

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Appointed Person assesses lifts and classifies as either standard or complex

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1.3

Classified complex lift due to nature of lift i.e. location, tandem lift, unusual load, high risk i 2.2

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Standard lift classified as crane lift with no extraordinary hazard

Appointed person interfaces with specialists engineers, designers, temporary works co-ordinators to assess options and limitations

Company supply relevant information and agree with specialist crane company the parameter for a complex lift 3.6

In cases of tower cranes, specialist advice on selection and type of crane is required taking into account site conditions, access, foundations and 3.5, 3.7

1.2

Appointed person prepares, reviews Lift Plan and ensures permits in place. NB additional permit required for multi positions 1.2, 3.3

Key

Activity Guidance

Slinger/Signaller & Operators

Tower crane thoroughly examined before use and lifting schedule in place 3.7

Crane lift supervisor made aware of operational requirements including any 1.4, 3.1, 3.9, Appendix 1

Slinger,/Signaller and operator(s) made aware of operational requirements including any restrictions 1.5, 1.6, 3.1, 3.4, 3.9, Appendix 1

Crane Lift Supervisor to inform appointed person of situation or 1.4

Stop and inform of any abnormal situations or changes in work practice from agreed method or sequence 1.6

Page 2

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PURPOSE 1

The purpose of this procedure is to ensure the correct selection, safe use and maintenance of all lifting equipment and lifting accessories as prescribed in the Lifting Operations and Lifting Equipment (LOLER) section of the Qatar Regulatory Document (Construction). SCOPE

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2.3.10.1 Responsibilities 1

The following duty holders must be appointed for all crane operations in accordance with current guidance and their responsibilities are detailed below : SHE DIRECTOR

1

Authorises this procedure PROJECT/SITE MANAGER Their responsibilities are as follows: Ensure this procedure is implemented for all types of lifts.

(b)

Ensure appropriate measures are in place for the control of change for risk assessment/method statements.

(c)

Ensure the COMPANY nominate an authorised person to sign off Crane Permit to Lift.

(d)

Ensure all persons involved in the planning and carrying out of lifting operations are competent.

(e)

Ensure a COMPANY person is appointed to co-ordinate the relevant plans, permits, forms and associated paperwork for the COMPANY filing system.

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(a)

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The Appointed Person will ensure that :

The assessment and planning of lifting operations is undertaken and complies with the requirements of the COMPANY lifting operations procedure.

(b)

The Crane Team is appointed and all are made aware of authorities and responsibilities.

(c)

There is an effective line of communication back to him in the event he is not present at the lift.

(d)

Close liaison is maintained with the technical crane suppliers throughout the installation, operational and dismantling phases of tower cranes.

(e)

Lifting operations are reviewed following advice from the Crane/Lift Supervisor/Signaller/Slinger on any matters of change in arrangements, and that the Permit to Lift and Risk Assessment are amended accordingly.

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APPOINTED PERSON (LIFTING OPERATIONS)

LIFT SUPERVISOR 4

The Lift Supervisor will : (a)

Act as a key member of the Crane Team and report to the Appointed Person as leader of that team, including details of any change in activities or arrangements.

(b)

Ensure that the Slingers/Signallers, the Crane Operator and any other person involved in the lift are familiar with and follow the safe system of work and the details and limitations recorded in the lifting plan.

(c)

Ensure that Tower Crane Operators’ working hours do not exceed the operating criteria.

(d)

Ensure that Crane Operators are suitably trained and competent.

(e)

Ensure the safe working load (SWL) is never exceeded, other than for the express purpose of testing a crane under the supervision of a competent person. There are no exceptions to this.

(f)

Ensure cranes do not operate in any weather conditions that exceed the limit stated for that type of crane.

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(g)

Ensure that man-riding is never carried out unless it is part of the agreed safe system of work.

(h)

Ensure grab work, demolition balling or pile driving are only performed by machines specially adapted and intended for these purposes.

SLINGER/SIGNALLER The Slinger/Signaller will : Read, understand and comply with the lifting plan and take instruction from the Lift Supervisor.

(b)

Establish weights, balance loads and judge distances, heights and clearances.

(c)

Select the correct lifting gear in suitable condition for the loads to be lifted, reporting any defects where necessary.

(d)

Adopt correct slinging techniques.

(e)

Give precise and clear instructions to the Lifting Equipment Operator.

(f)

Initiate and direct the safe movement of the crane and load.

(g)

Signallers shall be identified on site by their orange hi-vis tabards and/or orange helmets.

(h)

Stop operations if any changes to the agreed method are undertaken or required.

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OPERATORS

Ensure they are in possession of and have been briefed on the Permit to Lift and have signed the relevant section.

7

Position the crane, as instructed, in accordance with the Permit to Lift.

8

Operate in accordance with the Permit to Lift.

9

Inform the Lift Supervisor/Signaller/Slinger if any problems arise which would affect the lifting operation.

10

Operate the crane in accordance with the crane’s operating instructions.

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2.3.10.2 Definitions

STANDARD LIFT 1

Any lift using lifting equipment. 2.2

Complex Lift

2

A lift where the lifting operation requires more than one crane to lift the load, or cranes using load enhancement attachments (super lift etc), or the lift is to take place at a location with exceptional hazards, e.g. chemical plant or lifting loads on or near live equipment, including Rail Infrastructure. CONTRACT LIFT

3

COMPANY may enter into a contract with a third party (usually a crane hire company) who will undertake the work on its behalf. Before entering into such a contract, COMPANY has a duty to satisfy itself that the third party has the necessary competence to carry out the work in accordance with the requirements of BS 7121.

4

In a Contract Lift the crane hire company will plan the lift, select a suitable crane, specify the slinging and signalling arrangements, supervise the lift and be responsible for the lifting operation.

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CRANE HIRE ARRANGEMENTS 5

In a crane hire arrangement (including tower cranes), the crane and operator will work to the client’s instructions. Under this arrangement, COMPANY will plan the lift and specify the slinging and signalling arrangements, supervise the lift and be responsible for the lifting operation. LIFTING EQUIPMENT Lifting equipment means work equipment used to lift or lower loads (cranes, hoists, tele handlers, vehicle mounted lifting arms i.e. ‘Hiab’ etc) and includes the attachments for the anchoring, fixing or supporting of lifting equipment.

7

Should an excavator be used for lifting materials, other than for excavated material or fill, then by definition it becomes lifting equipment (eg. an excavator used to lift and lower a manhole section in position).

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Lifting accessories are items of work equipment used to attach loads to lifting equipment, eg. chains, shackles, strops, slings, eye-bolts, spreader beams, etc.

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LIFTING ACCESSORIES

2.3.10.3 Action Required To Implement This Procedure

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Lifting operations if not properly planned, managed and executed can result in accidents, serious incidents or fatalities.

The Lifting Operations and Lifting Equipment requires the appointment of Duty Holders to ensure: All lifting operations are properly planned, managed and executed.

(b)

Those involved in lifting operations are competent.

(c)

All crane lifts must be planned and approved by an Appointed Person.

(d)

The risks from lifting operations are assessed and lifting equipment and lifting accessories selected and used are suitable for the task. When in use, the equipment must be stable and the safe working load of equipment and accessories MUST NEVER be exceeded.

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(e)

Lifting equipment is inspected, maintained and thoroughly examined as required.

(f)

Lifting accessories (eg. chains, shackles, strops) are thoroughly examined every 6 months.

(g)

Any lifting accessory found not to have a current test certificate should be taken out of service immediately and be quarantined and clearly marked for re-testing or disposal.

(h)

Any defects found must be reported to the person in control of the lifting operation immediately so that appropriate action can be taken to repair or replace the equipment or otherwise ensure that potential dangerous equipment is withdrawn from use as soon as possible.

(i)

The safe working load must be marked on the lifting equipment. Where the configuration of the lifting equipment can be altered, affecting the safe working load, there must be adequate information to determine the safe working load in the different configurations.

(j)

Lifting equipment and accessories that are used for lifting persons must be marked to indicate this fact.

(k)

Consider the positioning and installation of lifting equipment, site conditions for proximity hazards, eg. overhead cables, space availability, and suitability of the ground or foundations eg. for outriggers in consultation with the manufacturer’s information.

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(l)

Ensure that there is a plan in place that also considers a safe system of work to prevent persons being trapped, eg. physical barriers to prevent access to restricted areas. Refer to theTemporary Works Co-ordinator if necessary.

(m)

The COMPANY Regional SHE Adviser is advised in advance, of any intention to carry out man-riding. (See also Appendix 1 – General Rules for the Use of Cranes).

(n)

Where there is more than one Appointed Person allocated to a project, then appropriate communications to co-ordinate any interfaces should be put in place and a ‘lead appointed person’ nominated.

3

See also:

Appendix 1 – General Rules for the Use of Cranes.

4

Appendix 2 – Table of examinations and inspections. LIFTS OTHER THAN CRANE LIFTS

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Other than crane lifts, numerous operations fall under the category of lifting operations as per the Lifting Operations and Lifting Equipment (LOLER). These may include : Fork Lift Trucks

(b)

Excavators (used as lifting devices).

(c)

Hoists & material lifting equipment (all types).

(d)

Hiab (or vehicle mounted lifting arm) operations. See SHE-FRM-10-06

(e)

Scaffold Pulley Wheels (Gin Wheels).

(f)

Working platforms i.e. MEWP’s, Mast Climbers

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(a)

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For lifting appliances other than cranes or Hiab, the checklist in form SHEFRM-10-05 should be considered.

7

Where the above does not cover the type of lift or equipment involved, the person managing the lift should consult with the manufacturer, supplier or a member of the SHE team to establish and record a safe system of work. CRANE LIFTS

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A Lift Plan must be received from the Appointed Person responsible for a Contract Lift carried out by a third party. Note: Tthe lift plan must include a detailed layout plan.

9

All lifting plans must be verified using the ‘Control of Lifting Operations – Permit to Lift Checklist’ to ensure all associated documents are included and authorised by the Appointed Person.

10

Once these checks are signed off the ‘Control of Lifting Operations – Permit to Lift’ can then be issued by the nominated person to authorise commencement of lifting operations. Note that in cases where the crane moves location (multiple crane position) around site then the Permit must be used for multiple positions (SHE-FRM-10-02).

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SLINGING PLANS 11

During standard lifting operations, the following slinging plan shall be followed by the Signaller/Slinger as part of their duties : (a)

Assess the weight of the load.

(b)

Choose the correct lifting equipment and control the lifting operation.

(c)

Ensuring lifting equipment is fit for use by carrying out pre-use checks.

(d)

Ensure that any physical controls ie. barriers are in place and nonessential personnel are kept out of the immediate working area of the operation.

(e)

Check the anticipated path of the load.

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(f)

Prepare a place to set down the load.

(g)

Fit the lifting equipment to the load together with tag lines as necessary.

(h)

Make the lift (a trial lift may be necessary to establish centre of gravity).

(i)

Release the lifting equipment after the lift has been completed.

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12

Clear up.

13

Where appropriate, return lifting equipment to a suitable secure storage location.

14

Be familiar with any appropriate communication arrangements, documentation or operational requirements such as risk assessments, method statements or Permit to Lifts.

2.3.10.4 Application of Procedures to Cranes under the Control of Contractors When contractors provide cranes for their own use and operate them under their own control, then the principles of this procedure shall apply, however COMPANY will retain permit control.

2

These requirements shall be discussed at the initial safety meeting with contractors. It shall be agreed at that meeting:

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When a method statement is required from the Contractor.

(b)

Who the Contractor has nominated as his competent Appointed Person.

(c)

The Contractor’s Appointed Person shall prepare a Crane Lift Plan (it will be necessary for ourselves to provide details of the ground conditions). COMPANY shall complete the Permit to Lift Checklist and Permit to Lift.

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SPECIAL OR COMPLEX LIFTS

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(a)

Special lifts include Tandem, Complex, Floating Lifts etc. Additional advice must be sought from the SHE team during the planning of such lifting operations.

4

Where possible this should be arranged as a contract lift.

5

Certain crane applications, such as handling temporary pile casings or piling hammers/extractors can be controlled by a trained Signaller/Slinger provided that a detailed risk assessment/method statement has been produced by the Appointed Person, and it is worked to, and the Signaller/Slinger has been specifically instructed in its application.

6

Complex lifts may be common and repetitive during piling operation ie. Tandem Lifts, Diaphragm Walls, Topping and Tailing Loads etc. Where it has been identified by the Appointed Person that this is the case, the Appointed Person shall be in attendance for the duration of the first lift. Once satisfied the Lifting Operation, Risk Assessment and Method Statement are correct they may delegate their supervisory duties to the Crane/Lift Supervisor for the remainder of the operation. Thereafter the Appointed Person will be required to monitor the lifting operation at intervals agreed with the Project Manager. Where changes to lifting operation, Risk Assessment/Method Statement are required, the Appointed Persons must be notified immediately and shall review and revise the lifting operation, Risk Assessment/Method Statement for the duration of the lift. Once satisfied, the Appointed Person can once again delegate the supervisory duties back to the Crane/Supervisor.

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TOWER CRANES 7

Due to the high risk nature of tower crane selection, erection, use, maintenance and dismantling operations, specialist advice must be sought.

8

The Appointed Person must ensure there is an appropriate plan/lifting schedule in place for lifting operations. A typical example of a tower crane lifting schedule is included in the Lifting Plan and Schedule (SHE-FRM-10-03).

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9

Where more than two tower cranes are operating within the same radius zone automatic proximity warning devices must be fitted, ie. anti clash systems,

10

Where tower cranes are operating, systems should be in place which take account of protestors, unauthorised entry, etc. Controls should include : For internal cranes, first/base section of the mast, in the region of 4 m. high, or to the underside of the upper floor, can be covered with heavy gauge 50 mm. squared (maximum) weld mesh secured with either wire or zip ties (not welded). Access for the crane driver can be in the form of an outward opening lockable door, with a turnbuckle on the inside with key access from the outside. Keys can be held by the crane driver and the Slinger/Signallers for use in the event of an emergency. The gate is to remain closed at all times whilst the driver is up the crane.

(b)

For external cranes, a 2.4 m. high plywood hoarding with a security fan, independent of the crane, gated as above, with mesh viewing panels to give additional natural lighting to facilitate safe access/egress.

(c)

Where the building is progressed around the tower crane, 2 m. high double clipped demountable Heras type fencing to be placed around the floor aperture at each floor slab level as the building progresses.

(d)

Lockable access doors to the cab/jib installed and padlocked shut when the crane driver vacates the crane.

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When the crane driver vacates the crane, the machine to be locked off, isolated and secured into free slew either from the cab or from the isolator situated at the base.

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(a)

COMPANY must ensure that suitable arrangements are put in place for emergency situations (rescue from tower crane, crane failure etc). Any such arrangements shall be subject to liaison with emergency services and appropriate rescue practices carried out to test any agreed arrangements.

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EMERGENCY ARRANGEMENTS

A list of general rules for the use of cranes is included at Appendix 1 and shall be made known to persons involved in lifting operations

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GENERAL RULES

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2.3.10.5 Guidance To This Procedure

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MINIMUM TRAINING REQUIREMENTS 1

Appointed Person must hold training certification following attendance and successful completion of a recognised Appointed Persons (Lifting Operations) training course.

2

Lift Supervisors must have received suitable and sufficient training. Slinger/Signaller must have received suitable and sufficient training certification for Slinger/Signaller.

3

Mobile or Tower Crane Operator must have received suitable and sufficient training certification for crane operation.

4

Pedestrian Operated Tower Crane Operator must have received suitable and sufficient training certification for crane operation.

5

Other Lifting Equipment, operators must hold suitable training certification relevant to the category of lifting equipment being used.

6

Lifting Equipment and Accessories – Testing (see Appendix 2)

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The implementation of LOLER and BS 7121 Part 2:2003: Code of Practice for Safe Use of Cranes - Inspection, Testing and Examination’, provides the opportunity for either a “specified period” or an “examination scheme” approach to the 12 monthly thorough examination.

8

If the examination scheme approach is to be used, the owner must produce a scheme in consultation with the manufacturer or another competent engineer.

9

Mobile cranes with a rated capacity of less than 500 tonne that are not thoroughly tested in accordance with an examination scheme should be load tested every 4 years.

10

Any lifting accessory found not to have a current test certificate should be taken out of service immediately and be quarantined and clearly marked for re-testing or disposal.

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APPENDIX 1 - GENERAL RULES FOR THE USE OF CRANES The following rules apply to all COMPANY sites and shall be made known to all persons involved in lifting operations : Cranes shall only be used for vertical lifts.

(b)

The weight of the load (including lifting gear, etc.) shall be confirmed before lifting.

(c)

A common lift schedule for tower cranes to be produced.

(d)

The safe working load shall never be exceeded; if the Rated Capacity Indicator is activated this shall be investigated.

(e)

When lifting a load for the first time the crane stability shall be checked when the load is just off the ground.

(f)

No operation shall be carried out where high winds affect the stability of the load or the crane. Limits on wind speeds shall be determined (i.e. by reference to the operator’s manual). The means for determining wind speed shall be by use of an anemometer fitted to the crane or available on site.

(g)

An audible alarm shall be capable of being heard at the crane’s maximum operation radius.

(h)

No crane shall be left unattended with the load suspended or the engine running.

(i)

The crane shall be left secured when unattended.

(j)

Persons shall only be lifted by a crane in power lowering mode and automatic brakes. Cranes with keys to set power lowering shall be locked in this mode and the key retained by the Appointed Person or Project/Site Manager whenever persons are to be lifted.

(k)

Crane Selection for Carriage of Persons: The following points are mandatory:

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(a)

Cranes with the “traditional manually operated slipping friction clutch will not be used

(ii)

Cranes with hydraulically driven permanently engaged clutches are preferred.

(iii)

Cranes must be used in a power load lowering mode. Cranes which have a free fall mode must be ‘locked out’ of free fall with a key operated selector and indications of this shown externally on the crane and within the cab, by light or sound. The keys must be held secure by the Project/Site Manager or other Appointed Persons whilst the crane is engaged in man riding duties.

(iv)

The cranes must have automatic brakes which will be automatically applied if the hoisting lever is not in the operating position.

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Besides the automatic brake, there must be other means of arresting the load, i.e. by the hydraulic winch motor and a foot operated brake.

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(v)

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(i)

(vi)

Cranes with latchable controls must have the latching mechanisms removed, ie. controls must automatically return to the neutral position when released.

(vii)

Lifting equipment used shall comply with relevant Qatar Regulatory Document (Construction) together with the relevant British Standard.

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(viii) Each crane must be individually assessed and a technical statement, with appropriate information, obtained from the owner as to its suitability for the carriage of persons. This statement must be appraised by a technically competent person and agreed prior to the commencement of man-riding. (ix)

Technical assistance is available from the SHE Manager/Team.

(x)

Overhoist device shall be fitted for all man-riding operations or where an overhoist risk exists.

(l)

Cranes shall not slew within 600 mm. of any fixed object that may cause a trap.

(m)

Only trained and certificated Signaller/Slingers shall direct crane drivers. If more than one Signaller is appointed only one shall have authority to direct the Crane Driver and that Signaller shall be known to the Crane Driver.

(n)

Site conditions, both underfoot and overhead, shall be checked for hazards before a crane is used. This includes checking access to and egress from the site before attendance.

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APPENDIX 2 - TABLE OF INSPECTION AND EXAMINATIONS TYPE OF EQUIPMENT Mobile cranes and tower cranes

INSPECTION REQUIREMENTS

Daily pre-use checks and weekly inspection by trained operator. Daily pre-use checks and weekly inspection by trained operator.

Lorry mounted cranes

Daily pre-use checks and weekly inspection by trained operator.

Excavator

Weekly inspection by trained driver.

Mobile elevating work platforms (MEWPs)

Daily pre-use checks and weekly inspection by trained operator.

Passenger and goods lifts

In accordance with the manufactures’ instructions.

Scissors lifts (fixed)

Refer to manufacturers’ instructions.

As above and initial test and examination before use required 12 monthly by competent person 12 monthly by competent person

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In accordance with the manufactures’ instructions. In accordance with the manufacturers’ instructions.

Visually check for obvious defects in accordance with training / experience immediately prior to use.

6 monthly by competent person 6 monthly by competent person 12 monthly by competent person 6 monthly competent person 12 monthly by competent person 12 monthly by competent person

6 Monthly by competent person.

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Overhead cranes (motorised or manual) Vehicle tail lifts, maintenance lifts Lifting chains, chain slings, spreader beams, lifting frames ring hooks, shackles, swivels, eyebolts, turnbuckles, wire ropes & slings, strops, fibre ropes, slings & all textile based slings.

Daily pre-use checks and weekly inspection by trained operator. Weekly inspection by trained driver.

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Fork lift trucks

6 monthly by competent person

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Tele-handlers (all terrain)

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Tower cranes

PERIOD OF THOROUGH EXAMINATION 12 monthly* by competent person (6 monthly if used for lifting persons)

Flood lighting winches

None.

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Hydraulic jacks and screw jacks

Periodic visual inspection depending upon usage. Periodic visual inspection depending upon usage.

Fixed lifting beams

12 monthly by competent person 12 monthly by competent person 12 monthly by competent person

Tie down straps for lorry loads.

Weekly visual inspection by trained Not required driver. Visual inspection of all webbing 6 monthly by competent stitching and attachments every Body harness person month, and before use. * Can be a specified examination scheme in lieu of the 12 monthly thorough examination for cranes. Equipment such as pallet trucks, sack barrows and manhole cover lifters do not require a thorough examination under LOLER but shall be subject to regular visual inspections as required by the Provision and Use of Work Equipment - PUWER (refer to separate procedure and guidance).

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2.3.10.6 Reference Documents PROCEDURES FORMS Site/crane Permit to Lift Part 1 (SHE-FRM-10-01)

2

Site/Crane Permit to Lift Part 2 (Multiple Operations) (SHE-FRM-10-02)

3

Control of Lifting Operations - Lift Plan and Schedule (SHE-FRM-10-03)

4

Control of Lifting Operations – Pre-Permit to Lift Checklist (SHE-FRM-10-04)

5

Lifting Appliance Use for Loading (Tele Handler etc) (SHE-FRM-10-05)

6

Lorry Mounted Crane Checklist (Hiab) (SHE-FRM-10-06)

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FURTHER REFERENCE

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Lifting operations are properly planned and appropriately supervised. Detailed information on all these issues can be found in: Qatar Regulatory Document (Construction) RD1.3 and RD1.4

(b)

BS 7121-1:2006 Code of practice for the safe of cranes – Part 1: General

(c)

BS 7121-2:2003 Code of practice for the safe of cranes – Part 2: Inspection, testing and examination

(d)

BS 7121-3:2000 Code of practice for the safe of cranes – Part 3: Mobile Cranes

(e)

BS 7121-4:2010 Code of practice for the safe of cranes – Part 4: Lorry Loaders

(f)

BS 7121-5:2006 Code of practice for the safe of cranes – Part 5: Tower Cranes

(g)

Management of temporary works and equipment is covered in QCS Section 1, Part 14

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POSITION IN COMPANY

NAME

CONTACT DETAILS

SHE Manager

POSITION IN COMPANY

SHEQ Director

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Approved by:

SIGNATURE & DATE

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NAME

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2.3.10.8 Approvals

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QCS 2014


FORM SHE-FRM-10-04 CRANE/PERMIT TO LIFT CHECK LIST COMPLETED

Page 15

YES

Contract : Location : Task/Method Statement No. (If applicable): Appointed Person : Employed by:

Date and Time of Visit :

Standard Lift

Contract Lift

Complex Lift

Single Crane Position Complete Part 1 only

Multiple Crane Positions Complete Parts 1 & 2

Description of Works :

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LOAD DETAILS Max. Size of Load : Max. Lift Height :

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Max. Weight : Max. Radius : Others e.g. Unusual Centre of Gravity, Lifting Points etc. :

CRANE DETAILS

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Capacity and Type :

Max. Boom Length To Be Used For Lift :

Counterweight Req :

Hook Block Reeving (No. of Falls) :

Outrigger Spread (centre to centre) :

m. x

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Max. Available Boom Length : m.

Outrigger Pad Size (without mats) :

Max. Outrigger Load:

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SITE SURFACE CONDITIONS

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Access for Crane : Access for Transport : Lifting Position : Laydown Area : Safe Ground Bearing Capacity Under Outrigger : Assessed by : Proximity Hazards, provide details and attach sketch (eg overhead lines, public roads, drains, ground conditions etc) : A temporary works design for the lifting platform must be in place and signed off prior to setting up/commencing lifting operations. (Permit part 2 shall be completed for all crane positions/repositions of the crane.)

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CRANE ACCESSORIES REQUIRED (State type and safe working load) Chains : Shackles : Outrigger Mats (state size) :

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Wire ropes : Web Slings : Beams : Others (including specialist equipment) :

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Operational Requirements e.g. road closures/possessions/site clearance : Permit Valid From

To

CRANE TEAM Name Appointed Person Crane Supervisors Crane Operator

Qualifications

Signature

Date

No. Expires: No. Expires: No. Expires:

Signaller/Slinger

No. Expires Where contractors are required to complete this form, assistance shall be given by COMPANY Authorised Person who shall agree the details entered on the form and sign below. Lifting operations must not commence until this form has been signed by Details agreed on behalf of COMPANY COMPANY Authorised Person. Distribution: Site File Appointed Person Crane Operator

Crane Supervisor

Signature

Date

If for any reason the details contained within this permit cannot be adhered to, the lifting operation must not continue, the Appointed Person must be notified immediately.

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ARRANGEMENTS FOR MULTIPLE CRANE POSITIONS I agree that the crane described in part 1 may be re-positioned within the constraints defined within the Lift Plan provided that each time it is set up in a new position the items in the list below are checked and signed for by the Crane Supervisor. When the crane is being operated by a Contractor, each entry shall be countersigned by an COMPANY person, authorised by the Project Manager. The signature(s) shall be entered on this form prior to allowing the crane to operate in the new position.

.............................................................................

........................

Appointed Person

Date

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Additional items to be inserted by AP, if required

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Mats as Defined in Lift Plan Correctly Placed Under Each Outrigger

All Outriggers on Crane Platform and Within Designated Lifting Area Defined in Lift Plan

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Time

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Position Ref. as Lift Plan

Outriggers Extended to Spread Stated in Lift Plan

This form shall remain in the crane cab during lifting operations and be returned to the COMPANY Project Manager on completion of the lifting operations as described in part 1.

Crane Lift Supervisor Signature

COMPANY Authorised Signature

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances LIFT PLAN AND SCHEDULE

Page 17

This Lift Plan is specific to the lifting operations described in the “Scope”. It is not and should never be considered “Generic”

Contract: Date of Lifting Operation: Lift Plan Ref or Activity: Appointed Person Preparing this Lift Plan: Signed:

.

Date:

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Lift Supervisor: Purpose

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The crane overturning The load falling from the crane The load or machine striking someone or any other identified hazard

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1. 2. 3.

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The purpose of this lifting plan is to identify the control measures necessary to negate the primary hazards of :

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Scope of Works

Company Name:

Telephone:

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Contact Name:

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Address:

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Details of Crane Hire Company

Details of Crane Operator Qualifications and Operating History:

Load Details Max Size of Load: Other Details (centre of gravity, lifting points, packaging, pallets etc): Max Weight:

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Details of Crane Capacity and Type: Height (Ground – Jib Head): Radius: Main Jib Length: Fly Jib Length: Total Jib Length: Safe Working Load: Actual Working Load:

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Out Rigger Spread: Counterbalance Weight:

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Ground Conditions (CBR, Strata), Temporary Works Design in Place and Checked Off (where appropriate) : Out Rigger Loadings:

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Lifting Accessories & Configuration

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Spread Mat Requirements: Note: Where operating (Jib) height equals or exceeds 10m at any time, the Appointed Person must advise and consult with the Manager from any airport/airfield with 6km of the site. Airport/Airfield Requirements:

Equipment Details:

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Safe Working Load:

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Type (e.g. spreader beam):

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Sketch of Slinging Method:

(Note: will configuration affect SWL?)

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Site Conditions and Hazards

The following non-exhaustive list should be considered during the lift plan along with any other factors which could affect any aspect of the lift. Excavations, embankments, overhead and underground services or obstructions, culverts, drainage, manhole/inspection chambers, buildings, stationary objects, scaffolding, plant and equipment, roads, rivers, railways, personnel and public, other cranes, environmental considerations. Hazard

Control

.

Strength and Stability

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Ground conditions must be suitable and sufficient and remain so during crane lifts to take the anticipated loads. Include details of the ground conditions and any additional works required to the ground, including spreader mats specification and any testing regime required e.g. CBR tests. A temporary works design must be in place and checked off before any lifting operation or crane set up takes place.

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Weather / Environmental Considerations

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Indicate in this section detail of wind speeds / environmental conditions that have been referenced / anticipated for the duration of the lifting operations.

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Access

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Include any special travelling routes, road closures / highways notifications, access problems.

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Third Party Considerations

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Over-sailing, works adjacent to railways, noise and restriction of view.

Emergency / Breakdown Procedures

Signalling

Indicate whether hand signals or radios are to be used. Also indicate signalling source and radio frequency/channel. This section can also include any unique slinger/signaller identification (i.e. different colour helmet / hi-vis) if required.

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Site and Crane Layout Plan

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Safe System of Work - Methodology

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Include crane position, lay-down / rigging area, position of delivery vehicles, landing points, banksman positions, ground and overhead hazards and exclusion zones. If required use elevation drawings.

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Include pre-lift, lift and post lift.

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Lift Team The details of this Lift Plan along with any other associated Risk Assessment, Method Statement or Safe System of Work have been brought to the attention and explained to the persons listed below who have acknowledged that they understand the contents, hazards and associated control measures. Other Relevant Documentation (list and attach)

Position

Name

Signature

Date

Site/Project Manager:

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Lift Supervisor:

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Crane Operator:

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Slinger / Signaller:

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Others:

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This plan is specific to the lift as detailed in the scope of works.

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In the event of any changes to circumstances, personnel or equipment, the plan should be reviewed and revised by the Appointed Person and any changes re-communicated to the lift team.

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Lifting Accessories SWL Used

Comments

Loading platform

Forks & netting

2.5 Tonne

Forks must be slid fully home and netting wrapped around load after having lifted the pack approx 300mm from original position.

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Drop chain

3 Tonne

Drop chain only to be used, not longer chains hooked back up to main lifting ring

Max Weight

Crane Used

Lifted From

Lifted To

Pallets of Bricks/blocks

2 tonne

tower

Lorry or store

2 tonne

tower

RMC truck

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Item to be Lifted

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SCHEDULE OF LIFTS (Common Lifts) :

Concrete skip

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QCS 2014

Section 11: Health and Safety Page 23 Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

This checklist must be completed fully before the permit to lift is issued. Contract: Date of Lifting Operation: Lift Plan Ref or Activity:

1

Check

Yes

Has a Lift Plan been produced by an Appointed Person and accepted by COMPANY? Has the correct crane, as stated in the Lift Plan, been supplied, complete with manufacturer’s operating manual including a maintenance inspection checklist and duty charts?

3

Is a current report of last thorough examination of the crane (within the last 12 months or 6 months in the case of man-riding operations) available?

4

Are current 6 monthly test/thorough examination certificates for all lifting equipment / accessories available on site and their ’ID’ numbers checked.

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Have all maintenance inspections, including last daily / weekly checks been carried out and recorded, and evidence of PPM scheme available? Last recorded entry in register:

6

Is the Crane Driver’s training certification available and current for the category of crane being operated? (Check that the Driver has experience of this type of crane or operation e.g. grabbing or balling operations.)

7

Is the Banksman/Slinger’s certificate of training / competence available and current?

8

Has the Crane / Lift Supervisor been appointed?

9

Is the crane sited in the position identified in the Lift Plan?

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5

Have all risks from obstructions, such as foul sewer and surface water drain manholes, overhead cables or adjacent structures, been identified and suitable precautions implemented?

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No

.

No.

11 12

Are the lifting accessories suitable for the task and as identified within the Lift Plan, is there safe access to sling the load and will the load(s) be stable while being slung / unloaded and are any lifting points on the load identified and correct? Has the ‘Crane Lift Team’ (and others that may be affected) been made aware of the requirements in the Lift Plan, received an induction, and signed acknowledgement of the content of the Plan and the operations associated control measures? A complete copy of the Lifting Plan and associated crane documentation must be retained in the site safety file and be ready for inspection at any time.

If the answer to any of the above questions is ‘NO’, the Permit to Lift must not be issued until the query has been resolved. Site / Project Manager Completing this Checklist: Date:

Signature:

QCS 2014


Operator’s Confirmation I have carried out all statutory and maintenance inspections as detailed above. Operator’s Details __________________________________________________

Signature:

__________________________________________________

Crane Type:

__________________________________________________

Qualifications:

__________________________________________________

Registration No :

__________________________ Date: ___________________

Crane Operator

Site File

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Distribution :

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Name (print):

QCS 2014


DELIVERIES Vehicle Registration Number (as applicable):

Type of Plant/Equipment: Project Name: Supplier:

Driver Name:

Delivery For:

Date:

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CHECKLIST

Yes

No

Is the driver’s qualifications correct for the required task?

2.

Is a current 12 month certificate of thorough examination in place for the Appliance?

3.

Is the common Lift Plan in place?

4.

Are certificates in place for lifting accessories?

5.

Does the driver understand the requirement to have assistance loading/unloading transport vehicles?

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Location:

Defects Found:

Comments:

Signature: On completion file.

Date:

QCS 2014


DELIVERIES Type of LORRY MOUNTED Vehicle Registration Plant/Equipment: CRANE (HIAB) Number: Project Name: Supplier:

Driver Name:

Delivery for:

Date:

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CHECKLIST Yes

No

Is the driver’s qualifications correct for the required task?

2.

Is a current 12 month certificate of thorough examination in place for the ‘HIAB’?

3.

Is the common lifting plan in place?

4.

Does the above include the operation in hand?

5.

Does the driver understand that a lift must not take place if they are beneath the load, is this identified in the plan (Item 3)?

6.

Does the driver understand the ‘No Lone’ working rule relative to the loading and unloading of the wagon?

Location:

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1.

Defects found:

Comments:

Signature: On completion file.

Date:

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 1

2


2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................ 1

2.3.11 PERMIT TO WORK SYSTEMS ......................................................................... 1 2.3.11.1 Responsibilities .............................................................................................. 4 2.3.11.2 Definitions ...................................................................................................... 4

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2.3.11.3 Action Required To Implement This Procedure ............................................ 5 2.3.11.4 Guidance to this procedure............................................................................ 7

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2.3.11.6 Author........................................................................................................... 10

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2.3.11.7 Approvals ..................................................................................................... 10

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PROCESS MAP Project Site/Manager

Authorised Person

SHE Advisor

Supervisor

Liaise with Project manager to ensure suitable persons are appointed to control permits on sale

Appoint an Authorised Person to control permits for the project

3.1, 3.3

3.1

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Ensure that the Appointed Person is trained to carry out

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For some activities, the contract may run their own permit system. When this is the case, the PM/SM will issue an overriding permit to enable the system to be run 3.3

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Issue and sign off Company permits – after ensuring necessary checks have been carried out and

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3.1

In conjunction with the Authorised Person, assess and confirm the competency of the individual undertaking the task 3.3

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In conjunction with the task supervisor, assess and confirm the competency of the individual undertaking the task 3.2

Monitor the Permit to Work system and advise the relevant person of any change required so that an appropriate review can be made of the Permit requirement and issue

3.1

Key Activity Guidance

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PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work to control hazards (which under normal circumstances are difficult to control), by means of a recognised permit system. SCOPE

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Authorises this procedure. CONTRACTS MANAGER

2

Ensures that the authorised person(s) are appointed. PROJECT/SITE MANAGER Ensures this procedure is established on the project under their responsibility and where applicable a permit to work system is applied.

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3

Has responsibility for the overall co-ordination and signature for the permit to work system

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AUTHORISED PERSON

5

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SHE ADVISER/MANAGER

Provides advice and support in the application of this.

Work in accordance with this procedure.

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CONTRACTORS

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HAZARD/ ASPECT/IMPACT

Something with the potential to cause harm, this can include substances, workplaces, machines, tools, etc and includes the potential to harm/damage the environment including the potential of causing a statutory nuisance.

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2

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RISK

Is the likelihood that the potential harm from a particular hazard is realised.

Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix. METHOD STATEMENT PERMIT TO WORK SYSTEM 3

The arrangements, confirmed by a written permit, by which a competent person/s satisfies that all necessary precautions have been taken and provisions made to secure the safety of persons associated with an activity. PERMIT TO WORK

4

A permit is a signed document that provides assurance that work may safely take place. It does not replace any requirements for risk assessments or method statements

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Page 5

2.3.11.3 Action Required To Implement This Procedure 1

In order to control hazards which under normal circumstances are difficult to control such as fire, dangerous substances electrical equipment, confined spaces, excavations etc. A formal written procedure shall be used to ensure a safe place of work/safe system of work strategy and full compliance with current legislation.

2

Permit to Work Systems Shall be used on COMPANY Projects in the following circumstances: Work on/test on electrical equipment which could give rise to risk of injury or death from electrical shock or burn, including commissioning work and, particularly, work involving exposed live conductors operating at dangerous voltages. (USE ELECTRICAL PERMIT FORMS).

(b)

Welding, flame cutting, use of ignition sources, or work on electrical equipment which could give rise to an incentive spark. (USE HOT WORK PERMIT FORM).

(c)

Work in confined spaces or at any poorly ventilated place where toxic/flammable gases, fumes, or vapours are likely to be present in dangerous concentrations, or where there may be oxygen deficiency or oxygen enrichment. (USE CONFINED SPACE PERMIT FORM).

(d)

Permit to excavate to be produced prior to any ground being broken. Information relative to services etc. shall be identified on the permits. (USE EXCAVATION WORK PERMIT).

(e)

Controlling access to complete or specific areas. (USE WORK ACCESS CONTROL PERMIT FORM).

(f)

Any other clearly dangerous circumstances e.g. site radiography where formal coordination of people and precautions is necessary in order to secure safety. (BESPOKE PERMIT FORM TO BE PRODUCED REFER TO SHE DEPARTMENT FOR ASSISTANCE).

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(a)

Only competent persons fully conversant with the COMPANY and/or client permit to work procedures shall be appointed as an Authorised Person by the Project/Site Manager

4

The Project / Site Manager responsible for the Project will ensure that the Authorised Person(s) have received suitable and sufficient training in order to execute their duties in this procedure, and should take into account the practical experience of the proposed Authorised Person of the particular plant, equipment and/or situation involved.

5

The Authorised Person shall ensure that on large sites, particularly where more than one permit system is operating, a suitable map(s) or plan(s) shall be produced and posted at a focal point(s). The map/plan shall where appropriate indicate the type of permit operating in, what areas, and shall make clear that only personnel covered by the permit shall enter those areas. The map or plan shall be updated, and removed immediately all work which demands a permit is closed.

6

N.B. Where more than one permit is issued on plant or an operating system a cross referencing procedure shall be adopted to ensure safety.

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GENERAL

HOT WORK PERMITS 7

The Authorised Person shall ensure that conditions are safe for work to be carried out, and where necessary, carry out, or arrange for atmospheric tests to ensure safety. Additionally, the Authorised Person shall ascertain the presence, nature and properties of any flammable, combustible, or explosive agent involved in the work (e.g. LEL, UEL, WEL, Flash Point, Density, Threshold of Smell, etc).

8

In addition the Authorised Person shall consider the possible sources of ignition such as:

QCS 2014


Page 6

(a)

Matches, lighters, cigarettes, etc.,

(b)

Oxyacetylene and other gas welding, cutting and burning, Electrical arc welding

(c)

Electrical sparks from electric motors, circuit breakers, capacitors etc.

(d)

Static Electricity

(e)

Percussive Sparks from metal tools etc.

(f)

Solar refraction

(g)

Any other source of ignition

WORK IN CONFINED SPACES Before signing this Form the Authorised Persons shall be sure he knows the exact nature and properties of any gases, liquids, vapours, solids or sludges present in the confined space (LEL, UEL, OEL, WEL, density, flash point, threshold of smell etc.).

10

The Authorised Person should carry out or arrange to carry out air tests if breathing apparatus is not worn by operatives entering the confined space and ensure that any working, escape or rescue respirator or breathing apparatus is suitable for the hazard involved, users have been instructed in correct usage and the time for which it will remain effective.

11

If breathing apparatus is to be worn, the Authorised Person must ensure that the operative is attached to a trained observer outside the confined space by means of a lifeline and harness and that any necessary rescue equipment is in position, and that operatives never work unattended in confined spaces.

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WORK INVOLVING THE PRESSURE TESTING OF PLANT AND EQUIPMENT Pressurisation of air and gases produce a much greater hazard if a vessel or pipe bursts than when hydrostatic pressurisation is used. Therefore, hydrostatic testing shall be used whenever practicable.

13

All tests shall be carried out in full consultation with the relevant Designer. If for technical reasons air or gas pressure testing is unavoidable the Project / Site Manager shall obtain formal permission to carry out such testing from the relevant Designer and safety procedures agreed with them.

14

Where the risk of an explosion or injury through pressure testing is evident the Project / Site Manager shall ensure that the Authorised Person ultimately signing the permit is a trained and experienced engineer who fully understands the hazards involved.

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OUT OF HOURS PERMIT

15

This is a delegation of control permit (it does not delegate responsibility which will still rest with the Project / Site Manager) and is intended to be used on projects where a contractor wishes to work outside normal site hours and no COMPANY supervision is available. It must only be used where the risk from the activity has been assessed as acceptable and can only be used for Single Contractor Works, where co-ordination between more than one contractor is an issue an COMPANY Manager or Supervisor must be in control of the site. WORK ACCESS CONTROL PERMIT

16

Where an access Control permit is to be used before issuing the permit the Authorised Person must ensure clear demarcation of the area is in place by means of notices and barriers so that personnel know the existence of such an area and its limits.

17

A means of identifying personnel permitted to enter the restricted area, must be established by the Supervisor of the works (The permit shall list the names of those permitted in the restricted area).

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Page 7

ACTIVITIES UNDERTAKEN BY COMPANY Whenever COMPANY operates a permit to work system the Project / Site Manager shall liaise with the SHE Department and agree who shall have responsibility for overall signature of the particular permit to work form. In all cases such persons shall be appointed in writing as Authorised Persons.

19

The Authorised Person who signs the Permit to Work shall assess the persons who are to carry out the work and decide in conjunction with the supervisor in charge of those persons whether they are competent to undertake the work safely.

20

The Authorised Person has a clear responsibility to satisfy themselves that the precautions required by any particular permit to work they issue are in place before work is authorised, and must be aware of any risk assessments and controls identified therein associated with the activity to be undertaken.

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ACTIVITIES UNDERTAKEN BY CONTRACTORS

In some circumstances sub/work package contractors may wish to operate their own permit to work systems, and it may be that COMPANY will require some contractors to control their own works by a permit system. In these cases the following actions should be undertaken.

22

The Site Manager will issue an over riding permit of the appropriate type authorising the Contractor to control the works in accordance with an agree permit system, this permit shall be reviewed regularly by the Project Site Manager to verify it is still appropriate and updated as necessary. The review shall be at intervals not exceeding 7 days.

23

The Project Site Manager shall liaise with the SHE Department and agree who from the Contractors team shall have responsibility for overall signature of the particular permit to work form. In all cases such persons shall be appointed by the Contractor in writing as Authorised Persons and this appointment `notified to the Project Site Manager.

24

The Contractors Authorised Person who signs the Permit to Work shall assess the persons who are to carry out the work and decide in conjunction with the supervisor in charge of those persons whether they are competent to undertake the work safely.

25

The Contractors Authorised Person has a clear responsibility to satisfy themselves that the precautions required by any particular permit to work they issue are in place before work is authorised, and must be aware of any risk assessments and controls identified therein associated with the activity to be undertaken.

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2.3.11.4 Guidance to this procedure 1

In some circumstances, particularly where COMPANY is modifying or enlarging an existing plant, the client may require his own permit to work system to be used and that sub/work package contractors working on the site be subject to it. AUTHORISED PERSONS

2

All Authorised Persons shall be aged over 21 years.

3

Authorised Persons shall formally accept and not delegate their duties.

4

Authorised Persons shall be identified in the SHE Management Plan. TYPES OF PERMITS AND THEIR APPLICATION ELECTRICAL WORK PERMITS

QCS 2014


Page 8

5

Electrical work is subject to the Electricity at Work Regulations. The procedures for complying with them are contained in SHE-PRO-004 together with any COMPANY Electrical Safety Instructions

6

All work on electrical equipment that has the potential to be energised at a dangerous voltage shall be covered by a permit to work and the necessary signs displayed. HOT WORK PERMITS

The permits are for use where hot work on plant or equipment is required and a permit for general hot work within buildings where flammable materials are liable to be present. The advice of the SHE Department shall be sought when determining which the appropriate permit to be used in is circumstances where there is any doubt, and should be used where one or more of the following are present in significant quantities:

(b)

Flammable liquids (particularly highly flammable liquids whose flash points lie below 32ºC). It should be remembered that vapours from such liquids are normally heavier than air, and may collect in sumps, drains etc

(c)

Flammable gases or vapours where the concentration involved could approach or exceed the lower explosive limit. (NB whilst methane is lighter than air, most other hydrocarbon gases are heavier than air e.g. propane, butane).

(d)

Flammable dusts (particularly organic dusts like grain, wood, sugar, etc. Also certain metal and other inorganic dusts which are explosive e.g. aluminium. It should also be remembered that a relatively minor initial explosion may disturb lying dust and give rise to a catastrophic secondary explosion.

(e)

Solid organic and other materials, for instance timber structures or combustible insulation materials such as paper, polystyrene, polyurethane foam, etc.

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(a)

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The permit shall also be used in circumstances where (a)

Dangerously hot plant (e.g. steam heated) has to be isolated to avoid burns, scalds, etc., to personnel working on that plant.

(b)

Metal cutting is being undertaken either by gas or mechanical means

(c)

Welding or brazing operations are required

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8

The objective of these permits is to allow work that may give rise to a source of ignition in circumstances where there is risk of fire and/or explosion, and/or burns to personnel.

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10

The presence of potentially dangerous sludges or deposits shall also be considered which may, when disturbed, give rise to hazardous gas etc. Further hazards may also arise from flammable liquids, gases, and vapours, introduced by the work itself, or the ingress of steam or corrosive/hot liquids etc. or lack of oxygen.

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WORK IN CONFINED SPACES

The objectives of the permit are to minimise these hazards, and secure compliance with the Qatar Regulatory Document (Construction). EXCAVATION WORK PERMIT

11

See procedure SHE-PRO-003 for the procedure to be adopted for excavation work. Work Access Control Permit

12

This permit shall be used where it is necessary to control the access of personnel to certain work areas for the following reasons: (a)

To prevent damage and vandalism to installed plant within a particular area.

(b)

To know the exact whereabouts of personnel on "high security" sites at given times.

(c)

To restrict personnel who enter potentially hazardous areas to a limited number, all with appropriate specialist knowledge and training.

QCS 2014


Page 9

WARNING SIGNS AND TAPES The following warning signs/tapes shall be used where applicable. Danger Permit to Work Area Entry Forbidden Except to Authorised

(b)

Persons

(c)

Scaffolding Incomplete Do Not Use

(d)

Caution Men Working on Apparatus

(e)

Danger Keep Away Exposed Live Conductors

(f)

Danger No Unauthorised Person to Touch This Switchgear

(g)

Danger No Smoking or Naked Flames

(h)

Danger Plant Equipment Under Test Do Not Touch/Operate

(i)

Caution Risk of Ionising Radiation (Provided by Specialist Contractor)

(j)

Restricted Work Area Entry Only to Listed Workmen on COMPANY Access Permit

(k)

Danger Buried Cables

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(a)

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2.3.11.5 Reference Documents

Confined Space Entry Work Permit (SHE-FRM-11-01)

2

General Permit to Work (SHE-FRM-11-02)

3

Hot Work Permit General (SHE-FRM-11-03)

4

Hot Work Permit Plant and Equipment (SHE-FRM-11-04)

5

Pressure Test Work Permit (SHE-FRM-11-05)

6

Work Access Control Permit (SHE-FRM-11-06)

7

Permit to Work on Test Electrically Isolated Apparatus

8

(SHE-FRM-11-07) Permit to Test Electrically Live

9 10

Out of Hours Work Permit (SHE-FRM-11-09)

11

Permit to Excavate (SHE-FRM-3-02)

12

Site Crane Permit to Lift (SHE-FRM-10-02)

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FORMS

Apparatus (SHE-FRM-11-08)



14

Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHE-PRO-001)

15

Safe Working in the Vicinity of Buried and Overhead Services (SHE-PRO-003) Electricity at Work (SHE- PRO-004)

QCS 2014


Page 10

16

The Safe use of Cranes and Other Lifting Appliances (Excavators, Tele Handlers and Lorry Loaders (SHE-PRO-010)

17

Fire Precautions During Construction Work in Buildings (SHE-PRO-013)


POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

POSITION IN COMPANY

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NAME

SHEQ Director

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Approved by:

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2.3.11.7 Approvals

SIGNATURE & DATE

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Page 11

Contract: …………………………………………………………………Permit No: ……………………………. Location: ……………………………………………………………………………………………………………………… Description of Work: ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… Valid From …………..…hrs on (Date)…………..……To……..…. .hrs on (Date) ……..………(Max 1 shift) Hazard Restrictions, Comments: ……………………………………………………………………………….

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REQUIRED Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory

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MANDATORY CONTROL MEASURES Supervision – Nominated and Completed Means of Communication Instruments to detect adverse atmospheres Gas Purging Forced Air Ventilation Intrinsically Safe Lamps or Lighting Removal of residues (without causing additional hazards) Suitable Access/Egress arrangements including emergency evacuation Emergency Rescue equipment and procedure

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PERMIT MUST NOT BE ISSUED OR WORK COMMENCED UNTIL ALL THE CONTROL MEASURES ABOVE ARE IN PLACE OPTIONAL CONTROL MEASURES Isolation (Gases, Electrical, Mechanical) RPE Full BA, Escape Breathing Apparatus or External Air Feed Fire Precautions (Intrinsically safe lamps etc) Task and Emergency Lighting Additional permits for specific activities i.e. hot work ISSUE OF PERMIT

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REQUIRED YES NO YES NO YES NO YES NO YES NO YES NO

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I confirm that all atmospheric checks have been made and all persons required to enter the Confined Space for any reason are medically fit and have proof of having received the relevant training in Confined Space Entry to the correct category.

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Authorised Person: …………………………… Signed: …………………………………Date:………………. Names of persons entering the Confined Space are attached RECEIPT OF PERMIT I confirm that work by myself or by any person under my control in the Confined Space will be carried out in accordance with this permit, all statutory requirements and company safety policy. All persons entering the Confined Space will receive information and instruction in the requirements of this permit and safety measures necessary prior to entry into the Confined Space.

Competent Person: …………………………… Signed: …………………………………Date:………………. CLEARANCE (Competent Person Confined Spaces) I certify that all persons have been withdrawn and warned that it is no longer safe to enter the Confined Space above and that all tools and equipment have been removed.

Competent Person: …………………………… Signed: …………………………………Date:………………. CANCELLATION – AUTHORISED PERSON I acknowledge receipt of the clearance of this Permit. THE PERMIT IS NOW CANCELLED

Name: …………………………………… Distribution: White copy – Workplace recipient copy)

Signed: …………………………………Date:………………. Pink copy – Distribute as required

Blue copy – Retain in book (file

QCS 2014


Page 12

This Permit is valid only for the period specified Contract Name:

Contract No:

Location of works:

Description of works:

Part 1

Permit No:

Names of persons in working party:

Part 2 Details of work to be carried out (risk assessment, method statement, etc, to be attached)

Y N

.

Other

Action to be taken

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N N N N N N N

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Y Y Y Y Y Y Y

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Part 4 Other hazards Heat source Steam Electricity Noise Work at height Mechanical power Others (specify)

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Part 3 Precautions to be observed (e.g. other permits, lock off, access control) Protective clothing Y N Breathing Y N Gloves Y N required apparatus Safety helmet Y N Eye protection Y N Ear Y N defenders Safety harness Y N Wellingtons Y N Overalls Y N Safety boots Y N Face mask Y N RPE Y N

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Part 5 Issue of Permit: I hereby certify that the precautions detailed above have been carried out and that it is safe to commence work. Signed: Name: (Authorised person) (Print) Date: Time: Valid from: Valid to:

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Part 6 Receipt of Permit: I hereby declare that I accept responsibility for carrying out work detailed in this permit including all precautions noted. Name: Signed: (Authorised person) (Print) Date: Time: Part 7 Clearance of Work Area I hereby declare that the work for which this permit was issued is now complete and that all employees under my control have been withdrawn. All equipment, tools, material and gear has been removed. All guards have been replaced and the area has been checked as safe. Signed: Name: (Authorised person) (Print) Date: Time: Part 8 Permit cancellation I declare that this permit and all copies of it are cancelled Signed: Name: (Authorised person) (Print) Date: Time: Distribution: copy)

White copy – Workplace recipient

Pink copy – Distribute as required

Blue copy – Retain in book (file

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Page 13

Contract: …………………………………………………………Permit No: ………………………. Location: ………………………………………………………………………………………………… Description of Work: …………………………………………………………………………………………………………… …………………………………………………………………………………………………………… Valid From ………………hrs on (Date)…………………. To ……….hrs on (Date) ……………… Hazard Restrictions, Comments: ……………………………………………………………………..

CONTROL MEASURES

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…………………………………………………………………………………………………………… REQUIRED

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Combustible materials to be removed from the working area Suitable Fire Fighting Equipment (FFE) is in position Person received appropriate fire safety training No combustible liquids, vapours, gases or dusts within the work area Work location has been thoroughly examined Exposed wooden flooring or skirting etc, covered to prevent ignition Gas cylinders secured upright and flash back arrestors fitted Hot work to cease one hour before end of shift Operatives familiar with emergency procedures Screens positioned when welding, cutting or grinding operations

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ISSUE OF PERMIT I confirm that all persons carrying out hot work have been made aware of the contents of this permit Authorised Person…………………………….Signature……………………

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RECEIPT OF PAYMENT I confirm that work by myself or by any person under my control carrying out hot work will do so in accordance with this permit, all statutory requirements and company safety policy. All persons involved will receive information and instruction in the requirements of this permit and safety measures necessary prior to work commencing. Competent Person…………………………….Signature……………………

Weekly Issue Fire Watch Checks

Day Mon Tues Wed Thur Fri Sat Sun

Initial

Initials confirm temporary cancellation for weekly issue

FINAL CANCELLATION – Sub-contractor Representative

I confirm that all sources of ignition have been removed and the relevant fire watch stood Name……………………………………………………… Signed ......................................... Date……………

FINAL CANCELLATION – Authorised Person

I acknowledge receipt of the cancellation of this Permit. THE PERMIT IS NOW CANCELLED Name .............................................................................. Signed .......................................... Date…………...

QCS 2014


Page 14

Permit Serial No. Date of Issue Hot Work Permit - Plant/Equipment 1. Details of location and work to be carried out Plant/equipment no. 2. This permit is valid from hrs on (date) to hrs on (date) 3. Description of fire/explosion/hazards involved: Quote flammable gases, liquids, vapours involved, and give lower and upper explosive limits etc. or steam 4. Description of other hazards: Give details of noise, toxic dangerous chemicals, steam, hot liquids etc. Quote OELs where applicable YES

NO

Comment

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Precautions Valves (designate) padlocked off Total disconnection Spades fitted Open-ended pipes/vessels sealed Fire-fighting systems locked off Other isolation methods (specify) Drains, sewers within 25 metres sealed Mechanical ventilation Flame-proof electrical equipment or equivalent Fire blankets 'Don't Touch' labels Local electrical circuits isolated Dangerous machinery isolated/guarded Earthing against static electricity Smoking/naked lights prohibited Danger area demarcated Operators instructed in hazards and precautions Caution signs posted Standby fire-fighting equipment

Explosimeter reading:

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Atmospheric tests (not for steam) Reading taken by Print Name

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Other necessary precautions (including breathing apparatus) 6.

Date: Time:

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Title Gas detector reading Specify gases Authorisation I have personally checked the above conditions and consider it safe to carry out this work Authorised person Print Name Title: Signature: Date: Time: Acknowledgement I understand the hazards of this work and the precautions to be taken. These have also been fully explained to the operatives carrying out this work, and I consider them competent to do it safely. I will return my copy of this permit to the authorised person when this work has been safely completed Competent supervisor Print Name Title: Signature: Date: Time: Time extension Subject to the following precautions Mark N/A if none are required the expiry time of this permit is extended from hours on (date) to hours on (date) Signed Authorised person Date: Cancellation I have completed the work detailed in this permit, and have restored the location to a safe condition. I have returned my copy (white) of this permit to the authorised person Signed Competent supervisor Date: I accept that the work has been safely completed. The top (white) copy of this permit has been destroyed Signed Authorised person Date: Time:

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9.

10. 10.1

10.2 Notes a) b) c)

Permit is automatically suspended upon sounding of emergency alarms, instructions via public address system etc. Check with authorised person before recommencing work. Where the authorised person is also the competent supervisor he should sign all parts of the form and issue the top original (white) copy to himself as a check on procedure. Signatures for paragraphs 10.1 and 10.2 to be placed only on duplicate (blue) copy which is to be retained for record purposes.

QCS 2014


Permit Serial No………………………………….

Date……………………………

1.

Details and location of plant to be pressure tested:

2.

This permit is valid from: .........................

3.

Page 15

hrs on (date) ……………………to

…………………hrs on (date) …....................

Nature of pressure test: Hydrostatic

4.

Gas

Air

Pressure involved………………….

Description of any other hazards associated with pressure test (noise, hot liquid, steam, toxic/corrosive agents etc.): Precautions

6.

Authorisation

Applicable Yes No

Comment

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5.

7.

Time (hrs)………………….

Date………………………………

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Signed ……………………………………

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Authorised Person : Print Name…………………………………………Title………………………….............

Acknowledgement:

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I understand the hazards of this work and the precautions to be taken. These have also been fully explained to the operatives carrying out this work, and I consider them competent to do it safely. I will return my copy of this permit to the authorised person when this work has been safely completed. Print Name………………………………………Title…………………………..........

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Competent Supervisor:

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Signed …………………………………………………Time (hrs)…………………. Date………………………… Time Extension: Subject to the following precautions – Mark N/A if none required

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8.

The expiry time of this permit is extended from …........................ hrs on (date) …………………………

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To …........................hrs on (date) …………………………

9.

Cancellation:

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9.1 I have completed the work detailed in this permit, and have restored the location to a safe condition. I have returned my copy (white) of this permit to the authorised person. Signed Competent Supervisor…………………………………….. Time (hrs)…………………. Date…………………………………….. I accept that the work has been safely completed. The Top copy (white) of this permit has been destroyed. Signed Competent Supervisor…………………………………….. Date……………………………………..

Time (hrs)………………….

Notes a) Permit is automatically suspended upon sounding of emergency alarms, instruction via public address system etc. Check with authorised person before recommending work.

Distribution:

White copy Pink copy Blue copy

b) Where the authorised person is also the competent person, he should issue the top copy (white) to himself as a check on procedure.

-

Workplace recipient Distribute as required Retain in book (file copy)

c) Signature for paragraphs 9.1 and 9.2 to be placed on duplicate copy (blue) which is to be retained for record purposes. Top copy (white) to be destroyed to prevent re-issue.

QCS 2014


Page 16

1.

Project:

2.

Description of controlled work area:

3.

The above work area has been demarcated in the following manner:

4.

This permit is valid from: …................ ……….….hrs on (date) ………............

5.

The person(s) designated below is hereby authorised to enter and work in the controlled area described in 2. above

Name and initials

Title

Name and initials

Title

Name and initials

Title

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Title

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Name and initials

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hrs on (date) ………………. to

Special conditions (if any):

7.

I hereby agree to return my copy of this permit to the authorising person in 8. Below immediately after the expiry time /date at 4. above

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8.

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Signed Work Access Controller…………………………… Notes

Date……………….

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Signed person requesting access…………………………..

a) Top copy (white) to be issued by Works Access Controller to person requesting

Distribution:

White copy Pink copy Blue copy -

b) Duplicate copy (blue) to be retained in file

Workplace recipient Distribute as required |Retain in book (file copy)

Date……………….

QCS 2014

1.


Page 17

Details of apparatus and work on/test* to be done: Contract No:…………………………………….. Location:………………………………………………………………….. Precautions and authorisation

2.1

Isolation: State isolation point(s), whether or not isolators have been padlocked off, fuses drawn, etc.

2.2

Warning notices and access control: State where caution/danger notices have been posted and if appropriate, how work area has been fenced off.

2.3

Prove apparatus dead: State what tests have been made, where and with what instruments.

2.4

Earthing: State where apparatus has been earthed and, for testing, which earths may be removed.

2.5

Other precautions: Specify if required for special circumstances.

2.6

Validation period: This permit is valid from ……hrs on (date)………to……..hrs on (date)……… I hereby declare that the above precautions have been taken and made known to the competent person in charge of the work. I consider that the apparatus specified in paragraph 1 is safe to work on/test*

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3.

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Signed (Authorised Person)…………………………Time (hrs)………………Date………………… Acceptance and receipt of Top copy (White) by competent person

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I acknowledge receipt of this permit and understand the safety precautions described above. Neither I nor the men under my control will work on/test* any other electrically dangerous apparatus. I will return this permit to the authorised person when the work on/test is complete.

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Signed (Authorised Person)………………………… Time (hrs)………………Date………………… Cancellation

4.1

I hereby declare that the work on/test*- detailed in paragraph 1 has been completed/stopped, earths removed, and men/gear withdrawn. The apparatus is now in safe condition.

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4.

4.2

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Signed (Authorised Person)………………………… Time (hrs)………………Date………………… I hereby declare this permit cancelled. The top copy (white) has been returned to me by the competent person and destroyed. The apparatus detailed in paragraph 1 may be reconnected for service.

Signed (Authorised Person)…………………………Time (hrs)………………Date………………… Notes a) Where the authorised person is also the competent person, he should sign all parts of the form and issue the top (white) coy to himself as a check on procedure.

b) Top copy (white) is to be retained by competent person whilst work on test is going on and returned to authorised person for destruction when work is complete.

Distribution: Top Copy – White 2nd Copy - Blue This form is intended to be used in a PAD format only

c) Signature for paragraphs 4.1 and 4.2 to be placed only on duplicate copy (blue) which is to be retained for record purposes. Top copy (white) to be destroyed to prevent re-issued.

QCS 2014

1.


Page 18

Details of apparatus and test to be done Contract No.

Location

2.

Reasons why test cannot be carried out with apparatus isolated

3.

Person(s) involved in test Only authorised or competent persons may work on/test live apparatus at or above 55 volts AC/DC Competent person name and initials Observer name and initials Precautions and authorisation

4.1

Safety equipment: The following safety equipment will be provided and used throughout the test Max safe voltage

insulating rubber boots

Max safe voltage

insulating rubber mats

Max safe voltage

insulating push bars

Max safe voltage

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Other tools and equipment: State type and when to be used

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insulating rubber gloves

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4.

Adjacent live equipment: The following precautions are to be taken to ensure that the persons named in paragraph 3 cannot come into contact either adjacent live equipment

4.3

Danger and caution notices have been posted at

4.4

Atmospheric conditions: The following precautions are to be taken to avoid danger from wet and humid conditions

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4.2

From 4.6

hrs on (date)

to

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Validation period: This permit is effective

hrs on (date)

Authorisation: I declare that all precautions specified in paragraph 4 are in force and that the test described in paragraph 1 may now begin. Signed Authorised person

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Important: No electrical test is to be carried out in potentially flammable atmospheres unless a hot work permit is in force

Time

hrs

Date

Acceptance by competent person and observer

5.1

I acknowledge receipt of the top (white) original of this permit and understand/will use the safety precautions listed in paragraph 4. I will work only under the surveillance of the observer, and will return this permit to the authorised person when the test is complete.

5.2

I acknowledge receipt of the first (pink) copy of this permit and will monitor the safe progress of the competent person. I have been instructed what to do in the case of emergency, and will return the permit to the authorised person when the test is complete.

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Signed Observer 6.

hrs

Date

Time

hrs

Date

Clearance I hereby declare that the test described in paragraph 1 is complete. The apparatus is safe and tools/gear have been withdrawn. Signed Competent person

7.

Time

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Signed Competent person

Time

hrs

Date

Cancellation For cancellation complete blue copy I hereby declare this permit cancelled. I have received back respectively from the competent person and the observer the white original and pink copy of the permit. These copies have been destroyed. Signed Authorised person

Time

hrs

Date

NOTES a) Top original (white) and first copy (pink) to be issued by authorised person to competent person and observer respectively and retained by them during the work/test. Both copies to be returned to authorised person for destruction on completion of test.

b) Where the authorised person is also the competent person he should issue the top original (white) to himself as a check on correct procedure.

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Page 19

CONTRACT: ......................................................................................Permit No. ................ LOCATION: .................................................................................................. DESCRIPTION OF WORK: .............................................................................. DATE & DURATION OF WORKS:

/

/

Hours: ........................

.

IS THE WORK TO BE CARRIED OUT A HIGH RISK ACTIVITY (e.g. Steel erection, roofwork, cladding, asbestos removal, work at height, excavations over 600mm deep etc.) Refer to initial risk assessment Construction Phase Safety Plan. (circle appropriate risk rating)

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HIGH

LOW

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If the work is high risk or multi discipline, COMPANY supervision must be on site at all times.

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Name and position of competent person supervising work activities. (person named must stay on site at all times) Name ................................................Position ..............................

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FURTHER CONTROL MEASURES

Safety Courses attended

YES OR

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Is there a first aid trained person on site? Is there access to welfare and washing facilities? Can the emergency services be called? Is there sufficient lighting and access to work areas? Have emergency contact numbers been passed to the supervisor? Are all staff inducted and aware of fire and emergency procedures? Have all applicable risk assessments / method statements been accepted? Confirm tool-box talk has been held to communicate this permit? Are there any specific environmental considerations i.e. consented noise levels IF NO IS INSERTED IN THE RESPONSE BOX THEN THE WORK MUST NOT CONTINUE

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OTHER SITE SPECIFIC CONTROLS:

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Site Manager: ................................................... Contract Manager: .........................................

Signed: ............................................................ Date Approved: .....................................................

RECEIPT OF PERMIT I confirm that work by myself or by any person under my control carrying out work out of hours or without on-site COMPANY supervision will do so in accordance with this permit. All persons involved will receive information and instruction in the requirements of this permit and safety measures necessary prior to work commencing Named Supervisor:

Sub-contractor:

Signature:

Date:

Works Completed:

YES

/ NO

Permit Return Date:

Further Permit Required:

YES

/ NO

Site Manager Signature:

*Out of hours

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ........................................................... 1

2.3


2.3.12 CONTROL OF WORKING AT HEIGHTS ......................................................... 1


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2.3.12.2 Definitions ...................................................................................................... 4 2.3.12.3 Procedure ...................................................................................................... 5

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2.3.12.5 Author............................................................................................................. 7

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2.3.12.6 Approvals ....................................................................................................... 7

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Process Map Scaffold/Work at Height Coordinator

Project Manager/Contractor

SHE manager/Adviser

To ensure this procedure is established and prior to tender ensure detailed scaffold specification is produced, including for all production etc.

Contractor

Operatives

Provide details, including Design as appropriate to Project/Site Manager 1.5

1.2, 3.1

Prior to erection of scaffold, appoint scaffold Co-ordinator

Provide support and identify requirements for training 1.3

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3.1

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Ensure work at height/scaffold requirements are discussed at contractor pre-start monitoring

Understand scaffold specification and comply with defined duties including ensuring the availability of risk assessment and method statements

Erect/Inspect scaffold and protection in accordance with this procedure

1.5, 3.3

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3.1

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Arrange for scaffold Co-ordinator to attend scaffold inspection course, if required

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3.1

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3.1

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Check scaffolders training certificates and retain copies

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3

Ensure scaffold inspected after erection and every 7 days. Record using Company Register or similar ti t d d 3.2, 3.3

Monitor that scaffolding etc. Erected by Company or Sub/Works Package Contractor are safe and inspected 3.2

Receive scaffold handover certificate from scaffolding contractor etc. 3.4

Key

Activity Guidance

Provide the appropriate certificates 3.2

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PURPOSE 1

The purpose of this procedure is to control the hazards and associated risks of working at height by ensuring proper design and safe systems of work including the requirements for statutory inspections. SCOPE

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This procedure covers all COMPANY Projects projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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1

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Authorises this procedure. PROJECT/SITE MANAGER

2

Ensures this procedure is established and that works are carried out in accordance with this procedure. SHE MANAGER/ADVISOR

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3

SCAFFOLD/WORK AT HEIGHT CO-ORDINATOR

Ensure duties are carried out in accordance with this procedure

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4

To provide all relevant information including where appropriate design details, specifications and calculations to COMPANY and to work in accordance with this procedure and any other information/rules provided in relation to this procedure.

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5

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CONTRACTOR

EMPLOYEES

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To work in accordance with this procedure and any other information/rules provided in relation to this procedure.

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6

This procedure has been prepared to control the risk of falls, falling objects and collapse of all work places and is particularly aimed at scaffolds, working platforms, and personal fall protection systems.

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SCOPE AND SUMMARY OF WORK AT HEIGHT

THE REQUIREMENTS 2

The control of scaffolding and working at heights are contained in the Qatar Regulatory Document (Construction) Work at Height Section, relevant British or International Standards and Codes of Practice, National Access and Scaffolding Confederation Current TG20 for Technical Guidance on the use of BS EN/2811-1. The current NASC SG14 Guidance for Preventing Falls in Scaffolding and False work. PERSONAL FALL PROTECTION IS

3

A fall prevention, work restraint, work positioning, fall arrest or rescue system, other than a systems in which the only safeguards are collective safeguards, or,

4

Rope access and positioning techniques.

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2.3.12.3 Procedure MANAGEMENT RESPONSIBILITIES The Project/Site Manager will appoint a Scaffold Co-ordinator to ensure the proper control of all scaffolding, working platforms, working restraint mitigation. If no appointment is made the Project/Site Manager will assume the duties himself.

2

Specific details in relation to contractors scaffold etc and working at height shall be discussed at the initial SHE meeting SHE-PRO-007.

3

The person appointed will be site based and competent to carry out his duties. Training where necessary shall be arranged through the regional Training Coordinator.

4

Erection and dismantling of scaffolds shall be carried out in accordance with the National Access and Scaffolding Confederation (NASC) Guide (SG4).

5

Ensure all risk assessments and method statements have been prepared in relation to the erection use and maintenance of scaffolds

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USE OF SCAFFOLDS, WORKING PLATFORMS, PERSONAL FALL PROTECTION AND WORK RESTRAINT MITIGATION MEASURES PROVIDED BY COMPANY COMPANY retain the responsibility for ensuring that any such equipment it provides for use by its own personnel or others is safe for proper use.

7

Sub or Work Package Contractors have a responsibility to check any equipment/scaffold etc. provided for their use is safe before they use it and that their operatives are adequately trained.

8

COMPANY has a responsibility to ensure that any workplace that is part of a scaffold is safe before others under COMPANY control or COMPANY own employees use it.

9

COMPANY Scaffold and Work at Height Co-ordinator shall also monitor that scaffolds etc. erected by COMPANY/sub/work package contractors are safe and inspected as required by Regulations and are only erected by trained, competent and certified persons.

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6

10

11

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SCAFFOLDS, WORKING PLATFORMS AND PERSONAL FALL PROTECTION ERECTED/USED BY SUB OR WORK PACKAGE CONTRACTORS' PERSONNEL All sub/work package contractors' personnel retain the responsibility for ensuring that any such equipment provided is safe for proper use and inspected as required by the Regulations.

Each sub or work package contractor has a responsibility to inspect equipment provided to it by another contractor before they use it. MANDATORY ITEMS RELATIVE TO WORK AND ACCESS/EGRESS TO HEIGHT

12

Staircases shall be the default primary means of access/egress to scaffolding/working platforms where practicable, and shall only be excluded by Risk Assessment.

13

Where ladders are to be used as a means of access/egress following considerations in above, they shall be incorporated into a ladder tower/ladder landing platform.

14

Where the above is not practicable ladder access openings shall be protected with a gravity gate, (running the top guard rail into the ladder access point as an alternative is not permissible.)

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Where ladders are incorporated within a scaffold/working platform the access shall be protected by a ladder flap or suitable guard rails and toe boards, to protect the opening.

16

When considering the use of ladders including step ladders, they shall not be used for Work at Height unless Risk Assessment has demonstrated the other systems such as Podium or Tower Scaffolds are not practicable or are for very short duration only. A Ladder Permit must be issued for their use.

17

All working platform edges including edge protection to roofs, floor slabs and loading bays shall incorporate material fall protection whether in use or not

18

Material Transport Loading/unloading plans shall be produced by the material receiving company and applied and shall form part of the traffic management plan, and shall include fall prevention during these operations

19

To compliment the above, a pre unload check shall be carried out prior to releasing the ropes/chains/straps.

20

All Loading Bays shall be located away from building pedestrian access points where practicable and in all cases incorporate triple guard rails to sides and a proprietary front loading gate which protects users at all times.

21

Requirements for passive collective fall arrest where there is a risk of persons falling and edge protection cannot be provided, a fall mitigation system such as nets, air/beanbags shall be supplied and used. Where this is not practicable fall restraint shall be considered before fall arrest.

22

Where safety harnesses and lanyards are used by employees they shall be inspected before use and thoroughly examined at least every 3 months or as recommended by the manufacturer if a lesser period. Safety belts are prohibited.

23

Scaffolds must not be used until a scaffold handover certificate has been issued by the person erecting the scaffold and an entry has been made in the appropriate register.

24

Scaff-tag or similar notices are to be displayed on ALL scaffolding - in particular tower scaffolds.

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Checklist for Scaffold Design Requirements (SHE-FRM-12-01)

2

Ladder/Step Ladder Use Authorisation (SHE-FRM-12-02)

FURTHER REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.3

2

COMPANY Register Handover Certificates, Inspection Records and Training Records.

3

Contractors Check List for Initial Safety, Health and Environmental Meeting (SHE-PRO-007)

4

Standards and Guidance Risk Assessment Guides

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2.3.12.5 Author

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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SHE Manager

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2.3.12.6 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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All scaffolds and working platforms shall be properly constructed to provide a safe working place and be suitable for the type and nature of the work being carried out. There shall be provided suitable and sufficient safe access to and egress from every working place. Scaffolds shall only be erected or altered by competent, trained and experienced workmen. Materials used shall be of suitable quality, in good condition and free from patent defect. Scaffolds shall conform to current British or International Standards.

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Before the erection of any scaffold the following question shall be addressed: What is the scaffold for? 1 Where is it to be erected? 2 What materials are to be used? 3 Can safe access be provided for:4 Erection? I) Use? II) Dismantling? III) How many working platforms are needed? 5 What loading will be imposed? 6 Are the ground conditions or supporting structure suitable? 7 How and where can the scaffold be tied in? 8 What bracing will be used? 9 Will the scaffold be sheeted? 10 Is there a need to provide protection for the public? 11

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EXCLUDING INTERNAL SCAFFOLD LADDERS

Contract Name ……………………………………........ Date

Contract Number…………………..

……………………

Area check – description of work to be carried out Height to be accessed …………………………………………………………………………………….. Location

………………………………………………………………………………………………

………………………………………………………………………………………………………………..

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……………………………………………………………………………………………………………….. Yes

No

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Section A Can a mobile tower/MEWP be used?

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Can podium steps be used?

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Can fixed erected scaffold be used? If NO is answered to all questions in section A, is a step ladder the only means of access for the work activity?

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Section B – (If steps are the only option, the following must be answered

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Is the work of a light nature? Is the work of a short duration? Repetitious short use does not constitute short duration works

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Will the tools be of a light nature and hand held? If No is answered to any questions in section B, futher consideration must be given to providing a suitable working platform before completing sections C and D

Wood

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Type of steps to be used (tick as appropriate) Aluminium

Fibreglass

Number of treads required e.g. 6,10,12 Section C Has the operative read and understood the risk assessment and method statement?

Yes

No

Section D – Authorisation Employee

Signature …………………………………….. Print Name …………………………….

Supervisor

Signature …………………………………….. Print Name …………………………….

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 1

2


2.3


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2.3.13 ........................................................................................................................... FIRE PREVENTION AND CONTROL ON SITE ............................................ 1

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2.3.13.2 Definitions ...................................................................................................... 5 2.3.13.3 Actions Required to Implement This Procedure ............................................ 6

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2.3.13.5 Author........................................................................................................... 15

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2.3.13.6 Approvals ..................................................................................................... 15

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Process Map Tender Team

Projects Engineer (CDM)

Design

Project Manager

SHE Dept

Appoint Fire Safety Co-ordinator

Ensure adequate resources for fire control/protection

1.2, 3.4

Ensure fire risk has been considered by designers 1.6, 3.2

Consider fire risks during development

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1.5, 3.2

Carry out a specific Fire Risk Assessment and Site Emergency 3.4

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1.4

3.4

Provide advice on certificates, training, etc. If necessary, liaise with Anon 1.3, 3,4

Ensure specific Fire Risk Assessment is produced for office and storage units and monitor

Monitor controls are in place

3.1

3.4

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SHE Management Plan to detail relevant appointments and emergency details

Ensure information on fire risk is provided at project induction 3.4

Ensure adequate monitoring arrangements are in place and carry out emergence drills as required by the SHE Plan 3

Key

Activity Guidance

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PURPOSE The purpose of this procedure is to ensure adequate controls are in place from fire and the adequate provision of emergency procedures.

SCOPE

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Introduction

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This Section provides guidance on Fire prevention and control on site which is a legal requirement under the Regulatory document Section 1.7.

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It is strongly advised that reference is made to BS 5839 BS 5839-1:2013- Fire detection and fire alarm systems for buildings Code of practice for design, installation, commissioning and maintenance of systems in non-domestic premises.

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Fire extinguishers, emergency lighting, fire alarms and fire signs must comply with current local civil defense Standards and / or British Standards.

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Every year there are a number of large fires on construction sites and in buildings undergoing alteration and refurbishment. All have serious consequences: Injury and fatality to people, environment and property damages. Some irreplaceable buildings burn down.

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The risk of fire is greater during the construction, refurbishment or demolition of buildings than at any other time, and the loss of equipment, working time and resultant financial implications can be severe.

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Such fires have been started by the careless use of blowlamps, faulty electrical wiring etc.

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The practical steps which can be taken to prevent fire are a cost-effective investment that may bring great benefits. The majority of fires can be prevented by taking simple precautions and by adopting safe working practices. Every fire, no matter how large the end result, starts from a small beginning. But certain fundamentals are common to every fire, and knowledge of these will help to prevent or to control a fire. Everyone who has been trained will know the different types of fire that can occur and the right extinguisher to use in each case. Using the wrong extinguisher can make a fire situation deteriorate rapidly. If you are not trained, do not attempt to use them. Sources of fuels, such as bonfires, LPG cylinders, dangerous substances, and flammable materials, shall be identified as well as sources of ignition, such as smoking, cooking and heating appliances and operations involving hot works (e.g. welding and cutting) Controls shall take into account site security with respect to trespassers and acts of vandalism. Materials storage and all waste produced present a fire hazard and needs to be taken into account in the risk management process.

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Fire alarms, emergency lighting, fire-fighting equipment, signage, fire safety procedures, emergency plans and staff training should keep in step with the progress of construction works so that all areas are adequately covered throughout all stages of development. The simplest fire procedure is as easy as A B C = •

Raise the alarm

•

Call the fire brigade (Civil Defense)

•

Immediate evacuation

REMEMBER!

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Fire legislation is designed to reduce the risk of a fire starting and ensures that, if it does there are adequate means of escape and measures to control the fire.

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The majority of fires on site can be prevented by taking simple precautions and by adopting safe working practices.

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2.3.13.1 Responsibilities

SHE DIRECTOR Authorises this procedure. PROJECT / SITE MANAGER Ensures that works are carried out in accordance with this procedure.

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SHE MANAGER / ADVISER

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ESTIMATING / TENDER TEAM

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Ensure necessary resources are available for fire precautions.

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DESIGNERS

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Designers and specifies shall consider their proposals in terms of the potential for reducing construction phase fire risks at source. The ability to do this will vary according to the circumstances.

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PROJECT ENGINEER (CDM)

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The Engineer shall ensure that the relevant information provided by clients or designers is included in the tender stage information pack.

et

ito

They shall also monitor design proposals and if they note designs that appear to ignore significant fire matters, or introduce significant fire hazards for the construction phase, then they shall be referred back to the designer for resolution.

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INCIDENT CONTROLLERS, FIRE MARSHALS, ETC. Ensure duties are carried out in accordance with those detailed.

2.3.13.2 Definitions CDM Construction (Design and Management) and the definitions therein. INTRODUCTION AND SUMMARY OF CONTRIBUTION TO FIRE SAFETY FROM KEY PARTIES As with all health and safety issues, fire safety during construction work will best be achieved through adoption of the principles set out in the CDM i.e. design and planning to avoid or reduce the risks followed by thorough planning, organisation and control of the execution of the works.

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The material contained in this document shall be used in the preparation of site fire plans that shall be included in the SHE Management Plan.

2.3.13.3 Actions Required to Implement This Procedure TENDER STAGE The person responsible for preparing the tender shall ensure that all necessary resources for fire precautions has been included and where necessary seek the advice of the SHE Department. DESIGN PHASE

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Where COMPANY is the designer, the design leader shall ensure that fire risks are considered in the process of developing the design. In practice designers shall consider the elimination or mitigation of construction phase fire risks as part of the design risk assessment.

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Where COMPANY is the Engineer the in house co-ordinator shall ensure that fire risks have been considered by designers in their design.

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PRE CONSTRUCTION PHASE

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All sub and work package contractors shall be required as a condition of contract, to comply with the requirements of the Qatar Regulatory Document (Construction) and as such this requirement has been incorporated in the COMPANY standard rules for sub and work package contractors.

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The location and fire precautions required for temporary site accommodation e.g. offices, canteens, cargo containers and caravans etc as well as parts of the existing buildings used for these purposes demand special consideration and the Project/Site Manager shall seek the advice of the SHE Department during the planning of such facilities.

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CONSTRUCTION PHASE

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The Project/Site Manager shall appoint a Incident Controller for the site whose name shall be recorded in the SHE Management Plan. In addition, and where appropriate, a sufficient number of fire marshals shall also be appointed.

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The Project/Site Manager in association with the SHE Adviser for the site shall undertake a Fire Risk Assessment and prepare a site specific emergency plan which shall be integrated into the SHE Management Plan. Safety induction of all personnel onto the project/site shall include fire related risks and arrangements. The Project/Site Manager shall in consultation with the SHE Manager/Adviser, prepare, undertake and record a specific Fire Risk Assessment for all Site Offices/Temporary Accommodation units. Contact the SHE Department for advice. The SHE adviser appointed for the site shall provide any necessary fire training requested and undertake fire audits, as circumstances dictate. The Project Manager shall arrange and carry out emergency evacuation drill as required by the SHE Management Plan. The Project/Site Manager must ensure that arrangements are in place to monitor the effectiveness of this procedure including the maintenance of any fire fighting equipment etc.

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2.3.13.4 Managing fire risks On every construction site, there will always be the risk of fire. By the very nature of the operations carried out (cutting, burning, grinding, welding, etc.), the use of flammable substances and the amount of wood and other combustible materials used or stored on site, the potential for fire is always present and must be properly guarded against. As with all potential workplace problems, the situation can be effectively managed by: taking steps to prevent a fire starting in the first place preparing for, and effectively reacting to, a fire situation if it occurs. Contractors must make a suitable and sufficient assessment of the risks to health and safety of their employees whilst they are at work, and of the risks to any person not in their employ but who may be affected by their actions. The purpose of these risk assessments is to:

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establish the risks to health and safety arising from those hazards

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identify any hazards that may be inherent within any work process

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establish the control measures necessary to reduce the risks to an acceptable level. In circumstances where fire is an on-site hazard, a 'fire risk assessment' must be carried out.

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In many cases, fire risk assessments may be quite straightforward and completed relatively quickly. As outlined above, the principles of fire risk assessment are the same as for the risk assessment of any other construction work activity or process.

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In more complicated situations, carrying out a fire risk assessment may need more consideration and may need to be reviewed as the construction project progresses or new situations arise. It almost goes without saying that anyone carrying out a fire risk assessment on site needs to have both knowledge and competence in the subject. TEMPORARY BUILDINGS

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The design for Fire prevention and control need to include temporary structures and works such as office accommodation, canteens and other temporary accommodation and their maintenance.

BONFIRES

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2.3.13.5 Personal responsibilities

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Where bonfires are allowed, no fire should be left unattended at any time.

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A bonfire should only be lit after conducting a risk assessment: Special attention is to be given to drifting smoke which could be a nuisance and represent danger to road. They should be situated well away from any buildings, boundaries, roadways, fuel stores or other combustible materials or structures. Consideration must be given to wind direction and strength.

Never light a bonfire by using a flammable liquid. There is a danger of the person lighting the fire being burnt by the 'flash' as the flammable liquid ignites and also a chance of secondary fires starting as heavier-than-air vapours spread. SMOKING RESTRICTIONS

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Where it is decided that smoking can be allowed in 'non-enclosed' areas, these areas must exclude any 'fire-risk' areas such as storage areas for combustible materials, flammable liquids and gas storage areas. The official NO SMOKING notice must be clearly displayed in any area where smoking is not allowed, including all entrances to all enclosed working places. Areas where smoking is allowed should be equipped with adequate fire-fighting equipment. Non-combustible containers should be provided to aid safe disposal of discarded smoking materials. As work progresses and the site develops it will be necessary to monitor the changes in the 'fire risk areas' and review the areas where smoking is allowed accordingly.

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Site rules should ensure that smoking is prohibited for an appropriate period at the end of each working day, for example the last hour. This will allow any developing fire to be discovered and dealt with before the site closes at the end of the day.

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TRESPASSERS

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Children and other trespassers may start fires on site. Sites should, as far as possible, be secured against intruders. In every case, combustible materials should be cleared on a regular basis (daily) and not left lying around. Storage areas for flammable liquids and gases should be secured during non-working hours. Everyone should know the correct action to take if they discover a trespasser on site during working

qa

hours.

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HOT WORK

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Cutting, burning and welding operations, together with the use of blowlamps and other LPG-fuelled tools, are the cause of many fires on building and construction sites. It is essential that anyone engaged in hot works is aware of the fire risk, and is trained and competent to use the equipment that will produce the heat.

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Precautions must be taken where heat from a work process could be transmitted to other combustible materials, for example where hot works are carried out on steelwork or pipes adjacent to or passing through flammable materials such as stud-work walls or timber floors.

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Where this kind of operation is anticipated, it is essential that all combustible materials (and liquids) are protected before any work is allowed to start. Special care should be taken when working with cutting or welding equipment at raised levels. Any equipment or combustible items situated below cutting or welding operations where there is a danger of sparks or fragments of hot metal dropping, should, if possible, be removed or covered with fire-resisting material.

m

When working with blowlamps, welding, flame-cutting or grinding equipment, thorough checks should always be made to ensure that nothing is left smouldering after the work is finished. As an added precaution, always check into cavities, around eaves, behind studding and into other voids after any hot work has been completed. In many cases such work must be carried out in compliance with a Hot Work Permit. This will stipulate the safety conditions under which the work must be carried out and will usually require: that a suitable and serviceable fire extinguisher is available at the place of the work that hot work ceases at least one hour before the end of the working day that a check for the presence of fire or potential fire is carried out before the end of the working day.

HEATING APPLIANCES The risk of fire arises from the use of heating appliances if they are sited and installed incorrectly, inadequately maintained or are not suitable for the intended use or location. Fuel supplies for gas-fired appliances, especially propane or butane, should be kept secured outside the building and piped in through fixed pipework. Any flexible pipework should be kept as short as possible,

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and used only for the final connection to the cylinder. Any room in which a gas fire is used must be fitted with a permanently open vent or louvre to enable the fire to operate properly without producing excess carbon dioxide. (A window that could be closed in cold weather, for example, is not acceptable.) Gas fires, plus the associate pipework and connections and so on must be regularly serviced. The use of oil heaters is not recommended due to the inherent risk of fire if they are knocked over or otherwise misused. Combustible material should be kept well away from heaters and stoves. The practice of drying wet clothing in front of fires should be prohibited. Care must be taken to see that newspapers, clothing or other combustible materials are not allowed to build up around such heaters. Care must be taken also to ensure heaters are not used near liquid fuel cylinders. Heat applied to the surface of such cylinders will cause the contents to pressurise and could trigger an explosion.

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All heaters and stoves, including cookers and kettles, must be turned off at the end of the working day. Portable electrical apparatus should be switched off, unplugged and disconnected from the mains supply.

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STORAGE OF MATERIALS

Many of the materials used in the construction process are combustible.

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Whilst it is appreciated that there is a need for enough material to be available to do the job, only an amount equivalent to one day's work supply should be stored in the work area. Where it is possible to use a material which is less flammable, but will do the same job, then that type of material should be specified by the designer.

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Wherever possible, the stockpiling of flammable materials should be avoided, as quantity increases the scale of any fire.

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DISPOSAL OF WASTE

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Where possible, all combustible materials should be stored outside the building under construction in a locked compound or storage container with adequate separation between differing types of product. Such items as LPG and flammable adhesives should be isolated into a separate locked compound.

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Most construction sites generate large quantities of rubbish and waste material which present a potential fire risk.

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Good housekeeping is essential. Rubbish and waste should be cleared from site on a regular basis, if the risk of fire is to be controlled. Although not all rubbish and waste can be taken to a centralised point for disposal, places should be organised so that skips and other waste disposal containers can be safely positioned not less than 3 metres way from any building or structure.

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Skips and other waste disposal containers should not be placed adjacent to means of escape from buildings or the site, but must be so positioned as to be readily available to vehicles contracted to collect skips or to clear the accumulations of rubbish and waste material.

PROTECTION OF FINISHED SURFACES Once a building is nearing completion, it is common practice to use temporary coverings to protect finished surfaces during the remaining fitting-out phase. These coverings often take the form of plastic sheeting, fibreboard, or similar materials, some of which may be flammable. They can therefore add to the fire loading of the building, and consequently increase the risk of fire. Ideally, fire retardant materials will be used. Care should be taken in such situations to ensure that, where possible, materials with flame-retardant surfaces are used, that fire precautions are upgraded as appropriate, and that features requiring such protection are installed as late as possible into the project.

2.3.13.6 Protection of employees FIRE RISK ASSESSMENTS

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The Regulatory Document, in particular Section 1.7 sets out the law regarding Fire prevention and control and stipulates specific duties for conduct of fire risk assessments. The Regulatory Document requires that a ‘responsible person’ must carry out, and keep up to date, a risk assessment and implement appropriate measures to minimise the risk to life and property from fire. The responsible person will usually be the main contractor in control of the site or in teh case of a property the property owner. Sources of fuel and ignition shall be identified and general fire precautions including, means of escape, warning and fighting fire shall be established based on fire risk assessment. In occupied buildings such as offices, works must not interfere with existing escape routes from the building, or any fire separation, alarms, dry risers, or sprinkler systems. There are five steps in carrying out a fire risk assessment: Identify hazards: consider how a fire could start and what could burn;

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People at risk: employees, contractors, visitors and anyone who is vulnerable, e.g. person with physical disabilities; pregnant woman etc

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Evaluation and action: consider the hazards and people identified in the above and act to remove and reduce risk to protect people and premises;

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Record, plan and train: keep a record of the risks and action taken. Make a clear plan for fire safety and ensure that people understand what they need to do in the event of a fire; and

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Review: your assessment regularly and check it takes account of any changes on site. MEANS OF ESCAPE

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Key aspects to providing safe means of escape on construction sites include:

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Routes: your risk assessment should determine the escape routes required, which must be kept available and unobstructed;

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Alternatives: well-separated alternative ways to ground level should be provided where possible;

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Protection: routes can be protected by installing permanent fire separation and fire doors as soon as possible;

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Assembly: make sure escape routes give access to a safe place where people can assemble and be accounted for. On a small site the pavement outside may be adequate; and

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Signs: will be needed if people are not familiar with the escape routes. Lighting should be provided for enclosed escape routes and emergency lighting may be required.

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MEANS OF GIVING WARNING Set up a system to alert people on site. This may be temporary or permanent mains operated fire alarm (tested regularly), a klaxon, an air horn or a whistle, depending on the size and complexity of the site. The warning needs to be distinctive, audible above other noise and recognisable by everyone. MEANS OF FIGHTING FIRE Fire extinguishers should be located at identified fire points around the site. The extinguishers should be appropriate to the nature of the potential fire: wood, paper and cloth – water extinguisher; flammable liquids – dry powder or foam extinguisher; electrical – carbon dioxide (C02) extinguisher. Nominated people should be trained in how to use extinguishers RESPONSE TO A FIRE ALARM

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In the event of a fire occurring, it is essential that the alarm is raised as quickly as possible so that employees and others, such as visitors, can quickly and safely reach a place of safety. This can be achieved by considering the steps outlined in Module HI that cover: emergency procedures calling the fire and rescue service means of escape. However, if a fire starts inside a building which is under construction, demolition or refurbishment, particularly in a basement, the location of the fire exits may be unknown to many of the people on the site. Therefore, publicised and clearly signposted escape routes must be established. As part of the site emergency planning, dedicated escape routes should be decided on during the planning phases of the project, and arrangements made for them to be clearly signed and adequately lit.

.

Escape routes and their signage may have to be reviewed and reorganised as construction work progresses.

rw

.l. l

As part of establishing a satisfactory means of escape, it will be necessary to install an emergency lighting system in circumstances where failure of primary lighting would create a hazardous situation.

2.3.13.7 Fire Alarm system and compliance

ta

A good fire alarm system should be installed within the site compliant to the current standards, and provides the level of protection demanded by current legislation.

qa

Correct documentation to be in place: An up-to-date risk assessment

as

A log book that records the date and time of weekly tests, and a record of any faults detected, false alarms and the service history, by whom.

er

se

A design certificate (such as a BS 5839-1 G1 Design certificate or equivalent) with Specification, Fire Plan or cause and effect, a set of drawings that clearly states the category or level of protection, plus any variations that have been agreed with interested parties such as Civil Defence, the Insurers or Building Control.

ov

An Installation certificate (such as a BS 5839-1 G2 Installation certificate or equivalent) including a set of ‘as fitted’ drawings. A commissioning certificate (such as a BS 5839-1 G3 Commissioning certificate or equivalent) including equipment manuals with user instructions.

ito

An acceptance certificate that confirms the date of handover

et

An inspection and servicing certificate (such as a BS 5839-1 G6 Inspection & Servicing certificate or equivalent) that record all tests and checks made at each service visit since original installation – handover.

m

Modification certificates as applicable (such as a BS 5839-1 G7 Modification certificate or equivalent) identifying any work undertaken on the system since the date of handover. The responsible person should ensure that certification is in place covering these subjects as identified in BS 5839-1. If there is inadequate certification available, it is recommended that a Verification Certificate (such as a BS 5839-1 G5) is obtained from a competent maintainer In the case where installations don\t have the certificates, it is recommended that the system is assessed by a competent service provider who can issue the necessary certificates detailed above. Anyone who will undertake the works will need to be competent and those carrying out works on a fire alarm system shall hold either a BAFE SP203 or LPS1014 certificate approved from Kahramaa. The certificates should include details of their capability to Design, Install, Commission and/or Maintain a fire alarm system. It is also important to ensure that any service provider is competent to advise of any potential sources of false alarms and their corrective action. EMERGENCY LIGHTING The provision of emergency lighting should always be considered when assessing the fire safety requirements for

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Page 12

a construction site. This is particularly important where being able to carry out work safely is dependent on artificial lighting because there is no natural light, for example in basements. If the lighting circuits should fail, any standby emergency lighting system must switch on automatically and clearly illuminate the following: exits and directional signs corridors and associated exits circulation areas changes in levels any projections and protrusions, such as temporary partitioning, trestles, scaffolding, items of plant and machinery

.

internal and external staircases, including ladders, particularly if these are essential to evacuate the site.

rw

.l. l

Emergency exit routes from the premises may have to be provided or maintained through the construction area for use by the occupiers of the premises. This is relevant where the building in which construction is taking place is partially occupied by others. It may be necessary to amend the location and extent of the emergency lighting system as works progress.

ta

Emergency lighting, whether powered by battery or standby generator or a combination, should be tested on a regular basis by a competent person in accordance with BS 5266 Part I.

qa

Records of tests of the emergency lighting equipment should be kept and must be available for inspection when required.

as

2.3.13.8 Fire-fighting equipment

se

As work progresses, the requirement and suitability of fire-fighting equipment must be reviewed, and amended as necessary.

ov

er

All mechanically-propelled site plant should carry its own fire extinguisher of the correct type. On large or costly items of equipment or plant, the installation of automatic fire detection and extinguishing systems should be considered if there is a risk of fire. MAINTENANCE OF FIRE-FIGHTING EQUIPMENT

et

ito

In addition to the monthly inspections of fire-fighting equipment it is particularly important to check extinguishers which, within a year, are sent to more than one site. When a site is being set up, on receipt of the fire extinguishers, the Site Manager must inspect them for the date that the next check is due.

m

2.3.13.9 Staff training

The Contractor must ensure that employees are provided with adequate safety training that includes suitable and sufficient instruction and training on the appropriate precautions and actions to be taken by employees in order to safeguard themselves and other relevant persons on the premises. It needs to take account of the fire risk assessment and the emergency procedures, and be easily understandable and repeated periodically. The training should cover: discovering a fire how to raise the alarm what to do on hearing the alarm procedure for alerting visitors and all staff calling the fire service evacuation procedures, assembly points and fire drills location and use of fire-fighting equipment location of escape routes

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Page 13

how to open escape doors importance of fire doors how to stop equipment and isolate power not using lifts use and risks of highly flammable and explosive substances good housekeeping smoking policy and smoking areas. FIRST AID

Site security

.l. l

2.3.13.10

.

Trained first aiders will know how to deal with anyone who has been burnt in a fire on site. However, it may not be a trained first aider who is first on the scene.

rw

Effective site security is a way of preventing malicious fires caused by trespassers.

Irrespective of the site boundary fence, buildings and storage areas for flammable liquids, liquefied petroleum gas cylinders and other combustible materials should be individually fenced or otherwise suitably protected.

qa

ta

Illumination of the site, the provision of security guards or guard dogs or the installation of CCTV is additional deterrents to unauthorised access.

Fire safety and the Construction (Design and Management) CDM Regulations

se

2.3.13.11

as

At the end of each working day a fire check should be undertaken, particularly in areas where hot work has been carried out. Where 24-hour security is provided, fire checks should be undertaken throughout the night, during holiday periods and at weekends.

ov

er

CDM imposes duties with regard to the safe operation of construction sites on Contractors and Sub-Contractors. These duties focus on minimising the risk of fires and ensuring that, if a fire should occur, it can be correctly dealt with. Fire should be one of the hazards covered in a fire safety plan that will form a part of the construction phase health and safety plan. These Regulations require that the Contractor appoints a competent person to be responsible for continually assessing the fire risk and updating the Fire Safety Plan.

ito

Designers, who will be guided by the fire prevention and control elements of the QCS, should attempt to 'designout' fire risks where possible.

et

Additionally, CDM requires that:

m

suitable and sufficient steps are taken to prevent, so far as is reasonably practicable, the risk of injury from fire or explosions. measures to be taken to detect and fight fires in relation to work are carried out on construction sites.

2.3.13.12

Guarding against fire

DESIGN PHASE Effective fire prevention planning begins at the design stage. The architect or designer must consider the measures which will eliminate or diminish the potential for fire. It is essential that, where appropriate, an experienced and qualified person is appointed to consider the fire aspects of the design phase; not only to ensure that fire risk and potential for damage are properly assessed and kept to a minimum during construction, but also to see that the finished building will comply with all statutory requirements in respect of fire precautions. FIRE SAFETY PLAN On a site of sufficient size or complexity, or if required by the Contractor they may need to appoint a competent

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Page 14

person (for example, a site fire-safety adviser). This person should be responsible for formulating and regularly updating the site fire safety plan as construction work proceeds. A site fire safety plan should include details of: the organisation of fire safety procedures the names and positions of persons, and their responsibilities for the various aspects of fire safety, for example calling the fire and rescue service general site fire precautions fire detection and warning alarms installed on site arrangements for maintaining fire escape routes and changing them as necessary as work progresses arrangements for notifying staff of the emergency escape routes and any changes to them

.l. l

the location, construction and maintenance of site accommodation

.

the procedures for a Hot Work Permit system, if such is in use

rw

fire evacuation plans and procedures for calling the fire and rescue service fire and rescue service access

ta

fire drills and training, and also procedures for maintaining a written record of all checks.

qa

The person responsible for site fire safety should:

ensure that the site fire safety plan is clearly understood and complied with by all those on the site

as

ensure that a system using Hot Work Permits is established, as necessary, and monitor its effectiveness carry out regular checks of fire-fighting equipment and facilities installed on site

se

test all alarms and detection devices weekly

carry out weekly inspections of emergency escape routes

er

ensure that fire and rescue service access is always maintained

ov

liaise with site security staff, if they are employed arrange for the necessary inspections, tests and fire inspections to be carried out

ito

regularly monitor and check the arrangements and procedures for calling the fire and rescue service carry out the duties required for the safe evacuation of the site in the event of an emergency situation

et

ensure that all staff and visitors report to the assembly points.

m

The site fire adviser or other competent person may, in consultation with the Contractor, need to arrange for the appointment of fire marshals to assist in the implementation of the site fire safety plan, particularly any site evacuation. On large sites it is usual for a fire marshal to be appointed from each company of subcontractors to account for that company's staff in the event of a site evacuation. Where fire marshals' duties are more extensive, they must be allowed sufficient time to carry out their duties and to undertake any training that may be necessary. Notices detailing the action to be taken in case of a fire should be displayed on all notice boards and adjacent to fire alarm call points.

2.3.13.13

SAMPLE PROCEDURE FOR CONTRACTORS

2.3.13.14

Reference Documents

FORMS Fire Prevention Checklist (SHE-FRM-13-01)

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Page 15

REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.7 SHE Management Plan Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHE-PRO-001) QCS 2007 Fire Prevention Standards and Guidance for Buildings under Construction.

Author POSITION IN COMPANY

CONTACT DETAILS

rw

NAME

ta

SECTION

.l. l

.

2.3.13.15

Approvals

ito

ov

NAME

er

2.3.13.16

se

as

qa

SHE Manager

m

et

Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014


Para No. 1.0

Page 16

Tick Box for yes

Question Design Phase Has a Co-ordinator been appointed for the Design Phase? Does the Co-ordinator understood the full scope of his responsibilities?

2.0

Construction Phase Has a Site Fire Safety Co-ordinator been appointed by the COMPANY? Has the Fire Safety Co-ordinator : formulated a fire safety plan? ensured that staff are familiar with the plan and understood it?

.l. l

.

monitored compliance are fire safety plan, especially with regard to hot?

rw

work permits?

established a regime of checks and inspections office protection

ta

equipment and escape routes?

established effective liaison with security contractors or staff?

qa

written records of checks, inspections, maintenance work, fire patrols and fire drills?

as

carried out a fire drill and analysed the results?

3.0

se

checked the arrangements and procedures for calling the fire brigade? Large Projects

er

On the large projects, has the Fire Safety Co-ordinator:

ov

appointed fire marshals and/or deputies, trained them and delegated responsibilities to them?

ito

provided site plans for the emergency services detailing the escape routes, fire protection equipment and facilities for the fire brigade?

et

Fire Safety Plan

Does the fire safety plan detail:

m

4.0

•

the organisation and responsibility for fire safety?

•

the site precautions?

•

the means for raising the alarm in case of fire?

•

the procedure for calling the fire brigade?

•

the means of escape in case of fire?

•

the hot work permit scheme?

•

the site accommodation, its use, location, construction and maintenance?

•

the points of access and sources of water for the fire brigade?

•

the control of waster materials?

•

the security measures to minimise the risk of arson?

•

the staff training programme?

QCS 2014


Para No. 5.0

Page 17 Tick Box for yes

Question Emergency Procedures Is the means of warning of fire known to all staff? It is checked routinely and can be heard in all areas above background noise? Are fire instruction notices prominently displayed? Are the fire brigade access routes clear at all times? Have specified personnel been briefed to unlock barriers when the alarm sounds? Have signs been installed indicating fire escape routes and the positions of fire protection equipment? Fire Protection

.l. l

Have measures been taken to ensure the early installation and operation of:

.

6.0

rw

escape stairs (including compartment walls)? lighting conductors?

ta

automatic fire alarms automatic sprinkler systems

qa

hose reels?

are fire dampers and fire stopping provided at the earliest opportunity? •

are adequate water suppliers available for fire fighting purposes?

•

are all hydrants clear of obstruction?

Temporary Covering Materials

se

as

is steel work protected as soon as possible?

er

7.0

•

ov

Are temporary protective materials required to protect surfaces and fittings? Have these been selected so that the fire load is still acceptable?

Portable Fire Extinguishers

et

8.0

ito

Where flexible covering materials are used do they comply with relevant Standards? Are adequate numbers of suitable extinguishers provided?

m

Are sufficient personnel trained in their use? Are extinguishers located in conspicuous positions near exits? Are carbon dioxide extinguishers in place adjacent to electrical equipment? Does all mechanically-propelled site plant carry suitable extinguishers? Have procedures been implemented for the regular inspection and maintenance of extinguishers? 9.0

Site Security Against Arson Are adequate areas of the site, including all storage areas, protected by hoarding? Is security lighting installed? Has closed circuit television (CCTV) been installed? If CCTV is in position are the screens monitored and/or recorded? Is the site checked for hazards at the end of each work period, particularly where hot work has been in progress?

QCS 2014


Para No. 10.0


Question Temporary Buildings Is the fire break between the temporary building and the structure undergoing work more than 10 meters? If the fire break is less than 6 meters Is the temporary building constructed with materials which will not significantly contribute to the growth of a fire? Is the building fitted with an automatic fire detection system?

is access for the Civil Defence (Fire Department) readily available?

•

is the building fitted with an automatic fire detection system?

.l. l

•

.

If the temporary building is within the building under reconstruction or refurbishment: • is escape for personnel sufficiently easy?

ta

rw

If the floor of the building is raised above ground level is the space beneath enclosed with non-combustible material? Are heaters enclosed with guards and securely fixed on the walls? If separate buildings contain heaters for drying clothes, are the heaters

as

qa

thermostatically controlled? (with enclosed elements) are the drying racks fixed firmly at a safe distance? Are all heaters and cookers properly installed and is adequate ventilation provided?

11.0

ov

er

se

Are automatic fire and intruder alarms installed and is temporary buildings used for storage of flammable liquids and gases? Do temporary buildings contain the minimum of furniture and fittings made from synthetic materials? In all areas of fire hazard does a no smoking policy prevail and there adequate “No Smoking” signs in place? Site Storage of Flammable Liquids and LPG

m

et

ito

Are containers of flammable liquids and LPG stored in purpose designed compounds? If flammable liquids are not stored in compounds, is the quantity less than 50 litres (or half a days’ supply, whichever is less) and is it kept in a fire resistant cupboard or bin? Is the storage area at least 10 meters from temporary and permanent buildings If not, are the recommended precautions taken? Are cylinders of oxygen and chlorine and containers of similar agents kept separately from flammable liquids and LPG? Are the stores properly signed? Has the store a paved or compacted base, and is clear if weeds and rubbish? Are all electrical fittings of intrinsically safe design? Is automatic gas detection equipment installed? Are suitable fire extinguishers provided at the entrances? 12.0

Site Storage of Flammable Liquids and LPG Do electrical installations conform to British or International Standards? Is all electrical work undertaken by competent electricians? Are all circuits, other than those controlling security devises and security lights,

QCS 2014


Para No.


Question turned off when work ceases? Are all gas suppliers installed by a competent gas fitter? Are all gas suppliers in fixed piping or armoured flexible tubing? Where gas cylinders are used are they located outside building, secured and protected from interference? Are flexible links for LPG supplies only connected by a competent person?

13.0

Hot Work Is a permit to work system in operation? Does that system include an adequate maintained register?

ta

rw

.l. l

.

Is the area involved cleared of combustible materials before work commences, and are the opposite sides of walls or partitions also inspected? Is a careful watch maintained while hot work is in progress, with suitable extinguishers of appropriate type at hand? Is wooden flooring and other combustible material which is not movable covered before commences? Is the work area screened when welding or grinding is undertaken?

qa

Are gas cylinders secured vertically, and are they fitted with flashback arresters?

Waste Materials

se

14.0

as

Are tar boilers supervised by experienced operatives, and only taken onto roofs in exceptional circumstances? Is the work area thoroughly examined and hour after work is finished?

Are provisions made for the safe storage and removal of waste materials?

ov

er

Are checks carried out routinely to ensure that waste materials are not accumulating on the site? Are metal bins, with metal lids provided for oily rags?

ito

Is collected waste, awaiting disposal, kept away from temporary buildings stores and equipment? Is all dry vegetation removed regularly from around the site?

Plant

m

15.0

et

Is there an absolute prohibition on burning rubbish on site?

Is all plant with internal combustion engines positioned in well-ventilated, noncombustible enclosure with the exhaust pipes clear of combustible materials? Are compressors housed away from other plant? Do notices and staff training make it clear that fuel tanks must not be refilled whilst engines are running? Is plant equipment protected from accidental impact? Are air intakes positioned so that air is cool and free from flammable gases and vapours? Are sand-trays provided to absorb drips of fuel and lubricant?

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 1

2


2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................. 1

2.3.14 ASBESTOS ....................................................................................................... 1


.

2.3.14.2 Definitions ...................................................................................................... 4

.l. l

2.3.14.3 Types of Asbestos Surveys ........................................................................... 5

rw

2.3.14.4 Procedure ...................................................................................................... 5 2.3.14.5 Project Delivery .............................................................................................. 6

ta

2.3.14.6 Monitoring & Performance ............................................................................. 8

qa

2.3.14.7 Feedback & Action ......................................................................................... 8 2.3.14.8 Records .......................................................................................................... 8

as

2.3.14.9 Appendices .................................................................................................... 9 Reference Documents .............................................................................. 14

2.3.14.11

Author ....................................................................................................... 14

2.3.14.12

Approvals .................................................................................................. 14

m

et

ito

ov

er

se

2.3.14.10

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Page 2

PROCESS MAP Client

Project Manager

Competent Person/Contractor

Estimator

Supervisor

SHE Advisor

Ensure that the system is

Provide PreConstruction information including Asbestos S

1.2

Review PreConstruction Information



4.1

4.1

4.1

.l. l

.

4.2

Ensure Risk Assessment findings/controls are incorporated into the Plan of work if identified 5.5

Ensure that the Induction references asbestos material is on site

Issue Asbestos Survey, Risk Assessments/ Method Statement /Emergency Plan to supervisor 5.5

as

5.1, 6.1

se

Provide details to relevant personnel 1.4

ov

er

5.13

Provide support and training if

rw

Authorises and implements method statement/risk assessment

Produce and record a suitable and sufficient asbestos risk assessment 5.5

ta

4.2

Inform team of Asbestos Risks

qa

Ensure that Asbestos Survey has been completed and the report is available

Monitor activities to ensure compliance

m

et

ito

5.1, 6.1

Provide Health Surveillance as required 5.12

Monitor activities to ensure compliance

1.5, 5.8

Monitor and review performance

5.1, 6.1

Notify competent person of any change needed to controls

Conduct a subcontract review and record results

Attend a subcontract review

7

7

Ensure that the Induction references any changes in asbestos material on site

Ensures that all relevant records are maintained and/or archived 8

Key

Activity Guidance

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Page 3

PURPOSE 1

The purpose of this procedure is to define how Asbestos related activities shall be carried out safely.

SCOPE

et

ito

ov

er

se

as

qa

ta

rw

.l. l

.


m

1

QCS 2014


Page 4


Authorises this procedure. PROJECT/SITE MANAGER

2

Ensures the procedure is established and that the identification and removal of asbestos containing materials (ACMs), is carried out in accordance with this procedure and relevant information is communicated to interested parties.

.l. l

Ensures that the information provided by the client or his representative is considered when pricing the works and informs the relevant persons of details with regards to asbestos and asbestos containing materials.

rw

3

.

ESTIMATOR

Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures preparation of the necessary control documents required by this procedure.

as

qa

4

ta

SUPERVISOR

SHE MANAGER/ADVISER

se

Provides advice and support in the application of this procedure and monitors effectiveness to control the activities.

er

5

Person’s undertaking the work activities and required to carry out the task in accordance with this procedure.

et

ito

6

ov

OPERATIVE/CONTRACTOR EMPLOYEE

m


PROJECT MANAGER

1

For the purpose of this procedure, Project/Site Manager may also mean Depot Manager or Office Manager. SUPERVISOR

2

Ensures duties are carried out in accordance with this procedure. CONTRACTORS

3

Means work package contractors and their sub-work package contractors. (Includes work equipment supplies.)

QCS 2014


Page 5

2.3.14.3 Types of Asbestos Surveys TYPE 1 – PRESUMPTIVE SURVEY The purpose of the survey is to locate, as far as reasonably practicable, the presence and extent of any suspect ACM’s in the building and assess their condition. This survey essentially defers the need to sample and analyse for asbestos (or the absence thereof) until a later time (e.g. prior to demolition or major refurbishment). The duty holder bears potential additional costs of management for some non asbestos-containing materials. All areas should be accessed and inspected as far as reasonably practicable (e.g. above false ceilings and inside risers, service ducts, lift shafts etc), or must be presumed to contain asbestos. Any material which can reasonably be expected to contain asbestos must be presumed to contain asbestos, and where it appears highly likely to contain asbestos, there should be a strong presumption that it does. All materials which are presumed to contain asbestos must be assessed.

.l. l

.

1

The purpose and procedures used in this survey are the same as for Type 1, except that representative samples are collected and analysed for the presence of asbestos. Samples from each type of suspect ACM found are collected and analysed to confirm or refute the surveyor’s judgment. If the material sampled is found to contain asbestos, other similar homogeneous materials used in the same way in the building can be strongly presumed to contain asbestos. Less homogeneous materials will require a greater number of samples. The number should be sufficient for the surveyor to make an assessment of whether asbestos is or is not present. Sampling may take place simultaneously with the survey, or as in the case of some larger surveys, can be carried out as a separate exercise, after the Type 1 survey is complete.

This type of survey is used to locate and describe, as far as reasonably practicable, all ACM’s in the building and may involve destructive inspection, as necessary, to gain access to all area’s, including those that may be difficult to reach. A full sampling programme is undertaken to identify possible ACM’s and estimates of the volume and surface area of ACM’s made. The survey is designed to be used as a basis for tendering the removal of ACM’s from the building prior to demolition or major refurbishment so the survey does not assess the condition of the asbestos, other than to note areas of damage or where additional asbestos debris may be expected to be present.

m

et

ito

ov

3

er

TYPE 3 – FULL ACCESS

se

as

qa

ta

2

rw

TYPE 2 – SAMPLING SURVEY

2.3.14.4 Procedure TENDER 1

It is the responsibility of the client and their nominated representatives to provide detailed information including an Asbestos Survey. Pre-Construction Information should be examined by the Project Manager, Estimator and SHE Adviser to determine the presence of asbestos containing materials (refer to Asbestos Control Procedures Pre-Construction Stage Flow Chart at Appendix 1). PROJECT START-UP

2

The Estimator should inform the site team of the Asbestos Risk including previous asbestos removal during handover meeting. If an Asbestos Survey has not been provided, the Project Manager must request from the client information regarding the presence of asbestos. If the

QCS 2014


Page 6

client confirms asbestos is or may be present the Project Manager must request a survey be carried out – the type of survey should be determined by the nature of the work to be undertaken but where practical a Type 3 survey should be requested. Any identified asbestos must be removed by an approved and licensed contractor prior to commencement of works (refer to Asbestos Control Procedures Pre-Start Flow Chart at Appendix 1).

2.3.14.5 Project Delivery ON SITE ACTIVITIES The Project Manager should ensure that relevant control measures from the asbestos risk assessment have been implemented. In addition, all relevant information shall be communicated to personnel during the site induction process (refer to Asbestos Control Procedures On Site Flow Chart at Appendix 1).

.l. l

STOP – ISOLATE – PREVENT – INFORM

rw

ASBESTOS SURVEY

The results of all types of survey should be recorded and the information provided to anyone who may work on, disturb, be exposed to or supervise work on these materials.

ta

2

.

1

A list of approved surveys shall be monitored and held by the Procurement/SHE Department

as

3

qa

COMPANY APPROVED ASBESTOS SURVEYORS

Work with the most dangerous asbestos-containing materials (which give off high fibre levels when disturbed), require a competent contractor to undertake the removal works. Further guidance is available from the SHE Manager/Advisor.

ov

er

4

se

ASBESTOS REMOVAL CONTRACTORS

ASBESTOS RISK ASSESSMENT

(a)

If any work which will, or could, disturb asbestos is planned, has the risk assessment been done by a competent person? Does it relate specifically to the particular job and site?

m

(b)

ito

A suitable risk assessment should be made before carrying out any work which may expose employees to asbestos.

et

5

(c)

Does it cover other risks (like falls from height or electricity?

ASBESTOS REMOVAL 6

Selection of an approved competent contractor should be made from the company approved supplier/subcontractor database. Database administrators monitor the approval status of these specialists.

7

Although COMPANY appoints a specialist contractor for the removal of Asbestos, the Project/Site Manager should ensure that they work in accordance with the requirements of the Qatar Regulatory Document (Construction) and do not put others at risk from their operations.

8

The appropriate checklists should be used to assess the suitability of the method of removal and to monitor the on-site activities. The checklist should be used in conjunction with the method statement/risk assessment review form.

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Page 7

ASBESTOS WASTE 9

All forms of asbestos (including overalls used for removal & enclosure materials) requires double bagging and specialist waste removal procedures. ROLE OF VIEWING PANELS AND CCTV A sufficient number of viewing panels should be installed in enclosures. The purpose of such panels is to allow supervisors, managers to monitor work, thereby minimising the need to enter enclosures. Viewing panels should be located to ensure that all areas inside the enclosure are visible, as far as reasonably practicable.

11

Where such panels are not reasonably practicable or where they do not allow good visibility of the active work area, a CCTV system should be installed such that ongoing work can be seen.

12

Entry will be required on appropriate occasions in order to check compliance with the plan of work and relevant health and safety procedures. CCTV and/or viewing panels do not replace the need for enclosure entry but they may help to reduce the frequency of entry.

ta

rw

.l. l

.

10

All air testing, sampling of asbestos and clearance certification must be carried out by someone who is accredited by an appropriate body.

as

13

qa

SAMPLING, AIR TESTS AND CLEARANCE CERTIFICATION

SITE MANAGEMENT

se

In any circumstance where there is an emergency including an accidental uncontrolled release of asbestos fibres or uncovering of previously unidentified ACM, it is essential to limit exposure and the subsequent risks to health by implementing the Site and SHE Advisors emergency procedures (refer to Asbestos Control Procedures Site Emergency Flow Chart at Appendix 1).

ov

er

14

All asbestos removal contractors must have prepared procedures which can be put into effect should an incident, accident or emergency occur which could put persons at risk because of the presence of asbestos e.g. employee collapsing or suffering serious accident within the active stripping enclosure or an uncontrolled release of asbestos fibres.

16

m

et

15

ito

ASBESTOS REMOVAL CONTRACTORS

These procedures should include sufficient information to enable the emergency services (paramedics, Civil Defence (Fire Department) to properly protect themselves against the risks of asbestos when attending an on-site emergency. Spare PPE and RPE should be available for the use of emergency personnel who may have to attend to persons removed from an enclosure without full decontamination procedures being carried out.

MEDICAL AND HEALTH SURVEILLANCE 17

In circumstances where cases of inadvertent exposure to asbestos may have occurred, the following steps should be considered: (a)

Ascertain as far as possible the type of asbestos, the likely exposure levels involved and the duration of exposure.

(b)

Where employees may have been significantly exposed (for instance exposure may have exceeded the relevant action level), obtain advice from the appointed occupational health service provider, particularly regarding the medical assessment and counseling of exposed employees.

QCS 2014


Page 8

(c)

Consider offering those involved – employers, employees or members of the public, the opportunity to discuss the situation with a medical or occupational health advisor, particularly where they are otherwise unlikely to have access to an occupational health service.

(d)

Complete and archive an Inadvertent Exposure Record for each person who may have been exposed to airborne asbestos dust in the course of work for COMPANY.

INFORMATION, INSTRUCTION AND TRAINING Personnel who are, or may be, exposed to asbestos should attend asbestos awareness training given at regular intervals.

19

The safety induction format for the project shall include the discovery of asbestos whilst working within the premises and working at height.

20

All workers should attend a safety awareness tool box talk.

rw

.l. l

.

18

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2.3.14.6 Monitoring & Performance

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THE PROJECT MANAGER SHALL:

Review the Management System/Asbestos Management Plan every 6 Months and record details.

2

Review Risk Assessments and Method Statements (SHE-PRO-001) at regular intervals or, if there is a significant change to either the task to be carried out or substances to be used or produced.

3

Inspect known ACM for deterioration at least every 12 months or as indicated in the Asbestos Management Plan and record results.

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Project/Site Manager should conduct a sub-contract review of all contractors and record their findings on the Procurement Database

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2.3.14.8 Records

An effective Management System/ Asbestos Management Plan should be in place to protect staff, operatives and the public. Details should include: (a)

Label ACMs clearly with a suitable asbestos warning sign and make personnel aware of where it is located;

(b)

Make a note of where ACMs are on a site plan or other records and keep this information up-to-date;

(c)

Maintain records demonstrating that both training and information in relation to asbestos has been delivered to personnel;

(d)

Inadvertent Exposure and Health Records shall be kept and archived for a period no less than 40 years.

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2.3.14.9 Appendices

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APPENDIX 1 – ASBESTOS CONTROL PROCEDURES 1 - 5

PRE-CONSTRUCTION (TENDER) STAGE

Examine documents to see whether Asbestos is mentioned

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CONTROL PROCEDURE 1

Request assistance from SHE Advisor

Looking For

Asbestos Survey

Does the survey cover the work area and is it a Type 3 Survey

Request that client TYPE 3 survey be carried out

Proceed to next stage (Pre-Start)

Refer to SHE Advisor

PRE-START Internal Tender Handover Meeting

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Control Procedure 2

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Is TYPE 3 Survey in place?

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Refer back to Pre-

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Estimator to inform site team of Asbestos Risk including previous asbestos removal during handover meeting

Training Required

Have you attended Asbestos Training

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SHE Advisor to organise Asbestos Training

Actions for SITE MANAGER

Arrange Asbestos removal by a competent Contractor

Proceed to next stage

Request assistance from She Advisor

Team review of Asbestos Survey

Ensure all Asbestos associated Surveys and documentation (including Risk Assessments and Asbestos Management Controls are retained.

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ON SITE

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Control Procedure 3

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Inform all persons on site of risk of Asbestos Risk

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Is Asbestos present on site?

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Site Manager to inform all operatives of controlled Asbestos areas during site induction process

Asbestos Management

If Asbestos materials are suspected, which have not been previously identified?

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Asbestos Removal

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Contractor to Monitor Asbestos Removal Subcontractors

Ensure relevant control measures from risk assessment been implemented?

STOP WORK ISOLATE AREA PREVENT EXPOSURE

Notify Line Managers Contractor

INFORM SHE ADVISOR Refer to site emergency procedure

Notify Sampling Contractor

SITE EMERGENCY PROCEDURES

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Control Procedure 4

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Potential Asbestos Disturbance

Site Manager to notify SHE Advisor

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Notify Line Managers

STOP, ISOLATE, PREVENT FURTHER

SHE Advisor to notify MD & SHE Manager

SHE Advisor & Site Team commence incident investigations

Confirmation of Asbestos Containing Materials NO

Proceed with Works

Appoint competent contractor to carry out clean up/removal

Notify Sampling Contractor

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SHE ADVISORS EMERGENCY PROCEDURES

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Control Procedure 5

Discuss emergency procedures (stop work, isolate, limit, prevent)

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SHE Advisor receives phone call/notification

Notify MD & SHE Manager

Decide if incident investigation should be carried out, then attend site

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Assist in planning for professional clean up/removal

Complete RIDDOR Dangerous Occurrence notification F100 within 10 days

Undertake Investigation

Contact fellow SHE Advisor for advice

Is exposure considered a Dangerous Occurrence in accordance with RIDDOR

Note: Decision to be undertaken in consultation with MD & SHE Manager

Record notification decision outcome within incident investigation report and close out investigations with regional and site management

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2.3.14.10

Reference Documents

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FORMS Asbestos Removal Method Statement Checklist (SHE-FRM-14-01)

2

Asbestos Removal On-Site Activity Checklist (SHE-FRM-14-02)

3

Inadvertent Exposure Record (SHE-FRM-14-03)

4

Method Statement Tracking and Content (SHE-FRM-1-04)

5

Permit to Work (SHE-FRM-11-02)

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2.3.14.11

Author POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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FURTHER REFERENCE DOCUMENTS

Approvals

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2.3.14.12

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SHE Manager

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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REMOVAL METHOD – CHECK LIST

ACL 1

ASBESTOS

Introduction Although we appoint a specialist contractor for the removal of Asbestos we still have a duty to ensure that they work in accordance with current legislation and do not put others at risk from their operations. This checklist must be used in conjunction with your method statement review form. Training and Capability

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Operatives undertaking this nature of work should have been trained annually on working methods, types of equipment used, types of works carried out and PPE & RPE use. Note young persons must not undertake asbestos removal works.

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Control Arrangements

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6 7 8

Checked

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Item Name and address of asbestos removal contractor Asbestos competency evidence Name and address of the site to which the method statement relates Names of the supervisor/foreman and appointed safety adviser and arrangements for monitoring the work Type of work e.g. removal of roof sheets, insulation boarding or lagging Type and quantity of asbestos and the results of any analysis Probable duration of works The controls to be applied to reduce exposure other than by PPE e.g. controlled wetting method Details of expected exposures Details of the steps to be taken to control the release of asbestos to the environment e.g. enclosure arrangements, negative pressure equipment, reassurance monitoring, clearance certificate on completion etc. Location of decontamination unit Arrangements for 240v power supply and clean water supply Details of the equipment, including PPE, to be used for the protection and decontamination of those carrying out the work Procedures for the removal of waste from the work area and the site, and disposal of contaminated water Procedures for dealing with emergencies

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No. 1 2 3 4

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Asbestos removal method statements should normally include the following so far as is relevant to the specific works:

11 12 13 14 15 Note

The above list is not exhaustive for every asbestos removal task but should be used as an aid. Consult with your regional SHE advisor for further guidance.

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ON-SITE ACTIVITY – CHECK LIST

ACL 2

ASBESTOS

Introduction Although we appoint a specialist contractor for the removal of Asbestos we still have a duty to ensure that they work in accordance with current legislation and do not put others at risk from their operations. Site Management Requirements

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Site Managers and their appointed supervisors must understand company procedures on Asbestos management. Read through procedures and discuss with your regional SHE advisor. Control Arrangements

4

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Checked

Suitable plan/method statement has been supplied, outlines the method of work and any health and safety issues raised by the risk assessment Facilities provided by the asbestos removal contractor are suitable and do not obstruct any access, etc This applies particularly to the enclosure, the hygiene facility and air ducting. Before work commences, that the enclosure within which the contractor is to work, will not permit any escape of asbestos fibre into the atmosphere. This can be achieved by witnessing the smoke test being carried out. Insist that the enclosure includes a viewing panel. A maintenance/inspection schedule is in place for the enclosure and any air extraction equipment.

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Asbestos removal works must be monitored throughout their duration and this check list is intended to assist in this process.

That asbestos does not escape into the atmosphere during the stripping operation. Air monitoring around the enclosure during stripping works will indicate efficiency.

6

The adequacy of the personal decontamination procedure, so that asbestos is not released from persons moving through the site. That the area being stripped is clean, both visually and with the supporting air sampling results. That the removal of the enclosure does not give rise to the release of asbestos fibre. Air monitoring around the enclosure before stripping work commences and during enclosure removal. That the storage of removed asbestos on site does not give rise to asbestos fibre release and that all asbestos is effectively removed from site double bagged and in suitable skips. Air clearance certification received for work area concerned prior to re occupation by Anon and associated contractors.

8 9 10

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5

Note The above list is not exhaustive for every asbestos removal task but should be used as an aid. Consult with your regional SHE advisor for further guidance.

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Inadvertent Exposure Record

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Region:

ASBESTOS

Department: The person named below may have been exposed to airborne asbestos dust in the course of work for COMPANY. The circumstances are detailed for record purposes. Worker Number: Name: Home Address:

DOB:

Job Title

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Project where incident occurred:

Finish:

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Date of Exposure; Start:

Finish:

Activity at time of exposure:

□ □ □ □

YES/NO

Type of asbestos: Crocidolite (Blue) Amosite (Brown) Chrysotile (White) Other:

□ □ □

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Respiratory Protective Equipment in use?

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Time of Exposure; Start:

Indicate nature of product: Cement AIB Lagging Sprayed

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Employer:

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Other:

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Air testing results attached? Sampling date:

YES/NO Time:

Name of person completing this form: Signature:

Title:

Region:

Department

Date: This record should form part of the investigation into the inadvertent exposure; all records must be kept for a minimum of 40 years.

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

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SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ........................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ................................... 1



ENVIRONMENTAL PROTECTION ........................................................................ 1

2.3.15.1 Responsibilities ...................................................................................................... 4

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2.3.15.2 Definitions .............................................................................................................. 5 2.3.15.4 Guidance to This Procedure .................................................................................. 9 2.3.15.5

Reference Documents ..................................................................................... 12

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2.3.15.13 Author ................................................................................................................ 25

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2.3.15.14 Approvals ........................................................................................................... 25

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2.3.15.14 Approvals……………………………………………………………………………26

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Process Map Input

Design

Procurement

Contact SHE for input

Receive contract documents Communicate any design decision that impacts in waste and environment

Risk Assessment and ECCoP Procedures

Project Management

SHE

Dept: Complete Risk Assessment and produce specific ECCoP and SWMP opportunity/early decision

SWMP documents or client documents

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Assist Audit, check and correct

Tender ECCoP SWMP

ECCoP Guidance

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SHE-FRM8 05 01

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SWMP

Develop and complete on site – record Waste through TRAKER

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SWMP Archive documents O & Ms

SWMP

SHE-FRM-1-03 Method Statement or Task Risk Assessment

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Works Order Request

Assist

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Monthly Data Collection Form (SHE-FRM-8 05-01)

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Construction

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Draft ECCoP and Risk Assessment

Output

With Project team/Estimati ng assist with Risk Assessment / ECCoP and SWMP

.

Pre-Construction

Contract Documents

Estimating

SHE-FRM-1-02

Assist

O & Ms,

Issue to client

Documents for archive SWMP Consent Records Etc. Issue to Client

Key

Activity Guidance

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PURPOSE The purpose of this procedure is to provide a framework by which environmental impacts and aspects will be managed. COMPANY Policies and in compliance with the requirements of the Environmental Management System Standard BS EN ISO 14001.

4

The Environmental Protection Law No. 30 of 2002 translates environmental policy objectives into a benchmark standard of environmental operation and this Environmental Management System may be subject to third party, independent certification by external Environmental Auditors.

5

The Environmental Protection Law No. 30 of 2002 provides a structure in which legislative requirements, best practice and pollution prevention obligations can be addressed in a logical, orderly manner. The framework can be extended to incorporate Client and/or regulatory nonstandard requirements. The law also provides a vehicle for corporate commitments to be translated into everyday activities.

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SCOPE

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1. This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Note: Environment Ministry is the competent authority in relation to matter relating to environmental protection and any spillages of hazardous material/substances must reported accordingly.

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2.3.15.1 Responsibilities 2.3.15.1.1 SHE Director 1

Authorises this procedure. PROJECT/SITE MANAGER/SUPERVISORS Ensure this procedure is established and works are carried out in accordance with this procedure.

3

Environmental or SHE Advisers should be contacted to carry out the Environmental Survey and Risk Assessment and assist site management in the implementation of the Environmental Protection Law No. 30 of 2002. Successful operation of the system is dependant on Project Management's commitment to make it work.

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2.3.15.1.2 ENVIRONMENTAL MANAGER/ADVISOR/SHE ADVISER

Provide advice and support in the application and monitoring of this procedure. In conjunction with Project Management, carry out Environmental Survey and Risk Assessment form and produce project specific framework.

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2.3.15.1.3 PROCUREMENT/ESTIMATING

Determine the relevant issues identified by this procedure and provide for adequate resources at the tender stage.

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Consider environmental issues in the preparation of designs and provide input to the construction process to facilitate environmental best practice.

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2.3.15.1.4 DESIGNER

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2.3.15.1.5 ENVIRONMENTAL CO-ORDINATOR In most cases the Site Safety Co-ordinator shall assume the role as Site Environmental Coordinator.

2

Where more than one Site Environmental Co-ordinator is appointed their areas of responsibility shall be clearly defined and agreed with them.

3

The role of the Site Environmental Co-ordinator is to assist the site/location manager to comply with their environmental responsibilities.

4

The main duties of the Site Environmental Co-ordinator are as follows:

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(a)

To assist management in identifying environmental requirements set out in the contract documentation.

(b)

Accompany Environmental Advisers during visits to site.

(c)

Assist management in the implementation of the Environmental Protection Law No. 30 of 2002.

(d)

Co-ordinate and attend Environmental forum meetings.

(e)

Conduct regular environmental inspections to check compliance with the Environmental Protection Law No. 30 of 2002.

(f)

Liaise with management to facilitate environmental improvement where deficiencies have been highlighted.

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Page 5

(g)

Respond to observations/comments from personnel with environmental concerns.

(h)

To maintain a liaison role with COMPANY Environmental Adviser and the appropriate local agencies (e.g. Labor & Environment Ministries)

(i)

Assist the Site Safety Co-coordinator in the timing of environmental awareness talks.

(j)

To assist in site induction preparations and/or presentations.

(k)

Ensure adequate emergency procedures are developed for the site/location

2.3.15.1.6 DUTIES OF WASTE CO-ORDINATOR In association with the Purchasing Team, monitor sub or work package contractors’ replies relating to waste.

2

Notify sub or work package contractors of site requirements relating to waste including separation.

3

Monitor waste handling and containment on site or at the permanent location ensuring that the requirements of the Environmental Protection Law No. 30 of 2002 are being fulfilled.

4

Check that the waste is disposed of at an appropriately authorized facility obtaining relevant copies of documentation and as necessary follow loads to disposal facilities to support this requirement.

5

Report any inadequacies in carrier performance immediately to the site or permanent location manager and the Purchasing Team.

6

Report any failure of sub or work package contractors to handle waste correctly to the site or permanent location manager.

7

Liaise with the SHE Team if there are any doubts on classification of waste such as hazardous waste.

8

Where COMPANY vehicles carry waste, determine that the waste to be carried is acceptable to the authorized waste manager/disposer for whom it is destined.

9

Maintain records for archiving for a period of three years.

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2.3.15.2.1 RISK ASSESSMENT 1

2.3.7.1.2 2

The process of hazard, aspect and impact identification, assessment of the risk and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity and the protection of the environment from harm. HAZARD/ASPECT/IMPACT Is something with the potential to cause harm (this can include substances or machines, methods of work, harm/damage to the environment including the potential of causing a statutory nuisance and other aspects of work organization).

2.3.15.2.3 METHOD STATEMENT 1

A statement describing the proposed working methods that address the output from a risk assessment process. A Method Statement provides instruction and guidance for those individuals carrying out the activities.

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ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002

The Environmental Protection Law No. 30 of 2002 forms a key part of COMPANY’s Environmental Management System, particularly on larger projects, and provides an effective environmental management tool for a project, office or other fixed location.

2.3.15.3 Action Required To Implement This Procedure 2.3.15.3.1 INITIAL CONTRACT OR SUB-CONTRACT ENQUIRY On receipt of the tender enquiry, the contract documents shall be reviewed by the Estimating Team to ascertain the following (where required assistance should be sought from the Environmental Adviser) : (a)

Pollution sources potential or impact identified

(b)

Possible areas of pollution/contamination, or potentially contaminated past and use, e.g. landfill, heavy industrial works.

(c)

Conditions of any Environmental Statement (contact the Environmental Adviser).

(d)

Waste types and quantities likely to be generated.

(e)

Other environmental issues such as special Client requirements.

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In view of the necessity to identify applicable legislation and prevent breaches, advice, where appropriate, shall be sought from the following sources:

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The environmental issues identified in 3.1 shall be communicated to the project team to allow environmental issues to be addressed by appropriate team members such as Designers, Estimators etc.

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2.3.15.3.2 TENDER

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(a) The Client (b) Enforcing Authorities (e.g. Labor & Environmental Ministries) (c) Environmental Adviser/Manager

The elements of the Environmental Protection Law No. 30 of 2002 (Appendix 1) shall be taken into account in the tender submission in addition to any other requirements identified through section 3.1.

2

Any tendering sub or work package contractors shall be made aware of any environmental constraints or issues potentially affecting their works and likely commercial effects.

3

It is a policy requirement that only sub or work package contractors who can demonstrate a commitment to environmental management shall be invited to tender for work. Estimators or procurement personnel shall therefore implement this requirement where the environmental performance of a sub or work package contractor is previously unknown.

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2.3.15.3.3 DESIGN 1

Initial and any subsequent design shall take into account the requirements of the Environmental Protection Law No. 30 of 2002 (see Appendix 1).

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2.3.15.3.4 CONTRACT AWARD/PRE-COMMENCEMENT The Project Manager shall contact the Environmental Adviser to initiate an Environmental Risk Assessment (Appendix 1) for applicable contracts and advise on establishing contact with the appropriate regulatory authorities (e.g. Labor & Environment Ministries). The Environmental Adviser shall carry out the baseline Risk Assessment with assistance from the Project Team.

2

On contract award the Project Manager shall review the Environmental Protection Law No. 30 of 2002 (Appendix 1) in conjunction with an Environmental Adviser and relevant parts implemented. Additional environmental requirements identified in section 3.4 shall be incorporated in and be managed through the SHE Management Plan specific to the contract.

3

The project Supply Chain Manager/Procurement Team shall make sub and work package contractors shall be made aware of their environmental obligations as detailed under the Environmental Protection Law No. 30 of 2002 and if applicable the SHE Management Plan.

4

For smaller projects that are instructed via a works order an Environmental Protection Law No. 30 of 2002 is not required. Environmental Management (Document, efficient etc) must be considered as part of the Risk Assessment SHE-PRO-001.

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2.3.15.3.5 CONSTRUCTION PHASE

The Construction Manager/Project Manager/Site Manager shall ensure that the Environmental Protection Law No. 30 of 2002 has been implemented on site where applicable.

2

In the event of a works order being placed environmental impact is assessed via a ‘Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) or detailed ‘Method Statement’ (SHE-FRM-1-03) dependent on the scope of work.

3

The Project Team shall include Environmental issues in site inductions within Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, and Subcontractors, (SHE-PRO-006)

4

Environmental issues shall be covered in detail within Safety, Health and Environmental Risk Management and Written Safe Systems of Work SHE-PRO-001

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The Project Management Team shall ensure that all site supervisory staff regularly monitors environmental matters whilst executing their normal site duties.

6

The Project Management Team shall ensure environmental matters shall be listed and discussed as an agenda item.

7

Project Manager, with the SHE Adviser, shall review the Environmental Protection Law No. 30 of 2002 on a regular basis throughout the project, and in line with the SHE Management Plan, to take into account changes in the job.

8

The Project Team and Environmental Adviser shall, in pursuance of good relationships with enforcing authorities and where it is deemed practicable, contact the statutory authority (e.g. Labor & Environment Ministries), invite them to site to inspect works and keep them fully informed of the progress of the works. This should be managed through the SHE Management Plan.

9

The Project Team shall record and report any environmental incidents in accordance with SHEPRO-008 – The Report and Investigation of Accidents and Incidents procedure.

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2.3.15.3.6 OFFICES/FIXED LOCATIONS 1

The Office/ Facility Manager shall develop an Environmental Protection Law No. 30 of 2002 and waste plan for each office/fixed location (yard/depot/factory etc), in conjunction with the Environmental Adviser.

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2.3.15.3.7 HANDOVER 1

The Project Team shall ensure all temporary consents are closed out with the appropriate authority or handed over to the Client; the Client shall be informed of any statutory and/or on-going environmental restrictions, permits, and consents operating on the contract at handover.

2.3.15.3.8 SITE CLEARANCE 1

All waste materials under the control of COMPANY shall be removed from site in accordance with the COMPANY Environmental Standards and Guidance documents.

2

Following site clearance the client shall be invited to agree that the site is clear of any waste, polluting or contaminating materials. Agreement shall be recorded in writing.

2.3.15.2.9 NOTICES Any Environmental Notice pertaining to any environmental matter shall be notified using the COMPANY SHE Alert System, SHEPRO-008 – The Report and Investigation of Accidents and Incidents procedure.

2

Any such notice shall be fully complied with and copies served on sub contractors or others likely to be affected by the document contents.

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Should any summons be received in relation to environmental matters it shall be referred to the COMPANY SHE Director who shall forward it immediately to the COMPANY MD and Regional MD and will brief solicitors and handle the matter directly.

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PROSECUTIONS

Formal visits to site by a Workplace Inspector shall be accompanied at all times and the Project Manager made aware of their visit who in return will notify the Environmental Adviser or Environmental Manager using the First Alert Form SHE-FRM-8-01

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2.3.15.3.10 VISITS BY LABOR & ENVIRONMENT MINISTRIES, WORKPLACE INSPECTORS

(

).

Notes shall be made of any action taken, comments, testing and/or sample taken including locations at which samples have been taken during a formal visit.

3

Should any sample be taken off site the company should request a share of the sample and this shall be retained, if it is refused the fact shall be recorded. Details of the exact origin of the sample, time of sampling and the method used shall be requested.

4

Should a statement be requested the following should be adhered to:

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(a)

Immediately notify the COMPANY SHE Director and Line Manager.

(a)

Request the presence of a third party (Project Manager or equivalent) who shall take notes.

(b)

Request a copy of any statement you have made and make it clear that you wish a copy of the statement to be made available to your employer.

For routine visits by a Workplace Inspector, record in the Project Diary and notify the SHE Team.

2.3.15.3.11 MAINTENANCE PERIOD 1

Where maintenance operations impose a serious environmental risk any such operation shall only be carried out under the guidance of, and in compliance with a prepared environmental method statement and/or Client's occupier's environmental codes of practice.

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Maintenance staff/operatives shall be briefed that their operations shall not affect the environmental integrity of plant and control measures shall be put into place to ensure that all environmental risks are adequately controlled.

2.3.15.3.12 POST CONTRACT AND COMPLETION ENVIRONMENTAL 1

Wherever an environmental problem is raised by the client after occupation the COMPANY Environmental Manager shall be notified as soon as possible.

2.3.15.4 Guidance to This Procedure 1. The framework Environmental Protection Law No. 30 of 2002 (Appendix 1) is designed to

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be tailored to the environmental risks that are specific to the project/office, through the use of the Environmental Risk Assessment which precedes it. The Environmental Protection Law No. 30 of 2002 provides a robust framework detailing the company’s minimum environmental performance and community engagement standards, and can be amended to include any contract or Client specific requirements. 2. In the event of a works order being placed environmental impact is assessed via a

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‘Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) or detailed ‘Method Statement’ (SHE-FRM-1-03) dependent on the scope of work.

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APPENDIX 1 - ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002, ENVIRONMENTAL SURVEY AND RISK ASSESSMENT FORM (SHE-FRM-15-12) HOW TO DEAL WITH POTENTIAL THREATS TO THE ENVIRONMENT Site-specific environmental threats should be identified through the review of contract documentation and desk studies with the Project Team and incorporated in to the Environmental Survey and Risk Assessment Form. The control measures identified should be included within the Template of Environmental Protection Law No. 30 of 2002 and site specific controls (mitigation) included in order to control these threats.

2

Task Specific Method statement (SHE-FRM-1-03) or Job/Task Risk Assessment /Method Statement (SHE-FRM-1-02) should also include specific environmental controls. As detailed below:

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IDENTIFICATION OF POTENTIAL THREATS TO THE ENVIRONMENT

.

1

All activities which will require a risk assessment to be completed for the Health and Safety of the personnel undertaking the task must also include any environmental risks associated. Some commonly occurring potential threats to the environment can exist when:

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(a) there is a quantity of polluting material stored on site,

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(b) a site/material is located in an environmentally sensitive location such as near to a water source or surface water drain, next to a residential property/school (Examples of polluting materials: diesel, silty water, lubricant oils, paints, adhesives, battery acid, slurry, cement, treated timber, pesticide), (c) a site contains contaminated ground/materials,

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(d) noise/ vibration levels are predicted to be high,

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(e) an invasive species is present (Japanese Knotweed, Himalayan Balsam etc.), (f) waste is produced,

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(g) dust is generated,

Note: The above are commonly occurring however this does not cover all potential environmental risks, which could be present on any specific site.

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(h) plant/machinery is refueled

COMMUNICATING THE ENVIRONMENTAL RISKS 1

Once a specific risk assessment or method statement – (SHE-FRM-1-03) or Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) has been produced then all affected personnel must be informed of the relevant controls specified, most probably through a method statement briefing.

REVIEWING THE ENVIRONMENTAL RISKS 1

Once the specific risk assessment has been established it is imperative that it is periodically reviewed in light of changing circumstances on site, different materials and locations.

CHECK 1

All risk assessments should include any environmental risks associated with the activity. As an example, any activity which uses plant/ machinery will have diesel as a potential pollutant.

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Suitable control measures in the risk assessment should ensure that diesel from our site does not cause any pollution during either refueling or operations. 2

Action owners shall be assigned to all appropriate sections of the Environmental Protection Law No. 30 of 2002 and a regular review of progress shall be held at a separate environmental meeting or environmental issues can be discussed at regular site meetings.

ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 (SHE-FRM-15-13) 1

The following items shall be addressed in order to ensure that the Environmental Protection Law No. 30 of 2002 is implemented effectively: (a) Assign responsibility to site management; (b) Assess needs for training or awareness; (c) Co-ordinate liaison with Ministry’s

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(d) Measure environmental performance of the project against that planned; (e) Amend Environmental Protection Law No. 30 of 2002 ; (f) Review environmental inspections/audits;

(g) Develop the profile of environmental performance on-site;

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(h) Ensure continuous improvement.

The above actions and review of progress may be conducted by the Project Management Team,

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Environmental Team, SHE Advisers, Engineers, Client.

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The Environmental Protection Law No. 30 of 2002 shall be revised on a regular basis, and in line with the SHE Management Plan (e.g. every 3 months), to take into account changes in the job; the revision programme will be dictated by the SHE Management Plan.

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Environmental Forum Structure

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2.3.15.5 Reference Documents 2.3.15.5.1 FORMS (a) Site Waste Management Plan Options (b) SWMP Word Version (SHE-FRM-15-01) (c) Complaints/Comments/Compliments Record (SHE-FRM-15-02) (d) Water Discharge Inspection Sheet (SHE-FRM-15-05) (e) Controlled Waste Transfer Note (SHE-FRM-15-06)

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(g) Communication Record (SHE-FRM-15-09)

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(f) Environmental Vibration Recording Sheet (SHE-FRM-15-07) (h) Environmental Check – Open culvert/Stream (SHE-FRM-15-10)

(i) Environmental Noise Survey Summary Sheet (SHE-FRM-15-11)

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(j) Method Statement – (SHE-FRM-1-03)

(l) First Alert (SHE-FRM-8-01)

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(k) Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02)

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(m) Environmental Survey and Risk Assessment (SHE-FRM-15-12)

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2.3.15.5.2 REFERENCE DOCUMENTS

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(n) (SHE-FRM-15-13)

Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHEPRO-001)

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Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, Promoters and Sub-Contractor Personnel (SHE-PRO-006)

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Contractors Check List for Initial Safety, Health and Environmental Meeting (SHE-PRO-007)

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The Report and Investigation of Accidents and Incidents (SHE-PRO-008)

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2.3.15.6 Contractor Requirements 1. The Contractor will be required to appoint a suitably qualified Contractor’s Environmental Manager (CEM) who will ensure that all reasonably practicable means are adopted to fulfill the environmental requirements of the Employer. The Section D Technical Deliverables indicates the qualifications and experience required. The CEM will hold regular meetings, at least monthly, with the Engineer to discuss construction activities and compliance with the Construction Environmental Management Plan (CEMP).

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2. All CVs of contractor’s environmental management personnel will be subject to review and approval by the Engineer and, if appropriate, candidates will undertake a formal interview and be subject to an agreed probationary period. The Engineer has the right of rejection if environmental management candidates do not reach the required criteria during the probation period.

2.3.15.7 Legal Framework

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1. The Contractor working on the Work Order shall comply with relevant national and international legislation, local bylaws and codes of practice. In the absence of appropriate legislation, recognized best practice will be followed.

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2. The contractor shall ensure that all subcontractors and works under their control also comply with all relevant legislation and codes of practice. Best practice will be followed at all times. 3. The following national legislation and codes, but not limited to, will apply:

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QCS (Qatar Construction Specifications) latest edition; Labor Law 14 of the Year 2004; Qatar Traffic Law No 19 of the Year 2007; Environmental protection Law 30 of the Year 2002; Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) of 2002CDD (Department of Civil Defense) – Fire Safety Handbook; and Worker Rights Booklet 2009 (National Human Rights Committee).

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a. b. c. d. e.

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4. In the event that legislation is updated the latest version shall be followed. All relevant new legislation will be followed as appropriate. 5. The contractor shall comply with all Environment Impact Assessment Mitigation and Environmental Permit Conditions.

2.3.15.8 Programme Management Delivery System (PMDS) 2.3.15.9 Environmental Management and Responsibilities 2.3.15.9.1 General Requirements 1. The contractor shall be required to have a recognized environmental management system such as ISO 14001:2004 or be able to demonstrate that they are actively working towards implementing such a system. Prior to the commencement of the project the contractor shall produce a CEMP that will be reviewed by the Engineer. The CEMP will be submitted for approval within 30 days of the award of contract. The CEMP must be approved by the Engineer prior to the start of construction. The Contractor shall review

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and update the CEMP as appropriate but no less than quarterly. A record of the review and any recommendations shall be produced and retained on file by the Contractor. 2.3.15.9.2 Environmental Policy 1. The Contractor shall have an environmental policy dated and signed by the most senior person in the company. The policy shall:

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(a) Be appropriate to the nature, scale and environmental impacts of the organizations activities, products and services. (b) Include a commitment to continual improvement in environmental performance (c) Include a commitment to comply with all applicable legislation and with other requirements to which the organization subscribes which relate to its environmental aspects (d) Provide a framework for setting and reviewing objectives and targets (e) Be documented, implemented and maintained (f) Communicated to all persons working for or on behalf of the organization (g) Be available to the public

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2.3.15.9.3 Environmental Aspects

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1. The Contractor is expected to use a qualitative approach to identify and evaluate potential environmental aspects along with any controls to prevent or mitigate environmental damage. A simple risk matrix should be used to assess and evaluate all environmental risks on the project. An example of a risk assessment is presented below.

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2. Environmental Risk Assessment

A. STAGE ONE: Identify your Environmental Aspects

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1. Your environmental aspects are how you interact with the environment e.g. your activities, products or services. These will be identified for normal, abnormal and emergency conditions. 2. Key to operating conditions:

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3. Normal ‐ those activities, products or services as they are carried out or used on a regular day to day basis and operating as intended.

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4. Abnormal ‐ those activities, products and services as they are carried out or used on an irregular or limited basis but as intended e.g. maintenance 5. Emergency‐ those activities, products or services as they are carried out or used in an unintentional manner B. STAGE TWO: Identify your Environmental Impacts 1. Your environmental impacts are how your activities, products or services cause a change to the environment. These impacts can be positive or negative.

2. Consider the environmental media that could be affected:        

Air quality; Water quality; Land (contamination); Waste (solid, liquid, hazardous); Resource use (energy, water, materials consumption); Nuisance (noise, odour, dust); Wildlife; and Carbon.

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C. STAGE THREE: Detail Existing Control Measures 1. There may be control measures in place that limit the risk. The controls may be documented in procedures, physical controls (e.g. spill kits, interceptors) or control through training. D. STAGE FOUR: Evaluate the Environmental Risk 1. Evaluate the significance of the environmental risk. Example criteria:    

Legal Breach; Risk of environmental damage or harm; Significant use of resources; and Third party interest (stakeholder interest, source of complaints / questions).

E. STAGE FIVE: Determine Environmental Risk Rating

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1. Determine whether the risk to environment is High or Low risk. An example of how to do this is provided in the Environmental Register, available on the PDMS.

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2. If the activity is identified as High risk ‐ It will require management action to improve level of control e.g. permit may be required, EIA, mitigation detailed in CEMP. It will require documentation of control within EMS e.g. development of procedure or training requirement

F. STAGE SIX: Implementation

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3. If the activity is identified Low risk ‐ It does not require further action at this stage.

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1. The risk assessment process should be reviewed during the activity and any changes or updates should be communicated to those involved in the project. 2. Worked Example

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3. Activity: Storage Oil stored in tank used for powering generator

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4. Environmental Aspect: Leak identified from fully bunded Oil storage tank 5. Environmental impacts:

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 Potential for contamination of land;  Potential contamination of local water bodies; and  Hazardous waste from clean-up activities. 6. Controls:  Ensure oil tank is fully bunded capable of holding 110% of tank capacity;  Ensure sight gauge and pipe work are contained within the bund;  Introduce delivery procedures, signage and training;  Carry out regular inspection of the bund and tank to check for leaks; and  Have a spill kit at the location. 7. Risk: (a) High Risk ‐ If the fuel escapes to water or land it would be in breach of regulations and would be costly to clean up.

2.3.15.9.4 Objectives, Targets and Improvement Programmes 1. The Contractor shall establish, implement and maintain documented environmental objectives and targets at relevant functions and levels within the organization. Objectives and targets shall be measurable and should be consistent with the environmental policy and the sustainable development objectives set out in the PMDS. When establishing and reviewing its objectives and targets the contractor shall take into account the legal and other requirements to which it subscribes and its significant environmental aspects. 2. The contractor shall establish, implement and maintain programmes for achieving its objectives and targets. Programmes shall include:

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a) Designated responsibility for achieving objectives and targets at relevant functions and levels of the organization; b) The means, resources and timeframes by which they are to be achieved 2.3.15.9.5 Roles and Responsibility

1. The contractor shall ensure that resources are available to develop, implement, maintain and improve the CEMP including: (a) (b) (c) (d) (e)

Human resources; Skills and training; Organizational infrastructure; Technology, plant and equipment; and Financial resources.

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2. The Contractor shall define, document and communicate the roles, responsibilities and authorizations in order to facilitate effective environmental management.

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1. The following provides guidance on roles and responsibilities at various function levels and shall be used as a basis for further development in conjunction with the PMDS and QCS 2010.

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2. Business Head/Director: Responsible for implementation of the Environment Policy and overall environmental performance.

3. Contractor Environmental Manager (CEM): Responsible for development and

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implementation of the CEMP. Duties shall include but not be restricted to:

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(a) Development and implementation of the CEMP to meet the requirements of the Work Order in general, and PMDS; (b) Monitoring and reporting on environmental performance; (c) Ensuring that all staff are appropriately trained and informed; (d) Setting, monitoring and reviewing environmental objectives and targets; (e) Maintaining adequate environmental records; (f) Liaising with the client and others as required; (g) Ensuring that relevant statutory legislation is monitored and the requirements followed; (h) Ensuring that accidents and incidents are appropriately reported; (i) Ensuring that environmental issues are considered by all staff and are applied to their work; Responding to unplanned and emergency situations as required; and (j) Reviewing performance against relevant objectives and targets.

4. Site Based Responsible Environmental Person (SBREP): Duties shall include but not be restricted to: (a) Ensuring that the CEMP is developed, implemented and maintained on site according to the LR&DP PMDS requirements; (b) Reporting on performance of the CEMP and make recommendations for improvement; (c) Undertaking daily/weekly checks as required ; (d) Undertaking monitoring and reporting on environmental performance as required; and (e) Delivering toolbox talks. All staff: Duties shall include but not be restricted to: (a) Being environmentally aware and implementing the CEMP as appropriate;

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(b) For undertaking their work in a manner that does not adversely impact on the environment; and (c) Reporting environmental accidents, incidents and near misses. 2.3.15.9.6 Competences, Training and Awareness 1. The Contractor shall identify the training needs associated with the project, CEMP and its environmental aspects and produce a training plan. The training plan shall be subject to approval by the Engineer. The contractor shall provide appropriate training or take other action to meet these needs and shall retain associated training records. 2. The Contractor shall establish and implement a procedure to ensure that all persons working for it or on its behalf are aware of: The importance of the Environmental Policy and compliance with it; The requirements of the PMDS and CEMP; The significant environmental aspects and the potential impacts of the work; The benefits of improved environmental performance; The importance of complying with relevant environmental law and environmental permit (f) conditions; (g) The importance of complying with specified procedures; and (h) The potential consequences of departure from specified procedures, work instructions and method statements. (i)

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(a) (b) (c) (d) (e)

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3. The Contractor shall ensure that all staff with specific responsibility for the environment is trained in accordance with the PMDS.

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2.3.15.9.7 Communication

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1. The Contractor shall establish, implement and maintain communication procedures to enable the effective implementation of the CEMP. Specifically the communication procedure will be for:

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(a) Internal communications between the various levels and functions within the organization; and (b) Receiving, documenting and responding to relevant communications from external stakeholders including (but not limited to) GEC, PMC, PWA, MMUP and MoE.

2. All communication procedures must be compliant with the PMDS. 2.3.15.9.8 Documentation

1. The Contractor shall develop, implement and maintain a document system to include, but not be restricted to: (a) (b) (c) (d) (e)

The Environmental Policy; Environmental improvement objectives and targets; Including competencies and training; Relevant EIA documentation; CEMP:

 Procedures  Method statements  Work instructions (f) Record Keeping:

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Daily inspections Weekly inspections Internal and external audit reports Environmental permits and consents.

3. The Contractor shall develop, implement and maintain a procedure to:

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(a) Approve documents for adequacy and accuracy before issue; (b) Review, update and reapprove documents; (c) Ensure that changes to documents and the current revision status of documents are identified; (d) Ensure that relevant and up to date documents are available at the point of use; (e) Ensure that documents are legible and identifiable; (f) Ensure that documents of external origin are identified and their distribution controlled; (g) Prevent the unintended use of obsolete documents retained for any purpose. 2.3.15.9.9 Environmental Control Plans

The controls to manage and mitigate environmental damage will be identified and put in place during the design and development phase of the project. Despite this there are activities that can result in environmental damage which can only be managed and prevented through appropriate construction methods, awareness and training and appropriate contingency measures. Where a project has been the subject of an Environmental Impact Assessment (EIA) study and report, many of these measures will be stipulated in that EIA Report and associated CEMPs.

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2. The Contractor shall establish, implement and maintain documented environmental control procedures to manage the activities associated with the identified significant environmental aspects. These procedures should be consistent with the PMDS and the Environmental Policy, objectives and targets. It should be noted that all significant environmental aspects should be controlled. Environmental Control Plans must include, but not be limited to:

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(a) Soil Erosion and Sedimentation; (b) Waste Management; (c) Air Quality; (d) Pollution Prevention; (e) Water and Energy Use; (f) Dewatering activities; (g) Construction Noise; (h) Light Pollution; (i) Archaeological and Cultural; (j) Stockpile management; (k) Dust and air-born particulate control; (l) Contaminated land; and (m) Surface and groundwater protection

2.3.15.9.10 Environmental Inspections, Monitoring and Reporting (a) Daily Site Inspections 1. The Contractor shall carry daily site inspections to monitor environmental performance in accordance with the PMDS (Site Environmental Inspection Form). The inspections should include, but not be limited to, checking that:

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All waste is appropriately stored and segregated; Waste skips are covered to prevent windblown litter; Drip trays are in place for all stored equipment and plant; All chemicals/fuels are stored with appropriate containment/bunds/cover; Construction noise is within permitted limits and does not create a nuisance; Dust does not create a nuisance; Spill kits are present; and Fencing is secure.

2. Where there are particular permit conditions that require routine checks or similar, these should be included as appropriate. Records of daily inspections shall be kept and maintained. (b) Weekly Inspections

1. The Contractor shall carry out weekly inspections to monitor environmental performance in

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accordance with the PMDS. The inspections should include, but not be limited to checking that:  Daily checklists have been completed;  Waste storage areas have been checked and there is no build-up of waste materials ;  Spill kits have been checked and contain all relevant materials;  The performance of all pollution control equipment has been checked and the equipment is working effectively;  Noise reduction equipment has been checked and is operating effectively; and  Septic tanks are not overfull/discharging.

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Records of weekly inspections shall be kept and maintained

(c) Monitoring and Reporting

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1. The contractor shall be required to establish, implement and maintain procedures to

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monitor, measure and report, on a monthly basis, statistics in accordance with the requirements of the PMDS (Monthly Environmental Statistics Report). Statistics will include, but will not be restricted, to:

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 General Environmental Statistics: o Environmental incidents, accidents and near misses; o Site inspections; o Environmental audits; o Environmental complaints; o Number of training sessions delivered including topic and numbers of attendees.  Waste Management o Total amount of waste produced by type:  General;  Hazardous;  Excavated Material;  Metals;  Liquid. o Total amount of waste disposed of by type to:  Landfill;  Recycling;  Recovery/reuse;  Ground.  Total amount of water consumed:

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o Ground water; o Mains, potable water.  Noise and Vibration: o Number of complaints; o Monitoring undertaken; o Mitigation measures applied.  Air quality, dust and odour: o Number of complaints; o Monitoring undertaken; o Mitigation measures applied.  Ecology, protected species and habitats: o Protected species or habitats identified on site; o Vegetation removed.

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 Archaeological or cultural artefacts: o Number of archaeological or cultural artefacts identified on site. 2.3.15.9.11 Auditing

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1. The Contractor shall conduct internal audits of the CEMP at regular planned intervals to ensure that it is:

Audits shall be conducted in line with the requirements of ISO 19011 2002 ‘Guidance for quality and/or environmental systems auditing’. Audit Reports will be maintained by the contractor.

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(a) Properly implemented and maintained; (b) Conforms to the requirements of the PMDS.

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2.3.15.9.12 Nonconformity and Corrective and Preventative Action

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1. The Contractor shall establish, implement and maintain procedures to deal with actual and potential non-conformity (ies) and for taking corrective and preventative action.

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2. Non-conformities may be identified through: Internal contractor audits; Audits by GEC/PMC; Audits undertaken by external certification bodies; and General observations.

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(a) (b) (c) (d)

3. The Contractor’s procedures shall define the requirements for: (a) Identify and correct non-conformities; (b) Mitigating the environmental impacts of non-conformities; (c) Investing non-conformities including identifying root causes and implementing appropriate actions to avoid their reoccurrence; (d) Evaluating the need for actions to prevent non-conformities and implementing appropriate actions designed to avoid their reoccurrence; (e) Setting realistic timeframes for undertaking effective corrective and preventative actions; (f) Recording the results of corrective and preventative actions taken; and (g) Reviewing the effectiveness of corrective and preventative actions.

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3. All actions identified should be appropriate to the nature and magnitude of the problem and the environmental impacts encountered

2.3.15.10 Emergency Response Plan 2.3.15.10.1 Introduction 1. The Contractor shall establish, implement and maintain procedures to identify and manage potential environmental emergency situations and potential accidents. The contractor shall respond to actual emergency situations and prevent and mitigate adverse environmental impacts. 2. The Contractor should periodically test, review and update emergency preparedness and response procedures

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2.3.15.10.2 Key Requirements

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1. During construction accidents, incidents and emergencies that have an environmental impact may occur. In the event of an emergency, the first response is to locate the source and stop continuation of the situation, followed by the containment, control and mitigation of the situation.

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A copy of the Material Safety Data Sheets and an inventory for all the chemicals and their types and quantity used on the project site shall also be kept at each site office and in every vehicle used on the project site.

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(a) Site Offices; (b) Remote offices on site; and (c) Every vehicle on site.

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2. For each construction site the Emergency Response Procedure will be displayed at:

All Contractor personnel and sub-contractors shall be instructed and rehearsed, as appropriate, in the requirements of the emergency response procedure. Following control of an incident or emergency, an investigation will be conducted and corrective actions identified and addressed. The Site HSE Manager shall verify the close out of environmental related actions. The CEM shall be responsible for notifying the Engineer of any emergency.

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4. The main objectives of the Emergency Preparedness Response Plan are to: (a) To ensure that all means are available to contain the consequences of an accidental spill, fire or release of oil/fuel. (b) To ensure that employees are suitably trained to respond to fire and spill. (c) To ensure that proper reporting takes place. (d) To ensure that proper investigation is undertaken.

2.3.15.10.3 Incident Classification and Notification Requirements 1. What is an Environmental Incident (a) Near miss  An accident or incident that was narrowly avoided; and  An unplanned event that did not result in environmental damage or harm, but had the potential to do so. (b) Non-Compliance with legislation or permit  A breach of conditions set out in the environmental permit e.g. noise limits, waste water effluent, air quality, hazardous waste disposal; and  Breach of Qatar Environmental Protection Law. (c) Typical environmental incidents:

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Spillage of hazardous substance e.g. oil, detergent, paint, fuel; Loss of containment – fuel, oil, liquid waste; Fire; Explosion; Release to atmosphere e.g. gas, dust, pollutants; Excessive noise, vibration, light, dust or odour; Land contamination; Pollution from de-watering processes/unauthorised discharge; Incorrect disposal or storage of waste; Contamination of water course, drains, marine environment; Disturbance of or unplanned/unpermitted damage to or destruction of protected species, habitat or artefact; Legal breach/noncompliance with permit conditions; and Other environmental incidents.

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2. Incident Classification Major

Minor

The material is highly toxic or hazardous

The material has a low toxicity

The incident occurred in sensitive area e.g. close to residential areas, water course, marine environment

Incident can easily be controlled e.g. spill contained with spill kit and materials disposed of correctly  A site worker can usually clean up  Small spill of oil or diesel fuel  A spill of less than 200 litres (or 1 drum) The incident occurred in a area low sensitivity e.g. industrial area, hard standing

Large number and different type of sensitive receptors affected

Small number and type of sensitive receptors affected

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The quantity of material released to environment was very large (even if not dangerous)

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3. Reporting Requirements

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(a) Major Environmental Incidents – Report to the Engineer within 24 hours of the incident and complete Report Form

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(b) Minor Environmental Incidents – Report to the Engineer within one week of the incident and complete Report Form

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(c) Non-compliance with legislation, environmental permit or procedure - Report to the Engineer within one week of the incident and complete Report Form (d) Near Miss – Include detail in Monthly Environmental Report 4. Spill Contingency Plan (a) The main causes of contamination can occur through:  Spillage of hazardous material including fuel oils, waste materials or chemicals;  Spillage of wastewater sewage and other liquid effluents; and  Spillage of contaminated wash down water with oils, chemicals etc from vehicles, equipment and machinery. (b) Prior to commencing activities on site, the Contractor shall develop, implement and maintain a Spill Contingency Management Plan. The Plan should include but not be restricted to the mitigation measures below. Activity

Mitigation Measures

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Mitigation Actions Emergency

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Response

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The Contractor shall carry out regular inspections/ audits of hazardous materials usage, handling and storage areas and regular/thorough maintenance of vehicles and hydraulic systems and inspections of sanitary facilities and disposal. In the event of a spill, immediate action shall be taken to contain or clean up the spill using sand or a suitable absorbent material. All contractors handling hazardous materials will keep appropriate spill clean-up material adjacent to storage and maintenance areas. Minimise the amount of diesel, oil, paint, thinners and other chemicals stored on site that pose potential spillage environmental hazards and use materials that minimize environmental impact such as lead free paints, asbestos free materials etc. Storage areas will be located away from drains/trenches/wastewater collection devices in an impervious bund area (volume of the storage bund >110% of the largest storage tank contained within the bund). Collection systems will be provided/bunded if necessary under machinery or equipment that may leak hydrocarbons/hazardous substances. All spillages of hazardous materials shall be reported immediately in accordance with the requirements of the PMDS. The area shall be inspected by the Contractor’s Project Manager and the Engineer and this shall form part of the incident report. Contaminated soil, rags and other clean up material shall be kept in appropriate containers before being disposed of in accordance with DoE guidelines to an approved site. The Contractor shall be responsible for training all staff in the Procedures for handling spills and shall provide all staff with appropriate personal protective equipment. The Contractor shall provide all staff with appropriate personal protective equipment. Avoid impacting adjacent sites by ensuring all contractors activities, equipment and waste storage is confined to the allocated site boundary.

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5. Contamination Discovery

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(a) The contractor must report any suspected contamination discovery, even if the Contractor did not cause it, to the Engineer.

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(b) During construction, indications of possible contamination include, but are not limited to, the following:  Barrels and containers;  Stained or discoloured earth in contrast with adjoining soil;  Industrial waste debris;  Non-earthy odours which emanate when the earth is disturbed;  Oily residue intermixed with earth;  Sheen on groundwater;  Underground storage tanks;  Fuel/diesel tanks; and  Proximity to petrol stations.

2.3.15.11

Completion and Site Clearance 1.

On completion of construction works the Contractor shall ensure that all waste and polluting material is removed from the site and is disposed of using appropriately authorized contractors and ensure that the site is restored in compliance with the terms of the contract. Following site clearance the Engineer will undertake a final inspection of the site. Any environmental issues identified during the final inspection will be raised with the contractor. Mitigation measures and timeframes for completion shall be agreed between the contractor and the Engineer in line with agreed procedures prior to final sign off.

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2. 3.

4. 5. 6. 7.

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Audit – regular check of an organisational or project’s compliance with procedures, standards, legislation or other stipulated requirements Auditor – person with the training competence to conduct an audit. Continual improvement – recurring process of enhancing the environmental management system (EMS) to achieve improvements in overall environmental performance consistent with the environmental policy. Corrective action – action taken to eliminate the cause of a detected nonconformity. Environment – surroundings in which the organisation operates including air, land, water, natural resources, flora, fauna, humans and the interrelation. Environmental aspect – element of the organisations (or project’s) activities or products that interact with the environment. Environmental impact – and change to the environment, whether adverse or beneficial resulting wholly or partly from the organisations environmental aspects. Environmental Management Plan (EMP) - The EMP is the lead environmental management document that defines the procedures for achieving the objectives set out in the Environmental Policy and the identified environmental performance targets for the project. An EMP can also provide the framework for which commitments made in an Environmental Impact Assessment report or the requirements of planning or other development conditions can be realised. A Construction Environmental Management Plan (CEMP) outlines a contractors approach to environmental management, with respect to project commitments, throughout the construction phase and with the primary aim of reducing any adverse impacts from construction on sensitive receivers. Environmental Policy and identified environmental performance targets for the project. Environmental Management System (EMS) – management system used to develop and implement an organisations environmental policy and manage its environmental aspects. Environmental objective – overall environmental goal, consistent with the environmental policy. Environmental performance – measurable results of an organisations management of its environmental aspects. Environment policy – overall intention and directions of an organisation or project, related to its environmental performance as formally expressed by top management. It provides a framework for action and for the setting of its environmental objectives and targets. Environmental target – a detailed performance requirement applicable to the organisation or parts thereof that arises from the environmental objectives and that needs to be set and met to meet those objectives. Glare – uncomfortable brightness of a light source viewed against a dark background. Interested party – person or group concerned with or affected by the environmental performance of the organisation. Internal audit – systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to determine the extent to which the environmental management system audit criteria set by the organisation are fulfilled. MSDS – Material Safety Data Sheets: instructions for the safe use and potential hazards associated with particular products or materials. Light Trespass – the spilling of light beyond the boundary or the property of the area being lit. Nonconformity – non-fulfilment of a requirement. Preventative action – action to eliminate the course of a potential nonconformity. Prevention of pollution – use of processes, practices, techniques, materials, products, services or energy to avoid or control the creation, emission or discharge of any type of pollutant or waste, in order to reduce adverse environmental impacts.

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15. 16. 17.

18. 19. 20. 21. 22.

23. Procedure – specified way to carry out an activity or process, procedures can be

documented or not.

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

2.3.15.14 Approvals POSITION IN COMPANY

SIGNATURE & DATE

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NAME

SHEQ Director

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ov

er

se

as

Approved by:

QCS 2014


Page 26

Responsibility Name of client Name of contractor Name of person who drafted the plan Notes, amendments Construction Project Location (address, postcode if appropriate)

.

Estimated project cost

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Notes, amendments Materials Resource Efficiency

ta

Describe here any methods adopted during the conception, design and specification phase to reduce the amount of waste arising. Resource saving (quantify if possible)

se

as

qa

Method

er

Waste Management

ov

Declaration

m

Signatures

et it

o

The client and COMPANY will take all reasonable steps to ensure that – a) all waste from the site is dealt with in appropriately. b) materials will be handled efficiently and waste managed appropriately.

QCS 2014


Page 27

STAGE 1 –Design/Tender/Planning Period Yes

No

N/A

Comment

Has the client and key suppliers been consulted in production of the SWMP Have alternative options been considered which produce less waste on site? Identify waste management areas on site plan - is there sufficient space for segregation of waste types (3 or more skips)?

rw .l. l

.

Is sufficient space allocated for material storage to avoid damages? Have you consulted Supply Chain to identify waste minimisation options?

qa

ta

Has a programme been produced for estimated waste costs for the Project for monitoring against during the works?

se

er

Has a careful evaluation of materials been made to avoid over-ordering?

as

Can unused materials be returned to Supplier or used on another job?

ov

Has full consideration been given to use of secondary or recycled materials?

et it

o

Is unwanted packaging to be returned to the Supplier after use?

m

Have materials been ordered to fit – e.g. plasterboard sized to avoid offcuts etc? Have opportunities for re-use of wastes on-site been considered? Have opportunities for re-use of wastes off-site been considered?

Action owner

QCS 2014


Page 28

STAGE 2 –Construction

m

et it

o

ov

er

N/A

Comment

rw .l. l ta qa as

se

Has responsibility for waste minimisation been identified? NB it is recommended to identify an individual to Champion and drive waste min onsite. Has use of Tool Box Talk been planned into the project programme. Are sufficient skips available for segregating wastes? Are all skips clearly labelled? Are you measuring your waste costs against the programmed budget from your Planner? Have any materials or products been identified by design, your supply chain or Project team, for re-use? Can you monitor any cost savings from any re-use of materials during the Project? Does your supply chain (waste removal) recycle waste from site, can they give monthly figures for materials, which have been recycled & landfilled? Can your supply chain offer a reduced rate for providing a segregated system? Can any materials be re-sued on other construction sites locally? Have you identified any best practice that we can learn from?

No

.

Yes

Action owner

QCS 2014


Page 29

SITE MANAGEMENT PLAN Waste type

Quantity (m3 or tonnes) Reuse onsite

Reuse offsite

Recycling on-site

Recycling off-site

Other form of recovery on-site

Other form of recovery off-site

Estimates

rw .l. l

.

Inert

qa

ta

Non Hazardous

se

as

Hazardous

ov

er

Total (m3 or tonnes) Actual

m

et it

o

Inert

Non Hazardous

Hazardous

Totals (m3 or tonnes) Difference between estimates and actual

Sent to landfill

Other disposal

QCS 2014


Page 30

SITE MANAGEMENT PLAN WASTE RECORDS Waste type

Identity of the person removing the waste

Site the waste is being taken to and whether licensed or exempt

Waste carrier and registration number*

Confirmation of delivery*

qa

ta

rw .l. l

.

Date removed

as

Post-Construction

se

[Within three months of the construction work being completed]

er

Confirmation

et it

o

ov

This plan has been monitored on a regular basis to ensure that work is progressing according to the plan and has been updated to record details of the actual waste management actions and waste transfers that have taken place. Signature

m

Issue Explanation of any deviation from the planned arrangements Waste forecasts – exceeded Waste forecasts – not met Cost savings achieved

Details

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Page 31

Complaints/Comments /Compliments

Name & Phone Number

Date Actioned

se

Name:

er

Number:

ov

Name:

Name:

m

et

Number:

ito

Number:

Name:

Action Taken

as

Date

qa

ta

COMPLAINTS/COMMENTS/COMPLIMENTS RECORD

Number: Name: Number: Name: Number:

THIS RECORD SHOULD BE KEPT CAREFULLY ON SITE AND MADE AVAILABLE TO THE CCS MONITOR FOR INSPECTION AS REQUESTED

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Page 32

Complaints/Comments /Compliments

as

Name:

se

Number:

er

Name:

ov

Number:

et

Number:

ito

Name:

Name:

qa

Name & Phone Number

m

Date

ta

COMPLAINTS/COMMENTS/COMPLIMENTS RECORD

Number: Name: Number: Name: Number: Name: Number: Name: Number:

Action Taken

Date Actioned

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QCS 2014


WATER DISCHARGE INSPECTION SHEET

qa

Comments and Remedial Action

et

ito

ov

er

se

as

Person Monitoring

m

Date

ta

Contract :

Page 33

pH Reading

Priority

1.1.1.1.1.1.1 High/Med/Low

Action By

Date Completed

QCS 2014


Page 34

DUTY OF CARE CONTROLLED WASTE TRANSFER NOTE SINGLE TRIP DESCRIPTION

A

MULTIPLE TRIP

1. Describe the waste being transferred: ……………………………………………………………………………………………………..…………………… (Description)…..……………………………………………………..………… 2. Has the waste been treated to reduce its hazard or volume? etc. 3. How is it contained? Loose

Sacks

Drums

Skip

E.g. minimised, segregated, sorted

Other Describe: ………………………………………..……….

4. Quantity (number of drums, skip weight etc.): ……………………………………...…………………………. 5. Season ticket YES NO HOLDER Transfer

1. Name and address of company and contract:

B

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.

…………………………………………………………………………………………………………..……………… ………………………………………………………………………………………………………………..………… 2. Current location of waste:

ta

………………………………………………………………………………………………………..…………………

qa

3. Which of the following are you?: (Tick one or more boxes)

Registered Waste Carrier* Licence No.: ……………………………….

Waste producer

*Licence and exemption details and copies of documentation must be obtained by HOLDER prior to transfer

collecting or

as

………………………………………………………………………………………………………………………..… 2. Which of the following are you?: (Tick one or more boxes)

ov

disposing

………………………………………………………………………………………………………………..…………

se

Person

1. Name and address of the company:

er

TRANSFER

D

ito

Registered waste carrier* No.: ………………...………………

*Licence and/or exemption details and copies of documents must be furnished to HOLDER prior to transfer 1. Transfer location address:

et

DISPOSAL

Holder of waste management licence* Licence No.: …………………

m

C

Producer of waste Waste disposal Authority Waste exporter

…………………………………………………………………………………………………………..……………… 2. Date of transfer: …………………………………………………………..……………………………………………………………… 3. Time(s) of transfer (for multiple consignments, give period for which note is valid): …………………………………………………………………………………………………………………..……… 4. Name and address of broker arranging the waste transfer (if applicable):

……………………………………………………………………………………………………………………..…… *Licence and/or exemption details and copies of documents must be furnished to HOLDER prior to transfer COMPLETION

E

Person collecting or disposing of waste (Part C or D):

Waste Holder (as in Part B):

Signed: Signed: Name: Name: Representing:

Representing: * For Hazardous Waste please use Hazardous Waste Consignment note. Speak to Environmental Adviser for guidance. Distribution: White copy – Workplace recipient Pink copy – Distribute as required Blue copy – Retain in book (file copy)

QCS 2014


Page 35

ENVIRONMENTAL VIBRATION RECORDING SHEET Contract:

Date:

Weather/Environmental Conditions:

Vibration Monitor used:

Serial/Certificate No: Calibration:

Comments on Building/Structure (if relevant)

Results Summary:

rw .l. l

Works/Operation:

ito

ov

er

se

as

qa

ta

Monitoring Location:

.

Monitor Mode:

m

et

Site Sketch:

Person Undertaking Monitoring : Date : Position :

Print-out attached? Comments/Recommendations:

Yes/No

QCS 2014


Page 36

COMMUNICATION RECORD Site Set-Up Pack

Revision No.:

Date:

Community Relations

Reference No.:

Page

rd

*Example investigation by Enforcing Authority, Workplace Inspector, solicitor etc.

Address:

Name:

Position:

rw .l. l

Date/Time:

.

Representative (Person making comment/complaint)

as

qa

ta

Detail Comment/Complaint

se

Comment/complaint received by:

ov

er

Date:

m

et

ito

Action Taken

Follow Up

Project Manager:

Date:

Party*

Page 37

et

ito

ov

er

se

as

qa

ta

rw .l. l

.


m

QCS 2014

. rw .l. l


qa

ENVIRONMENTAL NOISE SURVEY SUMMARY SHEET

Monitoring Location :

Weather/Environment :

as

Contract :

Page 38

ta

QCS 2014

er

Survey Location (Freefield/Façade) :

se

Date:

ov

Start Time :

ito

Finish Time :

Calibration Certificate no.:

Serial Number: Type 1 or 2: Time Response (Slow/Fast) :

Start :

YES/NO

L90 (dB)

LAeq (dB) (

Finish :

Results Sheet Attached: mins)

YES/NO

Comments/Events

SPL MAX

m

Activity/Operation

et

Location Map Attached:

Sound Level Meter:

(dB)

SURVEYOR Sign: SURVEYOR Print:

Date :

Distribution:………………………………………..

. rw .l. l


Page 39

ta

QCS 2014

qa

ENVIRONMENTAL NOISE SURVEY SUMMARY SHEET

Monitoring Location :

Weather/Environment :

as

Contract :

Survey Location (Freefield/Façade) :

ov

er

Start Time :

se

Date:

Finish Time :

et

Calibration Certificate no.:

Serial Number: Type 1 or 2: Time Response (Slow/Fast) :

Start :

YES/NO

SURVEYOR Sign: SURVEYOR Print:

L90 (dB)

LAeq (dB) (

Finish :

Results Sheet Attached: mins)

m

Activity/Operation

ito

Location Map Attached:

Sound Level Meter:

YES/NO

Comments/Events

SPL MAX

(dB)

Date :

Distribution:………………………………………..

. rw .l. l

QCS 2014


ta

Environmental Survey and Risk Assessment Form

qa

Surveyor(s) Methodology

Page 40

Survey Date

ov

er

se

as

1. Desk study: Review drawings, understand nature of project, the construction processes, their aspects and their potential effects. Note existing features, eg. current occupation, geography especially drainage, infrastructure and surrounding built environment. Check for existence of designated sites, heritage features, eg. ancient monuments. 2. Site visit: Identify potential receptors of environmental harm or damage and assess the significance of construction effects on them. Effects are significant if they have the potential to cause  particularly in regard to pollution of Controlled waters  harm or damage resulting in costs to remedy  complaint from any stakeholder including the general public

m

Desk Study Notes

et

ito

3. Assess the environmental risk rating. 4. Identify the measures required to minimise construction effects and where baseline and construction stage surveys should be carried out.

. rw .l. l

ta

P – Personnel engaged in construction processes 0 – Others on or off the site, e.g. other contractors, visitors, neighbours, passersby, road traffic E – Environmental receptors e.g. land, air, water, flora and fauna, geological and historical features

qa

Effects Risk

Page 41

F – Frequency C – Consequence R – Risk resulting from construction effects. NA = not Targets Effects

applicable Environmental Aspect of Construction Works

Yes No NA

ito

Nuisance – noise, vibration, visual, dust and odour

ov

Significant waste streams and potential for minimisation. Opportunities for greater sustainability

m

et

Existing and potential levels. Sensitive receptors. Potential sources, e.g. piling. Workplace issues. New earthworks, dirt roads, sewage provision, litter.

Water and Effluents Existing drainage and effects of construction. Site water disposal and pollution prevention. COSHH controls.

Materials and Fuels, Oils and COSHH Storage Significant planned materials with potential for pollution and/or substitution.

P O E Potential Effects

er

Waste

as

Potential Targets


se

QCS 2014

Mitigation / Control Measures /Consent requirements F

C R

Risk of Residual Effects

. rw .l. l

QCS 2014


ta

Ecology, Archaeology & Built Environment

qa

Designated sites, existing flora and fauna, noxious weeds. Listed sites and structures, archaeology.

as

Plant & Equipment

se

Traffic movements, setting, site access, pedestrians, parking

Resources and Energy Use

Former land use, existing condition, site investigations.

ito

Community Relations, etc

ov

Contaminated Land

er

Scope for reductions and efficiencies

Training

m

et

Proximity to housing, schools, hospitals, parks, delicate installations etc. Site security, community involvement. Site specific training requirements likely

Other Aspects

Page 42

. rw .l. l

QCS 2014


Examples of Aspects v Effects Rating (R)

Page 43

ta

Risk Level 2-3 Varied wastes generated, both hazardous and non-hazardous.

0-1 Minimal quantities of waste likely to be generated.

Noise, Vibration, Visual, Dust and Odour

Noise: Higher than background levels expected but no receptors nearby. Vibration: Expected but at levels below that unacceptable to neighbours or sensitive structures. Visual: Site remote, well screened from site or in existing building or facility. Dust and Odour: No emissions expected and/or no receptors nearby. No change in existing water regime likely. No effluents arising.

Noise: High/disturbing levels, receptors in vicinity. Complaints may arise. Vibration: High day time levels of vibration, receptors nearby. Complaints may arise. Minor damage may occur. Visual: Site noticeable in landscape or setting, temporarily affecting amenity value. Dust and Odour: Minor emissions, receptors nearby.

Noise: High/disturbing levels, receptors in vicinity. Expect complaints especially at night. Vibration: High levels of vibration, receptors in vicinity. Expect complaints and/or damage especially at night. Visual: Site in area of high visual quality and affecting normal enjoyment for some time. Dust and Odour: High levels of emissions, receptors nearby. Expect complaints.

Water regime affected by works, discharge off site may require consent. Minor effluents arising from site compound.

Material inputs negligible, e.g. mainly site clearance, landscaping. Minimal volumes of fuels and COSHH materials stored. None in vicinity or no disturbance expected.

Considerable material inputs required, with some environmental impact in resource use. Some fuels and COSHH materials stored on site. Local designated area or minor disturbance likely to designated site or protected species.

Works in main river or disturbance of receptors likely, e.g. downstream fishery. Large site with significant effluent discharge. Large material inputs with corresponding impacts in resource use and/or transport. Large site with significant volumes of fuels and COSHH materials stored. Major disturbance expected to designated site or protected species.

No road works expected but access may cause some minor delays. No large plant

Road works will not close access. Local traffic may be delayed by site traffic. Some items of larger plant.

m

et

ito

ov

er

se

as

qa

Aspects Waste

Water and Effluents

Materials, Fuels, Oils and COSHH Storage Ecology, Archaeology & Built Environment Plant & Equipment

4-9 Significant wastes with large disposal costs, e.g. wastes from large asbestos strip.

Road works close access. Existing access unsuitable for site plant /vehicles. Considerable amount of larger plant, e.g. for major earthworks

. Few material and plant resources necessary and minor site establishment.

Contaminated Land

No contamination proven or is unlikely.

Community Relations, etc

No sensitive receptors nearby. No additional security required.

Some additional training required.

ov

er

se

as

Night time work, receptors in vicinity. Full time security required.

No services in vicinity needing consideration.

Day time works, receptors in vicinity. Normal out-of-hours security measures required. Some services present, requiring diversion/protection.

ito

Major construction site with large establishment for extended period

Contamination proven, potential pathways and receptors nearby. Spread of contamination likely.

et m

Some significant resource use and medium sized site establishment

Possibility of contamination exists, potential pathways and receptors nearby.

No training beyond normal site inductions.

Training

Page 44

qa

Resources and Energy Use

Other

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ta

QCS 2014

Important and valuable service assets affected by works requiring significant design/temp and diversion works. Extensive environmental training required.

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QCS 2014


Page 45

ta

Risk resulting from construction effects = Consequence times Frequency

ov

er

se

as

qa

HAZARDOUS LEVEL ACTION No further preventative action. Consideration shall be given to more cost-effective solutions or Insignificant Impact improvements that impose no additional cost burden. Monitoring required ensuring that controls in place are properly maintained. Work shall not be started or continued until the Impact level has been reduced to an acceptable Impact level. While the control measures selected shall be cost-effective, legally there is an absolute Significant Impact duty to reduce the Impact, this means that if it is not possible to reduce the Impact even with unlimited resources, then the work shall not be started or shall remain prohibited.

et

Aspects Significance

m



SIGNIFICANT

ito

Do not starts work if The HAZARDOUS IMPACT IS?

Severity Likelihood Certain 5 Very Likely 4 Likely 3 Unlikely 2 Very Unlikely 1

Very High 10

High 8

Moderate 6

Low 4

Minor 2

None 1

50

40

30

20

10

5

40

32

24

16

8

4

30

24

18

12

6

3

20

16

12

8

4

2

10

8

6

4

2

1

Significant Impact

Insignificant Impact

QCS 2014


Page 46

FRAMEWORK ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 – INDEX REGISTER OF CONSENTS AND AUTHORISATIONS SITE WASTE MANAGEMENT PLANNING (WM)

4947

5048

NUISANCE – NOISE, VIBRATION, VISUAL, DUST & ODOUR (NU) WATER & EFFLUENTS (WAT)

5250 5351

ECOLOGY, ARCHAEOLOGY & BUILT ENVIRONMENT (ECO)

5552

rw .l. l

5653

RESOURCES & ENERGY USE (RES) 5754 5855

ta

CONTAMINATED LAND (CL)

.

MATERIAL AND FUELS, OILS and COSHH STORAGE (MFS) PLANT & EQUIPMENT (PLA)

5149

5956

qa

COMMUNITY RELATIONS, COMMUNICATION AND REPORTING (COM) Completed - No Further Action Required

as

Completed - But Ongoing Work Needed

se

Not Completed - Action Required

er

Not Applicable at Present

ov

Contract/Office: Initial Meeting Attendance:

et it

o

Date:

Revision:

m

Abbreviations:

The Environmental Protection Law No. 30 of 2002 shall be revised on a regular basis, and in line with the SHE Management Plan (e.g. every 3 months), to take into account changes in the job; the revision programme will be dictated by the SHE Management Plan.

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QCS 2014


qa

ACTIONS REQUIRED FOR COMPLIANCE

et

ito

ov

er

se

as

ISSUEING AUTHORITY Contact details

m

CONSENT TYPE / NUMBER

ta

REGISTER OF CONSENTS AND AUTHORISATIONS

GUIDANCE FOR COMPLIANCE

Page 47

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

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qa

ta

SITE WASTE MANAGEMENTPLANNING (WM)

Page 48

ACTION

MANDATORY

WM1

Waste Planning Identify and quantify waste streams likely throughout project including waste disposed of via subcontractors Complete Site Waste Management Plan for project

SHE-FRM-15-01 (Checklists) SHE-FRM-15-02 (Word)

MANDATORY

WM2

Trained competent Waste Coordinator for the project

Training Records

MANDATORY

WM3

Select and appoint waste management contractors ensuring ‘Duty of Care’ checks are carried out prior to disposal

Audit Records SWMP

MANDATORY

WM4

Waste Minimisation Carry out waste minimisation workshop.

Waste Minimisation

MANDATORY

WM5

GUIDANCE

ACTION OWNER


MANDATORY

m

et

ito

ov

er

se

as

REF

WM6

Waste Storage 

Assess requirement for Waste Management



Ensure waste can not leach or cause dust nuisance



Establish waste management compound/area to allow segregation where required. Provide clear signage



ALWAYS Keep hazardous waste separate to general waste



Ensure waste is segregated as per SWMP

Waste Disposal 

Ensure the appropriate waste transfers notes are completed.



Record waste movements off-site in SWMP

Environmental Advisors Records

Visual Inspection

Consignment Notes Waste Carriers Details

TARGET DATE

CLOSE DATE Frequency

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Page 49

ta

NUISANCE – NOISE, VIBRATION, VISUAL, DUST & ODOUR (NU) ACTION

WHERE REQUIRED

NU1

Conduct baseline environmental noise/vibration survey prior to works commencing, if noise/vibration identified as an issue at risk assessment stage

WHERE REQUIRED

NU2

Conduct ongoing environmental noise/vibration surveys during course of works as required.

WHERE REQUIRED

NU3

Establish traffic plan to minimise nuisance from deliveries & site traffic. Ensure safety of pedestrians. Provide adequate parking for site personnel & visitors and avoid parking nuisance to local community

Traffic Plan

WHERE REQUIRED

NU4

Locate site cabins to shield neighbours from site activities. Where possible locate generators / pumps away from site boundaries.

Visual Inspection Site set up plan

WHERE REQUIRED

NU5

Identify and implement procedures and methods to minimise noise/vibration nuisance and include in method statements (MSs). Adopt Best Practicable Means (BPM) in accordance with BS5228

WHERE REQUIRED

NU6

Communicate noise/vibration & other nuisance issues & control methods to staff, operatives & visitors

Training /induction records

WHERE REQUIRED

NU7

During periods of dry weather, use methods to damp down sites and access roads to inhibit dust generation (e.g. road sweepers)

Continual monitoring Site inspections

WHERE REQUIRED

NU8

Site Inspections

WHERE REQUIRED

NU9

Install wheel-washing facilities, fit dust covers to scaffolds and use other mitigation measures to reduce dust nuisance Assess lighting requirements and position to avoid glare and nuisance to neighbours

GUIDANCE

SHE-PRO-015

er

se

as

qa

REF

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS Survey / Monitoring Results SHE-FRM-15-07 SHE-FRM-15-11

m

et

ito

ov

Survey / Monitoring Results SHE-FRM-15-07 SHE-FRM-15-11

SHE-PRO-001 BS5228

SHE-FRM-1-03

Site inspections

TARGET DATE

CLOSE DATE

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Page 50

ta

QCS 2014

qa

WATER & EFFLUENTS(WAT) ACTION

MANDATORY

WAT1

Ensure Environmental Impact Assessments (EIAs) and method statements address issues associated with any consents within register, including pollution prevention measures

MANDATORY

WAT2

Monitor discharges

WHERE REQUIRED

WAT3

Identify areas of potential run-off and take appropriate protection measures (install French drains etc)

Design & Visual Inspection

WHERE REQUIRED

WAT4

Conduct dewatering / over pumping discharges to foul sewer in compliance with consent conditions

Operational records Site inspections

WHERE REQUIRED

WAT5

Design and construct settlement lagoons appropriately

Design documents Site inspection

WHERE REQUIRED

WAT6

Maintain and inspect settlement lagoons regularly to ensure effectiveness.

Operational records Site inspections

WHERE REQUIRED

WAT6

Provide wash out facility for concrete wagons with adequate pollution prevention measures in place. Record in MS.

SHE-FRM-1-03

WHERE REQUIRED

WAT7

Know site drainage systems, flow directions and outlets. Colour code drainage gullies to minimise risk of pollution. Blue for surface water drainage and red for foul drains.

Drawings Site inspections

WHERE REQUIRED

WAT8

Monitor and report water consumption for site activities and office space

Meter Readings

WHERE REQUIRED

WAT9

Set project specific targets for water resource use

Project specific Targets and Objectives in SHE

GUIDANCE

SHE-PRO-001

ACTION OWNER


TARGET DATE

CLOSE DATE

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

SHE-FRM-1-03

m

et

ito

ov

er

se

as

REF

Monitoring Records

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Page 51 plan

ta

QCS 2014

ACTION

MFS1

Oils / Fuels and other liquid materials to be stored with secondary containment:

se

as

REF

 Either within a bund, on a catchment pallet or within a proprietary double-skinned tank  Bunds and trays to have no less than 110% of capacity of largest container and no less than 25% of total container volume when several stored  Do not allow rain water to escape from bunds and trays  All hoses, nozzles to be locked inside bund or double skinned tank when not in use  Check tanks, pipework, bunds and pollution prevention equipment regularly. Ensure no build-up of rainwater Locate oil /fuel storage areas away from surface waters and site drainage

GUIDANCE

ACTION OWNER


TARGET DATE

CLOSE DATE

Site inspections

Ongoing

End of project

Site inspection

Ongoing

End of project

SHE-FRM-1-01 SHE-FRM-1-03

m

et

ito

ov

er

MANDATORY

qa

MATERIAL AND FUELS, OILS and COSHH STORAGE (MFS)

MANDATORY

MFS2

MANDATORY

MFS3

Locate oil /fuel storage areas on hard standing or on sacrificial layer of sand underlain with impermeable membrane

Site inspection

Ongoing

End of project

MANDATORY

MFS4

Locate appropriate spill response equipment close to storage facilities and operating plant. Check regularly and maintain

Site inspection

Ongoing

End of project

MANDATORY

MFS5

Establish site specific spill response plan and train staff in spill response

Plan & Training Records

WHERE REQUIRED

MFS6

Store and handle dusty materials (aggregates) in ways to minimise nuisance

Site inspection

Ongoing

End of project

MANDATORY

MFS7

Maintain high standard of site housekeeping. Store materials to avoid damage, wastage and potential pollution

Site inspection

Ongoing

End of project

. Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 52

qa

ta

ECOLOGY, ARCHAEOLOGY & BUILT ENVIRONMENT (ECO)

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QCS 2014

ACTION

Mandatory

ECO1

Undertake Ecological assessment of site to determine actions to improve ecology of project and any mitigation measures required

WHERE REQUIRED

ECO2

Ensure preventative / mitigation measures are detailed in RAs and MSs and are implemented

SHE-FRM-1-03

WHERE REQUIRED

ECO3

Avoid disturbing natural habitats (including trees/vegetation) whenever possible and especially during nesting seasons

SHE-FRM-1-03

WHERE REQUIRED

ECO4

Manage invasive plant species (Japanese Knotweed, Himalayan Balsam etc) appropriately, contacting Env. Advisor in first instance (Baseline Environmental Risk Assessment should identify these)

SHE-FRM-1-03

m

et

ito

ov

er

se

as

REF

GUIDANCE

ACTION OWNER


TARGET DATE

CLOSE DATE

Ongoing

End of project

Eco survey recommendations incorporated in to project Site inspections Site inspections Site inspections

. rw .l. l

QCS 2014


MANDATORY

PLA1

WHERE REQUIRED

qa

ACTION

EVIDENCE REQUIRED SHE FORMS

TARGET DATE

CLOSE DATE

Ensure plant is adequately maintained, fit for purpose and in a safe condition

Supervisor Checklist Site inspections

Ongoing

End of project

PLA2

Where appropriate, establish dedicated plant storage area(s) away from surface waters and drains

Site inspections Site Layout plan

WHERE REQUIRED

PLA3

Where appropriate use drip trays under temporary static plant (pumps, generators etc.)

Site inspections

Ongoing

End of project

WHERE REQUIRED

PLA4

Where appropriate, specify and use plant with low emissions and particulate filters

Plant Records

WHERE REQUIRED

PLA5

Ensure all authorised plant. Conduct regular monitoring

Monitoring records

Ongoing

End of project

m

et

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REF

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PLANT & EQUIPMENT (PLA)

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GUIDANCE

ACTION OWNER

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RESOURCES & ENERGY USE (RES) REF

ACTION

MANDATORY

RES1

Ensure no-cost energy efficiency practices are adopted on site (switching off lights and heaters, closing windows etc)

WHERE REQUIRED

RES2

ECO Cabin low cost energy efficiency measures adopted (i.e. motion sensors in toilets, timers on office equipment)

WHERE REQUIRED

RES3

Ensure plant / equipment is not left running unnecessarily

WHERE REQUIRED

RES4

Record energy consumption on site (mains and diesel plant)

MANDATORY

RES5

WHERE REQUIRED

RES6

Consider Environmental Impact and waste hierarchy of material specification.

Material specifications and supplier orders

MANDATORY

RES7

Ensure materials are stored to avoid damage, vandalism or theft

Site inspections Supervisor checklist

WHERE REQUIRED

RES8

Consider off-site manufacturing – can this be used to produce quality, safety and environmental improvements?

SHE-FRM-1-03

Procurement ECO Cabin Specification

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GUIDANCE

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Ensure compliance with COMPANY Sustainable Timber Policy

ACTION OWNER


TARGET DATE

CLOSE DATE

Site inspections

Ongoing

End of project

Site inspections

Ongoing

End of project

Records of consumption (bills)

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

Site inspections

COMPANY Policy

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CONTAMINATED LAND (CL)

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ACTION

MANDATORY

CL1

Ensue Site Investigation includes risks to human health and the environment from contaminated land, water and ground gas

Completed SI Checklist New Form

WHERE REQUIRED

CL2

Formulate plans to deal with contaminated land

SHE-FRM-1-03

WHERE REQUIRED

CL3

Establish preventative measures to avoid pollution of water courses or ‘clean’ land.

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Where practicable conduct remedial treatment of contaminated soils in-situ or on-site. Regard off-site disposal as least preferred option

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CL4

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WHERE REQUIRED

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GUIDANCE

ACTION OWNER


SHE-FRM-1-01 SHE-FRM-1-03

Site inspections SHE-FRM-1-03

TARGET DATE

CLOSE DATE

Ongoing

End of project

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COMMUNITY RELATIONS, COMMUNICATION AND REPORTING (COM) ACTION

MANDATORY

COM1

Forward any communication from Enforcing Authority.

MANDATORY

COM2

Provide details of surface water and foul drainage discharge consents and, if appropriate, permission to work in/adjacent to rivers to SHE Team for records

MANDATORY

COM3

Report significant spills of polluting materials (oil, chemicals) as RIDDOR procedure

WHERE REQUIRED

COM4

MANDATORY

COM5

Record all comments/compliments/complaints/external environmental enquires using a logbook or form, ensure complaints are investigated and closed out where appropriate

MANDATORY

COM6

MANDATORY

MANDATORY

GUIDANCE

TARGET DATE

CLOSE DATE

As occur

As occur

SHE-FRM-15-14 Complaints Log / RIDDOR Procedure SHE-FRM-8-02/02 SHE-FRM-8-01

Ongoing

End of project

Notify SHE Department if any invasive or protected flora / fauna are encountered. Stop work if archaeological remains found

E-mails to SHE Department

As occur

As occur

COM7

Record and Report delivery staff and delivery mileage in Site Register (starting point and destination)

Site Register / Staff Mileage claims

Ongoing

End of project

COM8

Disseminate best practice and learning points across the business via SHE Department

Case-Studies Produced

As occur

As occur

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EVIDENCE REQUIRED / SHE FORMS Communication SHE-FRM-15-09 Database of consents

SHE-PRO-008

First Alert SHE-FRM-801 AIR SHE-FRM-8-2/02

Develop Community doc strategy

Newsletters / Minutes of meetings

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ACTION OWNER

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 1

2


2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................. 1

2.3.16 LEARNING EVENT REPORTING ..................................................................... 1

Responsibilities ............................................................................................ 4

2.3.16.2

Definitions ..................................................................................................... 4

2.3.16.3

Actions required to implement this procedure.............................................. 5

2.3.16.4

Reference Documents.................................................................................. 5

2.3.16.5

Author ........................................................................................................... 6

2.3.16.6

Approvals...................................................................................................... 6

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2.3.16.1

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PROCESS MAP Project/Site Manager

COMPANY Employees

Subcontractor Employees

SHE Team

Include information regarding the reporting of Learning in the Site I d ti 1.3, 3.2 Ensure Learning Event cards are available on site

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3.2

Ensure details are recorded

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For high potential events complete a First Alert form and distribute as appropriate

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*Complete the learning Event Form and identify the potential severity 3.3

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Where possible and safe to do so, take action to put right the unsafe situation/condition

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Where observed, record and report any Learning Event to the Line Manager/ Company Manager using the learning Event cards 3.2

.

3.1

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3.3

For high potential events complete a First Alert form and distribute as appropriate

Feedback details of outcome to the original person submitting the report

3.3

Review all Learning Event reports at the Project SHE meeting 3.3

*Or nominated person

Key

Activity Guidance

Circulate significant learning to all of Company to prevent reoccurrence in other areas

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PURPOSE 1

To ensure that all learning events (near misses) are recorded and the lessons communicated. A learning event is an event or condition that occurs that has the potential of causing damage or injury to people, property or the environment (not to include actual accidents). SCOPE

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Authorises this procedure. CONTRACTS DIRECTOR/MANAGER

2

Provides support in the application of this procedure PROJECT/SITE/OFFICE MANAGER Ensures that any reporting and investigation of Learning Events is carried out in accordance with this procedure (and any associated client procedures).

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3

To actively report Learning Events to the appropriate person.

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SHE MANAGER/ADVISER

Provides advice and support in the application of this procedure.

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EMPLOYEE / CONTRACTOR EMPLOYEE

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A learning event is an event or condition that occurs that has the potential of causing damage or injury to people, property or the environment (not to include actual accidents).

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LEARNING EVENT (NEAR MISS)

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2.3.16.3 Actions required to implement this procedure LEARNING EVENT CARDS (HOTLINE) 1

Learning Event Cards and poster displaying the COMPANY hotline number will be made available onsite and will be included in the site induction. Consideration should be given to placing Learning Event returns boxes onsite. COMPLETING LEARNING CARDS All employees and contractors employees on site will be encouraged to report all learning events observed onsite, either verbally to the appropriate person or by completing a learning event card or through the COMPANY Hotline number ……………, which is displayed on posters around site. Where possible and safe to do so, take immediate action to rectify any unsafe situation or condition.

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REPORTING AND INVESTIGATION OF A LEARNING EVENT

Complete the Learning Event Form to assess potential outcome and severity, investigate immediate and root causes, consider lessons learned and take actions to prevent recurrence.

4

Inform the SHE Team of the event.

5

If potential severity has been identified on the learning event form as high or above the Project / Site Manager / SHE Adviser / Manager will complete First Alert report and circulate as appropriate.

6

The Project/Site Manager or nominated person should communicate the learning throughout the project and give feedback on the actions to the person who reported the learning event.

7

Ensure that Learning Events are reviewed on a regular basis at the appropriate project/site meetings.

8

Details of all learning events should be passed to the appropriate person for entering on to the COMPANY record system.

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Learning Event (SHE-FRM-16-01)

2

Learning Event Card (SHE-FRM-16-02)



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POSITION IN COMPANY

NAME

CONTACT DETAILS

SHE Manager

POSITION IN COMPANY

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SHEQ Director

SIGNATURE & DATE

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NAME

Approved by:

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2.3.16.6 Approvals

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Date

Page 7

Print name Contact No. Location On Site

Time Project Classification Health

Safety

COMPANY

Environment

COMPANY Sub-Contractor

Other Sub-Contractor

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Details of the Learning Event (include all relevant information) :

Potential Severity (please tick)

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Potential Outcome (please tick) Personal Injury

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Property Damage

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Equipment Damage

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Environmental Issue

Slight Moderate First Alert to be issued if ‘High’ or above High Very High

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Other (please detail in comments box)

Negligible

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Lessons Learned (consider immediate and root causes) (please tick) Work environment Defective workplace

Design/layout

Housekeeping

Lack of room

Lighting

Noise/distraction

Weather

Access/egress

Management System of work

Supervision

Training

Communication

Management of change Plant/equipment Construction/design

Installation

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Safety device

Operation/use

Mechanical Failure

Maintenance

Human Factors Failure to follow rules

Instructions misunderstood

Error of judgement

Lack of experience

Unsafe attitude

Undue haste

Horseplay

Lapse of concentration

Fatigue

Working without authorisation

Design

Wrong type used

Maintenance

Not provided/unavailable

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Not Used Other

Under investigation

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Third Party

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Responsible

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Actions Required

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FOLLOW UP

Signed:

Date:

Completed

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LEARNING EVENT CARD Date:

Time:

Location on site:

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Brief details of observation:

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Action taken:

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Optional Information:

Reported by:

Company:

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 1

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................................................................................................

2.4

RISK ASSESSMENT GUIDES AND METHOD STATEMENT .................................................

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INTRODUCTION What is risk assessment? Legal requirements for risk assessment and written method of Work Risk assessment in practice Hazard and risk Risk assessment Process Identify the Hazards Work out who might be harmed and how evaluates the risks and decides on precautions Record your findings and implement them Review your risk assessment and update if necessary Suitable and sufficient risk assessment Recording the assessment Qualitative and quantitative risk assessments Qualitative assessments Quantitative assessments Consultation in development of risk assessment Young persons and children Language issues Safety Culture and other Behavioral Safety issues Other issues Health Surveillance Example of work activities requiring risk assessment Safe method of work (Method statement) Review of the method statement Communication of risk assessment and method statement Training programmes Appendix

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2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.6.1 2.4.6.2 2.4.6.3 2.4.6.4 2.4.6.5 2.4.7 2.4.8 2.4.8.1 2.4.8.2 2.4.8.3 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15 2.4.16 2.4.17 2.4.18 2.4.19 2.4.20

.

2.

2 2 3 3 3 6 6 6 6 7 7 7 8 8 8 9 11 11 12 12 13 13 13 14 14 14 15 16

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Page 2

INTRODUCTION Risk assessment is a fundamental principle in the management of health and safety. It is an important step in protecting workers and business, as well as complying with the law. It helps you focus on the risks that matter in or in connection to your work activity or construction work.

2

Section 1.1.7 of the Regulatory Document places legal duty on Contractors and the self-employed to assess the risks to the health and safety of their employees and others that arise out of or in connection with their work activities. They are also legal duty to develop written methods of work commonly referred to as method statement.

3

A risk assessment can be interpreted as a structured examination of a work activity so as to identify what could cause harm to people (employees or others) and how appropriate control measures can be put in place to eliminate or control risks.

4

For any risk assessment is to be effective, it is essential that the person who carries it out is familiar with all aspects of the task being assessed, specialist advice is sought where necessary and those to deliver the work activities are consulted in development of the risk assessment.

5

For any risk assessment to be effective, it is essential that the risks and controls are communicated to those affected.

6

The legal requirement on contractors to carry out risk assessments and written method of work support the requirements for a Contractor to provide for their employees A safe place of work

(b)

Safe access and egress to and from that place of work

(c)

Safe method of work

(d)

Safe plant and equipment

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(a)

Risk assessment and written method of work should identify the requirements for the contractor to provide for his employees information about how to undertake the work activity safety and without risk to their health

(b)

implementation of instructions for undertaking the work activity safety and without risk to their health

(c)

necessary training to employees so that they have the understanding and skills to undertake the work activity without risk to their health and safety

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(a)

(d) 2.4.2

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implementation of supervision of the work activity

What is risk assessment

1

A risk assessment is a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. Workers and others have a right to be protected from harm caused by a failure to take reasonable control measures.

2

A risk assessment should usually involve identifying the hazards present in any working activity and identifying the associated risks, evaluating them, identifying those affected and putting in place suitable and sufficient mitigation. The exercise should take into account any existing precautions and their effectiveness.

3

Accidents and ill health can ruin lives and affect business too if output is lost, machinery is damaged, insurance costs increase or you have to go to court. Contractors are legally required to

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assess the risks for or in connection to their work so that a plan to control the risks are put in place and implemented 2.4.3

Legal requirements for risk assessment and written method of work Section 1.1.7 of the Regulatory Document requires all contractors (employers and self-employed people) to assess the risks to workers and any others who may be affected by their work activity or construction work. The risk assessment will enable them to identify the measures they need to have in place and implement in order to comply with section 1.1.7.

2

There are requirements to undertake suitable and sufficient risk assessment, to record the assessment and to monitor & review its implementation. Development of risk assessment shall involve consultation with expert knowledge as required and it findings shall be communicated to those affected.

3

Any risk assessment shall give consideration to young persons and take into account risk barriers such as safety culture, behavioral safety and language issues as applicable to the place of work.

4

There are requirements for risk assessments to be supported by effective and written method statement identifying and implementation of training needs, instruction and supervision.

5

The contractor should work with other contractors, subcontractors to identify the hazards and assess the risks related to their work, including the risks they may create for others. Risk assessment in practice

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The principle of risk assessment to eliminate and control risk to safety and health is not new. In fact, many Contractors will have been carrying out risk assessments to their day to day business as part of business planning and success. However section 1.1.7 imposes specific legal requirements on the Contractor to undertake risk assessment for health and safety.

2

If the task to be assessed is substantial, difficult or complex then, it will not be practical or effective to carry out a single risk assessment to cover the whole of the work. The job will need to be broken down into separate elements or work activities, each of which will have to be assessed separately.

3

Many Contractors, who have recognized potential problems in course of their business as they occur, will have taken the necessary action to avoid an incident (including near misses and accidents). Conducting risk assessment, proper recording and ongoing review of the risk assessments is an essential process in preventing incidents.

4

Factors that need to be considered during the risk assessment process is the complexity of the activity, the number of persons involved or affected, the plant or equipment being used, and the types and nature of the materials involved. The environment where the work will be carried out is also a factor which should be taken into account.

5

In many instances, straightforward measures can readily control risks, for example ensuring spillages are cleaned up promptly so people do not slip, or cupboard drawers are kept closed to ensure people do not trip. For most, that means simple, cheap and effective measures to ensure your most valuable asset – your workforce is protected.

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2.4.5

Hazard and risk

1

A hazard is something with the potential to cause harm and this can include articles, workplace, substances, plant or machines, tools, methods of work, the working environment and other aspects of work organization and includes the potential to harm/damage the environment and/or causing a statutory nuisance.

2

A risk is the likelihood of potential harm from that hazard being realized. The extent of the risk will depend on:

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(a)

the likelihood of that harm occurring

(b)

the potential severity of that harm, i.e. of any resultant injury or adverse health effect; and

(c)

the population which might be affected by the hazard, i.e. the number of people who might be exposed

(d)

The frequency and time of exposure Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix

A risk is the chance, high or low, that somebody could be harmed by these and other hazards, together with an indication of how serious the harm could be. i.e. is the likelihood of potential harm from that hazard being realized. The extent of the risk will depend on: the likelihood of that harm occurring

(f)

the potential severity of that harm, i.e. of any resultant injury or adverse health effect; and

(g)

the population which might be affected by the hazard, i.e. the number of people who might be exposed

(h)

The frequency and time of exposure

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(e)

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Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix It is very important to distinguish between hazard and risk; the two terms are often confused.

5

Construction works are inherently hazardous and the risk associated with it will be reduced as controls are implemented. The level of risk remaining when controls have been adopted is known as the residual risk. There should only be high residual risk where there is poor health and safety management and inadequate control measures.

6

“‘Reasonably practicable’ is a narrower term than ‘physically possible’ … a computation must be made by the owner in which the quantum of risk is placed on one scale and the sacrifice involved in the measures necessary for averting the risk (whether in money, time or trouble) is placed in the other, and that, if it be shown that there is a gross disproportion between them – the risk being insignificant in relation to the sacrifice – the defendants discharge the onus on them.

7

Who is responsible for managing risk?

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All employers (and self-employed) are required to take reasonably practicable steps to assess the risk to both employees and others who could be affected by the undertakings of their business. Others who could be affected include: (a) Visitors to the workplace (b)

Consumers of products or services

(c)

Service providers working on the premises

(d)

Work colleagues and fellow persons working in the vicinity

(e)

Neighbours or residents in the surrounding area

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Minor injury, damage or environment impact

Major injury, damage or environment impact

.

Fatality building loss, catastrophic environment impact

3

4

A

A

U

A

A

U

U

A

U

U

U

A

U

U

U

1

A small probability

2

A high probability

3

A

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Almost no probability

4

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Almost Certain

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Risk Factor

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2

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Risk Assessment Methodology

Acceptable

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Acceptable

Unacceptable

Unacceptable 1–4

Action No further preventative action. Consideration shall be given to more cost-effective solutions or improvements that impose no Additional cost burden. Monitoring required to ensure that Controls in place are properly maintained. Work shall not be started or continued until the risk level has Been reduced to an acceptable risk level. While the control measures selected shall be cost-effective, legally there is an absolute duty to reduce the risk, this means that if it is not possible to reduce the risk even with unlimited resources, then the work shall not be started or shall remain prohibited.

4

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Page 6

Risk assessment Process A risk assessment is a five-stage process: (a)

Identification of all the hazards and associated risks

(b)

Work out who might be harmed and how

(c)

Evaluate the risks and decide on precautions

(d)

Record your findings and implement them

(e)

Review your assessment and update if necessary

2.4.6.1

Step 1: Identify the Hazards

Identification is simply working out how people could be harmed. Some techniques for risk identification are: brainstorming, refer to sources of information such as relevant legislation, code of practice and guidance, supplier manuals and manufacturers’ instructions, data sheets, safety alerts, lessons learnt, use information supplied by designers (pre-construction information), the residual risk supplied by designers, seeking advice from experts and competent sources and guidance from trade associations, etc.

2

Identification of hazards can also be undertaken by walking around the place of work and consult with employees or their representative about concerns in relation to the place or work or the work activity.

3

Checking the accident and ill-health records often helps to identify the less obvious hazards.

4

A valuable source for such information is obtainable from the UK governing body for Health and safety; known as the Health and Safety Executive (HSE). The HSE publishes practical guidance on where hazards occur and how to control them. Visit the HSE website (www.hse.gov.uk). 2.4.6.2

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Step 2: Work out who might be harmed and how

For each hazard you need to be clear about who might be harmed; it will help identify the best way of managing the risk. That doesn’t mean listing everyone by name, but rather identifying groups of people (e.g. ‘people working in the storeroom’ or ‘passers-by’). In each case, identify how they might be harmed, i.e. what type of injury or ill health might occur. For example, ‘shelf stackers may suffer back injury from repeated lifting of boxes’.

2

Remember that some workers have particular requirements, e.g. young persons or others with impaired mobility, expectant mothers etc.

3

Extra thought will be needed for some hazards to visitors, other contractors, members of the public etc if they could be hurt by your activities.

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2.4.6.3

Step 3 Evaluate the risks and decide on precautions

1

Having spotted the hazards, you then have to decide what to do about them. The law requires you to protect people from harm. You can work this out for yourself, but the easiest way is to compare what you are doing with good practice.

2

Think about what controls you have in place and how the work is organized. Then compare this with the good practice and see if there’s more you should be doing to bring yourself up to standard. In asking yourself this, consider: Can I get rid of the hazard altogether? If not, how can I control the risks so that harm is unlikely?

3

When controlling risks, apply these principles: try a less risky option (e.g. switch to using a less hazardous chemical); prevent access to the hazard (e.g. by guarding); organize work to reduce exposure to the hazard (e.g. put barriers between pedestrians and traffic); issue personal

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protective equipment (e.g. clothing, footwear, goggles etc); and provide welfare facilities (e.g. first aid and washing facilities for removal of contamination). 2.4.6.4

Step 4: Record your findings and implement them

1

Putting the results of your risk assessment into practice will make a difference when looking after people and your business. Writing down the results of your risk assessment, and sharing them with your staff, encourages you to do this. When writing down your results, keep it simple, for example ‘Tripping over rubbish: bins provided, staff instructed, weekly housekeeping checks’, or ‘Fume from welding: local exhaust ventilation used and regularly checked’.

2

You need to be able to show that: a proper check was made; you asked who might be affected; you dealt with all the significant hazards, taking into account the number of people who could be involved; the precautions are reasonable, and the remaining risk is low; and you involved your staff or their representatives in the process. 2.4.6.5

Step 5: Review your risk assessment and update if necessary

The risk assessment should be appropriate to the nature of the work and should identify the period of time for which it is likely to remain valid. This will enable the existing control measures to be reviewed and modified, and to put in place as necessary.

2

Construction sites do not stay the same. Thus hazards would be dynamic as the environment changes and works progresses and also with the bringing in of new equipment and substances etc. It makes sense, therefore, to review what you are doing on an ongoing basis. This means that any significant change to a place of work, process, or activity requires the risk assessment to be reevaluated or the introduction of any new process, activity or operation to be subject to a new risk assessment.

3

Look at your risk assessment again and the changes. Consult workers and lessons learnt from accidents or near misses.

4

Make sure your risk assessment stays up to date and set a review date proportionate to the complexity of the work activity or construction works. If there is any significant change to activities or a new sub/work package contractor starting work which could lead to new hazards then these shall be incorporated into the assessment. The need for review will depend upon the level of risk but in every case will be reviewed on sites at the same time as the Contract Management Plan or at permanent locations annually.

5

A risk assessment should always therefore be viewed as a ‘live’ document and must be reviewed following certain trigger events, or at least annually.

6

Risk Assessments should be reviewed when: (a)

2.4.7 1

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There has been an incident (accident or near miss)

(b)

Any significant change to processes, equipment or substances occurs

(c)

When there have been changes in the law

(d)

When enforcement action has taken place

(e)

When people identify an opportunity for improvement

Suitable and sufficient risk assessment An assessment required under The Management of Health and Safety at Work which: (a)

Correctly identifies a hazard

QCS 2014 (b)

Disregards negligible hazards and those associated with life in general

(c)

Determines the likelihood of injury, harm or loss 

Probability of exposure



Maximum probable loss



Number of persons at risk and/or the financial loss to the company

(d)

Identifies any specific legal duty or requirement relating to the hazard

(e)

Provides sufficient information to enable appropriate control measures to be taken

(f)

Enables control measures to be prioritized

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.

Suitable and sufficient risk assessment means the risk assessment should do the following: Should identify the risks arising from or in connection with work

(g)

The level of detail in a risk assessment should be proportionate to the level of risk the work activity entails

(h)

The level of risk arising from the work activity should determine the degree of sophistication of the risk assessment; for example risks which require specialist knowledge such as a particularly complex process or technique, or large and complex projects, hazardous sites will require the most developed and sophisticated risk assessments to address the level of risks.

(i)

Risk assessments must also consider all those who might be affected by the undertaking, whether they are workers or others such as members of the public.

(j)

Whenever specialist advisers are used, contractors shall ensure that the advisers have sufficient understanding of the particular work activity they are advising on, this will often require effective involvement of everyone concerned contractor, subcontractor, employees and specialist.

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2.4.8

Risk assessment shall be recorded in writing. This means writing down the significant hazards identifying the associated risks coming, evaluate the risks by identifying those affected, the impacts and the controls put in place.

2.4.8.1

Qualitative and quantitative risk assessments

1

The risk of something going wrong is considered in terms of probability (likelihood) and the consequences (seriousness).

2.4.8.2

Qualitative assessments

1

The probability of a hazard actually causing harm or an accident is rated as being High, Medium or Low in accordance with the following:

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(a)

HIGH: it will happen regularly, or it could be a usual or a common occurrence

(b)

MEDIUM: it is less regular, but is still recognized as being likely to happen

(c)

LOW: it has not happened for a long time, is known to be infrequent and is not likely to happen

QCS 2014 2

3


Page 9

The consequences of the event, should it happen, can then be categorised as follows: (a)

HIGH: the result could be a fatal accident or multiple injuries / major property damage / substantial pollution or environmental impact

(b)

MEDIUM: it would probably cause serious injuries, or persons would be off of work for over three days due to their injuries / substantial property damage / there may be some pollution

(c)

LOW: there would be minor injuries to persons or some slight damage to property

Probability and consequences can then be shown on a matrix as follows High Medium Low

Probability

Medium Consequences

High

Probability and consequences can then be assessed and the highest outcome of the two entered in the matrix as follows

Medium Low Low

High Medium Medium Medium Consequences

High High High High

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High

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High Medium Low

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Low

A combined risk of HIGH should be totally unacceptable and the work should not be undertaken until the risk has been reduced MEDIUM: it would probably cause serious injuries, or persons would be off of work for over three days due to their injuries / substantial property damage / there may be some pollution.

(b)

When there is a combined risk of MEDIUM, action must be taken, and work stopped if necessary, to reduce the risk level.

(c)

If the combined risk is LOW, start the work as long as everything reasonably practicable has been done in order to reduce the risk, and that the assessment is reviewed at regular intervals

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Using this information, decisions can now be made on whether an activity is safe to continue, or whether control measures are necessary, either to completely change the way that the job is done or measures put in place so as to bring the risks down to an acceptable level. In the ideal situation, both probability and consequences should be LOW.

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Probability and consequences can then be shown on a matrix as follows

2.4.8.3

Quantitative assessments

1

The principle is the same as for Qualitative assessments, but numerical scores rather than a grade are assigned to probability and consequences.

2

The probability or likelihood of the event is rated on a scale of 1 to 5 as follows: (a)

It is certain to happen.

(b)

It is very likely to happen, and would not be at all unusual

QCS 2014 (c)

Likely to happen, and would not be totally unexpected

(d)

Unlikely to happen, but not by any means impossible

(e)

Very unlikely to happen

Page 10

The consequences or the severity of the event, should it happen, are also then rated on a scale of 1 to 5 as follows: (a)

No injury. It would be a 'near miss'. Minor property damage.

(b)

Minor injury. Less than three days' work time lost. Property damage more than just minor likely to happen, and would not be totally unexpected.

(c)

Reportable injury to the HSE with over three days’ time lost, but not a major injury. Substantial property damage or something causing environmental damage.

(d)

Major injury, long term absence. Major damage, serious environmental impact.

(e)

Fatal accident or multiple major injuries. Public or others could be involved as well.

(f)

A matrix can then be constructed using these numbers, as follows

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All possible resulting numbers are calculated by multiplying all the probability figures by all the consequence figures. These are included in the matrix, as shown below. This means that once a risk assessment has been made on a particular activity, and the probability factor is multiplied by the consequence factor, the number produced indicates where the assessment places the risk associated with the activity on the matrix

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3 4 Consequences

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5 4 3 2 1

5 4 3 2 1

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Probability

5

5 4 3 2 1 1

10 8 6 4 2 2

15 12 9 6 3 3 Consequences

20 16 12 8 4 4

25 20 15 10 5 5

Clearly, the higher the resulting number, the less acceptable the level of risk. The matrix shows where actions need to be taken to reduce either the probability or the consequences in order to reduce the risks to an acceptable level

Probability

5 4 3 2 1

5 4 3 2 1 1

10 8 6 4 2 2

15 12 9 6 3 3

20 16 12 8 4 4

25 20 15 10 5 5

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Page 11

Consequences

Contractors themselves can use these numbers to set in-house criteria, if desired, along the following lines, and as indicated by the shaded areas in the above matrix: (a)

Risks with a rating above 16 are totally unacceptable and the work will not be undertaken until the risk has been reduced.

(b)

Where the risk rating is between 10 and 15, immediate action must be taken, including a stoppage of work if necessary, to reduce the risk level.

(c)

If the rating is between 5 and 9, the risk is acceptable provided that everything reasonably practicable has been done to reduce the risk.

(d)

With a rating of 4 or less then the risk is acceptable, provided that the assessment is reviewed at regular intervals and further reduced if possible.

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Note: - It is stressed that it is for individual companies or managers to decide where the boundaries between what is and what is not acceptable lie, and the numerical score at which certain actions should be taken

Consultation in development of risk assessment

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If either the qualitative or quantitative methods are used in conjunction with a simple form, then the Contractors will have a straightforward basic risk assessment procedure

Consulting employees or their representatives about matters to do with their health and safety and in developing risk assessment is a requirement under section 1.1.7 of the Regulatory document and is a good management practice as well.

2

Any risk assessment shall involve effective consultation with the workforce who will undertake the job.

3

Thus contractors need to involve employees concern or their representative in developing risk assessment.

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2.4.10 Young persons and children Contractors are required to specifically assess and review the risks to the health and safety of children and young person’s due to their lack of maturity, lack of experience and lack of knowledge of potential risks.

2

There is a requirement that young people should not carry out certain types of work, except in circumstances involving training and supervision where the young person is no longer a child.

3

A 'child' is anyone under the minimum school leaving age and a 'young person' is anyone over the minimum school leaving age but less than 18 years of age.

4

A young person under 16 years of age cannot be employed at all in a Qatar workplace; this is stated in Labor Law 14, Article 86.

5

Before a young person is employed, the Contractors must ensure that any risk assessments pertaining to the job take account of the following factors in relation to the young person:

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(a)

their inexperience

(b)

their immaturity and lack of awareness of risks

QCS 2014


(c)

the tools and equipment that they may have to use as part of their training

(d)

the layout of the workplace and the environment in which they may have to work.

(e)

any hazardous substances with which they may come into contact

(f)

exposure to physical, chemical or biological hazards

(g)

the organization of work processes and activities

(h)

the extent of health and safety training that is to be provided

Page 12

Careful consideration must be given to the way in which information is conveyed to young person’s to ensure that it is fully and readily understood.

6

Where children are employed either for work experience or work in offices then the Contractors must, before commencing the employment of the child, provide that child's parents or guardians with details of any risk assessment which has been carried out. This information must contain details of any risk and a description of any preventative or protective measures, whether the risk arises from the Contractors own activity or the activities of others at the workplace.

7

Contractors are further required to consider the special nature of young person’s due to their lack of experience, knowledge of risks and the fact that they are not fully mature. To that end, young people must not be employed in any work.

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with which they cannot physically or psychologically cope

(b)

that exposes them to a range of hazardous substances, including any carcinogen, toxic substance or radiation

(c)

where they might not recognize the risk of accidents due to their inexperience or lack of training

(d)

where their health would be at risk from excessive cold, heat, noise or vibration

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The prohibition above does not apply when a young person is undergoing recognized training, or being properly supervised by a competent person, or when any risks identified in a risk assessment have been reduced to the lowest level that is reasonably practicable.

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2.4.11 Language issues

Site workers who have a poor or no understanding of either written or spoken Arabic must be taken into account when compiling risk assessments. Effective communication is an essential element of controlling risk; how such communication can be established must be a priority issue where there is the potential for language difficulties on site.

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2.4.12 Safety Culture and other Behavioral Safety issues 1

Site workers coming from abroad have different backgrounds and different perception of risks and safety culture. The contractor needs to consider this as an important factor in developing the risk assessment and implementing it.

2

The contractor must be proactive in monitoring behavioral safety issues and address them as part of the risk assessment.

3

The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management.

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Page 13

2.4.13 Other issues 1

While it is a legal obligation for contractors to regularly review risks at the place of work, some other issues to consider would be persons with impaired mobility and new and or expectant mothers. The assessment will help to decide additional action that needs to be taken in such scenarios.

2

Any such risks identified must be included and managed as part of the general workplace risk assessment.

3

The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management. 2.4.14 Health Surveillance The contractor is required have in place health surveillance programmes where the findings of a risk assessment identify health risks to employees that can be eliminated or reduced by applying health surveillance techniques.

2

Health surveillance should be introduced where the risk assessment indicates that:

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there is an identifiable disease or adverse health condition related to the work concerned

(b)

there are valid detection techniques

(c)

there is a reasonable likelihood that the disease or condition may occur under the particular conditions of work

(d)

health surveillance has the potential to increase the protection of the health of the employees concerned.

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(a)

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The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management.

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2.4.15 Example of work activities requiring risk assessment Example of work activity that need to be risk assessed are: (a)

the use of hazardous substances

(b)

noise in the place of work

(c)

manual handling activities

(d)

the presence of asbestos

(e)

work at height

(f)

Work with vibrating tools and equipment

See appendix A for more examples of work activities and guidance for undertaking risk assessment.

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2.4.16 Safe Method of Work (Method Statement) A written method of work is commonly referred to as a method statement which is developed for construction activities including temporary works. The method statement describes the logical sequence of how a work activity is to be carried out safely and without risk to health. It should identify the risks and the controls to be put in place, responsibilities like induction supervision training and other elements needed to complete the work e.g. man power, plant, equipment etc.

2

It is good practice at planning stage of construction to identify a list of work activity which will need development of method statement. This is sometimes referred to a schedule of method statement which gets updated in the construction phase of the project as and when required, according to the project complexity and the level of risks it entails.

3

The Contractor shall submit a Method Statement Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract. The Method Statement Schedule shall define all Method Statements to be prepared for the Works forming part of the Contract and the target dates for their submission to the Engineer for approval.

4

The Contractor shall submit Method Statement for his work activities to the Engineer for approval thirty (30) days prior to the commencement of the work activity covered by a Method Statement.

5

The method statement should be developed prior to undertake any such work activity identified as mentioned above and should be unique to each work activity means No work covered by a Method Statement shall begin until it has been approved by the Engineer.

6

The risk assessment will provide support to the development of the method statement.

7

Any development of method statement shall involve consultation with the workforce and shall identify the requirements for:

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information about how to undertake the work safety and without risk to health

(b)

implementation of instructions for undertaking the work safety and without risk to health

(c)

identify and conduct necessary training to employees before execution of the activity; so that they have the understanding and skills to undertake the work activity without risk to their health and safety

(d)

implementation of supervision of the work activity

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The method statement should be briefed and acknowledged by the supervisor and the worker respectively before undertaking of the work activity.

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An example template for method statement is at appendix B.

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2.4.17 Review of the method statement 1

Any method statement needs to be reviewed after any incident in undertaking or related to the works, so that additional necessary mitigation can be embedded into the work procedure. 2.4.18 Communication of risk assessment and method statement

1

Any risk assessment and safe working method will be as good as the way they are communicated to those affected.

2

The contractor should make sure they are communicated to employees and their representatives so that they are aware of the health and safety risks for a work activity and the preventive and protective measures in place. Thus establishing effective means of communication should be devised by the contractor.

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Page 15

Effective communication will ensure that employees are provided with sufficient information and they understand the risks and control measures can be implemented effectively.

The method statement should be developed prior to undertake any such work activity identified as mentioned above and should be unique to each work activity 2.4.19 Training programmes The contractor needs to have in place and implement necessary training to employees so that they have the understanding and skills to undertake the work activity without risk to their health and safety.

2

Risk assessment should identify opportunities for training of workers and ensure they are competent for the work activity.

3

Contractor should maintain training records.

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2.4.20 Appendix 2.4.20.1 Appendix A: Example of work activities requiring risk assessment

NUMBERED ASSESSMENTS Associated with this project (Tick boxes)



SITE ESTABLISHMENT

REF NO. 2



HOARDING/FENCING (TEMPORARY)

REF NO. 3



DEMOLITION GENERAL

REF NO. 4



DEMOLITION (ASBESTOS REMOVAL)

REF NO. 5



BUILDINGS ADJACENT TO WORKS

REF NO. 6



OVERHEAD SERVICES/OBSTRUCTIONS

REF NO. 7



UNDERGROUND SERVICES

REF NO. 8



PILING (DRIVEN/BORED/BENTONITE)

REF NO. 9



EXCAVATIONS (SHALLOW/DEEP/CONTAMINATED)

REF NO. 10



HAUL ROAD CROSSINGS ON CONSTRUCTION SITES

REF NO. 11



BULK EARTHWORKS

REF NO. 12



REDUCED LEVEL DIG AND IMPORTED FILL

REF NO. 13



CONTAMINATED GROUND (WORKING WITH)

REF NO 13B



POTENTIALLY CONTAMINATED GROUND/BUILDING FABRIC (ANTHRAX)

REF NO. 14



REF NO. 15



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REF NO. 1

ENVIRONMENTAL ISSUES WORKING ON PUBLIC ROADS



WORKING OVER OR ADJACENT TO WATER

REF NO. 17



WORKING OVER OR ADJACENT TO RAILWAYS

REF NO. 18



CONCRETE WORKS AND REINFORCEMENT

REF NO. 19



CONCRETING, CONCRETE REPAIR, CONCRETE FINISHING

REF NO. 20



PRE CAST CONCRETE STAIRS, WALLS AND FLOORS

REF NO. 21



SCAFFOLD (ALL TYPES)

REF NO. 22



STRUCTURES (WORKING AT HEIGHTS)

REF NO. 23



STEEL ERECTION (GENERAL)

REF NO. 16

QCS 2014




WELDING, BURNING, STEELWORK

REF NO. 25



ROOFWORK/WORK NEAR FLOOR ETC OPENINGS

REF NO. 26



INFILLING OF FLOOR OPENING(S)

REF NO. 27



ROOFWORK (FLAT)

REF NO. 28



ROOF STRUCTURE (PLATES/TRUSSES/TIMBER)

REF NO. 29



ROOF COVERINGS (FELT/BATTEN/TILE)

REF NO. 30



EXTERNAL CLADDING (INC GLAZING)

REF NO. 31



WATER STORAGE DEVICES

REF NO. 32



LIFTING OPERATIONS

REF NO. 33



MANUAL HANDLING

REF NO. 34



SITE PLANT MOVEMENT/CARE

REF NO. 35



TOOLS (ELECTRIC/PNEUMATIC/CARTRIDGE)

REF NO. 36



CONFINED SPACES

REF NO. 37



NIGHT WORK

REF NO. 38



REF NO. 39



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REF NO. 24

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SPECIALIST SUB-CONTRACTOR PROCESSES e.g. BITUMINOUS SURFACING, PAINTING WATERPROOFING, SILANE

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STORAGE OF HIGHLY FLAMMABLE MATERIALS (COVERS SOME USAGE REQUIREMENTS)



REF NO. 42



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REF NO. 41

INSTALLATION OF FIRE PROTECTION COATINGS (BOARD)

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REF NO. 40

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INSTALLATION OF FIRE PROTECTION COATINGS (SPRAY) LIFT INSTALLATION

REF NO. 43



ELECTRICAL/MECHANICAL SERVICES

REF NO. 44



PLUMBING WORKS

REF NO. 45



CARPENTRY/JOINERY

REF NO. 46



PLASTERING AND EXTERNAL RENDERING

REF NO. 47



CEILING FIXING

REF NO. 48



FLOOR AND WALL TILING

REF NO. 49



PAINTING AND PAPERING

QCS 2014 REF NO. 50




USE OF SPECIALIST EQUIPMENT (e.g. NUCLEAR DENSOMETERS, THERMIC WELDERS AND LANCES, LASERS H.P. WATER JETTING

REF NO. 51

Page 18



USE OF CLASS 3B LASERS (PREDOMINANTLY IN CONFINED OR



ARC WELDING

REF NO. 53



RADIOGRAPHY

REF NO. 54



COMMISSIONING PLANT

REF NO. 55



BLOCK PAVING, FLAGGING KERBS AND EDGINGS

REF NO. 56



ROAD/PATH SURFACING

REF NO. 57



FENCING (PERMANENT)

REF NO. 58



LANDSCAPING

REF NO. 59



TREE SURGERY/CHAINSAW WORK

REF NO. 60



FIRE PREVENTION IN WORK AREAS

REF NO. 61



FIRE IN OFFICES

REF NO. 62



OFFICE ENVIRONMENT (PERMANENT/TEMPORARY)

REF NO. 63



YOUNG PERSON IN CLERICAL POSITION (SITE)

REF NO. 64



CABLE PULLING OPERATIONS

REF NO. 65



WORKING IN CHEMICAL/RADIOACTIVE DRAINS

REF NO. 66



BRICK/BLOCKWORK OPERATIONS

REF NO. 67



REF NO. 68



REF NO. 69



LEAD BURNING/PLUMBING WORK

REF NO. 70



MOBILE ELEVATED WORKING PLATFORMS (MEWP's)

REF NO. 71



UNLOADING OF VEHICLES

REF NO. 72



USE OF STEP LADDERS

REF NO. 73



TRAFFIC MANAGEMENT

REF NO. 74



BLANK GENERIC ASSESSMENT FORM

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REF NO. 52

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RESTRICTED AREAS)

CLEANING/BUILDER'S CLEAN LADDERS

QCS 2014


RISK ASSESSMENT GUIDE Assessment for: Significant risks:

Page 19

REF NO. 1

SITE ESTABLISHMENT Falls of persons, falling objects, Moving plant/equipment, Trapping of personnel/limbs, Overhead obstruction. DETAILS OF CONTROL MEASURES Layout drawings prior to delivery of cabins. Location of services (gas, water, electric, sewer and telephone).

Instruction

General safety instruction before activity commences e.g. Toolbox talks on general risks etc.

Training

General health and safety. Certificated crane/HIAB operator. Banks man training where appropriate.

Supervision

Competent person familiar with activity. Check no power lines/overhead services in vicinity of lift.

Access

Safe access for vehicles – suitable base. Safe access/egress to roof of temporary accommodation to fix or unfix lifting slings. Proper access to cabin doorways to be provided. Secure doors at first/second floor levels not provided with staircases.

Environment

Establish ground loading and set up before delivery. Check location of necessary services.

Equipment

Crane/HIAB and lifting slings – check Safe Working Load (SWL) and radii. Check statutory documents before lift. Adequate ladder for access to roof level.

Emergencies

Standard COMPANY procedures to be in place ie. Mobile/phones/radios, first aid etc.

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CONTROL ITEM Information

PPE

Other

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COSHH

Activity to be under the control of one competent person familiar with task/activity/types of hazards.

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Communications

Check that ground is not highly contaminated. If so conduct COSHH assessment. Hard hats, safety footwear, gloves and outdoor clothing. Harness at roof level if appropriate. Keep third parties/general public well away from lifting operation area. Obtain certificate for electrical integrity for inclusion in COMPANY register. Fire precautions.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

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Page 20

REF NO. 2 RISK ASSESSMENT GUIDE Assessment for: SITE FENCING/HOARDING Significant risks:

Manual handling, striking underground services, crushing/trapping by plant & equipment


Instruction/Training

DETAILS OF CONTROL MEASURES Emergency telephone numbers. Permits to dig contact all service companies and private service owners for service plans and tracings. Site boundary lines structuring and height of fence/hoarding details. Operatives to work to Safety method statements. Operatives to sign Safety method statements. Operatives to be advised on hitting buried services. Do Not assume depth. Use of detection equipment. Operatives to temporarily fence when working adjacent to public. To be fully conversant with services in work area. Must be qualified to working in public highways/footpaths. If using crane/HIAB banks man to be present.

Access

Traffic management for works in public highways/footpaths. Compliance with relevant guidance when working adjacent to overhead lines. Ground conditions. Exclusion zone prior to concrete curing.

Environment

Working adjacent to buildings. Overhead services. Traffic. Consider effects of tree/shrub removal. Consider washing out facilities for concrete delivery vehicles. Consider emergency action plan when near water courses.

Equipment

As applicable. Detection equipment. Temporary support for fence posts/gates/hoardings as applicable whilst concrete cures.

Emergencies

Liaise with emergency services and service providers. First aid kit, fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedure to be detailed in contract safety plan. Ensure openings/gates in hoardings/fencing are suitable for emergency services.

Communications

PPE

Other

Warning signs. Hazard tape. Phone/radio. As applicable for products used. Possible ground contamination.

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Supervision

High visibility clothing, hardhats, protective footwear, ear protection, gloves, goggles. Detailed review of service drawings. Consider colour scheme for hoardings. Viewing panels for security in hoardings.


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Page 21

REF NO. 3 RISK ASSESSMENT GUIDE Assessment for: Significant risks:

DEMOLITION GENERAL Falls from height, entrapment, health hazards. Injury from falling/flying objects to operatives and general public, sudden collapse of buildings/structures, fragile roofs, fires, flooding, explosion, electrocution, contamination. Inadequate access/egress.


DETAILS OF CONTROL MEASURES Surveys, Safety Method Statements, structural assessments, scoping exercise for hazards, equipment’s and structures etc. Previous drawings and plans. Site history, past use, desk top study. Consultation at all levels. Description of work to be carried out and methods to be used i.e. piecemeal or controlled collapse. Specific responsibilities for plant and tools to be used. Restrict others from area. Operatives to sign Safety Method Statement. Induction: Lifting and manual handling; hazardous materials and hazardous areas; oxygen and fuel cutting equipment; abrasive wheels; confined spaces when applicable.

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Instruction

Training

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Other

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COSHH PPE

Work to be placed under competent person qualified and experienced in demolition operations of work. Monitor certification of drivers. Monitor works. Essential to restrict access of personnel at place of work being carried out. Effect on adjacent areas. Prohibition of unauthorised persons. Traffic marking of danger zones. State of existing property. Adequate welfare facilities. Overhead and general services. Security of site during operations. General public, traffic, contaminated material, dust, noise etc. No rubbish burning. Effect on residents, monitoring requirements. Provision of all relevant certification. Type to be approved as suitable to carry out operations. Warning notices. Monitoring equipment. Consider transport safety. Use of harnesses and equipment checks. Standard first aid, fire protection, evacuations, accident and investigation reporting. Emergency procedures to be detailed in the contract safety plan. Other workers in the vicinity should be made aware of restricted access. Use of lookouts, warning signs, letter drops to public, advice to other sub-contractors. Handling of explosives, adhesives used for temporary support fixings, dust, biological hazards and various chemical hazards must be identified and actioned. Hard hats, boots, protective clothing, goggles, ear protection, face masks, harnesses. Discuss storage/operations/use of explosives with Qatar Police as appropriate. Carry out administration and monitoring on daily basis. Structural assessments must be carried out by a suitably competent person. Disposal of smoke sensor heads must be in accordance with manufacturer’s recommendations due to heads containing radioactive isotopes. Because hot/cold water systems may be contaminated, i.e. legionella, personnel involved in the dismantling/demolition of such systems should wear suitable respiratory protective equipment. Contact/discuss with your Safety SHE Dept prior to commencing work.

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Supervision


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RISK ASSESSMENT GUIDE

Page 22

REF NO. 4

Assessment for: Significant risks:

DEMOLITION (ASBESTOS REMOVAL) Asbestosis lung disease, mesothelioma, respiratory infections to operatives and public. Increased risk for smokers. Dust inhalation, ingestion and absorption. Contaminated clothing.


DETAILS OF CONTROL MEASURES Analysis of type of asbestos and evaluate the required measures. Safety Method Statements. Provide specification for work. Survey the area.

Instruction

Consult the Safety and Environmental Department, strict control of personnel to trained persons. Medical surveillance. Operatives to sign Safety Method Statement. Normally a specialist operation. Personnel to be fully trained in the handling and removal of asbestos. Check all details.

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Training

Specialist training is required for all persons supervising the plant, equipment and labour associated with asbestos.

Access

Clean, tidy. Consider airlocks into work area decontamination unit. Designated and controlled access are to be used. Exclusion zones.

Environment

Zoning of areas to be established provision of ventilation etc. Consider sealed working area to control dust, damping down and effects of weather, i.e. wind and rain. Monitor atmosphere against the allowed levels of exposure. Clearance tests if applicable. Disposal as special waste.

Equipment

Consider suitable decontamination plant and materials to seal area, and dispose of asbestos. Good separate welfare facilities. Air monitoring equipment.

Emergencies

Clearance tests, first aid (seek medical advice). Fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedures to be detailed in the contract safety plan.

Communications

Standard warning signs and labelling of material for disposal. Advise all persons who may be affected by work. Warning systems in event of emergencies.

Other

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Supervision

Suitable respirators, disposable overalls, gloves, goggles, masks. This is a highly specialised activity; seek advice from Safety and Environmental Department.


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RISK ASSESSMENT GUIDE Assessment for: BUILDINGS ADJACENT TO WORKS Significant risks:

Page 23

REF NO. 5

Collapse/settlement. Associated services. Effect upon occupiers from vibration and general inconvenience etc. Undermining


DETAILS OF CONTROL MEASURES Details of existing construction and condition of the adjacent structure should be used to produce a method statement. A detailed sequence, after consultation with a qualified engineer, should be arrived at where applicable. Design checks on excavations. Consider dewatering risks. Site induction, briefing in position of existing services, methods to be employed and special measures to limit noise, dust etc. Operatives to sign Safety Method Statement. Ensure all plant and equipment operators are certificated.

Instruction

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Training

Supervisors to mark all services and monitor building, and wherever possible verify details of foundations etc. Permits to dig to be issued and possible additional supervision of operations.

Access

Safe access and egress to be provided for operators and occupiers. Consideration to be given to restricted access zone.

Environment

Noise, dust and vibration to be kept to a level that does not interfere with client installation or operations and monitored if applicable.

Equipment

As required by specific operation, possible monitoring equipment required for noise, dust, movement and vibration.

Emergencies

Standard site first aid, reporting procedures. Emergency procedures for occupiers to be considered. Major incident response plan.

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Supervision

Communications

Warning signs and hazard markers.

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Other

Standard for activities being undertaken.

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PPE

Depends on exact activity undertaken.

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COSHH

Agreed dilapidation survey of structure prior to work commencing (if possible). Temporary works coordinator involvement.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: OVERHEAD SERVICE/OBSTRUCTIONS Significant risks:

Page 24

REF NO. 6

Electrocution, structural damage to services, injury from structural collapse or plant capsize. Disruption to client/public services. Explosion DETAILS OF CONTROL MEASURES Contact service provider and clients for plans, details and exclusion zones. Seek possibility of isolation of overhead electrics.

Instruction

All employees advised of location of all overhead services (with sketches and clearances) and nature of services (electricity, gas, steam, air etc.). Working Safety Method Statements are to consider installation dangers. Operatives to sign Safety Method Statements.

Training

All personnel in the work area are to be inducted and given Safety Awareness Talks on handling long object and plant movements in vicinity of overhead services.

Supervision

Regular inspection of barriers and notices. To be fully conversant with services in the work area.

Access

Consider exclusion zones, designated accesses and ground conditions.

Environment

Consider the effects of weather and ground conditions. In particular wind and rain e.g. heightened risks of arcing.

Equipment

Provide crash deck where possible. Barriers to be of suitable construction and design. Warning signs, hazard tapes and markers. Use of nonconductive material. Height restrictions in plant.

Emergencies

Liaise with Civil Defence (Fire Department) Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan.

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PPE Other

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COSHH

Emergency contacts to be posted as applicable. Warning signs and hazard markers.

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Communications

As appropriate to the operations. Hard hats and as appropriate to operations. Note that the highest risks often exist at the time of erection and removal of barriers and height restrictions.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: UNDERGROUND SERVICES Significant risks:

Page 25

REF NO. 7

Electrocution, explosion, asphyxiation, serious injuries, working in vicinity of underground services with mechanical equipment, disruption to public/client services.


DETAILS OF CONTROL MEASURES Emergency telephone numbers. Permits to work. Contact service provider and private service owners for service plans, tracings, as available. Marking and hand excavation as appropriate. Working to Safety Method Statements. Operatives to sign Safety Method Statements. Operators to be advised on hitting buried services, (tracing services). Do not assume depth. Use of detection equipment, confined spaces.

Instruction

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Training

To be fully conversant with services in the work area. Consider exclusion zones. Review on hourly/daily basis to suit service in work area.

Environment

Working adjacent to buildings. Overhead services. Traffic. Consider the effects of water/flooding/weather on services and possible emissions/discharges from services.

Equipment

As applicable. Detection equipment. Possible shoring, Protection and Support systems.

Emergencies

Liaise with Civil Defence (Fire Department). Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major Incident Response Plan. Emergency procedure to be detailed in contract safety plan.

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Supervision Access

Communications

Warning signs, hazard tape and markers.

Other

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High visibility clothing, hard hats, protective footwear, ear muffs, goggles, gloves etc.

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PPE

As applicable for possible emissions/discharges, ground contamination.

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COSHH

Detailed review of available plans for identification of buried services. Note also the following that may be in the area, Cable television, hydraulic, process fluids, pneumatics, Railway signalling, petroleum fuel oils, private communications, civil aviation, military authorities, also gas transmission pipe lines (refer to owners requirements). Plastic pipes – not detectable.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: PILING (DRIVEN/BORED/BENTONITE) Significant risks:

Page 26

REF NO. 8

Crushing/laceration and entrapment injuries, drowning, damage to plant and structures, plant and equipment instability, reversing and slewing machinery, noise and dust. Lifting reinforcing cages, piling gates, top men. Contact with contaminated ground.


DETAILS OF CONTROL MEASURES Obtaining information relating to services, ground conditions, adjacent structures/foundations. Produce Safety Method Statement. Employees are to be briefed on the Safety Method Statement and correct use of equipment. Operatives to sign Safety Method Statement. Visitors are to be escorted. Personnel are to receive Safety Awareness Talks as appropriate. Operators, banks men and piling hands are to be suitably trained and certificated where appropriate.

Instruction

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Training

Supervisors to ensure that plant and equipment is operated and banked ONLY by persons who have been trained, certificated and authorised to do so. Ensure that weekly registers and maintenance requirements are performed.

Access

Keep work area clear and tidy. Consider exclusion zones. Stabilise or harden and maintain the piling mat/work area as appropriate for the work proposed.

Environment

Consider weather, adequate lighting, ground conditions, ground water, nearness of buildings, traffic, noise, fumes, dust and vibration. Consider disposal of arisings – in particular those contaminated.

Equipment

To be suitable for operations being carried out and test certificated (including subcontractor’s). Regular inspection, maintenance, cleaning and reporting on condition. Check condition of plant and equipment upon arrival on site. Weighted or anchored covers to Bentonite filled holes and bored holes. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

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Communications

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Emergencies

Warning signs, hazard lights and markers, audible warning units. Consider the use of radio/transmitters.

COSHH

As applicable to materials used.

PPE

As appropriate together with high visibility clothing, ear defenders and head protection, boots in particular for driven piling.

Other

Refer to generic risk assessment lifting equipment and contaminated land. Avoid inhalation of Bentonite powder. Seek specialist advice as necessary.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: EXCAVATIONS

Page 27

REF NO. 9

(SHALLOW/DEEP/CONTAMINATED/BORROW PITS) Significant risks:

Water ingress/flooding. Collapse of adjacent structures. Injury from falling equipment and materials. Entrapment, Contact with overhead/underground service, personal injury to oneself or others. Failure to check and ensure safe use of equipment. Overturning of vehicles/plant etc. Collapse of excavation sides. DETAILS OF CONTROL MEASURES Check for services in area , evaluate ground conditions and investigate possible flooding. Obtain adequate propping material before commencement. Major excavations must be the subject of design check. Check for buildings, scaffolds and other operations around trench. Operatives to enter and leave excavation by safe access only. Monitor for possible gas. Prevent access to public (remember blind persons require firm barriers). Adequate lighting and signs. Check for contaminated ground. Prevent unauthorised access to excavation. Method statement for installation and removal of support system, also services support systems. Operatives to sign Safety Method Statement. Permit to dig system to be adopted in identified areas of service location i.e. urban areas, factory premises etc. Operatives to be trained in the use of support systems and gas monitors. Machine drivers to be conversant with support systems, also banks man and possible confined space training. Advice on any identified risk and control measures.

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Training

Competent person must be in attendance at all times. Daily/shift checks on trench/support system. Weekly inspection and register kept up to date. Watch for deterioration of ground in wet conditions. Materials and plant not stored too close to edges of excavations. Edge protection.

Access

Safe access and egress in and around excavation to be provided. Use ladders, ramps, cut in steps. Well lit at night. Handrails to top of batters. Stop blocks for vehicles. Excavations area to be kept clear of unnecessary material or plant. Keep any water levels to acceptable levels (ensure adequate sumps). Rain could affect ground conditions. Monitor for gases and contaminated ground. Consider disposal of pumped water. Plant and equipment to be suitable for operation especially support system. Adequate supply of support materials. Pumping equipment to be available if water present. Standard first aiders. Rescue procedure in place. Possible major incident response plan to be put in action. Emergency procedures to be established in contract safety plan. Surrounding area for excavation to be adequately signed. Quick safe warning system considered. Monitor for gas, contaminated ground and general assessments of all materials to be used. Identify any control methods such as the provision of mechanical ventilation. Hard hats, suitable footwear, possible disposable overalls, gloves and high visibility vests. Machine operatives to have good vision of work in progress if possible. Cross reference to confined space generic risk assessment for further information.

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Emergencies

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PPE Other


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: HAUL ROAD CROSSINGS ON CONSTRUCTION SITES Significant risks:

Page 28

REF NO. 10

Impact injury due to collision of plant and machinery with private vehicles or pedestrians.


DETAILS OF CONTROL MEASURES Temporary Traffic Orders for speed restriction on approach to crossing points. Method statements for installation of such schemes will also be required on major schemes, to include all identified requirements of a safe system of work.

Instruction

Appropriate experienced personnel only to be used for actual installation/removal of traffic management works. Specific training for all drivers using crossing points and those who will operate the crossing. An experienced member of staff to be nominated as the Traffic Safety Manager with special responsibility for plant crossings.

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Training

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Crossing to be kept clean and free of debris. Lights and warning signs on both haul road and main road to be cleaned regularly.

Environment

Consideration must be given to poor visibility during adverse weather conditions. Lights and signs soon become observed by dirt. Similarly during extremely dry weather dust will be a problem.

Equipment

All traffic management equipment to conform confirm to current standards and to be regularly maintained/washed.

Emergencies

Emergency call out/liaison list to be established. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan.

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Access

Radios for traffic management team. Mobile phone/radios for traffic safety coordinator. Information signs. Close liaison with police.

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Communications

Other

High visibility clothing, hard hats etc.

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PPE

If using portable generators, noise and handling of fuel.

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COSHH

Provision of shelter and adequate welfare facilities especially for plant crossing operatives well away from temporary offices.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: EARTHWORKS Significant risks:

Page 29

REF NO. 11

Injuries from plant movements, unstable excavations/embankments, tipping vehicles, overhead/underground services, contaminated ground, dust.


DETAILS OF CONTROL MEASURES Safety Method Statements. Detailed review of available plans for identification of buried services. Detailed review of ground conditions/boreholes before commencement. Desk study, advice from Engineering Department. Operatives to be instructed on safe system of work appropriate to the type of operation. Operatives to sign safety method statements. Induction and Safety Awareness Talks to include the care to be taken on earthworks operations. Supervisors responsible for daily/weekly inspections are to be suitably trained. Operators to be suitably trained and certified for the equipment used and Banks man duties as required. Work is to be controlled by an appropriately competent experienced earthworks supervisor. Inspections before work shift commences. Site register to be completed weekly. Temporary Works coordinator to be appointed.

Instruction

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Training

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Supervision

Designated routes, access points and exclusion zones. Consideration is to be given to separation from, and control of, public and non-earthworks traffic within the working area. Safe haul route.

Environment

Evaluate ground conditions to establish nature, groundwater, nearness of buildings or traffic. Weather and flooding should be considered when planning operations. Consider the stability of stockpiles and batters; and the control of noise, dust and fume. Consider any details of contamination.

Equipment

Plant inspection and periodic testing, buried service detectors, guard rails, barriers, warning signs, adequate lighting. Air monitoring equipment where appropriate. Wheel wash facilities. Reversing alarms.

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Access

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Communications

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Emergencies

Warning signs, hazard tape, markers, hazards lights and audible warning units. Consider use of radio/transmitters. Use traffic signs.

COSHH

Not applicable, except on contaminated ground where a COSHH evaluation of ground contaminants will be required to determine protection required.

PPE

Hard hats, protective footwear, protective clothing in adverse weather conditions, high visibility clothing etc.

Other

Consider use of speed limits and mobile welfare facilities.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: REDUCED LEVEL DIG AND IMPORTED FILL Significant risks:

Page 30

REF NO. 12

Contact with plant, reversing vehicles, overhead and underground services, dust, noise, contaminated land. DETAILS OF CONTROL MEASURES Equipment to be certificated, inspected and records kept. Underground services drawings. Safety signs, warning notices.

Instruction Training

Competent, certificated and authorised plant operators. Banks men required for reversing vehicles/plant movement. All operatives to sign method statement as understood.

Supervision

Supervisors to ensure plant and equipment only operated by certificated, authorised persons.

Access

Segregate plant from pedestrians.

Environment

Dust suppression methods. Ground conditions. Daily log of dust emissions. Protection of features/foundations/safe batters/support/proper compaction. Good working order, regularly maintained. Overhead power lines to be suitably protected by high/low level barriers. Segregate from pedestrians.

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All plant to be fitted with fire extinguishers.

Communications

Warning signs, barriers and audible warning units.

COSHH

Dependent upon soil analysis/as applicable during breakdown/regular maintenance to plant and equipment.

PPE

Banks men to wear high visibility clothing, safety footwear/safety helmets to be worn at all times. Hearing protection to be worn as applicable.

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Emergencies

Stop blocks required for reversing plant where applicable. Ref contaminated land risk assessment No 9 if appropriate.

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Other

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: CONTAMINATED GROUND Significant risks:

Page 31

REF NO. 13

Contact with toxic, irritant corrosive harmful and radioactive materials. Injury through skin absorption, skin puncture, ingestion, inhalation or radiation. Toxic/explosive fumes or materials.


DETAILS OF CONTROL MEASURES Seek all information available and where this is inadequate obtain the appropriate chemical analysis before commencement/recommencement of the work. Produce detailed hazard risk assessments and Safety Method Statements. Operatives to sign Safety Method Statement. Personnel are to be made aware of the type of contamination and possible dangers. Operatives are to be given safety awareness talks. Operatives to be made aware of procedure if coming into contact with unexpected material/smells. Demonstrations and briefings are to be given to personnel on the method of handling contaminated material, the effects and remedies, the correct use of protective clothing and personal hygiene. This should be updated as necessary.

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Instruction

Training

A competent person is to obtain the appropriate information on the contaminated material and ensure that operatives are given and adhere to the training information above. Designate a waste controller as appropriate. Regularly monitor the material exposed and ensure adequate testing.

Access

Exclusion zones and designated safe access as necessary related to the type and level of contaminant exposed.

Environment

Evaluate the effects of weather, heat, dust, vibration, corrosion, polluted atmosphere/water, ground conditions (stability).

Equipment

To be individually assessed to suit the operation. Consider gas monitors, breathing apparatus, chemical indicator tubes, wheel washers, decontamination units.

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Supervision

Together with standard procedure for first aid, fire protection, evacuation and reporting; specific procedures are to be considered to suit the operation and contaminants present. Procedures for environmental emergencies i.e. spill, groundwater contamination etc.

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Emergencies

Communications

Warning signs, hazard markings and exclusion zones as appropriate.

COSHH

As appropriate. Specialist advice to be sought where necessary.

PPE

Consider suitable, masks, goggles, gloves, boots, barrier creams, and suits etc. Also consider whether these should be disposable/regularly renewed.

Other

Good welfare, washing and hosing down facilities. Seek advice from Safety & Environmental Department where necessary.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: POTENTIALLY CONTAMINATED GROUND/BUILDING FABRIC Significant risks:

Page 32

REF NO. 13 B

Infection through skin absorption, skin puncture, ingestion or inhalation


Instruction

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Training

DETAILS OF CONTROL MEASURES Seek all information available about the site including site investigation reports, trial pit records, maps and plans. Produce Safety Method Statements. Operatives to sign Safety Method Statements. Personnel are to be made aware of the type of contamination and possible dangers. Operatives are to be given safety awareness talk. Operatives to be made aware of procedure if coming into contact with unexpected material. Demonstrations and briefings are to be given to personnel on the method of handling contaminated material, the effects and remedies, the correct use of protective clothing and personal hygiene. This should be updated as necessary. Give operatives information on the level of residual risk. A designated, competent person is to obtain the appropriate information on the potentially contaminated material and ensure that operatives are given and adhere to the training information above. Designate a waste controller as appropriate. Regularly monitor the material exposed and ensure adequate identification/testing. Effective procedures for health surveillance to enable early diagnosis of infection. Exclusion zones and designated safe access as necessary related to the type and level of contaminant exposed. Evaluate the effect of weather, wind strength and direction, heat, dust, polluted water. Measures to prevent exposure of the general public to wind borne contamination. To be individually assessed to suit the operation. Consider breathing apparatus, wheel washers, and decontamination units. Together with standard procedure for first aid, fire protection, evacuation and reporting, specific procedures are to be considered to suit the operation and contaminants present. Procedures for environmental emergencies, ie spills, groundwater contamination, etc. Prior contact shall be established with a local general practitioner. Warning signs, hazard markings and exclusion zones as appropriate. As appropriate. Specialist advice to be sought where necessary. Check for and protect skin cuts or scratches before using PPE. Consider suitable masks, goggles, gloves, boots, barrier creams and suits, etc. Also consider whether these should be disposable/regularly renewed Facilities for decontamination or disposal of clothing. Adopt procedures for decontamination by heat treatment or chemical disinfecting of any animal remains encountered during the work. Consider immunisation Good welfare, washing and hosing down facilities. Seek advice from Safety & Environmental Department where necessary.

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QCS 2014



REF NO. 14


Page 33

ENVIRONMENTAL ISSUES Demonstrations/sabotage, pollution, damage/destruction of flora, fauna, ancient monuments or protected areas etc.


DETAILS OF CONTROL MEASURES Obtain details of all information and restrictions relevant to the operational area from the Enforcing Authority, the client/employer.

Instruction

Induct personnel appropriately in relation to the information obtained above and any effects on methods of working. Safety awareness talks “environmental awareness” are to be given where applicable. Consideration should be given as to whether further specialist training is necessary for certain operations or localities

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Training

The site manager where appropriate will make personnel aware of information/restrictions and institute suitable controls.

Access

Consideration to be given to restricted zones, security measures and damage caused by equipment/plant movements.

Environment

Consideration to be given to the effects of weather, noise, dust contamination and construction methods upon the local environment/population/watercourses.

Equipment

Fencing, covers, bunds (soil), noise and atmosphere monitors and security equipment as applicable.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Establish environmental emergency response if applicable.

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Supervision

Warning signs, contact Health and Safety Department, emergency telephone list.

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Communications

Other

As appropriate.

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PPE

As appropriate.

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COSHH

Record photographs, incident/insurance reports. Diesel/oil/flocculants/silt laden water are potentially major environmental problems. Please refer to Safety Department for further guidance.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: Significant risks:

Page 34

REF NO. 15

WORKING ON PUBLIC QATAR ROADS Injury from passing/reversing vehicles, debris, services, Subsidence. Dangers to public from construction operations.


DETAILS OF CONTROL MEASURES Safety Method Statements Permits to work on highways. Notify and liaise with the appropriate authorities. Traffic management assessment, requirements for emergency routes for vehicle access i.e. ambulance, Civil Defence (Fire Department), Police etc. Wearing of high visibility clothing. Form of traffic control. Access and egress routes. Crossing points, pedestrian routes, specific risks involved requirements of speed limits. Inductions on traffic management and working on public highways.


To be suitably qualified. Monitor work to Safety Method Statements. Action any non-conformities.

Access

Maintain public and property access where possible or make alternative arrangements. Establish suitably signed works access. Adequate signing of access and egress points.

Environment

Evaluate: noise, dust, fumes, identification of sensitive locations such as schools, hospitals, surgeries, shops, public services when planning works. Consider the hazards to blind persons.

Equipment

Plant/equipment flashing lights (if appropriate).

Emergencies

Standard first aid, fire protection, evacuation, accident reporting and investigation. Liaise with all emergency services, and highways departments – dates, times’ etc., work being carried out. Major incident response plan. Emergency procedures to be detailed in contract safety plan.

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Supervision

Warning and information signs. Hazard markers. Traffic control requirements. Liaise with local residents.

PPE

Other

As required – may include use of various materials such as black top or assessment for dust and fumes generated by traffic.

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COSHH

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Communications

High visibility clothing. Hard hats, protective footwear, ear muffs, goggles, gloves, wet weather clothing. Monitor approved Traffic Diversions Plans on a regular basis and review if needed.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration Qatar Work Zone Traffic Management Guide, all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014


RISK ASSESSMENT GUIDE Assessment for: WORKING OVER OR ADJACENT TO WATER SOURCES Significant risks:

Page 35

REF NO. 16

Drowning. Shock. (Fatigue with clothing on in water). Possible Weils disease.


DETAILS OF CONTROL MEASURES Operatives advised on risk of falling/slipping into water while working in and around docks, swimming pools, tanks and water retaining structures/pits. Operatives advised of risk of falling/slipping into water. Safety Awareness Talks. Safe methods of working. Access and egress routes. Rescue procedures. Tide tables, weather.

Instruction

Inductions, Safety Awareness Talks, use of life jacket, harness, lifebuoys, throwing lines, warning systems. Communications. Rescue procedures. First aiders. Rescue boats. Hygiene – Weils disease.

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Training

Competent supervisor to monitor and check safety and rescue equipment and working method.

Access

Scaffold if possible over water. Handrails beside water, or fencing. Safe access and egress route to and from work areas.

Environment

Good lighting. Weather, tides and ground conditions.

Equipment

Safety boat. Life jackets, lifebuoys, safety nets, throw lines, radios, harnesses, scaffolds, pontoons, rescue lines, audible alarms etc.

Emergencies

Trained first aiders. Rescue procedures in place. Audible alarms. Standard site first aid/reporting procedures.

Communications

Good communications, i.e. radios, telephones or hand signals. Post list of emergency contact numbers. Warning signs.

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Supervision

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Other

Life jackets, safety harnesses. Loose, warm, high visibility clothing. Suitable warm footwear. Hard hats, etc.

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PPE

Considerations to be given if water is contaminated - weils disease.

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COSHH

Good welfare facilities. Adjacent water traffic movement to be considered.


QCS 2014


Page 36

RISK ASSESSMENT GUIDE Assessment for: WORKING OVER OR ADJACENT TO RAILWAYS

REF NO. 17 RISK CATEGORY

Significant risks:

BEFORE CONTROLS

Electrocution/Collision of plant and operatives with trains. Possible collapse or subsidence of railway equipment. Derailment.

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Tick as appropriate CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtain from the relevant railway authority all information relative to the operation, such as “structural gauge” and fencing. All safety method statements to be agreed with railway before commencement of work. Possessions, if required, to be agreed with railway authority.

Instruction

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Training

Ensure all rail procedures and Safety Method Statements are adhered to.

Access

Use only identified walking routes and work areas as agreed in Safety Method Statements. Possessions to be agreed with railways. Establish exclusion zones as necessary.

Environment

Consider the effect of dust, weather and construction operations upon the railway. Good lighting required.

Equipment

Check requirement for structural barriers. Consider the limitation of construction plant adjacent to railway operations. Comply with railway authority requirements for non-conductive equipment such as wheelbarrows, ladders, approved CAT scanner, etc.

Emergencies

Standard site first aid (with particular reference to electric shock), fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

Site wardens and lookouts to be used as required. Warning signs and hazard markers as required by railway authority. Consider use of approved radio/transmitters. Rail emergency telephone number to be prominently posted. As applicable to the operations.

PPE Other

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COSHH

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Communications

Approved high visibility vests. Hard hats (white), suitable footwear (No Rigger Boots) Harnesses if working at height. Only personnel with good hearing and eyesight are to work on or adjacent to railways


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: REINFORCEMENT Significant risks:

Page 37

REF NO. 18

Collapse of reinforcement. Poor housekeeping, falls when accessing structures. Access across reinforcement DETAILS OF CONTROL MEASURES Relevant drawings and reinforcement/structural engineers recommendations N.B. temporary requirements relating to stability especially in wind.


Ensure all personnel are subject of induction and are briefed in method statement/risk assessment content.

Supervision

Competent supervision to be in attendance for duration of operation. Ensure method statement content is applied at workface.

Access

Ensure board walkways 600mm wide are provided across slab reinforcing. Ensure guarded and boarded platforms are provided for fixing reinforcement at height: prohibit the use of ladders. Provide scaffold stair towers. Prohibit the climbing of reinforcement. Expedite the installation of permanent staircases. Provide protection to exposed starter bars.

Environment

Caution required on damp plywood decks or following application of release agents. Limit and control mechanical and manual handling of shutters in high wind.

Equipment

Cut off wheel operations to be certificated.

Emergencies

See site general emergency procedure.

Communications

Works to be closely coordinated with erection of false work and form work. Formal paperwork system to be applied for control of loading and striking formwork.

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PPE

Low risk for handling steel, tying wire and spacers. Assessment as appropriate for any other substances.

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COSHH

Other

Safety helmet, boots, eye protection and rigger gloves. Full body harness only when attachment location identified and agreed in method statement. Eye protection recommended when using tying wire. Agree methods of attachment of slings when mechanically lifting fabricated cages. See Risk Assessment No19 for concrete works.


QCS 2014


Page 38

RISK ASSESSMENT GUIDE REF NO. 19 Assessment for: CONCRETING, CONCRETE REPAIR, CONCRETE FINISHING. Significant risks: Plant and equipment, noise/vibration, concrete burns, dermatitis, working at heights, protruding reinforcement, manual handling, failure of materials/equipment. CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Method statements. Safety signs. Warning notices.


Operatives to sign method statements. Operator certificated and competent to use items of plant/equipment. Manual handling/vibration training. Constantly monitoring concreting operations, particularly situations where point loading/collapse could occur. Rotate workers on vibratory tools where feasible.

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Supervision

Consideration of mechanical access equipment. Provision of safe means of access/egress suitably secured. Segregate pedestrians from plant and equipment. Edge/hole protection.

Environment

Consider noise produced from plant and equipment particularly for out-ofhours working on curing concrete. Dust suppression methods. Adequate lighting. Dust from mixing dry concrete – locate mixers externally. Protect vertical ends of protecting starter bars.

Equipment

Good working, least vibration order, regularly maintained and records kept. Operators to be certificated / competent.

Emergencies

Suitable First Aid facilities to be available, particularly eye-bath stations to be situated nearby. Operatives aware of emergency procedure and location of assembly points. Establish systems of work/emergency contact numbers for out of hours working.

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Access

Communications

Provision of suitable safety signs warning and barriers.

Other

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PPE

Assessments/information and instructions to be given to operatives on materials. Personal hygiene essential when dealing with concrete/content.

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COSHH

Suitable protective footwear, including wellington boots where necessary. Hand, head and eye protection. Hearing protection where necessary. Safe system of work for dismantling/stripping formwork to prevent falls onto persons to be included in method statement.


QCS 2014


Page 39

RISK ASSESSMENT GUIDE REF NO. 20 Assessment for: PRE-CAST CONCRETE, STAIRS, WALLS AND FLOORS Significant risks: Falls from height, crushing, collapse, handling, access, lifting appliances, heavy plant. CONTROL ITEM Information


DETAILS OF CONTROL MEASURES Operatives to be given appropriate information to ensure full knowledge of possible hazards associated with the fixing of pre-cast concrete units. Details of designed safe Method Statements to include specific risks. Where applicable, operatives to be inducted on the construction methods. Operatives to be trained by competent person in use of plant and equipment. The installation and fixing of pre-cast units to be controlled by experienced supervisor.

Access

Designated safe access/egress to be provided to all work areas. Control of access of pedestrians and plant to be in place to prevent unauthorised work under pre-cast flooring/wall installation.

Environment

Monitor for noise. Consider the effect of wind loadings on hoisted sections, and ground conditions to be checked for cranage equipment.

Equipment

All cranage/lifting gear/mobile and static scaffolds to be properly maintained and inspected.

Emergencies

Emergency procedures to be drawn up for the recovery of persons working at height, to include contact numbers and location of first-aider. Standard first aid equipment and accident reporting.

Communications

Radios to be used if possible. Systems to be in place for tandem lifting on heavy/large pre-cast sections. Signs and hazard markers.

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Supervision

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N/A

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Other

Hard hats, boots, high-visibility vests and harnesses.

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PPE

Transportation of long/wide loads to be planned with Police if applicable. Unique Method/Risk Assessments to be drawn up for individual erection processes with sub-contractor.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: SCAFFOLD (ALL TYPES) Significant risks:

Page 40

REF NO. 21

Injury from falling equipment and materials. Danger of collapse in exposed places, falling from height.


DETAILS OF CONTROL MEASURES Usage of scaffolding and adequate materials/fittings. Equipment to be used. Safety Method Statements. Evaluate ground and loading conditions. Assess the need for any design requirements. Operatives to be provided safe access and egress. Prevent unauthorised access. Prevent access to any incomplete areas. Tie-ins. Drawings of system being erected. Number/width of platforms. Provision of handover certificates on completion. Inductions. Safety Awareness Talks – Working at Heights. Interpretation of scaffold design drawings. No scaffold to be erected modified or dismantled, except under the supervision of a competent person.

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All scaffold erection must be under the supervision of a competent person. Thoroughly examine before first use, after substantial alteration after bad weather, or every 7 days. Receive scaffold handover certificate as appropriate. Keep platforms and area base clear.

Access

Keep access area to scaffold clean and tidy. Notice warning of dangers. Identify incomplete scaffold. Adequate widths of access platforms. Further consideration required if access by hoist, etc.

Environment

Evaluate ground conditions. Proximity to water/buildings or traffic. Overhead services. Consider the general public. Consider weather conditions such as wind loadings on sheeted scaffolds.

Equipment

To suit requirements.

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Supervision

Standard first aid. Accident reporting and investigation. Contract safety plan emergency procedures.

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Emergencies

Inform others working in area of proposed scaffolding to be erected. Supply information to other employees who may be using the scaffold. Warning signs and hazard tape and markers (lighting/traffic protection in urban areas). N/A Hard hats, protective footwear, harnesses, gloves.

COSHH PPE Other

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Communications

Review scheme if modification takes place. Ensure that a scaffold handover certificate is issued where appropriate. Secure scaffold against unauthorised access. Carry out manual handling assessment of the work.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: STRUCTURES (WORKING AT HEIGHTS) Significant risks:

Page 41

REF NO. 22

Injuries from falls, falling materials and equipment, reinforcement instability, structural failure, harmful substances, pressure bursts, power tools, entrapment, plant instability, splinters, dust, fragments, excessive noise, vibration, fumes, confined spaces. DETAILS OF CONTROL MEASURES Operatives are to be given the appropriate information to ensure that they are conversant with the hazards of operations and equipment associated with false work, reinforcement, concrete placement, scabbling / grit-blasting, working at heights, roof work as applicable to the type of structure. Details of design risk assessment to be incorporated into Safety Method Statement. Hierarchy of secure platform/workplace – safety nets – safety harnesses to be determining fall protection measures. Where applicable, operatives are to be inducted on the construction methods, and given potential hazard details. Operatives to sign Safety Method Statements. Operators to be trained by competent person in use of plant and equipment.

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Work is to be controlled by a competent experienced supervisor and temporary works coordinator as required. Appropriate registers to be completed.

Access

Designated safe access is to be provided to all areas of work.

Environment

Monitor for noise, vibration, dust atmosphere. Evaluate access, wind loading, weather, ground conditions, watercourses, nearness of buildings, traffic or services, stacking of materials at ground level and above.

Equipment

Access equipment/platforms, guard rails, adequate lighting, false work / scaffold design and inspection, lifting equipment.

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Supervision

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedures to be detailed in contract safety plan for recovery of persons injured at heights.

COSHH

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Emergencies

Emergency contact names, organisations, telephone numbers. Warning signs. All materials to be assessed for COSHH.

PPE

Hard hats, protective footwear, protective clothing, goggles, high-visibility clothing, masks, harnesses, etc., as appropriate.

Other

Management individual to be appointed to have responsibility for coordination of design and procurement of false work and access scaffold, etc.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: STEEL ERECTION (GENERAL) Significant risks:

Page 42

REF NO. 23

Lifting, Work at Heights. Injuries from falls/falling objects


DETAILS OF CONTROL MEASURES Detailed Safety Method Statements particularly in respect of lay down facilities sequence, access, temporary stability and safety are required. Location of anchor points.

Instruction

Site Induction, safety awareness, unique Safety Method Statement briefing. Operatives to sign Safety Method Statements. Competent steel erectors only should be used – familiar, as a minimum, with rigging, erection methods, lifting equipment, tools and plant, erection of accesses (mobile and static). Individual training for unique types of plant such as mobile lift platforms. Certification of Banks men.

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Training

Competent supervisors with knowledge of lifting duties, planning, safety equipment as well as general operative training above. Operative training certification verified and registered.

Access

Generally via fixed scaffold system, cradles, mobile platforms or harnesses etc. Fixed access to be properly erected and inspected. Mobile plant to be certificated. Consider exclusion zones.

Environment

Ground conditions to be checked for cranage/mobile access equipment. Services to be marked etc. Monitor weather conditions.

Equipment

All cranage/lifting gear/mobile and static platforms, to be properly maintained and inspected.

Emergencies

Emergency procedures to be drawn up for recovery of persons injured at height including contact numbers and location of first aider. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Supervision

PPE Other

N/A

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COSHH

Radios to be used if possible. Signs and hazard markers.

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Communications

High visibility vests, harnesses, helmets and boots. Unique assessments should be drawn up for individual erection processes with sub-contractor.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: WELDING, BURNING, STEEL WORK Significant risks:

Page 43

REF NO. 24

Fires, explosion, respiratory disease/eye damage. Various occupational health risks.


DETAILS OF CONTROL MEASURES Use Hot Work Permit System. Welding procedures, details of gases to be used and storage details is included.

Instruction

Site induction, explanation of unique Safety Method Statement.

Training

Welding and burning should only be performed by suitably trained/certificated individuals who can show proof of such training appropriate to the operation. Generally by a suitably experienced supervisor who does not have to be a certificated welder but must be experienced in welding safety, working at heights etc.

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Supervision

As general steel erection, however, due allowance must be made for safe positioning of equipment, screens, hoses and welding leads.

Environment

Storage of bottles must be controlled with oxygen at least 3 meters from LPG/ACETYLENE, in open air, upright, out of sunlight. Firefighting equipment must be present. Flash guards whilst welding.

Equipment

To be regularly maintained with daily checks on hoses, regulators, leads, flashback arrestors leak tests, etc. Only proprietary fittings to be used. Secure bottle storage as above. Handling to be via trolleys etc.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Additional firefighting facilities locally.

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Access

Communications

N/A

Materials to be welded / cut should be identified and full COSHH assessment performed. Give particular attention to coatings on materials to be welded / cut. Iron oxide (vapour), carbon monoxide and nitrous fumes may be created, natural ventilation generally OK, but induced ventilation may be required in confined spaces.

PPE Other

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COSHH

Specialist welding visors, goggles, helmets, masks, gauntlets and overalls to protect bare skin. Assess the need for fire watchmen, screen the public from welding. Unburnt gas builds up in voids behind work piece from preheating operations.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: ROOF WORK/WORK NEAR FLOOR ETC OPENINGS Significant risks:

Page 44

REF NO. 25

Falls from height. Falls of materials/tools etc. DETAILS OF CONTROL MEASURES Loading sequence/Lifting arrangements. Operatives advised of contents of risk assessment/Safety Method Statements. Operatives to sign Safety Method Statements.


Instruction on fall arrest equipment, edge protection, wearing of harness, fragile materials, equipment/material control.

Supervision

Competent supervisor to be present for all associated works. Supervision to implement Safety Method Statement requirements.

Access

Guard rails/toe boards/material guards provided and used. Adequate ladder access etc.

Environment

Weather implications i.e. winds, sand factors etc.

Equipment

Adequate access. Where used safety netting properly secured. Anchorage points for clip-on facilities for full arrest equipment.

Emergencies

First aid, evacuation, recovery arrangements for possible injured person and fire control.

Communications

Warning notices and where appropriate segregation at ground level to protect pedestrians.

COSHH

As appropriate to roof work type e.g. Hot Bitumen etc.

PPE

Inertia reels for fall arrest. Full body harnesses, safety helmet, boots, warm clothing etc.

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Material movement onto roof and loading sequence be controlled. Consider point loading.

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Other

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: INFILLING OF FLOOR OPENING(S) Significant risks:

Page 45

REF NO. 26

Falls of person, falls of materials, collapse of support work (temporary or permanent). Health risk from contact with materials. Muscular skeletal injuries. DETAILS OF CONTROL MEASURES All persons involved in the work will receive information regarding the hazards associated with the operation and the precautions to be taken.


The supplier of bolts and fixings should be requested to instruct installers on the correct procedures to be used for the fixings specified.

Supervision

All work involving the support at floor infill’s shall be under the control of a competent person experienced in the methods used.

Access

Proper access must be provided for installation of support system. Barriers must be provided to the edges of the opening prior to the infilling operations. Where appropriate fall protection to be provided.

Environment

All support work whether temporary or permanent must be subject to a methodical system of checking to include, connections, fixings, access etc and compliance with design drawings and specification prior to loading. Permit system to be introduced prior to loading system with concrete.

Equipment

All equipment must be checked for good condition and suitability prior to being used.

Emergencies

Arrangement to be put in place for recovering persons injured etc whilst carrying out work on high level areas.

Communications

All relevant information including Safety Method Statements and Risk Assessments, Manufacturer’s Instructions and design drawings should be communicated to all persons involved.

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Other

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Assessments should be made for materials classified under COSHH which should be communicated to all persons.

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COSHH

May include, eye protection, clothing, footwear, safety helmet and hearing protection. Safety Method Statements must be produced for all elements of the works including preparation of existing structure, installation and inspection of support system and access systems. Installation of Formwork and preloading checks.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: ROOF WORK (FLAT) Significant risks:

Page 46

REF NO. 27

Falls from height, falls of materials, fragile materials, unsecured materials, manual handling. DETAILS OF CONTROL MEASURES Sequence of work. Location of materials, raising of materials to roof level. Means of providing fall protection. To elevations leading edge and openings. Handling of large sheets.


Operatives and supervisors must be trained and competent. Must be inducted and briefed in method statement content.

Supervision

Competent supervisor to be in attendance for duration of operation. Ensure method statement is formally discussed with all roofing operatives. Supervision to review roof operations daily.

Access

Provide ladder or access tower or identify other means of access.

Environment

Confirm maximum safe working wind speed for type of roofing. Be aware of increased risk in dusty conditions.

Equipment

NB the options for protection are (in order of preference):1 –safety nets; 2 –Lead guard type leading edge protection trolley systems; 3 –Safety harnesses/running lines/ fall arrestors. Adequate access. Where used safety netting properly secured by certificated erectors. Anchorage points / clip-on facilities for full arrest equipment. Anemometer.

Emergencies

Agree emergency procedure for recovery and treatment of person injured at a height. Ensure adequate firefighting and first aid provision available.

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Warning notices and where appropriate segregation or protection at ground level to protect pedestrians.

PPE

Other

Assessments as appropriate for materials to be used.

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Communications

Full body harnesses, safety helmets, boots, warm clothing. Gloves, eye protection

Confirm controls for hot works and storage of flammables at height.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: ROOF STRUCTURE (including wall plates/trusses/timber) Significant risks:

Page 47

REF NO. 28

Falls, falling objects, manual handling, fire.


DETAILS OF CONTROL MEASURES Agree safety method statement. Store materials in a safe manner. Provide suitable working platform. Precautions to be taken to prevent operatives falling whilst installing trusses e.g. safety nets or boarding. Visually check electrical tools and leads. Obtain COSHH assessments. Ensure circular saws are in good working order with guard and dust extraction bag in place. Carry out manual handling assessment, use lifting appliances to lift trusses into position. Complete crane checklist. Inspect lifting gear before use. Keep work area free from tripping hazards. Store waste material in the proper bins. Operatives to receive risk, manual handling and COSHH assessment. Carry out induction, all relevant assessments to be given as Tool Box Talks. If using Mobile Elevated Work Platforms adequate training must be given. Slingers to be properly trained.

Instruction

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Training

Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register. Crane controller to complete crane checklist. Provide suitable ladders, properly secured. Keep access free of materials and electrical leads.

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Access

Weather implications i.e. winds and dusty conditions.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturers instructions for maintaining Mobile Elevated Work Platforms. Safety nets to be properly secured. Crane and lifting gear certificates to be kept in site register. Provide first aider. Provide fire extinguishers. Operatives to be informed of all emergency procedures at induction. PPE, “Danger Men Working Overhead”, Scaff tag or similar to be displayed. Assessment for all materials to be obtained.

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Emergencies

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Other

Hard hats, safety footwear, gloves, eye protection, dust mask and ear protection. If using mobile elevated work platforms fall body harnesses must be worn. Do not overload scaffold platforms, provide suitable roof truss rack.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: ROOF COVERINGS (felt/batten/slate/tile/cladding) Significant risks:

Page 48

REF NO. 29

Falls, falling objects, manual handling


DETAILS OF CONTROL MEASURES Agree Safety Method Statement. Store materials in a safe manner. Provide suitable working platform. Precautions to be taken to prevent operatives falling i.e. safety nets. Visually check electrical tools and leads. Abrasive wheels to be kept in good order and guards in place. Obtain COSHH assessments. Carry out manual handling assessment, use lifting appliances to lift materials into position. Complete crane checklist. Inspect lifting gear before use. Keep work area free from tripping hazards. Store waste material in the proper bins. Operatives to receive risk, manual handling and COSHH assessment. Carry out induction, all relevant assessments to be given as tool box talks, abrasive wheel operator to be trained in its use and how to change the abrasive wheels safely.

Instruction

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Training

Competent person to inspect working platforms and areas before work starts. Inspection of working platforms to be entered in Site Register. Crane controller to complete crane checklist.

Access

Provide suitable pitched roof/ridge ladders, properly secured. Keep access areas free of materials and electrical leads. Access on tile batten to be agreed with roofers. Prohibit walking on tiled areas. Weather implications i.e. winds and dust etc.

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Supervision

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Environment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Safety nets to be properly secured. Crane and lifting gear certificates to be kept in site register.

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Equipment

Provide First Aider. Operatives to be informed of all emergency procedures at induction.

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Emergencies

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COSHH

PPE, “Danger Men Working Overhead”, Inspection report or similar to be displayed.

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Communications

Assessment for all materials to be obtained. Dust generation from cutting tiles with powered abrasive cutters.

PPE

Hard hats, safety footwear, gloves, eye protection, dust mask and ear protection.

Other

Do not overload scaffold platforms, only load out on loading bay. Consider material movement onto roof and load points.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: EXTERNAL CLADDING Significant risks:

Page 49

REF NO. 30

Falls of persons, handling panels at high levels, falling materials, broken glass or unprotected edges of panels.


DETAILS OF CONTROL MEASURES Instruction for supervisors and operatives in the safe storage and working procedures. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds Where appropriate training must be provided in the operation of Mobile Elevated Work Platforms (MEWP’s). Operatives must be trained in working at heights. Operatives to be instructed to work to Safety Method Statements, operatives to sign Safety Method Statements.

Instruction

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Training

Supervision

Works are to be controlled by an appropriately competent and experienced supervisor. Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Supervisors to ensure that Safety Method Statements are being worked to and those materials are being properly handled and stored. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed; mobile scaffolds and access platforms must be properly erected with guardrails fitted and inspection details recorded. Where MEWP’s are used, operatives must wear and use safety harnesses when working at height, operatives must not leave the confines of the MEWP whilst at height. Exclusion zone must be established at work location.

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Access

Works must be restricted in windy conditions. Consideration must be given to working in the vicinity of overhead services.

Equipment

Equipment must be kept in good working order and be regularly maintained with records being kept. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. MEWP’s must not be used as a lifting device to transport men or materials e.g. used as a hoist.

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At least one person in any glazing team should have been trained in first aid. Each glazing team should have appropriate first aid equipment available to them. Warning signs, notices and barriers used as appropriate. Assessments must be produced for hazardous materials e.g. sealants and training provided. Safety harnesses, goggles, gloves, safety footwear, helmets must be worn. Consideration must be given to adequate segregation of the works with other contractor’s employees and members of the public. See also Risk Assessment no. 32 - use of lifting appliances/gear to lift/move/store stillages and panels where appropriate.

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Emergencies


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: WATER STORAGE DEVICES Significant risks:

Page 50

REF NO. 31

Falls from heights, falling materials, eye injuries during drilling operations. Inhalation, skin absorption or ingestion of harmful substances.

CONTROL ITEM Information Instruction

DETAILS OF CONTROL MEASURES Instruction for supervisors and operatives in the safe storage and working procedures. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds. Where appropriate training must be provided in the operation of Mobile Elevated Work Platforms (MEWP). Operatives must be trained in working at heights. Operatives to be instructed to work to Safety Method Statements, operatives to sign Safety Method Statements.

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Training

Works are to be controlled by an appropriately competent and experienced supervisor. Supervisors to ensure that equipment and plant is operated and erected only by persons who have been trained, certificated and authorised to do so. Supervisors to ensure that Safety Method Statements are being worked to and that material are being properly handled and stored. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed, mobile scaffolds and access platforms must be properly erected with guardrails, mid rails, and toe boards fitted. Where MEWP’s are used, operatives must wear and use safety harnesses when working at height, operatives must not leave the confines of the MEWP whilst at height. Exclusion zone must be established at work location.

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Supervision

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Access

Environment

Works must be restricted in windy conditions. Consideration must be given to working in the vicinity of overhead services. Equipment must be kept in good working order and be regularly maintained with records being kept. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. MEWP’s must not be used as a lifting device to transport men or materials e.g. used as a hoist.

Emergencies

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Equipment


Provide First Aider. Operatives to be informed of all emergency procedures and first aid provision at induction. Warning signs, notices and barriers used as appropriate i.e. "Danger Men Working Overhead". Assessments must be produced for hazardous materials e.g. sealants and training provided. Safety harnesses, goggles, gloves, safety footwear, helmets must be worn. Consideration must be given to adequate segregation of the works with other contractor’s employees and members of the public.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: LIFTING OPERATIONS Significant risks:

Page 51

REF NO. 32

Injury from falling equipment and materials. Entrapment, personal injury to oneself or others. Failure to check and ensure safe use of equipment. Overturning of crane/excavators used as cranes.


DETAILS OF CONTROL MEASURES Operatives to be advised of risks from lifting by manual or mechanical means. Proximity of any overhead services. Safety Method Statement required. Advice to be given on any specific control measures including safe systems of work and Safety Method Statements. Colour coding of lifting equipment. Operatives to sign Safety Method Statements. Moving unusual objects. Using correct equipment. Check all crane and lifting test certificates are in date. Check equipment supplied. Visual inspection of equipment prior to any lifting operations. Identify if a dedicated method statement is needed, i.e. over 10 ton. Induction – mechanical and manual lifting, banks man training certificated. The use of competent/certificated drivers. Specifics of individual tasks. Appoint a lifting supervisor. Nominate crane coordinator to assess local conditions and lift requirements. Determine weight, centre of gravity, sharp edges, condition of load. Visual inspection of equipment being used. Reporting. Monitor driver’s performance. Plan route and assess any hazards. Keep work area clear. Ground conditions. Exclusion zones where appropriate. Level area for lifting. Check ground conditions. Closeness of buildings, excavations and services. Monitor lighting and weather (including response actions during high wind conditions).

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Instruction

Training

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Supervision

Access

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Environment

Check valves fitted to excavator. To be suitable for operations being carried out and test certificated. Setting up of equipment to be adequate and verified by crane coordinator. Assess the need for a planned preventative maintenance scheme.

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Standard first aid, evacuations, accident reporting and investigation. Major incident response plan. Emergency procedures in contract safety plan.

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Emergencies

COSHH

Other workers to be informed of lifting operations being carried out. Warning signs. Hazard markers etc. Radio/transmitters. Ability to hear audible warnings during lifting operations. One banks man only directing crane driver. As required.

PPE

Hard hats, high visibility clothing, gloves and footwear etc. Identification of banks man.

Other

Excavators used for lifting must be rated or exempt with current documentation. Provision of equipment such as tag lines. Further considerations for lifting operations in tunneling or for man-riding will be needed.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: MANUAL HANDLING Significant risks:

Page 52

REF NO. 33

Various back injuries (i.e. strains, slipped discs etc.) possible injury through dropping, torn ligaments, tendons, hernias, general cuts and abrasions.


DETAILS OF CONTROL MEASURES Operatives informed of possible back injury and strains and sprains due to lifting tasks on site and in office. Issue “Manual Handling” information to personnel. Clear labelling of weights if possible. Assess all the details and working practices of the work to be done. Complete specific assessment form as appropriate. Avoid manual handling if possible. Use mechanical means if appropriate. Seek help from others if no mechanical aid available. Follow the control methods detailed in an assessment. Operatives trained in correct method of lifting and handling. Not to exceed personal capability.

Instruction

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Training

Constantly monitor storing and stacking to keep manual handling as minimal as possible. Ensure specific instructions are followed, supervisors to be aware of manual handling requirements.

Access

Good flat, clear, stable ground and scaffolds are free of obstacles and debris.

Environment

Areas to be kept clean and tidy. Free of trip hazards. Well lit. Special attention to areas of restricted space.

Equipment

Various lifting aids available to assist manual handling. Ensure lifting aids are subject to any applicable inspection testing etc.

Emergencies

Standard site first aid, fire protection, spillage control, accident reporting and investigation.

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Supervision

Other

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Possible hazards from material being handled in case of spillage.

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COSHH

Good communications between operatives in dual handling.

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Communications

Gloves, foot protection, hard hats, possible eye protection, masks as appropriate. Size of packaging to be reviewed to give consideration to manual handling. Operatives should be screened to assess the suitability of the person to the task.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: SITE PLANT MOVEMENT/CARE Significant risks:

Page 53

REF NO. 34

Crushing/laceration and entrapment injuries, damage to structures and plant, plant instability, structural failure, reversing vehicles, slewing machinery. Loss of loads.


DETAILS OF CONTROL MEASURES Operatives and visitors to be aware of dangers of equipment and related locations. Produce Safety Method Statements where appropriate. Ensure that plant manuals are kept with equipment where appropriate. Any traffic/pedestrian routing to be detailed in safety plan and clearly marked. Visitors to be inducted/escorted, operatives to receive appropriate safety awareness talks. Use of banks man in movement areas if applicable. Operators and banks men to be competent suitably trained and certificated. Supervisors to ensure that plant and equipment is operated and banked ONLY by persons who have been trained, certificated and authorised to do so. Ensure that weekly registers and maintenance requirements are performed. Regular inspection of any traffic management systems to ensure safe access etc.

Instruction

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Training Supervision

Safe access to be assessed and provided before movement of plant. Assess requirements for level ground. Consider pedestrian segregation and high visibility clothing.

Environment

Consider weather, ground conditions, adequate lighting, dust, nearness of excavations/buildings, traffic, noise and fumes. Suitably plan any cleaning, wheel washing, sheeting areas, loading. Damp down in dry weather. Bund diesel tanks.

Equipment

Regular inspection, reporting of condition, maintenance procedures and manuals, periodic tests, cleaning. Instructions to be in English. Hazard lights and audible warning units where applicable. Adequate marking.

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Access

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Use warning signs, hazard markers and audible warning units where appropriate. Personnel in the vicinity should be made aware of plant movements. Consider use of radio/transmitters. Use of dedicated banks man using the appropriate signals.

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Emergencies

COSHH

PPE Other

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As applicable to maintenance activities. Specific hazardous loads to be loaded and carried may need assessing. As appropriate to maintenance operations, together with high visibility clothing. Check condition of plant upon arrival on site.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: TOOLS (ELECTRICAL/PNEUMATIC/CARTRIDGE) Significant risks:

Page 54

REF NO. 35

Personal injuries due to misuse and failure such as electrocution and laceration; excess noise, dust and vibration.


DETAILS OF CONTROL MEASURES Assess tool requirements, location of use and obtain data sheets as appropriate. Any relevant marking requirements e.g. ear protection (symbol visible on the tools). Regular tool box talks with individual reference to unusual tools. Certificate and Authorisation of Plant Operators. Cartridge tool operators are to be certificated by the manufacturer/supplier.


Supervisors are to monitor condition, inspection records, certification and use. Consider exclusion zones and controlled issue of tools. Adequate working space is to be provided for the safe use of tools.

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Supervision Access

Evaluate weather, water, earthing requirements, vibration, noise, dust, fumes, dry storage area, security etc. Safe storage for cartridges/gas cylinders.

Equipment

Delivery test certificates where appropriate. Maintenance, cleaning, periodic testing and regular inspection. Ensure electrical equipment is 110v and properly earthed.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Give particular consideration to electrocution in conductive environments.

Communications

Tool box talks, warning signs.

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Environment

As applicable. Consideration to be given to dust, swarf, oils, greases, cleansing fluids, epoxy etc. Consider the presence of asbestos.

Other

Goggles, ear muffs, gloves, masks, etc. Consider ventilation/breathing apparatus.

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Two of the most important considerations with tools are PPE and adequate training.


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Page 55

REF NO. 36

Assessment for:

CONFINED SPACES

Significant risks:

Asphyxiation from lack of oxygen or poisoning of noxious fumes/gases, explosive gases, entrapment, flowing solid material overcome by high heat conditions, drowning if present, fall injuries. All possibly exacerbated by the introduction of mechanical or electrical equipment into confined areas .


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Instruction

DETAILS OF CONTROL MEASURES Seek all available information on the ground/location to be entered and establish safe systems of work. Undertake all appropriate tests to identify the nature of the environment to be entered e.g. sludge’s, rust (lack of oxygen). Procedures to be developed to take account of complexity of confined spaces e.g. tunnels, underground shelters, caverns, vessels etc. and the number of persons within confined spaces. All employees who have involvement with any confined spaces work (including the writing of Safety Method Statements) to be given specific instruction concerning particular spaces to be entered and relevant information. This includes supervision, employees entering confined spaces persons employed as top men and rescue personnel. All personnel to sign Safety Method Statements/Permits to enter and/or work. All employees entering confined spaces are to receive training for entry procedures, atmospheric testing equipment, emergency evacuation, lifesaving equipment and procedures. The practical use of equipment will also be covered. Emergency rescue team to be formed and trained where appropriate. Designate the “category” if space to be entered. A trained competent person is to be appointed to carry out tests before entry and be in continuous attendance during work within confined space. Entry controlled by permit system. Safe and unrestricted access to/from confined spaces to be monitored and ensured by this person at all times. Supervisor to be aware if the requirements of confined space work. Unrestricted access and egress essential. Use tally boards where appropriate to monitor entry and exit. Forces ventilation and requirements must be assessed but they are to be mandatory in any area where any possibility of oxygen deprivation or noxious gases identified or known to exist, unless a system utilising working BA has been established. Traffic management scheme to be drawn up and implemented for protection of access/egress points in roadway. Evaluate for ventilation requirements, consider need for non-spark (intrinsically safe) lighting and equipment. The effects of flooding or weather, hot or cold temperatures, contaminated ground to be established. Identify toxic or flammable atmospheres to ensure that continuous gas monitors are compatible. Consider the effects of noise, dust and fumes. Provide emergency lighting. Saver rescue and working breathing apparatus, ventilation units, gas detectors, man hoist and harness, chemical indicator tubes to identify fumes/gases or substances. Also consider the intrinsic safeness of all electrical systems. Ventilation systems to have visual or audible warning in event of failure. Consider pre-determined system of shouts/whistles/horns etc, between all members of the team. Clear access to be maintained to the working area for emergency services. Standard site first aid, fire protection, recovery, evacuation, accident reporting and investigation. Major incident response plan. Emergency boards, drawings, telephone numbers etc. to be displayed at point of entry. Consider internal telephone/radio/transmitters/bell/rope signals. Consider the hazards of all material such as epoxies, resins, adhesives, fuels, cleansing fluids, solvents, dust, concrete, paints etc, when used in confined spaces.

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PPE

Page 56

Hard hats, protective footwear, protective clothing, goggles, masks, hearing protection, harnesses etc. as appropriate and breathing equipment. Gas monitors. Consideration should be given to confined space procedures when personnel enter restricted spaces within form work or reinforcement cages. Contact with Safety and environmental Department.

Other

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: NIGHT WORK Significant risks:

Page 57

REF NO. 37

Injury from falling/tripping/fatigue in particular, plus generally increased risks due to limited visibility.


DETAILS OF CONTROL MEASURES Generally a method statement either unique to a single night’s work or to an activity over a number of nights, should be prepared incorporating the requirements of the preceding shift and personal response alarms. All involved should be given a briefing on the work involved including which accesses are to be used and which areas are suitable for working. Give specific induction and safety awareness talks on night work. Refer to specific risk assessments and Safety Method Statements.


Plan safe and adequate lighting both in place of work and access there to (i.e. working and background lighting). Ensure all access ways are completely lit, are of good standard and free of materials. Establish exclusion zones and designated working areas. Give particular attention to edge protection and barriers.

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Supervision Access

Good lighting. Special attention to all edges, trip hazards, noise and vibration. Consider weather i.e. low temperatures and slippery surfaces. Avoid lighting that may have stroboscopic effect particularly if using moving equipment. If practical check lighting levels. Prevent nuisance/risk to public from lighting/dust/noisy operations.

Equipment

All equipment required for night work, especially lights, should be checked during prior daylight shift. Special attention to lighting cables.

Emergencies

Checks to be made on availability of night cover from local hospitals etc. Standard site first aid and reporting procedures to apply, list of emergency/night call out numbers. Where applicable emergency lighting shall be provided on emergency access routes.

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As required by activity.

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Greater use of radios to minimise unnecessary movements at night. A tally system may be required on certain operations.

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As well as normal helmets and boots, high visibility clothing should be utilised. Attention to warm clothing, as required, should also be made. Shifting of labour resources to be arranged to prevent prolonged day and night shift working. Consider increased supervision in working areas and control of unauthorised access. Consider use of light sensitive cells for lighting systems.


QCS 2014


Page 58

RISK ASSESSMENT GUIDE REF NO. 38 Assessment for: SPECIALIST SUB-CONTRACTOR PROCESSES eg. BITUMINOUS SURFACING, PAINTING, WATERPROOFING, SILANE ETC. Significant risks: Depends on process, however tend to be more COSHH/pollutant orientated. Burns, skin complaints and asphyxiation etc. CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Ensure that a Safety Method Statement risk assessment and COSHH assessment have been supplied by the sub-contractor. Ensure that the sub-contractor is appropriately experienced. Special care in confined spaces and using highly flammable materials. Require the sub-contractor to brief a member of your supervisory staff on ALL safety requirements/hazards etc. Ensure that any employees who may come into contact with the specialist work have been briefed, tool box talks inductions etc. Sub-contract personnel to be trained and certified as appropriate.

Instruction

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Training

Ensure that the sub-contractor adequately supervises his works and works to the Safety Method Statement. Hot work permit to be issued where appropriate.

Access

As required to ensure safe access and egress.

Environment

Monitor environment and set up exclusion zones etc. as appropriate.

Equipment

As required for activity. Consider standoff distances, atmospheric monitoring and ventilation.

Emergencies

Ascertain from the sub-contractor if specialist measures are necessary. Check fire precautions etc. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

Communications

As appropriate, warning signs.

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Supervision

Obtain COSHH information assessment from sub-contractor. Ensure compliance. Check disposal of waste etc.

Other

To be established with sub-contractor/Safety Environmental Department as appropriate.

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Seek advice from Safety and Environmental Department as necessary.


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Page 59

RISK ASSESSMENT GUIDE REF NO. 39 Assessment for: STORAGE AND LIMITED USE OF HIGHLY FLAMMABLE MATERIALS ETC Significant risks:

Explosion, fire, vapours, manual handling injuries.


DETAILS OF CONTROL MEASURES Assess type and quality of gases/liquid/materials to be used, quantities to be minimised, storage/fire precaution recommendations from suppliers to be obtained as required. Personnel to be briefed on supplier’s information safety precautions. Safety awareness talks. Ensure that all employees who come into contact have cause to use materials and are trained on safe usage, storage disposal and fire procedures. Implement checks on storage and usage. On larger sites with greater usage have formal issue/collection system. Establish demarcated remote storage location.


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Supervision

Control access to secure storage area.

Environment

Individual outdoor stores to be constructed to recommended type, including all relevant signing and fire points precautions. Ensure no sources of ignition including electrical.

Equipment

Gas cylinders etc. to be obtained from company suppliers only. Any damage being reported and bottles/containers exchanged immediately. Dry powder extinguishers.

Emergencies

Fire – summon Civil Defence (Fire Department) and inform them accordingly of type and quantities of bottles and containers. Ensure that dry powder extinguishers are available but do not endanger life, clear area. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Access

Clear signage, including type of materials stored and “no smoking” signs.

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Perform COSHH assessments on individual materials particularly for inhalation of fumes.

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Depends on materials being stored. In the case of adhesives/resins, particular care to be taken when handling. Flammable paints/resins may not be suitable for external storage. Consider ventilated/controlled temperature stores. Consider storing and removing waste.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: INSTALLATION OF FIRE PROTECTION COATINGS (BOARD) Significant risks:

Page 60

REF NO. 40

Manual handling, falls, trailing leads, electricity, circular saws, noise, housekeeping, storage of materials.


DETAILS OF CONTROL MEASURES Provide suitable working platform. Visually check electrical tools and leads. Carry out Manual Handling assessment. Obtain COSHH assessment. Ensure circular saw is in good working order with guard and dust extract bag in place, if using bench saw provide push stick and emergency stop button. Store materials in a safe manner. Keep work area free from tripping hazards. Store waste material in the proper bins. Ensure adequate task lighting. Operatives to receive Risk, COSHH and Manual Handling assessment. Carry out Induction, all relevant assessments to be given as Tool Box Talks. Operatives to be trained in the safe use of circular saw. If using Mobile Elevated Work Platforms or Mobile Towers operatives to be suitably trained.

Instruction

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Training

Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register.

Access

Provide suitable ladders, properly secured. Keep access areas free of materials and electrical leads.

Environment

Dust levels to be kept suppressed.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturer’s instructions for maintaining Mobile Elevated Work Platforms.

Emergencies

Provide First Aider. Operatives to be informed of all emergency procedures at induction.

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Supervision

PPE notices to be displayed and if working at height ‘Danger Men Working Overhead’.

PPE

Other

Assessment for the fire protection coating board and adhesives.

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Hard hats, safety footwear, eye protection, dust mask and ear protection. If using Mobile Elevated Work Platforms fall body harnesses must be worn. If there is a lot of cutting of boards to be carried out it may be worth considering job rotation to prevent one person being exposed to the noise and dust problem.


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Page 61

RISK ASSESSMENT GUIDE REF NO. 41 Assessment for: INSTALLATION OF FIRE PROTECTION COATINGS (SPRAY) APPLIED

Significant risks:

Materials, inhalation, skin contact, falls.


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DETAILS OF CONTROL MEASURES Agree method statement. Store materials in a safe manner. Provide suitable working platform. Visually check electrical tools and leads. Obtain COSHH assessments. Provide and maintain suitable extract equipment. Enclose work area. Keep work area free from tripping hazards. Store waste material in the proper bins. Ensure adequate task lighting. Operatives to receive Risk and COSHH assessment. Carry out Induction, all relevant assessments to be given as Tool Box Talks. If using Mobile Elevated Work Platforms of Mobile Towers operatives to be suitably trained. Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register.

Access

Provide suitable ladders, properly secured. Keep access areas free of materials and electrical leads.

Environment

Provide suitable extract equipment to maintain a clean and healthy environment for all workers. Segregate/enclose work area.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturer’s instructions for maintaining Mobile Elevated Work Platforms. Screening of scaffolding to prevent overspray will require checks carried out on number of ties.

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Supervision

Provide First Aider. Operatives to be informed of all emergency procedures at Induction.

COSHH

PPE notices to be displayed and if working at height ‘Danger Men Working Overhead’. ‘No Unauthorised Persons Beyond this Point’ notices to be displayed outside the enclosure.

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Emergencies

Assessment for all materials to be obtained.

PPE

Hard hats, safety footwear, overalls, gloves, eye protection, dust or fume mask (in poorly ventilated area a Fresh Air Feed mask) and ear protection. If using Mobile Elevated Work Platforms fall body harnesses must be worn.

Other

If operatives are exposed to Man Made Mineral Fibres (MMMF) over a prolonged period there is a danger of serious damage to their health.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: LIFT INSTALLATION Significant risks:

Page 62

REF NO. 42

Falls from height, manual handling, confined spaces, electrocution.


DETAILS OF CONTROL MEASURES Obtain layout of plant rooms/switchgear/isolation points prior to starting work.

Instruction/Training Working Safety Method Statements are to consider installation dangers. Operatives to sign Safety Method Statements. Tool Box Training to be given on relevant topics. Work to be carried out under the supervision of a competent experienced person.

Access

Access to lift shafts and plant rooms to be strictly controlled. Where scaffolds are used for access these must comply with the relevant requirements.

Equipment

Work equipment e.g. power tools etc. to be tested in accordance with manufacturers requirements.

Emergencies

Method Statement to include procedures for rescue of persons from the shaft in emergency situations.

Communications

Permit to Enter Shafts and Plant room to be in place and displayed. Warning signs and barriers to be in place.

COSHH

As applicable to materials used e.g. Hydraulic Oils.

PPE

As site rules and appropriate to hazard i.e. gloves when lifting machine parts etc.

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Supervision

Refer to Generic Risk Assessment No. 14, 20, 22, and 23.

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: ELECTRICAL/MECHANICAL SERVICES Significant risks:

Page 63

REF NO. 43

Electrocution/fire, fume inhalation, entanglement, vibration, explosion, fall from height, manual handling, paint use/radiation


DETAILS OF CONTROL MEASURES Risk Assessments and Safety Method Statements, PPE, Permits to Work (Hot Work), Flash Screens, Fire Precautions, Permits to Work (Electrical Systems), Tower Scaffolds, Display Notices, Locking off Procedures. Documentation for lifting appliances/gear

Instruction/Training Inductions, Safety Awareness Talks, Permit to Work Procedures, Scaffold Erection (Towers), Abrasive Wheels. Permit to Work issue. Competent persons appointment. Electrical Duty Holder. Operation of visible inspection system displayed. Work Place Inspections.

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Supervision

Position of temp. Cables, step ladders inspected and of sufficient length (split head trestles not used as steps). Ladders inspected and secure gangways clear.

Environment

Welding fume control, noise control assessments, non-destructive testing, dust control (drilling), housekeeping (Inc. flammable debris), waste disposal (conduit off cuts), oil drips (threading machines).

Equipment

Guarding of threading machines/welding machines to external air, fire extinguisher adjacent to machines, flash back arrestors, bottle stands/gas storage, equipment inspection procedures.

Emergencies

Evacuation procedures/fire procedures/emergency lighting, access routes, alarm systems, first aid, gas check.

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Access

Communications

Posters, Notices, Tool Box Talks.

Other

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COSHH assessment for and including welding fume, cutting oils, paints, fluxes, dusts (grinding) oxygen, acetylene propane etc.

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COSHH

Head protection, foot protection, overalls, including visors, eye protection, noise protection, gloves, RPE etc. Ducting installation (Geanie hoists). Special precautions for special welding operation.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: PLUMBING WORKS Significant risks:

Page 64

REF NO. 44

Potential for inhalation, ingestion or absorption of toxic substances (e.g. lead, solvents etc.). Fire whilst undertaking hot work, entanglement with pipe threading machine, vibration from percussion tools. Confined working. DETAILS OF CONTROL MEASURES COSHH assessment details made available. Detailed method statement for pressure testing and non-destructive testing.


COSHH, manual handling, fire prevention training required.

Supervision

Effective supervision for hot work and working with lead. Health surveillance required for significant exposure.

Access

Safe access required to all work locations.

Environment

Disposal of waste in accordance with waste procedure.

Equipment

Maintain in good condition.

Emergencies

Site arrangements and local segregation.

Communications

Tool Box Talks.

COSHH

Assessment required for flux, lead, solvents, epoxy resins, maintain.

PPE

Safety helmets, safety footwear, gloves, overalls, RPE where identified in COSHH assessment.

Other

No smoking or eating whilst exposed to lead fume. Specific welfare for specific lead work.

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RISK ASSESSMENT GUIDE Assessment for: CARPENTRY/JOINERY Significant risks:

Page 65

REF NO. 45

Dust (hard and soft wood), fall from height, contact with cutting machinery, glues, manual handling, treated timber, slips and trips. DETAILS OF CONTROL MEASURES Risk assessments, safety method statements, information posters, safety reminders.


Inductions, safety awareness talks, cartridge gun training, tower scaffold training, manual handling, wood working machine training.

Supervision

Working at height supervision, scaffold inspections, work place inspections, small tool inspections, tools in good order.

Access

Ladders secured and in good order, gangways clear, staircases as alternative to ladders.

Environment

Housekeeping, dust controlled at source, flammable material, solvent glues.

Equipment

Electrical equipment in good order, hand tools in good condition, vibration (hammer drill) checked.

Emergencies

Induction site plans and notices displayed. Access routes clear. Sufficient staircases.

Communications

Induction/safety awareness, site notice boards, duty holders indicated, supervision training, risk assessments and safety method statements explained.

COSHH

COSHH assessments, materials use training, data sheets, Sypol system.

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Head protection, foot protection, respiratory protection (dust mask), noise protection, gloves, eye protection and overalls.

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Page 66

REF NO. 46 RISK ASSESSMENT GUIDE Assessment for: PLASTERING AND EXTERNAL RENDERING Significant risks:

Falls from height, falling objects/material, manual handling, skin contact with wet mortar, dust from mixing unit. DETAILS OF CONTROL MEASURES General safety information on safe access e.g. ladders etc.


Manual handling of equipment/materials

Supervision

Scaffold use above 2 meters to be under control of competent person.

Access

Suitable access to be provided to all work locations e.g. hop-ups to full scaffolds etc. segregate lower work areas whilst working in elevated situations.

Environment

Consider weather conditions.

Equipment

Suitable access equipment to work location. Maintain equipment in good condition.

Emergencies

General site arrangements for first aid and evacuation.

Communications

General information and tool box talks.

COSHH

As appropriate to substances in use e.g. mortar.

PPE

Safety helmets, safety footwear, warm clothing, gloves etc. Face mask when mixing.

Other

Maintain good standards of personal hygiene.

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RISK ASSESSMENT GUIDE Assessment for: CEILING FIXING Significant risks:

Page 67

REF NO. 47

Entanglement, fall from height, manual handling, electrocution, hand injuries from sharp components, eye injuries during drilling operations.

CONTROL ITEM Information Instruction/Training

DETAILS OF CONTROL MEASURES Risk assessments and safety method statements, PPE, permits to work, tower scaffolds. Inductions, safety awareness talks, permit to work procedures, scaffold erection (towers), abrasive wheels. Permit to work issue. Competent persons appointment. Electrical duty holder. Operation of a visible inspection system. Work place inspections.

Access

Position of temp, cables, and step ladders inspected and of sufficient length (split head trestles not used as steps). Ladders inspected and secure gangways clear. Erection of suitable scaffold. Use of MEWP’s.

Environment

Noise control assessments, dust control (insulation), housekeeping (inc flammable debris) and waste disposal.

Equipment

Equipment inspection procedures. Scaffold inspection system visible to operatives.

Emergencies

Evacuation procedures/fire procedures/emergency lighting, access routes, alarm systems, first aid.

Communications

Posters, notices, tool box talks, wage packet inserts, videos, supervision.

COSHH

COSHH assessment for and including dusts (grinding) insulation.

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Head protection, foot protection, overalls, eye protection, noise protection, gloves, RPE etc.

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: FLOOR AND WALL TILING Significant risks:

Page 68

REF NO. 48

Inhalation, skin absorption or ingestion of harmful substances. Falls from heights, fire or explosions.


DETAILS OF CONTROL MEASURES Operatives should be made aware of what materials are being used, The associated hazards and the required control measures to be applied. Induction training should cover site rules and action to be taken in the event of an emergency. Where appropriate operatives should be certificated for the erection of mobile tower scaffolds. Training should be provided in the safe use of respiratory equipment.


Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Ensure that COSHH assessments have been produced and training provided. Ensure that suitable access is being provided and used and that all highly flammable materials are being stored in a safe manner.

Access

Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Mobile scaffold and access platforms must be properly erected with guardrails fitted where required and inspection details displayed. Adequate ventilation must be provided. Consideration should be given to the safe storage of flammable materials. Controlled waste must be properly disposed of. Equipment must be kept in good working order and be regularly maintained, with records being kept. The ventilation system provided should be checked regularly. Any mobile towers, scaffolding should be checked at least every seven days with a record of inspection being kept. If overcome by adhesive vapours, remove to fresh air, keep warm and fetch first aider, contact emergency services if necessary. Suitable fire procedures should be in place and fire extinguishers should be available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs and notices and barriers as appropriate. Alternatives to harmful adhesives should be considered. Adequate ventilation should be provided, backed by respiratory protective equipment where necessary. Barrier cream or suitable gloves can be used to protect hands, overalls to protect remainder of body. Adequate hygiene facilities should be provided. Operatives should not eat, drink or smoke at the work location or when their hands are contaminated. Appropriate respiratory equipment if required. Goggles/glasses, gloves, safety footwear, overalls, helmets must be worn. Consideration should be given to work in confined spaces e.g. small rooms

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: PAINTING & PAPERING Significant risks:

Page 69

REF NO. 49

Inhalation, skin absorption or ingestion of harmful substances. Falls from heights, falling materials, slips on spillages, fire or explosions.


DETAILS OF CONTROL MEASURES Operatives should be made aware of what materials are being used, the associated hazards and the required control measures to be applied. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds. Where appropriate training must be provided in the operation of MEWP’s. Training should be provided in the safe use of respiratory equipment. Safety method statement to be signed by all operatives.

Instruction

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Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Ensure that COSHH assessments have been produced and training provided. Ensure that suitable access is being provided and used and that all highly flammable materials are being stored in a safe manner. Safe means of access/egress must be provided and maintained. If working at height an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed. Mobile scaffolds and access platforms must be properly erected with guardrails fitted where required and inspection records displayed.

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Consideration should be given to the safe storage of flammable materials. Adequate ventilation must be provided. Controlled waste must be properly disposed of. Equipment must be kept in good working order and be regularly maintained, with records being kept. The ventilation system if provided should be checked regularly. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. If overcome by paint vapours, remove to fresh air, keep warm and fetch first aider, contact emergency services if necessary. Suitable fire procedures should be available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs and notices and barriers as appropriate. Alternatives to harmful paints, varnishes or adhesives should be considered. Adequate ventilation should be provided, backed by respiratory protective equipment where necessary. Barrier cream or suitable gloves can be used to protect hands, overalls to protect remainder of body. Adequate hygiene facilities should be provided. Operatives should not eat, drink or smoke at the work location or when their hands are contaminated with paint. Appropriate respiratory equipment if required. Goggles/glasses, gloves, safety footwear, overalls, helmets must be worn. Consideration should be given to work in confined spaces.

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Page 70

RISK ASSESSMENT GUIDE REF NO. 50 Assessment for: USE OF SPECIALIST EQUIPMENT (NUCLEAR DENSOMETERS, THERMIC WELDERS AND LANCES, LASERS) H.P. WATER JETTING Significant risks:

Varies according to equipment i.e. radiation injuries, eye damage, general injuries to public and personnel.


DETAILS OF CONTROL MEASURES Normally a specialist operation requiring Safety Method Statements. List of specialist equipment likely to be required to be drawn up and discussed with safety adviser. Establish and issue Safety Method Statements. Information from suppliers of equipment. Sub-contractor or manufacturer’s recommendations/training to be sought and personnel instructed as appropriate. Certificated operators. Information obtained will establish the extent of instruction required. As required for the particular type of specialist operation.

Instruction

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Training

Designated responsible person to be nominated to ensure that equipment is correctly used and method statement adhered to.

Access

Exclusion zones where appropriate.

Environment

To be monitored/controlled as required by manufacturers/codes of practice etc.

Equipment

To be obtained and used as manufacturers/specialist recommendations. Appropriate storage required.

Emergencies

Specialist first aid information to be obtained. Specialist emergency procedures to be set up as appropriate (nuclear densometer). Standard site safety reporting procedures apply.

Communications

Warning signs, hazard markers.

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As required by particular process.

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As applicable to particular process.

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A specific assessment should always be performed for an item of specialist equipment.


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Page 71

RISK ASSESSMENT GUIDE REF NO. 51 Assessment for: USE OF CLASS 3B LASERS (PREDOMINANTLY IN CONFINED OR RESTRICTED AREAS) Significant risks:

Exposure to non ionising radiation (laser light) being caused by striking persons directly or indirectly (reflection) physical risks include eye damage, production of toxic gases, electrical hazards.


The requirements for medical supervision should be assessed, in particular in the event of injury due to ocular exposure. Overall supervision shall be controlled by a competent person who has received adequate training. Class 3B lasers are potentially hazardous if a direct beam or specular reflection is viewed by the unprotected eye and therefore access must be strictly controlled to those people who have received the adequate information, instruction and training. The entrance to areas should be posted with a standard laser warning sign. The laser beam should be terminated where possible at the end of its path by suitable diffusion material. Reflections must be avoided. Location and direction of beam must be clearly marked. The equipment must be suitable for use and any maintenance requirements detailed.

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Emergency procedures must be linked in with the specific site procedures in particular when considering the hazards that exist including fire, electrocution etc. All relevant information should be communicated to all personnel involved. An assessment must be made if there are any identified hazardous environments in particular contamination from chlorine, hydrogen sulphide and bromine. The need to use PPE against the hazardous effects of laser operation should be kept to a minimum by admin controls, engineering design and beam enclosure. However where the risk exists the PPE may include eye protection, clothing, respiratory etc. A safe system of work should be devised (with all the other controls listed above) that reduces the risk by means of cutting down the operational times.

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PPE

DETAILS OF CONTROL MEASURES All personnel exposed to hazard/risk from the use of class 3B lasers shall receive information, instruction and training regarding the hazards and risks. Information should be sought from the supplier. All the above measures also include the provision, fitting and wearing of PPE.


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Page 72

REF NO. 52

Assessment for:

ARC WELDING

Significant risks:

Fire/flammable atmospheres, electric shock, noise, substances/chemicals/fumes/dusts, burns, radiation, heat, falls, trips and slips, flying particles, vibration, oxygen depletion, asphyxiation, manual handling. DETAILS OF CONTROL MEASURES Permits to work. (Confined space/hot work) Method statements.


Operatives trained in fire prevention methods/precautions.

Supervision

Regular inspection of barriers, fireproof screens and notices.

Access

Safe access egress to be provided and maintained. Consideration to be given to restricted access zone.

Environment

Good lighting. Dust and noise suppression methods.

Equipment

Flameproof welding screens. Fire protective equipment sited adjacent to welding set. Earthling of work piece.

Emergencies

Standard first aid, fire protection. Operatives inducted in emergency procedures and assembly points.

Communications

Warning signs and barriers. Permits to work.

COSHH

Local exhaust ventilation and others as required for location/materials used for welding.

PPE

Welding gloves, flameproof overalls, boots, spats, eye protection, and respiratory protection. Local exhaust ventilation.

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QCS 2014



REF NO. 53

Assessment for:

RADIOGRAPHY

Significant risks:

Radioactive substances, burns, inhalation radiation, contamination damaged/lost sources.


Page 73

DETAILS OF CONTROL MEASURES Risk assessment/method statements. Permit to work. Approved subcontractors. All operatives to sign method statement/local rules. All operatives to receive induction training. Regular inspection of working barriers, signs and notices.

Access

Safe means of access/egress to provide and maintain to work area.

Environment

Safety zones/storage of sources. Audible warning systems available.

Equipment

Good working order regularly maintained. Records kept.

Emergencies

Operatives aware of emergency procedures and assembly points. Details of radiation protection adviser.

Communications

Barricade areas, warning notices posted, audible warnings of exposure of isotope.

COSHH

Assessment, information and instruction to all personnel

PPE

Film badges, safety helmet/footwear worn at all times. Eye/hearing protection as/when required. Hand/body protection as required.

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Supervision

Ensure supervision for out of hours working. Work to be carried out, outside normal working hours. Account will be taken of project standard requirements.

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Other

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QCS 2014



REF NO. 54

Assessment for:

COMMISSIONING PLANT

Significant risks:

Electrocution, steam/hot liquid scalds, toxic/flammable gas or liquid release, bursting of vessels/pipes/joints under pressure, falls from height, trapping or being struck by plant in motion.


Page 74

DETAILS OF CONTROL MEASURES Induction training should cover site rules and action to be taken in the event of an emergency. All operatives must be briefed on the hazards, precautions and emergency procedures before testing and commissioning starts. Operatives should be trained in the operation of the permit to work procedure and the actions required by the system. A formal testing/commissioning procedure must be prepared before testing/commissioning commences and operatives signed to confirm understanding. Leak testing will precede pressure testing; pressure testing should be carried out at the lowest pressure acceptable to the specifier / specification and should be avoided unless there are sound technical reasons for carrying out such tests. Hydraulic testing should be the preferred method where practicable. Supervisor must ensure that only authorised, experienced and competent persons will carry out testing and commissioning operations. Supervisor must ensure that the permit to work system is being properly operated and that all appropriate elements of the plant have been isolated locked off and specified safety devices have been provided. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed, mobile scaffolds and access platforms must be properly erected with guardrails fitted and inspection records displayed.

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Access

Access to commissioning and test areas must be restricted. Consideration must be given to the surrounding environment e.g. plant, operations etc. when planning and carrying out the works. Prior to the commencement of electrical testing and commissioning works a check should be made to verify that all switch rooms/control rooms have been cleared of loose materials and that all temporary installations have been removed. Equipment covers and doors are to be closed and guards refitted to machinery. Any circuits to be worked on will be treated as live until verified as dead. Equipment must be kept in good working order and be regularly maintained with a record of maintenance being kept. Only suitable and appropriate equipment must be used for testing and commissioning works. Suitable fire procedures should be in place and fire extinguishers available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs, hazard markings and exclusion zones as appropriate. Assessments produced for material used in testing and commissioning operations, including possible emissions/discharges from plant in operation. Hard hats, protective footwear, gloves, goggles, overalls and any specialist equipment required e.g. insulation mats etc.

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Emergencies



QCS 2014



REF NO. 55

Assessment for:

BLOCK PAVING, FLAGGING KERBS AND EDGINGS

Significant risks:

Manual handling, materials/substances, plant and equipment, power tools, cutting, noise, dust, underground services, public protection (to and from).


Page 75

DETAILS OF CONTROL MEASURES Necessary permits when adjacent to underground services. Safety signs, warning notices. Operatives to sign method statement as understood. Certification for abrasive wheel changing. Competent supervision, monitoring work activity.

Access

Safe means of access/egress provided and maintained.

Environment

Dust/noise suppression/reduction methods e.g. enclosure for omitting operations. Traffic protection – coning/signing/safety zones.

Equipment

Good working order regularly maintained. Records maintained. Segregate plant from pedestrians. Manholes cover handling equipment. Wet cutting of materials.

Emergencies

Operatives aware of emergency procedures and assembly point.

Communications

Provision of suitable safety signs, warning notices and barriers.

COSHH

Assessments, information and instructions given to operators. Personal hygiene essential.

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Safety helmets, footwear to be worn at all times. Eye/hearing protection to be worn as necessary. Yellow waistcoats adjacent to traffic.

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Other

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Supervision

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QCS 2014



REF NO. 56


Page 76

ROAD/PATH SURFACING Manual handling, materials and substances, reversing vehicles, plant and equipment, underground services, noise, heat and fumes. Fire/explosion. DETAILS OF CONTROL MEASURES Method statements, safety signs, warning notices.


All operatives to sign method statement applicable to their work activity.

Supervision

Supervisors to ensure plant and equipment only operated by certificated authorised persons. Traffic management.

Access

Safe means of access/egress in/around plant and equipment segregate plant from pedestrians/traffic.

Environment

Noise and dust suppression. Traffic protection – coning/signing/safety zones.

Equipment

Good working order regularly maintained. Records kept. Overhead power lines suitably protected. Reversing alarms fitted to equipment.

Emergencies

Operatives aware of emergency procedure and assembly points. First aid treatment for burns.

Communications

Warning signs, audible warnings, suitable barriers.

COSHH

Assessment, information and instructions.

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Safety helmets/footwear to be worn at all times. High visibility clothing to be worn at all times. Eye/hearing protection to be worn when necessary. Hand/body protection as required. Traffic management schemes. Interface/overlap with Client personnel/members of public.

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QCS 2014



REF NO. 57


Page 77

FENCING (PERMANENT) Manual handling, materials and substances, noise, underground/overhead services, plant and equipment. DETAILS OF CONTROL MEASURES Method statement/utilities drawings/permit to dig.


All operatives inducted in site requirements/manual handling/buried services. All operatives to sign method statement applicable to their work activity.

Supervision

Competent supervision. Supervisor to ensure on trained, certificated authorised persons use/operate plant and equipment.

Access

Safe means of access/egress to provide and maintain to work area. Segregate plant/equipment from pedestrians.

Environment

Noise and dust suppression methods. Soil analysis.

Equipment

Good working order, regularly maintained and records kept. Overhead power lines suitably protected.

Emergencies

Operatives aware of emergency procedure and assembly points.

Communications

Warning signs and notices, suitable barriers and audible warnings on plant and equipment. As appropriate to work/location.

COSHH

Assessment, information and instruction given to all operatives e.g. preservatives/paints.

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Safety helmets/footwear to be worn at all times. High visibility clothing when adjacent to traffic routes. Eye hearing protection as necessary. Interface/overlap with Client personnel/members of public.

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QCS 2014



REF NO. 58


Page 78

LANDSCAPING Manual handling, materials and substances, plant and equipment, overspray of substances, noise. DETAILS OF CONTROL MEASURES Method statements, safety signs, warning notices, buried services, overhead services.


Operatives trained in use of pesticides. All operatives to attend induction training. All operatives to sign method statement applicable to their work activity.

Supervision

Competent supervision. Supervisors to ensure only trained certificated and authorised persons use pesticides, plant and equipment.

Access

Safe means of access/egress to provide and maintain segregation of plant from pedestrians.

Environment

Noise and dust suppression methods. Safe storage of pesticides/disposal of containers.

Equipment

Good working order regularly maintained. Records kept. Check gradability of plant on slopes.

Emergencies

Operatives aware of emergency, procedure and assembly points.

Communications

Warning signs, warning notices, suitable barriers and audible warnings.

COSHH

Assessment, information and instruction given to all operatives.

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Safety helmets/footwear to be worn at all times. High visibility clothing to be worn when adjacent to traffic routes. Eye/hearing protection when necessary. Respiratory protection as required. Interface/overlap with Client personnel/members of public.

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QCS 2014


Page 79

RISK ASSESSMENT GUIDE REF NO. 59 Assessment for: TREE SURGERY AND CROSS CUTTING OF TIMBER WITH A CHAINSAW Significant risks:

Falling from heights, falling objects, uncontrolled fall of trees/limbs, personal injury from cutting equipment, injury to members of the public/passing vehicles.


DETAILS OF CONTROL MEASURES Safety method statement to be signed by operatives. All operatives felling trees to have received training from recognised body in ‘Tree Surgery’. Those engaged in ‘cross cutting’ of timber with a chainsaw are to have received, as a minimum, training in use of chainsaw ‘cross cutting’. Whilst cutting operations in progress a minimum of one person trained as above to supervise. No burning of debris on site.

Access

If possible low level branches to be cut from footed ladders or mobile scaffolds, high level tree cutting to be done using approved harness and lines. Ensure that operative attaches away from cutting point and above.

Environment

Consider noise, refueling away from drains/watercourses. Ensure saw dust/chips not causing airborne hazard. All chainsaws to have chain break. Chains to be sharp. Test certificates for harnesses and ropes.

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Supervision

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Equipment

Rescue from height of injured person. Ensure communications are available on site. First aider to be on site. Fire extinguisher for refuelling operations

Communications

Radio/mobile phones to communicate in the case of emergency.

COSHH

COSHH assessment’s required for petrol, chain oil and two stroke oil. Check type of wood being cut, sawdust of some trees could be a hazard.

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Emergencies

Forestry type safety helmet, visor and ear protection, chainsaw protective trousers, jacket and gloves. Respirator protection as appropriate to type of wood being cut forestry type safety boots. High visibility tabard when working in traffic management. NOTE: harnesses for tree surgery are different from general purpose harnesses.

Other

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QCS 2014



REF NO. 60


Page 80

FIRE PREVENTION WORKING AREAS Burning, explosion, asphyxiation, electrocution and structural collapse.


DETAILS OF CONTROL MEASURES Obtain material manufacturer’s data where applicable. Provide site fire plan. Liaise with the Civil Defence (Fire Department) as appropriate to the construction undertaken. If applicable fire points to be identified and put on plan and post at relevant positions. Induct employees on methods and procedures where fire risk is apparent. Safety awareness talks. Where applicable employees are to be trained in evacuation and the proper use of the correct types of fire extinguishers.

Instruction

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Training

Site management to ensure that sufficient suitable fire extinguishers are correctly positioned, maintained and inspected and additionally ensure that accesses are kept clear and materials suitably stored. Use of fire watchmen during and after hot work operations. Issue/monitor hot work permit.

Access

Suitable accesses/escape routes are to be kept clear of obstructions.

Environment

Consideration is to be given to the safe storage of flammable materials and fuels. Ensure cleanliness, tidiness, control of burning, regular disposal of waste. Consider damping down where there may be a risk of self ignition. Establish no smoking zones/site where risk is apparent.

Equipment

Site electrical equipment is to be tested and certified at 3 monthly intervals. Monitor plant for leakage/fuel spillage.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

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N/A

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COSHH

Warning signs and audible alarms where appropriate.

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Communications

Use as appropriate to operation i.e. welding, burning. Hot work permits will be required in high risk areas.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: FIRE PREVENTION IN OFFICE Significant risks:

Page 81

REF NO. 61

Burning, explosion, asphyxiation, electrocution.


DETAILS OF CONTROL MEASURES Carry out a risk assessment on the premises and produce a fire plan. Induct employees on escape procedures and the hazards of construction, convection, radiation and direct burning. Instruction manuals are to be provided for equipment. Safety awareness talks. Staff must be trained in evacuation and the proper use of the correct types of fire extinguishers.

Instruction

Training

Appoint fire warden as appropriate. The office manager is to ensure that sufficient and suitable fire extinguishers are correctly positioned, maintained and inspected together with carrying out 6 monthly fire drills where applicable. Emergency routes and exits are to be clearly identified and kept clear of obstructions, establish suitable assembly points. Emergency exits are to remain unlocked on the inside at all times.

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Access

Consideration to be given to the effects of weather and in particular dust, externally, rain leakage, wind and flooding. Consideration is to be given to the safe storage and flammability of solvents, fluids and canisters.

Equipment

Electrical equipment is to be electrically tested and certificated at intervals no greater than 12 months, temporary office accommodation every 3 months. Alarms, extinguishers, hose reels, sprinklers, smoke detectors to be tested in accordance with procedures. Emergency lighting is installed/tested where appropriate.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Environment

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PPE

N/A

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COSHH

Warning advisory signs and alarms.

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Communications

Generally not applicable. Ensure tidiness, control of smoking, regular disposal of waste. Give attention to the effects of dust on office equipment. Ensure availability of water and clear access for emergency services.


QCS 2014


Page 82

RISK ASSESSMENT GUIDE REF NO. 62 Assessment for: OFFICE ENVIRONMENT (PERMANENT AND TEMPORARY INSTALLATIONS) Significant risks:

Fire, visual fatigue, manual handling injuries, poor internal environmental i.e. ventilation, temperature etc. Poor design and layout.



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Supervision

DETAILS OF CONTROL MEASURES Obtain details of hazards from manufacturers for any special equipment/materials. Assessment on VDU operators and provision of appropriate information. Manual handling review. Regular fire practices, instruction on safe use of specialist equipment/materials. Also instruction on use of fire extinguishers. Safety awareness talks. As appropriate to equipment used and task being undertaken. Appoint a fire warden. Ensure regular checks on firefighting equipment etc. as well as all electrical installations/equipment. Keep register. To be maintained as required by fire precautions also in generally good condition. Prevent trip/fall hazards from trailing leads.

Environment

To be kept clean and clear of debris. Noise to be monitored if immediately adjacent to the works. Consider limitations on smokers. Establish adequate ventilation and temperature controls. Lighting requirements ergonomic layout of work stations. Security/location (access for visitors). No smoking policy.

Equipment

To be kept clean, regularly maintained and tested.

Emergencies

Standard first aid, fire protection, evacuation, accident reporting and investigation.

Communications

Warning advisory signs, hazard markers and use of notice boards as appropriate.

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Access

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Other

Not applicable

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PPE

As appropriate to solvents, fluids and adhesives etc.

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COSHH

Ensure general welfare conditions such as toilet facilities and heating are to requirements. Give consideration to disabled facilities. Regular inspection.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: YOUNG PERSON IN CLERICAL POSITIONS (SITE) Significant risks:

Page 83

REF NO. 63

Fire, visual fatigue, manual handling injuries, slips trips and falls, overturning filing cabinets, electricity, office machinery.

Training

DETAILS OF CONTROL MEASURES Induction carried out. Site specific induction required. Training required in specific items of office equipment involved in tasks. Manufacturers/suppliers equipment information to be available.

Supervision

Close supervision required.

Access

Safe means of access/egress to be provided and maintained. Trailing cables to be protected / routed to eliminate possible slips/trips/falls.

Environment

Adequate ventilation, temperature. Lighting and cleanliness provided and maintained.

Equipment

Young persons to be trained in use of all types of office equipment involved in tasks. Do not overload electrical sockets. Cabinets to be secured to prevent overturning.

Emergencies

Emergency routes not to be obstructed. Fire test/drills to be observed and acted upon where necessary. All accidents however minor to be reported.

Communications

Use of notice boards as appropriate. Direct contact with line managers.

COSHH

Should not be applicable except in use of solvent based correction fluid.

PPE

Not applicable in present environment – if on site must be closely supervised and wear appropriate PPE i.e. safety helmet, safety footwear.

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CONTROL ITEM Information Instruction

Manual handling assessment to be carried out for replacing paper rolls on large printer. When assessment formulated young person to receive copy and be advised of contents/trained. Work area to be checked by young person at end of each shift to ensure no cigarettes/combustible materials smoldering.

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QCS 2014


RISK ASSESSMENT GUIDE Assessment for: CABLE PULLING OPERATIONS Significant risks:

Page 84

REF NO. 64

Electrocution, falls of persons, falls of materials, fire, manual handling DETAILS OF CONTROL MEASURES Risk assessments and safety method statements. Permits to work (electrical systems). Operatives to work to safety method statements. Operatives to sign safety method statements. Documentation for lifting equipment/gear. PPE. Layout drawings. Design checks.


Inductions. Safety Awareness Talks. Permit to work procedures. Mobile tower erection. PPE.

Supervision

Permit to work issue. Competent persons appointment. Electrical Duty Holder. Operation of scaff tag system. Workplace inspections. Work under competent person. Careful planning of cable route.

Access

Provision of adequate access equipment. Inspection training in erection. Use of competent persons to erect.

Environment

Waste disposal of offcuts. Overhead services. Adjacent existing services. Integrity of existing tray supports to be investigated. Suitable anchor points for attaching harnesses. NB Not from tray supports unless properly tested for adequacy. Suitable access for vehicles. Level ground for jack supports.

Equipment

Certification for winches/tirfors. Check SWL. Barriers of suitable construction and design. Adequate number of rollers available. Rollers of correct size and type. Appropriate size cable stacking to be provided. Appropriate support of cable drum.

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Evacuation procedure/fire procedure/emergency lighting. Access routes, alarm systems, first aid.

PPE

Other

Tool box talks, supervision, warning signs, liaison with other contractors/client personnel.

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Communications

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Emergencies

Assessments as appropriate to operation. Head protection, safety footwear, (high visibility clothing, hearing protection, eye protection as identified in risk assessment). Segregation of third parties from operations.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: WORKING IN CHEMICAL/RADIOACTIVE DRAINS Significant risks:

Page 85

REF NO. 65

Contact with unsealed sources of chemicals and radiation, injury through skin puncture, ingestion, absorption, toxic/explosive fumes, entrapment and fall injuries, spread of contamination, improper disposal


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DETAILS OF CONTROL MEASURES Obtain information from the Client and establish a safe system of work within the requirements of a permit to work system. Produce a detailed hazard risk assessment. Operatives to sign safety method statement. Personnel to be made aware of the types of chemicals/radiation and the possible dangers. If classified personnel are to work in radioactive drains their current dosage rates must be assessed and taken into account before entry into the drain is permitted. Operatives to be made aware of procedures for contact with chemicals or radioactive substances. Operatives taking samples or wipe testing ductwork must be made aware of the procedures laid down in the safety method statement and suitable demonstrations and briefings on the methods of handling contaminated materials must take place and must include the correct use of PPE and personal hygiene. A competent person is to obtain appropriate information e.g. previous/current used materials/concentrations on the contaminated substances and supply reports and results of analysis.

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Supervision

Exclusion zones to be set up with permit to work system. Designated safe access as necessary to the type and level of contamination discovered.

Environment

Consider the risk of local flooding to drains especially if ductwork has been stopped with drainage bungs. Special waste to be considered.

Emergencies

Together with standard procedures for first aid, evacuation, fire and explosion. Specific procedures to suit any contaminants present.

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Specialist advice to be sought from a Radiological Protection Adviser.

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COSHH

Warning signs, Bio-hazard, chemical hazard markings and exclusion zones as are appropriate.

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Communications

Visor, gauntlets, waders/wellingtons, chemical suit as levels demand. Full BA or airflow system. Rescue winch, safety harness, special waste bags for disposal of contaminated equipment, Geiger counter, sample tubes, air monitor, compressor for airflow system, wash down matting, communication system e.g. radio.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: BRICK/BLOCKWORK OPERATIONS Significant risks:

Page 86

REF NO. 66

Falling from height/through work-face, slips, trips and falls, manual handling, contact with hazardous substances, noise/vibration, confined spaces, contact with machinery/transport, dermatitis, falling from ladders, cut/abrasions, eye injury, falling through floor voids.

CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives, copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training including repetitive injury identification. COSHH training identified. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement ensure statutory registers and plant certification is up to date. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and safe. Area free of contaminates including dust, slippery conditions and lighting sufficient. Confined spaces (permits completed). Plant/transport/operative separation. All required edge protection around working platforms in place/precautions in place to eliminate falling through work-face and/or internal fall protection platforms or rails etc. provided. Hop-up systems at suitable width. Brick-guards in place prior to loading out platforms. Other persons not to work below brick/block work operations. Tools, mixers, scaffolding, clippers, fork-lift trucks, low vibration tools obtained. All lifting equipment in good order and certificated /inspected. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders, no access notices and incomplete notices displayed. COSHH information obtained for all products including MMMF, assessments carried out alternative materials/systems of work identified. Safety helmets, gloves, safety footwear, eye protection, noise protection(noise assessments done), cover-alls.

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Page 87

RISK ASSESSMENT GUIDE REF NO. 67 Assessment for: CLEANING STRUCTURE INTERNALLY PRIOR TO HANDOVER Significant risks: Falls from heights, slips, trips and falls, cuts/abrasions, contact with hazardous substances(including biological agents), noise/vibration, contact with machinery, contact with electricity, manual handling. CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training including repetitive strain injury identification. COSHH training identified. Training and instruction provided in correct use of plant and equipment. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement ensure statutory registers and plant certification is up to date. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time. Proper and suitable access equipment to be provided. Sufficient lighting to be provided, area to be kept clear of obstructions and all trailing cables managed and minimised. Warning notices to be placed on wet floors, electric shock possible by the overzealous use of water in the vicinity of electrical sockets (isolation of electrical supply maybe required). All sharp tools to be carried in holder/sheath, plant/equipment inspected and maintained in good order, low vibration tools used where possible. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders, no access notices and incomplete notices displayed. All substances potentially hazardous to health will have COSHH assessments carried out on them and the circumstances of their use, alternative materials/systems of work identified. If biological hazards are encountered COSHH assessment to be carried out. Safety helmets, gloves, safety footwear, eye protection, noise protection(noise assessments done), cover-alls. Do not use plastic overshoes when working from steps or ladders. Limitation of access permits for clean areas.

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Communications

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QCS 2014


Page 88

RISK ASSESSMENT GUIDE REF NO. 68 Assessment for: USE OF LADDERS TO CARRY OUT GENERAL TASKS AT HEIGHT Significant risks:

Falls from heights, contact with overhead power lines

CONTROL ITEM Information /

Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Staircases to be used as an alternative to ladders. Ladders are only to be used as a result of a specific risk assessment that shows no alternative can be identified. Safety method statement to be explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training, instruction and training in the safe erection, use and lowering of ladders required. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement/risk assessment, ensure routes are free of debris and are maintained in a safe condition, avoid others working below/near the ladder. NB: remember three points of contact rule when working from a ladder. Do not carry equipment/materials whilst climbing ladders. Climb holding onto the rungs when climbing vertical ladders and it is safer using this method on inclined ladders. Sufficient lighting to be provided, area to be kept clear of obstructions, ensure equipment is only used in the correct environment (firm level ground), if un-insulated over-head power lines are present all operatives to be informed of potential contact hazard - do not use metal ladders. Regular inspection of equipment to ensure safe use, all ladders to be tied off or footed when 3m or more high. Always foot the ladder whilst securing. Never climb to very top rung/tread of ladder/step, all damaged equipment to be removed from service immediately, where reasonably practicable use a safe means of access. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. Not Applicable Safety helmets, gloves, safety footwear. Ladders should only be used for short term work, and priority must be given to other forms of access particularly if plant or equipment is to be used at height. Operate Permit system.

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QCS 2014


Page 89

RISK ASSESSMENT GUIDE REF NO. 69 Assessment for: LEAD BURNING/PLUMBING WORK - Lead burning(welding) of lead sheet or pipe Significant risks: Inhalation, ingestion or absorption of the toxic substance. Manual handling heavy lead, fire, lead spatter from molten lead. CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training required, operatives should be informed of associated hazards and relevant control measures before work begins, operatives should have received extensive trade &safety training in this work, operatives should be trained in fire prevention and use of fire extinguishers. Managers/supervisors should be adequately trained to monitor work. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure "Hot Work" permit system used. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time. Proper and suitable access equipment to be provided. Eating, drinking and smoking prohibited in all areas likely to be contaminated by lead. Adequate washing & changing facilities provided/used by operatives to ensure good personal hygiene, workers must wash hands/arms thoroughly & scrub under nails to remove traces of lead. All equipment must be inspected and maintained in a good condition. Firefighting equipment must be inspected and be of a suitable type. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. The degree of exposure to lead should be assessed by a competent person to determine if exposure is significant or not, where exposure significant local exhaust ventilation should be used to reduce exposure levels to an insignificant level. Medical surveillance should be carried out if exposure is significant Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, eye protection, respiratory protection and cover-alls. No contaminated clothing or PPE should be taken into canteens/welfare facilities.

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Access

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Environment

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Equipment

PPE

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Emergencies

Other


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: MOBILE ELEVATED WORKING PLATFORMS Significant risks:

Page 90

REF NO. 70

Falls of persons, falls of materials, striking against fixed structures, collision with other plant, overturning platform.

CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Only trained and certificated operatives to operate plant. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time, control traffic and pedestrians, segregate the work area, beware of use of trailing leads for power tools (entanglement or tripping). Ensure ground conditions are suitable Inspected and maintained in a good condition. The manufacturer's maintenance schedule should be followed, proof of maintenance, inspection and testing must be obtained. Ensure MEWP's SWL (Safe Working Load) is adequate for the work. Stabilisers used where necessary, MEWP's should not be moved at height unless designed for it. All personnel induction will include emergency alarms, escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Emergency plan and safety method statement shall include need to get persons from the platform whilst still elevated. (Control key available at ground level where needed to operate controls from that position) Tool box talks on regular basis, safety reminders. Not Applicable Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, eye protection, respiratory protection and cover-alls depending on work carried out from platform. Safety harnesses must be worn and secured to a suitable anchorage point whilst operatives are in the platform. Collision with any structure or other plant should be reported immediately and the damaged assessed. NB: frequent accidents occur when operatives trap their hands between the upper guard rail of the MEWP and fixed structures. Regularly remind operators of this hazard.

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Access

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Environment Equipment

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Communications COSHH PPE

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Emergencies

Other


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: UNLOADING OF VEHICLES Significant risks:

Page 91

REF NO. 71

Being struck by a maneuvering vehicle, falling objects, falls of persons off the load platform.

CONTROL ITEM Information /


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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Only trained and certificated operatives to act as banks man. Only trained and certificated operatives to use plant for unloading (cranes, hiab, fork-lift, excavators). Instruction on loads to be obtained, instruction on safe methods required eg. Sequences of unloading and release of restraints. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement/risk assessment, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that access by traffic and pedestrians is controlled, segregate the work area. Ensure ground conditions are suitable, ensure offloading area is as level as possible, if unloading area is sloping, extra care must be taken with whole sequence of events. Ensure good standard of lighting for the work area. Minimise number of people in offloading area. All equipment must be inspected and maintained in a good condition. Ensure SWL (Safe Working Load) of lifting equipment and gear is adequate for the work, obtain load weights and centre of gravity before moving anything. Stabilisers to be used where necessary. All personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. Delivery driver to be fully consulted and briefed prior to unloading. COSHH assessment should be carried out prior to handling potentially hazardous materials; this should take cognisance of possible spilled materials. Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, cover-alls and high visibility clothing. Eye protection, respiratory protection may be required depending on materials being handled, Wherever possible, minimise human involvement by using mechanical handling methods, where manual handling is required ensure that enough trained handlers are available. Follow safe system for release of all load restraints and sequence of unloading, inspect load for shift prior to release as load may have worked loose during transit.

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Access

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Equipment

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Emergencies

PPE

Other

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COSHH

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Communications


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: USE OF STEP LADDERS Significant risks:

Page 92

REF NO. 72

Falls from heights, contact with overhead power lines, falling tools & materials



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Supervision

DETAILS OF CONTROL MEASURES Safety induction carried out and signatures obtained. Specific risk assessment and safety method statement explained to operatives and signatures obtained. Manual handling training, instruction and training in the safe erection, use and lowering of step ladders required. Stress overstretching as main cause of falls and never to climb to very top tread / step the knees of the person using the step ladder should be kept below the top of the steps. Daily briefings of operatives by supervisors. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Check training/instruction given to all operatives. Ensure clear, well-lit access/egress. Identify all aspects of access on safety method statement/risk assessment Sufficient lighting to be provided, area to be kept clear of obstructions. Step-ladders should only be used on firm, level ground. If un-insulated over-head power lines are present all operatives to be informed of potential contact hazard - do not use metal ladders. Avoid others working near / below the step ladder.

Access

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Environment

Equipment

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Where risk assessment dictates a safer means of access should be

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used, i.e. mobile access scaffold or mobile elevated work platform

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(scissor lift / cherry picker) etc.

Emergencies

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Regular inspection of equipment to ensure the treads /steps, bolts, screws and fixings are sound and secure. Retaining cords or hinges should be equal length and in good condition, all damaged equipment to be removed from service immediately. The step-ladder must be stable when open and standing on a level base. The legs of the step-ladder should be positioned as far apart as the retaining cord or hinges allow, with all four legs firmly on the ground. They should be set at right-angles to the work, whenever possible. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Safety awareness talks on regular basis, safety reminders.


Safety helmets, gloves, safety footwear, overalls. The use of plastic overshoes should be avoided on step-ladders. Step-ladders should only be used for short-term work or where space restricts the use of safer working places particularly if plant or equipment is to be used at height.


QCS 2014


RISK ASSESSMENT GUIDE Assessment for: TRAFFIC MANAGEMENT Significant risks:

Page 93

REF NO. 73

Impact injury to workforce/accidents to public and vehicles


DETAILS OF CONTROL MEASURES A full traffic management scheme detailed out which caters for: flow of public vehicles; access and egress of work vehicles; safety zones; pedestrian routes; provision for Emergency Services. Method statements for installation of such schemes will also be required on major schemes.

Instruction

To include all identified requirements of safe system of work and method statements. Layout drawings, appropriate experienced personnel only to be used for actual installation/removal of traffic management works.

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Training

Supervision

An experienced member of staff to be nominated as the Traffic Safety Coordinator to check all traffic management works and monitor systems. By designated signed access and egress points only. Prevent unauthorised access. Adverse weather to be taken into consideration. Glare, live traffic, lighting, snowing, any obscured traffic signs must be cleaned as soon as reasonably practicable or work stopped if practicable Suitably marked vehicles with flashing lights if required. Assess the need for a planned preventative maintenance scheme. Emergency lane if required. Emergency call out/liaison list to be established. Vehicle recovery to be in attendance if specified. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan. Radios for traffic management team. Mobile phones/radios for traffic safety co-ordinator. Information signs. Close liaison with police. No Applicable

Access

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Environment

Equipment

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Emergencies

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Communications

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COSHH

High visibility clothing, hard hats, etc.

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PPE

Ensure adequate provision of spare signs, cones and markers to cover loss and waste.

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Other


QCS 2014



REF NO. 74



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Supervision

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Access

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Environment

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Equipment Emergencies

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Communications

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Other

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PPE

Page 94

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2.4.20.2

Appendix B: Example of a risk assessment for erecting roof trusses

Signature..........................

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Risk and identity of persons who might be harmed

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Hazard

Serious injury, death (anyone working at height)

Level of uncontrolled risk

High

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Working at height (general)

Workers being struck by falling objects

Controls introduced to reduce risk

Assessed level of remaining risk

Work at height only carried out by workers who are competent to do so Low

Injury, possibly serious, or death from being struck by a falling object (anyone on site who might be passing below)

High

Working platform to be fully boarded and adequately sheeted or netted. Entrances to buildings protected by nets or fans. Exclusion zones to be created and monitored where necessary Low Debris guards properly fitted to all elevations of working platform

Electrocution - serious burns and death (anyone working at height)

High

If possible, arrange for supply to be turned off for duration of job. As a minimum, arrange for electricity supply company to sheath the cables Toolbox talk on electrical safety given to all who will be required to work at height, including scaffold contractors If cables remain live, monitoring that safety distances are being maintained

Site manager Before work at height starts

All waste materials transferred to ground level via a waste chute

Presence of live overhead electrical cables

Action placed on, and by when

A safe working platform with edge protection and a safe means of access and egress provided

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Workers falling from height

Position in company..................................

Date risk assessment due a review ..................

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Process

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Risk assessment compiled by......................................

Risk assessment number.................................

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Contract number / name.............................................

Date risk assessment compiled.............................

Page 95

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QCS 2014

Low

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QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement Risk and identity of persons who might be harmed

Hazard



Slips and trips at height (anyone working at height)

Medium

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Debris left on scaffold platforms

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Process

Page 96

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Slips and trips at height and during access/egress (anyone working at height)

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Adverse weather conditions

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Working at height (general) (continued)

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Off-loading trusses from delivery Manual handling injuries lorry (delivery driver/carpenters)

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Raising trusses to roof height

Falling through trusses whilst fixing

Manual handling injuries (carpenters)

Cuts, broken bones, serious injury, death (carpenters)

Electrocution - serious burns and death (anyone working at height and crane driver)

Low

Waste skips provided to enable the disposal and segregation of waste

Work suspended during adverse weather conditions. Site manager to monitor

Low Low

Medium

Trusses off-loaded and transported

Low

Medium

High

Roof truss assembly to be prefabricated at ground level and crane to be hired to lift it into place

Close-boarded scaffold platform, complete with guard-rails erected at eaves height. Consider installing safety nets across span of building if suitable fixing points and sufficient clear height below net are available. Otherwise install soft landing system below

Low

Site manager Before handling of roof trusses starts

Low Lifting operation to be under the control of a competent person. Safe working distance between electrical cables and crane to be maintained at all times

Site manager

Low

Electricity supply company contacted to establish minimum safe working distance for crane High


Before work at height starts

Medium

Erection of roof trusses

Presence of live overhead electrical cables

All contractors instructed to clear up their waste materials within a reasonable time of it being created and before it becomes a hazard


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Hazard

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Process


Unstable and unsafe lifting operation resulting in equipment failure and/or dropped load (anyone in the vicinity)

Medium


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Medium

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Other plant activity

Injury to pedestrians caused by insecure load falling from machine (any site worker on foot)

Person injury resulting from the use of defective hand tools (carpenter)

Contract lift organised using the equipment and staff of a reputable crane-hire company

Medium

All plant operated by trained, competent operators

Physical segregation of plant and pedestrians as far as is possible

Low

Toolbox talk on safe plant operations given to everyone on site Low

All tools fit for purpose and maintained in good condition

Use of hand tools and power tools

Low Electric shock resulting from the use of defective power tools (carpenter)

Medium

Battery tools used where practical. Otherwise only 110 volt tools used. Checks made that all power tools have a current PAT test sticker


Site manager

Persons not involved in lifting operation excluded from the area

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Workers being run over or suffering crush injuries (any site worker on foot)


Low

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Lifting operations

Erection of roof trusses (continued)

Page 97

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QCS 2014

Before handling of roof trusses starts

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2.4.20.3

Appendix C: Example of a risk assessment for loading out and fixing tiles

Signature..........................

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Risk and identity of persons who might be harmed

Hazard

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Process

Position in company..................................

Date risk assessment due a review ..................

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Date risk assessment compiled.............................

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Risk assessment compiled by......................................

Page 98

Risk assessment number.................................

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Contract number / Name.............................................

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QCS 2014





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Working at height See risk assessment for handling generally and erecting roof trusses

Loading out and fixing tiles

Abrasions to the skin of the hands potentially leading to dermatitis (tiling contractors)

Medium

Manual handling injury from carrying tiles

Rigger gloves to be provided and worn at all times that tiles are being manually handled

Low

Site manager

Palletised tiles to be moved to vicinity of where they will be used by telehandlers Strains and other manual handling injuries (tiling contractors)

Medium

Powered inclined hoist to be used to transfer tiles to roof level. Hoist to be loaded, off-loaded and operated by a competent person Toolbox talk on manual handling to be given to tiling contractors

Before manual handling of tiles commences Low

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Hazard


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Process

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QCS 2014

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Serious burns and death (tiling contractors)



Site manager High

Toolbox talks on electrical hazards to be given to tiling contractors

Low

Before manual handling of tiles commences

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Inclined hoist to be positioned to maintain a safe working distance from cables

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Tiling contractors to observe minimum safety distance. Site manager to periodically monitor

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Loading out and fixing tiles (continued)


Investigate feasibility of electrical supply being turned off. As a minimum, arrange for electricity company to sheath cables

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The presence of live overhead electrical cables

Page 99

Scaffold collapse

Necessary load rating of scaffold agreed at contract stage. Loading bays to be included Serious injuries or death (anyone working at height or at ground level in vicinity of scaffold)

Medium

Scaffold erected and inspected as necessary by a competent scaffold contractor

Low

Tiling contractor informed of loading [imitations around eaves-level working platform. Periodic monitoring by site manager

Person injury resulting from the use of defective hand tools (carpenter)

Low

Site manager

All tools fit for purpose and maintained in good condition

Use of hand tools

Low Slips and trips resulting from tools being left lying around (carpenter)

Medium

All tools returned to tool box or tool-belt when not in use

Before handling of roof trusses starts

QCS 2014

Section 11: Health and Safety Page 100 Part 2.4.01: Risk Assessment Guides and Method Statement

2.4.20.4 Appendix D: Suggested Structure for Written Method of Work (Section 1.1.7 of the Regulatory Document) The structure for a complete written method of work is composed of: (a) Site Checklist template, (b) The Method Statement and (c) The Inspection and Tests plan. A suggested template for the Site Checklist and the Method Statement are given below. A template for the Inspection and Test plan can be found in Section 2.

(A)

SITE CHECKLIST TEMPLATE

Occupational Health and Safety Checklist / Questionnaire Template Department :

Project Manager :

Project Name :

Project Starting Date:

Project Completed Date:

Consultant :

Project No. :

Contractor :

Inspection Date :

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Affairs :

Report No.:

Description

         

2

OH&S plan submitted for approval Within 30 days of the award of the contract? OH&S organization chart available OH&S Policy displayed Regular meetings record Responsibilities defined Near Miss & Hazard reporting and follow up Provision for visitors Monitoring effectiveness implementation of OH&S program Generic Risk Assessment & Management Monitoring & Control Sub-contractor to comply with all existing rules & regulations? In general, contractor following the government rules & regulation.

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MANAGEMENT

Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.1.8/9/14 + 1.10.2 + 11.1.1 + 11.2.1 + 11.2.3 + 11.2.4). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 35).

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Completion & Stamped By Consultant then Reviewed & Approved By Project Manager (Mob: ---------)

SAFETY STAFF  OH&S Safety Staff CV submitted for approval within 30 days of the award of the contract?

Ref. to: (QCS: 1.10.1.3 + 11.1.1.8 + 11.2.1.5).

QCS 2014


Item

Description



Ref. to: (QCS: 11.1.1 + 11.2.2 + 11.2.3.6). (Labor Law: Article 99).

.

Orientation / Site Induction Tool Box Talk (TBT) – daily documented Task specific (Equipment Operators, Scaffolders, Riggers, Fire Watchers, Emergency Drill, … etc) Management Refresher courses

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 

Ref. to: (QCS: 1.10.9 + 1.10.10 + 11.1.2 + 11.2.2 + 11.2.3.15). (Worker Rights Booklet 2009 – Page 41 & 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 9 & 10).

WORK ENVIRONMENT

Ventilation Removal of fumes and dust Dust controls preventive measures Noise levels (instrument available?) Vibration Lighting:  General purpose for evening work  For a particular task around construction site  Absence of glare  Work area  Corridors  Exterior Ergonomics - layout of work area The disposal of surplus water and the accompanying growth of trees and the proliferation of insects and rodents Does the site pose danger to the surrounding environment? Site office furniture?

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OH&S Officer available during all working hours OH&S Officer is exclusive for site & for H&S jobs

TRAINING   

Comments / Hold Points

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3

N/A

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

Yes

Satisfactory Submission No Date (If No)

WELFARE FACILITIES         

Clean toilets with exhaust fan Toilets & Sanitary in good condition? Potable water provided Eating and resting areas Messing / Canteen facilities Washing facilities Regularly cleaned area Work clothes lockers and hanging areas Prevent the breeding of mosquitoes on the site

Ref. to: (QCS: 1.10.9 + 1.10.10 + 11.1.2) (Labor Law: Article 103,106 & 107).

QCS 2014


Item

FIRST AID & MEDICAL  

Less than 100) First Aider (100) above Nurse (500) Above Doctor &Nurse

Paramedics available & names displayed (according to number of workers) Average Manpower = ---------------------Labor Accident reporting, records available &follow up



Periodic medical examinations for workers and follow up

  

Medical record book existing Paramedics Telephone numbers displayed Adequate first aid kits supplies & expiration dates (as per Hamad Medical Corporation Requirement)



Adequate first aid equipment



Availability of stretcher / ambulance / Standby Vehicle Clean room with potable water supply Doctor, Site Nurse & Site Clinic must be approved from Supreme Council of Health

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First aid box for each 25 labor (500) Above Clinic

      

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Procedures Assembly / Muster point Conducted Emergency Drill Training every 6 month Availability of Fire / Smoke / Gas detection mobile devices Emergency contact telephone numbers / Communications Breathing apparatus and / or respirators (if applicable) Torches Loud Hailer Emergency lighting Adequate and safe Emergency Exit / Doors are provided Escape routes, access ways to assembly points, extinguishers, hydrants and other firefighting equipment's and first aid kits kept clear of obstruction at all times

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EMERGENCY EQUIPMENT

HOUSEKEEPING & TIDINESS  

Ref. to: (QCS: 1.10.7.2). (Labor law: Article 100). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 16).

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Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.6 + 11.1.2.4 + 11.1.6 + 11.2.2 + 11.2.3). (Labor Law: Article 100,104,105 & 115).

Description

Segregation of waste and scrap Sufficient bins

Ref. to: (Labor Ministry Decision No. 20 of 2005). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 17).

QCS 2014


Item

Description Waste and scrap regularly collected & removed from site No build up of flammable materials Removal of combustibles

Ref. to: (QCS: 11.1.2.7). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 10). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 12).

STORAGE - RACKS, BINS, SHELVES

Aisles and walkways kept clear Neat and orderly Not too high Heavy items kept low Sufficient space to access items Are chemicals, paints, flammable liquids and gas cylinders stored only in designated areas?

SITE SECURITY & ACCESS  Adequate transportation between working site & accommodations  Security check correctly performed  Guardhouse continuously manned  Round check register updated  Perimeter fence intact  Inspection of materials gate passes  Need for the existence of surveillance cameras inside the site  Need for security personnel within the site

11

PERSONAL PROTECTIVE EQUIPMENT

Ref. to: (QCS: 1.10.9.2 + 11.1.1.12).

12

Coveralls Eye protection Head protection Hand protection Foot protection Hearing Protection Safety reflecting vests Dust mask Any other protection

SAFE WORK PRACTICES   

Ref. to: (QCS: 1.10.9.2 + 11.1.2 + 11.2.3). (Labor Law: Article 101).

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10

.

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N/A

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Yes


Avoid manual handling (Use mechanical handling equipment) Not working alone Cap (cover) for rebar / reinforcement steel

Ref. to: (Worker Rights Booklet 2009 – Page 45).

QCS 2014


Item

EXCAVATIONS

 

Adequate guarding on machines Inspected regularly with color code sticker & maintenance records Grounding installed to equipment/machine Unused machines electrically isolated Emergency isolation switches Safety devices Heating equipment

ELECTRICAL

      

16

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Insulation, cables, industrial plugs in good condition Cables suspended using S hooks and lead stands Inspected regularly with color code sticker ELCB provided to site power boards Qualified electrician hired to install (Name & Qualification) Protection of fittings against external damage Trailing leads used? Ovens and furnaces in good condition?

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

SCAFFOLDS & LADDER     

Ref. to: (QCS: 1.10.5.14 + 11.1.5.3 + 11.2.2). (Worker Rights Booklet 2009 – Page 46). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 10).

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MECHANICAL

as

14

Ref. to: (QCS: 1.10.5.3 + 11.1.1.4). (Worker Rights Booklet 2009 – Page 46). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 10).

ta



Location of existing utilities confirmed Signs posted Adequate hard barrier installed Adequate warning tape & lighting Bracing & Shoring provided (if applicable) 1m spoil clearance from the excavated pit Sloping maintained (if applicable) Correctly made ladders provided for access into excavation Appropriate access provided (temporary bridges & footpaths)

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13

Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.5.5 + 11.1.5.4 + 11.2.2 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

Description

Certified scaffold supervisor and scaffolders Scaffolds correctly erected Scaffolds properly secured Toe boards, guardrails (top & mid rail), handrails & access checked Fully boarded platforms

Ref. to: (QCS: 1.10.5.10 + 11.1.3 + 11.2.3.12). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

QCS 2014


Item

Description

Ref. to: (QCS: 1.10.5.13 + 11.1.3 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 11, 12 & 19).

Ref. to: (QCS: 1.10.5.3 + 11.1.4 + 11.2.2 + 11.2.3.5/10).

PLANT & EQUIPMENT



LIFTING OPERATIONS       

20

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Qualifications of operators available Available Qatar license for drivers / operators Banks man available Used as per its design (for intended purpose) Vehicle and equipment condition Reverse alarm installed Flashing light installed Generators and welding machine in good condition? Compressors and water pumps in good condition? Oil / fuel leak causing environmentally pollution

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Personnel working above 1.2 m using fall protection devices Fall protection devices condition / Certificate Adequate safe access in place to working height elevations Personnel properly trained in the selection and use of fall protection devices All loose material & tools at heights secured or removed

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 

18

Scaffolds correctly tagged Materials in good condition

WORKING AT HEIGHT 


ov

17

N/A

qa

 

Yes


Ref. to: (QCS: 1.10.5.8 + 11.1.4 + 11.2.3.10). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

Available Qatar license/third party certificate for operators and certificate of training for banks men and riggers Load capacity displayed Certification updated Condition of access and ground Lifting locations barrier off Outriggers/supports fully extended Hoist limiting device and SWL indicator working

LIFTING GEAR

Ref. to: (QCS: 1.10.5.9 + 11.1.4 + 11.2.3.10). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

QCS 2014


Item

Description     

Yes


N/A


Ropes, Chains, Shackles etc. in good condition Identity number and SWL displayed Color-code system in place Available 3rd party certificate for every lifting gear Damaged lifting devices removed from the workplace

COMPRESSED GAS CYLINDERS  Stored upright, valves protected  Regulators Gauges working; hoses inspected  Flashback arrestor fitted  Cylinders are securely tied or with trolley  Type of gas clearly marked on cylinders  Segregation of incompatible gases  Transported on appropriate trolley  Correct signage

Ref. to: (QCS: 1.10.5.12 + 11.1.2.14).

22

SAFETY OF THE PUBLIC (For Road Works)  Approval from Traffic Dep. & Environmental ministry  International Warning signs  Warning yellow lights  Adequate Barricades (to comply with Traffic law no. 19)  Railing  Pedestrians pathway signs & not interacted with work zoon  Adequate safe access to all properties  Night watchman available  To provide road hump to reduce & control speed with approval from Traffic Department.

Ref. to: (QCS: 1.10.5.4 + 1.10.8 + 11.1.1.10).

23

SAFETY SIGNAGE & NOTICE BOARD

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21

Ref. to: (QCS: 1.10.1.6 + 1.10.5.6 + 11.1.8.2). (Labor Ministry Decision No. 20 of 2005).

WORK PERMITS

Ref. to: (QCS: 1.10.5.1/4/11 + 11.2.2 + 11.2.3).

     

24

   

Clearly displayed Shall be in Arabic, English & other languages Clean and legible Enough traffic diversion signboard? Adequate warning signs and guides are provided Shall be fully illustrated and provide details of key safety procedures to be followed

Confined Space Hot Work Excavation Scaffolding

QCS 2014


Item

Description

   

    

  

.

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Toxic/ hazardous substance correctly tagged/ labeled and secured Adequate & proper storage provided Appropriate spill containment provided Disposal Spill kit (location, appropriate, easy access) Material Safety Data Sheet (MSDS) present & required training delivered to concerned employees Class B fire extinguisher near by Correct signage Register of chemicals Correct labeling

CONFINED SPACES 

Ref. to: (QCS: 11.1.2.3 + 11.2.2 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 15, 16, 17 & 18).

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  

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HAZARDOUS SUBSTANCES 

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

Is the firefighting equipment which approved by Civil Defense available at working area? Welding and grinding at working area properly secured Firefighting equipment not obstructed Expiration date of firefighting equipment checked. Monthly firefighting equipment visual inspected & recorded Availability of Fire / Smoke / Gas detection system Alarm and Emergency Evacuation system Are Alarms audible in all areas Minimum quantities of flammable material shall kept on site with full precautions required Access for Fire Brigade cleared

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 

27

Ref. to: (QCS: 1.10.7 + 11.1.7 + 11.2.2 + 11.2.3.13). (Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 8).

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Electrical Work Work permit correctly issued and signed Ashghal’ s work permit enforced

FIRE PROTECTION / PREVENTION 


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N/A

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  

Yes


Gas detectors/monitors with rechargeable batteries and battery charger (2 No.) Full body safety harnesses with lifelines and shackles (6 No.) Lifting frame with fall arrest device (1 No.) Constant flow escape breathing apparatus complete with storage cases (2 No.)

Ref. to: (QCS: 1.10.5.7 + 11.1.5.5). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 13 & 14).

QCS 2014


Item

Description   

N/A

Automatic positive pressure self contained breathing apparatus with storage case (1 No.) To train employee for confined space activity & supervision monitoring All equipment maintained & calibrated up to date with 3rd party certificate (record is available)

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OTHER RELATED SAFETY ITEMS           

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28

Yes



QCS 2014


Key Performance Indicator (KPI’s)

=

Accumulating up to Date

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Accumulative Accident Rate

No. Per Last Month

.

Description No. of Medical Treatment Cases No. of First Aid Cases No. of Near-Miss No. of Fatal Cases No. of RTA (Road Traffic Accidents) No. of Manpower (Average) No. of Direct Man-hours No. of Hours Lost No. of Man-hours from Last Lost Time Accident No. of Lost Time Accidents No. of Safety Meeting No. of Emergency Drill No. of Audit Kilometres Driven

(Clasue1+4+5+10) x 100,000

=

(Clasue1+4+5+10) x 100,000

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Monthly Accident Rate

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Caluse6 (No. of Manpower Average)

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Caluse6 (No. of Manpower Average)

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Accumulative Frequency Accident =

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Monthly Frequency Accident

(Clasue1+4+5+10) x 1000,000

Caluse7 (No. of Direct Man-hours)

=

(Clasue1+4+5+10) x 1000,000 Caluse7 (No. of Direct Man-hours)

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 Consultant Name:

Mob. No.:

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Filled By: Signature: Date:

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Indicator No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Stamp:

 References:        

QCS (Qatar Construction Specification – Latest Edition). Labor Law No. 14 of the year 2004. Qatar Traffic Law No. 19 of the Year 2007. Environmental Protection Law No. 30 of the Year 2002. CDD (Civil Defense Department) – Fire Safety Handbook. Law No. 13 of 1997 - Civil Defense Law No. 9 of the Year 2012 - Amending some provisions of Law No. 13 of 1997 Concerning the Civil Defense Worker Rights Booklet 2009 (National Human Rights Committee).

QCS 2014


Site Approval Log (Supplementary Element Specific Log) SITE APPROVAL LOG (TITLE / NAME) To be signed before work activity is undertaken

Issue:

REF:

Work Activity:

PROJECT NAME: Corridor No:

Corridor Name: COMMENTS:

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LOCATION FROM:

Approvals: signature/date

Checks

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5

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3

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2

Other

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e.g: Check licenses are received from MOPW, Check TM arrangements, Check utilities (locate & confirm), Check corridor specific Environmental issues, etc

1

Engineer

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Contractor

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Note: Contractor to ensure that checklist is signed off by all relevant parties before work activity can begin Confirmation that work completed in accordance with contract, safety and quality requirements: Construction Manager:

date:

HSEQ Manager:

date:

QCS 2014

(B)


METHOD STATEMENT TEMPLATE

Project Name:

Method Statement Number:

Work Activity:

Date:

Reviewed By:

Date:

Approved By:

Date:

PURPOSE, SCOPE AND LOCATION MAP

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Item

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Prepared By:

BRIEF DESCRIPTION OF THE CONTENT OF THIS MS, THE PURPOSE AND DETAIL ON THE SCOPE OF

Person Responsible INCLUDE PERSONS WITH RESPONSIBILITY FOR TASK

MANDATORY INDUCTION, TRAINING, SUPERVISION AND INSTRUCTION REQUIREMENTS

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2

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WORKS. AND INCLUDE LOCATION MAP AND REFERENCES

FOR MAKING SURE WORKERS ARE INDUCTED, TRAINED



INDUCTION

FOR THE WORK



TRAINING



INSTRUCTION



SUPERVISION

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LIST ALL MANDATORY REQUIREMENTS FOR THE WORK ACTIVITY IN TERMS OF

PRELIMINARIES    

ACTIVITY, WORKS ARE INSTRUCTED AND SUPERVISED E.G. SITE ENGINEER/ SUPERVISOR WHO IS RESPONSIBLE TO MAKE SURE THAT

LICENSES

RELEVANT LICENSES,

TRAFFIC MANAGEMENT

TMS ETC ARE IN PLACE

DETECTION AND ISOLATION OF UTILITIES

AND COORDINATING

DISCONNECTION/ RECONNECTION OF SERVICES

AND MANAGING

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3

WHO IS RESPONSIBLE

UTILITY WORKS

4

SEQUENCE OF WORKS

INCLUDE PERSONS WITH RESPONSIBILITY



WRITE OUT THE JOB PROCEDURE STEP BY STEP

FOR AUTHORISING A



USE ACTIVE, NOT PASSIVE VOICE

CONTINUATION OF



SEQUENCE IDEAS LOGICALLY

WORKS AT EACH HOLD



KEEP SENTENCES SHORT AND CLEAR

POINT

INCLUDE: PRECAUTIONS TO BE TAKEN HAZARDS HOLD POINTS PERMIT REQUIREMENTS, COORDINATION, APPROVAL AUTHORITIES ETC

QCS 2014 5


IDENTIFIED HAZARDS/RISKS AND CONTROLS IN PLACE

INCLUDE WHO IS RESPONSIBLE TO





LIST ALL IDENTIFIED HAZARDS AND RISK IMPACTING ON THE WORK ACTIVITY AND THE

COMMUNICATE RISKS

CONTROLS IN PLACE

AND CONTROLS IN

INCLUDE REFERENCE TO RISK ASSESSMENT

PLACE FOR THE WORK ACTIVITY

6

ENVIRONMENTAL CONSIDERATIONS AND IMAPCT CONTROL MEASURES

ALSO INCLUDE WHO IS RESPONSIBLE FOR NEIGHBOURHOOD



LIST ENVIRONMENTAL IMPACTS, MITIGATION AND PRECAUTIONS



IDENTIFY PUBLIC NUISANCE AND SOURCES OF NUISANCE FOR NEIGHBOURING

LIAISON

PEOPLE/PROPERTIES

MANDATORY PPE FOR THE WORK ACTIVITY 

EMERGENCY PROCEDURES:

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

WHO IS RESPONSIBLE FOR CALLING THE EMERGENCY SERVICES

REGARDING



CONTACT DETAILS FOR OUT-OF-HOURS EMERGENCIES

EMERGENCIES

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IDENTIFY EMERGENCY TYPES AND ARRANGEMENTS INCLUDING SITE EVACUATION

QUALITY CONTROLS REFERENCE TO INSPECTION AND TEST PLAN NUMBERS

INTERFACES 

IDENTIFY ALL INTERFACES AND LIAISON REQUIREMENTS IMPACTING ON THE WORK

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ACTIVITY

SAFETY OF THE PUBLIC AND OCCUPIERS 

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11

RESPONSIBLE FOR





10

INCLUDE WHO WILL BE

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9

LIST ALL IDENTIFIED MANDATORY PPE FOR THE WORK ACTIVITY

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8

E.G SUPERVISOR

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7

DESCRIBE HOW THE HEALTH AND SAFETY OF THE PUBLIC AND OTHERS AS RELEVANT

COMMUNICATIONS

E.G. QUALITY MANAGER, SITE ENGINEER, QUALITY INSPECTOR WHO RESPONSIBLE TO COORDINATE INTERFACES IMACTING ON AND IMPACTED BY THE WORK ACTIVITY WHO WILL ENSURE THAT THE HEALTH AND SAFETY OF THE PUBLIC

WILL BE PROTECTED.

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RESOURCE PLANNING

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

PERSONNEL



PLANT AND EQUIPMENT



13

E.G. SITE ENGINEER, SUPERVISOR

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12

MATERIALS

REFERENCES 

WORK PROGRAMME



DRAWINGS



RISK ASSESSMENTS



COORDINATION PROCEDURE



WORK CHECKLIST



INSPECTION AND TEST PLAN ETC

(C)

INSPECTION AND TEST PLAN

Refer to Section 2 for template Inspection and Test Plan

END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 01: General

Page 1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9

Scope References Ground Investigation Site Clearance Preservation of Property Not to be Affected by the Works Disposal of Historical Artefacts Special Requirements of Utility Authorities Control of Ground Water Record Procedure

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1

2 2 2 3 3 4 4 4 4

QCS 2014


Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for excavation and filling as necessary to facilitate the construction of the Works. It does not include earthworks associated with trenches for pipelines or service ducts.

2

The cost of all operations needed for the excavation and disposal work as required and specified, including temporary and permanent support work, breaking, loading, hauling and dumping in accordance with the provisions of the Project Documentation shall be included in the Contractor’s rates.

3

The Contractor shall be deemed to have examined the site and verified for himself the exact nature and quality of the materials to be excavated. The Contractor shall carry out his own survey of the existing ground levels and satisfy that the quantities of all excavated and imported materials are correct.

4

Removal operations shall be conducted with the least interference to the public and shall not be started until approved by the Engineer.

5


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1

Filling


General Building Demolition Roadworks Sewerage Landscaping

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This Section Part 3

References

1

The following standards are referred to in this Section:

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1.1.2

BS 812........................Testing Aggregates BS 1377 .....................Methods of test for soils for civil engineering purposes BS 6906 .....................Methods of tests for geotextiles 1.1.3

Ground Investigation

1

The Contractor shall be deemed to have satisfied himself as to the character of the Site and all the various materials, strata, ground water levels, etc., and of all items liable to affect, or be encountered in, the excavations and earthworks.

QCS 2014


Page 3

If a ground investigation is not included in the Project Documentation the Contractor shall immediately after taking possession of the Site prepare a minimum of two trial pits in positions to be agreed with the Engineer. Chemical analysis tests are to be carried out on the materials from each of the pits and the results submitted to the Engineer. Similarly, chemical analysis tests shall be carried out on any water present in the pits and the results submitted to the Engineer. Ground investigation tests in accordance with the relevant provisions of BS 812, BS 1377 and BS 6906 shall be undertaken where geotextiles are to be used for temporary or permanent protection.

3

The Contractor shall inform the Engineer when the trial pits are ready for inspection and shall not commence excavation work until approval to proceed has been given. All trial holes and their subsequent backfilling shall be carried out at the Contractor’s expense and will only be allowed in positions approved by the Engineer. All trial holes shall be backfilled as soon as the required information has been obtained and open excavations shall be adequately protected and cordoned off using temporary lights and barriers or similar method approved by the Engineer.

4

If a ground investigation is included in the Project Documentation, it is provided solely for the guidance of the Contractor and no guarantee is given regarding its accuracy, nor is it guaranteed that similar conditions apply elsewhere on the Site.

1.1.4

Site Clearance

1

Before commencing any excavation or fill, the area shall be cleared of all trees, stumps, roots, bushes, vegetation, debris, materials or other obstructions.

2

Before removal of any trees or shrubs the Contractor shall obtain written consent from the Engineer at least two weeks in advance of the planned removal.

3

All bushes, undergrowth, etc. to be removed shall be grubbed up and disposed of in a manner as agreed with the Engineer. Holes left by stumps or roots shall be filled with suitable material, compacted to the Engineer’s satisfaction in accordance with Part 3 of this Section within one week of the work being performed.

4

The Contractor shall at his own expense make good any damage done to other property during the site clearing. Sweet soil excavated during the course of these works shall be preserved and protected by the Contractor, until removed by the Employer or until the expiration of the Contract.

1.1.5

Preservation of Property Not to be Affected by the Works

1

Attention is directed to the Contractor’s obligations with regards to damage, particularly with regard to protection of property, plants and landscape and to responsibility for damage claims.

2

The form of protection to vegetation within the Site shall be as agreed with the Engineer.

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2

QCS 2014


Page 4

1.1.6

Disposal of Historical Artefacts

1

Where specified, certain materials arising from site clearance and excavation work are to remain the property of the Owner. All fossils, antiquities and other objects of interest or value which may be found or uncovered on the Site shall remain or become the property of the Owner. Upon discovery of such an object the Contractor shall forthwith: (a)

use his best endeavours not to disturb or damage the object

(b)

cease work which would endanger the object or prevent or impede its removal

(c)

inform the Engineer of the discovery and precise location of the object.

The Engineer will issue an instruction on the procedure to be adopted which may include conditions to permit the examination, excavation or removal of the object by a third party.

1.1.7

Special Requirements of Utility Authorities

1

Prior to commencing excavation work, the Contractor shall ascertain from the responsible Utility Authorities whether any mains or services need to be diverted or cut-off in accordance with the procedure described in Part 19 of Section 1.

1.1.8

Control of Ground Water

1

Prior to the commencement of construction at any particular location, the Contractor shall install and maintain a system of standpipes and other devices to monitor ground water levels in any area, which in the opinion of the Engineer, is likely to be affected by the dewatering. The number, location and depth of all standpipes shall be to the satisfaction of the Engineer.

2

The Contractor shall check ground water levels weekly or when instructed by the Engineer. The results of such checks shall be submitted to the Engineer in a written report within 24 hours of the level being taken. The format of the report shall be as agreed with the Engineer.

3

In the case of uncontrolled flow of water into any excavation, the Engineer reserves the right to order the Contractor to take immediate action to control the inflow of water. Such actions and remedial works shall be to the Engineer’s approval.

1.1.9

Record Procedure

1

If the Engineer requires foundation or formation level depths to be varied from those shown on the drawings it shall be the responsibility of the Contractor to ensure that proper records of the actual excavated levels are kept.

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2

END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 02: Excavation

Page 1

2

EXCAVATION ................................................................................................ 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2

Scope References

2.2

EXCAVATION FOR STRUCTURES .............................................................. 2

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8

Excavation Support Removal of Water Approvals Inspection Unsound Materials Over-Excavation Finishing to Excavation Storage of Excavated Material

2.3

MATERIALS .................................................................................................. 4

2.3.1 2.3.2 2.3.3 2.3.4

Excavated Material Common Excavation Rock Excavation Blasting

2.4

DISPOSAL OF SURPLUS MATERIAL .......................................................... 5

2.4.1

General

2 3 3 3 4 4 4 4

4 4 5 5

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5

QCS 2014


Page 2

EXCAVATION

2.1

GENERAL

2.1.1

Scope

1

This Section specifies the requirements for the excavation for structures, culverts, headwalls, catch basins, manholes, inlets, retaining walls and the like. The work includes all necessary clearing and grubbing and the disposal of all material resulting from such excavation. The work also includes the provision, and subsequent removal, of all necessary bailing, drainage, pumping, sheeting, strutting, coffer dam construction and crib construction.

2

Rates for excavation shall include for excavation in any material. Excavation in any material shall include common excavation, side shoring, support systems, excavation in artificial hard material and shall be inclusive of all encountered impediments, including roots, boulders etc. Blasting will not be permitted without the written approval of the Engineer.

3


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General Roadworks

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Section 1 Section 6

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2

References

1

The following standards are referred to in this Part;

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2.1.2

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BS 1377 .....................Method of test for soils for civil engineering purposes

EXCAVATION FOR STRUCTURES

2.2.1

Excavation Support

1

Prior to Commencing any structural excavation work which is 1.5 m or greater in depth, the Contractor shall design an excavation support system.

2

Details of the excavation support system shall be submitted to the Engineer for review and approval at least one week before any excavation work commences. Details of the excavation support system shall be complete with, but not limited to, the following:

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2.2

(a)

drawings of the structural support members showing materials, sizes and spacing,

(b)

calculations showing the maximum theoretical deflection of the support member.

3

The system is to be designed so that no members extend through surfaces exposed in the finished construction, and no shoring or bracing is placed under permanent structures.

4

The Contractor shall submit to the engineer calculations of lateral earth pressure for the full excavation depths, surcharge loads of any description, equipment loads, forces at various stages of support during excavation, the maximum design loads to be carried by various members of the support system and strut pre-load forces.

5

If the structure support system proposed includes tieback anchors, the Contractor’s submitted details shall include drawings that show the profile of the soil in which each anchor is to be installed.

QCS 2014


Page 3

Tieback anchors that project beyond the vertical limits of the Site boundary on to adjoining property shall only be permitted if permission to do so is given by the owner of the property in writing. Copies of such written permission shall be submitted to the along with excavation support system proposals.

2.2.2

Removal of Water

1

At locations where the excavation extends below the groundwater table, a dewatering system is to be provided which will lower ambient groundwater levels. The resulting groundwater level shall be at a depth which is sufficiently below the excavation level so as to allow the safe and proper execution of the work. The resulting foundation level shall be a stable, dry sub-grade which is suitable for the execution of subsequent operations.

2

The Contractor is to design the dewatering methods and settling basins so that no critical amounts of soil, sand or silt are removed during either the dewatering operations.

3

Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted to the Engineer for his review. The Contractor’s submittal shall include drawings that show the arrangement, location and depths of the proposed dewatering system. A complete description of the equipment and materials to be used and the procedures to be followed to be given, together with details of required standby equipment and standby power supply. The Contractor shall also indicate his proposed location(s) for the discharge of extracted groundwater.

4

The dewatering system design should also include the details of measures required to prevent damage due to settlement of roads, pavements, utilities, sewers, buildings and other structures outside the excavation but within the area affected by the dewatering.

2.2.3

Approvals

1

The designs of the structure excavation support system and the dewatering systems specified above is to be prepared by and signed by a qualified engineer experienced in this type of design work. Approval of the designs and shop drawings will not relieve the Contractor of the adequacy and performance of these temporary works.

2.2.4

Inspection

1

In addition to the provisions of Part 13 of Section 1, the Contractor shall also undertake the following described in the following Clauses unless otherwise instructed by the Engineer.

2

Following a detailed inspection of all adjacent structures, the Contractor shall prepare a report on the pre-construction condition of all structures that may be affected during construction of the Works. The report will include photographs, drawings and sketches with levels and dimensions fully illustrating the structure's condition. In particular, it shall note any existing damage or structural inadequacy. Deficiencies and damage are to be suitably marked on the structure in a way that it is not permanently defaced.

3

Three (3) copies of the Report shall be submitted for the approval of the Engineer. Once approved, five (5) additional copies shall be supplied to the Engineer.

4

The Contractor shall carry out a survey of levels of undisturbed ground before commencing any excavations.

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QCS 2014


Page 4

When the excavation has been carried down to formation level the Contractor shall advise the Engineer’s Representative that the excavation is ready for inspection and the Engineer’s Representative shall, without reasonable delay, inspect the excavation unless he considers it unnecessary.

2.2.5

Unsound Materials

1

Any loose, improperly compacted, soft or other unsuitable material which is encountered below or adjacent to structural foundation levels shall be completely removed, backfilled with a suitable material and compacted to 95% of the maximum dry density as determined by BS 1377 Part 4. Backfilling shall be done in layers with an unconsolidated thickness not exceeding 200 mm up to the foundation level. The limits of such work shall be as directed by the Engineer. Alternatively, the Engineer may instruct that removed material be replaced with Class C25 concrete.

2.2.6

Over-Excavation

1

Any over excavation is to be backfilled with Class C25 concrete at the Contractors expense.

2.2.7

Finishing to Excavation

1

All rock or other hard foundation material is to be cleaned of all loose material. All seams or crevices are to be cleaned and grouted. All loose and disintegrated rock and thin strata is to be removed.

2

When the structure is to rest on material other than rock, excavation to final grade should not be made until just before the structure is to be placed/constructed and special care is to be taken not to disturb the excavated surface. The surface required shall be rolled and compacted to 95% of the maximum dry density.

2.2.8

Storage of Excavated Material

1

Excavated material is not to be stored or deposited in such a way as to endanger structures or cause an obstruction of any kind.

2.3

MATERIALS

2.3.1

Excavated Material

1

All excavated material will be the property of the Owner and no material shall be removed, transported and disposed of without the prior written approval of the Engineer.

2.3.2

Common Excavation

1

Common excavation consists of the excavation and satisfactory disposal of all soils, certain strata and rock boulders less than one (1) cubic metre in volume. Strata which are altered and weathered and are in place, but which are not firm enough, or in the opinion of the Engineer are not rigid enough to have all the characteristics of rock excavation is to be classified as common excavation.

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QCS 2014


Page 5

Rock Excavation

1

Rock excavation consists of the excavation and satisfactory disposal of all unaltered and unweathered firm and rigid igneous, metamorphic and sedimentary solid rock that in the opinion of the Engineer can only be excavated by the use of pneumatic hammers or other such similar apparatus.

2.3.4

Blasting

1

Blasting will not be permitted without prior approval. (Refer to Section 6: Roadworks).

2.4

DISPOSAL OF SURPLUS MATERIAL

2.4.1

General

1

All materials arising from site clearance or excavation which are surplus, suitable or unsuitable for use in the Works will become the property of the Owner and will not be disposed of by the Contractor either off the Site to an approved tip without written approval from the Engineer. If directed, or otherwise agreed by the Engineer, the Contractor may dispose of surplus material on the Site in an approved manner as directed by the Engineer.

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2.3.3

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 03: Filling

Page 1

3

FILLING ......................................................................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

EARTHWORKS MATERIALS ........................................................................ 2

3.2.1 3.2.2 3.2.3 3.2.4

Top Soil Suitable Material Unsuitable Material Utilisation of Excavation Materials

3.3

MAIN PLANT FOR EARTHWORKS CONSTRUCTION ................................ 3

3.3.1

General

3.4

BACKFILLING ............................................................................................... 3

3.4.1

General

3.5

COMPACTING IMPORTED OR SELECTED EXCAVATED FILL MATERIAL ..................................................................................................... 4

3.5.1 3.5.2

General Water

3.6

FILL BELOW GROUND SLABS .................................................................... 5

3.6.1

General

3.7

FILLING ......................................................................................................... 5

3.7.1

Concrete Blinding

2 2

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4 5

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3

FILLING

3.1

GENERAL

3.1.1

Scope

1

This Part specifies materials for filling purposes.

2

Related parts and Section are as follows:

Page 2

This Section

.

Roadworks

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Excavation

References

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3.1.2

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Part 2

BS 812........................Testing Aggregates

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BS 1377......................Methods of test for soil for civil engineering purposes

EARTHWORKS MATERIALS

3.2.1

Top Soil

1

Top soil is to be fertile, friable soil obtained from well drained arable land and to be free draining, non-toxic and capable of sustaining healthy plant growth.

3.2.2

Suitable Material

1

Suitable material for earthworks shall be approved soil with a liquid limit not exceeding 35% and a plasticity index not exceeding 10%. The material passing the 0.075 mm sieve shall not exceed 20% and the organic matter content shall not exceed 2% (as determined by BS 1377 – Part 3).

2

Where excavated rock is to be used as fill material elsewhere on the site, the Contractor is responsible for ensuring that the excavated rock meets the requirement of the Specification for fill material.

3

The Contractor is responsible for mixing the excavated rock with suitable fill material imported and/or excavated from within the site should it be necessary in order to produce a suitable fill material that complies with the requirements of the Specification and he should allow in his rates and programme for carrying out the work.

4

Sweet soil and any excavated materials which are considered re-usable by the Engineer, shall be preserved and protected by the Contractor, until they are removed by the Owner or until the expiration of the Contract.

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3.2

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5

No excavated suitable material is to be removed from the Site without the Engineer’s written permission. Should the Contractor be permitted to remove suitable material from the site to suit his operational requirements, then he is to make good any consequent deficit or filling arising therefrom at his own expense.

3.2.3

Unsuitable Material

1

Unsuitable materials include: rock particle exceeding 75mm in size

(b)

organic material (as defined in BS 1377 Part 3) containing greater than 2% stumps and other perishable material

(c)

material susceptible to spontaneous combustion

(d)

soils of a liquid limit exceeding 35% and/or a plasticity index exceeding 10%.

(e)

material containing more than 5% of water soluble salts by weight of dry soil (individually, water soluble chloride exceeding 1% or water soluble sulphate exceeding 1.5%) or more than 10% of acid-soluble salts (individually, acid soluble chloride exceeding 2% or acid soluble sulphate exceeding 3.0%) as determined by BS 1377: part 3

(f)

any other material which the Engineer may deem to be unsuitable for earthworks

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(a)

Utilisation of Excavation Materials

1

All excavated material determined as suitable by the Engineer, is to be utilised as backfill. The surplus material shall be disposed of as specified in Part 2 of this Section.

3.3

MAIN PLANT FOR EARTHWORKS CONSTRUCTION

3.3.1

General

1

The Contractor is to employ only plant which is suited to the soils to be handled. He should not at any time use plant which damages or reduces the natural strength of the soil either in its in-situ state or during handling and placing or in its final compacted state. Unsuitable or faulty plant shall be removed from the work site and borrow pits at the order of the Engineer.

3.4

BACKFILLING

3.4.1

General

1

Excavation is only be backfilled after the permanent works therein have been approved and after the removal of any building debris or deleterious material from the excavations.

2

Selected excavated material will normally be used or backfilling in the manner described in Clause 3.5 of this Part. Where the excavated material is not considered suitable, selected material form an approved source is to be used.

3

The backfill will be brought to a suitable level above grade to provide for anticipated settlement and unless indicated otherwise, is to be sloped away from the structure.

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3.2.4

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The bottom of all excavations are to be probed and any poor bearing area shall be reported to the Engineer who will direct remedial work. Soft spots and other unsound materials are to dealt with as specified in Part 2 of this Section.

5

In circumstances where backfill has to be deposited below standing water, only rock, as specified in Section 6, Roadworks, is to be used.

3.5

COMPACTING IMPORTED OR SELECTED EXCAVATED FILL MATERIAL

3.5.1

General

1

Fill to be compacted by a suitable plate type vibrator, pedestrian operated vibrator roller, small tandem roller or other approved compaction plant.

2

The material is to be placed in layers within the effective range of compaction of the plant provided that the maximum loose (uncompacted) thickness of each layer dose not exceed 200 mm.

3

The material is to be watered and mixed as necessary to ensure that prior to compaction the moisture content of the whole layer is ± 3% of the optimum moisture content. Compaction of each layer is to continue until a density of a least 95% of the maximum dry density has been achieved.

4

The dry density/moisture content relationship will be determined by the heavy compaction test (4.5% rammer method) of BS 1377.

5

All fill material used in earthworks shall be compacted as per related Specification by plant approved by the Engineer for that purpose. If required by the Engineer the Contractor shall carry out compaction trials on the material supplemented by laboratory testing to determine the correct plant and number of passes required to achieve the specified requirements.

6

Potable water shall be used for compaction of all fill material within the area of excavation.

7

The Contractor shall carry out moisture content determinations at frequent intervals or when there is a change in the material on the soils undergoing compaction so as to ensure that the moisture content of the soil is within the optimum range for the field compaction determined from compaction trials.

8

All adjustment of moisture content shall be carried out in such a way that the specified moisture content remains uniform through out compaction.

9

No completed fill layer shall be covered by the next layer until it has been tested, inspected and approved by the Engineer.

10

The finished surface of earthworks for paved surfaces (other than public roads) shall be shaped and rolled and then tested for accuracy so that maximum local irregularities in the finished profiles lie within the tolerance of  20mm for formation, as well as  10mm and  5mm respectively for longitudinal and transverse profiles of finished surfaces, when tested by a straight edge or level instrument. The frequency of local irregularities shall be at the discretion of the Engineer.

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Where fill material is to be deposited in areas where the existing ground is sloping, the Contractor shall excavate benches so that fill material is deposited onto a horizontal surface. The levels of the benching terraces shall match the layers of the fill material that are deposited in the adjacent areas.

3.5.2

Water

1

The water to be mixed with the soil / fill materials to achieve the desired moisture content in the filling / earthworks operations shall be potable.

3.6

FILL BELOW GROUND SLABS

3.6.1

General

1

The installation of cable ducts for service entries and service pipework is to be completed before placing of the fill to receive the ground slab.

2

The compacted fill or hardcore is to be shaped and trimmed to the required levels and dimensions and blinded with sand.

3.7

FILLING

3.7.1

Concrete Blinding

1

Immediately on completion of excavations for concrete structures a blinding layer of concrete Grade OPC 25 not less than 75mm thick shall be placed to prevent deterioration of the formation and to provide a clean working surface for the structure.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 04: Utility Trenches

Page 1

4

UTILITY TRENCHES ..................................................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References Excavation of Utility Trenches Backfilling of Utility Trenches

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4

UTILITY TRENCHES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirement for utility trenches. It does not include trenchworks for pipelines and service ducts.

2

Related Sections and Parts are as follows: This Section Filling

Part 3

Excavation

References

1


Methods of tests for soils for civil engineering purposes.

qa

BS 1377

ta

4.1.2

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Part 2

Excavation of Utility Trenches

1

The trench to be excavated with the width and to the depth shown on the drawings or as indicated by the Engineer.

2

The sides of pits and trenches are to be vertical and adequately supported at all times. Excavation may if considered necessary be battered with a safe slope, but only with the Engineer’s written permission.

3

Care is to be taken to excavate to the depths indicated. Where rock is encountered, the rock is to be excavated 150 mm lower than the required depth. Such depth in rock is to be backfilled with approved fill material and compacted as specified and/or as directed by the Engineer.

4

Excavated material will, if found unsuitable as defined in Part 3 of this Section, be disposed of to an approved tip and replaced with suitable material. All surplus material to be disposed of in accordance with Part 2 of this Section.

4.1.4

Backfilling of Utility Trenches

1

After the utilities have been laid, the trench refilling is to commence with approved fill in compacted layers not exceeding 150 mm unconsolidated thickness. Each layer shall be well compacted by hand with iron rammers weighing not less than 5 kg, until the trench has been filled to a height of 300 mm above the top of the utility.

2

The remainder of the trench is then to be refilled in compacted layers not exceeding 250 mm unconsolidated thickness. Each layer being well compacted, with power rammers, vibrating plate compactors or other mechanical means of a type to be approved until the ground is thoroughly consolidated up to the required level for surface reinstatement. Each layer is to be compacted to 95% of its maximum dry density as determined by BS 1377.

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3

Trenches are not to be backfilled until all required tests are performed on the utilities and until the Engineer has verified that the utilities have been installed in accordance with the Project Documentation.

4

Where cover to utilities is less than 400 mm, or where ordered by the Engineer, protection in the form of precast concrete tiles is to be provided according to an approved drawing or as ordered by the Engineer.

5

PVC warning tape shall be laid above the utility or the concrete tiles, after partial backfilling and approximately 300 mm below finished ground level.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 05: Installation of Protective Membranes

Page 1

5

INSTALLATION OF PROTECTIVE MEMBRANES ....................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3

Scope References General Requirements

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5

INSTALLATION OF PROTECTIVE MEMBRANES

5.1

GENERAL

5.1.1

Scope

1

This Part specifies geotextile fabric systems used for temporary or long term stabilisation of earthworks during construction.

2

Related Sections and Parts are as follows: Concrete

Section 6

Roadworks

5.1.2

References

1

The following standards are referred to in this part:

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BS 6906......................Methods of test for Geotextiles

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Section 5


1

In areas where the Engineer deems the use of geotextile fabric necessary, the Contractor is to furnish and place geotextile fabric as specified and as directed by the Engineer.

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5.1.3

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The geotextile fabric furnished by the Contractor is to be of an approved grade suitable for placement over fine sand. The geotextile fabric shall be a woven or non-woven fabric consisting only of long chain polymeric filaments or yarns formed into a stable network such that the filaments or yarns retain their relative position to each other. The fabric is to be stabilised against ultra violet light, inert to commonly uncounted chemicals and chemical properties of the in-situ soil and water, and it should conform to the following minimum requirements: Weight

135 g/m 2

m

Thickness under load (2 kN/m )

2

2

0.7 mm

Tensile Strength (200 mm width) ASTM D1682

1.6 kN

Puncture Resilience (DIN 54307)

1.5 kN

Permeability

50 litres/m /s

2

The surface to receive the geotextile fabric is to be prepared to a relatively smooth condition free of obtrusions, depressions, and debris. The geotextile fabric should not be laid in a stretched condition. In the event that the width of the proposed area for fabric requires more than one panel width of fabric, the panels are to be overlapped a minimum 15 percent of the panel width. Longitudinal joints in the fabric are to have an overlap of 500 mm. To prevent slippage of the overlapping fabric, the areas of overlap are to be stabilised as approved by the Engineer with pins, anchor blocks, or aggregate piles. In the event that construction machinery is used to place the fabric, the working platform for the machinery should be the soil and not the previously laid fabric.

QCS 2014


Page 3

3

Prior to placement of the granular material (stabilising crushed material) the Contractor is to spread a layer of sand over the geotextile fabric as directed by the Engineer. The aggregate material should not be dumped directly on the fabric. Haulage trucks are not to be driven on the fabric. The aggregate is to be spread by a wheeled front-end loader. The blade or bucket is to be kept sufficiently high so that the aggregate is not being pulled over the fabric, but being dropped at a minimum height to the satisfaction of the Engineer.

4

Fabric damaged or displaced before or during installation or during placement of overlaying aggregate material is to be replaced of repaired to the satisfaction of the Engineer at the Contractor’s expense.

5

Where pipes or other elements pass through the geotextile fabric, the openings around such are to be made watertight by methods as approved by the Engineer.

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END OF PART

QCS 2014

Section 13: Masonry Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3

Scope References Definitions

1.2

APPROVAL OF SUPPLY SOURCE .............................................................. 2

1.2.1


1.3

SAMPLES, TESTING AND SUBMITTALS .................................................... 2

1.3.1 1.3.2

General Requirements Sample Panels

1.4

PRODUCT HANDLING.................................................................................. 3

1.4.1

Storage of Materials

1.5

WORKMANSHIP ........................................................................................... 3

1.5.1


1.6

CLEANING .................................................................................................... 4

1.6.1 1.6.2 1.6.3

General Requirements Brickwork Concrete Masonry Units

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2 3

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1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section covers the products, erection and all associated accessories for construction of concrete and clay masonry unit blockwork as well as requirements for glass block units, gypsum units, and stonework.

2


References

1

The following standards referred to in this Part:

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1.1.2

.

Concrete Thermal Insulation of Buildings Finishes to Buildings Painting and Decorating

ta


qa

BS 6100......................Glossary of building and civil engineering terms Definitions

1

Definitions used in this Section follow the requirements of BS 6100 unless otherwise stated.

1.2

APPROVAL OF SUPPLY SOURCE

1.2.1


1

All products supplied under this Section must be obtained from an approved source.

2

The Contractor will not be permitted to change his source of supply without the permission of the Engineer.

1.3

SAMPLES, TESTING AND SUBMITTALS

1.3.1


1

Samples of each type of masonry unit to be used shall be submitted to the Engineer for approval before use. All subsequent units are to be up to the standard of the approved samples.

2

Initially, twelve (12) units will be selected by the Engineer from the first batch of units manufactured or delivered. The units shall be delivered by the Contractor to an approved independent testing laboratory, or if the Engineer so directed, to the Government Materials Testing Laboratory.

3

The sample is to be accompanied by the following written information:

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1.1.3

(a)

type of unit

(b)

means of identification of unit

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Page 3

(c)

name of manufacturer

(d)

type of masonry units making machine

(e)

capacity of plant and present stocks available

(f)

certificates stating that the units are suitable for the purpose for which they are to be used.

A number of units to indicate colour range for exposed work to be submitted to the Engineer for approval prior to commencement of the Works.

5

Further samples will be selected and tested as directed by the Engineer.

6

The Contractor shall submit details of his proposed methods for reinforcement to the Engineer for approval. The Contractor shall also submit details of his proposed methods for constructing lintels, anchors and anchor channels.

1.3.2

Sample Panels

1

Before any fair or faced masonry work is commenced, the Contractor is to erect one sample panel, size 1800 mm long x 2000 mm high, of each type of finish to be used.

2

The panels should incorporate a typical opening detail and a typical corner detail, and a typical movement joint.

3

Before starting face brickwork, the Contractor shall lay up a sample panel 2 m long by 1 m high for the Engineer’s approval. Random piles of brick as delivered to the Site shall be used. Brickwork to be incorporated in the Works is to match original sample brickwork panels as approved by Engineer. Sample panels must not be removed until directed by Engineer.

1.4

PRODUCT HANDLING

1.4.1


1

Masonry units delivered to the Site are to be carefully unloaded and handled so as to prevent chipping and breakage. Tipping of units will not be allowed.

2

The units are to be stacked on a level area in an orderly manner on planks or other suitable supports to ensure that they are free from contact with the ground. Stored units shall be kept under waterproof covers.

3

Packaged materials shall be stored in their original containers.

1.5

WORKMANSHIP

1.5.1


1

Tops of walls shall be covered with waterproof covering when the work is not in progress.

2

When starting or resuming work, loose mortar and foreign materials shall be cleaned from the top surface of the work. Surfaces of clay type masonry shall be wetted before resuming work.

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Newly laid blockwork and brickwork shall be protected from the harmful effects of sunshine, rain, drying wind, and surface water.

4

Blockwork shall be water cured for a minimum of three days.

5

Units that will be exposed to view in finished work shall be supplied in adequate quantities to permit selection and mixing of brick from several deliveries in advance of laying. Units shall be exposed to the atmosphere for minimum of two weeks before laying.

1.6

CLEANING

1.6.1


1

Clean exposed masonry surfaces on completion. Protect material liable to damage.

1.6.2

Brickwork

1

Cut out defective exposed new joints to a depth of approximately 20 mm and repoint. Remove mortar droppings and other foreign substances from the wall surfaces. First wet surfaces with clean water and then wash down with a solution of soapless detergent specially prepared for cleaning brick. Brush with a stiff fibre brush and immediately after, hose down with clean water. Clean surfaces from any traces of detergent, foreign streaks or stains of any nature. Protect adjoining construction materials during cleaning operations. Use of muratic acid for cleaning brickwork is prohibited.

1.6.3

Concrete Masonry Units

1

Immediately following setting, brush exposed surfaces free of mortar or other foreign matter.

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END OF PART

QCS 2014

Section 13: Masonry Part 02: Mortar and Grout

Page 1

2

MORTAR AND GROUT ................................................................................. 2

2.1

GENERAL DESCRIPTION ............................................................................ 2

2.1.1 2.1.2

Scope References

2.2

MORTAR MATERIALS .................................................................................. 2

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

Preparation Requirements Cement Aggregates Water Lime

2.3

EPOXY .......................................................................................................... 4

2.3.1


2.4

HIGH BOND .................................................................................................. 4

2.5

GROUTS ....................................................................................................... 4

2.5.1


2.6

PIGMENTS FOR COLOUR ........................................................................... 5

2.6.1


2.7

TUCK POINTING ........................................................................................... 5

2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6 2.7.7

General Protection Existing Mortar Joints Installation of Tuck Pointing Mortar Tooling of Joints Replacement of Masonry Units Cleaning

2 3 3 3 3

4

4

5

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2

MORTAR AND GROUT

2.1

GENERAL DESCRIPTION

2.1.1

Scope

1

This Section specifies mortar and grout for masonry, glass blocks and stone work.

2


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Unit Masonry Reinforced Unit Masonry Masonry Laying Concrete

References

1


ta

2.1.2

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This Section Part 2 Part 3 Part 5 Section 5

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ASTM C270 ................Standard Specification for Mortar for Unit Masonry BS EN 459-1 ..............Building lime. Definitions, specifications and conformity criteria

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BS EN 934-3 ..............Admixtures for concrete, mortar and grout. Admixtures for masonry mortar. Definitions, requirements, conformity and marking and labelling BS EN 998-2 ..............Specification for mortar for masonry. Masonry mortar evaluation

of

conformity,

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BS EN 12004 .............Adhesives for tiles. Requirements, classification and designation

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BS EN 12878 .............Pigments for the colouring of building materials based on cement and/or lime. Specifications and methods of test

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BS EN 13888 .............Grout for tiles. Requirements, evaluation of conformity, classification and designation

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PD 6472 .....................Guide to specifying the quality of building mortars PD 6678 .....................Guide to the specification of masonry mortar

2.2

MORTAR MATERIALS

2.2.1

Preparation Requirements

1

The required class of mortar, together with the type of mix, shall be as described in the Project Documentation.

QCS 2014

2


Page 3

Mortar shall be mixed only as and when required in the relevant proportions indicated in Table 2.1, until its colour and consistency are uniform. The constituent materials shall be accurately gauged allowance being made for bulking of sand. Table 2.1 Mortar Mixes Nominal Mix by mass and their compressive strength Cement (C), Lime (L) & Sand Cement (C) & Sand (S) Compressive (S) with or without entrainment with or without entrainment strength at 28 days Class (kg) (kg) 2 N/ mm C L S C S 740

85

775

M4

105

35

725

110

755

M6

135

25

700

155

710

M12

190

20

655

190

675

2

.

50

.l. l

70

4 6

12

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M2

The inclusion of mortar plasticisers will not be permitted without approval of the Engineer.

4

All mortar shall be conveyed fresh to the works as required for use. Mortar which has begun to set or which has been site-mixed for a period of more than one hour in the cases of Classes M2, and M6, and two hours in the case of classes M4 and M12 shall not be used.

5

Plasticizing and set retarding mortar admixtures shall comply with BS EN 934-3 and shall be supplied with instructions for use.

6

Ready-mixed lime: sand for mortar and ready-to-use retarded mortar shall comply with the relevant provisions of BS EN 998-2 or ASTM C270.

2.2.2

Cement

1

Cement is to comply with the relevant provisions of Section 5, Concrete.

2

Mortar for use in contact with the ground will be mixed using sulphate resistant cement and comply with the relevant provisions of Section 5, Concrete.

2.2.3

Aggregates

1

Aggregates are to generally comply with the relevant provisions of Section 5, Concrete.

2.2.4

Water

1

Water is to comply with the relevant provisions of Section 5, Concrete.

2.2.5

Lime

1

Lime for mortar shall be in the form of lime putty, complying with the relevant provisions of BS EN 459-1.

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EPOXY

2.3.1


1

Epoxy grouts shall comply with the relevant provisions of BS EN 12004, BS EN 13888 as applicable.

2.4

HIGH BOND

1

Mortar mixture is to consist of, by volume, one-part Portland cement, three-parts sand with addition of water and liquid acrylic resin.

2

The mortar will have the following properties when tested in accordance with the relevant provisions of PD 6678:

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2.3

compressive strength : minimum 20 N/mm², using 50 x 50 x 50 mm cubes

(b)

tensile strength :

minimum 4 N/mm², using the 25 x 25 x 25 mm briquettes

(c)

flexural strength :

minimum 6 N/mm², using flexural bar

(d)

brick bond strength :

minimum 3 N/mm², using crossed brick.

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(a)

GROUTS

2.5.1


1

The required class of mortar, together with the type of mix, shall be as described in the Project Documentation.

2

Cement grout shall be mixed in the relevant proportions indicated in the Table 2.2 using the minimum quantity of water to ensure the necessary fluidity and to render it capable of penetrating the work.

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Table 2.2 Grout Mixes

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Class G1 G2 G3 G4 G5 G6

Nominal Mix by Mass Cement

Sand

pfa

1 1 1 1 1 1

3 10 -

10 4 ½

3

Cement grout shall be used within one hour of mixing, except where containing a retardant admixture.

4

Sulfate-resisting cement shall not be used as a constituent of grouts containing pulverised fuel ash.

5

Grout to have a compressive strength of 17,500 kPa at 28 days.

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Page 5

PIGMENTS FOR COLOUR

2.6.1


1

Mineral pigments only to be used.

2

Any pigments used to colour cement or cement products should meet the requirements of BS EN 12878.

3

Pigments shall be inert, stable to atmospheric conditions, alkali resistant and water insoluble.

2.7

TUCK POINTING

2.7.1

General

1

This Clause specifies the requirements for tuck pointing of existing masonry and stone work.

2

Mortars to comply with the relevant provisions of Clause 2.2 of this Part.

2.7.2

Protection

1

Newly pointed joints are to be protected from rain, until pointed joints are sufficiently hard enough to prevent damage.

2.7.3

Existing Mortar Joints

1

The existing mortar joints (both bed and head joints) are to be cut out and removed by means of a toothing chisel or a special pointer’s grinder, to a uniform depth of 20mm, or until sound mortar is reached. Care is to be taken so as not to damage the edges of existing masonry units.

1

Remove all dust and debris from the joints by brushing, blowing with air or rinsing with water.

2.7.4

Installation of Tuck Pointing Mortar

1

Immediately prior to application of mortar, the joints to be tuck-pointed are to be dampened. After dampening, the masonry units should be allowed to absorb all surface water prior to application of pointing mortar

2

The mortar is to be tightly packed into the joints in thin layers, approximately 5 mm thick maximum.

3

Each layer should become “thumbprint hard” before applying the next layer.

4

The final layer is to be flush with surfaces of masonry units. When the mortar becomes “thumbprint hard”, joints can be tooled.

2.7.5

Tooling of Joints

1

A jointing tool is to be used to produce a smooth, compacted, concaved joint.

2

Tool joints in patch work are to be finished to match the existing surrounding joints.

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2.6

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Replacement of Masonry Units

1

Mortar joints surrounding masonry units which are to be removed and replaced are to be cutout with a toothing chisel. The units which are to be removed may be broken and removed, provided that the surrounding units to remain are not damaged. Once the units are removed, old mortar is to be carefully chiselled out, and all dust and debris are to be swept out with a brush. If the units are located in a cavity wall, care should be exercised not to allow debris to fall into the cavity.

2

The surface of the surrounding units are to be dampened before the new units are placed. The existing masonry should absorb all surface moisture prior to the installation of the new replacement units. The contact surfaces of the existing masonry and the new replacement masonry units are to be buttered with mortar. The replacement masonry units should be centred in the opening and pressed into position. Excess mortar is to be removed with a trowel head and bed joints are to pointed. When the mortar becomes “thumbprint hard”, joints are to be tooled.

2.7.7

Cleaning

1

Exposed masonry surfaces shall be cleaned on completion.

2

Mortar droppings and other foreign substances shall be removed from the wall surfaces.

3

Surfaces shall be wetted with clean water, and then washed down with a solution of soapless detergent specially prepared for cleaning masonry. Brush with stiff fibre brushes while washing, and immediately thereafter hose down with clean water. Free clean surfaces from any traces of detergent, foreign streaks or stains of any nature.

4

Protect adjoining construction materials during cleaning operations.

5

Use of muratic acid for cleaning brickwork is prohibited.

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2.7.6

END OF PART

QCS 2014

Section 13: Masonry Part 03: Accessories

Page 1

3

ACCESSORIES ............................................................................................. 2

3.1

GENERAL DESCRIPTION ............................................................................ 2

3.1.1 3.1.2

Scope References

3.2

ANCHOR AND TIE SYSTEMS ...................................................................... 2

3.2.1

Cavity Wall Ties

3.3

CONTROL JOINTS........................................................................................ 3

3.3.1

Movement Joints

3.4

JOINT REINFORCEMENT ............................................................................ 3

3.4.1

Reinforcement for Concrete Block Masonry

3.5

LINTELS ........................................................................................................ 3

3.5.1

Precast or Cast In-situ Lintels

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ACCESSORIES

3.1

GENERAL DESCRIPTION

3.1.1

Scope

1

This Part specifies anchor and tie system, joint control, reinforcement and lintels associated with masonry works.

2

Related Parts and Sections are as follows: General Masonry Laying

Section 1 Section 6

General Concrete

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3

References

1


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3.1.2

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BS EN 845-1:2003+A1:2008 Specification for ancillary components for masonry. Ties, tension straps, hangers and brackets

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BS EN 10346:2009 ....Continuously hot-dip coated steel flat products. Technical delivery conditions

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BS EN 10143:2006, ...Continuously hot-dip coated steel sheet and strip. Tolerances on dimensions and shape

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BS EN 13658-2:2005 .Metal lath and beads. Definitions, requirements and test methods. External rendering

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GSO ISO 4998:2007, .Continuous hot-dip zinc-coated carbon steel sheet of structural quality

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ISO 14657:2005, .......Zinc-coated steel for the reinforcement of concrete

3.2

ANCHOR AND TIE SYSTEMS

3.2.1

Cavity Wall Ties

1

Cavity wall ties to comply with BS EN 845-1 and be of one of the following types as directed by the Engineer or as noted in the Project Documentation: (a)

Butterfly wall tie fabricated from stainless steel wire

(b)

Double triangle wall tie fabricated from stainless steel wire

(c)

Vertical-twist tie fabricated from stainless steel strip.

2

Ties fabricated from wire are not be used for cavities exceeding 75 mm.

3

All connections between masonry walls or partitions and concrete columns or walls shall be made using propriety stainless steel ties secured to stainless steel fixing channels embedded in the concrete.

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CONTROL JOINTS

3.3.1

Movement Joints

1

Movement joints to be 12 mm wide and formed where indicated or where continuous runs of block walling exceed 8 metres in length.

2

The joints are to be straight and vertically formed with uncut faces of the blocks to each side and filled with an approved compressible material manufactured specifically for building into movement joints.

3

External joints are to be sealed with a mastic compatible with the joint filling material when the block walling is thoroughly dry and the joint surfaces have been cleaned with a wire brush or mechanical tool.

4

A primer is to be applied to the joint surface if specified by the manufacturer of the mastic.

5

Mastic sealing to unfilled movement joints to be on an approved foam backing strip placed to ensure the correct depth of sealant.

3.4

JOINT REINFORCEMENT

3.4.1

Reinforcement for Concrete Block Masonry

1

Expanded mesh lath reinforcement is to be fabricated from minimum nominal thickness 0.3 mm as per BS EN 13658-2:2005 , or welded wire lath or mesh with a minimum weight of 0.87 kg/m² as per BS EN 13658-2:2005; or Zinc coated steel with one of the surface quality Types "B" or “C” with minimum zinc coating - 225 g/m² as per BS EN 10346:2009, as directed by the Engineer or Project Documentation.

2

The widths of reinforcement for various wall thicknesses to comply with Table 3.1.

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3.3

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Table 3.1 Expanded Steel Mesh Joint Reinforcement Widths

Block Thickness (mm)

Reinforcement Width (mm)

100

50

150

60

200

110

3.5

LINTELS

3.5.1

Precast or Cast In-situ Lintels

1

Precast or cast in-situ lintels to be manufactured in accordance with the relevant provisions of Section 5.

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2

An open joint not less than 12 mm are to be left between the ends of precast or cast in-situ concrete lintels and the blocks adjacent to these ends. These open joints should be left as long as possible during construction and not be filled in until plastering or other works necessitate such filling.

3

Lintels are to have a minimum end bearing of 200 mm.

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END OF PART

QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 1

UNIT MASONRY ...................................................................................................................... 2

4.1 4.1.1 4.1.2 4.1.3

general ..................................................................................................................................... 2 Scope 2 References 2 Definitions: 3

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7

clay masonry units ................................................................................................................... 3 Clay Bricks 3 Clay Blocks 3 Classification of Clay Masonry Units 3 Requirements of Clay Masonry Units 3 Marking of Clay Blocks 5 Testing of Clay Blocks 5 Criteria of Technical Conformity of Clay Blocks 5

4.3 4.3.1

Calcium Silicate Bricks ............................................................................................................. 6 General Requirements 6

4.4 4.4.1 4.4.2 4.4.3 4.4.4

concrete masonry units ............................................................................................................ 6 Concrete Blocks 6 Manufacture of Concrete Blocks 8 Block Dimensions 9 Precast Concrete Bricks 9

4.5 4.5.1 4.5.2 4.5.3 4.5.4

glass units .............................................................................................................................. 10 General Requirements 10 Submittals 10 Material Storage and Handling 10 Laying 10

4.6 4.6.1

gypsum units .......................................................................................................................... 11 General Requirements 11

4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10

STONE Work ......................................................................................................................... 11 General Requirements 11 Anchorage Devices 11 Mortar 12 Fabrication 12 Installation 12 Wall Cladding 13 Paving and Flooring 13 Erection Tolerances 14 Submittals 14 Visual Mock-ups 14

4.8 4.8.1 4.8.2 4.8.3 4.8.4

CASt stone ............................................................................................................................. 15 General Requirements 15 Submittals 15 Product Delivery, Storage and Handling 15 Anchorage Devices 15

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4

UNIT MASONRY

4.1

GENERAL

4.1.1

Scope

1

This Part specifies clay and concrete masonry units.

2

Approval from Qatar Standards shall be obtained for masonry units intended to be used in elements subject to thermal insulation.

3

Related Parts and Sections are as follows: General Mortar And Grout Accessories Masonry Laying


General Concrete Thermal Insulation of Buildings

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This Section Part 1 Part 2 Part 3 Part 5

References

1


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ASTM C270 ................Standard Specification for Mortar for Unit Masonry

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ASTM C1364 ..............Standard Specification for Architectural Cast Stone BS 187........................Calcium silicate bricks

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BS 1217 .....................Cast stone

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BS 6073-2 ..................Precast concrete masonry units. Guide for specifying precast concrete masonry units

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BS EN 771 .................Specification for masonry units BS EN 772-2 ..............Methods of test for masonry units. Determination of percentage area of voids in masonry units (by paper indentation) BS EN 771-3 ..............Specification for masonry units. Aggregate concrete masonry units (dense and light-weight aggregates) BS EN 771-5 ..............Specification for masonry units. Manufactured stone masonry units EN 771-1 ....................Specification for masonry units. Clay masonry units EN 771-2 ....................Specification for masonry units. Calcium silicate masonry units EN 998-2 ....................Specification for mortar for masonry. Masonry mortar PD 6678 .....................Guide to the specification of masonry mortar

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Definitions:

1

Aggregate: granular material used in construction and may be natural, manufactured or recycled.

2

Natural aggregate: aggregate from mineral sources which has been subjected to nothing more than mechanical processing.

3

Manufactured aggregate: aggregate of mineral origin resulting from an industrial process involving thermal or other modification.

4

Recycled aggregate: aggregate resulting from the processing of inorganic material previously used in construction.

5

Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding 2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.

4.2

CLAY MASONRY UNITS

4.2.1

Clay Bricks

1

A clay brick is a masonry unit not exceeding 290 mm in length and 115 mm in height.

2

Semi-solid bricks are bricks having up to 25 % holes or cavities of their gross volume.

3

Cellular bricks contain the same voids as hollow bricks but with the cavities closed at one end.

4

Clay bricks to conform to the requirement of EN 771-1.

4.2.2

Clay Blocks

1

A clay block is a masonry unit which exceeds in any of its normal dimensions the maximum dimensions given for clay bricks in Clause 4.2.1-1.

4.2.3

Classification of Clay Masonry Units

1

Units shall be classified as follows:

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4.1.3

(a)

non-load-bearing blocks

(b)

blocks produced for use in non-load-bearing walls

(c)

load-bearing blocks

(d)

blocks produced for use in load-bearing walls.

4.2.4

Requirements of Clay Masonry Units

1

Clay masonry units shall be of a uniform shape, free from surface cracks which decrease its properties. Its outer surface shall be serrated to increase the bonding force with the mortar. It should be well burnt, of a uniform texture and free from pebbles of lime.

2

The dimensions of the clay masonry blocks for walls to be as given in Table 4.1.

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Table 4.1 Dimensions of Clay Masonry Blocks Nominal Dimensions (mm) Length

Width

Height

Length

Width

Height

300

100

200

290

100

190

300

150

200

290

150

190

300

200

200

290

200

190

400

100

200

390

100

190

400

150

200

390

150

190

400

200

200

390

200

190

The tolerance in the actual dimensions of the blocks shall be ±4 %, provided that the difference between the largest actual dimension and the smallest one in the same consignment does not exceed 5 % as shown in Table 4.2.

Width

390

406

375

20

290

302

278

15

200

208

192

10

156

144

7.5

198

182

10

Smallest

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150 Height

Permissible difference between largest actual size and smallest one in one (consignment)

Largest

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Length

Permissible size (mm)

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Size (mm)

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Dimension

ta

Table 4.2 Dimensional tolerance

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Actual Dimensions (mm)

Adjacent faces of the units are to be at right angles, and the tolerance of the squareness not to exceed 2 mm for each 100 mm length.

5

The faces should have a plain surface, and the tolerance not to exceed 5 mm from the straight line.

6

Water absorption of the units shall not exceed 25 % by weight for the individual block and 20 % by weight for the average of tested blocks.

7

The compressive strength of the units, calculated for the total area including holes shall not to be less than the limits shown in Table 4.3.

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Table 4.3 Compressive Strength Class of Block

Minimum Value for Compressive Strength of One Block

Minimum Average of the Compressive Strength

N/mm²

(kg/cm²)

N/mm²

(kg/cm²)

6

6

(60)

7.5

(75)

Class 12

12

(120)

15

(150)

Class

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4.2.5

Marking of Clay Blocks

1

Every clay block is to be marked with the name of the manufacturer and/or his registered mark.

2

The class of block should be shown on every load-bearing block.

4.2.6

Testing of Clay Blocks

1

The following tests are to be carried out on the representative sample taken according to Clause 4.2.6-3 of this Part: appearance

(b)

dimensions

(c)

compressive strength

(d)

water absorption (optional)

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Appearance and dimension tests are to be carried out on the same units that are to be tested for compressive strength and water adsorption. Appearance and dimension tests are to be carried out before the other referenced tests.

3

A representative sample is to be taken from the consignment not exceeding 15,000 blocks as shown in Table 4.4. As for consignments exceeding that number, one excess block is to be taken for each 1,000 additional blocks. The sample is to be taken at random during loading or unloading by dividing the consignment into a convenient number of real or imaginary sections. From each section, a corresponding number of units are to be taken, provided that the total number of samples units is equal as shown in Table 4.4.

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Table 4.4 Sample Sizes Number of units for each test Appearance and size measurements (mandatory) Compressive strength (mandatory)

Water absorption (optional)

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Number of units in consignment

5,000 or less

5

3

More than 5,000 and up to 10,000

10

5

More than 10,000 and up to 15,000

15

10

4

The methods of test for clay bricks shall be in accordance with the relevant provisions of EN 771-1.

4.2.7

Criteria of Technical Conformity of Clay Blocks

1

The consignment is to be accompanied with a certificate indicating its conformity with all the requirements of this standard.

2

The consignment is to be considered complying with this standard if the representative sample passes all the mandatory tests mentioned in this standard.

QCS 2014

3

Page 6

Compressive test : the consignment will be considered complying with this standard if the following two conditions are fulfilled: (a)

each of the tested blocks meets the minimum limit of compressive strength mentioned in this standard

(b)

the tested blocks meet the minimum limit of the average compressive strength mentioned in this standard.

Water absorption : the consignment is to be considered complying with this standard if the following two conditions are fulfilled: (a)

each tested block should meet the minimum limit of water absorption mentioned in this standard

(b)

the average water absorption for the tested blocks will meet the minimum limit of the average water absorption mentioned in this standard.

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If the tested units do not comply with the requirements of the appearance, dimension and/or absorption tests, other units may be taken for testing. If these units do not pass the test(s), the consignment is to be considered non-complying with this standard.

4.3

CALCIUM SILICATE BRICKS

4.3.1


1

Calcium silicate bricks are to conform to the requirements of EN 771-2.

2

The brick is to be constructed of sand consisting mainly of quartz or uncrushed siliceous gravel or crushed siliceous gravel or crushed rock or a combination of such materials.

3

Suitable pigments may be mixed into the constituents to produced bricks of the required colour.

4.4

CONCRETE MASONRY UNITS

4.4.1

Concrete Blocks

1

Blocks are to be made with Portland cement unless used below ground level in which case sulphate resisting Portland cement shall be used.

2

All blocks are to be manufactured, supplied and tested in accordance with BS EN 771-3, BS 6073-2, and approved by Qatar Standards.

3

Recycled Aggregates may be used to replace up to 50% of natural coarse aggregates when 2 the average compressive strength is equal to or greater than 7.0 MPa (N/mm ).

4

Recycled Aggregates may be used to replace up to 100% of natural aggregates (fine and 2 coarse) when the average compressive strength is less than 7.0 MPa (N/mm ).

5

Aggregate shall meet the following requirements:

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(a)

The manufacturer shall declare the materials to be used, the percentage of each material, their grading and shall be responsible for their suitability.

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Page 7

(b)

The acid soluble sulphate, as measured by BS EN 1744-1, shall not exceed 0.8% by weight of aggregate.

(c)

The acid soluble chloride, as measured by BS EN 1744-5, shall not exceed 0.2% by weight of aggregate.

The use of blocks shall comply with Table 4.5. The minimum compressive strength of the average of 3 blocks shall be as given in Table 4.5. The associated mortar requirements for use with different applications for blocks is also provided in Table 4.5. Details of mixes for the class of mortar specified is provided in Part 2 of this Section. Table 4.5 Compressive Strength

.

Uses for which Blocks are Suitable

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Minimum Compressive 2 Strength (N/mm )

Class of Mortar

Average of 3 Blocks

Lowest Individual Block

1

7.0

5.6

External non-load bearing walls

2

10.4

8.3

Load bearing walls

3

17.4

14

4

14.0

11.2

5

4.0

3.6

Internal non-load bearing walls

M6

5

4.0

3.6

Roof Block

M4

5

4.0

Protective skins to foundations

M6

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Classes

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Classification

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M6

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M6 M12

Soakaways and manholes

M12

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Load bearing walls below ground

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3.6

Manufacturer should label or clearly define the classification or the uses of the blocks in factory.

8

Consultant or contractor should also mention the classification or the uses of the blocks in request sheet when the samples submit for testing in laboratory.

9

The volume of the cavities in the block shall not exceed 50 % of the gross volume of the block. The overall dimensions and wall and web thicknesses shall comply with Table 4.6.

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Table 4.6 Block Dimensions and Wall and Web Thicknesses Minimum Thickness (mm)

Coordinating (nominal) size (mm)

Work size (mm)

400 x 200 x 100

Wall

Web

390 x 190 x 100

19

19

400 x 200 x 150

390 x 190 x 150

25

25

400 x 200 x 200

390 x 190 x 200

32

30

Notes: (a) (b)

Co-ordinating size is the size of the space allocated to the block including the joints and tolerances. Work size is the actual size for manufacture within the tolerances specified.

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Page 8

Subject to the tolerances specified in Table 4.7 and to any requirement for blocks with special faces, all surfaces should be flat and rectangular and adjacent surfaces are to be at right angles to one another with clearly defined undamaged arises. Table 4.7 Block Tolerances Dimensions

Work Size of Block

Length

+ 3 mm to - 5 mm

Height

+ 3 mm to - 5 mm

Thickness

 2 mm for any measurement  1.5 mm for the average of 7 measurements in any one block.

Unless otherwise specified, all block faces are to provide a satisfactory bond for mortar, plastering or rendering.

12

Each block manufactured from sulphate resisting cement is to be colour coded with an identifying mark.

13

All connections between masonry walls or partitions and concrete columns or walls shall be made using propriety stainless steel ties secured to stainless steel fixing channels embedded in the concrete.

14

Full Water Absorption:

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Water absorption by capillarity method:

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The average water absorption of the tested sample shall not exceed 7% and no individual block shall have a water absorption greater than 7.5% (in accordance with CML Method 997).

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The manufacturer shall declare in g/m²s the maximum water absorption coefficient due to capillarity action of the exposed face of the unit.(according to EN 771-3:2003 ) Manufacture of Concrete Blocks

1

Blocks are to be manufactured in a vibrated/pressure block making machine using cement and aggregate in the proportions required to produce the minimum strengths given in Table 4.5.

2

The design of the cavities and webs in hollow blocks is to be submitted to the Engineer for approval before production commences.

3

The materials to be mixed in a mechanical mixer and placed in the block-making machine in layers not exceeding 100 mm, each layer being thoroughly vibrated and compacted before the addition of the next.

4

Immediately after manufacture the blocks are to be stacked on clean, level, non-absorbent pallets in honeycomb fashion. The pallets are to be marked with the date of production (in English and Arabic) and stored in a level curing and stacking area in such a manner that one day’s production is separated from the next.

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Blocks manufactured from mobile machines are to be cast on to a clean concrete hardstanding. Each day’s production shall be easily identifiable and kept separate from the next.

6

All blocks, however manufactured, are to be immediately protected from the effects of the sun and wind by suitable moisture retaining coverings.

4.4.3

Block Dimensions

1

Block dimensions are to be measured in accordance with BS EN 772-2.

2

Blocks not exceeding 75 mm thick and blocks for use in the ground are to be solid unless otherwise directed. All other blockwork is to be hollow.

4.4.4

Precast Concrete Bricks

1

Precast concrete bricks are to conform to the requirements of BS 6073-2.

2

Precast concrete bricks are to be manufactured by compacting concrete under high pressure into a mould.

3

The pressure employed is to be such that a high initial strength is achieved, enabling the brick to be removed immediately, by extrusion, from the mould.

4

The cement used should be rapid hardening Portland cement and conform to the requirements Part 3 of Section 5.

5

The aggregate used to be sand or manufactured sand.

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GLASS UNITS

4.5.1


1

Glazing units shall incorporate expansion-contraction thermal foam tape, sealants, flashings, and other items necessary for complete installation.

4.5.2

Submittals

1

The Contractor shall submit assembly instructions and installation drawings as required to indicate methods on construction, location and spacing of anchorage, joinery, finishes, sizes, shape, thickness of all materials and relationship to the adjoining work.

4.5.3

Material Storage and Handling

1

Material shall be stored in a dry place, off the ground, where temperature will not exceed 32 ºC handle material to prevent damage to finished surfaces. Do not install scratched or damaged components.

2

After installation, finished surfaces shall be protected from damage caused by ensuing work.

4.5.4

Laying

1

The Contractor shall verify all applicable field dimensions and adjust as necessary to accommodate the glazed wall.

2

The glass block grid system for the wall shall be assembled and sealed in accordance with instructions furnished by the manufacturer.

3

The assembled glass block grid system frame shall be placed into a properly prepared and sized rough opening and adjust until plumb and level. The grid system shall be screwed or nailed into place utilising all predrilled holes in the nailing flange.

4

A foam tape gasket shall be adhered to each of the glass blocks according to instructions furnished by manufacturer of the glass block grid system. The glass blocks shall be carefully inserted into the grid system from the exterior side of the wall so that each block is pressed against the T-Bar and the foam tape does not roll back.

5

Sealant to completely fill the channel shall be applied around each glass block and wipe flush with the surface. The sealant shall be applied to the exterior frame corners according to instruction furnished by the grid system manufacturer.

6

All exposed surfaces of the glass block grid system shall be cleaned with a clean, soft cloth and mild hand soap using gentle rubbing action. Abrasive or solvent-type cleaner, detergents or paint removers shall not be used.

7

All labels shall be removed from the glass blocks and cleaned with a soft cloth and water.

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4.5

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4.6

GYPSUM UNITS

4.6.1


1

Blocks for claustra walls are to be manufactured and built generally in accordance with the preceding clauses for blockwork, except where otherwise noted below.

2

Blocks may be constructed of either white gypsum plaster

(b)

concrete

(c)

white concrete using white Portland cement and white aggregates, as described in the relevant provisions of Section 5, Concrete, or as described in the Project Documentation.

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(a)

All blocks are to be finished with a fine finish to an approved ornamental pattern and are to be 100 m thick unless otherwise noted with slots in ends of blocks to receive reinforcement.

4

Claustra walls should be built with vertical straight joints reinforced with 12 mm mild steel reinforcing bars vertically at each straight joint pinned to structure at each end and surrounded solid with mortar.

5

Blocks are to be bedded in a mixture of white cement and sand (1:4) and struck pointed to approval.

4.7

STONE WORK

4.7.1


1

Stone work includes rough cut stone, marble, limestone, granite.

2

Stone work shall be executed by an approved specialist sub-Contractor

3

Stone should be sound and free from defects which would impair strength, durability or appearance. Each species of stone is to be provided from a single quarry. Quarries and fabrication plants should be available for inspection by the Engineer.

4

All stone to be of soundness (hardness and density), texture, graining colour, tone and range matching the Engineer’s sample.

5

Dielectric separator: Bituminous paint is to be used in accordance with the manufacturer’s instructions and shall be approved by the Engineer.

6

Cushions: Clear plastic or neoprene, 25 by 50 mm, thickness as required.

4.7.2

Anchorage Devices

1

Anchors, dowels, cramps, plug anchors, angles, relieving anchors: Fabricated of stainless steel or non ferrous metal (e.g. bronze) complying with thickness as required to system imposed loads but not less than 5 mm.

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Embedded items shall be of malleable iron castings or steel fabrications, thickness as required to sustain imposed loads but not less than 5 mm thick products to be stainless steel or non-ferrous. Devices embedded in concrete or masonry include the following: (a)

edge inserts with tee-shaped wedge-action slot, with askew head bolt, washer and nut

(b)

dovetail anchor slots of size to receive specified anchor, filled with waterproof filler and open face sealed

(c)

adjustable insert with square nut slinging in integral track.

Reinforcing mesh used for anchorage shall be stainless steel.

4.7.3

Mortar

1

Mortar shall comply with the relevant provisions of Part 2 of this Section. The cement used for stone work mortar shall be white Portland cement. The Class of mortar

2

Mortar for setting stone flooring, steps and treads shall be Class M7 mortar. The grout shall incorporate a waterproofing additive for wet area flooring.

3

Mortar for setting all other stone shall be Class M3 mortar. The mortar shall incorporate a waterproofing additive for wet areas and exterior stone. The mortar shall incorporate a shrinkage-reducing accelerator diluted with water in the ratio as recommended by the manufacturer.

4

Pointing mortar: shall be Class M5 mortar with a mineral colouring admixture as required to match the stone. The mortar shall incorporate a waterproof additive for exterior and wet area pointing.

4.7.4

Fabrication

1

The Contractor shall accurately cut, dress, drill, fit and finish stonework to shapes and dimension shown on the approved Shop Drawings. Exposed plane surfaces shall be made true in line and exposed curved surfaces true in radius. The thickness of the stone shown is the minimum thickness.

2

For wall facings, the Contractor shall do the following:

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(a)

cut exposed external corners of stone as shown

(b)

ease exposed external edges where shown

(c)

cut all other joints and edges square and at right angles to face, and with backs parallel to face

(d)

make arises straight, sharp, true and continuous at joints

(e)

cut curved stone panels true to radius as shown to produce an even, flush curved surface.

4.7.5

Installation

1

Dovetail anchor slots, wedge type inserts, and other items requiring building in to concrete or masonry work shall be furnished in sufficient time so as not to delay the progress of the work. Tie inserts shall be wired into reinforcing to prevent displacement. No forced entry anchorage device will be allowed.

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Stone shall be set in accordance with the approved Shop Drawings, level, plumb, square and true with uniform joints, accurately aligned with grain running in the direction as approved by the Engineer unless otherwise stated elsewhere in the Project Documentation. The work shall match mock-ups.

3

Dowels, anchors and ties in shall be provided in sufficient quantity to eliminate “rattle” or loose pieces and to ensure a rigid installation. The extent of the anchorage and installation details shown are intended to indicate minimum requirements. In general, a minimum of one 2 anchor per 0.18 m is required, with additional anchorage provided where necessitated by the size, thickness and setting or shape.

4

Steel backup support shall be provided for the stone work where shown on the Project Drawings and as required to provide rigid installation. Steel support framing shall be anchored securely to the building structure.

4.7.6

Wall Cladding

1

Relieving angles shall be set as required for the proper support of stone. Before setting, the Contractor shall clean the stones and the backing. The stone shall be saturated with water before setting in mortar in order to prevent total absorption of moisture from the mortar.

2

Stone shall be set with two cushions per stone in every horizontal joint, extending full depth of the stone and to within the dimension from the face as shown. Secure with anchors, dowels, and cramps of approved construction, as required for a rigid and secure installation. Fill anchorage holes with accelerated setting mortar. Rigidly secure strap anchors to the backing.

3

Flashing materials shall be repaired to their original condition where they have been punctured by anchorage or damaged during setting.

4

Cavities shall be kept behind the facing free of mortar or other foreign material.

5

Fill and seal joints as indicated in the Project Documentation.

4.7.7

Paving and Flooring

1

The following shall be performed by the Contractor when laying paving and flooring:

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(a)

place reinforcing mesh in the setting bed

(b)

tamp the stone into the setting bed with mallet until firmly bedded to the proper level

(c)

remove stone, cover the back of the stone with wet cement and return to position on the setting bed; before applying the wet cement, wet the back of the stone to prevent major absorption of moisture from the cement

(d)

use cushions and spacers to maintain uniform jointing and setting.

Joints shall be grouted with water and neat cement by buttering the edges of the stones as they are laid. Surplus joint cement cleaned from face of the stone immediately.

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Page 14

3

Where grinding is required to completely align and level joints, permit a minimum of six days of setting time to elapse before commencing grinding. Perform grinding by wet abrasion, in a manner as to retain the finish, to match the balance of stone paving, and so as to be free of depressions and grind marks. The Contractor shall exercise care to avoid damage to or soiling of adjacent work.

4.7.8

Erection Tolerances

1

The following maximum non-cumulative erection tolerances shall be complied with: variation from plumb

+/- 3 mm in storey height

(b)

variation from level

+/- 3 mm in any bay

(c)

variation in location

+/- 6 mm in any bay

(d)

edge alignment

1.5 mm

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(a)

Submittals

1

Submittals shall be made in accordance with the relevant provisions of Section 1, General and the following Clauses.

2

Shop Drawings: The Contractor shall submit shop drawings of the stonework showing in detail the layout, jointing, anchors and dowels, dimensions, sizes and locations of cut-outs, adjoining work, etc. Each piece on the Shop Drawings is to correspond to the identification number on the back of each stone. The Contractor shall co-ordinate all components which are specified elsewhere (flashing, insulation) which comprise the system into this submittal. Shop Drawings shall be co-ordinated with all related trades.

3

Samples: The Contractor shall submit to the Engineer 600 x 600 mm sample panels with cross-joints to show the sealant materials of each type and finish of stone required. The samples shall show the full range of colour and texture expected in the finished work. In addition the Contractor shall submit one (1) full size sample of each type and finish, falling in the average colour and texture range. The Engineer’s review and approval of the sample is to be for colour, texture and pattern only. Compliance with all other requirements is the exclusive responsibility of the Contractor.

4.7.10

Visual Mock-ups

1

Following the approval of the samples, the Contractor shall construct mock-ups for approval by the Engineer prior to installation. Mock-ups to be provided shall be as follows:

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4.7.9

(a)

wall facing: assembled to simulate the final condition, direction of graining, and indicating joint conditions, use of spacers, shims, anchorage, relieving angles, supports, and all other features of the final work

(b)

flooring: samples of flooring/skirting, etc, of each type of stone work specified is to consist of a full pattern and be complete with all anchors, bedding, jointing, sealers, etc., in accordance with approved shop drawings

(c)

provide mock-up for any other stonework as shown on the drawings and as required by the Engineer.

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CAST STONE

4.8.1


1

The requirements for manufactured stone for vertical applications and for trim, including copings and sills shall comply with the relevant provisions of BS 1217 or ASTM C1364 and reconstructed masonry shall comply with the relevant provisions of BS EN 771-5.

2

Cast stone work is to be executed by an approved specialist subcontractor.

3

All cast stone is to be sound and free from defects which would impair strength, durability or appearance. Each type of stone is to be supplied from the same quarry. Quarries and fabrication plants are to be available for inspection by the Engineer.

4

Joint sealing compounds used with stone will conform to Section 24, Part 15.

4.8.2

Submittals

1

Samples: The Contractor shall supply cast stone sample panels, size 200 x 200 x 300 mm, for each colour and finish of stone for approval by the Engineer.

2

Shop Drawings: The Contractor shall provide drawings of cast stone work showing anchorages for the approval of the Engineer.

3

Certificates: The Contractor shall provide certification documentation as necessary, describing in detail testing laboratory facilities and qualifications of its principals and key personnel. The Contractor shall also provide certification that the cast stone meets requirements of the Project Documentation.

4.8.3

Product Delivery, Storage and Handling

1

Cast stone shall be cured for a minimum of 30 days before delivery. Each unit is to have the date of manufacture impressed in the back of the stone.

2

Cast stone shall be stored under waterproof covers on boarding clear of the ground and shall be protected from handling damage, dirt, stain, water and wind.

4.8.4

Anchorage Devices

1

Coping stones shall be anchored to the masonry with no less than two dowels to each stone. Dowels may be either 8 mm stainless steel pipe 75 mm long or 12 mm diameter stainless steel bars 75 mm long.

2

Course stones shall be anchored to the backing with one metal anchor for each 600 mm in length. Each stone shall have not less than two anchors. Anchors are to be stainless steel 4 mm x 30 mm with the end in the stone turned down 25 mm and other end turned up to 50 mm

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4.8

END OF PART

Section 13: Masonry Part 05: Masonry Laying

Page 1

5

MASONRY LAYING....................................................................................... 3

5.1

INTRODUCTION ........................................................................................... 3

5.1.1 5.1.2

Scope References

5.2

WORKMANSHIP ........................................................................................... 3

5.2.1


5.3

BLOCKWORK................................................................................................ 3

5.3.1 5.3.2 5.3.3

Setting Out of Blockwork Wetting Blockwork Units Laying of Blockwork

5.4

BRICKWORK ................................................................................................. 5

5.4.1 5.4.2

Brickwork Wetting and Brick Wetting Test Brickwork Laying

5.5

REINFORCEMENT........................................................................................ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General Requirements Placing Reinforcing High Lift Grouting of Cavity Walls Low Lift Grouting of Cavity Walls Water Penetration Testing

5.6

FAIR FACED BLOCK WALLS ....................................................................... 8

5.6.1


5.7

OPENINGS .................................................................................................... 8

5.7.1


5.8

INTERSECTING WALLS AND PARTITIONS ................................................ 8

5.8.1


8

5.9

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QCS 2014

CONNECTIONS BETWEEN WALLS OR PARTITIONS AND COLUMNS .... 9

5.9.1


9

5.10

JOINTS BETWEEN PARTITIONS AND FLOOR SOFFITS ........................... 9

3 3

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6 6 7 7 7 8 8

9 9

CAVITY WALLS ........................................................................................... 10

5.12.1 General Requirements 5.13

5 5

FILLING HOLLOW BLOCK WALLS............................................................... 9


3 4 4

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3

10

SERVICES ................................................................................................... 10

5.13.1 General Requirements 5.13.2 Fixings

10 10

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5.14


Page 2

DAMP-PROOF COURSES .......................................................................... 10

5.14.1 General Description 5.15

10

PROTECTION OF FINISHED WALLING..................................................... 11 11

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5.15.1 General Description

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5

MASONRY LAYING

5.1

INTRODUCTION

5.1.1

Scope

1

This Part specifies workmanship and setting out of masonry works.

2

Related Parts and Sections are as follows: Mortar and grout Unit Masonry

Section 6

Concrete

5.1.2

References

1


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BS 743........................Materials for Damp-Proof Courses

BS 6398:1983 ............Specification for bitumen damp-proof courses for masonry

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BS 6515:1984 ............Specification for polyethylene damp-proof courses for masonry

as

BS 8215:1991 ............Code of practice for design and installation of damp-proof courses in masonry construction

WORKMANSHIP

5.2.1


1

Work is to be performed by experienced workers under the direction of a qualified supervisor who is fully aware of the Project requirements. Final work is to be equal to any sample panels submitted to, and approved by, the Engineer.

5.3

BLOCKWORK

5.3.1

Setting Out of Blockwork

1

All blockwork is to be fully set out before laying commences to ensure:

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(a)

correct bonding over all lengths of wall particularly at openings and piers

(b)

minimum cutting

(c)

compliance with Table 5.1

The average thickness of both vertical and horizontal mortar joints is to be 10 mm exclusive of any key in the joint surfaces of the unit.

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Table 5.1 Setting Out of Blockwork Item of Construction

Permissible Deviation (mm)

Type of Dimensions

Size and shape of wall elements

20

At Soffit

30

Height up to 3,000 mm

40

Straightness in 5,000 mm

8

Verticality up to 2,000 mm

15

Level of bed joints in 3,000 mm

15

Position in plan of any point or specified face in relation to nearest grid line on the same level

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Walls

At floor

.

Space between walls

Position in elevation from design position

15

Level of sill or soffit for each 1,000 mm of width

5

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Door, window and other openings

15

with maximum of

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Verticality of any point for each 1,000 mm of height

5 15

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with maximum of

15

Wetting Blockwork Units

1

All blocks are to be adequately wetted with water before they are laid and the tops of walls left off from the previous day’s work are to be similarly wetted before the new work commences.

5.3.3

Laying of Blockwork

1

Block walls are to be built from undamaged blocks in stretcher bond unless otherwise specified.

2

All bed and vertical joints are to be spread with mortar to ensure complete and solid bedding and grouting through the full thickness of the wall. All keys in jointed surfaces must be completely filled.

3

Mortar extending into the cavities of hollow blocks which are to be reinforced and filled shall be removed.

4

Each block is to be adjusted to its final position in the wall whilst the mortar is still plastic. Any block which is moved after the mortar has stiffened shall be removed and relaid with fresh mortar.

5

Half blocks and special blocks are to be used as required to ensure correct bonding.

6

All perpends, quoins and joints are to be kept true and square, other angles are to be plumbed and bed joints levelled as the work proceeds.

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5.3.2

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The work is to be carried out course by course not leaving any part more than 800 mm lower than another. Work, which is left at different levels, is to be racked (stepped) back to the approval of the Engineer.

8

In cavity wall construction both leaves are to be carried up together, not leaving any leaf more than 400 mm below the other.

9

Partitions shall be 100 mm thick unless otherwise noted. Partitions having lavatories or other plumbing fixtures secured to them back-to-back (or approximately so) are to be a minimum of 150 mm thick. Solid concrete masonry units shall be built in where full units cannot be used or where needed for the fixing of accessories. Bells or hubs of pipes must be completely enclosed.

10

Reinforced masonry partitions are to fully extend to the underside of slabs.

11

When pipes or conduits or both occur in plastered partitions, at least one web of the hollow masonry units must be retained.

12

When new masonry partitions start on existing floors, the existing floor finish material is to be cut down to the concrete surface. New masonry partitions are not to abut any existing plastered surfaces, except suspended ceilings.

5.4

BRICKWORK

5.4.1

Brickwork Wetting and Brick Wetting Test

1

Bricks shall be laid dry unless the following test indicates the need for wetting:

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draw a 30 mm circle with wax crayon on bed surface of dry brick. Using a medicine dropper, place 20 drops of water inside the circle and measure the time required for absorption of the water

(b)

if water is absorbed in less than 1½ minutes the brick must be wetted before being laid.

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Bricks are to have no visible moisture when laid.

5.4.2

Brickwork Laying

1

Unless otherwise specified elsewhere in the Project Documentation, bricks are to be laid in a running bond with each course of masonry bonded at the corners. The bond of facing bricks in existing buildings shall be matched. Before starting work, facing bricks shall be laid on the foundation wall and the bond adjusted as needed for openings, angles, corners, etc. Exposed brickwork joints are to be symmetrical about centre lines of openings. No brick smaller than a half-brick shall be used at any angle, corner, break, or jamb. The bond pattern shall be maintained plumb throughout. Jumping of the bond is prohibited. Brickwork shall be anchored to concrete columns, beams and walls, to steel stud construction and to masonry backup with ties and anchors in accordance with the relevant provisions of BS 5628.

2

Bricks shall be laid in a full bed of mortar. The mortar shall be spread over a few bricks at a time and shall not be furrowed. The mortar bed shall be slightly levelled to incline towards the cavity. The brick shall be placed before the mortar has had chance to stiffen. Head joints in stretcher courses are to be completely filled with mortar. Bricks shall be pushed into place so that the mortar oozes out at the top of the joints.

3

Before connecting new masonry with masonry previously laid masonry, loose bricks or mortar shall be removed, and the previously laid masonry shall be cleaned and wetted. New work is to be toothed into unfinished work.

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Brick headers are not to project into the grout space.

5

Cleaning holes are to be left in double cavity walls during construction by omitting units at the base of one side of the wall. In general, clean-out holes are to be provided at each location of vertical reinforcement.

6

Cavities shall be kept clean of mortar and debris. The cavity shall be cleaned every day using a high pressure jet stream of water, compressed air, industrial vacuum, or by laying wood strips on the metal ties as the wall is built. If wood strips are used, lift strips with wires or heavy string as the wall progresses and before placing each succeeding course of wall ties.

7

Exterior walls shall be built with 100 mm of facing brick, backed-up with inner leaf of brick or concrete masonry units. Solid brick jambs shall be constructed not less than 200 mm wide at exterior wall openings and at recesses.

8

Joints are not to be tooled until mortar has stiffened enough to retain a thumb print when the thumb is pressed against the mortar, however, mortar is to be soft enough to be compressed into joints. Joints in exterior face brick work shall be finished with a jointing tool to produce smooth, watertight concave joints. Exposed interior joints in finished work shall be tooled to a concave profile.

5.5

REINFORCEMENT

5.5.1


1

Expanded stainless steel mesh joint reinforcement, if specified, will be embedded in the horizontal mortar joints not closer than 20 mm from the external face of the wall and, except at movement joints, is to be continuous and lapped at least 75 mm at all passings. Full lap joints are to be provided at angles.

2

Vertical bar reinforcement is to be properly positioned and secured against displacement. The cavities containing the reinforcement are to be completely and solidly filled with the specified concrete. The whole surface of the reinforcement is to be in contact with the mortar or concrete. The minimum clear distance between the vertical bars and the block is to be 12 mm.

5.5.2

Placing Reinforcing

1

At the time of placement, steel reinforcement is to be free from loose flaky rust, mud, oil, or other coatings that will destroy or reduce the bond.

2

Steel reinforcement is to be in place at the time of grouting. Horizontal reinforcement shall be placed as the masonry work progresses.

3

The minimum clear distance between reinforcing and masonry units shall be 12mm.

4

The minimum clear distance between parallel bars shall be one bar diameter.

5

Vertical steel reinforcement shall be held in place by centring clips, caging devices, or other approved methods.

6

Vertical bars shall be supported near each end, and at intermediate intervals not exceeding 80 bar diameters.

7

Horizontal reinforcement shall be set in a full bed of grout.

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8

Reinforcement shall be spliced or attached to dowels by placing in contact and wiring together.

9

Splices shall be staggered in adjacent reinforcing bars. Reinforcing bars shall be lapped at splices at a minimum of 40 bar diameters.

5.5.3

High Lift Grouting of Cavity Walls

1

Grout shall be placed by hand bucket, concrete hopper, or grout pump. Each lift of grout shall be consolidated after free water has disappeared but before plasticity is lost.

2

When placing grout by the high lift method, the Contractor shall: not pour grout until the masonry wall has properly cured for a minimum of 72 hours

(b)

close cleaning holes with masonry units

(c)

place grout in one continuous operation (grouting of any section of a wall between control barriers is to be completed in one day with no interruptions greater than one hour)

(d)

provide vertical solid masonry dams across the grout space for the full height of the wall at intervals of not more than 9 m

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(a)

High lift grouting of double cavity walls should be undertaken in a single, continuous pour of grout to the top of the wall in 1 m layers or lifts in the same working day, with a minimum waiting period of 10 minutes between each 1 metre layer or lift. Each layer or lift of grout is to be vibrated. The vibrator is to be extended 300 mm to 450 mm into the preceding lift to close any shrinkage cracks or separation from the masonry units.

4

Grout for cavities of double cavity walls less than 50 mm wide should not be poured from a height exceeding 300 mm.

5.5.4

Low Lift Grouting of Cavity Walls

1

Grout shall be placed by hand bucket, concrete hopper, or grout pump. Each lift of grout shall be consolidated after free water has disappeared but before plasticity is lost.

2

Double cavity masonry walls are to be constructed and grouted in lifts not to exceed 200 mm. Slushing with mortar will not be permitted.

3

The grout space shall be kept clean from mortar droppings and clean the space before placing the grout.

4

All grout is to be puddled with a grout stick during and immediately after placing.

5

The cores of concrete masonry units containing reinforcing bars shall be grouted as the masonry work progresses. Slushing with mortar will not be permitted.

5.5.5

Water Penetration Testing

1

Seven days before plastering or painting, the Contractor shall test exterior masonry walls for water penetration. The number and location of tests shall be as stated in the Project Documentation or as directed by the Engineer.

2

Water shall be directed at masonry for a period of one hour at a time when wind velocity is less than eight kilometres per hour.

3

The areas showing moisture on the inside of the walls shall be corrected and re-tested to insure that moisture penetration has been stopped.

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4

Unless otherwise instructed, testing shall take place in the presence of the Engineer.

5.6

FAIR FACED BLOCK WALLS

5.6.1


1

Fair faced block walls and walls built of facing blocks are to be constructed generally as Clause 5.3.3 with particular care being taken to ensure: (a)

the specified bonding or joint pattern is consistent

(b)

the perpends are truly plumb for the full height

(c)

the blocks used are of the same texture and appearance to avoid a patchy effect

(d)

the colour of the mortar is consistent.

When a block has been placed in the wall, the extruded mortar is to be struck off flush, extra care being taken to avoid smearing the mortar on the face of the block.

3

Joints are to be left to stiffen slightly (thumb print hard) and then be firmly compacted with a jointing tool to the required profiles. The tooling of wet mortar will not be permitted.

4

If mortar droppings have struck to the blocks it must be allowed to dry and the surplus removed by a trowel. The remaining residue shall be cleaned by rubbing with a small piece of block and subsequent brushing down.

5

Where the cutting of blocks in fair face work is unavoidable, this should be done using a mechanical saw.

6

The cutting of facing blocks will only be permitted where this can be achieved without a visible alteration to the facing pattern.

5.7

OPENINGS

5.7.1


1

Openings are to be square and the jambs, vertical and formed with the uncut faces of the blocks.

2

If door and window frames are to be built-in the requirements of Clause 5.3.4 of Section 18 shall be complied with and the fixing cramps built-in solid in the mortar joints.

3

The jamb walling is to be built up against the frame all round as the work proceeds.

5.8

INTERSECTING WALLS AND PARTITIONS

5.8.1


1

Walls and partitions are to be bonded or tied to one another at junctions, unless movement joints are indicated.

2

If ties are used they should consist of 3 x 20 mm stainless or galvanized steel as directed by the Engineer fully embedded in the horizontal mortar joints at vertical spacings not exceeding 600 mm.

3

The ends of the ties are to project a minimum of 75 mm into each wall or partition.

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CONNECTIONS BETWEEN WALLS OR PARTITIONS AND COLUMNS

5.9.1


1

All connections between block walls or partitions and concrete or steel columns are to be reinforced at maximum 400 mm centres by means of stainless steel or zinc coated expanded metal as directed by the Engineer or approved proprietary ties shot fired to the column and built into and fully embedded in the mortar joints of the block walls or partitions.

2

Stainless steel or expanded metal ties as directed by the Engineer are to be a width that will allow 20 mm clearances from each face of the wall or partition and be embedded for a minimum distance of 200 mm in the mortar joint.

5.10

JOINTS BETWEEN PARTITIONS AND FLOOR SOFFITS

5.10.1


1

Non-load bearing internal walls and partitions shall be built-up to leave a 20 mm joint between the top of the wall or partition and the soffit of the slab.

2

After the walling has thoroughly dried out and after the expected deflection in the slab due to dead load has taken place, the joint is to be filled solid with a Class M7 mortar in accordance with the relevant provisions of Part 2 of this Section.

3

Where concrete slabs are supported on blockwork, a layer of polythene sheet is to be provided between the top of the wall and the slab for the full width of the wall.

5.11

FILLING HOLLOW BLOCK WALLS

5.11.1


1

In the following situations, the cavities of hollow block walls are to be filled solid with either Class M7 mortar in accordance with the relevant provisions of Part 2 of this Section or concrete Grade C15:

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5.9

jambs of all openings

(b)

ends, angles and junctions of walls and partitions

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junctions of walls and partitions with columns

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(c)

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(a)

(d)

at sills

(e)

at tops of partitions, if so specified

(f)

to provide a solid fixing for false ceiling perimeters

2

The filling to courses is to be supported on a strip of expanded metal lathing embedded in the joint below.

3

Walls which are to be filled solid are to be built up in lifts not exceeding 1,200 mm and be filled after allowing a minimum period of 24 hours to elapse to enable the mortar to harden. The initial compaction of the concrete is to be carried out by hand using a 25 x 50 mm wooden rod or by vibrator. The final compaction shall take place 10-15 minutes after initial compaction.

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CAVITY WALLS

5.12.1


1

Cavity walls are to consist of two walls separated by a minimum space of 50 mm and bonded together with stainless steel or approved other cavity wall ties.

2

The air space between the walls is to be kept clear and clean of mortar droppings by the use of laths drawn up the cavity as the work proceeds or by other approved methods.

3

Any mortar which inadvertently falls on wall ties is to be removed.

4

Wall ties are to be spaced at the intervals given in the Table 5.2 unless otherwise indicated elsewhere in the Project Documentation. Additional ties are to be provided in each course within 250 mm of openings or at end wall situations and on each side of movement joints.

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Table 5.2 Spacing of Wall Ties in Cavity Walls

.

5.12

Maximum Horizontal Spacing (mm)

Maximum Vertical Spacing (mm)

50 - 75

1,000

75 - 100

800

400

100-150

500

400

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Cavity Width (mm)

se

Notes:

400

er

(a) The spacing of ties may be varied providing that the number per unit area is maintained. (b) The Table is applicable to cavity walls constructed of two blockwork skins.

SERVICES

5.13.1


1

Where walls are constructed of hollow blocks, the mechanical and electrical services are to be run in the cavities of the blocks wherever possible. No services are to run within the cavity of a cavity wall.

2

Where chases have to be cut, suitable power tools, as approved by the Engineer, are to be used.

5.13.2

Fixings

1

Where fixing blocks, anchors, accessories, wall ties, etc., are specified they are to be built into the walls or partitions and solidly bedded in mortar.

2

Fixings which are not built-in are to be drilled or shot fired to the blockwork.

3

Expanded bolt fixings are only to be drilled into solid blocks or blocks having their cavities filled solid.

5.14

DAMP-PROOF COURSES

5.14.1

General Description

1

Damp-proof courses shall comply with the relevant provisions of BS 743 or one of the other references mentioned in 5.1.2.

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Damp-proof courses are to extend through the full thickness of the wall, including pointing, applied rendering or any other facing material.

3

The mortar bed upon which the damp-proof course is to be laid is to be even and free from projections liable to cause damage to the damp proof course.

4

Where the damp-proof course is situated in a hollow block wall, the blocks are to be filled solid in the course below the damp proof course.

5

All damp-proof courses are to be solidly bedded in mortar.

6

Joints of all damp-proof courses shall be lapped a minimum of 100 mm at all passings and sealed.

5.15

PROTECTION OF FINISHED WALLING

5.15.1

General Description

1

All newly or partially built walls are to be protected against drying out too rapidly in the sun’s heat by covering with hessian or other approved material which is to be kept wet for a minimum of 3 days.

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END OF PART

QCS 2014

Section 14: Roofing Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3


1.2

PREPARATION WORK ................................................................................. 4

1.2.1 1.2.2

General Requirements Storage of Materials

1.3

GUARANTEE ................................................................................................ 4

1.3.1


1.4

PROTECTION ............................................................................................... 5

1.4.1


1.5

TESTING ....................................................................................................... 5

1.5.1


2 2 3

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4 4 4 5 5

QCS 2014


Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies general requirements for various types of roof covering materials and accessories.

2

Related Sections are as follows: Carpentry, Joinery and Ironmongery Thermal Insulation of Buildings

References

1


-------- Black paint (tar based) -------- Wood wool cement slabs up to 125 mm thick -------- Concrete flooring tiles and fittings -------- Nails -------- Wood screws -------- Wrought aluminium and aluminium alloys for general engineering purposes: Bars, extruded round tube and sections BS 1494 -------- Fixing accessories for building purposes BS 1521 -------- Water proof building papers BS 3083 -------- Hot-dip zinc coated and hot-dip aluminium/zinc coats corrugated steel sheets for general purposes BS 3379 -------- Flexible polyurethane cellular materials for load bearing applications BS 3416 -------- Bitumen based coatings for cold application, suitable for use in contact with potable water BS 3690 -------- Bitumens for building and civil engineering BS 3797 -------- Lightweight aggregates for concrete BS 3837 -------- Expanded polystyrene boards BS 3869 -------- Rigid expanded polyvinyl chloride for thermal insulation purposes and building applications BS 3927 -------- Rigid phenolic foam (PF) for thermal insulation in the form of slabs and profiled sections BS 4016 -------- Building papers (breather type) BS 402 ---------- Clay plain roofing tiles and fittings BS 4154 -------- Corrugated plastic translucent sheets made from thermo-setting polyester resins (glass fibre reinforced) BS 4841 -------- Rigid polyurethane (PUR) and polyisocyanurate (PIR) form for building applications BS 4868 -------- Profiled aluminium sheet for building BS 5075 -------- Concrete admixtures BS 5284 -------- Methods of sampling and testing mastic asphalt used in building and civil engineering BS 5534 -------- Code of Practice for slating and tiling BS 6229 -------- Flat roofs with continuously support coverings BS 6515 -------- Polyethylene damp-proof courses for masonry

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BS 1070 BS 1105 BS 1197 BS 1202 BS 1210 BS 1474

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Section 18 Section 15

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Page 3

.

BS 6676 -------- Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 680 ---------- Roofing slates BS 747 ---------- Roofing felts BS 8000 -------- Workmanship on Building Sites BS 812 ---------- Testing aggregates BS 8217 -------- Code of Practice for built-up felt roofing BS 882 ---------- Aggregates from natural sources for concrete BS EN 485 ----- Aluminium and aluminium alloys – Sheet, strip and plate BS EN 490 ----- Concrete roofing tiles and fittings-product specifications BS EN 491 ----- Concrete roofing tiles and fittings-test methods BS EN 538 ----- Clay roofing tiles for discontinuous laying-flexural strength test BS EN 539 ----- Clay roofing tiles for discontinuous laying-determination of physical characteristics.

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EN 197-1 ------- Portland cement Definitions

1

For purposes of this Section, certain terms are designated in the following paragraphs:

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1.1.3

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BASE SHEET is one layer of felt or combination sheet secured to the deck over which may be applied additional felts, a cap sheet, organic or inorganic fibre shingles, smooth coating or mineral aggregate.

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BUILT-UP ROOF COVERING is two or more layers of roofing consisting of a base sheet, felts and cap sheet, mineral aggregate, smooth coating or similar surfacing material

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CAP SHEET is roofing made of organic or inorganic fibres, saturated and coated on both sides with a bituminous compound, surfaced with mineral granules, mica, talc, ilmenite, inorganic fibres or similar materials

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CEMENTING is solidly mopped application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material COMBINATION SHEET is a glass fibre felt integrally attached to kraft paper

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CORROSION-RESISTANT is any non-ferrous metal or any metal having an unbroken surfacing of non-ferrous metal, or steel with no less than 10 % chromium or with not less than 0.20 % copper FELT is matted organic or inorganic fibres, saturated with bituminous compound FELT, NONBITUMINOUS SATURATED is matted asbestos fibres with binder for use with wood shingle and wood shake assemblies GLASS FIBER FELT is a glass fibre sheet coated on both sides with bituminous compound INTERLAYMENT is a layer of felt or non-bituminous saturated asbestos felt not less than 450 mm wide, shingled between each course of roof covering INTERLOCKING ROOFING TILES are individual units, typically of clay or concrete, possessing matching ribbed or interlocking vertical side joints that restrict lateral movement and water penetration

QCS 2014


Page 4

METAL ROOFING is metal shingles or sheets for application on solid roof surfaces, and corrugated or otherwise shaped metal sheets or sections for application on solid roof surfaces or roof frame works NON-NAILABLE DECK is any deck, which is incapable of retaining an approved fastener PREPARED ROOFING is any manufactured or processed roofing material, other than untreated wood shingles and shakes, as distinguished from built-up coverings SPOT CEMENTING is discontinuous application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material

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UNDERLAYMENT is one or more layers of felt or non-bituminous saturated asbestos felt over which the finish roofing is applied.

PREPARATION WORK

1.2.1


1

Before commencing installation of the roof, waterproofing and insulation system all construction work and installations above roof level are to be completed as far as possible. Particular care is to be taken to ensure:

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1.2

all rainwater, plumbing, air-conditioning and ventilation duct outlets have been fixed in position and are protected against blockage or accidental damage

(b)

supports to ductwork, pipework, cable trays and the like have been installed

(c)

all kerbs to roof lights, access doors, plant and water tanks have been installed

(d)

all chases for skirtings, etc., have been prepared.

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(a)

The surface of the roofing substructure is to be clean and dry, free from ridges or indentations, laid to falls as required and not contaminated with oil or other deleterious matter.

3

No waterproofing membrane is to be applied until the roofing substructure has been inspected and approved by the Engineer.

1.2.2


1

Polystyrene insulation boards are to be protected against prolonged exposure to sunlight.

2

Blanket type insulation is to be protected from moisture.

1.3

GUARANTEE

1.3.1


1

The Contractor is to provide the Engineer with a seven (7) year unconditional guarantee against failure of the roof waterproofing system whether caused by defective materials or workmanship. The guarantee should be valid from the date of completion of the installation and must be provided to the Engineer in accordance with Section 1, General.

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Page 5

PROTECTION

1.4.1


1

Adequate protection against damage to the roof waterproofing system is to be provided where further construction work is necessary in the area.

1.5

TESTING

1.5.1


1

On completion of application of new roof waterproofing material to an existing roof but before application of insulation and protection, the Contractor shall seal off all rainwater outlets and flood the roof to a depth of 25mm. After 48 hours, visual inspection of the roof shall be undertaken from inside the building in the presence of the Engineer's Representative to establish that there are no leaks in the structure. The Contractor shall make up any loss of water during the test due to either evaporation or leakage. The Contractor shall be responsible for the locating and sealing of any leaks found. The test shall be repeated, at the Contractor's expense, until no leaks exist.

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END OF PART

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1.4

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 1

2

MEMBRANE ROOFING ................................................................................ 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References General Description of Workmanship

2.2

BUILT-UP BITUMINOUS FELT ROOFING.................................................... 3

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12

General Requirements Delivery, Storage and Marking Materials Execution of Work Surface Preparation Existing Roofs and Repair Areas Installation of Built-Up Roofing Membrane Base Flashing Stripping Roof Pour Coat and Aggregate Roof Walkways Alterations to Existing Roofs

2.3

COLD APPLIED BITUMINOUS COATING .................................................. 12

2.3.1


2.4

PREPARED ROLL ROOFING ..................................................................... 13

2.4.1


2.5

MODIFIED BITUMINOUS SHEET ............................................................... 13

2.5.1


2.6

SINGLE LAYER MEMBRANE ..................................................................... 13

2.6.1

General Requirement

2.7

FLUID APPLIED MEMBRANES .................................................................. 13

2.7.1 2.7.2

General Description Liquid Applied Waterproofing Systems

2.8

COATED SPRAY APPLIED FOAM ............................................................. 15

2.8.1 2.8.2

Description Installation

2.9

PERMEABLE FILTER MEMBRANE ............................................................ 15

2.9.1


2.10

PROTECTED MEMBRANE ......................................................................... 15

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2 2 3 3 3 4 5 8 8 8 10 11 11 11 11 12 13 13 13 14 14 15 15 15 16

TORCH APPLIED WATERPROOF MEMBRANE ....................................... 16

2.11.1 General Requirements

16

QCS 2014


Page 2

2

MEMBRANE ROOFING

2.1

GENERAL

2.1.1

Scope

1

This Part specifies requirements for flexible roof coverings of various types.

2

Related Sections are as follows: Section 5 Section 15 Section 18

Concrete Thermal Insulation of Buildings Carpentry, Joinery and Ironmongery

References

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ASTM D412 - 06ae2 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

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ASTM D1227 ..............Standard Specification for Emulsified Asphalt Used as a Protective Coating for Roofing

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ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness ASTM E96 ..................Standard Test Methods for Water Vapor Transmission of Materials

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ASTM G154................Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials BS 747 ........................Specification for roofing felts

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BS 882 ........................Aggregates from natural resources BS 1070 ......................Black paint (tar based) BS 1197 ......................Concrete flooring tiles and fittings

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BS 1202 ......................Nails

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BS 1210 ......................Wood screws BS 1494 ...................... Fixing accessories for building purposes

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BS 1521 ......................Waterproof building papers BS 3416 ...................... Bitumen based coatings for cold application, suitable for use in contact with potable water BS 3690 ......................Bitumens for building and civil engineering BS 4016 ......................Building papers (breather type) BS 5284 ...................... Methods of sampling and testing mastic asphalt used in building and Civil Engineering BS 6229 ......................Flat roofs with continuously supported coverings BS 6920 ......................Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of the water BS 7263 ......................Pre-cast concrete flags, kerbs, channels, edgings and quadrants BS 8000 ......................Workmanship on Building Sites BS 8217 ......................Code of practice for built-up felt roofing

QCS 2014


Page 3

General Description of Workmanship

1

The roof coverings are not to be applied to a damp base and care is to be taken to ensure that no moisture is trapped between successive layers.

2

Skirtings are to be a minimum of 150 mm above the roof finish at any point.

3

Protective finishes and surface treatments are to be applied as soon as possible after completion of the roof coverings.

4

Projections passing through the roof covering are to be provided with hoods or caps to permit the roof covering to terminate beneath the hood and be protected by it from weather elements.

5

Outlets for surface water, whether in gutters or roof areas, are to be set slightly below the adjacent roof surface and be suitably flashed to allow a bonded lap of roofing felt and flashing material of 100 mm (minimum).

6

Roof waterproofing materials shall be applied by specialist personnel or a specialist subcontractor having previous experience of the system and approved by the Engineer's Representative. The specialist sub-contractor shall provide the guarantee specified in Part 1 of this Section in favour of Public Works Authority.

7

On completion of application of waterproofing material to an existing concrete roof but before the application of insulation and protection, the Contractor shall seal off all rainwater outlets and flood the roof to a depth of 25mm. The Contractor shall make up any loss of water due to evaporation or leaks. After 48 hours, visual inspection of the roof shall be undertaken from inside the building in the presence of the Engineer’s Representative to establish if there are any leaks in the structure. The Contractor shall locate and seal any leaks. The test shall be repeated at the Contractor’s expense until no leaks exist.

8

On new roofs the test detailed in sub-clause 7 shall be carried out prior to application of lightweight screed and waterproofing membrane.

2.2

BUILT-UP BITUMINOUS FELT ROOFING

2.2.1


1

This section specifies built-up bituminous felt roofing on new roofs and for repairs to existing roofs.

2.2.2

Delivery, Storage and Marking

1

Roofing materials shall be delivered to the Site in original sealed packages or containers marked with the name and brand, or trademark of the manufacturer or seller.

2

Roofing materials shall be kept dry and stored in weathertight facilities or under canvas tarps. Use of polyethylene or plastic tarps to cover materials is not permitted. Roofing materials shall be stored above ground or deck level on wood pallets. Ground under stored materials shall be covered with a plastic cover.

3

Rolled materials (felts, base sheets, paper) shall be stored on end. Materials shall not be stored on top of rolled materials.

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2.1.3

QCS 2014


Page 4

4

Aggregate are to be maintained in a surface dry condition as defined by BS 812 and BS 882.

5

Materials shall be protected from damage from handling, weather and construction operations before, during, and after installation.

2.2.3

Materials

1

Built-up bituminous materials are to conform to applicable Standards listed in Clause 2.1.2.

2

Asphalt materials (general) include:

organic felt

(c)

asphalt

(d)

glass reinforced felt

(e)

venting asphalt base sheet

(f)

mineral surface roll roofing

(g)

roof cement

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(b)

Coal tar materials include: primer

(b)

organic felt

(c)

coal-tar bitumen

(d)

roof cement

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(a)

Miscellaneous component requirements are as follows: (a)

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primer

aggregate requirements include: aggregates to comply with requirements of BS 882.

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(b)

(c) 5

chippings are to be approved, clean, crushed white or pale grey aggregate size 15 to 30 mm. (rounded gravel shall e free of sharp angular or broken pieces.

roof walkway requirements include: (i)

prefabricated asphalt plank consisting of a homogeneous core or asphalt, plasticizers and inert fillers, bonded by heat and pressure between two saturated and coated sheets of felt. The top side of planks shall be surfaced with ceramic granules.

(ii)

concrete masonry paving units shall comply with BS 1197 and BS 7263.

building paper (sheating paper) shall comply with BS 1521 and BS 4016.

Fasteners to be used include the following: (a)

nails and staples shall comply with BS 1210 and BS 1202

(b)

nails for securing built-up flashing and base sheets to wood deck shall be either:

QCS 2014

(c)


Page 5

(i)

zinc coated steel roofing nails with a minimum head diameter of 9 mm through metal discs at least 25 mm across

(ii)

one piece nails with an integral flat cap at least 24 mm across.

fasteners for securing building paper and dry felt edge strips to wood nailer and decks shall be either: (i)

zinc coated steel roofing nails with a minimum head diameter of 16 mm

(ii)

flat top crown, zinc coated staples

(d)

nails for plywood are to be annular thread type and shall penetrate plywood by at least 19 mm

(e)

nails for securing built-up flashing to masonry shall be either: hardened steel nails through metal discs at least 25 mm in diameter

(ii)

one piece nails with an integral flat cap at least 24 mm across.

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(i)

nails for securing venting base sheet to insulating concrete shall be galvanized steel self-clinching type having a integral flat cap at least 25 mm across. They are to have a holding power of not less than 130 kg when pulled from approximate dense concrete

(g)

nails for securing base sheet, building paper, or first layer of vapour retarder to structural wood fibre decks shall be the self-clinching type having an integral flat cap not less than 25 mm across. They are to have a holding power of not less than 85 kg per fastener

(h)

nails for securing base sheet to poured gypsum roof deck shall be specially shaped nails providing a diverging or hooking point. They shall have a flat cap not less than 32 mm across and have a withdrawal resistance of not less than 85 kg per fastener.

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(f)

Execution of Work

1

Roofing materials shall not be applied if the deck will be used as a subsequent work platform, for storage of materials, or if staging or scaffolding will be erected thereon.

2

The entire roof deck construction of any section of the building is to be completed before roofing work is begun including: installation of curbs, blocking, edge strips, fillets, and other components where insulation, roofing and base flashing is attached shall be in place ready to receive insulation and roofing

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2.2.4

(b)

co-ordination of roof operations with roof insulation and sheet metal work so that insulation and flashing is installed concurrently to permit continuous roofing operations.

3

Roofing materials are to be dry when applied.

4

Surfaces, including the flutes of metal deck, that become wet from any cause during progress of the work shall be dried out before roofing work is resumed. Materials shall only be applied to dry substrata.

5

Except for temporary protection, materials shall not be applied during damp or rainy weather, during excessive wind conditions, nor while moisture (dew or fog) is present in any amount in or on the materials to be covered or installed.

6

Materials shall not be applied when the temperature is below 10 ºC.

QCS 2014


Page 6

7

Phased construction is not permitted. The installation of all layers is to be completed in the same day, including insulation, base flashings, and the layers surfaced with either the flood coat and aggregate or with a glaze coat except for the area where temporary protection is required when work is stopped.

8

Temporary protection shall comply with the following requirements: install temporary protection consisting of glazed coats and water cut-offs at the end of each day’s work and when the work is halted for an indefinite period or work is stopped when precipitation is imminent

(b)

glaze coat all exposed surfaces of felts to seal in the bitumen coating. No felt surfaces or edges are to be left exposed

(c)

install temporary cap flashings over the top of base flashings where permanent flashings are not in place. Temporary cap flashings are to provide complete protection against moisture entering the roof system through or behind the base flashing. Securely anchor in place to prevent blowing off and damage by construction activities

(d)

provide for removal or drainage of water away from the work

(e)

provide temporary protection for roofing by means of duckboard walkways, plywood platforms, or other materials, as approved by the Engineer, for roof areas that are to remain intact, and that are subject to foot traffic and damage.

(f)

provide notches in sleepers to permit free drainage.

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Heating of bitumen for installation of roofing shall comply with the following requirements: (a)

heat the asphalt to the equiviscious temperature 1 °C; at the time of application

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asphalt should not be heated greater than 35 °C above the equiviscous temperature coal-tar bitumen is not to be heated above 215 °C with an application temperature ranging from 160 °C to 200 °C

(c)

at no time should bitumen be heated above the flash point temperature

(d)

provide heating kettles with a thermometer kept in operating condition at all times. Kettlemen are to be in attendance at all times during heating to insure that the bitumens are heated within the temperatures specified.

10

11

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(b)

Asphalt or coal-tar products shall be used, except as specified below: (a)

use asphalt only with asphalt-saturated or asphalt-impregnated felts

(b)

use coal-tar pitch and coal-tar-saturated felts in conjunction with coal-tar roofing

(c)

Asphalt-saturated felts may be used for flashings.

Installation of roofing materials with hot bitumen shall comply with the following requirements: (a)

apply bitumen in quantities required, immediately followed by felts or other materials to be embedded therein before bitumen cools below the application temperature limit

(b)

do not apply more material than can be covered at one time

(c)

re-coat cooled bitumen areas with hot bitumen

(d)

roll felts into bitumen, rolling, squeezing or brushing down to firmly embed in the hot bitumen free of wrinkles, blisters, bubbles, voids, air pockets or other defects that prevent complete adhesion. Use squeegees only on glass felts

QCS 2014

Page 7

(e)

felts shall be lapped shingle fashion for the number of layers specified starting with starter strips at right angles to slope of roof

(f)

the laying of the roofing materials should commence at the low points

(g)

bitumen is to separate all felts or substrata so that subsequent layers do not touch previous placed layers of felt or substrata unless noted specifically

(h)

cut the felt to fit closely around pipes, roof drains, bitumen stops, and similar roof projections.

Laps for felts and base sheet shall be as follows: base sheet shall be lapped 75mm

(b)

two layers of felt with 500 and 900 mm starting widths shall be lapped 600 mm

(c)

three layers of felt with 300, 600 and 750 mm starting widths shall be lapped 600 mm

(d)

four layers of felt with 225, 500 mm and 750 starting widths shall be lapped 700 mm.

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Primer shall be applied with 3.5 litres of primer per 10 m2 of surface area unless otherwise recommended by the manufacturer and approved by the Engineer.

14

Quantities of bitumen used shall be as follows:

coal tar, 44 to 66 kg/m

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asphalt, 9 to 13 kg/m

glaze coats:

2

(i)


(ii)


2

pour or flood coats:

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(ii)

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between substrata and layers of glass fibre felts

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(i) (c)

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(b)

between substrata and layers of organic felt:

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13


2


2

Nailing or anchorage of felts or base sheets to nailable decks shall include the following requirements: (a)

nails or fasteners appropriate for type of deck to be covered shall only be used.

(b)

two layers of felt shall be laid as follows:

(c)

(i)

nail down both layers along bottom edges at intervals not to exceed 225 mm

(ii)

nail down both layers at both edges at intervals not to exceed 225 mm

anchorage of base sheets shall be as follows: (i)

nail along laps and edges at intervals not to exceed 225 mm with end and edge laps solidly sealed with roof cement

(ii)

stagger nails down centre of sheet in two rows 300 mm apart at intervals of not more than 500 mm in each row.

QCS 2014

16


Page 8

Building paper shall be laid as follows: (a)

lay paper smoothly without buckles or wrinkles at right angles to the roof slope starting at the low point

(b)

lap each sheet of paper at least 50 mm over proceeding sheet, and at the ends

(c)

staple or nail sufficiently to hold in place until the roofing is installed.

Surface Preparation

1

Sweep decks and remove all dust, dirt and debris.

2

Remove projections that might penetrate or damage roofing felt materials.

3

Preparation of concrete decks, (except insulating concrete) for installation of roofing shall comply with the following requirements:

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2.2.5

test concrete decks for moisture prior to application of roofing materials. Heat bitumen as specified and pour approximately 0.5 litres of bitumen on surface to which roofing materials are to be applied. If bitumen foams upon contact with the deck or if after bitumen has cooled and bitumen is stripped from deck leaving no residue, the deck is not dry enough for application of prime coat or roofing

(b)

prime concrete decks, including precast units, with primer as recommended by the manufacturer for certification. Keep the primer 100 mm back from the joints in precast units

(c)

allow primer to dry before application of bitumen.

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(a)

Roof surfaces of wood sheathing, gypsum, gypsum plank and cement wood fibre plank shall be covered with a layer of building paper.

2.2.6

Existing Roofs and Repair Areas

1

Where new penetrations occur and in areas where repairs are required, loose aggregate and aggregate that is not firmly embedded shall be removed.

2

Where new work to be installed, the existing membrane should be cut out and removed and a temporary seal to cut surfaces installed. The temporary seal shall consist of roof cement and one layer of 33 kg/m2 glass fibre felt or fabric strip. The glass fibre felt or fabric strip shall extend 150 mm on each side of cut surface and shall be completely embedded in the roofing cement.

3

If the existing built-up base flashing is to be repaired, either bend up the cap flashing or temporarily remove the cap flashing. Brush and scrape away all deteriorated and loose bitumen, felts, or surface material of built-up base flashing, and repair as necessary in accordance with the requirements of this Section.

4

A venting base sheet shall be used over all insulating concrete and poured gypsum decks to relieve possible vapour pressures that may occur.

5

The same bitumen shall be used for roof repairs and alterations as used in the existing roofing construction.

2.2.7

Installation of Built-Up Roofing Membrane

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Page 9

1

The built-up roofing membrane is to be aggregate surfaced, three layer, glass fibre felt construction using asphalt or four layer organic felt and coal tar bitumen. Building paper or a base sheet is not considered as a layer.

2

General requirements of installation of built-up roofing membrane are as follows: where nailers occur at roof edges under gravel stops or penetrations to receive metal base flashing, nail a continuous strip of 400 mm wide dry organic felt envelope over the nailers before the first layer sheet is applied. The organic felt strip is to be installed on top of the venting base sheet. After the membrane is installed, turn the dry felt back over the roofing, and secure in place with hot bitumen before gravel stops or other metal flanges extending out onto the membrane are installed

(b)

where fillets occur at vertical surfaces, cut off layers of the membrane 50 mm above, the top of fillet strips. At prefabricated curbs, scuttles and other roof accessories having integral fillets, extend the membrane over the fillet and up the vertical surface to the top of the curb or nailer as shown in drawings

(c)

where a fascia-fillet occurs at the roof edges, extend the membrane beyond the outside fillet face and cut off at the outside after the base flashing is installed. Do not cut off the venting base sheet outside the fillet face, extend it down over the outer fillet face to allow for venting

(d)

where a recessed flashing occurs at vertical surfaces, extend layers of roofing up into recessed flashing the full depth of the recessed flashing.

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(a)

Built-up roofing installed over on insulation shall be sealed down as specified Clause 2.2.7-3.

4

Built-up roofing installed on concrete and precast concrete Units shall comply with the following requirements:

er

prime deck as specified Clause 2.2.4-13

(b)

keep bitumen back 100 mm from joints in precast units

(c)

seal down membrane as specified Clause 2.2.4.

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o

ov

(a)

Built-up roofing installed on nailable decks shall include requirements as follows: (a)

on insulating concrete decks, install one layer of venting base sheet with the mineral aggregate surface down. Fasten base sheet to deck as required, followed by membrane as specified

m

5

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3

(b)

(c)

termination venting base sheet: (i)

at vertical surfaces: extend venting base sheet up vertical surface over fillets to top of base flashing or curb

(ii)

at the roof edges under gravel stops install a venting base sheet over the blocking. The base sheet shall be extended not less than 50 mm beyond the outer edge and it shall be turned down so that venting can be accomplished

(iii)

at the roof edge over a fascia-fillet: extend the base sheet over the top of the fillet and turn it down over the outer face of the fillet to permit venting at the edge.

on poured gypsum, precast gypsum plank, cement-wood fibre plank, wood plank or plywood decks, install one layer of building paper followed by either:

QCS 2014


Page 10

(i)

two layers of 33 kg organic felt laying both layers down dry to deck except to seal between laps. Lap and nail as specified to deck. Follow immediately by the membranes sealed down to the felt

(ii)

one layer of base sheet or venting base sheet. Lay base sheet down dry on the deck. Lap as specified and seal the edge laps with roofing cement. Nail as specified followed by the roofing membrane sealed down to the base sheet.

Cover the exposed surface of the last layer of felt, except on fillets and under concrete pavers or runners of wood roof walkways, with bitumen and aggregate as specified.

2.2.8

Base Flashing

1

Provide built-up base flashings over fillets and wherever necessary to make the work watertight.

2

Install flashing before final bituminous coat and roof aggregate is installed.

3

Prime vertical surfaces of masonry and concrete with asphalt primer except where the vented base sheet is required to provide edge venting.

4

When applying a flashing on top of built-up roofing, up the face of fillets and up the face of the vertical surfaces, between 200 mm and 300 mm above the built-up roofing, the following shall apply:

as

at fascia-fillets, extend the flashing to the top of fillet and cut off at the top of fillet

(b)

at recessed flashings, extend the flashing full depth into the recessed flashing

(c)

where venting base sheet is used with insulating concrete, do not seal edges of venting base sheet with bitumen in order to allow for venting.

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(a)

extend the first layer of flashing 100 mm out on the roofing, and the second layer of flashing 75 mm beyond the first layer. Lap ends 75 mm with joints broken 500 mm in each layer

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(a)

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Flashing is to consist of two layers of 33 kg/m2 glass fibre felt or fabric, surfaced capped as specified.

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6

(b)

6

cap sheet is to be mineral surfaced roll roofing or modified bitumen sheet extending from toe of fillet to top of base flashing. Lap the ends 75 mm with joints not coinciding with joints in under layers.

Base flashings may be set either in asphalt (hot applied method) or in roof cement (cold applied method), with only one method only used throughout. Application of either method shall be as follows: (a)

(b)

cold applied method: (i)

embed each layer of flashing in roof cement so layers do not touch felt

(ii)

cover the last layer of flashing with a troweled on coat of the roof cement, into which embed the cap sheet from toe of the fillet to top of the base flashing and seal laps with roof cement

(iii)

Use cold applied method with coal tar roofing.

hot applied method:

QCS 2014

(c)


Page 11

(i)

embed each layer of flashing and cap sheet in asphalt so that the layers do not touch

(ii)

set the cap sheet in hot bitumen with laps sealed with hot bitumen.

except for venting roof edges, seal the top edge of the base flashing with roof cement.

Except at metal fascia fillets, secure top edge of the base flashing with nails on a line approximately 25 mm below the top edge, and at not more than 200 mm centres. All nail heads shall be covered with roof cement. The top of the base flashing shall be covered with counter flashing. At fascia fillets, secure the top edge of the flashing with fascia compression clamps.

2.2.9

Stripping

1

Before the final bituminous coat and roof aggregate is installed, cover that portion of the horizontal flanges of metal base flashings, gravel stops, and other flanges extending out onto the roofing with a composition flashing consisting of two layers of glass fibre felt or fabric. Use organic felt with coal tar bitumen for stripping.

2

Extend the first layer of flashing out on the roofing 100 mm beyond the edge of the flange and the second layer 75 mm beyond the edge of the first layer. Cut edges to fit tight against vertical members of the protruding flange.

3

Each layer of flashing shall be embedded in hot bitumen or roofing cement.

2.2.10

Roof Pour Coat and Aggregate

1

After bituminous base flashing and stripping have been installed uniformly coat the entire roof surface except fillets with hot asphalt or coal-tar bitumen poured on, as directed in Clause 2.2.4 of this Part.

2

While still hot, embed necessary amount of aggregate to cover the roofing felt completely without bare spots, but not less than 888 kg/m2 of dry gravel or 666 kg/m2 of dry slag. The aggregate cover shall be such that no bitumen is left exposed.

3

Placing the aggregate material in piles or rows on bare or glaze coated felt before placement is prohibited.

2.2.11

Roof Walkways

1

Walkways may be concrete masonry units or prefabricated asphalt planks.

2

Place concrete masonry units on top of the pour coat. Aggregate shall not be embedded under runners of wood roof walkways. Butt concrete masonry units to provide a continuous walkway surface.

3

When prefabricated asphalt planks are used, sweep away loose roof aggregate from the areas to receive planks. Set the planks in hot bitumen poured over the firmly embedded roof aggregate as specified for pour coat. Maintain a minimum of 75 mm to a maximum of 150 mm space between planks.

2.2.12

Alterations to Existing Roofs

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QCS 2014


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1

Roof repair and alteration work is to match existing roofing material and construction. Bitumen compatible with the existing bitumen shall be used for roof repair and alterations.

2

Make cut-outs of existing roof system to confirm the condition of the roof. Cuts are to be made in the presence of the Engineer in locations as directed by the Engineer. Each cut-out opening shall be photographed. The cut-out area shall be repaired immediately upon confirmation of the condition of the roof. Any moisture found in the roof membrane or insulation shall be reported to the Engineer.

3

Repairs to existing membrane and base flashing shall be carried out as follows: (a)

remove temporary patches prior to starting repair work

(b)

blisters and fish mouths:

heat membrane to facilitate bending and to dry out surface of blistered areas exposed

(iii)

seal down turned back membrane in hot bitumen. Roll to insure full adhesion and embedment in substrata

(iv)

cover cut areas with two layers of felt. Extend first layer 100 mm beyond cut area edge. Extend second layer 100 mm beyond first layer. Seal down in hot bitumen as specified for new work. Resurface as specified.

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cut away exposed deteriorated edges of organic felt

(ii)

glaze coat felt edges

(iii)

resurface as specified.

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(i)

built-up base flashing:

restore felts and cap sheet removed, lapping 100 mm over existing remaining

et it (ii)

install new felts and cap sheet as specified for new work.

horizontal metal flanges:

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exposed felts:

(i)

(e)

.

(ii)

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(d)

cut blisters open and turn membrane back to fully adhered portion. Cut fish mouth so membrane can be turned back and subsequently laid flat

o

(c)

(i)

(i)

remove loose, buckled, or torn stripping

(ii)

remove loose fasteners and install new fasteners

(iii)

restrip flanges as specified for new work.

resurfacing: (i)

over repaired membrane, re-pour and embed new or cleaned aggregate as specified for new work

(ii)

cover all membrane areas. Do not leave any exposed membrane surface.

2.3

COLD APPLIED BITUMINOUS COATING

2.3.1


QCS 2014


Page 13

The Contractor is to clean and prepare roofing surface areas immediately prior to application of bitumen coating. Black bitumen coating solutions to be applied in accordance with BS 3416, BS 6920.

2

Application of cold applied bituminous solution is to be done by a qualified experienced personnel.

3

All openings and roof vents are to have watertight flashings.

2.4

PREPARED ROLL ROOFING

2.4.1


1

Prepared roll roofing is the top layer in a built-up roofing membrane. Standard prepared roll roofing material consists of a glass fibre mat coated on both sides with a stabilised asphalt coating and surface coated with non-combustible ceramic granules.

2

Prepared roll roofing material is to be compatible with, and manufactured by the supplier of, the built up roofing membrane.

3

Prepared roll roofing is to be sealed with hot bitumen or cold adhesive as recommended by manufacturer.

4

The Contractor shall guarantee roll roofing for fifteen (15) years.

2.5

MODIFIED BITUMINOUS SHEET

2.5.1


1

Modified bituminous sheet is a cold applied membrane composed primarily of modified bituminous material prefabricated in sheet form.

2

Modified bituminous sheet is reinforced with glass fibre, polypropylene, or polyester fabric which may be bonded to a plastic sheet, and supplied in this form by the manufacturer.

3

The standard sheet thickness shall be 4 mm.

4

The sheet is to be provided with a release sheet to prevent bonding of the sheet to itself.

2.6

SINGLE LAYER MEMBRANE

2.6.1

General Requirement

1

A single layer membrane is a 4mm (minimum) single layer bituminous felt membrane and is torch applied.

2

Overlaps in the applied membrane are to be in the same direction as the roof slope.

3

Base flashing items as specified in Clause 2.2.8 of this part are to be completed prior to the installation of the single layer membrane.

2.7

FLUID APPLIED MEMBRANES

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QCS 2014


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2.7.1

General Description

1

Liquid applied membranes shall be non-aqueous and should consist of a one component high quality polyurethane elastomeric coating or a two component coal tar polyurethane elastomer.

2

If polyurethane elastomeric coating is used then it shall cure by reacting with the humidity to form an elastic strong film with excellent adhesion to different substrate.

3

Elastomeric waterproofing liquid membrane shall have the minimum following properties or equivalent standards:-

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If two component coal tar polyurethane elastomer used then it shall cure, when mixed, to form a flexible, elastomeric waterproof membrane having the following minimum properties after ageing:

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Tensile strength: Elongation: Shore Hardness: Total Solids: Moisture vapour transmission:

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4

> 5 N/mm² > 500 % > 70 0.8 gr/m² (2000hrs) Passed o -40 to 80 C

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Tensile Strength, ASTM D412: Elongation, ASTM D412: Shore A, ASTM D2240: Vapor transmission, ASTM E96: QUV accelerated weathering test, ASTM G154: Service Temperature:

2

4.0 N/mm . 300-400 % I.R.H.D. 70 %. 90-95 % 2 8.5 ml/m /24 hours

The waterproofing membrane is to incorporate the sealer/primer, reinforcing and reflective coating materials recommended by the manufacturer of the membrane.

6

The Contractor is to submit to the Engineer the manufacturer’s literature concerning the shelf life of each component material of the system to be used, together with authoritative evidence of the dates of production

2.7.2

Liquid Applied Waterproofing Systems

1

Surfaces receiving the waterproof membrane are to be treated with the recommended primer. sealer and allowed to dry.

2

When all the surfaces receiving the membrane and the equipment to be used are ready, the materials are to be mixed in strict accordance with the manufacturer’s instructions using a mechanical mixer. Only that amount which can be used within the pot life of the material is to be prepared.

3

Reinforcing strips at construction and movement joints, shrinkage cracks, pipe inlets/outlets, electrical conduit, air-conditioning ducting etc., must be applied in the widths and thickness recommended by the manufacturer prior to final applications of the membrane.

4

When the reinforcing strips and expansion joint covers have cured, the membrane is to be applied using an airless spray, trowel, squeegee or any other recommended method producing the required membrane thickness.

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QCS 2014


Page 15

Site operatives are to be kept off the membrane until it has cured sufficiently to accept foot traffic. Tackiness of the surface may be neutralised by dusting with dry cement. Areas where labourers will be working applying topping materials should be covered with a protective layer of fibreboard.

6

Surfaces which are not to receive a permanent protective covering are to be treated with a solar reflective finish recommended by the manufacturer of the membrane.

2.8

COATED SPRAY APPLIED FOAM

2.8.1

Description

1

This Clause specifies general requirements for spray applied foam insulation which is covered with a protective coating.

2.8.2

Installation

1

Prior to spray application of the foam all welding or other hot work required on the roof is to be completed and all surfaces not to receive the insulation are to be securely wrapped or otherwise protected with suitable covering.

2

The equipment used by the Contractor is to provide thorough mixing of components and be calibrated prior to commencing work to ensure correct metering of the material components.

3

Under no circumstance should spraying be carried out in the presence of water or when the wind speed is in excess of 25 kilometres per hour.

4

The foam to be applied in minimum 12 mm layers to build up the specified thickness.

5

The first coat or layer of the protective covering is to be applied the same day the foam insulation is installed.

6

If for any reason more than 48 hours elapses between application of the foam and a protective coating, the foam surface is to be inspected for contamination or oxidation. Should either be present, the surface is to be brushed with a stiff broom or mechanically scoured and reformed prior to application of the protective covering.

2.9

PERMEABLE FILTER MEMBRANE

2.9.1


1

Permeable filter membrane are to be chemically stable and made of rot resistant fabric, manufactured from synthetic, thermally bonded, non woven fibre weighing not less than 140 g/m2 and minimum 0.7 mm thick. The membrane is to be capable of freely passing water but preventing the passage of salt and clay particles.

2

Application and execution of workmanship must comply with procedures recommended by the manufacturer.

3

Fabric must be applied around projections or areas of reinforcement in the widths and thickness recommended by the manufacturer prior to final applications of the membrane.

2.10

PROTECTED MEMBRANE

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QCS 2014


Page 16

2.10.1


1

Protective membranes to membrane roofing shall be as specified in Part 4 of this Section.

2.11

TORCH APPLIED WATERPROOF MEMBRANE

2.11.1


1

Torch applied waterproofing membrane shall consist of a reinforced bitumen-polymer membrane having the following minimum properties: Thickness

3mm BS 2782

7.5N/mm

Elongation

BS 2782

40%

Tear Resistance

ASTM D1004

100N

Moisture Vapour Permeability

BS 2782

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Tensile Strength

2

8.5g/m /day

The waterproofing system shall incorporate the priming and reflective coating materials recommended by the manufacturer of the membrane.

2

The waterproofing system shall be applied strictly in accordance with the instructions supplied by the manufacturer.

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END OF PART

QCS 2014

Section 14: Roofing Part 03: Metal and Plastic Roofing

Page 1

3

METAL AND PLASTIC ROOFING ................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

FITTINGS AND ACCESSORIES ................................................................... 2

3.2.1 3.2.2

Fittings for Rigid Sheet Roofing Fixing Accessories

3.3

ALUMINIUM SHEET FLASHING AND APRONS .......................................... 3

3.3.1 3.3.2

Materials Description Installation of Aluminium Flashings and Aprons

3.4

CORRUGATED METAL SHEETS ................................................................. 3

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

Profiled Aluminium Sheets Hop-Dip Zinc Coated Corrugated Steel Sheets Installation of Corrugated and Troughed Roof Coverings Fixing Profiled Aluminium Sheets Fixing Galvanized Corrugated Sheets

3.5

CORRUGATED TRANSLUCENT SHEETS................................................... 6

3.5.1 3.5.2 3.5.3

Materials Description Submittals Fixing Corrugated Translucent Sheets

2 2

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QCS 2014


Page 2

3

METAL AND PLASTIC ROOFING

3.1

GENERAL

3.1.1

Scope

1

This Part specifies requirements for use of metal and plastic roofing systems for buildings and structures.

2

Related Sections are as follows: Thermal Insulation of buildings Carpentry, Joinery and Ironmongery

References

1

The following standards are referred to in this Part: BS 1210 ......................Wood Screws

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3.1.2

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes. Bars, extruded round tube and sections BS 1494 ......................Fixing accessories for building purposes

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BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes

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BS 3416 ......................Bitumen based coatings for cold application, suitable for use in contact with potable water

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BS 4154 ......................Corrugated plastic translucent sheets made from thermo-setting polyester resins (glass fibre reinforced)

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BS 4868 ......................Profiled aluminium sheet for building BS EN 485 ..................Aluminium and aluminium alloys - Plate, sheet and strip

FITTINGS AND ACCESSORIES

3.2.1

Fittings for Rigid Sheet Roofing

1

Fittings are to match the profile of the specified sheet and shall be supplied by the same manufacturer.

3.2.2

Fixing Accessories

1

Screws for fixing aluminium roof edging, aprons, and the like are to be stainless steel to BS 1210, minimum 50 mm long.

2

Hook bolts and nuts shall comply with BS 1494, Part 1 and be 8 mm diameter cadmium or zinc coated steel with plastic sleeves or applied plastic coating, shaped to suit the sheets and roof members and complete with plastic washers.

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3.2

QCS 2014


Page 3

Seam bolts and nuts for aluminium sheets are to be aluminium and to galvanized sheets to be galvanized steel, 6 mm diameter and 40 mm long complete with plastic washers.

4

Filler pieces at ridges and eaves are to be approved pre-moulded cellular plastic or rubber bitumen units to fit exactly the contours of the corrugations.

5

Sealant strip are to be approved flexible expanded polyurethane foam strip impregnated with waxes and/or resins having an elastic recovery of 98% minimum and a density of not less 3 than 145 kg/m .

3.3

ALUMINIUM SHEET FLASHING AND APRONS

3.3.1

Materials Description

1

Aluminium sheet flashings, aprons, etc., are to be fabricated from 99.8 % aluminium sheet and strip to BS EN 485, material designated 1080A, 0.9 mm thick.

2

Aluminium roof edging is to be fabricated form materials 6063-TB or 6063-TF complying with BS 1474 to profiles to suit the verges and roof covering material.

3

Black bitumen coating solution shall comply with BS 3416, Type 1.

3.3.2

Installation of Aluminium Flashings and Aprons

1

Flashings, aprons, and the like, are to be formed from sheets not more than 1800 mm long and to be lapped a minimum of 75 mm at intersections.

2

After folding and dressing, two coats of black bitumen coating solution are to be applied to all areas, which will come into contact with materials containing cement. Repeated folding and dressing should be avoided to prevent work hardening.

3

The top edge of flashings are to be provided with a 13 mm turn-back to act as a waterstop and recessed a minimum of 25 mm into the wall. The flashing are to be fixed with 20 x 20 mm strips of aluminium folded into a wedge shape, covered with two coats of bitumen solution and driven into the full depth of the recess at 400 mm centres. Upon completion of fixing the recess are to be pointed in Class M6 cement mortar in accordance with Part 2 of Section 13, Masonry.

4

Materials containing steel, copper, brass or bronze should not be allowed to come into contact with aluminium.

3.4

CORRUGATED METAL SHEETS

3.4.1

Profiled Aluminium Sheets

1

Profiled aluminium sheets shall comply with BS 4868 and be manufactured from aluminium alloy to BS EN 485, material designation 3103-H8, with a minimum tensile strength of 2 175 N/mm . Unless otherwise specified, Profile S, with a minimum thickness of 0.9 mm shall be installed.

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QCS 2014


Page 4

Hop-Dip Zinc Coated Corrugated Steel Sheets

1

Hop-Dip zinc coated corrugated steel sheets shall comply with BS 3083 and shall have a 2 sheet thickness of 0.9 mm and minimum 450 g/m zinc coating.

3.4.3

Installation of Corrugated and Troughed Roof Coverings

1

The sheeting is to be laid with the open joint of side laps away from the prevailing wind. The Contractor is to obtain the approval of the Engineer as to which end of the structure the laying is to commence before beginning sheeting work.

2

The eaves course are to be laid first and subsequent sheets laid in tiers up to the roof from eaves to ridge, aligning sheets on both slopes on double pitched roofs.

3

Corrugations or troughs are to be in line from eaves to ridge and eaves and verges are to maintain proper alignment.

4

Sheets are to be cut to clean, true lines with no distortion. All burrs, drilling swarf or dust and any other foreign matter to be removed before positioning sealing strips, filler pieces and washers.

5

Openings for outlets, vent pipes, etc., are to be cut to the minimum size necessary. Vent pipes and the like should always pass through the centre line of the crown and are to be offset below roof level if necessary.

6

Holes through the sheets are to be drilled 2 mm larger than the diameter of the bolt and always through the crown of the profile. No hole should be nearer than 40 mm to the end of the sheet. All fixings are to be of the specified type and size and be in the correct position true to line and secure.

7

Fittings are to be fixed, where possible, by the same bolts that secure the sheeting.

8

Filler pieces shall be installed between the corrugations or troughs and flat surfaces or supports at the end of sheet runs wherever necessary to ensure airtightness of the structure.

9

A movement joint shall be provided in all lengths over 45 m. The joint is to be formed by installing an approved proprietary movement joint cover in a suitably sized space between the sheet.

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3.4.2

QCS 2014


Page 5

3.4.4

Fixing Profiled Aluminium Sheets

1

Corrugated or troughened sheets are to be laid to comply with the requirements of with Tables 3.1 and 3.2. Table 3.1 Minimum Laps for Roof Sheeting Side Lap

mm

Corrugations

more than 15

150

1½

less than 15

230

1½

vertical

100

1

less than 15

150

1

more than 15

230

1

vertical

100

1

150

1½

230

1½

Corrugated Galvanized

2

more than 15

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Sheet

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Troughed aluminium sheet

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Corrugated aluminium sheet

ta

Slope

.

End Lap

Material

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less than 15

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Table 3.2 Maximum Permissible Dimensions for Roof Sheeting Maximum Rail Spacing (mm)

Maximum Unsupported Overhang (mm)

1350

1500

150

2200

2400

350

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Sheet Material

Maximum Purlin Spacing (mm)

o

Corrugated aluminium

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Corrugated galvanized steel

The centre line of end laps to coincide as nearly as possible with the centre line of supports, or the back of angle purlins. All end laps to be fully supported.

4

Roofing sheets are to be fixed to metal purlins by hook bolts. Each bolt is to be fitted with a metal washer shaped to the profile of the sheet and placed on the outer face together with a plastic, or similar approved material, sealing washer, positioned between the metal washer and sheet so that the bolt hole is sealed when the bolt is tightened. The bolt should be tightened only sufficiently to seat the washer and so as to permit slight movement between the structural frame and the sheeting.

5

Each sheet is to be fixed at every purlin or rail by at least two bolts situated at the side laps or edges together with intermediate fastenings at maximum 375 mm centres.

6

In addition to purlin or rail fixings, side laps are to be secured by means of bolts or rivets passing through the crown of the profile at the following maximum centres:

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3

(a)

roofs more than 15 pitch

375 to 450 mm centres

(b)

roofs less than 15 pitch

300 to 375 mm centres

QCS 2014

(c)

Section 14: Roofing Part 03: Metal and Plastic Roofing vertical sheeting

Page 6

450 mm centres.

Ridge cappings are, where possible, to be secured to the roof by the same bolts that secure the sheeting or, if the ridge purlin in not sufficiently near the ridge to permit this, the capping should be secured to the sheeting on each side by seam bolts or rivets at maximum 450 mm centres. The lap of the capping along the ridge should not be less than 150 mm with the open joint away form the prevailing wind.

3.4.5

Fixing Galvanized Corrugated Sheets

1

Galvanised corrugated sheets are to be installed as described in Clause 3.4.3.

3.5

CORRUGATED TRANSLUCENT SHEETS

3.5.1

Materials Description

1

This Section covers pre-formed plastic panels or corrugated translucent sheets made from thermosetting polyester resins to comply with BS 4154 and are to match the profile of the adjoining metal sheets.

2

The colour of plastic panels shall be as designated in the Project Documentation unless otherwise approved by the Engineer.

3.5.2

Submittals

1

Shop drawings for plastic panels shall show details of construction and installation, including profiles, fastener types and flashing details.

2

Plastic panel samples, 750 mm square, shall be submitted for each colour or varying texture finish used.

3.5.3

Fixing Corrugated Translucent Sheets

1

The sheets are to be laid with the same minimum side and end laps as the adjoining sheets. Sealing strips be used where the end lap is less than 300 mm on roof pitches below 15.

2

Pre-moulded filler strips and clear mastic shall be used to seal laps.

3

Fixing accessories and holes are to be the same as used for the adjoining sheets.

4

Each sheet should be fixed at every purlin or rail by at least two bolts situated at the side laps and three intermediate fastenings for use with galvanized or aluminium corrugated profiles.

5

In addition to purlin or rail fixings, side laps are to be secured by means of seam bolts at maximum 300 mm centres. The use of self-tapping screws or blind rivets are not permitted.

6

Provide neoprene washers under bolt heads. If other fastenings are recommended by plastic sheet manufacturer, install in accordance with manufacturer’s recommendations.

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END OF PART

QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 1

4

ROOF AND DECK INSULATION .................................................................. 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References Submittals General Application

4.2

RIGID BOARD INSULATION......................................................................... 3

4.2.1


4.3

PROTECTION OF INVERTED ROOF SYSTEMS ......................................... 3

4.3.1


4.4

POLYSTYRENE BOARD INSULATION ........................................................ 3

4.4.1


4.5

CEMENT-FIBRE ROOF DECK ...................................................................... 4

4.5.1 4.5.2 4.5.3 4.5.4

General Description Cement-Fibre Roof Deck Planks Accessories Installations

4.6

INSULATING CONCRETE ROOF SCREEDS............................................... 5

4.6.1 4.6.2 4.6.3

General Description Materials Execution of Work

2 2 2 3

3 3 4 4 4 5

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QCS 2014


Page 2

4

ROOF AND DECK INSULATION

4.1

GENERAL

4.1.1

Scope

1

This Part specifies requirements for types of roofing and deck insulation.

2

Related Sections are as follows: General Membrane Roofing Metal and Plastic Roofing Roof tiles and Shingles


General Thermal Insulation of Buildings

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References

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BS 3379 ......................Flexible polyurethane cellular materials for load bearing applications BS 3797 ......................Lightweight aggregates for concrete

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BS 5075 ......................Concrete admixtures

BS 1105 ......................Wood wool cement slabs up to 125 mm thick

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BS 3837 ......................Expanded polystyrene boards BS EN 490 ..................Concrete roofing tiles and fittings - Product specifications

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BS EN 491 ..................Concrete roofing tiles and fittings - Test methods EN 197-1 ....................Portland Cement Submittals

1

The contractor is to submit the following to the Engineer for approval before commencement of work in this section.

2

Manufacturers literature and samples of roofing, thermal insulation, vapor barrier, roof accessories, bitumen waterproof membranes, waterproofing materials, dampproof coursing and elastometric sealants, etc.

3

Primary roofing materials inclusive of insulation, barriers or membranes should be obtained from only one manufacturer if possible. Where secondary materials must be used, the primary manufacturer is to be provided with adequate literature and samples for concurrence that the secondary products are compatible for roofing warrantees. Concurrence will be provided by the Contractor in writing to the Engineer prior to commencement of work.

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General Application

1

Expanded extruded polystyrene boards shall comply with BS 3837, Grade EHD, Type A, extruded board with skins.

2

Spray applied polyurethane or isocyanurate foam insulation is to be protected from deterioration due to ultra violet light by a covering approved by the manufacturer of the foam.

3

Where spray applied foam is used as an integral part of the roof waterproofing system it must be specifically included in the manufacturer’s guarantee requirements.

4

Unless otherwise specified the insulation is to be at least equivalent to 50 mm thick material having an ultimate thermal conductivity of 0.032 W/mK at a mean temperature of 10C and a compressive resistance of not less than 150 kN/m2.

4.2

RIGID BOARD INSULATION

4.2.1


1

Rigid insulation boards are to be installed as a single layer to the thickness specified.

2

All joints between rigid insulation boards are to be tight and no gaps should exist where the board meets rooflights, edge details and services penetrating the roof structure. End joints are to be staggered.

3

On corrugated surfaces all long edges are to be supported by the crown of the corrugations.

4.3

PROTECTION OF INVERTED ROOF SYSTEMS

4.3.1


1

Insulating material having a water absorption in excess of 1.5% by volume in seven (7) days at 20 ºC are not to be used in inverted roof systems.

2

The insulation is to be covered by a layer of permeable filter membrane, laid loose and lapped 200 mm at all intersections before the paving slabs or solar reflective chipping is laid.

3

Paving slab protection is to be loose laid with 6 mm open joints on 100 x 100 x 6 mm inorganic spacers positioned at the corner junctions of the slabs. The paving slabs will have a minimum thickness of 40 mm on insulation boards of up to 50 mm and for every 10 mm increase in the insulation thickness the slab thickness should be increased by 5 mm.

4

Aggregate protection is to consist of a 50 mm minimum layer of chippings on insulation boards of up to 50 mm. The thickness of the aggregate layer to be increased to a depth equal to the thickness of insulation boards over 50 mm.

4.4

POLYSTYRENE BOARD INSULATION

4.4.1


1

Polystyrene board insulation shall conform to BS 3837, and shall include the following requirements:

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4.1.4

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(a)

water absorption shall not be more than 0.1 % by weight

(b)

density shall not be less than 32 kg/m for Type VI

3

Standard polystyrene boards shall conform to the following requirements: (a)

nominal size shall be approximately 600 by 1200 mm minimum

(b)

they shall have a drainage channel on the bottom longitudinal edge of the board

(c)

they are to have a flat top surface where gravel ballast in used or ribbed bottom pavers are used

(d)

they are to have ribbed top surface where flat bottom paver is used

(e)

they are to be tapered for roof slope where top surface is level

(f)

the edges shall be square, except for drainage channels.

density

(ii)

compressive strength (28 days)

(iii)

bond strength to insulation1 MPa

(iv)

troweled finish with texture

25 MPa

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(a) boards shall be top surfaced with 10 mm thick facing of Portland cement latex mortar having the following physical properties:

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(a)

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Mortar faced boards shall conform to the following requirements:

drainage channels on bottom longitudinal edges of board

(c)

nominal size shall be approximately 600 by 1200 mm minimum

(d)

they shall have tongue and grooved longitudinal edges

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CEMENT-FIBRE ROOF DECK

4.5.1

General Description

1

This Clause covers the furnishing and installation of cement-fibre roof deck planks.

4.5.2

Cement-Fibre Roof Deck Planks

1

Cement-Fibre planks shall be manufactured from treated wood fibres and Portland cement, bonded under pressure to BS 1105. The length and width of planks to be shown on plans will comply with manufacturer’s requirements to suit span and load. The long edges are to be tongue and grooved and the ends square. Zinc coated steel channels will be factory applied in the groove of the plank. A factory bonded layer of urethane foam insulation shall be applied to the top of the plank.

2

Examine planks before installation. Broken or cracked planks should not be used. Where exposed, repaint soiled planks with paint recommended by the plank manufacturer to match colour and texture of adjacent planks.

4.5.3

Accessories

1

Clips shall be as recommended by the cement-fiber plank manufacturer to suit the supporting members.

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Nails shall be galvanized cork type with integral 25 mm washer, of length to penetrate wood support not less than 25 mm.

4.5.4

Installations

1

Planks shall be cut to fit tight at perimeters, vertical surfaces, projections and openings. All edges and ends of planks and perimeter of openings greater than 200 mm are to be supported by framing members and bearing walls.

2

Planks are to be laid progressively with side joints (edges) tightly butted and with end joints in adjacent rows staggered.

3

Clips or nails are to be installed progressively as each plank is installed. Clips or nails are to be installed in accordance with the manufacturer's instructions.

4

Install a barrier, full depth of the plank, over the top of sound rated partitions and at the perimeter of exterior walls.

4.6

INSULATING CONCRETE ROOF SCREEDS

4.6.1

General Description

1

This section covers insulating concrete placed on a prepared structural deck.

2

Insulating concrete placed on steel deck forms are to have underside venting through slotted holes formed in the metal deck, combined with edge venting or topside venting through roof relief vents.

3

Insulating concrete placed over cast-in-place concrete or precast concrete substrates, is to be vented through the use of topside roof relief vents combined with edge venting.

4.6.2

Materials

1

Refer to Section 5, Concrete, for specifications relating to sand, cement, aggregates and water.

2

Portland cement shall conform to EN 197-1.

3

Concrete roofing tiles shall conform to BS EN 490 and BS EN 491.

4

Light weight aggregates shall conform to BS 3797.

5

Chipping shall be approved, clean, crushed white or pale grey, size 15 to 30 mm and shall comply with BS 3379.

6

Air entraining agent refer to BS 5075 Prt 2 and shall be a type as recommended by aggregate suppliers. Admixtures with chloride salts or pre-generated foam types are not acceptable.

7

Permeable filter membrane shall be to Clause 2.9.1.

8

Control joint filler shall be glass fibre or similar highly compressible material, which will compress to half of its thickness under a load of 170 KPa or less.

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Wire mesh reinforcing shall be used when roof deck slopes exceed 1:3 and for fire rated roof assemblies using metal decking. The wire mesh shall be 1 mm galvanized steel wire twisted to form 50 mm hexagons with 1.6 mm galvanised steel wire woven into mesh spaced 200 mm apart. Welded wire fabric of equivalent size may also be used an approval of the Engineer.

4.6.3

Execution of Work

1

The surface of the concrete base must be clean, firm and rough to ensure a good bond.

2

The base should be soaked with water for at least 12 hours and all surplus water removed before laying commences.

3

To obtain the required falls and thickness of screed, leveling battens are to be used, carefully fixed to line and level and fully bedded. There should be a minimum thickness of 40 mm of screed over the top of any conduit or duct.

4

Immediately prior to laying the screed, a thick brush coat of wet cement grout should be applied to the damp surface of the base concrete and be well scrubbed in. The brush coat must not be applied more than 10 minutes before it is covered with screed. Alternatively, the Engineer may required that surfaces which have been left for an excessive period of time before the screed is laid be treated with an approved bonding agent.

5

The screed is to consist of 1 part of cement to 5 parts of sand by weight. The mix shall only contain sufficient water that will allow full compaction and be evenly spread to a thickness approximately 10 mm greater than that required. The screed is to be thoroughly compacted by tamping and drawing off to the required level with a screed board.

6

The screed is to be laid in alternated bays, maximum 10 m², with plain butt joints to provide minimum falls of 1:80 and a minimum thickness of 50 mm. Movement and construction joints in the base should be carried through the screed.

7

The joints between bays and at junctions with all upstands are to be minimum 12 mm wide and be filled for the full depth of the joint with sealing strip or an approved polysulphide joint filler and sealing compounds.

8

A 75 x 75 mm triangular fillet is to be provided at the junction with all upstands.

9

The top surface is to be floated to smooth and even falls suitable for the waterproofing system to be employed and be free of low areas, lumps and projections. Care should be taken to avoid excessive trowelling which may cause crazing.

10

As soon as each bay is completed and has hardened sufficiently to prevent damage to its surface, it should be covered with polythene or similar sheets which should be adequately lapped and held down. The screed must not be allowed to dry out for a minimum period of seven (7) days and no traffic should be permitted on the surface during this time.

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END OF PART

QCS 2014

Section 14: Roofing Part 05: Roofing Tiles and Shingles

Page 1

5

ROOFING TILES AND SHINGLES ............................................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2

Scope References

5.2

CLAY SHALE AND CONCRETE ROOFING TILES ...................................... 3

5.2.1 5.2.2 5.2.3

General Products Execution of Installation

5.3

ROOFING SHINGLES ................................................................................... 4

5.3.1 5.3.2 5.3.3

General Metal, asbestos-cement and Asphalt Shingles Shakes and Shingles of Other Materials

2 2

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5

ROOFING TILES AND SHINGLES

5.1

GENERAL

5.1.1

Scope

1

This Part specifies requirements for and the installation of roof tiles made of clay, shale and concrete, and additionally for shakes or shingles made of other materials.

2

Related Sections are as follows: General Membrane Roofing Metal and Plastic Roofing Roof and Deck Insulation

Section 1 Section 5 Section 13 Section 14 Section 15 Section 17 Section 18 Section 24

General Concrete Masonry Roofing Thermal Insulation of Buildings Metalwork Carpentry, Joinery and Ironmongery Finishes to Buildings

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In general, roofing tile and shingle materials and their application shall conform to BS 5534, BS 8000 Part 6, BS EN 490, BS EN 491 and BS EN 539.

5.1.2

References

1


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BS 402 ........................Clay plain roofing tiles and fittings BS 680 ........................Roofing slates

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BS 747 ........................Roofing felts BS 1202 ......................Nails BS 1521 ......................Waterproof building papers BS 4016 ......................Building papers (breather type) BS 5534 ......................Code of Practice for slating and tiling BS 8000 ......................Workmanship on building sites BS EN 490 ..................Concrete roofing tiles and fittings - Product specifications BS EN 491 ..................Concrete roofing tiles and fittings - Test methods BS EN 538 ..................Clay roofing tiles for discontinuous laying flexural strength test BS EN 539 ..................Clay roofing tiles for discontinuous laying - determination of physical characteristics

QCS 2014


Page 3

5.2

CLAY SHALE AND CONCRETE ROOFING TILES

5.2.1

General

1

Roofing tiles made of clay, shale and concrete roofing tiles shall comply with (but are not limited to) the respective standards as follows: clay, shale roofing tiles: BS 402, BS 680, BS EN 538, BS EN 539, and BS 8000 Part 6

(b)

concrete roofing tiles: BS 680, BS EN 490 and 491, and BS 8000 Part 6.

Submittals of roofing materials to be used will be made by the Contractor in accordance with the relevant provisions of Section 1, General, shall include furnishing of the following: (a)

samples of each colour of each type of tile required in the Works; the tiles shall be of finished product quality and shape

(b)

shop drawings with details of any fabricated custom shapes and installation requirements.

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Product Delivery, Storage and Handling:

tiles and setting materials shall be delivered in manufacturers’ original, unopened containers clearly identifying manufacture and the contents

(b)

tiles shall not be stored in the flat position.

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(a)

The Contractor shall guarantee materials and workmanship to be free from defects and leaks for a period of two (2) years.

5.2.2

Products

1

Clay and shale roofing tiles shall be English, French, Greek, Roman or Spanish type unless otherwise specified in the Project Documentation or approved by the Engineer, and all tiles are to be hard burned, dense, fully vitrified, clay or shale, free from fire cracks or defects.

2

Concrete roof tiles will be of quality materials to BS EN 490 and BS EN 491.

3

Non-interlocking locking or interlocking tiles are acceptable, but should not be intermixed in use.

4

Nails brads, staples and spikes and any other fasteners used to secure tiles shall be corrosion-resistant nails or wire to BS 1202.

5

Felt underlay should be to tile manufacturer’s recommendations for related roof slope. Felt underlay shall be asphalt saturated organic felt, without perforations, nominal 66 kg/m2 to BS 747 unless otherwise shown on the drawings and shall comply to BS 4016, BS 1521 and BS 747.

5.2.3

Execution of Installation

1

Vent pipes and other projections through roofs and flashing materials are to be in place before laying tiles.

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2

Felt underlay shall be laid in single thickness, parallel to eaves with double thickness at hips and ridges. Horizontal joints shall be lapped 75 mm and vertical joints lapped 150 mm. Vertical joints shall be staggered. Felt shall be extended up 150 mm at abutting vertical walls, chimneys and parapets. Under the edges of built-up gutters, valleys, and metal flashings, the felt shall be lapped not less than 100mm.

3

Laying Tile tiles shall be laid free of horizontal obstructions which would impede shedding of surface water

(b)

courses shall be laid parallel with eaves

(c)

each tile shall be secured by at least two nails, of copper or stainless steel wire and shall be fastened where practicable

(d)

nails and wire fastenings in finished work shall be covered

(e)

tiles shall be laid with an end lap of at least 75 mm

(f)

fill laps of end bands, of tiles on ridges, and gable rakes with roofers plastic cement

(g)

roofers plastic cement may be used for levelling tiles and for pointing around eave bridge closures.

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(a)

Upon completion of the tiling, any cement splatter shall be removed from tile and adjacent surfaces.

5.3

ROOFING SHINGLES

5.3.1

General

1

Roofing shingles, as specified in this Section, are inclusive of all non-clay, shale or concrete tiles which are used in the same manner as roofing elements used in an overlapping system on sloped roofs.

5.3.2

Metal, asbestos-cement and Asphalt Shingles

1

Metal, asbestos-cement and asphalt shingles shall be installed in an approved manner as established by acceptable proprietary manufacturers and as detailed in the drawings

5.3.3

Shakes and Shingles of Other Materials

1

Other shake or shingle products of man-made plastic or compounds will require submittal of product specification and samples for testing prior to approval. Such products shall be installed in an approved manner as established by acceptable proprietary manufacturers and as detailed in the drawings.

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END OF PART

QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2

1.2 1.2.1 1.2.2 1.2.3

MATERIALS ............................................................................................................ 4 General Requirements 4 Submittals 4 Storage 5

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1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section covers the type, quality and application of exterior wall and roof insulation, damp proof courses, waterproof; and related joints, caulking and insulation.

2

Related Sections are as follows: This Section

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Section 1 ......... General Section 13 ....... Masonry Section 14 ....... Roofing Section 16 ...... Structural Metalwork Section 17 ....... Metalwork Section 24 ....... Finishes to Buildings Section 25 ....... Glass and Glazing

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Part 2 ............... Building Insulation Part 3 ............... Cold Stores

References

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BS 874........................Methods for determining thermal insulating properties

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BS 1142......................Fibre building boards BS 1202......................Nails

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BS 1210......................Wood screws

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BS 1449......................Steel plate, sheet and strip BS 2502......................Manufacture of sectional cold rooms (walk in type)

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BS 2972......................Method of test for inorganic thermal insulating materials BS 3692......................ISO metric precision hexagon bolts, screws and nuts BS 3837......................Expanded polystyrene boards BS 3927...................... Rigid phenolic foam (PF) for thermal insulating in the form of slabs and profiled sections BS 3958......................Thermal insulation materials BS 4841......................Rigid polyurethane (PUR) and polyisocyanurate (PIR) foam for building applications BS 5250......................Code of practice for control of condensation in buildings BS 5617......................Urea-formaldehyde (UF) foam systems suitable for thermal insulation of cavity walls with masonry of concrete inner and outer leaves BS 5618......................Thermal insulation of cavity walls (with masonry of concrete inner and outer leaves) by filling with urea-formaldehyde (UF) foam systems BS 5803......................Thermal Insulation for use in pitched roof spaces in dwellings

QCS 2014


Page 3

BS 6203......................Guide to fire characteristics and fire performance of expanded polystyrene materials (EPS and XPS) used in building applications BS 6676......................Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 7021......................Code of practice for thermal insulation of roofs externally by means of sprayed rigid polyurethane (PUR) or polyisocyanurate (PIR) foam BS 7456 .....................Code of practice for stabilization and thermal insulation of cavity walls (with masonry or concrete inner and outer leaves) by filling with polyurethane (PUR) foam systems BS 8208......................Assessment of stability of external cavity walls for filling with thermal insulants

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BS 8216......................Code of practice for use of sprayed lightweight mineral coatings used for thermal insulation and sound adsorption in buildings

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BS 8233......................Sound insulation and noise reduction for buildings. Code of practice

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BS EN 998-1 .............Specification for mortar for masonry: Part 1: Rendering and plastering mortar BS EN 3261................Unbacked flexible PVC flooring

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BS EN 13162:2012..... Thermal insulation products for buildings. Factory made mineral wool (MW) products. Specification

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BS EN 13163..............Thermal insulation products for buildings. Factory made expanded polystyrene (EPS) products. Specification

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BS EN 13164 .............Thermal insulation products for buildings. Factory made extruded polystyrene foam (XPS) products. Specification

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BS EN 13165..............Thermal insulation products for buildings. Factory made rigid polyurethane foam (PU) products. Specification BS EN 13166..............Thermal insulation products for buildings. Factory made phenolic foam (PF) products. Specification

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BS EN 13167:2012. ...Thermal insulation products for buildings. Factory made cellular glass (CG) products. Specification

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BS EN 13168:2012.....Thermal insulation products for buildings. Factory made wood wool (WW) products. Specification BS EN 13169:2012.....Thermal insulation products for buildings. Factory made expanded perlite board (EPB) products. Specification BS EN 13170:2012.....Thermal insulation products for buildings. Factory made products of expanded cork (ICB). Specification BS EN 13171:2012.....Thermal insulation products for buildings. Factory made wood fibre (WF) products. Specification BS EN 13172..............Thermal insulation products. Evaluation of conformity BS EN 13467..............Thermal insulating products for building equipment and industrial installations. Determination of dimensions, squareness and linearity of preformed pipe insulation BS EN 14319-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed dispensed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products

QCS 2014


Page 4

BS EN 14320-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14496..............Gypsum based adhesives for thermal/acoustic insulation composite panels and plasterboards. Definitions, requirements and test methods EN 1745:2002 ............Masonry and masonry products — Methods for determining design thermal values EN 13501-1 ................Fire classification of construction products and building elements — Part 1: Classification using test data from reaction to fire tests

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GSO EN 13950 Gypsum plasterboard thermal/acoustic insulation composite panels Definitions, requirements and test methods

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ISO 12575-1 ...............Thermal insulation. Exterior insulating systems for foundations Material specification systems

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ISO 12575-2 ...............Thermal insulation products. Exterior insulating foundations: Principal responsibilities of installers

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ISO 11925-2 ...............Reaction to fire tests -- Ignitability of products subjected to direct impingement of flame -- Part 2: Single-flame source test

MATERIALS

1.2.1


1

Types for insulation are: thermal /acoustic / fire / damp proof courses / waterproof

2

Thermal insulation materials shall meet requirements of BS 2972 for testing for inorganic thermal quality and expanded polystyrene materials shall meet fire requirements of BS 6203 or EN 13501-1 or ISO 11925-2.

3

Insulation material shall comply with any reference in paragraph 1.1.2, or approved by Qatar Standards.

4

Insulation materials shall be approved by Civil Defence Department

1.2.2

Submittals

1

Submittals shall comply with the relevant provisions of Section 1, General.

2

The Contractor shall submit to the Engineer the manufacturer’s literature and data for the following:

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1.2

(a)

insulation, each type used

(b)

adhesives, each type used

(c)

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QCS 2014


Page 5

3

The Contractor shall submit to the Engineer details of all insulation materials to be installed. The details shall include, but not be limited to, the type, dimensions and thermal/acoustic/damp proof courses/waterproof insulating properties of the insulation. References to all applicable standards shall be included with the submission.

1.2.3

Storage

1

Materials shall be stored in accordance with the relevant provisions of Section 1, General.

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END OF PART

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 1

BUILDING INSULATION ......................................................................................... 2

2.1 2.1.1 2.1.2


2.2 2.2.1

THERMAL INSULATION ......................................................................................... 4 Minimum Envelope Performance Requirements 4

2.3 2.3.1

ACOUSTICAL CONTROL ....................................................................................... 5 References 5

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9

INSULATION MATERIAL TYPES ............................................................................ 6 General 6 External Thermal Insulation Composite System (ETICS) 6 Cavity Wall Insulation 6 Perimeter Insulation 6 Exterior Framing or Furring Insulation 7 Rigid Insulation 7 Masonry Fill Insulation 7 Adhesive 7 Tape 7

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7

INSTALLATION ....................................................................................................... 7 Execution and Workmanship 7 Masonry Cavity Walls 8 Perimeter Insulation 8 Exterior Framing or Furring Blanket Insulation 8 Rigid Insulation 9 Masonry Fill Insulation 9 Insulation Behind Marble Cladding 9

2.6 2.6.1 2.6.2

PREFABRICATED WALL INSULATION................................................................ 10 General 10 Quality and Requirements 10

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2

BUILDING INSULATION

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the type, quality and application of exterior wall insulation.

2

Related Sections are as follows: This Section

References

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Section 5 ......... Concrete Section 13 ....... Masonry Section 18 ....... Carpentry, Joinery and Ironmongery

.

Part 1 ............... General

BS 874........................Methods for determining thermal insulating properties BS 1202......................Nails

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BS 1210......................Wood screws

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BS 1142......................Fibre building boards

BS 3692......................Isometric precision hexagon bolts, screws, nuts

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BS 3837......................Expanded polystyrene boards

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BS 3958......................Thermal insulation materials BS 4841......................Rigid urethane foam

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BS 5250......................Code of practice for control of condensation in buildings

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BS 5617......................Urea-formaldehyde (UF) foam systems suitable for thermal insulation of cavity walls with masonry or concrete outer leaves

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BS 5618......................Thermal insulation of cavity walls (with masonry or concrete outer leaves) by filling with urea-formaldehyde (UF) foam systems BS 5803......................Thermal insulation for use for use in pitched roof spaces in dwellings BS 6203......................Guide to fire characteristics and fire performance of expanded polystyrene materials (EPS and XPS) used in building applications BS 6676......................Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 7021......................Code of practice for thermal insulation of roofs externally by means of sprayed rigid polyurethane (PUR) or polyisocyanurate (PIR) foam BS 7456 .....................Code of practice for stabilization and thermal insulation of cavity walls (with masonry or concrete inner and outer leaves) by filling with polyurethane (PUR) foam systems BS 8208......................Assessment of stability of external cavity walls for filling with thermal insulants

QCS 2014


Page 3

BS 8216......................Code of practice for use of sprayed lightweight mineral coatings used for thermal insulation and sound absorption in buildings BS 8233......................Sound insulation and noise reduction for buildings. Code of practice BS EN 998-1 .............Specification for mortar for masonry: Part 1: Rendering and plastering mortar BS EN 13162:2012.....Thermal insulation products for buildings. Factory made mineral wool (MW) products. Specification BS EN 13163..............Thermal insulation products for buildings. Factory made expanded polystyrene (EPS) products. Specification

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BS EN 13164 .............Thermal insulation products for buildings. Factory made extruded polystyrene foam (XPS) products. Specification

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BS EN 13165..............Thermal insulation products for buildings. Factory made rigid polyurethane foam (PU) products. Specification

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BS EN 13166..............Thermal insulation products for buildings. Factory made phenolic foam (PF) products. Specification

qa

BS EN 13167:2012. ...Thermal insulation products for buildings. Factory made cellular glass (CG) products. Specification

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BS EN 13168:2012.....Thermal insulation products for buildings. Factory made wood wool (WW) products. Specification

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BS EN 13169:2012.....Thermal insulation products for buildings. Factory made expanded perlite board (EPB) products. Specification

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BS EN 13170:2012.....Thermal insulation products for buildings. Factory made products of expanded cork (ICB). Specification

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BS EN 13171:2012.....Thermal insulation products for buildings. Factory made wood fibre (WF) products. Specification BS EN 13172..............Thermal insulation products. Evaluation of conformity

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BS EN 13467..............Thermal insulating products for building equipment and industrial installations. Determination of dimensions, squareness and linearity of preformed pipe insulation

m

BS EN 14319-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed dispensed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14320-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14496..............Gypsum based adhesives for thermal/acoustic insulation composite panels and plasterboards. Definitions, requirements and test methods EN 1745:2002 ............Masonry and masonry products — Methods for determining design thermal values EN 13501-1 ................Fire classification of construction products and building elements — Part 1: Classification using test data from reaction to fire tests GSO EN 13950 ..........Gypsum plasterboard thermal/acoustic insulation composite panels Definitions, requirements and test methods

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Page 4

ISO 12575-1 ...............Thermal insulation. Exterior insulating systems for foundations Material specification ISO 12575-2 ...............Thermal insulation products. Exterior insulating foundations: Principal responsibilities of installers

systems

for

ISO 11925-2 ...............Reaction to fire tests -- Ignitability of products subjected to direct impingement of flame -- Part 2: Single-flame source test Health Technical Memorandum 08-01: Acoustics

THERMAL INSULATION

2.2.1

Minimum Envelope Performance Requirements

1

For all new air conditioned buildings, exterior building elements must have average thermal transmittance (also known as U Value) and Shading Coefficients (SC) that does not exceed the values specified and Light Transmittance greater than or equal to the values specified. External Walls, Roofs and Floors:

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(a)

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.l. l

.

2.2

qa

Building elements forming the external walls and floors (where one side of the floor is exposed to ambient conditions) must have an average thermal transmittance (U Value) which does not exceed the following values: 2

U= 0.44W/m K

as

Roof

2

U=0.57W/m K

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External Wall Floor

2

U=0.57W/m K

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er

If the floor is in contact with the ground, the insulations should only be applied to one meter (1m) in from the perimeter of the building.

If the total area of external walls that let in light is forty percent (40%) or less of the external wall area, then the glazing elements must meet the following performance criteria:

m

2

Glazed Elements-Fenestration:

et it

(b)

o

Glazed elements with back insulated panels must be treated as walls (and therefore must meet the performance requirement for walls.)

3

4

2

Thermal Transmittance (Summer U Value)

U=2.1W/m K (max)

Shading Coefficient (SC)

0.4 (max)

Light Transmittance

0.25 (min)

If the total area of external walls that let in light is between forty percent (40%) and sixty percent (60%) of the external wall area, then the glazing elements must meet the following performance criteria: 2


U=1.9W/m k (max)


0.32 (max)

Light Transmittance

0.1 (min)

If the total of external walls that let in light is sixty percent (60%) or greater of the external wall area, then the glazing elements must meet the following performance criteria.

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5

Page 5

2


U=1.9W/m K (max)


0.25 (max)

Light Transmittance

0.1 (min)

For shop fronts and showrooms, other than those at ground floor level, glazing elements must meet the following performance criteria: 2


U=1.9W/m K (max)


0.76 (max)

If the glazing portion of a roof is ten percent (10%) or less of the roof area, then the glazing elements must meet the following performance criteria:

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.

6


2

U=1.9W/m K (max)


0.32 (max)

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qa

If the glazing portion of a roof is greater than ten percent (10%) of the roof area, then the glazing elements must meet the following performance criteria: 2

U=1.9W/m K (max)


0.25 (max) 0.3 (min)

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Light Transmittance

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se

7

0.4 (min)

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Light Transmittance

ACOUSTICAL CONTROL

2.3.1

References

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ov

2.3

et it

Building Type

m

Villas/Residential Buildings

Document Reference Building Regulations Approved Document E (revised 2003) (UK)

Healthcare Facilities

Health Technical Memorandum 08-01 (UK)

Educational facilities

Building Bulletin 93: Acoustic Design of Schools – A design Guide (UK)

Commercial Buildings

BS8233:1999 “Sound insulation and noise reduction for buildings-code of practice.” (UK)

Industrial


Public


*Residential buildings Accommodations.

include

Villas,

Apartments,

Worker

Accommodations

and

Student

**Educational Facilities include Nursery Schools, Primary Schools, Secondary Schools, Colleges and Universities.

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Page 6

INSULATION MATERIAL TYPES

2.4.1

General

1

Various types of insulation may be specified for varying conditions or wall construction. The BS, EN classification system is to be used for insulation material; or to any other reference mentioned in paragraph 2.1.2 , or approved by Qatar Standards.

2

The Contractor shall use only one type of insulation in any particular area where more than one type is optional unless approved other wise by the Engineer.

3

At least thermal insulation is to be used for exterior roofs and exterior walls of the building

4

Where insulation is used for exterior walls, roof surfaces, or below grade, the requirements for condensation control shall be to BS 5250 and BS 5803.

2.4.2

External Thermal Insulation Composite System (ETICS)

1

If specified the external thermal insulation composite system (ETICS) shall be bonded system and tested in accordance with ETAG-004 (European organization for technical approvals):-

2

The external thermal insulation system shall compose of the following components:-

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2.4

Adhesive layer

(b)

Extruded or expanded Polystyrene board

(c)

Insulation boards fasteners (Plastic or metal)

(d)

Cementitious adhesive protective mortar layer

(e)

Fibremesh reinforcement

(f)

Cementitious adhesive protective mortar layer

(g)

Decorative layer of acrylic or polymer modified cementitious mortar

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(a)

Cavity Wall Insulation

1

Mineral Fibre Board shall comply with the relevant provisions of BS 1142 and be faced with a vapour retarder having a perm rating of not more than 0.5.

2

Polyurethane or polyisocyanurate board shall comply with the relevant provisions of BS 4841 and be faced with a vapour retarder having a perm rating of not more than 0.5.

3

Polystyrene board shall comply with the relevant provisions of BS 3837.

4

Foam system insulation used in cavity walls shall be to BS 5617 and BS 5618.

5

Unless otherwise stated on the drawings cavity wall insulation shall be extruded polystyrene 3 board of minimum density 25 kg/m to the thickness detailed.

2.4.4

Perimeter Insulation

1

Polystyrene board where used for exterior perimeter insulation below ground and in contact with soil shall comply with the relevant provisions of BS 3837 and BS 8216.

2

Where sprayed lightweight mineral coatings are used, they shall be to BS 8216.

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2.4.3

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Page 7

Exterior Framing or Furring Insulation

1

On approval by the Engineer, batt or blanket type insulation can be used for exterior wall insulation provided that proper protection, as designated in the Project Documentation, is present.

2

Mineral fibre shall comply with the relevant provisions of BS 6676.

2.4.6

Rigid Insulation

1

Rigid insulation shall be applied to the inside face of exterior walls, spandrel beams, floors and where indicated in the Project Documentation.

2

Mineral fibre board shall comply with the relevant provisions of BS 6676 Part 1 and Part 2.

2.4.7

Masonry Fill Insulation

1

Vermiculite insulation shall comply with the relevant provisions of BS 8208.

2

Fasteners for masonry fill insulation shall be as follows:

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2.4.5

staples or nails complying with the relevant provisions of BS 1202, zinc-coated, size and type best suited for purpose.

(b)

screws complying with the relevant provisions of BS 1210 and BS 3692, with washer not less than 50 mm in diameter.

(c)

steel impaling pins with heads not less than 50 mm in diameter with adhesive for anchorage to substrata; the impaling pins shall be of sufficient length to extend beyond the insulation and retail cap washer when a washer is placed on the pin.

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(a)

Adhesive

1

Adhesives shall be as recommended by the manufacturer of the insulation.

2.4.9

Tape

1

Tape used to seal cuts, tears or unlapped joints of insulation shall have pressure sensitive adhesive on one face.

2

The perm rating of the tape shall not be more than 0.50.

2.5

INSTALLATION

2.5.1

Execution and Workmanship

1

Insulation shall be installed with the vapour barrier facing the heated side, unless specified otherwise.

2

Rigid insulating units shall be installed with joints close and flush, in regular courses and with cross-joints broken.

3

Batt or blanket insulation shall be installed with tight joints and filling framing void completely. Seal cuts, tears, and unlapped joints with tape.

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2.4.8

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Page 8

Insulation shall be fitted tight against adjoining construction and penetrations, unless specified otherwise.

2.5.2

Masonry Cavity Walls

1

Insulation shall be mounted on exterior faces of inner leaves of masonry cavity walls and brick faced concrete walls. Fill joints with the same material used for bonding.

2

Polystyrene board shall be bonded to surfaces with adhesive or Portland cement mortar mixed and applied in accordance with recommendations of insulation manufacturer.

3

Mineral fibreboard and polyurethane shall be bonded to surfaces with adhesive as recommended by insulation manufacturer.

2.5.3

Perimeter Insulation

1

When applying vertical perimeter insulation, the contractor shall:

.l. l

rw

fill joints of insulation with the same material as used for bonding

(b)

bond polystyrene board to surfaces with adhesive or Portland cement mortar mixed and applied in accordance with recommendations of the insulation manufacturer.

qa

ta

(a)

When applying horizontal perimeter insulation under concrete floor slabs the Contractor shall: lay insulation boards and blocks horizontally on level, compacted and drained fill

(b)

extend insulation from foundation walls towards the centre of the building.

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(a)

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2

.

4

Exterior Framing or Furring Blanket Insulation

1

The insulation shall be packed around door frames and windows and in building expansion joints, door soffits and other voids. Open voids are not permitted. The insulation shall be held in place with pressure sensitive tape.

2

Vapour retarder flanges shall be lapped together over the face of the framing for a continuous surface. Seal all penetrations through the insulation.

3

The blanket insulation shall be fastened between metal studs or framing and exterior wall furring by continuous pressure sensitive tape along flanged edges.

4

The blanket insulation between wood studs or framing shall be fastened with nails or staples through the flanged edges on the face of the stud. Fastenings shall be spaced the not more than 150 mm apart.

5

For roof rafter insulation or floor joist insulation, mineral fibre blankets shall be placed between the framing to provide not less than a two 50 mm space between the insulation and the roof sheathing or sub-floor.

6

Ceiling insulation and soffit insulation shall be as follows:

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2.5.4

(a)

at wood framing, blanket insulation shall be fastened between the wood framing or joist with nails or staples through flanged edges of insulation.

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Page 9

(b)

at metal framing or ceiling suspension systems, blanket insulation shall be installed above suspended ceilings or metal framing at right angles to the main runners or framing; the insulation shall be taped tightly together so no gaps occur and metal the framing members are covered by insulation.

(c)

in areas where suspended ceilings adjoin areas without suspended ceilings, either blanket, batt, or mineral fibreboard insulation shall be installed; the insulation shall extend from the suspended ceiling to underside of deck or slab above; the insulation shall be secured in place to prevent collapse or separation of the insulation and maintain it in a vertical position; blanket or batt insulation shall be secured to the structure above with continuous cleats.

Rigid Insulation

1

Rigid insulation shall be securely fixed to the interior face of exterior walls of solid masonry, or to concrete walls, beams, beam soffits, underside of floors, and to the face of studs where shown on the Project Drawings for interior walls unless otherwise approved by the Engineer.

2

The insulation shall be bonded to solid vertical surfaces with adhesive as recommended by insulation manufacturer. Joints shall be filled with adhesive cement.

3

Impaling pins shall be used for attachment of the insulation to the underside of horizontal surfaces. Fastenings shall be spaced as necessary to hold insulation in place and prevent sagging.

4

Insulation board is to be fastened at walls or underside of ceilings with screws, nails or staples. Fastenings shall be spaced not more than 25 mm apart and there shall be a fastening in each corner. The fasteners shall be staggered at the joints between boards.

5

Floor insulation shall be as follows:

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.

2.5.5

insulation shall be bond to concrete floors in attics by coating surfaces with hot asphalt applied at rate of not less than 35 kg per 10 m2, and firmly bed the insulation.

(b)

when applied in more than one layer, bed succeeding layers in hot asphalt applied at the rate to equal a total of not less than 35 kg per 10 m2 when completed.

et it

insulation may be installed with non-flammable adhesive in accordance with the manufacturer's instructions when a separate vapour barrier is used.

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(c)

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(a)

2.5.6

Masonry Fill Insulation

1

Fill insulation shall be poured into cavity voids of masonry units from the tops of walls, or from a sill where windows or other openings occur.

2

The fill insulation shall be poured in lifts of not more than 6 metres.

2.5.7

Insulation Behind Marble Cladding

1

Insulation to external walls is to be 60, 70 or 80 mm thick, as shown on the Project Drawings; resin bonded glass fibre slabs shall be approximate 600 x 1250 mm size

2

The wall insulation is to be mounted on the outside face of the external concrete walls, behind the marble cladding panels. After ensuring that the surface is even and free from dirt, grease, oil, concrete nibs etc an approved primer is to be applied.

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Page 10

The insulation slabs are to be fixed with an approved adhesive in accordance with the manufacturer’s instructions. Both sides of the insulation are to be covered building paper. The external face of the insulation is to be finished mat black.

2.6

PREFABRICATED WALL INSULATION

2.6.1

General

1

This Clause addresses the use of insulation in prefabricated wall systems.

2.6.2

Quality and Requirements

1

Insulation and related vapour barriers or weather proofing are to be as shown on the Project Drawings and as specified in the manufacturer’s literature, shop drawings and any other relevant supporting documentation.

2

Manufacturer’s literature, shop drawings, supporting documentation and certification that necessary thermal requirements will be met shall be submitted to the Engineer for approval prior to delivery.

3

Thermal requirements will at minimum meet specifications as stated in this Part 2 of this Section for standard wall construction unless stated otherwise in the Project Documentation.

4

Curtain wall or glass clad wall systems are also to meet the thermal requirements of this Section. Refer to Section 25 for additional requirements.

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3

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END OF PART

QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 1

3

COLD STORES ............................................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3


3.2

WALK-IN REFRIGERATOR OR FREEZER CONSTRUCTION .................... 2

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5

General Size Doors Floor Finish Metal Finishing

3.3

WALL PANEL CONSTRUCTION .................................................................. 3

3.3.1 3.3.2 3.3.3 3.3.4

General Panel edges Insulation Door Panel and Door

3.4

REFRIGERATION EQUIPMENT ................................................................... 5

3.4.1


3.5

INSTALLATION ............................................................................................. 5

3.5.1 3.5.2

General Requirements Start-Up, and Performance Tests and Instructions

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2 2 2 2 3 3 3 3 3 3 3 4 5 5 5

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Page 2

3

COLD STORES

3.1

GENERAL

3.1.1

Scope

1

This Part describes requirements specific to insulation and construction of Walk-in refrigerators and freezers which can be used for dietetics, autopsy and laboratory uses.

2


3.1.2

References

1


.l. l

.

Masonry Air Conditioning, Refrigeration and Ventilation Finishes to Buildings

rw


as

qa

ta

BS 874 ........................Methods for determining thermal insulating properties BS 1449 ......................Steel plate, sheet and strip BS 2502 ......................Manufacture of sectional cold rooms (walk in type) BS EN 3261 ................Unbacked flexible PVC flooring BS 6319 ......................Testing of resin and polymer/cement compositions for use in construction Submittals

1

The Contractor is to furnish the following prior to commencement of the works: manufacturer's literature and data: walk-in units, including assembly instructions

(ii)

condensing units, with mounting rack where required

(iii)

unit coolers

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(i)

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(a)

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3.1.3

temperature controls and alarms

(v)

temperature recorders for mortuary refrigerators

m

(iv)

(vi)

mortuary walk-in ventilation accessories

(vii)

diagrams and details of piping, wiring and controls

(b)

operating test data

(c)

manufacturer’s standard maintenance and operating manuals.

3.2

WALK-IN REFRIGERATOR OR FREEZER CONSTRUCTION

3.2.1

General

1

Walk-In refrigerators/freezers shall be prefabricated, sectional, all-metal clad, modular and designed for easy and accurate assembly and shall comply with the relevant provisions of BS 2502

QCS 2014


Page 3

Size

1

Room dimensions shall be as shown on drawings with a minimum overall height of 2500 mm, unless shown otherwise.

3.2.3

Doors

1

Doors shall be 1220 mm wide by 1980 mm high, except doors for freezers with floor area 2 less than 14 m may be 920 mm (nominal) wide.

3.2.4

Floor Finish

1

Floor finish shall be seamless modified epoxy polyurethane system with the following properties and conforming to BS EN 3261 Part 1.

rw

.l. l

> 95 MPA > 20 MPA > 10 MPA O -40 to 120 C Resist

ta

Compressive Strength, BS 6319 Flexural Strength, BS6319 Tensile Strength, BS6319 Service Temperature Thermal shock resistant

.

3.2.2

Metal Finishing

1

Inside facing of walls and ceiling, and outside facing of exposed walls shall be stainless steel, to BS 1449.

3.3

WALL PANEL CONSTRUCTION

3.3.1

General

1

Wall panels shall:

ov

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as

qa

3.2.5

be 100 mm thick with precisely formed interior and exterior metal pans

(b)

be filled with foamed-in-place urethane foam with an overall heat transfer coefficient (U) of 0.03

et it

be interchangeable

m

(c)

o

(a)

(d)

be available in nominal 300, 600, 900 and 1200 mm widths

(e)

be without wood or metal structural members

(f)

have quick-lock panel fasteners.

3.3.2

Panel edges

1

Panel edges shall be foamed-in-place, tongue-and-grooved urethane to assure tight joints.

2

There shall be gaskets on the interior and exterior of each panel along every tongue to provide a gasketed seal at each panel joint.

3.3.3

Insulation

1

Insulation shall be "pour-type" urethane, foamed-in-place with an expanding agent with a coefficient of thermal conductivity (k) of not more than 0.12.

QCS 2014


Page 4

The insulation shall be 97% closed cell with a flame spread rating of 25 or less, when tested in accordance with BS 2502.

3

Fibreglass, polystyrene or similar materials are not acceptable as insulation.

3.3.4

Door Panel and Door

1

There shall be a channel thermal breaker type reinforcing steel frame around the entire perimeter of the door opening.

2

The door is to be an in-fitting flush-mounted type with dual flexible blade wiper gasket on the bottom and a replaceable magnetic gasket on the top edge and along both sides.

3

The door shall incorporate a heated, double glass view window.

4

Door construction shall include an aluminium diamond plate on the inside of the door panel and shall be hung with a minimum of three hinges.

5

A hydraulic exterior door closer is to be incorporated to prevent slamming and assure secure closing.

6

For doors with a width of 1220 mm or wider, the door hinges shall be the self-closing cam-lift type hinges. They shall have a chrome plated or polished aluminium finish.

7

The doors shall be lockable but with an inside safety release mechanism to prevent anyone from being locked inside.

8

The door shall incorporate a concealed, energy use selective, anti-sweat heater wire circuit which will provide sufficient heat to prevent condensation and frost formation at the door jambs and exterior edges of the door on all sides.

9

A two way toggle switch outside the door and inside the unit shall be provided with a pilot light and a top mounted junction box. This switch is to operate all lights in the walk-in refrigerator/freezer. Fixtures shall be vapour proof incandescent

10

The door shall incorporate a 50 mm minimum diameter, dial type, flush mounted thermometer.

11

All freezers operating at -17 C or lower shall incorporate a two-way type port to allow for an increase or decrease of air pressure on the interior of the freezer in order to equalise with air pressure on the exterior. The ports shall be automatically controlled, UL approved, anti-sweat heaters. The complete device is to be provided and be listed assembled and ready for connection. The port shall be installed in a wall panel away from the direct air stream flowing from the coils.

12

Wherever compartment dimensions exceed clear-span ability of ceiling panels, an I-beam support on the exterior of the ceiling or other designated support system shall be provided. Beams or posts within compartments are not acceptable unless otherwise approved by the Engineer.

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REFRIGERATION EQUIPMENT

3.4.1


1

Mechanical equipment as needed for condensing units or unit coolers will be incorporated as designated and installed in accordance with the respective manufacturer’s specification as designated or as approved by the Engineer.

3.5

INSTALLATION

3.5.1


1

The Contractor shall assemble walk-in units and install refrigeration equipment as described in the respective manufacturer's instructions. All panel joints shall be made tight and all panel penetrations shall be sealed to prevent condensation or frosting.

2

Unit coolers shall be suspended below the ceiling sufficiently to allow cleaning the top of the unit cooler (890 mm minimum).

3

Penetrations for lights and other devices neatly drilled.

4

Piping, pipe insulation and refrigerant shall be provided in accordance with Section 22, Air Conditioning, Refrigeration and Ventilation.

5

Installation of controls shall be as specified by respective manufacturer’s.

3.5.2

Start-Up, and Performance Tests and Instructions

1

Testing shall be performed in accordance with manufacturer’s specifications. Each system shall be operated for eight hours and the conditions recorded hourly.

2

The Contractor shall submit the following information:

ta

qa

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compressor nameplate data: make, model, horsepower, RPM, refrigerant and charge in grams.

m

(b)

station, building name and system identification, Contractor, date and time.

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(a)

3

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3.4

(c)

compressor operation: approximate percentage running time, pressure gauge readings, actual amps (starting and running), condenser water temperature in and out, or condenser entering air temperature.

(d)

room temperatures

(e)

defrost and drain functions of unit coolers.

The Contractor shall demonstrate alarm functions. END OF PART

QCS 2014

Section 16: Structural Steelworks Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3

Scope References System Description

1.2

DEFINITIONS ................................................................................................ 2

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.12 1.2.13 1.2.14 1.2.15 1.2.16 1.2.17 1.2.18

General Connection Design Design Calculations Design Drawings Erection Drawings Fabrication Data Fabrication Drawings Fittings Foundation Plan Drawings Shop Drawings Inspection Authority Ordinary Bolts Production Test Plate Quality Assurance Fillet Weld Full Penetration Weld Partial Penetration Weld Full Strength Weld

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2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4

QCS 2014


Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements associated with all aspects of structural steelwork including materials, drawings, workmanship and protective treatment.

2

Related Sections and parts are as follows: All Parts

References

1


.

1.1.2

rw .l. l

This Section

BS 5950 ......................Structural use of steelwork in building

ta

Eurocode 3: Part 1.1 (DD ENV1993-l.l), General rules and rules for buildings System Description

1

This Section deals with structural steelwork designed in accordance with the following:

as

qa

1.1.3

BS 5950: Part 1,Code of practice for design in simple and continuous construction: hot rolled sections

(b)

Eurocode 3: Part 1.1 (DD ENV1993-l.l), General rules and rules for buildings, where the references to BS 5950 in the National Application Document are taken into account.

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(a)

DEFINITIONS

1.2.1

General

1

Terms which are defined in this section are treated as Proper Nouns throughout the text of the Specification. The following definitions apply for the purposes of this Specification:

1.2.2

Connection Design

1

The design of bolts, welds, cleats, plates and fittings required to provide an adequate load path between the end of a member and the component it connects to.

1.2.3

Design Calculations

1

Calculations, prepared by the Engineer, showing the design and analysis of the structure, including computer data sheets.

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1.2

QCS 2014


Page 3

Design Drawings

1

Fully dimensioned drawings prepared by the Engineer showing all members with their size and material grades, the forces to be developed in their connections, any cambers and eccentricities and other information necessary for the design of the connections and completion of Fabrication and Erection Drawings.

1.2.5

Erection Drawings

1

Drawings, prepared when necessary by the Contractor, showing details to amplify the information given in the Contractor's erection method statement and showing details of any temporary steelwork (see Part 8 of this Section).

1.2.6

Fabrication Data

1

Numerical control tapes, computer discs, data bases or other electronic means of communication for automatic methods of fabrication.

1.2.7

Fabrication Drawings

1

Drawings, prepared by the Contractor, showing all necessary information required to fabricate the structural steelwork.

1.2.8

Fittings

1

Plates, flats or rolled sections which are welded or bolted to structural steel components.

1.2.9

Foundation Plan Drawings

1

Drawings, prepared by the Contractor or the Engineer, indicating location of column bases and details of foundation connections to the steelwork.

1.2.10

Shop Drawings

1

Drawings, prepared by the Contractor, showing plans, cross sections and elevations, main dimensions and the erection marks of components.

1.2.11

Inspection Authority

1

A qualified independent body or association which verifies compliance with the Project Documentation.

1.2.12

Ordinary Bolts

1

A bolt used in a non-preloaded bolt assembly which is designed to carry forces in shear, bearing or tension.

1.2.13

Production Test Plate

1

A plate used for testing purposes, which is made of the same material and using the same procedures as the joint in a component.

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1.2.4

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Page 4

Quality Assurance

1

Activities concerned with the provision of systems, equipment and personnel necessary to achieve the required level of quality.

1.2.15

Fillet Weld

1

A weld, other than a butt or edge weld, which is approximately triangular in transverse cross section and which is generally made without preparation of the parent material.

1.2.16

Full Penetration Weld

1

A weld between elements which may be in-line, in the form of a tee, or a corner in which the weld metal achieves full penetration throughout the joint thickness.

1.2.17

Partial Penetration Weld

1

A weld formed using a technique which ensures a specified penetration which is less than the depth of the joint.

1.2.18

Full Strength Weld

1

Any of the above welds designed to develop the full strength of the element which it connects.

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1.2.14

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END OF PART

QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 1

10

PROTECTIVE TREATMENT ......................................................................... 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7

Scope References Method Statement Working Conditions Storage of Materials Application Procedures Handling and Storage

10.2

SURFACE PREPARATION ........................................................................... 3

10.2.1 10.2.2 10.2.3 10.2.4

General Wire Brushing Blast Cleaning Surface Defects

10.3

SPRAYED METAL COATINGS ..................................................................... 3

10.3.1 10.3.2 10.3.3 10.3.4 10.3.5

Method Storage and Handling Repair of Extensively Damaged Areas Repair of Minimally Damaged Areas Sealing Before Painting

10.4

GALVANIZING ............................................................................................... 4

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10.4.1 Procedures 10.4.2 Touch-up of Galvanized Surfaces 10.4.3 Vent Holes

3 3 3 3 3 3 3 4 4 4 4 4

SURFACE COATINGS (PAINT) .................................................................... 4

10.5.1 10.5.2 10.5.3 10.5.4 10.5.5 10.5.6 10.5.7 10.5.8 10.5.9

Surface Condition Prior to Painting Surfaces to be Embedded in Concrete Coatings Application Life Multiple Coats Stripe Coats Storage and Handling Painting on Site Painting of Site Fixed Bolts and Welding

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10

PROTECTIVE TREATMENT

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the requirements for protective treatment for structural steelwork.

2

Related Sections and Parts are as follows: This Section Part 2

Materials

References

1


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10.1.2

BS 729 ........................Hot dip galvanized coatings on iron and steel articles.

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BS 5493 ......................Code of practice for protective coating of iron and steel structures against

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corrosion.

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BS 7079 ......................Preparation of steel substrates before application of paints and related products. coatings

–Thermal

spraying-zinc

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BS EN 22063 ..............Metallic and other inorganic aluminium and their alloys.

Method Statement

1

The Contractor shall prepare a written method statement giving sequential details of the surface preparation and protective treatment procedure (including touching-in procedures) to be used in achieving the Employer's specification.

10.1.4

Working Conditions

1

Work shall he carried out in accordance with the recommendations given in BS 5493.

10.1.5


1

Protective treatment materials shall he stored in a clean, dry area which is protected from extreme temperatures, and used in order of delivery, in accordance with the manufacturer's recommendations and within the advised shelf life.

10.1.6

Application Procedures

1

Materials shall be prepared, and coatings applied to surfaces, in accordance with the manufacturer's recommendations.

10.1.7

Handling and Storage

1

The procedures for handling and storage shall be so arranged that the protected surface is unlikely to be damaged.

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SURFACE PREPARATION

10.2.1

General

1

Unless it has been specifically approved by the Engineer all steelwork surfaces which are to be painted shall be blast cleaned.

10.2.2

Wire Brushing

1

Surfaces which are not to be blast cleaned, but are to be coated, shall be wire brushed to remove loose mill scale, and cleaned to remove dust, oil and grease.

10.2.3

Blast Cleaning

1

The standard of blast cleaning specified shall be in accordance with BS 7079 Part Al.

2

The methods used shall be capable of cleaning all surfaces of the component. The surface roughness shall be compatible with that recommended for the coating to be applied but shall not be to a lesser quality than Sa 2 as defined in BS 7079

3

The cleanliness levels specified shall be those existing at the time of the application of coating.

4

When abrasives are recycled in the blast cleaning system, the equipment shall be fitted with a dust removal system to remove fines and contaminants.

10.2.4

Surface Defects

1

Surface defects revealed during surface preparation shall be dealt with in accordance with Clause 2.2.1-2 and 2.2.1-3 of this Section.

10.3

SPRAYED METAL COATINGS

10.3.1

Method

1

Sprayed metal coatings may consist of either zinc or aluminium applied to the surface as a molten dispersed spray in accordance with BS EN 22063 to a level given in the Protective Treatment Specification.

10.3.2


1

Storage and handling procedures shall be so arranged that the sprayed metal surface is unlikely to be damaged.

10.3.3

Repair of Extensively Damaged Areas

1

The area shall be cleaned using a needle gun or abrasive papers or cloths. After washing down and drying, the area shall be resprayed overlapping the undamaged area by 20mm.

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10.2

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Page 4

Repair of Minimally Damaged Areas

1

An area less than 10 cm2 may be repaired after cleaning, as described in Clause 10.4.3 of this Part, by applying a paint which is compatible and has similar properties to the metal spray.

10.3.5

Sealing Before Painting

1

Sprayed metal coating shall be sealed before the application of paint coats in accordance with BS 5493 Table 4C Part 2.

10.4

GALVANIZING

10.4.1

Procedures

1

Galvanizing shall be performed in accordance with BS 729.

10.4.2

Touch-up of Galvanized Surfaces

1

Small areas which are within 10mm of intact galvanized coating may be touched up in accordance with Appendix D of BS 729.

2

Preparation for touching up is to be as required by the manufacturer of the touch-up product.

10.4.3

Vent Holes

1

If so required by the Engineer, vent holes in hollow members, necessary during the galvanizing process, shall be sealed after galvanizing with a plug of approved material.

10.5

SURFACE COATINGS (PAINT)

10.5.1

Surface Condition Prior to Painting

1

Steelwork shall be dry and cleaned to the surface cleanliness specified in Clause 10.2 of this Part.

10.5.2

Surfaces to be Embedded in Concrete

1

Steel surfaces to be embedded in concrete shall be left unpainted and need not be blast cleaned unless required by the Project Documentation.

10.5.3

Coatings

1

Where steelwork is to be finished with a paint coating system it shall be carried out in accordance with the requirements of BS 5493 and to the requirements of the Project Documentation.

10.5.4

Application Life

1

All paint products shall be used within the manufacturer's recommended pot life.

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10.3.4

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10.5.5

Multiple Coats

1

Where two or more coats of a product are to be applied, a different colour shade shall be used for each coat.

10.5.6

Stripe Coats

1

Additional stripe coats of primer or undercoat shall be applied in the following circumstances: welded surfaces where a weld-through primer has been used

(b)

steelwork which will be exposed externally in the finished works

(c)

all edges and corners

(d)

seal gaps between adjacent components such as shop and site bolted connections.

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(a)


1

Storage and handling procedures shall ensure that damage to the protective system is minimised.

10.5.8

Painting on Site

1

Work shall not proceed when the steel surfaces are wet or the ambient temperature, or dew point, is below that recommended by the paint manufacturers. (See Clause 10.1.4 of this Part).

10.5.9

Painting of Site Fixed Bolts and Welding

1

All protruding portions of bolt assemblies and site weld surfaces shall be cleaned to remove traces of oil, dust, welding flux etc. to the levels specified in 10.5.1.

2

The paint system specified in the Project Documentation shall be applied to ensure similar properties and compatibility with the surface treatment system being used on the surrounding surfaces.

3

Bolt assemblies which are supplied with a protective treatment need not be painted except when the Employer's specification requires it.

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10.5.7

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 1

2

MATERIALS .................................................................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6

Scope References Material Qualities Material Testing Test Certificates Dimensions and Tolerances

2.2

SURFACE CONDITION ................................................................................. 4

2.2.1

General

2.3

SUBSTITUTION OF MATERIAL OR FORM .................................................. 5

2.3.1

General

2.4

WELDING CONSUMABLES ......................................................................... 5

2.4.1 2.4.2

Standards Storage

2.5

STRUCTURAL FASTENERS ........................................................................ 5

2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7

Ordinary Bolt Assemblies High Strength Friction Grip (HSFG) Bolt Assemblies Foundation Bolts. Cup and Countersunk Bolts Washers Lock Nuts Fastener Coatings

2.6

SHEAR STUDS ............................................................................................. 6

2.6.1

General

2.7

PROTECTIVE TREATMENT MATERIALS.................................................... 6

2.7.1 2.7.2 2.7.3 2.7.4 2.7.5

Metallic Blast Cleaning Abrasives Surface Coatings Sherardized Coatings Galvanizing Materials Proprietary Items

2 2 3 3 3 3

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4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6

QCS 2014


Page 2

MATERIALS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the materials requirements for structural steelwork.

2

Related Sections and parts are as follows: Bolting

Section 1

General

2.1.2

References

1


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.

2

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BS 4 ............................Structural steel sections, Part 1 1993, Hot-rolled sections.

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BS 639 ........................Covered carbon and carbon manganese steel electrodes for manual metal-arc welding BS 729 ........................Hot dip galvanised coatings on iron and steel articles.

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BS 2901 ......................Filler rods and wires for gas-shielded arc welding.

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BS 2989 ......................Continuously hot-dip zinc coated and iron-zinc alloy coated steel flat products.

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BS 3692 ......................ISO metric precision hexagon bolts, screw and nuts.

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BS 4165 ......................Electrode wires and fluxes for the submerged arc welding of carbon steel and medium-tensile steel. BS 4190 .....................ISO metric black hexagon bolts, screw and nuts.

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BS 4320 ......................Metal washers for general engineering purposes.

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BS 4395 ......................High strength friction grip bolts and associated nuts and washers for structural engineering.

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BS 4929 ......................Steel hexagon prevailing-torque type nuts BS 4933 ......................ISO metric black cup and countersunk head bolts and screws with hexagon nuts. BS 4848 ......................Hot rolled structural steel sections BS 4921 ......................Sherardized coatings on iron and steel BS 5950 ......................Structural use of steel work in building BS 6363 ......................Welded cold formed steel structural hollow sections BS 7079 ......................Preparation of steel substrates before application of paints and related products. BS 5135 ......................Process of arc welding of carbon and carbon manganese steels BS 7084 ......................Carbon and carbon-manganese steel tubular cored welding electrodes BS 7419 ......................Holding down bolts BS EN 10025 ..............Hot rolled products of non-alloy structural steels-Technical delivery conditions.

QCS 2014


Page 3

BS EN 10029 ..............Tolerances on dimensions, shape and mass for hot rolled steel plates 3mm thick or above. BS EN 10034 ..............Structural steel I and H sections-Tolerances on shape and dimensions. BS EN 10051 ..............Continuously hot-rolled uncoated plate, sheet and strip of non-alloy and alloy steels-Tolerances on dimensions and shape BS EN 10147 ..............Continuously hot-dip zinc coated structural steel sheet and stripTechnical delivery conditions. BS EN 10163 ..............Delivery requirements for surface conditions of hot rolled steel plates wide flats and sections. BS EN 10210 ..............Hot finished structural hollow sections of non-alloy and fine grains structural steels.

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BS EN 102101 ............Technical delivery conditions

EN 10051 ................... Specification for continuously hot-rolled uncoated plate, sheet and strip of non-alloy steels. Tolerances on dimension and shape

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EN 10113 ...................Hot rolled products in weldable fine grain structural steels.

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EN 10155 ...................Structural steels with improved atmospheric corrosion resistance. Technical delivery conditions. Material Qualities

1

Material shall be steel in rolled sections, structural hollow sections, plates and bars and shall comply with the appropriate standard shown in Table 2.1.

2

The steel designations used in this publication are those given in BS 5950.

2.1.4

Material Testing

1

All steel shall have been specifically tested in accordance with the appropriate material quality standard shown in Table 2.1.

2.1.5

Test Certificates

1

The Contractor shall obtain the manufacturer's test certificates and submit them to the Engineer for review.

2.1.6

Dimensions and Tolerances

1

Dimensions and Tolerances shall comply with the appropriate standard shown in Table 2.1.

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QCS 2014


Page 4

Table 2.1 Material and Dimension Standards Dimensions

Dimension Tolerances

U.B. and U.C.

BS 4 : Part 1

BS EN 10034

Joists

BS 4 : Part 1

BS 4 : Part 1

BS 4 : Part 1

BS 4 : Part 1

Angles

BS 4848 : Part 4

BS 4848 : Part 4

Plate and Flats

Not Applicable

BS EN 10029

1

Channels

BS EN 10025

Structural Hollow Sections

2

BS EN 10210-I

BS 4848 : Part 2

BS 4848 : Part 2

BS 6363

BS 6363

BS 6363

Cold Formed Galvanised Open Sections and Strip

Not Applicable

BS 2989

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BS EN 10147

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Hollow Sections

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Hot Finished

Notes:

Material quality requirements for Fine Grain Steels are given in EN 10113 Material quality requirements for Weather resistant grades are given in EN 10155. BS EN 10210-1 contains material quality requirements for Non-alloy and Fine Grain Steels. Tolerances for plates cut from wide strip produced on continuous mills are given in BS EN 10051.

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Material Quality

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SURFACE CONDITION

2.2.1

General

1

Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of BS 7079 Part Al.

2

Surface defects in hot rolled sections, plates and wide flats revealed during surface preparation which are not in accordance with the requirements of BS EN 10163 shall be rectified accordingly.

3

Surface defects in hot rolled hollow sections revealed during surface preparation which are not in accordance with the requirements of BS EN 10210-1 shall be rectified accordingly.

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SUBSTITUTION OF MATERIAL OR FORM

2.3.1

General

1

Material quality or section form of components may, with the agreement of the Engineer be substituted where it can be demonstrated that the structural properties are not less suitable than the designed component.

2.4

WELDING CONSUMABLES

2.4.1

Standards

1

Consumables for use in metal arc welding shall comply with BS 639, BS 2901, Part 1, BS 4165 or BS 7084 as appropriate.

2.4.2

Storage

1

Consumables to be stored in the Contractor's works and on the Site, shall be kept in a controlled atmosphere, in accordance with BS 5135. Any drying or baking of consumables before issue shall be carried out in accordance with the manufacturer's recommendations.

2.5

STRUCTURAL FASTENERS

2.5.1

Ordinary Bolt Assemblies

1

Shop and site bolts and nuts shall be to one the following grades:

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2.3

Grade 4.6 in accordance with BS 4190

(b)

Grade 8.8 or 10.9 in accordance with BS 3692.

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(a)

Dimensions, tolerance and threaded length to BS 4190.

3

Refer to Clause 6.2.1 of this Section for bolt/nut combinations.

2.5.2

High Strength Friction Grip (HSFG) Bolt Assemblies

1

HSFG bolt assemblies shall be in accordance with BS 4395.

2

Refer to Clause 6.4.1 of this Section for bolt/nut combinations.

2.5.3

Foundation Bolts.

1

Holding down bolts shall be in accordance with BS 7419.

2.5.4

Cup and Countersunk Bolts

1

Cup and countersunk bolts shall be in accordance with BS 4933.

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Page 6

Washers

1

Metal washers shall be made in accordance with BS 4320 Section 2. Unless otherwise specified, black steel washers to Form E shall be used.

2

Refer to Clause 3.4.6 for washers for holding down bolts.

2.5.6

Lock Nuts

1

Lock nuts shall be in accordance with BS 4929: Part 1.

2.5.7

Fastener Coatings

1

Where specific coatings are required, they shall be provided by the fastener manufacturer.

2.6

SHEAR STUDS

2.6.1

General

1

Proprietary studs used in composite construction shall be the headed type with the following properties after being formed:

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2.5.5

minimum yield strength - 350 N/mm2

(b)

minimum ultimate tensile strength -450 N/mm2

(c)

elongation of 15% on a gauge length of 5.65 A, where A is the area of the test specimen.

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(a)

PROTECTIVE TREATMENT MATERIALS

2.7.1

Metallic Blast Cleaning Abrasives

1

Chilled iron grit shall be in accordance with BS 7079 Part E2, and cast steel grit shall be in accordance with BS 7079 Part E3.

2.7.2

Surface Coatings

1

Paint materials and other coatings supplied shall be in accordance with the appropriate British Standard or European Standard for the materials.

2.7.3

Sherardized Coatings

1

Sherardized coatings shall be in accordance with BS 4921.

2.7.4

Galvanizing Materials

1

The composition of zinc in galvanizing baths shall be in accordance with BS 729.

2.7.5

Proprietary Items

1

All proprietary items shall be used in accordance with the manufacturer's recommendations and instructions.

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2.7

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 03: Drawings

Page 1

3

DRAWINGS ................................................................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3


3.2

GENERAL ARRANGEMENT DRAWINGS .................................................... 2

3.2.1 3.2.2

Marking System General Arrangement Drawings (Marking Plans)

3.3

FOUNDATION PLAN DRAWINGS ................................................................ 3

3.3.1


3.4

FABRICATION DRAWINGS .......................................................................... 3

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10

Fabrication Shop Drawings Attachments to Facilitate Erection Welding Packings, Clearances and Camber Hole Sizes Holding Down Bolt Covers Connections to allow Movement Machining Note Drilling Note HSFG Faying Surfaces

3.5

ERECTION DRAWINGS ............................................................................... 4

3.5.1 3.5.2

Erection Method Statement Temporary Steelwork

3.6

DRAWING ACCEPTANCE ............................................................................ 5

3.6.1 3.6.2 3.6.3

Acceptance by the Engineer Meaning of Acceptance Acceptance Classification

3.7

AS ERECTED DRAWINGS ........................................................................... 5

3.7.1


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Page 2

DRAWINGS

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for drawings associated with structural steelwork.

2

Related Parts and Sections are as follows: Welding Bolting Accuracy of Fabrication Erection Accuracy of Erected Steelwork

Section 1

General

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This Section Part 5 Part 6 Part 7 Part 8 Part 9

.

3

References

1


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3.1.2

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BS 499 ........................Welding terms and symbols

BS 1192 ......................Construction and drawing practice

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BS 4640 ......................Classification of metal working machine tools by types General Requirements

1

All design, fabrication and erection drawings shall be made in accordance with BS 1192 Parts 1 and 2.

2

All welding symbols shall conform to BS 499 Part 2.

3.2

GENERAL ARRANGEMENT DRAWINGS

3.2.1

Marking System

1

Every component which is to be individually assembled or erected shall be allocated an erection mark.

2

Members which are identical in all respects may have the same erection mark.

3.2.2

General Arrangement Drawings (Marking Plans)

1

Drawings shall be prepared by the Contractor showing plans and elevations at a scale such that the erection marks for all members can be shown on them. Preferred scales are 1:100 or larger.

2

The drawings shall show the grid locations as indicated on the design drawings, main dimensions, member levels and centre lines. Details at an enlarged scale should also be made if these are necessary to show the assembly of members.

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3.1.3

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Page 3

FOUNDATION PLAN DRAWINGS

3.3.1


1

Foundation Plan Drawings shall show the base location, position and orientation of columns, the marks of all columns, any other members in direct contact with the foundations, their base location and level, and the datum level.

2

The drawings shall show complete details of fixing steel or bolts to the foundations, method of adjustment and packing space.

3.4

FABRICATION DRAWINGS

3.4.1

Fabrication Shop Drawings

1

Fabrication Drawings shall show all necessary details and dimensions to enable fabrication of components to proceed.

3.4.2

Attachments to Facilitate Erection

1

The Fabrication Drawings shall show details of holes and fittings necessary to provide for lifting and erection of components (see Clause 8.2.1 of this Section).

2

Unless specifically agreed otherwise, such holes and fittings may remain on the permanent structure. Account shall be taken of Clause 5.4.5 of this Section when detailing the welding of temporary attachments.

3.4.3

Welding

1

Any requirements for edge preparations for welds shall be indicated on the Fabrication Drawings. Welding inspection requirements which differ from those specified in Clause 5.5.5 of this Section shall be indicated on the drawings.

3.4.4

Packings, Clearances and Camber

1

When preparing Fabrication Drawings, the Contractor shall make provision for the following:

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3.3

(a)

packings which may be necessary to ensure proper fit-up of joints (see Clauses 6.3.1 and 6.5.1 of this Section)

(b)

the need for clearances between the fabricated components so that the permitted deviations in fabrication and erection are not exceeded (see Parts 7 and 9 of this Section)

(c)

the Engineer's requirements for pre-set or cambers.

3.4.5

Hole Sizes

1

Holes shall be shown on the Fabrication Drawings to the following sizes: (a)

for ordinary bolts and HSFG bolts: (i)

not exceeding 24mm diameter - 2 mm greater than the bolt diameter

(ii)

greater than 24mm diameter - 3 mm greater than the bolt diameter

QCS 2014

(b)

Section 16: Structural Steelworks Part 03: Drawings For holding down bolts: (i)

(c)

Page 4

6mm greater than the bolt diameter, but with sufficient clearance to ensure that a bolt, whose adjustment may cause it to be out of perpendicular, can be accommodated through the base plate (see Table 9.1 Item 3 of this Section).

For fitted bolts: (i)

in accordance with Clause 6.2.8 of this Section.

Holding Down Bolt Covers

1

Holding down bolt details shall include provision of loose cover plates or washers with holes 3 mm greater than the holding down bolts.

3.4.7

Connections to allow Movement

1

Where the connection is designed to allow movement, the bolt assembly used shall remain secure without impeding the movement.

3.4.8

Machining Note

1

Any machining requirements shall be clearly noted on the Fabrication Drawings.

3.4.9

Drilling Note

1

The Fabrication Drawings shall indicate those locations where holes shall be drilled in accordance with the situations noted below (see also Clause 4.7.3 of this Section):

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in non-slip connections for HSFG bolts

(b)

at locations where plastic hinges are assumed in the design analysis

(c)

in elements of rigid connections where yield lines are assumed;

(d)

where repetition of loading makes fatigue critical to the member design

(e)

where the design code of practice does not permit punched holes.

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(a)

HSFG Faying Surfaces

1

When considering the coefficient of friction to use in the design of high strength friction grip bolted connections, the following values are to be used:

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3.4.10

(a)

unless the Engineer advises otherwise, untreated surfaces which are in accordance with BS 4604 may be considered as having a slip factor of 0.45; masking shall be used to keep the surfaces free of protective treatments.

(b)

surfaces which have been machined, or given any type of treatment, shall have the slip factor determined by tests carried out in accordance with BS4604 Part1.

3.5

ERECTION DRAWINGS

3.5.1

Erection Method Statement

1

When necessary to amplify the information given in his erection method statement, the Contractor shall prepare Erection Drawings.

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Page 5

Temporary Steelwork

1

Details and arrangements of temporary steelwork necessary for erection purposes shall be shown on the Erection Drawings.

3.6

DRAWING ACCEPTANCE

3.6.1

Acceptance by the Engineer

1

Drawings made by the Contractor shall be submitted to the Engineer for acceptance in the period designated by the Employer.

3.6.2

Meaning of Acceptance

1

Acceptance by the Engineer of drawings prepared by the Contractor means that the Contractor has correctly interpreted the design requirements and that the Engineer accepts the Connection Design.

2

Acceptance does not relieve the Contractor of the responsibility for accuracy of his calculations, detail dimensions on the drawings, nor the general fit-up of parts to be assembled on site.

3.6.3

Acceptance Classification

1

The designations given in Table 3.1 shall be used by the Engineer when accepting drawings:

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Table 3.1 Acceptance Classification of Drawings

Drawing is accepted and may be released for construction

Accepted subject to comments

Drawing must be amended in line with the comments, and re -submitted for acceptance. Drawing must be amended in the way indicated and re-submitted for acceptance.

Not Accepted

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Meaning

Accepted or Reviewed or Approved or No Comment

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Classification

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Ref.

3.7

AS ERECTED DRAWINGS

3.7.1


1

On completion of the contract, the Contractor shall provide the Engineer with one set of paper prints of "As Erected" drawings comprising: (a)

general Arrangement Drawings

(b)

fabrication Drawings

(c)

drawings made after fabrication showing revisions

(d)

the fabrication drawing register. END OF PART

QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 1

FABRICATION ........................................................................................................ 2

4.1 4.1.1

GENERAL ............................................................................................................... 2 Scope 2

4.2 4.2.1 4.2.2 4.2.3

IDENTIFICATION .................................................................................................... 2 Traceability of Steel 2 Material Grade Identification 2 Marking Steelwork 2

4.3 4.3.1

HANDLING .............................................................................................................. 2 General Requirements 2

4.4 4.4.1 4.4.2 4.4.3

CUTTING AND SHAPING ....................................................................................... 3 Cutting Operations 3 Flame-cut Edges 3 Columns 3

4.5 4.5.1

MACHINING ............................................................................................................ 3 Thickness of Machined Parts 3

4.6 4.6.1 4.6.2

DRESSING .............................................................................................................. 3 Removal of Burrs 3 Dressing of Edges 3

4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5

HOLING................................................................................................................... 3 Matching 3 Drilling Through More Than One Thickness 4 Punching Full Size 4 Punching and Reaming 4 Slotted Holes 4

4.8 4.8.1

ASSEMBLY ............................................................................................................. 4 General Requirements 4

4.9 4.9.1

CURVING AND STRAIGHTENING ......................................................................... 5 General Requirements 5

4.10 4.10.1

INSPECTION........................................................................................................... 5 General Requirements 5

4.11 4.11.1 4.11.2

STORAGE ............................................................................................................... 5 Stacking 5 Visible Markings 5

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Page 2

4

FABRICATION

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the general requirements for the fabrication of structural steelwork components.

2

Related Sections and Parts are as follows: This Section Part 2 Part 6 Part 7 Part 9

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Materials Bolting Accuracy of Fabrication Accuracy of Erected Steelwork

IDENTIFICATION

4.2.1

Traceability of Steel

1

All steel to be used in the Works shall have a test certificate (see Clause 2.1.5 of this Section).

4.2.2

Material Grade Identification

1

The material grades of all steel shall be identifiable except for design grades 43A and 43B, and in the case of structural hollow sections, 43D.

4.2.3

Marking Steelwork

1

Individual pieces shall be capable of positive identification at all stages of fabrication.

2

Completed components shall be marked with a durable and distinguish erection mark in such a way as not to damage the material. Hard stamping may be used, except where otherwise specified by the Engineer.

3

Where areas of steelwork are indicated on the drawings as being unmarked, they shall be left free of all markings and hard stamping.

4.3

HANDLING

4.3.1


1

Steelwork shall be bundled, packed, handled and transported in a safe manner so that permanent distortion does not occur and surface damage is minimised.

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Page 3

CUTTING AND SHAPING

4.4.1

Cutting Operations

1

Cutting and shaping of steel may be carried out by shearing, cropping, sawing, nibbling, laser cutting or machine flame cutting, except that where machine flame cutting is impractical, hand flame cutting may be used.

4.4.2

Flame-cut Edges

1

Flame-cut edges which are free from significant irregularities shall be accepted without further treatment except for the removal of dross, otherwise cut edges shall be dressed to remove irregularities.

4.4.3

Columns

1

Columns with ends not in direct bearing or intended to be erected on packs or shims, shall be fabricated to the accuracy given in Item 2 of Table 7.1 of this Section.

2

Columns intended to be in direct bearing shall be fabricated to the accuracy given Item 3 of Table 7.1 of this Section..

3

Column sections which are one metre and over in width or depth and are intended to be in direct bearing, shall be specially prepared at the butting ends so that the erection tolerances in Items 4 and 5 of Table 9.2 of this Section can be achieved.

4.5

MACHINING

4.5.1

Thickness of Machined Parts

1

The thickness of elements shown on the drawings as requiring machining shall mean the minimum thickness after the machining operations.

4.6

DRESSING

4.6.1

Removal of Burrs

1

Cut edges shall be dressed to remove dross, burrs, and irregularities. Holes shall be dressed as required to remove burrs and protruding edges.

4.6.2

Dressing of Edges

1

Sharp edges shall be dressed, but a 90 rolled, cut, sheared or machined edge is acceptable without further treatment.

4.7

HOLING

4.7.1

Matching

1

All matching holes for fasteners or pins shall register with each other so that fasteners can be inserted without undue force through the assembled members in a direction at right angles to the faces in contact. Drifts may be used but holes shall not be distorted.

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4.4

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Page 4

4.7.2

Drilling Through More Than One Thickness

1

Drilling shall be permitted through more than one thickness where the separate parts are tightly clamped together before drilling. The parts shall be separated after drilling and any burrs removed.

4.7.3

Punching Full Size

1

Full size punching of holes shall be permitted when: the tolerance on distortion of the punched hole does not exceed that shown in Item 3 of Table 7.2 of this Section.

(b)

the holes are free of burrs which would prevent solid seating of the parts when tightened

(c)

the thickness of the material is not greater than the hole diameter

(d)

the maximum thickness for all steel grades used from the standards listed in Table 2.1 of this Section is:

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(a)

2 mm for sub-grade A

(ii)

l6 mm for sub-grade B

(iii)

20 mm for sub-grade C or higher sub-grade; in spliced connections when the holes in mating surfaces are punched in the same direction.

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(i)

Punching and Reaming

1

Punching is permitted without the conditions in Clause 4.7.3 of this Part, provided that the holes are punched at least 2 mm less in diameter than the required size and the hole is reamed to the full diameter after assembly.

4.7.5

Slotted Holes

1

Slotted holes shall be made by one of the following methods:

(b)

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4.7.4

(c)

machine operated flame cutting.

punched in one operation formed by drilling two holes and completed by cutting

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(a)

4.8

ASSEMBLY

4.8.1


1

All components shall be assembled within tolerances specified in Section 7 of this Section and in a manner such that they are not bent, twisted or otherwise damaged.

2

Drifting of holes to align the components shall be permitted, but must not cause damage or distortion to the final assembly (see Clause 6.3.2).

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Page 5

4.9

CURVING AND STRAIGHTENING

4.9.1


1

Curving or straightening components during fabrication, shall be performed by one of the following methods: mechanical means, taking care to minimise indentations, or change of crosssection

(b)

the local application of heat, ensuring that the temperature of the metal is carefully controlled, and does not exceed 650oC

(c)

the induction bending process where the procedure used includes careful temperature control; after curving or straightening, welds within the area of curving or straightening shall be visually inspected. Welds which are to be subject to non destructive examination shall have these tests carried out after curving or straightening.

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(a)

INSPECTION

4.10.1


1

Sufficient components shall be checked for dimensional accuracy and conformity to drawing, to prove that the manufacturing process is working satisfactorily.

4.11

STORAGE

4.11.1

Stacking

1

Fabricated components which are stored prior to being transported or erected shall be stacked clear of the ground, and arranged if possible so that water cannot accumulate. They shall be kept clean and supported in such a manner as to avoid permanent distortion.

4.11.2

Visible Markings

1

Individual components shall be stacked and marked in such a way as to ensure that they can be identified.

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END OF PART

QCS 2014


Page 1

5

WELDING ...................................................................................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3


5.2

WELDER QUALIFICATION ........................................................................... 2

5.2.1 5.2.2

Testing Certification

5.3

WELDING PROCEDURES ............................................................................ 3

5.3.1 5.3.2 5.3.3

Preparation of Procedures Approval of Procedures and Procedure Tests Availability of Welding Procedure Sheets

5.4

ASSEMBLY ................................................................................................... 3

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7

Fit-up Jigs Tack Welds Distortion Control Fabrication or Erection Attachments Extension Pieces Production Test Plates

5.5

NON-DESTRUCTIVE TESTING OF WELDS ................................................ 4

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6

Record of Testing Visual Inspection of Welds Surface Flaw Detection Ultrasonic Examination Scope of Inspection Acceptance Criteria and Corrective Action

5.6

SHEAR STUD WELDING .............................................................................. 5

5.6.1 5.6.2 5.6.3 5.6.4

Method Trial Welding Tests and Inspection Defective Studs

2 2 2

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2 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 6 6

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Page 2

5

WELDING

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for welding associated with structural steelwork.

5.1.2

References

1

The following standards are referred to in this Part: BS 3923 ......................Methods for ultrasonic examination of welds

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BS 4570 ......................Fusion welding of steel castings

BS 4872 ......................Approval testing of welders when welding procedure approval is not required BS 5135 ......................Process of arc welding of carbon and carbon manganese steels

ta

BS 5289 ......................Code of practice for visual inspection of fusion welded points

qa

BS 6072 ......................Method for magnetic particle flaw detection BS 6443 ......................Penetrant flaw detection

as

BS EN 287 ..................Approval testing of welders for fusion welding

se

BS EN 288 ..................Approval of welding procedures for metallic materials System Description

1

Welding shall be a metal arc process in accordance with BS 5135 and BS 4570, as appropriate, together with other clauses contained in this section, unless otherwise specifically permitted by the Engineer.

2

Welding consumables used shall be chosen to ensure that the mechanical properties of the weld metal are not less than those required for the parent metal.

3

Joints shall be prepared in accordance with BS 5135. Precautions shall be taken to ensure cleanliness of the connection prior to welding.

5.2

WELDER QUALIFICATION

5.2.1

Testing

1

Welders shall be tested to meet the requirements of BS EN 287 Part 1 but, in the case of welders engaged on fillet welding only, BS 4872 Part 1 is an acceptable alternative.

2

As an alternative, when permitted by the Employer, welders may be tested to meet the requirements of the American Society of Mechanical Engineers, ASME IX, or the American Welding Society, AWS Dl.1.

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Page 3

Certification

1

Welder testing shall be witnessed and certificates endorsed by an independent Inspection Authority.

2

The certification shall remain valid providing it complies with the conditions for re-approval of certification specified in BS EN 287 Part 1.

5.3

WELDING PROCEDURES

5.3.1

Preparation of Procedures

1

Approved written welding procedures shall be available in accordance with BS 5135, and tested in accordance with BS EN 288 Part 3 by the Contractor.

5.3.2

Approval of Procedures and Procedure Tests

1

Procedures and tests shall be approved by an independent Inspection Authority.

5.3.3

Availability of Welding Procedure Sheets

1

Welding Procedure sheets shall be made available to the welder prior to the commencement of the work and shall be available to the Engineer and Inspection Authority on request.

5.4

ASSEMBLY

5.4.1

Fit-up

1

Joints shall be fitted up to the dimensional accuracy required by the welding procedure, depending on the process to be used, to ensure that the quality in Table 5.2 is achieved.

5.4.2

Jigs

1

Fabrications assembled in jigs may be completely welded in the jig, or may be removed from the jig after tack welding.

5.4.3

Tack Welds

1

Tack welds shall be made using the same procedures as for the root runs of main welds. The length of the tack shall be the lesser of 4 times the thickness of the thicker part or 50 mm, unless demonstrated by a weld procedure qualification.

2

Tack welds which are not defective may be incorporated into main welds provided that the welder is qualified as in Clause 5.2 of this Part. However, where joints are welded using an automatic or mechanised process, the suitability of the tack weld used for incorporation into automatic processes shall be demonstrated in the weld procedure qualification.

3

Where tack welds are made in circumstances other than those identified above, they must be removed.

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5.2.2

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Page 4

Distortion Control

1

The sequence of welding a joint or a sequence of joints shall be such that distortion is minimised (see Part 7 of this Section).

5.4.5

Fabrication or Erection Attachments

1

Welding of attachments required for fabrication or erection purposes shall be made in accordance with the requirements for a permanent weld.

2

When removal is necessary, they shall be flame cut or gouged at a point not less than 3 mm from the surface of the parent material. The residual material shall be ground flush and the affected area visually inspected. When thicknesses are greater than 20 mm it shall also be checked by magnetic particle inspection. Acceptance criteria are as set out in Table 5.2. Attachments shall not be removed by hammering. (See Clause 3.4.2 of this Section).

5.4.6

Extension Pieces

1

Where the profile of a weld is maintained to the free end of a run by the use of extension pieces they shall be of material of a similar composition, but not necessarily the same grade, as the component. They shall be arranged so as to provide continuity of preparation and shall be removed after completion of the weld and the surface ground smooth.

5.4.7

Production Test Plates

1

Where production test plates are required for testing purposes, they shall be clamped in line with the joint. The grade of material and rolling direction shall match the parent plate, but need not be cut from the same plates or cast.

5.5

NON-DESTRUCTIVE TESTING OF WELDS

5.5.1

Record of Testing

1

The test results shall be recorded and be available for inspection by the Engineer.

5.5.2

Visual Inspection of Welds

1

Visual inspection shall be made in accordance with guidance given in BS 5289 over the full length of the weld and before NDT inspection is performed (see Tables 5.1 and 5.2). Any welds which will be rendered inaccessible by subsequent work shall be examined in accordance with Tables 5.1 and 5.2 prior to the loss of access.

2

A suitably qualified person for visual inspection of welds may be a welding inspector or a welder who can provide evidence of having been trained and assessed for competence in visual inspection of the relevant types of welds.

5.5.3

Surface Flaw Detection

1

Where a closer examination of a weld surface is required in accordance with Table 5.1, magnetic particle inspection (MPI) shall be used in accordance with the recommendations given in BS 6072.

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5.4.4

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Page 5

If magnetic particle inspection equipment is not available, dye penetrant inspection (DPI) may be used in accordance with the recommendations given in BS 6443.

3

Final surface flaw detection of a welded joint shall be carried out not less than 16 hours from the time of completion of the weld to be inspected, or not less than 40 hours in the case of welds to Design Grade 55 material. The Contractor shall note that where a welding procedure requires an inspection after initial weld runs before further welding is performed, such inspections may be carried out when the weld metal has cooled to ambient temperature.

4

A suitably qualified person for surface flaw detection of welds may be a welding inspector or a welder who holds a current certificate of competence in surface flaw detection of the relevant types of work, from a nationally recognised authority.

5.5.4

Ultrasonic Examination

1

Where ultrasonic examination is required in accordance with Tables 5.1 and 5.2, it shall be made in accordance with BS 3923 Part 1, Level 2B. Examination shall be carried out not less than 16 hours from the time of completion of the weld to be inspected, or not less than 40 hours in the case of butt welds thicker than 40 mm or any welds to Design Grade 55 material.

2

Operators carrying out final ultrasonic examination of the weld shall hold a current certificate of competence from a nationally recognised authority.

5.5.5

Scope of Inspection

1

The scope of inspection shall be in accordance with Table 5.1.

5.5.6

Acceptance Criteria and Corrective Action

1

Acceptance criteria, corrective action and re-testing shall be in accordance with Table 5.2 for components subject to static loading.

2

The acceptance criteria shown in Table 5.2 are not intended to apply to bridges, offshore structures, or other dynamically loaded structures.

5.6

SHEAR STUD WELDING

5.6.1

Method

1

Shear studs shall be welded in accordance with the manufacturer's recommendations for materials, procedures and equipment.

5.6.2

Trial Welding

1

When specified by the Engineer and before production welding of studs commences, procedure trials shall be carried out. The trials shall be made on samples of material and studs representative of those to be used in the work. The samples of materials and studs shall be agreed with the Engineer.

2

Where primers are to be applied to the work prior to the welding of studs they shall be applied to the sample material before the procedure trials are made.

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2

QCS 2014


Page 6

Tests and Inspection

1

All studs are to be visually inspected. They shall show a full 360 collar.

2

At locations agreed with the Engineer a minimum of 5% of studs which have satisfied the visual inspection shall have a bend test. The bend test shall be made by striking the head of the stud with a 6kg hammer until it is displaced laterally a distance of about one quarter of the height of the stud. The stud weld shall not show any signs of cracking or lack of fusion.

3

Studs subjected to the bend test shall not be straightened.

5.6.4

Defective Studs

1

Studs with defective welding shall be removed in the manner described in Clause 5.4.5 of this Part, and replaced and re-tested as in Clause 5.6.3 of this Part.

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5.6.3

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Page 7

Table 5.1 Welds - Scope of Inspection The requirements of this table shall not preclude the use of Non- Destructive Testing outside the limits shown should the results of visual inspection or NDT indicate that a lapse in quality may have occurred in specific joints PART A.

VISUAL INSPECTION Prior to Non -Destructive Testing all welds to be visually inspected by a suitably qualified person (See Clause 5.5.2 of this Part) THICKNESS WHEN NON-DESTRUCTIVE TESTING BECOMES MANDATORY (all dimensions in mm)

Weld Type

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PART B.

Butt (full, partial penetration and with reinforcing fillets) In-line Single sided

Double sided and single sided plus backing

Single sided

Corner

Double sided and single sided plus backing

All

t max  10

1max  12

1max  20

1max ≤ 20

1max ≤ 20

t max  10

1max  10

1max ≤ 15

1max ≤ 15

1max ≤ 15

43/50

t max ≤ 10

1max ≤ 12

1max ≤ 12

1max  30

1max ≤ 30

55

t max ≤ 10

1max ≤ 10

1max ≤ 10

1max ≤ 20

1max ≤ 20

43/50

U/S

m

55

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MPI

o

Design Grade

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as

Examples

ta

Procedures

Tee and Cruciform

qa

Joint Type

Notation

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part) U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part) 

- Less than



- Less than or equal to

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Page 8

Table 5.1 (Continued) Welds - Scope of Inspection PART B. (Cont.)

THICKNESS WHEN NON-DESTRUCTIVE TESTING BECOMES MANDATORY (all dimensions in mm)

Weld Type

Fillet

Joint Type

Lap

Tee and Cruciform

Procedures

All

All

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Examples

t max ≤ 15 Not Mandatory

55

Not Mandatory

Notation

se

43/50

qa

55

as

t max ≤ 20

t max ≤ 20 t max ≤ 15 t max ≤ 20 t max ≤ 15

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part)

er

U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part)

ov

 - Less than

o

 - Less than or equal to

et it

U/S

43/50

m

MPI

ta

Design Grade

QCS 2014


Page 9

Table 5.1 (Continued) Welds - Scope of Inspection PART C

FREQUENCY OF TESTING OF JOINTS IDENTIFIED IN PART B

Connection Zones

Shop Welds

First 5 identified joints of each type having same basic dimensions, material grades and weld geometry and welded to the same procedures . Thereafter 1 in 5 joints of each type ( if the first 5 have complied with Table 5.2 ) All identified joints Traverse butts in web and flange plates before assembly

As for shop welds in Connection Zones

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Member Zones

.

Site Welds

Built up

Transverse fillet welds at ends of cover plates

Members

qa

e.g. for fixing purlins side rails, buckling stiffeners etc.

0.5 m in each 10 m or part thereof 1 in 20 Attachments

as

Secondary Attachment Welds

ta

Longitudinal welds

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Note :- Where only partial inspection is required the joints for testing shall be selected on a random basis, but ensuring that sampling covers the following variables as widely as possible : Joint Type , Material Grade and Welding Equipment .

Notation

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part) U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part) 

- Less than



- Less than or equal to

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Page 10

Table 5.2 Weld Quality Acceptance Criteria and Corrective Actions

PARAMETER

WELD TYPE

PARTICULAR CONDITIONS

REMEDIAL ACTION FOR NONCONFORMING WELDS (see Note 2)

ACCEPTANCE REQUIREMENTS (all dimensions in mm) (see Note 1 and 5 )

Fig

WELD GEOMETRY All

As specified on drawings

Repair

Weld Type

All

As specified on drawings

Refer to Engineer

Length

All

 As specified on drawings

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PROFILE

.

Location

Butt

tb  As drawing (Av.50)

Thickness

Fillet

tf  As drawing (Av.50)

ta

Throat

Repair

b,c

Repair

a

Repair or grind and MPI after grinding

Fillet

1f  As drawing

a

Repair

Toe Angle

All

  90

a

Grind and MPI after grinding

Cap/Root Bead (Height or concavity)

Butt

Butt Joint

-1  Cb  4

b

Repair or grind

Misalignment

Butt

Butt Joint

m  As drawing + 0.25t

d

Refer to engineer

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ov

 As drawing + 3 m  As drawing + 0.50t

Joint

and  As drawing + 6

o

Cruciform

e

m

Notes:-

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All

as

Leg Length

qa

 As drawing + 5

1. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average 2. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 3. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 4. All welds to the same procedure. 5. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 

Equal or greater than



Equal or less than



Sum of

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Page 11

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions PARAMETER

WELD TYPE




Single Sided

U1+ U2  0.1t (Av.100)

D,e

And  2

D,e

Transverse Weld

U1+ U2  0.05t (Av.100)

D,e

And  1

D,e

Longitudinal Weld

rp  As drawing+0.1t(Av.100)

(lack of)

and

Butt

and

if root is inaccessible

f f

d  10 in 100 (length)

f

Not Permitted

Repair

Repair and increase MPI to 100% (Note 4)

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o

All

c

d  20 in 100 (length)

ov

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Transverse Weld

Notes:-

3

se

Longitudinal Weld

Repair and double scope of Ultrasonic inspection

As drawing +2

d 

All Welds

All

Lack of Fusion and Cracks



as

Porosity

c

 As drawing +3

rp  As drawing+0.05t(Av.100)

Transverse Weld

Repair

.

Longitudinal Weld

ta

Root Penetration

DISCONTINUITIES

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SURFACE

qa

Undercut

Fig

m





Equal or less than



Sum of

QCS 2014


Page 12

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions PARAMETER

WELD


TYPE



All Welds

1`  10 )

g

1  6t in 200 (length)

g

Transverse Weld

1  3t in 200 (length)

g

Tee, Cruciform, Corner and Lap Joints

rg

 2(Av 100 )

and  3

All

er

Tee, Cruciform, Corner and Lap Joints

All

ov

Lamellar Tears

a,e a,e

Repair and double scope of U/S Inspection

Not permitted

Repair and increase U/S Inspection to 100%

Not Permitted ( Note 3)

Refer to Engineer and increase U/S Inspection to 100%

o

Notes:-

Repair and double scope of U/S Inspection

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Longitudinal Weld

se

Cracks

g

qa

Fillet or Partial Pen Butt

e,g

1  10 ) if h`  6

as

Root Gap

h  3 + As drawing

All

ta

Slag Lines and Lack of Fusion/Root Penetration

DISCONTINUITIES

.

SUB-SURFACE

Fig

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11. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average

m

12. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 13. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 14. All welds to the same procedure. 15. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 




Equal or less than



Sum of

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Page 13

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions DIMENSIONAL SYMBOLS

Notes:-

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DEFINITION OF MEASUREMENTS

m





Equal or less than



Sum of

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 06: Bolting

Page 1

6

BOLTING ....................................................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

ORDINARY BOLTED ASSEMBLIES ............................................................. 2

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8

Bolt/Nut Combinations Differing Bolt Grades Bolt Length Washers Taper Washers Galvanized Nuts Bolt Tightening Fitted Bolts

6.3

FIT-UP WHEN USING ORDINARY BOLTS .................................................. 3

6.3.1 6.3.2

Fit-up Reaming

6.4

HIGH STRENGTH FRICTION GRIP ASSEMBLIES ...................................... 3

6.4.1 6.4.2 6.4.3 6.4.4

Bolt/Nut/Washer Combinations Tightening Calibration of Torque Equipment Discarded Bolt Assemblies

6.5

FIT-UP WHEN USING HSFG BOLTS ........................................................... 4

6.5.1 6.5.2

Fit-up Reaming

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2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 4 4 4

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Page 2

6

BOLTING

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirements for bolting associated with structural steelwork.

6.1.2

References

1

The following standards are referred to in this Part: BS 2583 ......................Podger spanners

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BS 3692 ......................ISO metric precision hexagon bolts, screws and nuts BS 4190 ......................ISO metric black hexagon bolts, screws and nuts.

BS 4395 ......................High strength friction grip bolts and associated nuts and washers for structural engineering.

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BS 4606 ......................Recommendations for the co-ordination of dimensions in building. Coordination sizes for rigid flat sheet materials used in building.

ORDINARY BOLTED ASSEMBLIES

6.2.1

Bolt/Nut Combinations

1

The combinations of bolts and nuts shall be not less than the following:

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4.6 bolts with grade 4 nuts (BS 4190) 8.8 bolts with grade 8 nuts (BS 3692) 10.9 bolts with grade 12 nuts (BS 3692).

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(a) (b) (c)

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6.2

Any bolt assemblies which seize when being tightened shall be replaced.

6.2.2

Differing Bolt Grades

1

Different bolt grades of the same diameter shall not be used in the same structure, except when agreed otherwise by the Engineer.

6.2.3

Bolt Length

1

The bolt length shall be chosen such that, after tightening, at least one thread plus the thread run-out will be clear between the nut and the unthreaded shank of the bolt and at least one clear thread shall show above the nut.

6.2.4

Washers

1

When the members being connected have a finished surface protective treatment which may be damaged by the nut or bolt head being rotated, a washer shall be placed under the rotating part

2

A suitable plate, or heavy duty, washer shall be used under the head and nut when bolts are used to assemble components with oversize or slotted holes.

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Taper Washers

1

When the bolt head or nut is in contact with a surface which is inclined at more than 30 from a plane at right angles to the bolt axis, a taper washer shall be placed to achieve satisfactory bearing.

6.2.6

Galvanized Nuts

1

Nuts shall be checked after being galvanized for free running on the bolt and retapped if necessary to ensure a satisfactory tightening performance.

6.2.7

Bolt Tightening

1

Bolts may be assembled using power tools or shall be fully tightened by hand using appropriate spanners in accordance with BS 2583.

6.2.8

Fitted Bolts

1

Precision bolts to BS 3692 may be used as fitted bolts when holes are drilled or reamed after assembly so that the clearance in the hole is not more than 0.3 mm.

6.3

FIT-UP WHEN USING ORDINARY BOLTS

6.3.1

Fit-up

1

Connected parts shall be firmly drawn together. If there is a remaining gap which may affect the integrity of the joint, it shall be taken apart and a pack inserted.

6.3.2

Reaming

1

Where parts cannot be brought together by drifting without distorting the steelwork, rectification may be made by reaming, provided the design of the connection will allow the use of larger diameter holes and bolts.

6.4

HIGH STRENGTH FRICTION GRIP ASSEMBLIES

6.4.1

Bolt/Nut/Washer Combinations

1

Bolt/nut/washer combinations shall comply with BS 4395 Parts 1 or 2, as appropriate.

6.4.2

Tightening

1

The use of friction grip bolts shall comply with BS 4604. Part 1 or 2.

2

Tightening which complies with BS 4604 Part 1, may be by the torque control method, partturn method, or with load indicating devices used in accordance with the manufacturer's recommendations.

6.4.3

Calibration of Torque Equipment

1

Torque spanners and other devices shall have a calibration check at least once per shift, and shall be re-calibrated where necessary in accordance with BS 4604.

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6.2.5

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Page 4

Discarded Bolt Assemblies

1

If, after complete tightening, a bolt or nut has to be slackened off, the whole bolt assembly is to be disposed of.

6.5

FIT-UP WHEN USING HSFG BOLTS

6.5.1

Fit-up

1

Connected parts shall be firmly drawn together with all bolts partially tightened.The joint shall then be examined and if there is any remaining gap which may affect the integrity of the joint, it shall be taken apart and a pack inserted before recommencing the tightening procedure.

6.5.2

Reaming

1

Where parts cannot be brought together by drifting without distorting the steelwork, rectification can be made by reaming, provided that the design of the connection will allow the use of larger diameter bolts.

2

Calculations shall be made to demonstrate that the connection remains adequate for the forces in the connection.

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6.4.4

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END OF PART

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 1

7

ACCURACY OF FABRICATION .................................................................... 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2

Scope References

7.2

PERMITTED DEVIATIONS ........................................................................... 2

7.2.1 7.2.2 7.2.3 7.2.4

Permitted Deviations In Rolled Components After Fabrication Permitted Deviations for Elements of Fabricated Members Permitted Deviations In Plate Girder Sections Permitted Deviations in Box Sections

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2 2 2 3 4 7

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Page 2

7

ACCURACY OF FABRICATION

7.1

GENERAL

7.1.1

Scope

1

This Part deals with the accuracy of fabrication of structural steel sections.

7.1.2

References

1


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BS 4 ............................Structural steel sections BS 4848 ......................Hot rolled structural steel sections BS 5950 ......................Structural use of steelwork in buildings

PERMITTED DEVIATIONS

7.2.1

Permitted Deviations In Rolled Components After Fabrication

1

Permitted deviations in rolled components after fabrication (including structural hollow sections) are given in Table 7.1

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Table 7.1 Permitted Deviations in Rolled Components After Fabrication Component

Cross Section after Fabrication

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Item

Deviation In accordance with the tolerances specified in BS 4 or BS 4848 as appropriate.

Squareness of Ends Not Prepared for Bearing

m

See also clause 4.4.3-1.

Plan or Elevation of End 3

Squareness of Ends Prepared for Bearing Prepare ends with respect to the longitudinal axis of the member. See also Clauses 4.4.3-2 and 4.4.3-3. Plan or Elevation

QCS 2014


Page 3

Table 7.1 (Continued) Permitted Deviations in Rolled Components After Fabrication Item 4

Component

Deviation

Straightness on Both Axes

 = L/1000 or 3mm

5

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whichever is the greater Length

Curved or Cambered

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Length after cutting, measured on the centre line of the section of angles.

Deviation = L/1000 or 6mm whichever is greater

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Deviation from intended curve or camber at mid-length of curved portion when measured with web horizontal.

Permitted Deviations for Elements of Fabricated Members

1

Permitted deviations for elements of fabricated members are given in Table 7.2

m

7.2.2

Table 7.2 Permitted Deviations for Elements of Fabricated Members Item 1

Component Position of Fittings Fittings and components whose location is crucial to the force path in the structure, the deviation from the intended position shall not exceed .

Deviation

QCS 2014


Page 4

Table 7.2 (Continued) Permitted Deviations for Elements of Fabricated Members Item 2

Component

Deviation

Position of Holes The deviation from the intended position of an isolated hole, also a group of holes, relative to each other shall not exceed 

Punched Holes

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3

The distortion caused by a punched hole shall not exceed  (see clause 4.6.3)

Sheared or Cropped Edges of Plates or Angle

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 = D/10 or 1mm whichever is the greater

5

Flatness

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The deviation from a 90 edge shall not exceed 

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Where bearing is specified, the flatness shall be such that when measured against a straight edge not exceeding one metre long, which is laid against the full bearing surface in any direction, the gap does not exceed 

7.2.3

Permitted Deviations In Plate Girder Sections

1

Permitted deviations in plate girder sections are given in Table 7.3

QCS 2014


Page 5

Table 7.3 Permitted Deviations In Plate Girder Sections Item

Component

1

Depth

Deviation

Depth on centre Line

.

Flange Width

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2

Squareness of Section

B Flange width

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Width of Bw or Bn

4

 =B/100 or 3mm whichever is greater

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Out of Squareness of Flanges.

Web Eccentricity

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Intended position of web from one edge of flange.

5

Flanges

B Flange width

Out of flatness

 = B/100 or 3mm whichever is the greater

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Page 6

Table 7.3 (Continued) Permitted Deviations In Plate Girder Sections

Item

Component

Deviation

6

Top Flange of Crane Girder w = Rail width + 20 mm

7

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Out of flatness where the rail seats.

Length

Flange Straightness

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Straightness of individual flanges

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Length on centre line

9

 = L/1000 or 3mm whichever is the greater

Curved or Cambered

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Deviation from intended curve or camber at mid-length of curved portion, when measured with the web horizontal.

Deviation = l/1000 or 6mm whichever is the greater 10

Web Distortion Distortion on web depth or gauge length.

gauge length = web depth

 = d/150 or 3mm whichever is the greater

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Page 7

Table 7.3 (Continued) Permitted Deviations In Plate Girder Sections

Item

Component

Deviation

11

Cross Section at Bearings

12

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Squareness of flanges to web

Web Stiffeners

Web Stiffeners

whichever is greater

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 = d/500 or 3mm

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Straightness of stiffener out of plane after welding.

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Straightness of stiffener in plane after welding.

 = d/250 or 3mm whichever is greater

7.2.4

Permitted Deviations in Box Sections

1

Permitted deviations in box sections are given in table 7.4

QCS 2014


Page 8

Table 7.4 Permitted Deviations in Box Sections Item

Component

Deviation

1

Plate Widths Width of Bf or Bw

.

Squareness

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Plate Distortion

 = w/150 or 3mm whichever is the greater

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Web or Flange Straightness

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Straightness of individual web or flanges.

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Distortion on width or gauge length.

gauge length = width, w

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Squareness at diaphragm positions

 = L/1000 or 3mm whichever is the greater

QCS 2014


Page 9

Table 7.4 (Continued) Permitted Deviations in Box Sections Item

Component

Deviation

5

Web Stiffners Straightness in plane with plate after welding.

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 = d/500 or 3mm

whichever is the greater

Web Stiffners

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6

Length

whichever is the greater

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7

 = d/250 or 3mm

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Straightness out of plane to plate after welding.

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Length on centre line.

8

Curved or Cambered Deviation from intended curve or camber at mid-length of curved portion when measured with the uncambered side horizontal. Deviation = L/1000 or 6mm whichever is the greater

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 08: Erection

Page 1

8

ERECTION .................................................................................................... 2

8.1

GENERAL ...................................................................................................... 2

8.1.1

Scope

8.2

ERECTION .................................................................................................... 2

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7

Erection Method Statement Meaning of Acceptance Provision of Setting-Out Lines by the Employer Handling and Storage Damaged Steelwork Column Base Plates and Slabs Grouting

8.3

STABILITY ..................................................................................................... 3

8.3.1 8.3.2

Temporary Restraints until Permanent Features are Built Other Temporary Restraints used by the Contractor

8.4

ERECTION LOADS ....................................................................................... 3

8.4.1


8.5

LINING AND LEVELLING .............................................................................. 3

8.5.1 8.5.2

Alignment of Part of the Structure Temperature Effects

8.6

SITE WELDING ............................................................................................. 4

8.6.1


8.7

SITE BOLTING .............................................................................................. 4

8.7.1


8.8

CERTIFICATION OF COMPLETION ............................................................. 4

8.8.1


2 2 2 2 2 2 3 3 3 3 3 3 4 4

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8

ERECTION

8.1

GENERAL

8.1.1

Scope

1

This Part specifies the requirements for the erection of structural steelwork.

2

Related Parts and Sections are as follows: This Section Part 5 Part 6

Welding Bolting

ERECTION

8.2.1

Erection Method Statement

1

The Contractor shall prepare a written method statement, taking into account the requirement of the design, erection procedure and programme, respectively.

2

The Contractor shall submit the method statement to the Engineer for acceptance at least two weeks before erection commences.

3

Erection shall not commence before the method statement has been accepted by the Engineer.

8.2.2

Meaning of Acceptance

1

Acceptance by the Engineer of the Erection Statement does not reduce the contractors responsibility for the safety of the erection process.

8.2.3

Provision of Setting-Out Lines by the Employer

1

The Contractor shall provide and maintain until the steelwork is accepted, setting-outlines and datum levels within, or immediately adjacent to, the Works.

8.2.4


1

Components shall be handled and stored in such a manner as to minimise the risk of surface abrasion and damage.

2

Fasteners and small fittings shall be stored under cover in dry conditions.

8.2.5

Damaged Steelwork

1

Any steelwork damaged during off-loading, transportation, storage or erection shall be restored to conform to the standards of manufacture as given in this Specification.

8.2.6

Column Base Plates and Slabs

1

Steel packings shall be supplied to allow the structure to be property lined and levelled and of sufficient size to avoid local crushing of the concrete.

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8.2

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Page 3

Base packings shall be placed so that they do not prevent subsequent grouting to completely fill all spaces directly under the base plates.

3

Base packs may be left permanently in place.

8.2.7

Grouting

1

Grouting shall not be carried out under column base plates until a sufficient portion of the structure has been aligned, levelled, plumbed and adequately braced.

2

Immediately before grouting, the space under column base plates shall be clean and free of all extraneous matter.

8.3

STABILITY

8.3.1

Temporary Restraints until Permanent Features are Built

1

The Engineer shall advise the Contractor of positions on the structure where temporary bracing or restraints are necessary until walls, floors or other non-steel structures are built. He shall also provide details of the forces and moments in these elements.

2

The Contractor shall design and provide the temporary bracing or restraints.

8.3.2

Other Temporary Restraints used by the Contractor

1

If the Contractor uses temporary restraints during erection which do not substitute for permanent features, they may be removed after the structure has been lined, levelled and plumbed provided that sufficient steelwork and or permanent bracing has been erected to ensure the stability of the structure under the worst expected conditions of dead, imposed and wind loading.

8.4

ERECTION LOADS

8.4.1


1

The Contractor shall ensure that no part of the structure is permanently distorted by stacking of materials or temporary erection loads during the erection process.

8.5

LINING AND LEVELLING

8.5.1

Alignment of Part of the Structure

1

Each part of the structure shall be aligned as soon as practicable after it has been erected. Permanent connections shall not be made between members until sufficient of the structure has been aligned, levelled, plumbed and temporarily connected to ensure that members will not be displaced during subsequent erection or alignment of the remainder of the structure.

8.5.2

Temperature Effects

1

Due account shall be taken of the effects of temperature on the structure and on tapes and instruments when measurements are made for setting out, during erection, and for subsequent dimensional checks. The reference temperature shall be 30oC.

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2

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Page 4

SITE WELDING

8.6.1


1

Site welding shall be carried out in accordance with Part 5 of this Section.

2

Welding shall not be permitted during inclement weather, unless adequate protective measures are taken.

8.7

SITE BOLTING

8.7.1


1

Bolting shall be carried out in accordance with Part 6 of this Section.

8.8

CERTIFICATION OF COMPLETION

8.8.1


1

When the steelwork, or portion of the steelwork, has been completed, the Contractor shall present a certificate for the Engineer and the Contractor to sign.

2

The completion of the certificate means the following:

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8.6

the Contractor's signature signifies that an inspection has been made to ensure that all connections are completed and that the steelwork is erected in accordance with this Specification and contract requirements.

(b)

the Engineer's signature signifies acceptance that the structure, or part of the structure, has been built in accordance with this Specification and the contract requirements.

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(a)

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 1

9

ACCURACY OF ERECTED STEELWORK ................................................... 2

9.1

GENERAL ...................................................................................................... 2

9.1.1 9.1.2

Scope General Requirements

9.2

INFORMATION FOR SUB CONTRACTORS ................................................ 2

9.2.1

General

9.3

DEVIATIONS ................................................................................................. 3

9.3.1 9.3.2

Permitted Deviations For Foundations, Walls And Foundation Bolts Permitted Deviations of Erected Components

2 2

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2 3 4

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Page 2

9

ACCURACY OF ERECTED STEELWORK

9.1

GENERAL

9.1.1

Scope

1

This Part the requirements for the accuracy of erected structural steelwork.

2

Related Parts and Sections are: This Section Part 7 Part 8

Accuracy of Fabrication Erection


1

Permitted maximum deviations in erected steelwork shall be as specified in Clause 9.4.2 of this Part taking account of the following:

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9.1.2

All measurements be taken in calm weather, and due note is to be taken of temperature effects on the structure. (See Clause 8.4.2 of this Section).

(b)

The deviations shown for I sections apply also to box and tubular sections.

(c)

Where deviations are shown relative to nominal centrelines of the section, the permitted deviation on cross-section and straightness, given in Part 7 of Section, may be added.

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(a)

INFORMATION FOR SUB CONTRACTORS

9.2.1

General

1

The Contractor shall advise sub contractors engaged in operations following steel erection of the deviations acceptable in this document in fabrication and erection, so that they can provide the necessary clearances and adjustments.

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9.2

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Page 3

9.3

DEVIATIONS

9.3.1

Permitted Deviations For Foundations, Walls And Foundation Bolts

1

The permitted deviations for foundations, walls and foundation bolts are given in Table 9.1. Table 9.1 Permitted Deviations for Foundations, Walls and Foundation Bolts Item 1

Component

Deviation

Foundation Level

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Deviation from exact level.

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Page 4

Table 9.1 (Continued) Permitted Deviations for Foundations, Walls and Foundation Bolts Item 2

Component

Deviation

Vertical Wall Deviation from exact position at steelwork support point.

.

Pre-set Foundation Bolt or Bolt Groups when Prepared for Adjustment

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3

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Deviation from the exact location and level and minimum movement in pocket.

Pre-set Foundation Bolt or Bolt Groups when Not Prepared for Adjustment

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4

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Deviation from the exact location level and protrusion.

9.3.2

Permitted Deviations of Erected Components

1

Permitted deviations of erected components is given in Table 9.2. Table 9.2 Permitted Deviations of Erected Components Item 1

Component Position at Base of First Column Erected Deviation of section centreline from the specified position.

Deviation

QCS 2014

2


Page 5

Overall Plan Dimensions True overall dimension “ L”

Deviation in length or width

L  30 metres,  = 20 mm

.

L  30 metres,  = 20 mm +

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0.25 (L - 30) mm

where L is in metres

m

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Deviation of top relative to base, excluding portal frame columns, on main axes. See Clause 3.4.4 (c) of this Section regarding pre-setting continuous frames.

ta

Single Storey Columns Plumb

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3

 =  H/600 or 5 mm whichever is greater Max =  25 mm

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Page 6

Table 9.2 (Continued) Permitted Deviations of Erected Components

Item 4

Component

Deviation

Multi-storey Columns Plumb

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Deviation in each storey and maximum deviation relative to base.

 h = h/600 or 3 mm

ta

whichever is greater

5

Gap Between Bearing Surfaces

qa

 H = 50 mm maximum

Alignment of Adjacent Perimeter Columns

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6

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(See Clauses 4.4.3-3, 6.3.1 and Item 3 of Table 7.1)

critical face of columns

m

Deviation relative to next column on a line parallel to the grid line when measured at base or splice level.  = 10 mm

7

Floor Beams Level Deviation from specified level at supporting stanchion.

QCS 2014


Page 7

Table 9.2 (Continued) Permitted Deviations of Erected Components Component

Deviation

Item 8

Floor Beams Level at Each End of Same Beam Deviation is level.

.

Floor Beams Level of Adjacent Beams within distance of 5 metres

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9

10

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Deviation from relative horizontal levels (measured on centreline of top flange)

Beams Alignment

h  3 m,  = 5 mm h  3 m,  = h/600

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Horizontal deviation relative to an adjacent beam above or below.

11

Crane Gantry Columns Plumb Deviation of cap relative to base.

 =  Hc /1000 or 5 mm whichever is greater Max =  25 mm

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Page 8

Table 9.2 (Continued) Permitted Deviations of Erected Components

Item 12

Component

Deviation

Crane Gantries Gauge of Rail Tracks Deviation from true gauge

Joints in Gantry Crane Rails

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13

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 =  10 mm

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END OF PART

 = 0.5 mm

QCS 2014

Section 17: Metalwork Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

SUBMITTALS ................................................................................................ 3

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9

Samples Protection Materials Mock-ups Engineering Calculations Test Reports Inspection and Production Testing Programs Shop Drawings Maintenance Manual As-Built Drawings

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2 2 3 4 4 4 4 4 5 5 5

QCS 2014


Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Part provides the specification for preparation of shop drawings, engineering, testing, fabrication, delivery erection and installation of steel doors, roller shutters, aluminium doors, windows and fly screens, aluminium support and cladding systems and architectural metal work.

2


.l. l rw

ta

Concrete Roofing Thermal Insulation of Buildings Structural Steelworks Carpentry, Joinery and Ironmongery Glass and Glazing Painting and Decorating

qa

Section 5 Section 14 Section 15 Section 16 Section 18 Section 25 Section 26

.

1

References

1


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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanized coatings on iron and steel articles

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BS 1245 ......................Metal door frames (steel) BS 1282 ......................Guide to the choice, use and application of wood preservatives.

ov

BS 1449 ......................Steel plate, sheet and strip.

o

BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes, bars, extruded round tube and section

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BS 1615 ......................Method for specifying anodic oxidation coatings on aluminium and alloy

m

BS 1706 ......................Electroplated coatings of nickel and chromium BS 1722 ......................Fences BS 1723 ......................Brazing BS 1724 ......................Bronze welding by gas BS 2901 ......................Filler rods and wires for gas shielded and welding BS 2994 ......................Cold rolled steel Sections BS 2997 ......................Aluminium rainwater goods BS 3049 ......................Pedestrian guard rails (metal) BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes BS 3987 ......................Anodic coatings on wrought aluminium for oxidation external architectural applications. BS 4147 ......................Bitumen based hot applied coating material for protecting iron and steel, including suitable primers where required. BS 4254 ......................Two-part polysulphide based sealants

QCS 2014


Page 3

BS 4255 ......................Rubber used in pre-formed gaskets for weather exclusion from buildings BS 4300 ......................Specification (supplementary series) for wrought aluminium and aluminium alloys for general engineering purposes. BS 4315 ......................Methods of test for resistance to air and water penetration BS 4873: .....................Aluminium alloy windows BS 5368 ......................Method of testing windows. BS 5707 ......................Solutions of wood preservatives in organic solvents. BS 6213 ......................Guide to selection of constructional sealants BS 6375 ......................Performance of windows

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BS 6496 ......................Powder organic coatings for application and storing to aluminium alloy extrusion, sheet and pre-formed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and pre-formed sections coated with organic coatings

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BS 6497 ......................Powder organic coatings for application and storing to ho-dip galvanized hot-rolled steel Section and steel sheet for windows and associated external architectural purposes, and for the finish on galvanized steel Section and sheet coated with organic coatings.

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BS 6510 ......................Steel windows, bills, window boards, and doors

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BS 7036 ......................Code of practice for provision and installation of safety devices for automatic power operated pedestrian door systems

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BS 7773 ......................Code for practice for cleaning and preparation of metal surfaces BS EN 288 ..................Approval of welding procedures for metallic materials

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BS EN 485 ..................Aluminium and aluminium alloys –sheet, strip and plate

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BS EN 10142 ..............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions.

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BS EN 10143 ..............Continuously hot-dip metal coated steel sheet and strip –Tolerances on dimensions and shape

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BS EN 10152 ..............Electrolytically zinc coated cold rolled steel flat products –Technical delivery conditions

1.2

SUBMITTALS

1.2.1

Samples

1

The Contractor shall submit samples and mock-ups in accordance with the relevant provisions of Section 1, General, and as follows: (a)

submit samples of all materials and finishes including the following: (i)

samples matching the appearance, colour, texture, and other characteristics of each finish required.

(ii)

finished samples of panels and major extrusions.

(iii)

range samples showing the complete range of variation in colour, texture, and other characteristics resulting from the manufacture, finishing, fabrication, delivery, assembly, installation, and cleaning processes.

(iv)

samples showing finishes over welds and over materials welded.

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(b)

the size of all samples to be agreed with the engineer or as noted in the contract documents

(c)

the Contractor shall submit any pre-printed or prepared manufacturer’s performance data.

Protection Materials

1

The Contractor shall provide information or direction for application and removal procedures for all protection materials used on or for samples during shipping, storage, and installation.

1.2.3

Mock-ups

1

The Contractor shall provide test mock-ups as indicated in the Project Documentation, and as required for tests

2

The Contractor shall provide visual mock-up as indicated in the Project Documentation.

1.2.4

Engineering Calculations

1

The Contractor shall submit engineering calculations as directed in the Project Documentation

2

Engineering calculations shall be submitted concurrently with the corresponding shop drawings.

3

All engineering calculations are to bear the stamp of a professional engineer.

1.2.5

Test Reports

1

The Contractor shall submit test reports for all tests specified herein. Test reports shall be submitted in a timely manner and prior to execution of any Works.

2

Product test reports: a qualified independent testing agency approved by the Engineer shall be used to indicate and interpret test results on tests on components and assemblies relative to compliance with the requirements of the Project Documentation.

3

Reconstruction test reports: a qualified independent testing agency approved by the Engineer shall be used to indicate and interpret test results on test mock-ups relative to compliance with the requirements of the Project Documentation.

4

Field test reports: a qualified independent inspecting and testing agency approved by the Engineer shall be used to indicate and interpret field test results relative to compliance with the requirements of the Project Documentation.

1.2.6

Inspection and Production Testing Programs

1

The Contractor shall submit to the Engineer a detailed description of inspection and production testing programmes and inspection reports for all types of coating of aluminium or aluminium alloy.

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1.2.2

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Shop Drawings

1

Shop Drawings, shall be prepared in accordance with the relevant provisions of Section 1, General. Shop Drawings shall be prepared and approved by the Engineer prior to the fabrication of any off-site item.

1.2.8

Maintenance Manual

1

A maintenance manual describing the various materials, equipment, and procedures for cleaning and maintaining the parts of the Works included in this Section shall be submitted to the Engineer for approval upon completion of the Project.

1.2.9

As-Built Drawings

1

As-Built Drawings, prepared in accordance with the relevant provisions of Section 1, General, shall be submitted to the Engineer for approval upon completion of the Project.

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1.2.7

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END OF PART

QCS 2014

Section 17: Metalwork Part 02: Material Types and Finishes

Page 1

2

MATERIAL TYPES AND FINISHES .............................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4

Scope References System Description Metals

2.2

PROTECTIVE TREATMENTS FOR METALS ............................................... 3

2.2.1

General

2.3

ALUMINIUM FINISHES ................................................................................. 4

2.3.1 2.3.2 2.3.3

General Requirements Finishes for Aluminium and Aluminium Alloys Storage and Handling of Materials

2.4

CARBON STEEL FINISHES.......................................................................... 7

2.4.1 2.4.2 2.4.3

General Painted Steel Stainless Steel Finishes

2 2 3 3

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MATERIAL TYPES AND FINISHES

2.1

GENERAL

2.1.1

Scope

1

This part specifies the requirements for material types and finishes for non-structural metal work.

2



Structural Metalwork Carpentry, Joinery and Ironmongery Painting and Decorating

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General Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding System Workmanship

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2

References

1


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BS 729 ........................Hot dip galvanized coatings on iron on steel articles

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BS 1224 ......................Electroplated coatings of nickel and chromium BS 1285 ......................Metal door frames (steel)

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BS 1449 ......................Steel plate, sheet and strip

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BS 1615 ......................Method for specifying anodic oxidation coatings on aluminium and alloys

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BS 1706 ......................Electroplated coatings of cadmium and zinc on iron and steel

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BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes BS 3987 ......................Anodic coatings on wrought aluminium architectural applications

of oxidation external

BS 4147 ......................Bitumen – based hot-applied coating material for protecting iron and steel, including suitable primers where required. BS 6497 ......................Powder organic coatings for application and stoving to hot dip galvanized hot-rolled steel sections and steel sheet for windows and associated external architectural purposes, and for the finish on galvanized steel sections and sheet coated with organic coatings. BS 7773 ......................Code of practice for cleaning and preparation of metal surfaces BS EN 10142 ..............Continuously hot- dip zinc coated low carbon steel sheet and strip for cold forming; technical delivery conditions BS EN 10143 ..............Continuously hot-dip metal coated steel sheet and strip-tolerances on dimensions and shape

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BS EN 10152 ..............Electrolytically zinc coated cold rolled steel flat products–Technical delivery conditions System Description

1

Materials and components used shall be as specified or be suitable equivalents as approved by the Engineer.

2

Materials not specified are to be of the best quality and suitable for the purpose intended and as approved by the Engineer.

3

All materials are to be free from any defect that may impair the strength, functioning, durability, or appearance of the work of this Section or of adjacent construction.

2.1.4

Metals

1

It is the responsibility of the Contractor to select the alloy, degree of alloy control, homogeneity, temper, metallurgical quality, degree of hardness or softness, mill tolerances, cutting tolerances and flatness required to achieve the requirements of design, quality, and colour matching of finish set forth in the Project Documentation.

2

Suitable low-friction separation materials shall be provided where metal materials are adjacent and subject by design to relative movement against one another. Suitable lowfriction separation materials are as follows:

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2.1.3

teflon strip, 750 microns thick and teflon tape, 125 microns thick

(b)

high-impact polystyrene

(c)

other materials as approved by the Engineer.

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Low-friction material shall be impervious to moisture.

2.2

PROTECTIVE TREATMENTS FOR METALS

2.2.1

General

1

Galvanized carbon steel (hot-dip) shall comply with the relevant provisions of BS 729, BS 1245, BS 6497, BS EN 10142, BS EN 10143.

2

Zinc-rich coating system shall comply with the relevant provisions of BS 3083, BS EN 10152

3

Nickel and chromium shall comply with the relevant provisions of BS 1224.

4

Zinc plating shall comply with the relevant provisions of BS 1706.

5

Aluminium/zinc-coating shall comply with the relevant provisions of BS 1615.

6

Bituminous paint shall comply with the relevant provisions of BS 4147.

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ALUMINIUM FINISHES

2.3.1


1

The requirements and specification for finishes on aluminium as referred to in this Part shall comply with the following paragraphs.

2

Final colours will be selected by the Engineer from actual samples submitted by the Contractor.

3

Metal surfaces are to match the appearance, colour, and texture of samples submitted to and approved by the Engineer.

4

The Contractor shall submit a writing list of all aluminium products used in the Works. This list shall identify the location of each product and their finishes as per the following principal finishes:

(ii)

buffed

(iii)

directional textured

(iv)

non-directional textured.

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chemical finishes non-etched cleaned

(ii)

etched

(iii)

brightened

(iv)

chemical conversion coatings

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(i)

coatings

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as fabricated

(i)

anodic

(ii)

resinous and other organic coatings

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(b)

mechanical finishes:

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(iii)

vitreous coatings

(iv)

electroplated and other metallic coatings

(v)

laminated coatings

5

All aluminium and aluminium alloy products used in the Works that are to be finished in a similar way shall be obtained from the same source unless otherwise approved by the Engineer.

6

All metal surfaces which are required by Project Documentation or manufacturer’s standards to receive a chemical conversion coat pre-treatment are to meet the minimum requirements of BS 3987 and BS 1615.

2.3.2

Finishes for Aluminium and Aluminium Alloys

1

Unless otherwise specified for one of the alternative finishes listed Clause 2.2.1 in the specific Project Documentation, the finish in general for aluminium shall be as follows:

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Exterior exposed aluminium: All metal surfaces exposed to the exterior, including framing members, shall receive either a two or three coat polyvinyl di-fluorine (PVDF) liquid coating as follows: surfaces shall receive a thermally-cured, pigmented, PVDF coating system, containing not less than 70 % of the fluoropolymer resin

(b)

the coating system is to be spray applied under factory conditions to a pre-treated base metal in a two-coat, two-bake process or three-coat, three-bake process in accordance with the coating system manufacturers recommendations

(c)

unless otherwise stated in the Project Documentation, the coating system shall include a primer for added substrate protection as recommended by the manufacturer to meet any coating system guarantees

(d)

finished coating thickness is to be minimum of 55 microns dry film finish (18 microns primer, 18 microns colour coat, and 18 microns clear top coat to seal and protect the system). The final dry film thickness shall be 55 to 65 microns

(e)

the coating system is to be applied by a licensed applicator approved by the coating system manufacturer. The applicator is to propose a program of records and samples are to be made available to the Engineer upon request

(f)

the surface quality of the coating is to be smooth and free of flow lines, streaks, blistering, and other imperfections. The coating will be opaque and be uniform in colour and tonality, within the range of approved upper and lower limit samples when viewed under a uniform light source such as north daylight or light source approved by the Engineer

(g)

prior to production coating, the Contractor is to present for approval full-size extrusions and sample panels representative of the maximum proposed range of colour and tonality to be expected in the finished work. The number of full-size sample panels for each coating colour is to be as approved by the Engineer

(h)

to assure consistency of paint colour and tonality in the finished work, the Contractor should propose and implement a quality control program as approved by the Engineer. The quality control program is to be vertically integrated, and include controls by the coating manufacturer and applicator, as well as by the Contractor during assembly and installation of the finished work

(i)

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(a)

if required, the quality control program will include the use of co-ordinated empirical inspection methods, such as the use of calibrated multi-angle spectrophotometers to provide 3 independent checks of paint colour and tonality at the point of paint application, during assembly, and during installation

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(j)

no production coating application is to commence prior to approval of this quality control program, any installed work with coating defects or variation in colour or tonality in excess of the approved sample range will be subject to rejection

(k)

the colour and finish are subject to the sample approval procedures specified herein and shall include: (i)

surface exposed to view

(ii)

concealed surfaces

(l)

provide a compatible field touch-up PVDF coating system formulated for air-drying at ambient temperature.

(m)

the organic coating shall not peel, check, crack, chalk or change

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Interior used aluminium: All surfaces exposed to the interior and not exposed to the exterior shall receive a high-performance acrylic enamel organic non-metallic coating as follows: the coating is to be spray applied under factory conditions to pre-treated base metal in a one-coated process in accordance with the coating system manufacturer’s recommendations

(b)

unless otherwise stated in the Project Documentation, the coating system shall include a primer for added substrate protection as recommended by the manufacturer to meet any coating system guarantees

(c)

the finished coating thickness shall be a minimum of 25 microns dry film thickness (typical) unless otherwise approved by the Engineer

(d)

the coating system to be applied by a licensed applicator approved by the coating system manufacturer. The applicator is to propose a program of records and samples of the entire coating production for approval by the Engineer, and which records and samples shall be made available to the Engineer upon request

(e)

the surface quality of the coating shall be smooth and free of flow lines, streaks, blistering or other imperfections. The coating is to be opaque and be uniform in colour and tonality; within the range of approved upper and lower limit samples when viewed under a uniform light source such as north daylight or light source approved by the Engineer

(f)

prior to production coating the Contractor will present for approval full-size extrusions representative of the maximum proposed range of colour and tonality to be expected in the finished work.

(g)

to assure consistency of paint colour and tonality in the finished work, the Contractor should propose and implement a quality control program as approved by the Engineer. The quality control program to be vertically integrated, and include controls by the coating manufacturer and applicator, as well as by the Contractor during assembly and installation of the finished work. If necessary, such a quality control program is to include the use of co-ordinated empirical inspection methods, such as the use of calibrated multi-angle spectro-photometers to provide 3 independent checks of paint colour and tonality at the point of paint application, during assembly, and during installation.

(h)

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(a)

no production coating application should commence prior to approval of this quality control program by the Engineer. Notwithstanding the implementation of an approved quality control program, any installed work with coating defects or variation in colour or tonality in excess of the approved sample range will be subject to rejection

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(i)

the colour and finish are subject to the sample approval procedures specified herein and are to include a one-coat acrylic enamel to match Engineer’s sample

(j)

provide a compatible field touch-up acrylic enamel coating system formulated for airdrying at ambient temperature in a colour to match the factory applied finish

(k)

the organic coating shall not peel, check, crack, chalk or change colour for a period of 5 years from the completion of the Project.

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2.3.3

Storage and Handling of Materials

1

Material shall not be shipped, delivered or supplied when the finish of such material: (a)

has not been inspected and tested in the manner and by the means specified above and as approved

(b)

does not meet all the specifications for the finishes set forth in the alloy manufacturer’s instructions

(c)

does not fall within the colour and tonality range approved by the Engineer

(d)

has been rejected by the Engineer

(e)

has not otherwise been processed in accordance with the specified requirements.

Protection of Aluminium. All aluminium surfaces in contact with blockwork, concrete, render or other alkaline materials shall be coated with two coats of black bitumen solution or similar approved protective coating. Alternatively, shims of fibre, neoprene, or other materials which will not interact with the aluminium or other adjacent materials may be provided and gaps filled with backer rod and sealant as approved by the Engineer.

2.4

CARBON STEEL FINISHES

2.4.1

General

1

Requirements and specification for finishes on carbon steel as referred to this Section shall comply to the following:

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2

all surfaces of steel members incorporated in Works shall be finished as required in this Section

(b)

if concealed from view, steel surfaces are to receive a finish in accordance with Section 16, Structural Steel, and Section 26 Painting

(c)

if exposed to view, steel surfaces are to receive the following coating system:

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(a)

surface preparation: BS 7773

(ii)

primer: fast curing epoxy primer coat

(iii)

intermediate coat: high-build epoxy-polyamide paint

(iv)

top coat: aliphatic acrylic polyurethane finish system.

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(i)

2.4.2

Painted Steel

1

The Contractor will propose and implement a quality program for approval by the Engineer. The quality control program is to be vertically integrated, and include controls by the steel fabricator and the steel finisher, as well as by the Contractor to provide independent checks of steel quality and finish at the point of fabrication, finishing, and during installation.

2

Preparation of steel shall be as follows: (a)

steel received from the mill will be inspected for any defects or damage which could adversely affect the fabrication and finishing of the steel. All steel members are to be blast cleaned prior to final fabrication and assembly

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all fabrication is to be done prior to finishing. All welds are to be ground smooth and finished to match adjacent surfaces, all burrs and foreign particles removed, and any other defects remedied prior to finishing

(c)

prior to finishing all fabricated steel is to be inspected and if, in the determination of the coating applicator, the steel is not sufficiently cleaned to ensure a high-quality finish, the steel is to be further cleaned as required to achieve the finish desired.

(d)

verify that all surfaces to be painted are dry, clean and free of dust, dirt, oil, wax, grease, or other contaminants

(e)

after steel members are installed, inspect steel for damage and staining. Repair or replace damaged members. All repair procedures are subject to approval by the Engineer who will have the right to reject any installed work notwithstanding any rededication procedures instituted.

.

(b)

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Painting applications shall be as follows:

steel is to be shop-painted with one coat of fast-curing epoxy primer and one coat of epoxy intermediate coat as specified herein. The epoxy primer coat is to be in a contrasting colour from the epoxy intermediate coat

(b)

all steel to be painted in accordance with the recommendations of the coating manufacturer

(c)

mix and apply all coatings in accordance with paint manufacturer’s recommendations. Apply paint only under the climatic conditions recommended by paint manufacturer

(d)

check dry film thickness after application of each coat in accordance with the recommendations of the manufacturer

(e)

inspect finished steel members thoroughly prior to shipping to the Site. Package, ship, store and protect primed steel prior to installation

(f)

prior to application of the finish coat, inspect the primed substrates for any defects or conditions which may affect the application and quality of the finish coat

(g)

spray or roller apply the finish coating in accordance with paint manufacturer’s recommendations. If roller applied, finish coat is to be rolled in one direction; avoid backrolling of any kind. Avoid combining application procedures; all surfaces are to be rolled or all surfaces are to be sprayed

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(a)

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(h)

the surface quality of the coating is to be smooth and free of flow lines, sags, dry spray, overspray, imbedded particles, and other imperfections

(i)

the coating is to be opaque and uniform in colour and tonality when viewed under a uniform light source such as north daylight. Inspection shall be by visual comparison with previously approved range samples and if necessary, include the use of coordinated empirical inspection methods, such as the use of calibrated multi-angle spectrophotometers.

2.4.3

Stainless Steel Finishes

1

Stainless steel finishes as referred to in this Section shall comply with the following.

2

Stainless steel shall comply with BS 1449 Part 2.

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3

4


Page 9

Unless otherwise specified in the Project Documentation, the quality of metal work components manufactured from stainless steel shall comply with the following: (a)

externally

Type 316

(b)

internally

Type 304

Unless otherwise specified in the Project Documentation, the finish of metal work components manufactured from stainless steel shall comply with the following: (a)

non visible surfaces

2D mill finish (e.g., roof flashings)

(b)

visible surfaces

3B brush polished finish.

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The finish is to be uniform and free from blemishes, scratches, and other defects. Notwithstanding the above, the finish shall be appropriate for its function and selected so as not to invalidate its warranty. The grain of stainless steel and brushed finishes are to run in the same direction for contiguous or adjacent components.

6

For special applications (e.g. use in swimming pools or in environments where exposure to chemicals may occur), the usage of stainless steel type shall be as stated in the Project Documentation.

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END OF PART

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 1

3

METAL DOORS AND WINDOWS ................................................................. 2

3.1

ALUMINIUM DOORS AND WINDOWS ......................................................... 2

3.1.1 3.1.2 3.1.3

Scope of Work References Detailed Specification

3.2

FLYSCREENS ............................................................................................... 4

3.3

AUTOMATIC BI-PARTING DOOR OPERATORS ......................................... 4

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

General Requirements Safety Control Logic Drive System Track Fail Safe

3.4

FIXING ALUMINIUM WINDOWS AND DOORS ............................................ 5

3.4.1


3.5

STEEL DOORS AND WINDOWS ................................................................. 6

3.5.1 3.5.2 3.5.3

General Requirements Steel Doors and Frames Steel Windows

3.6

INSTALLATION OF STEEL DOOR FRAMES ............................................... 7

3.6.1


3.7

ROLLER SHUTTER FIRE DOORS ............................................................... 7

3.7.1 3.7.2 3.7.3

General Components Electrically Operated Doors

3.8

INSTALLATION ........................................................................................... 10

3.8.1


3.9

SUBMITTALS .............................................................................................. 10

3.9.1


4 4 4 5 5 5 6 6 7 7

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3

METAL DOORS AND WINDOWS

3.1

ALUMINIUM DOORS AND WINDOWS

3.1.1

Scope of Work

1

This Part provides specification for supply and installation of steel and aluminium doors and windows.

2

Windows and doors are collectively referred to as “units” in this Section.

3

Related Sections and Parts are as follows: General Materials Classification Workmanship


General Structural Metalwork Carpentry, Joinery and Ironmongery Glazing

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References

1

Standards referred to in this Part are as follows:

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BS 476........................Fire tests on building materials and structures BS 729........................Hot dipped galvanized coatings on iron and steel articles

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BS 990........................Steel windows generally for domestic and similar buildings

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BS 1245......................Metal door frames BS 1282......................Guide to the choice, use and application of wood preservatives

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BS 1449......................Steel plate, sheet and strip.

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BS 1474...................... Wrought aluminium and aluminium alloys for general engineering purpose bars, extruded round tubes and sections

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BS 3987......................Anodic oxide coatings on wrought aluminium for oxidation external architectural applications BS 4254......................Two-part polysulphide-based sealants BS 4255......................Rubber used in pre-formed gaskets for weather exclusion from buildings BS 4873......................Aluminium alloy windows BS 5368......................Method of testing windows BS 5707......................Solutions of wood preservatives in organic solvents BS 6213......................Guide to selection of constructional sealants BS 6375......................Performance of windows BS 6496......................Powder organic coatings for application and stoving to aluminium alloy extrusion, sheet and pre-formed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and pre-formed sections coated with organic coatings BS 6510......................Steel windows, gills windows boards, and doors

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BS 7036......................Code of practice for provision and installation of safety devices for automatic power operated pedestrian door systems BS EN 485..................Aluminium and aluminium alloys - Sheet, strip and plate BS EN 10142..............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions NFPA 80 .....................Standard for Fire Doors and Fire Windows Detailed Specification

1

Alternative alloys may be used where integral colour anodising is required provided the physical properties of the alloy meet relevant BS Standards for the specific material.

2

All screws, nuts bolts, reverts, washers and other fastenings are to be aluminium or stainless steel (Type 316 S16).

3

The units are to be fabricated at the manufacturer’s works as far as possible and delivered complete and ready for installation. Aluminium windows shall be to BS 4873, BS 1474, BS 3987, BS 6496, and BS EN 485.

4

The overall sizes of assembled units are to be maintained within a tolerance of ± 1.5 mm. Frame assemblies to be square with a maximum difference in the diagonals of 4 m.

5

The finished units to be free from all sharp edges, burrs and the like.

6

Joints in frames are to be made by screw spleen, shear block or other approved system capable of accommodating the thermal movement of the unit and providing tightly fitting and inconspicuous joints.

7

The main web of the aluminium outer frame should not be less than 1.2 mm thick. Frames to be self-draining and no holes for fastenings are to be located in the external channel at sill level.

8

All opening units are to be fully weather stripped using siliconized woven polypropylene, wool pile or neoprene retained in dovetailed or undercut grooves formed in the aluminium extrusions. The weather-stripping should be capable of being removed without disturbing the glazing system and without removing the outer frame from the structure.

9

The design of the units should permit re-glazing without the need to remove the outer frame from the structure.

10

All hardware is to be supplied and fixed by the unit manufacturer, and should match the finish of the surfaces of the units and be replaceable without removing the outer frame from the structure. Fasteners are to be designated so that they cannot be released from the outside by the insertion of a thin blade or other simple tool.

11

Windows are to meet the performance requirements of severe exposure to wind. Horizontal sliding units are to be supported on rustproof and dustproof bearing devices that may easily be repaired or replaced and that prevent contact between the unit and the track. Horizontal and vertical sliding units to be separated and not slide upon each other.

12

The mechanism for vertical sliding windows is to be accessible for adjustment, repair or replacement after the windows have been installed.

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No window is to be openable or removable from the outside when it is fastened in a closed position except by the use of special tools or by breaking part of the window or door.

14

All opening windows are to be fitted with flyscreens.

15

All unit surfaces which will be visible in the finished work are to be protected after manufacture by low tack tape or other suitable means capable of being removed after exposure to the high temperatures prevalent in Qatar to leave clean, undamaged surfaces.

16

Sill frames to slope outward (level frames are not allowed).

17

Weepholes where required are to be as detailed in the shop drawings

3.2

FLYSCREENS

1

Flyscreens are to be fabricated in accordance with Clause 3.1.3.

2

The frames to be fabricated from substantial, rigid sections and be easily removable from the window to permit maintenance, cleaning and repair. The frames are to allow the replacement of the mesh and be finished (anodised, powder coated, etc.) to match the windows in which they will be fitted.

3

The frames are to be infilled only with 0.4 mm aluminium wire woven to a 1.5 mm mesh, stretched tightly and evenly, and be free from visible joints.

3.3

AUTOMATIC BI-PARTING DOOR OPERATORS

3.3.1


1

Automatic bi-parting door operators are to be approved 240 V/50 Hz fully electric operators, fully housed in extruded aluminium or stainless steel housing.

3.3.2

Safety Control Logic

1

The equipment is to incorporate the following safety control logic:

auto retry (three times) at safety “creep” speed (1/3 speed) to detect obstruction.

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(b)

automatic reversing if obstructed during the closing sequence (fully adjustable sensitivity).

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(a)

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13

(c)

auto revert to normal mode after successful retry.

(d)

fully adjustable speed control with independent settings for Opening, Closing, Final Opening, Final Closing.

(e)

auto stop if obstructed during opening sequence (fully adjustable sensitivity).

3.3.3

Drive System

1

The equipment is to incorporate the following drive system: (a)

squirrel cage motor with output shaft and gearbox drive shaft shall use constant rated 7 kg torque capacitor for start and run. No intermediate belts, pulleys and couplings which are subject to failure, breakage, shearing or loss of tension shall be used

(b)

thermal protection: the motor must be able to be held in the stalled position indefinitely under full electric current without resultant damage to the windings

QCS 2014


Page 5

(c)

chain drive with minimum tensile strength of 1,950 kg and 12.5 mm pitch, directly connected to door leaf carriage assemblies. Chains or belts of lesser tensile strength will not be permitted

(d)

auto re-close circuitry to ensure doors close if partially opened (i.e. high wind condition)

(e)

self lubricating planetary gearbox with spiral bevel drive.

Track

1

The track is to be replaceable, made of extruded aluminium, hard coat anodise, carrying adjustable hanger bars supported by fully sealed raced fibber glass reinforced track wheels (min 50 mm diameter) for smoother wear and increased life.

3.3.5

Fail Safe

1

Depending on the location of doors the following systems shall be used:

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3.3.4

bi-parting doors to exterior: doors drive fully open automatically on power failure/fire alarm. Fail-safe shall consist of a 12v DC/110 vac inverter also incorporating battery alarm/monitory to alert user if power is low. Doors automatically return to original function mode when power is returned or fire signals are de-activated

(b)

bi-parting doors within building which serve to Section off or divide fire zones:

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(a)

doors to close under power failure/smoke alarm

(ii)

continuous operations under power failure (min. 50 operations required)

(iii)

to be operable manually.

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(i)

FIXING ALUMINIUM WINDOWS AND DOORS

3.4.1


1

Windows are to be fixed with sufficient fastenings to comply with Clause 3.1.3, and in no case will the number be less than the minimum specified in BS 6510 for the nearest applicable co-ordinating size.

2

All units are to be fixed square, level and plumb without distortion.

3

Where the method of fixing is be screw fastenings direct to concrete or blockwork surrounds, the screws are to extend a minimum of 25mm into the reveal and the plugs be of proprietary manufacture sized to suit the screw. Wooden plugs will not be permitted. Holes in the frames are be predrilled and the screws countersunk so as to avoid scratching, gouging or locally distorting the frame.

4

Frames are to be protected from alkaline materials in accordance with Clause 2.2.1 or by approved isolating tape.

5

Timber sub-frames to be treated in accordance with BS 1282 and to meet specified requirements of BS 5707. Treatment certificates to be submitted to the Engineer.

6

Timber sub-frames to be primed or sealed before the installation of the units.

7

Joints between the frames of external units and the surrounding construction are to be sealed in accordance with BS 6213 BS 4254 and Clause 2.2.1 in such a way as to form a complete weatherproof seal between the frame and the surround. The sills of sliding doors are to be bedded in mastic. Rubber used in pre-formed gaskets for weather exclusion to the building shall be to BS 4255.

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QCS 2014


Page 6

After installation all opening units to be eased and adjusted to provide free operation and all moving parts are to be lubricated.

3.5

STEEL DOORS AND WINDOWS

3.5.1


1

Steel doors and frames shall comply with the provisions of BS 1245 and steel windows and frames shall comply with the provisions of BS 990.

3.5.2

Steel Doors and Frames

1

The specification for proprietary steel doors shall be as follows unless otherwise specified in the Project Documentation.

2

All steel doors shall be manufactured in properly equipped workshops by tradesmen proficient in such work. All machinery employed shall be capable of accurately preparing, producing and finishing doors

3

The door shall be finished, 45 mm or 55 mm thick of double skinned, insulated sheet steel construction and shall be fabricated from two zink coated steel sheets not less than 1.6 mm thick with lock seam joints at sides. The door faces shall be free of seams or joints. Top and bottom of the doors shall be either welded flush or closed with recessed spot-channel closures. The doors shall be provided with continuous welded “U” shaped reinforcing channels to head and foot. Door construction shall be one of the following:

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not less than 1mm steel interlocking vertical channels of “Z” shaped members spaced not more than 300 mm apart or horizontal channels not more than 350 m apart

(b)

not less than 1 mm steel horizontal “U” shaped sections spaced in parallel rows not over 220 mm on centre welded in alternating sequence to the inside face of each outer sheet so that horizontal stiffening occurs approx

(c)

a continuous truss-formed inner core of not less than 1 mm sheet metal spot-welded to the face sheet every 70 mm horizontally and vertically over the entire surface of both sides.

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(a)

The doors shall be insulated with mineral wool or pressure injected polyurethane foam for sound and thermal insulation.

5

Doors clearance shall not exceed the following:

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(a)

3mm at jamb and heads

(b)

3 mm at meeting stile of pair doors with round or bevelled edges and 6 mm for doors with square edges

(c)

3mm at bottom measured from finished floor line.

6

Doors shall be provided with a sound deadening material to eliminate sound incident to the normal operation of the door as necessary or required by the Engineer.

7

The finished work shall be rigid, neat in appearance and free from defects, warp, or buckle. Moulded members shall be sharp in detail, straight, and true. Corner joints shall be coped or mitered, well-formed, in true alignment, welded and cleaned off.

8

Spot welding shall be used where practicable. Construction joints shall be welded along their full length. Exposed welded joints shall be cleaned off and dressed smooth.

9

The doors shall be suitably reinforced, morticed and tapped to receive all ironmongery.

QCS 2014


Page 7

Steel doors shall be finished as detailed in the Project Documentation. They shall be cleaned, filed, ground smooth and either painted with one coat of redhead primer prior to the finished painting or stove enamelled to a colour chosen by the Engineer.

11

Door frames are to be formed of not less than 1.2 mm nominal thickness mild steel hot dip galvanized after manufacture or, alternatively, may be made from hot dip galvanized steel sheet complying with BS EN 10142.

12

Door frames shall be given primer coat and finish as specified for the matching steel doors.

13

Where frames support door leaves in excess of 60 kg require one-hour fire resisting door assemblies, the minimum steel thickness is to be increased to 1.6 mm.

3.5.3

Steel Windows

1

Steel windows shall be constructed and assembled in accordance with the specification for proprietary steel windows shall be as detailed in the Project Documentation. In addition, steel windows shall comply with the provisions of BS 5368 and BS 6375 for testing and performance.

2

Steel windows and frames shall be manufactured in properly equipped workshops by tradesmen proficient in such work. All machinery employed shall be capable of accurately preparing, producing and finishing window frames.

3

Steel windows and frames made of hot dip galvanised steel shall additionally conform to BS 729.

4

Steel windows shall be finished as shown in the Project Documentation. They shall be cleaned, filed, ground smooth and either painted with one coat of redhead primer prior to the finished painting or stove enamelled to a colour chosen by the Engineer

3.6

INSTALLATION OF STEEL DOOR FRAMES

3.6.1


1

Frames will be fixed plumb, level and securely to prevent deflection or movement.

2

Frames built-in as the surrounding structure is constructed are to be fixed with cramps at maximum 600 mm centres. One cramp is to be located 200 mm from the bottom of the frame and 200 mm from the top or at the nearest adjacent bed joint. Voids in the backs of frames are to be filled in solid with grout as the work proceeds.

3

Frames which are to be built-in are to be braced with temporary struts to prevent distortion. Base ties to be removed after the blockwork has set and before the floor finish is laid.

4

Frames to previously prepared openings are to be fixed with screw fastenings extending into the structural reveal at least 40 mm and at maximum 450 mm centres. One fastening to be located 200 mm from the bottom of the frame and one 200 mm from the top.

3.7

ROLLER SHUTTER FIRE DOORS

3.7.1

General

1

Operation of rolling shutter fire doors shall be manual (push up, chain hoist or waist high crank hoist) or motor operated as stated in the Project Documentation.

2

Mounting of door shall be either interior face mounted on a prepared opening or interior mounted between jambs and under a lintel in a prepared opening.

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Page 8

3

Fire rating of doors to be 3 hours rated sized in accordance with BS 476, the Project Documentation and tested and approved by the Civil Defence Department.

4

Automatic Closing. To be fitted with an automatic closing device, triggered by a closing mechanism by melting of a fusible link at 71 ºC unit to be in operative during normal operations. The release mechanism to be easily reset. Smoke detection is also to be fitted to the release device.

5

Quality Assurance furnish each overhead roller shutter door as a complete unit produced by one manufacturer, including hardware, accessories, mounting and installation of components.

(b)

inserts and anchorages: Furnish inserts and anchoring devices to be set in concrete or built into masonry to install units. Provide setting out drawings, templates, instructions, and directions to install the anchorage devices.

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(a)

Components

1

The shutter door panel or curtain shall include at minimum the elements as follows:

(b)

each end of the slats to be fitted with malleable iron end locks, continuous, to act as wearing surface in the guides to maintain slat alignment and to prevent flame passage

(c)

the curtain shall be reinforced with a stainless steel or galvanized steel bottom bar of two (2) angles. Lift handles to be provided on both sides of the door.

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slats, formed in continuous lengths of stainless steel to BS 1449 or galvanized steel

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The spring counter balance shall comply with the following: the counter balance shall be housed in a steel pipe of diameter and wall thickness to restrict maximum defection to 2.5 mm/m of door width

(b)

springs shall be the helical torsion type designed to include an over load factor of 25 % and for optimum ease of operation. Springs to be grease packed and mounted on a cold rolled steel inner shaft

(c)

spring tension shall be adjustable from outside of end bracket plate

(d)

ball bearings shall be sealed to minimise wear of pipe rotation around inner shaft

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(a)

Bracket plates shall comply with the following:

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3.7.2

(a)

plates are to be made of stainless or galvanized steel thickness 6.35 mm carrying a pipe counter balancing shaft to house ends of door coil

(b)

the drive end bracket plate shall be fitted with a sealed ball bearing

(c)

the door shall be equipped with an oscillating governor as required to control the speed of descent.

4

Guides/wall angles shall be stainless or galvanized steel angles of 4.76 mm minimum thickness.

5

Hoods to house the coil are to be fabricated of stainless or galvanized steel.

6

Locking shall one of the following as stated in the Project Documentation: (a)

slide bolts - on bottom bar or manual push up, suitable for pad locks

(b)

hand chain lock - locking bracket to be provided on guide angle

(c)

locking disc - to be provided on crank box of crank hoist

QCS 2014

(d) 7


Page 9

integral gearing - on motor to provide locking of door.

The finish on galvanized surfaces shall be as follows: (a)

baked on coat of epoxy modified polyester on slabs and hood

(b)

shop coat of rust inhibiting metallic primer on all remaining ungalvanized surfaces, except bearings.

Electrically Operated Doors

1

Electric door operators shall conform to BS 7036

2

Unless otherwise indicated as having manual operation, provide electric operators for doors. Provide an electric door operator assembly of size and capacity recommended and provided by the door manufacturer, complete with electric motor and factory-prewired motor controls, gear-reduction unit, solenoid-operated brake, remote control stations, control panels conduit and wiring from controls to motor and central stations, and accessories required for proper operations

3

Disconnect mechanism - provide a hand operated disconnect or a mechanism for automatically engaging a sprocket-and-chain operated and releasing brake for emergency manual operation. Mount disconnect and operator so they are accessible from floor level. Include interlock device to automatically prevent motor from operating when emergency operator is engaged

4

Door operator type - provide a wall or bracket-mounted door operator units consisting of electric motor, worm gear drive from motor to reduction gear box, chain or worm gear drive from a reduction box to a gear wheel mounted on a counterbalanced shaft, and a disconnect release for manual operation. Provide a motor and drive assembly of horsepower and design as determined by the door manufacturer to the size of door required. The operator shall be designed so that motor may be removed without disturbing the limit-switch adjustment and without affecting the emergency auxiliary operator

5

Electric motors - provide high-starting torque, reversible, Class A insulated electric motors with overload protection. Size the motor to move the door in either direction, from any position, at not less than 0.2 m nor than 0.3 m per second. The wiring requirement and current characteristics of the motors shall be co-ordinated with the building electrical system. Supply totally enclosed, fan-cooled type motors, fitted with a plugged drain.

6

Remote control station - provide a momentary contact, three button control station with pushbutton controls labelled “Open”, “Close”, and “Stop”. Supply a keyed lockout feature with a key cylinder masterkeyed to the building system. Provide interior units with a fully guarded, surface-mounted, heavy-duty, general purpose NEMA type 1 enclosure

7

Automatic reversing control - supply each door with an automatic safety switch, extending the full width of the door bottom, and located within neoprene or rubber astragal mounted to bottom of the door rail. Contact with switch before closing will immediately stop downward travel and reverse direction to a fully opened position. Connect to control circuit through retracting safety cord and reel, or self-coiling cable. Provide electrically actuated automatic bottom bar. Ungalvanized or non stainless steel surfaces to be coated with rust inhibiting metallic primer on exposed ferrous surfaces, except bearings

8

Fail safe - depending on the location of doors the below systems shall be used for circumstances as follows:

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3.7.3

(a)

bi-parting doors to exterior: doors drive fully open automatically on power failure/fire alarm. Fail-safe shall consist of a 12 V DC/110 V AC inverter also incorporating battery alarm/monitory to alert user if power is low. Doors automatically return to original function mode when power is returned or fire signals are de-activated

QCS 2014

(b)


Page 10

bi-parting doors within building which serve to section off or divide fire zones: (i)

doors to close under power failure/smoke alarm

(ii)

continuous operations under power failure (min. 50 operations required)

(iii)

to be operable manually

INSTALLATION

3.8.1


1

Installation of units shall be undertaken by the manufacturer’s authorised representative and in accordance with manufacturer’s standards and instruction.

2

Installation shall comply with the latest NFPA 80.

3

After installation, doors are to be tested with multiple closing/opening and witnessed for normal operation.

3.9

SUBMITTALS

3.9.1


1

Provide product data, roughing-in diagrams, and installation instruction for each type and size of overhead coiling door

2

Provide operating instruction and maintenance information

3

Provide information describing fire release system including electrical rough-in instruction.

4

Provide shop drawings for special components and installation that are not dimensioned or detailed in manufacturer’s data sheet.

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3.8

END OF PART

QCS 2014

Section 17: Metalwork Part 04: Architectural Metal Work

Page 1

4

ARCHITECTURAL METAL WORK ............................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2

Scope References

4.2

HANDRAILS AND BALUSTERS ................................................................... 2

4.2.1 4.2.2 4.2.3

General Requirements Expansion Fitting and Fixing

4.3

DOWNPIPES AND GUTTERS ...................................................................... 4

4.3.1


4.4

FINISHES ...................................................................................................... 4

4.4.1


2 2

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QCS 2014


Page 2

ARCHITECTURAL METAL WORK

4.1

GENERAL

4.1.1

Scope

1

This Part provides specification for miscellaneous types of metal work not included elsewhere.

2



General Masonry Structural Metalwork

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General Material Types and Finishes Workmanship

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4

References

1


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4.1.2

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BS 729 ........................Hot dip galvanized coatings on iron and steel artivles

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BS 970 ........................Wrought steels for mechanical and allied engineering purposes

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BS 1387 ......................Screwed and socketed steel tubes and tubulars and plain end steel tubes suitable for welding or for screwing to BS 12 threads

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BS 1471 ......................Wrought aluminium and aluminium alloys for general engineering purposes

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BS 1473 ......................Wrought aluminium and aluminium alloys for general engineering purposes - forging stock

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes- bars, extruded round tubes and sections

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BS 1490 ......................Aluminium and aluminium alloy ingots and castings for general engineering purposes BS 1615 ......................Method for specifying engineering purposes

adonic

oxidation

coatings

for

general

BS 2997 ......................Aluminium rainwater goods BS 4360 ......................Weldable structural steels BS 6180 ......................Protective barriers in and about buildings BS 6323 ......................Seamless and welded steel tubes for automobile, mechanical and general engineering purposes

4.2

HANDRAILS AND BALUSTERS

4.2.1


1

Protective handrails and balusters shall be 1100 mm high and shall comply with the provisions of BS 6180 for Building.

QCS 2014

2


Page 3

Handrails and balusters shall be manufactured from material complying with the relevant provisions of the appropriate British Standard, as set out in Table 4.1. Table 4.1 Materials for Handrails and Balusters Material

Handrails Solid

Tubular

Solid

Tubular

BS

Grade

BS

Grade

BS

Grade

BS

Grade

4360

43A

1387

-

4360

43A

1387

-

-

or 6323 Pt 2

HFW2

HFW2

970 Pt 2

316S3 1

6323 Pt 8

LW17K M

970 Pt 1

316S3 1

6323 Pt 8

LW17K M

Aluminium

1474

6082

1474

6082

1490

LM6

1474

6082

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Stainless Steel

6082

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1471

6323 Pt 2

.

-

or

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Mild Steel

Balusters

-

or 1471

6082

After manufacture, mild steel and aluminium balusters shall be hot dip galvanized or anodised, as appropriate, in accordance with BS 729 or BS 1615, Grade AA25.

4.2.2

Expansion

1

Expansion joints shall be provided in horizontal members where required by design.

2

Expansion joints shall also be provided where the handrail or balustrade coincides with an expansion joint in the structure to which it is fixed.

3

Expansion joints shall be as detailed in the Project Documentation.

4.2.3

Fitting and Fixing

1

Mortises in concrete or blockwork to receive handrails and balustrades are to be formed as follows:

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(a)

with a minimum distance of 50 mm between the outer edge of the mortise and the outer edge of the concrete of blockwork excluding any finishing materials.

(b)

to the same shape as the handrail or balustrades allowing for a minimum clearance all round of 13 mm, e.g., a 51 mm diameter hole for a 25 mm diameter standard.

(c)

to allow a minimum fixed depth of 100 mm in the concrete or blockwork excluding any finishing material.

2

Mortises are to be thoroughly cleaned and wetted and made good with Class M5 mortar in accordance with Part 2 of Section 13, well compacted around the member being fixed

3

The handrail or balustrades should be securely located in position, true to line and level until the fixings have attained full strength.

QCS 2014


Page 4

Handrails and balustrades are not to be fixed to concrete or blockwork by means of screw fastenings. Drilled bolt anchorages and similar dry fixings may only be used with the approval of the Engineer and shall comply with the relevant provisions of BS 1473.

5

After installation handrails and balustrades are not to be used as strutting or supports for other work and shall be wrapped with polythene sheet or similar, securely taped to protect the finished work until completion.

4.3

DOWNPIPES AND GUTTERS

4.3.1


1

Aluminium rainwater items such as gutters, downpipes and outlets shall comply with the relevant provisions of BS 2997.

2

Rainwater items made of materials other than aluminium shall be as specified in the Project Documentation.

4.4

FINISHES

4.4.1


1

Finishes for metals covered in this Part shall be as detailed in Part 2 of this Section unless described otherwise.

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END OF PART

QCS 2014

Section 17: Metalwork Part 05: Light Metal Support and Cladding System

Page 1

5

LIGHT METAL SUPPORT AND CLADDING SUPPORT ............................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2

Scope References

5.2

PERFORMANCE REQUIREMENTS ............................................................. 2

5.2.1


5.3

COMPONENTS ............................................................................................. 3

5.3.1


2 2 2

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Page 2

LIGHT METAL SUPPORT AND CLADDING SUPPORT

5.1

GENERAL

5.1.1

Scope

1

This Part, which provides reference of specification for metal light weight cladding and support framing, is to be used in conjunction with Part 4 of Section 25, Glazed Curtain Walling.

2



General Structural Metalwork Glass and Glazing

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General Material Types and Finishes Workmanship

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5

References

1

The following standards referred to in this Section:

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5.1.2

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BS 5368 ......................Method of testing windows BS 6375 ......................Performance of windows

PERFORMANCE REQUIREMENTS

5.2.1


1

Performance of individual and aggregate components of the Work of this section are to be designed, fabricated, assembled, transported, installed and protected so that that no evidence of the following will be apparent, visually or measurable, when Work of this Section is subject to the pressures, loads, temperatures, and conditions specified.

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5.2

(a)

damage of any kind

(b)

deflections as specified in the project specification

(c)

panel flatness in excess of that specified herein

(d)

offset from the true alignment between consecutive components in line in excess of 1.0 mm in 6 metres

(e)

water Infiltration in accordance with BS 5368, Part 2

(f)

air Infiltration in accordance with BS 5368, Part 3 and BS 6375

(g)

colour variation in accordance with Part 2 of this Section

(h)

oil canning: panel surfaces are to remain flat without noticeable (detectable) oil canning or surface deformation.

QCS 2014


Page 3

5.3

COMPONENTS

5.3.1


1

Components are to be manufactured from extruded or sheet aluminium, unless otherwise indicated. Substitutions for aluminium may be considered only for such components that are not finished or exposed to the weather.

2

Metal Panels: metal panels are to be fabricated from the specified alloy of aluminium. Thickness (gauge) of aluminium sheet shall be as specified in the project specifications

(b)

metal panels are to comply with the profiles indicated on the Drawings

(c)

panels are to be fabricated so that the grain of all panels is oriented in the same direction upon installation

(d)

panel support construction to result in a panel visual flatness acceptable to the Engineer

(e)

panels subject to impact and where indicated on the Drawings are to be reinforced with aluminium members or other suitable method as approved by the Engineer

(f)

extruded aluminium stiffeners and other panel stiffening devices to be designed to prevent telegraphing or read-through of the stiffening device on the exposed face of the panel

(g)

panel anchorage is to be designed to permit replacement without disturbing contiguous work. All panels shall be easily removable and replaceable for inspection of the seam or sub-roof system.

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(a)

END OF PART

QCS 2014

Section 17: Metalwork Part 06: Workmanship

Page 1

6

WORKMANSHIP ........................................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

EXAMINATION .............................................................................................. 2

6.2.1


6.3

FABRICATION AND ASSEMBLY .................................................................. 2

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

General Requirements Fabrication and Assembly Manufacturer’s Standards Jointing and Reinforcing: Welding Visual Consistency of Metal Panels Sealant and Gasket Applications Application of Sealant

6.4

INSTALLATION ............................................................................................. 6

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6

General Requirements Anchors and Connections Corrosion Protection Lightning Protection Installation of Insulation and Safing (Fire Protection) Flashing

6.5

FIELD QUALITY CONTROL .......................................................................... 8

6.5.1

Site Tests

6.6

CLEANING .................................................................................................... 9

6.7

PROTECTION ............................................................................................... 9

6.7.1

General Requirement

2 2

2 3 3 3 4 4 5 5 6 6 7 7 8 8 8

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9

QCS 2014


Page 2

WORKMANSHIP

6.1

GENERAL

6.1.1

Scope

1

This Part provides general specification for workmanship of fabrication and assembly of architectural metalwork items

2



General Glass and Glazing

.l. l

General Materials Classification Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding System

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.

6

References

1


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6.1.2

se

BS 1723 ......................Brazing

BS 1724 ......................Bronze welding by gas

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BS 2901 ......................Filler rods and wires for gas-shielded are welding BS 5368 ......................Methods of testing windows

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BS 6375 ......................Performance of windows

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BS EN 288 ..................Approval of welding procedures for metallic materials

EXAMINATION

6.2.1


1

Prior to the start of the installation, the building to be inspected to verify all conditions and dimensions as being acceptable to receive the Work of this Section.

2

Should any conditions be found that may prohibit proper execution of the Work, the Contractor is to immediately notify the Engineer in writing of these conditions. Installation is not to proceed until remedial action, acceptable to the Engineer, has been executed.

6.3

FABRICATION AND ASSEMBLY

6.3.1


1

Use no materials, equipment or practices that may adversely affect the functioning, appearance and durability of the completed works.

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6.2

QCS 2014


Page 3

The works are to be installed in compliance with the specified criteria without buckling, opening of joints, undue stress on fasteners, sealants and gaskets, opening of welds, cracking of glass, leakage, noises or other harmful effects.

3

Conform to the materials, finishes, shapes, profiles, sizes, thicknesses, and joint locations required by the Project Documentation.

4

Match all materials to produce continuity of line, texture and colour.

5

All work to be of the highest quality, in accordance with the best trade practices, and performed by skilled workmen. All work shall be to the approval of the Engineer.

6

To the fullest extent practical, fabrication and assembly is to be executed in the workshop.

7

All components exposed in the finished work are to be free from wrapping, oil-canning effects, telegraphing of welds, studs, and other fasteners; streaks, and tool and die marks.

8

Exposed metal edges are to be finished to match typical finished surfaces.

9

To the fullest extent possible, all fabrication is to be done prior to finishing.

6.3.2

Fabrication and Assembly

1

The design of the works should endeavour to keep Project site operations to a minimum. Manufacturing, finishing, and assembly processes shall, wherever possible, be carried out off-site and under controlled environmental conditions.

2

Assembly procedures to be carried out on the Project site are to be simple to execute and capable of execution within the time allowed in the Project construction schedule.

6.3.3

Manufacturer’s Standards

1

Materials, components, and systems incorporated in the Work are to be mixed, applied and installed in accordance with the instructions and recommendations of the respective manufacturers.

2

Standards referred to in Section 25, Glazing, to apply to this Section.

6.3.4

Jointing and Reinforcing:

1

Accurately fit and firmly secure all exposed metal joints with metal-to-metal hairline joints.

2

All fastenings are to be installed at approved spacings. Fasteners are not to penetrate primary gutters and drainage systems. Fasteners may penetrate the secondary system; however, they must be properly sealed.

3

All screws and bolts up to and including 8 mm and all that are tapped into a aluminium shall be 300 Series stainless steel.

4

All bolts 10 mm and larger to be stainless steel.

5

No self-drilling fasteners are to be allowed outboard of the primary air-seal line of metal roofs and exterior wall cladding.

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All jointing and splicing of members are to be concealed. Exposed fasteners to occur only where approved by the Engineer. Where exposed in finished surfaces, screw heads shall be Phillips oval-head countersunk type, finished to match adjacent surfaces. Pop rivets are not to be used.

7

Conceal all joint sealants unless otherwise indicated in the Project Documentation.

8

All work is to be properly reinforced for hardware, anchors, and other attachments.

6.3.5

Welding

1

All welding of steel are to be in accordance with the recommendations of BS EN 288.

2

Steel welding is to be done by skilled mechanics qualified by test as contained in BS EN 288 and as applicable to the material thickness and type of welded joint on which the welders will be employed.

3

All welding is to be done with electrodes and/or methods recommended by the suppliers of the metals being welded. The type, size, and spacing of welds are to be as shown on the approved shop drawings. Welding materials and methods are to be such as not to cause distortion, discoloration, or result in any other adverse effect on the required profiles and finishes or visible surfaces of the work.

4

Welding of aluminium alloys and the qualifications of aluminium welders shall conform to BS 2901, Part 4.

5

Welding of stainless steel shall be by TIG welding or other methods subject to approval. Use double bevel butt welds, backing bars to remove heat, jigging, tack welds and any other measures necessary to minimise distortion to conform to BS 2901, Part 2.

6

Welds splatter and welding oxides on exposed surfaces to be removed. All exposed welds are to be finished to match and blend with adjacent parent metal prior to final finish application.

7

Stud welding is to be done by mechanics trained by the manufacturer of the stud setting system. The manufacturer will develop specific programs and instructions in co-operation with the fabricator to suit the needs of the specific details. The fabricator is to exercise particular care that all recommendations of the manufacturer are followed.

8

Brazing where required shall comply to BS 1723, Parts 1, 2 and 3.

9

Welding of bronze metals shall be to BS 1724.

10

Visible marks (telegraphing) on finished surfaces due to welding of studs will not be acceptable.

6.3.6

Visual Consistency of Metal Panels

1

All exposed flat metal panels are to be designated, fabricated, and installed in such a manner that they appear visually flat when viewed from any angle. Any short length distortions, ripples, waves, oil canning, or telegraphing of fasteners will not be permitted.

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Provisions are to be made to allow for differential thermal movement between framing members and the exposed metal components without noise and without distortion of the exposed face.

3

In the event that metal flatness requires interpretation by measurement, this is to be done by measuring and calculating the slope between any two points on the exposed surface 25 mm apart. This slope should not exceed 0.5 % from the nominal surface plane, when measured at an ambient temperature of 25 C.

6.3.7

Sealant and Gasket Applications

1

Sealing mechanisms (sealants and gaskets) shall be provided when required by the Project Documentation or required for a permanently weathering installation. The sealing mechanism for each location and use shall be as indicated in the Project Documentation. In those locations where a mechanism is necessary but is not indicated, it shall be of a type recommended by the Contractor and approved by the Engineer.

2

Unless otherwise specified sealants for perimeter caulking are to be either one part acrylic or one, two or three part polyurethane sealants having elastometric properties and not subject to ultraviolet degradation.

3

Sealant is to be used with the joint primer and filler recommended by the manufacturer for the type of material and width of joint to which it is to be applied. Exposed sealants are to match the colour of the adjacent metal component.

4

Bond breaker tape is to be self-adhesive polyethylene tape or other plastic tape recommended by the manufacturer of the sealant.

5

Joint backing is to be closed-cell polyethylene, non-bleeding neoprene, butyl rod or other flexible, permanent, durable non-absorptive material recommended for compatibility by the manufacturer of the sealant.

6

Specific alloys, compounds, etc. of gasket materials shall be appropriate for the function intended and are subject to approval by the gasket manufacturer and Engineer for compatibility and peel adhesion testing.

6.3.8

Application of Sealant

1

Sealants and primers are to be applied in the exact manner specified by the manufacturer and are not be used when the shelf life shown on the tins or cartridges has expired.

2

The minimum width and depth of the sealant is to be 6mm and for wider joints the depth shall be not less than half the width of the joint.

3

The surfaces of the joint are to be free from laitance, grease, loose particles, etc., and temporary protective coatings are to be removed from metal components. All surface are to be cleaned as necessary to ensure they are suitable for adhesion of the sealant and should be dry.

4

Unless the sealant manufacturer recommends otherwise:

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(a)

the joint surfaces are to be primed.

(b)

joint backing is to be used to control the depth of sealant.

QCS 2014

(c)


Page 6

where the joint design will not permit the use of joint backing, an adhesive backed polyethylene bond breaker tape is to be installed to prevent three sided adhesion.

Adjacent surface to the joint be masked with tape to prevent staining by the primer or sealant. The tape should be removed as soon as the joint has been sealed by drawing it across, and not away, from the joint.

6

The sealant to be applied with sufficient pressure to completely fill the joint, so as to exclude all air pockets and to ensure adhesion of the material to the joint bond surfaces equally on opposite sides. The surface of the sealant is to be tooled smooth and flush with the adjacent surfaces unless detailed otherwise.

7

Apply sealants and gaskets under the climatic conditions recommended by the manufacturers. All surfaces to receive sealants shall be treated (cleaned, primed or unprimed) in accordance with the instructions of the sealant manufacturer.

8

All exterior glazing gaskets shall be vulcanised, injection moulded, or heat-welded at the corners to form a continuous closure.

6.4

INSTALLATION

6.4.1


1

The Works are to be erected plumb, square, level, and correctly aligned within the following limitations:

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5

offset from true horizontal, vertical, and design location is not to exceed plus or minus 3 mm per 4 m nor plus or minus 12 mm over any one length or part thereof of the building.

(b)

maximum offset from true alignment between abutting components or components separated by less than 75 mm should not exceed 1 mm.

(c)

all tolerances shall be non-cumulative.

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(a)

Joint widths as indicated are the design joint width at an ambient temperature of 25 C. Installation procedures are to be adjusted to take into account the ambient temperature at the time of installation.

3

Care is to be exercised to properly support and reinforce units against racking during hoisting and installation.

6.4.2

Anchors and Connections

1

Anchors and connections are to be provided to comply with requirements for adjustability, movement and load transfer

2

Connections between different materials to be designed to allow for the differential thermal movement of the respected materials

3

Anchors and connections that are designed for movement are to be of such construction that friction is low enough to allow for such movement without buckling or distortion of the finished surface and other damage and without causing binding and noises

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Self-drilling, self-threading fasteners are to be Type 316 stainless steel, unless otherwise indicated

5

Metal surfaces shall be separated in such a manner that metal does not move on metal. Materials used for this purpose should be low-friction components, sealants, or gaskets as applicable

6

Anchorages to structural steel should not induce rotational forces in supporting members

7

All anchors, connections, fixings, and fasteners to be Type 316 stainless steel, unless otherwise indicated

8

Where indicated in the Project Documentation, bolted fasteners exposed to view are to be a corn-head bolts with matching nuts as approved by the Engineer

9

The total thickness of a shim pack is not to exceed a dimension equal to the diameter of the fastener/anchor

10

Shim packs that resist compressive forces only may be high-impact plastic. Shims subject to shear forces are to be stainless steel plates pinned together to form a monolistic shim.

6.4.3

Corrosion Protection

1

No metals, including alloys of the same base metal, are to be placed together in a manner, combination or location likely to give rise to damage by electrolytic action or other corrosion

2

Isolation of dissimilar metal surfaces to prevent electrolytic action is to be accomplished by materials which are impervious to moisture and non-absorptive

3

All steel parts are to receive a protective treatment commensurate with their respective functions and locations

4

Where used to the exterior of air-seals, or in any location vulnerable to moisture, steel shall be hot-dip galvanized after fabrication

5

Field welds on galvanized steel shall be treated with an approved field cold galvanizing process

6

Aluminium surfaces in contact with mortar, concrete, fireproofing, plaster, masonry, or absorptive materials of any kind shall be coated with an anti-galvanic material, impervious to moisture.

6.4.4

Lightning Protection

1

All metal cladding components, including panels, glazing frames, mullions, transoms, fixings, and support structures are to be fully bonded electrically to ensure electrical continuity of the building envelope

2

All metal cladding components, as above, are to be connected to the building ground by earthing jumper cables and connections

3

Provide for the installation of lightning arrestors, air terminals, and similar items without electrical bonding to the metal cladding components.

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Installation of Insulation and Safing (Fire Protection)

1

Install thermal insulation and safing where indicated and as required to meet overall fire separation requirements

2

Provide insulation with a minimum R-value of R-10 behind any opaque exterior surface which has conditioned space behind

3

Install insulation using welded or mechanically fixed impaling and/or retaining clips. Attachment methods are not to penetrate waterproofing membranes. Adhesive attachment of insulation is not permitted

4

Install foil tape around perimeter of foil-free of insulation board to adjacent metal framing to achieve a positive vapour barrier

5

Seal between foil-face of safing and foil-back of insulation at curtain wall with a smoke resistant sealant to provide a positive smoke barrier between floors.

6.4.6

Flashing

1

Where required or otherwise necessary to prevent leakage, flashing is to be formed from appropriate thickness of stainless steel, aluminium, or 1.5 mm thick neoprene (polychloroprene) or EODM sheet as part of a cured/uncured elastrometic sheet flashing system. Stainless steel flashing is to be a minimum 1.0-mm thick; aluminium flashing to be a minimum 1.5 mm thick

2

Where vertical or horizontal joints occur to accommodate movement, an elastrometric flashing system is to be used unless otherwise detailed in the Project Documentation and approved by the engineer.

3

Elastromeric flashing connecting to work of other Sections is to be provided by the work of this Section, including the attachment systems to this Work and to other work (except waterproofing or roofing)

4

Where elastomeric or other flashing connects to roofing and waterproofing work, provide 200 mm of flashing beyond the point of attachment to the Work of this Section. The connection to roofing work is to be provided by the roofing installer. Connections of such flashing to other than water proofing work is to be provided by the work of this Section

5

Elastomeric flashing exposed to view is to be bonded to the substrata without blistering; joints are to be neat and as infrequent as possible. Elastomeric flashing not supported by substrate material shall receive another layer of 1.5 mm flashing for reinforcement, fully bonded to the finish layer and the substrate and extending at least 25 mm beyond the unsupported area.

6.5

FIELD QUALITY CONTROL

6.5.1

Site Tests

1

The Contractor is to engage an independent testing and inspecting agency to perform field inspections and tests and to prepare test reports.

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6.4.5

(a)

the testing agency is to conduct and interpret tests and state in each report whether tested Work complies with or deviates from requirements

QCS 2014


Page 9

(b)

the Contractor is to correct deficiencies in or remove and replace work that inspections and test reports indicate do not comply with specified requirements

(c)

additional testing at Contractor’s expense, is to be performed to determine compliance of corrected Work with specified requirements.

Air Infiltration. Test areas of installed system indicated in the Project Documentation or as directed by the Engineer, BS 5368 and BS 6375.

3

Water Penetration. Test areas of installed system indicated in the Project Documentation or as directed by the Engineer for compliance with system performance requirements according to BS 5368 and BS 6375 at minimum differential pressure of 20 % of inward acting wind-load design pressure. Minimum Design Loads for Buildings and Other Structures, but not less than 300 Pa.

6.6

CLEANING

1

Clean the entire work not more than four (4) days prior to date scheduled for inspections that establish the date of Substantial Completion.

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clean all components of the Work in accordance with the recommendations of the manufacturers

(b)

clean the work from the topmost levels down in order to avoid staining of cleaned surfaces from cleaning solution residue and runoff

(c)

clean glass with approved glass cleaning solutions only and ensure that cleaning solution is completely removed from the surface after cleaning. Do not clean glass when it is exposed to direct sunlight.

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PROTECTION

6.7.1

General Requirement

1

Protect the works from material, equipment or procedures that may impair the functioning, appearance, or durability of the work or other construction.

2

Protect the installed work from damage by subsequent construction activities.

3

Protection materials, such as plastic membrane tapes and adhesive sheeting, are to be suitable for the intended protection application and protection period.

4

Protection materials are to be installed in a manner that will not trap harmful moisture or otherwise contaminate the Work.

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6.7

END OF PART

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 1

1

GENERAL ............................................................................................................... 2

1.1

GENERAL REQUIREMENTS .................................................................................. 2

1.1.1 1.1.2 1.1.3


1.2

TIMBER TYPES ...................................................................................................... 3

1.2.1

General Description

1.3

QUALITY ................................................................................................................. 3

1.3.1

General Description

1.4

MOISTURE CONTENT ........................................................................................... 5

1.4.1

General Description

1.5

STORAGE OF MATERIALS .................................................................................... 6

1.5.1


2 2 3 3

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1

GENERAL

1.1


1.1.1

Scope

1

Section 9 specifies materials, accessories, and workmanship for the use of wood in building construction. Part 1 of Section 18 defines general specifications as applicable.

2


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Wood Treatment Structural Timber Architectural Timber Joinery Fasteners and Adhesives Ironmongery

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This Section: Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 References

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1.1.2

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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanised coatings on iron and steel articles

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BS 1088 ......................Plywood for marine craft

BS 1142 ......................Specification for fibre building boards

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BS 1186 ......................Quality of timber and workmanship in joinery

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BS 1202 ......................Nails

BS 1203 ......................Synthetic resin adhesive for plywood

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BS 1204 ......................Synthetic resin adhesives (phenolic and aminoplastic) for wood

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BS 1210 ......................Wood screws BS 1282 ......................Guide to the choice, use and application of wood preservatives

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BS 2572 ......................Phenolic laminated sheet and expoxy cotton fabric laminated sheet BS 3444 ......................Specification for blackboard and lamination board BS 3621 ......................Thief resistant locks BS 3794 ......................Decorative laminated plastic sheet BS 4072 ......................Wood preservation by means of copper/chromium/arsenic BS 4079 ......................Compositions BS 4756 ......................Ready mixed aluminium priming paints for woodwork BS 4965 ......................Decorative laminated plastic sheet veneeral boards and panels BS 5268 ......................Preservative Treatments for Constructional timbers Part 5 BS 5358 ......................Plywood for marine craft BS 5589 ......................CP for preservation of timbers BS 5666 ......................Wood preservatives and treated timber BS 5707 ......................Solutions of wood preservatives in organic solvents BS 6459 ......................Door closers, mechanical performance

QCS 2014


Page 3

BS 6462 ......................Casement stays, mechanical performance BS 6566 ......................Plywood BS 7036 ......................CP for installation of safety devices for automatic power operated pedestrian door systems BS 7352 ......................Strength and durability performance of metal hinges BS 8201 ......................Timber flooring BS EN 635 ..................Plywood, clarification by surface appearance BS EN 1014 ................Wood preservatives, creosote and creosoted timber methods of sampling and analysis TRADA .......................Wood information sheets Definitions

1

Concealed surfaces: Surfaces which after installation in the building will be concealed by the surrounding work, not merely by decoration.

2

Semi-concealed surfaces: Surfaces such as the internal parts of cupboards or fittings which are not visible when the fittings are closed.

3

Class 1 finish: Refers to the exposed surfaces of joinery which are selected for clear finish.

4

Class 2 finish: Refers to the exposed surfaces of joinery which are selected for painting.

1.2

TIMBER TYPES

1.2.1

General Description

1

Softwood is to comply with the relevant provisions of BS 1186, Part 1.

2

Hardwood is to comply with the relevant provisions of BS 1186, Part 1. Planed representative samples of each hardwood species specified are to be submitted to the Engineer before the manufacture of any joinery work.

3

The following hardwoods are approved for use:

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1.1.3

(a)

Iroko

(b)

Afrormosia

(c)

Dark Red Meranti

(d)

Opepe

4

Under no circumstances shall Light Red Meranti be used.

5

Where Teak is specified no alternative hardwood will be acceptable.

1.3

QUALITY

1.3.1

General Description

1

Timber should comply with the requirements of Table 1.1 and should be free of the following defects:

QCS 2014


Page 4

(a)

unsound knots, dead knots, loose knots and knot holes.

(b)

sapwood on any external hardwood or Class 1 finish surface.

(c)

splits extending through the piece from one surface to another and ring shakes.

(d)

decay and insect attack other than pinholes as defined in Tables 1.1 and 1.2.

Except in Class 1 finish work, defects arising from manufacture and knots may be cut or bored out and replaced with a plug or inserts of the same species, well glued in. The plug is to be the full depth of the hole and the grain to be in the direction of the grain of the piece into which it is inserted. The width of any plug or insert should not be more than 6 mm greater than the maximum limit of the knot size.

3

In jointed panels each piece is to be of the same species and in Class 1 finish work all the exposed surfaces of each piece are to have the same character of grain and are to be matched.

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Table 1.1 Quality of Timber

Class 1 Finish

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Exposed Surfaces

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Features

Class 2 Finish

Pin knots up to 6 mm diameter only unless the knots are specified as a feature.

Up to 25mm width 25-50mm width 50-100mm width Over 100mm width

Checks, Width splits Length and Depths Shakes

0.3 mm 300 mm One quarter of timber

Pitch pockets

Not Permitted

Not Permitted unless cut out and filled

Plugs and inserts

Not Permitted

Width not to be 6mm greater than maximum limit of permitted knot size

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Rate of Growth

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None

- one half of timber - 15mm - one quarter - 25mm

1.5 mm (filled if over 0.5 mm) 300 mm One Quarter of timber

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Joints and Lamination Glue Lines

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Knots

Not fewer than 8 growth rings per 25 mm at any point on any cross section

Slope of grain

Not greater than 1 in 10 in softwoods and 1 in 8 in hardwoods

Boxed Heart

Permitted in softwoods only if there is no shake on exposed surfaces

Pitch

Not permitted

Permitted if hard

Pin-holes

Not permitted

Permitted if filled

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Page 5

Table 1.2 Quality of Timber Features

Concealed and Semi-Concealed Surfaces

Knots

Up to 45mm width 45-60mm width 60-100mm width Over 100mm width

Checks, Width splits Length and Depths Shakes

-

two-thirds of timber 20mm one half 50mm

Any width Not continuous for whole length One Half of timber

Pitch pockets

Permitted Width not to be 6mm greater than maximum limit of permitted know size

.

Plugs and inserts

No specified requirement

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Joints and Lamination Glue Lines

Not fewer than 8 growth rings per 25mm at any point on any cross section

Slope of grain

Not greater than 1 in 10 in softwoods and 1 in 8 in hardwoods

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Rate of Growth

Boxed Heart

Permitted in softwoods Permitted

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Pitch

Permitted

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Pin-holes

MOISTURE CONTENT

1.4.1

General Description

1

All timber is to be kept in stores, properly stacked, for a minimum period of three months to ensure conditioning to a maximum moisture content from time of delivery and during site storage to be no more than the following:

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1.4

timber 50mm and less in thickness to have a moisture content of 19% or less

(b)

boards to have a moisture content of 19% or less

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timber over 50mm thick to have a moisture content of 25% or less.

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(c)

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(a)

2

Particular care is to be taken to ensure that all carpentry and joinery timbers, plywood, blockboard and other timber based composite board, whether in prefabricated or loose form, are delivered and maintained at the required maximum moisture content stated. Refer to BS 6566 Part 5 for moisture content in plywood.

3

When instructed by the Engineer the Contractor is to make available a moisture meter for the testing of moisture content on site. The test is to be carried out according to the instrument manufacturer’s instructions at a point not nearer than 600 mm from either end or at the centre if the length is less than 1200 mm.

4

For information related to use of moisture meters refer to the following Timber Research and Development Association (TRADA) wood information sheets, reference: (a)

No. 14

Moisture in timber 4284 910

(b)

No. 18

Moisture metres for wood 461795.

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Page 6

1.5

STORAGE OF MATERIALS

1.5.1


1

The Contractor is to comply with the following requirements when dealing with structural timbers (rough carpentry): protect timber and other products from dampness both during and after the delivery to the site.

(b)

pile timber in stacks in such a manner as to provide air circulation around the surfaces of each piece.

(c)

stack plywood and other board products so as to prevent warping.

(d)

locate stacks on well drained areas, supported at least above ground and cover as necessary for protection from driving rain and prolonged sun exposure, whilst providing ventilation.

ta

The Contractor is to comply with the following requirements when dealing with architectural timber (finished carpentry and shopwork). joinery is to be stacked on bearers on level, dry floors. Components are to be staggered or separated with spacers as necessary to prevent damage by and to projecting ironmongery, beads, etc.

(b)

components which cannot be immediately unloaded into conditions of storage recommended by the manufacturer or approved by the Engineer are not to be delivered to the site.

(c)

during transit and while stored on site, doors are to be stacked horizontally in piles, each pile on not fewer than three cross bearers laid level and true.

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(a)

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(a)

END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 02: Wood Treatment

Page 1

2

WOOD TREATMENT .................................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3


2.2

PRESERVATIVE TREATMENT .................................................................... 2

2.2.1 2.2.2 2.2.3

General Application Standard Pressure Treated Preservative Other Preservative Treatments

2.3

FIRE RETARDANT TREATMENT ................................................................. 3

2.3.1

General Application

2.4

INSECT TREATMENT ................................................................................... 3

2.4.1

General Application

2 2 2

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Page 2

WOOD TREATMENT

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the use of preservative, insect protection and fire retardant treatment for wood construction, inclusive of Structural Timbers and Architectural woodwork. Unless stated otherwise in the Project Documentation, the guide to choice, use and application of wood preservatives is BS 1282.

2


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General Structural Timber Architectural Timber Joinery Fasteners and Adhesives

ta


.

2

References

1


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2.1.2

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BS 1282 ......................Guide to the choice, use and application of wood preservatives

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BS 5268 ......................Preservative treatments for constructional timbers BS 5707 ......................Solutions of wood preservatives in organic solvents

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BS 6566 ......................Plywood

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BS EN 1014 ................Creosote and creosoted timber Submittals

1

In accordance with the Project Documentation, provide certification as specified that required preservation treatment or fire retardant has been completed, or in the absence of specific requirement that at minimum the manufacturers required standard application has been used.

2

Provide a sample of woodwork as indicated by the engineer with required coatings or treatment application for testing where required.

2.2

PRESERVATIVE TREATMENT

2.2.1

General Application

1

The preservative treatment is to be applied by pressure impregnation or the double vacuum process. Dipping, deluging, spraying, brushing or other methods which only provide shallow protection are not permitted.

2

The treatment to be carried out under factory conditions at the source of supply of the timber and the Contractor is to provide a Certificate of Impregnation when required by the Engineer.

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2.1.3

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Page 3

Treatment is to be carried out after all cutting and shaping has been completed. If subsequent cutting of the timber is unavoidable all freshly exposed surfaces are to receive a liberal application of the preservative recommended in the relevant treatment specification.

2.2.2

Standard Pressure Treated Preservative

1

Wood members and plywood exposed to weather or in contact with plaster, masonry or concrete, including wood framing of openings in exterior walls of concrete or masonry, roofed structures; wood sills, sole plates, furring; and, wood members used in connection with roofing and flashing materials to be treated in accordance with BS 1282, BS 5268, BS 6566, and/or BS 5707.

2.2.3

Other Preservative Treatments

1

Creosote and creosoted timber where used as structural timber to be sampled or analysed to BS EN 1014.

2.3

FIRE RETARDANT TREATMENT

2.3.1

General Application

1

Each piece of treated material will bear identification of the testing agency and will show the performance rating. Treatment and performance inspection, is to be by an independent and qualified testing agency that establishes performance ratings.

2.4

INSECT TREATMENT

2.4.1

General Application

1

All hardwood and softwood for permanent incorporation in the Works is to be treated with preservative to provide protection against damage from insect larvae, termites and fungal decay to BS 6566, Part 7. Organic solvent type preservatives are to contain a water repellent. Certificates are to be provided confirming all necessary treatments required have been completed.

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3

END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 1

3

STRUCTURAL TIMBER ................................................................................ 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3 3.1.4

Scope References Submittals Product Delivery, Storage and Handling

3.2

FRAMING MATERIALS ................................................................................. 3

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

Structural Timber Plywood (used for Rough Carpentry) Rough Hardware - General Workmanship for Structural Timber Non-Structural Framing Plywood Sheeting

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2 2 2 2 3 3 4 4 5 5

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3

STRUCTURAL TIMBER

3.1

GENERAL

3.1.1

Scope

1

This part specifies requirements for wood framing, sheathing, subflooring, trusses, light timber construction and rough hardware as used in buildings.

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General Wood Treatment Architectural Timber Joinery Fasteners and Adhesives Ironmongery

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This Section Part 1 Part 2 Part 4 Part 5 Part 6 Part 7 References

1


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BS 1186 ......................Quality of timber and workmanship in joinery BS 1203 ......................Synthetic resin adhesives (phenolic and amnioplastic) for plywood

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BS 6566 ......................Plywood

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BS EN 635 .................Plywood

Submittals

1

The Contractor shall submit shop drawings showing framing connection details, fasteners, connections, dimensions, treatment and finishes in accordance with the relevant provisions of Section 1, General

3.1.4


1

Protect lumber and other products from dampness both during and after delivery at site.

2

Pile lumber in stacks in such manner as to provide air circulation around surfaces of each piece. Stack plywood and other board products so as to prevent warping.

3

Locate stacks on a well drained area, supported at least six inches above grade and cover as necessary for protection from driving rain and prolonged sun exposure whilst providing ventilation.

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Page 3

3.2

FRAMING MATERIALS

3.2.1

Structural Timber

1

Unless otherwise specified, each piece of lumber is to bear the grade mark, stamp, or other identifying marks indicating grades of material, and rules or standards under which produced.

2

Structural members shall be: (a)

any species to be used as structural timber is to be grade listed as in BS 1186 Part 1

(b)

the design of members and fastenings is to conform to BS 1186 Part 2.

Furring, blocking, nailers and similar items used for framing as structural timber shall conform to Tables 1.1 and 1.2, Quality of Timber.

4

Size references, unless otherwise specified, are nominal sizes, and actual sizes to be within manufacturing tolerances allowed by the standard under which the product is produced.

5

The moisture content of timber at the time of delivery and during site storage is to be as described in Clause 1.4.1-1 of Part 1 of this Section.

6

Framing timber is to have a minimum extreme fibre stress in bending of 7500 kPa unless otherwise approved by the Engineer.

3.2.2

Plywood (used for Rough Carpentry)

1

Each sheet of plywood is to bear the mark of a recognized association or independent inspection agency which will maintain continuing control over the quality of the plywood. The mark is to identify the plywood by veneer grade, group number, span rating where applicable, and glue type.

2

Plywood is to be free from bow, twist and warp.

3

The core in 3-ply is not to be more than 60% of the total thickness.

4

In plywood having more than 3 plies, the faces, and all plies with the grain running in the same direction as the faces, to have a combined thickness of between 40% and 60% of the total thickness of the plywood.

5

All plywood thicker than 10mm is to made of not less than 5 plies.

6

No face ply to be thicker than 3mm and no inner ply to exceed 5mm.

7

The direction of the grain of the veneer is to be at right angles in adjacent plies except in the case of boards comprising an even number of plies, when the grain of the center is to follow the same direction.

8

All plywood which is to be installed externally is to be manufactured using Type WBP adhesives to BS 1203, BS 1088 and BS 4079.

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Page 4

All plywood which is to be installed internally is to be manufactured using Type BR adhesives to BS 1203.

10

Face plies for Class 1 finish are to be of one or two pieces of firm, smoothly cut veneer. When of two pieces, the joint should be approximately at the center of the board and the veneers are to be matched for color. The veneer is to be free from knots, unless specified as a feature, insect holes, splits, dote, glue stain, filling or inlaying or any other kind of defect. No end joints are permissible.

11

Face splits for Class 2 finish are to present a solid surface free from open defects. Occasional splits not wider than 0.8mm at any point and not longer than one tenth of the length of any panel of slightly open joints may be filled with a suitable filler. Neatly made repairs consisting of inserts of the same species as the veneer, which present solid, level, hard surfaces and are bonded with an adhesive equivalent to that used for bonding the veneers are permissible. No end joints are permissible.

3.2.3

Rough Hardware - General

1

Rough hardware includes items for structural timber construction such as frame cramps, ties, anchors, framing connectors, joist hangers and similar items.

3.2.4

Workmanship for Structural Timber

1

Timber for carpentry work is to be finished sawn to the sizes shown on the drawings. A tolerance of +3.0 mm to -0.5 mm is permissible.

2

Joints are to be constructed so that they will transmit the loads and resist the stresses to which they will be subjected. The surfaces should be in good contact over the whole area of the joint before fastenings are applied. Unless otherwise specified all joints are to be secured with a suitable type and sufficient number of nails.

3

Holes for bolts are to be drilled from both sides of the timber. No nails, screws or bolts are to be placed in split ends. If splitting is likely holes for nails are to be predrilled at diameters not exceeding four-fifths of the nail.

4

Temporary bracing is to be provided to maintain structural timbers in position and to ensure stability during construction.

5

All cutting for services to be the minimum required to accommodate the services and comply with the following:

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(a)

notches shall be “U” shaped and be formed by straight cuts to drilled holes

(b)

notches and holes not to be positioned in a member where the remainder of the cross section contains a knot or other defect which would affect the strength

(c)

notches in joists are to be located at the top and not be deeper than one eight of the depth of the joist located within one quarter of the span from the centre of bearing. Holes in joists are to be located through the centre of the depth i.e., on the neutral axis.

Joists are to extend a minimum of 75 mm beyond the nearest edge of the supporting plate or member and be laid in parallel lines.

QCS 2014


Page 5

Where joists are to be notched over supports, the depth of the notch should not exceed twofifths of the depth of the joist. The bearing surface of the notch is to be cut smooth and true in relation to the surface on which it bears.

8

A clear 12 mm to be maintained around all joists if they extend into blockwork walls and they are to receive an additional liberal coating of preservative on all surface adjacent to walls. A 50 mm gap is to be left between joists and flanking walls.

9

Herring-bone strutting is to be constructed of 50 x 38 mm pieces nailed to form a system of crossing diagonals in a straight line transversely across the joists. Each diagonal strut is to be wedged tightly between the top and bottom edges of adjacent joists before being secured by nails.

3.2.5

Non-Structural Framing

1

Timber sections, stud partitions, bulkheads, etc., are to be accurately cut so that they fit together tightly without distortion. Each joint is to be fixed with at least two nails.

2

All timber sections to be fixed plumb, level and square to ensure that the lining material can be positioned accurately and securely to give flat surfaces, free from undulations.

3

The spacing of members should not exceed the permissible span of the lining material as recommended by the manufacturer. All edges of the lining material to be supported except where other methods of supporting the edges are provided e.g., tongued and grooved joints.

4

Holes for services to pass through the center of timber sections and the diameter of the hole should not exceed one third the width or thickness of the timber.

5

Additional supports are to be provided for appliances and fixtures.

6

Framing, grounds and bearers are to be fixed to the substrata at maximum 450mm centers using masonry nails unless described as “plugged and screwed” or “bolted”.

3.2.6

Plywood Sheeting

1

Wall and roof sheeting is to comply with the relevant provisions of BS EN 635 and BS 6566.

2

Wall Sheeting: Panels 1200 mm wide and 87 mm thick are to have supports at 400 mm centres if constructed without corner bracing and framing. Panels 100 mm thick are to have supports at 600 centres, if constructed without corner bracing or framing.

3

Roof Sheeting: minimum.

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Panels 87mm thick or greater shall have supports at 400 mm centres

END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 1

4

ARCHITECTURAL TIMBER .......................................................................... 2

4.1


4.1.1 4.1.2 4.1.3 4.1.4

Scope References Submittals Product Delivery, Storage and Handling

4.2

TIMBER MATERIALS (NON-STRUCTURAL FRAMES) ............................... 3

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

Grading and Marking Sizes Specific Items Moisture Content Fire Retardant Treatment Preservative Treatment Fixing of Exterior Shopwork Fixing of Interior Shopwork

4.3

PLYWOOD .................................................................................................... 5

4.3.1 4.3.2 4.3.3

Softwood Plywood Hardwood Plywood Marine Plywood

4.4

WOOD PANELING ........................................................................................ 5

4.4.1 4.4.2 4.4.3

General Board Planking Wall Sheet Paneling

4.5

BLOCKBOARD AND LAMINBOARD ............................................................. 6

4.5.1 4.5.2

General Requirements Fixing Laminated Timber Boards

4.6

LAMINATED PLASTIC SHEET ..................................................................... 6

4.6.1 4.6.2

General Requirements Fixing Laminated Plastics

4.7

MISCELLANEOUS WOOD PRODUCTS....................................................... 7

4.7.1

Building Board (Handboard)

4.8

STAIRWORK AND HANDRAILS ................................................................... 7

4.8.1

Wood Handrails

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QCS 2014


Page 2

4

ARCHITECTURAL TIMBER

4.1


4.1.1

Scope

1

This part includes specifications for fabrication and installation of exterior and interior finished carpentry and millwork, and plastic laminate covered counters, cabinets, and other such items.

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This Section Part 1 Part 3 Part 3 Part 5 References

1

The following references are referred to in this Part:

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4.1.2

BS 476 ........................Fire tests on building materials and structures

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BS 1142 ......................Specification for fibre building boards

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BS 1282 ......................Choice, use and application of wood preservatives BS 2572 ......................Phenolic laminated sheet and epoxy cotton fabric laminated sheet

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BS 3444 ......................Specification for blockboard and lamin board

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BS 4072 ......................Use of copper/chromium/arsenic compositions BS 4079 ......................Plywood for marine craft

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BS 4965 ......................Decorative laminated plastic sheet veneered boards and panels

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BS 5268 ......................Part 5 - preservative treatment of structural timber BS 5589 ......................Code of Practice for preservation of timber

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BS 5666 ......................Methods of analysis of wood preservatives and treated timber BS 5707 ......................Specification of solutions for timber BS 6566 ......................Plywood BS EN 635 ..................Plywood Part 2 Hardwood 4.1.3

Submittals

1

In accordance with the Project Documentation, provide Shop Drawings and Samples as specified, or at minimum as follows: (a)

shop Drawings showing detailed finished work such as cabinetry, counters, built-in furniture requiring shopwork finished carpentry should have large scale shop drawings provided.

(b)

samples of architectural woodwork) with final surface finishing and any required coatings of paint, varnish, stain or other coatings, at approximate size of 700 x 100 mm.

QCS 2014


Page 3

(c)

samples of plastic laminate finish on plywood or particle board at size of 300 x 15 mm

(d)

certificates indicating preservative treatments treatment of materials as meets the project requirements.

(e)

certificates indicating requirements.

moisture

content

of

materials

or as

fire meets

retardant the

project


1

Protect shopwork items from dampness both during and after delivery to site.

2

Store finished shopwork in weathertight well ventilated structures or in space in existing buildings designated by the Engineer.

3

Do not install finished shopwork in any room or space where concrete, masonry, or plaster work is not completed and dry.

4.2

TIMBER MATERIALS (NON-STRUCTURAL FRAMES)

4.2.1

Grading and Marking

1

Members are to bear the grade mark, stamp, or other identifying marks indicating grades of materials, and rules or standards under which produced.

4.2.2

Sizes

1

Size references, unless otherwise specified are nominal sizes, and actual sizes are to be within manufacturing tolerances allowed by the standard under which the product is produced.

4.2.3

Specific Items

1

Timber for (shopwork), exterior walkways handrails, shelves, handrails, seats, cabinets and other such items is specified in the Project Documentation and drawings.

4.2.4

Moisture Content

1

Moisture content of timber and shopwork at the time of delivery to the site should be as follows:

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4.1.4

(a)

interior finished timber, trim and shopwork 30 mm or less in thickness, moisture content to be 12 % minimum on 85 % of the work and a maximum of 15 % on the remainder.

(b)

exterior treated or untreated finished timber 100 mm or less in thickness, moisture content to be 15 % minimum.

4.2.5

Fire Retardant Treatment

1

Where timber members and plywood are specified to be fire retardant treated, the treatment is to be in accordance with BS 476.

2

Treatment and performance inspection is to be by an independent and qualified testing agency.

QCS 2014


Page 4

Each piece of treated material is to bear the identification of the testing agency and should indicate performance in accordance with such a rating.

4.2.6

Preservative Treatment

1

All softwood for permanent incorporation in the Works to be treated with preservative to provide protection against damage from insect larvae, termites and fungal decay. Organic solvent type preservatives are to contain a water repellant.

2

The preservative treatment is to be applied by pressure impregnation or the double vacuum process. Dipping, deluging, spraying, brushing or other methods which only provide shallow protection are not permitted.

3

The treatment is to be carried out under factory conditions at the source of supply of the timber and the Contractor is to provide a Certificate of Impregnation when required by the Engineer.

4

Treatment is to be carried out after all cutting and shaping has been completed. If subsequent cutting of the timber is unavoidable all freshly exposed surfaces are to receive a liberal application of the preservative recommended in the relevant treatment specification. Refer to BS 1282, BS 4072, BS 5268, BS 5589, BS 5666 and BS 5707.

4.2.7

Fixing of Exterior Shopwork

1

Fixing of exterior shopwork:

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all edges of timber members exposed to weather are to be end grain.

(b)

all shopwork is to be primed and back painted before fixing.

(c)

shopwork is to be nailed, screwed or bolted at each support (blocking).

(d)

all joints are to be close fitted, mitred, tongue and grooved, rebated or lapped to exclude water.

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(a)

Edges of members in contact with concrete or masonry are to have a square corner caulking rebate.

3

Staff beads are to have a caulking rebate.

4.2.8

Fixing of Interior Shopwork

1

Except where special profiles are shown, trim is to be standard stock molding and all members to be of the same species. All finished shopwork is to be free from pitch pockets. Plywood is to be a minimum 12 mm thick, unless otherwise shown or specified.

2

No interior woodwork is to be set until primed and back-painted; or until all concrete, masonry and plaster in buildings is complete and dry.

3

Interior shopwork which is to receive a transparent finish is to be primed and back-painted only on surfaces to be concealed. Secure trim with fine finishing nails and with screws and glue where required. Set nails for putty stopping.

4

All members such as moulding strips, chair rails, and base strips which are less than 4.25 m in length are to be from one piece of timber, back channeled and molded as shown.

5

Interior trim and items of shopwork to be painted may be fabricated from jointed, builtup, or laminated members, unless otherwise shown on the drawings.

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PLYWOOD

4.3.1

Softwood Plywood

1

Softwood plywood is to comply with the relevant provisions of BS EN 635 Part 2.

2

Fire resistant softwood plywood is to meet all requirements for flamespread and smoke developed when tested in accordance with BS 476.

3

Plywood is to bear the label of the testing agency designating rate of flame spread, fuel contributed and smoke developed.

4

Each sheet of plywood is to bear the mark of a recognized association or independent inspection agency that will maintain a continuing control over the quality of the plywood. The mark is to identify the plywood by species group or identification index, and show the glue type, grade, and compliance with BS 6566.

4.3.2

Hardwood Plywood

1

Hardwood plywood is to comply with the relevant provisions of BS EN 635 Part 2.

2

Fire resistant hardwood plywood

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4.3

core is to be exterior type softwood plywood; face and back veneer to be untreated; factory seal planed edges, to prevent loss of fire retardant by the manufacturers

(b)

plywood panels are to meet all requirements for flamespread, smoke developed and fuel contributed, when tested in accordance with BS 576

(c)

each panel is to bear the label of testing agency designating rate of flame spread, fuel contributed and smoke developed.

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(a)

Marine Plywood

1

Marine plywood shall comply with the relevant provisions of BS 1088 and BS 4079.

4.4

WOOD PANELING

4.4.1

General

1

This part specifies requirements for use of board planks or sheet panelling of unfinished or pre-finished surfaces for use as wall covering, wainscots, or built-in type furniture such as counter surfaces.

4.4.2

Board Planking

1

Timber type and finish to be applied is to be as specified by the Project Documentation.

2

Unless specified otherwise board planks are to be as follows:

4.4.3

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4.3.3

(a)

timber stock to be 19 mm thick with each board in one piece floor to ceiling, V-cut as shown on plans

(b)

blind nail each board at each bearing on furring strips.

Wall Sheet Paneling

QCS 2014


Page 6

Use hardwood plywood, premium grade, with unfinished or factory prefinished surface. Project drawings will specify, thickness and if surface will be vertical V-grove random planked, or flush grooved.

2

Joints are to be tightly butted and plumb.

3

Panelling is to be laid vertically and blind nailed to wood furring.

4

Wood mouldings are to be solid wood members of the same species as the wall paneling.

5

The Type of finish required on factory prefinished wall panels to be as specified on the drawings.

4.5

BLOCKBOARD AND LAMINBOARD

4.5.1


1

Blockboard and laminboard to be free from bow, twist and warp and conform to BS 3444.

2

On 3-ply boards the thickness of the veneers to be a minimum of 2.5 mm and a maximum of 3.6 mm.

3

Cores are to consist of strips of wood of the same species throughout any one board. In blockboard the width of each strip is not to be less than 8 mm and not more than 25 mm, and in laminboard it is not to be less 7 mm.

4

The strips are to be laid side by side with the grain parallel and run in the longer direction of the board. The strips may be butted end to end provided there is not gap at the butt and that the butts in adjacent strips are staggered by at least 150 mm. The strips are to be assembled in such a manner that the finished board is the equivalent of a solid slab free from all voids.

5

The grain of each veneer is to be parallel to that of the corresponding veneer and that of the veneers next to the core to be at right angles to the direction of the strips in the core.

6

Face plies Class 1 and Class 2 finish to be as for plywood except that Class 1 finish veneers may be of one or more pieces. When of more than one piece it is to be well jointed and matched for colour at the joints. The pieces are to be equal in width subject to a deviation of ± 10% and not less than 250 mm wide.

4.5.2

Fixing Laminated Timber Boards

1

Blockboard and laminboard are to be fixed with the laminations running in the direction of the longest span.

2

Blockboard and laminboard are not to be used externally.

3

Plywood is not to be installed with exposed edges in external work.

4

The new edges formed by cut-outs in laminated timber boards for sinks, taps and the like are to be liberally coated with waterproof glue to form a seal.

4.6

LAMINATED PLASTIC SHEET

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QCS 2014


4.6.1


1

Laminated Plastic is to comply with BS 2572 and BS 4965.

Page 7

(a)

standard grade: thickness is to be not less than 1.59 mm for horizontal work and 0.08 mm for vertical work

(b)

bending grade: thickness is to be not less than 0.60 mm for on site bending to a radius of 75 mm or less

(c)

post formed grade: minimum thickness to be 1.1 mm.

Fixing Laminated Plastics

1

Adhesive to be used in accordance with the manufacturer’s recommendations and be approved by the sheet surfacing manufacturer. Adhesives other than a contact type are to be bonded in presses.

2

Where veneers are next to each other they are to be matched both for colour and pattern.

3

When not otherwise specified, the Contractor is to apply to the back face a sheet of similar timber veneer the same thickness as the face veneer, ensuring that moisture content of the veneers is equal.

4

When using laminated plastics, a sheet of similar material and thickness to the face sheet is to be applied to the back face unless otherwise specified. The material to be conditioned before fixing in accordance with the manufacturer’s recommendations.

5

Edges of laminated plastics are to be chamfered at all external angles. Standard grade is to be used for flat work and postforming grades for shaped work. The material is to be bonded to chipboard, blockboard or plywood of at least 15 mm thickness.

6

Joints are to be made level by positioning cores splines or dowels and tightened by means of drawbolts. Joints between postformed sections should be mitred at 45º for accurate positioning. Vertical joints are to be bevelled to produce a V joint.

4.7

MISCELLANEOUS WOOD PRODUCTS

4.7.1

Building Board (Handboard)

1

Building board is to comply with the relevant provisions of BS 1142.

4.8

STAIRWORK AND HANDRAILS

4.8.1

Wood Handrails

1

To be installed in one piece and one length when practical. Where rails change slope or direction, a special or curved section is to be used.

2

Ends of rails are to be returned to the wall.

3

Rails are to be secured with wood screws to metal brackets at approximately 450 mm centres as detailed in the Project Documentation.

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4.6.2

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Page 8

Wall handrails for stairs are to start on line with the first riser and terminate on line with the last riser, or as indicated in the project documentation.

5

Joints are permitted only where the rail changes direction or slope, or where necessary for field erection or shipping. Scarf or dowel all joints to provide smooth and rigid connections. Glue all joints. Joints are to be fitted to show not more than a hair-line crack.

6

Handrails are to be completely shop fabricated in accordance with approved shop drawings.

7

Brackets for wood handrails are to be cast aluminum with satin polish finish or extruded aluminum with a mechanical applied medium satin finish or malleable iron castings or as specified in the project documentation.

8

Anchor brackets as detailed in the drawings. Install brackets within 300 mm of end of handrails and at evenly spaced intervals between, not exceeding 1500 mm on centres and at intervals between as shown on drawings.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 1

5

JOINERY ....................................................................................................... 2

5.1


5.1.1 5.1.2

Scope References

5.2

WORKMANSHIP ........................................................................................... 2

5.2.1

Joinery Workmanship

5.3

TIMBER DOOR TYPES ................................................................................. 3

5.3.1 5.3.2 5.3.3 5.3.4

Flush Doors Fire Resisting Door Assemblies Hanging Timber Doors Door and Window Frames, Sub-frames and Linings

5.4

PURPOSE MADE FITTINGS......................................................................... 5

5.4.1


5.5

ARCHITRAVES, QUADRANTS, BEADS ....................................................... 6

5.5.1


5.6

TIMBER SKIRTINGS ..................................................................................... 6

5.6.1


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Page 2

5

JOINERY

5.1


5.1.1

Scope

1

This Part specifies workmanship and special detail construction for doors, windows, architraves, beads, and timber skirting, and speciality wood flooring of block or parquet strips.

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General Wood Treatment Structural Timber Architectural Timber Fasteners and Adhesives Ironmongery

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5.1.2

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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanised coatings on iron and steel articles BS 1202 ......................Nails

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BS 1186 ......................Quality of timber and workmanship in joinery

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BS 1210 ......................Wood screws BS 3794 ......................Decorative laminated plastic sheet

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BS 4756 ......................Ready mixed aluminium priming paints for woodwork

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BS 5358 ......................Solvent-borne priming paints for woodwork

WORKMANSHIP

5.2.1

Joinery Workmanship

1

Timber used for joinery work is to be finished to the sizes indicated in the Project Documentation and to BS 1186.

2

The joinery to be constructed exactly as shown on the drawings. Where types of joints are not specifically indicated they are to be recognised forms of joints for each position and shall be made so as to comply with BS 1186, Part 2.

3

All joints are to be glued and screwed or doweled to BS 1204, BS 1210 or BS 1186 as applicable.

4

Exposed and semi-concealed joinery is to be planed and sanded to remove all machinery and other surface defects so that after application of the specified finish imperfections in manufacture will not be apparent.

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QCS 2014


Page 3

Exposed edges and corners are to be sanded off to form a “ pencil rounded” arris.

6

Architraves, cover fillets, skirtings and the like are to be accurately shaped to fit the contour of any irregular surface against which they are required to form a close connection.

7

Joinery for painting on site is to be primed before delivery to the site to BS 4756, BS 5358.

5.3

TIMBER DOOR TYPES

5.3.1

Flush Doors

1

Minimum door leaf thickness is to be: internal door

40 mm

(b)

external door

45 mm

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(a)

.

5

Solid core doors to be comprise of softwood timber battens laminated together with a minimum 4mm plywood skin. The core laminations softwood are to be a maximum 50 mm wide and are to be laid alternately to balance stresses.

2

Semi-solid core doors are to contain a minimum 50% timber and are to be constructed on the stressed skin principle having a minimum 4 mm plywood skin.

3

Exterior quality doors are to be constructed using Type WBP adhesives and an exterior quality 4 mm plywood skin.

4

All facing materials including veneered materials are to be such that the following defects do not appear on the finished surfaces: lifting at edges

(b)

blistering

(c)

sinking or raising of the surface due to knots or other defects in the core material

(d)

o

ripple effect whereby the construction of the core is seen on the face of the door. to BS 3794

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Doors are to be hardwood lipped on both horizontal and vertical edges. Lippings to be solid and measured at least 8 mm on the face of the door. Lippings to doors with a Class 1 finish are to match the face skin.

5

If the construction of the door is such that the lock, hinges or bolts can only be fitted where blocks are provided to receive them, the position and extent of the blocks are to be indicated by a suitable markings on the edge of the door. Where a surface mounted closer or a flush bolt is specified, blocks shall also be suitably positioned to receive them.

6

Where a flush or mortised door closer is specified a solid timber rail insert minimum 75 mm wide is to be provided for all door types. Closers are to not be fixed to the end grain of solid core doors.

7

Openings for glazing or grilles in semi-solid core doors are to be formed with a sub-frame all round the opening minimum 36 mm wide.

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Page 4

The maximum deviation from a true plane on either face of a door when measured by a straightedge is to be: (a)

(bow in length : 3 mm

(b)

horizontal bow : 2 mm

(c)

deviation from the true plane (twist) : 4 mm

(d)

the ends of the braces are to be splay notched to the ledges and the ends of the ledges set back 15 mm from the edges of the door. The direction of the braces should be upwards from the hanging stile.

Fire Resisting Door Assemblies

1

Half-hour and one-hour fire resisting door assemblies are to have a minimum fire resisting performance when tested in accordance with BS 476, Part 8 of 30/30 and 60/60 respectively.

2

The door and frame of fire resisting door assemblies are to be supplied by the same manufacturer and be installed strictly in accordance with his instructions.

3

A copy of the Test Certificate shall be submitted to the Engineering for each type of door assembly supplied.

4

The doors to generally comply with the requirements of Part 5.2.1 and are to have a minimum 4 mm plywood skin.

5

The doors are to be marked on the hanging stile with an appropriate reference indicating the fire resisting performance of the door assembly.

6

Doors are to be fitted with an automatic self-closing device and be hung on a minimum of three hinges, manufactured from non-combustible material having a melting point in excess of 850ºC. Rising butt hinges are not acceptable as an automatic self-closing device. No „HOLD OPEN OPTION‟ is permitted unless the magnetic catch is operated by the fire alarm system.

5.3.3

Hanging Timber Doors

1

The maximum clearance between frames and door when hung is to be 3 mm.

2

The maximum clearance between an internal door and finished floor level is to be 6 mm (unless noted to be undercut) and between an external door and threshold or finished floor level to be 3 mm.

3

External doors and doors exceeding 20 kg in weight are to be hung on three 100 mm x 75 mm hinges as a minimum.

4

Hinges to be stainless steel, aluminium or brass as noted in the project documentation or as directed by the Engineer and to BS 729 where applicable.

5.3.4

Door and Window Frames, Sub-frames and Linings

1

Frames, sub-frames and linings are collectively referred to as “frames” in this Part.

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5.3.2

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Page 5

Frames are to be manufactured with either mortise and tenon or tongued joints so as to be square and flat.

3

The backs of frames are to be painted with two coats of primer to BS 5358, or BS 4756 before installation.

4

Frames to be fixed plumb, level and securely to prevent deflection or movement.

5

Frames built-in as the surrounding structure is constructed are to be fixed with cramps at maximum 600 mm centres. One cramp to be located 200 mm from the bottom of the frame and one 200 mm from the top or at the nearest adjacent bed joint. All cramps are to be secured to the frame by two screws. Alternative fixing methods are to be approved by the Engineer and to BS 1202, BS 1204, and BS 1210 as applicable.

6

Frames which are to be built-in are to be temporarily braced sufficient to prevent distortion.

7

Frames to previously prepared openings are to be fixed with screw fastenings at maximum 450 mm centres. One fastening is to be located 200 mm from the bottom of the frame and one 200 mm from the top.

8

Packing between the frame and reveal to accurately position the frame in a previously prepared opening is to be hardwood, located only where the fastenings tighten against the reveal.

9

Screw fastenings are to extend into the structural reveal by at least 40 mm or the thickness of the frame excluding any stop, whichever is the greater.

10

Door frames which occur in wet areas should not extend below the finished floor level.

5.4

PURPOSE MADE FITTINGS

5.4.1


1

Fittings to be constructed in accordance with Part 7 and are to be installed plumb and true.

2

Critical site dimensions are to be checked before commencing manufacture of the fittings and no fittings dimension is to be altered without the approval of the Engineer.

3

All surfaces are to be smooth and free from splinters and no parts to have exposed rough or sharp edges whether on the inside or outside of the fitting.

4

Where a door overlaps the frame or another door the face of the rebate is not to be more than 1.5 mm from the face of the frame or door at any point.

5

Where a door is fitted into the surrounding framework the clearance between each edge of the door and the frame or another door should not be more than 1.5 mm.

6

Door hinges or pivots are to be fitted in alignment.

7

Drawers should slide freely and be fitted with runners and guides so that there is no undue play in any direction which could produce wedging or jamming.

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Page 6

Where a drawer overlaps the frame, the face of the rebate is not to be more than 1.5 mm from the face of the frame at any point when the drawer is closed.

9

Where a drawer is fitted into the surrounding frame work the clearance around the edge of the drawer when closed is not to be more than 1.5 mm.

5.5

ARCHITRAVES, QUADRANTS, BEADS

5.5.1


1

Architraves, quadrants, beads and the like are to be in unjointed lengths between angles or ends of runs. Angle joints to be mitred.

2

Architraves and quadrants should not be installed until after the wall coverings have been formed or constructed.

3

Glazing beads where required are to be wrought splayed and rounded and be neatly mitred and fixed with small brads or lost-head mails.

5.6

TIMBER SKIRTINGS

5.6.1


1

Skirting are to be fixed with screws at maximum 600 mm centres.

2

Angle joints to be mitred. Joints in the running length should be kept to a minimum and where necessary be splayed.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 06: Fasteners and Adhesives

Page 1

6

FASTENERS AND ADHESIVES ................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

FASTENERS ................................................................................................. 2

6.2.1 6.2.2 6.2.3

Nails and Screws Fastenings Pellating

6.3

ADHESIVES .................................................................................................. 3

6.3.1


6.4

ROUGH HARDWARE AND FRAME CRAMPS ............................................. 3

6.4.1 6.4.2

General Products

2 2

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FASTENERS AND ADHESIVES

6.1

GENERAL

6.1.1

Scope

1

This part deals with the specification of fasteners and adhesives.

2


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General Framing furring and blocking Wood doors Architectural timbers Joinery

References

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BS 729 ........................Hot dip galvanised coatings on iron and steel articles. BS 1202 ......................Nails

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BS 1210 ......................Wood screws

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FASTENERS

6.2.1

Nails and Screws

1

Nails and screws are to comply with BS 1202, Part 1 and BS 1210 respectively.

6.2.2

Fastenings

1

Fastenings in external areas are to be sheradised, galvanised or non-ferrous.

2

Nails are not to be less than 25 mm long or 2½ times the thickness of the member through which the nails are being driven, whichever is the greater.

3

Screws are not be less than 12 mm long or twice the thickness of the member through which the screws are being driven, whichever is the greater.

4

Regardless of the specified minimum lengths, nails and screws are not to be longer than the total thickness of the members being joined, less 5 mm.

5

Nail heads should be punched, and screw heads not required to be pellated to be countersunk, not less than 2 mm below surfaces which will be visible in the finished work, the holes filled with putty or a proprietary filler and sanded smooth and flush.

6

Plugs for screw fastenings into blockwork or concrete are to be of proprietary manufactured sized to suit the screw. Wooden plugs will not be permitted.

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Page 3

Pellating

1

Screw heads which are to be pellated are to be countersunk 6 mm below the timber surface. Pellets to be cut from matching timber not less than 6 mm thick, glued in with the grain matched, planed and sanded off flush with the face.

2

Screw heads are to be pellated where the timber surface is to receive a clear finish.

6.3

ADHESIVES

6.3.1


1

Adhesives used in carpentry and joinery work should be synthetic resin adhesives complying with BS 1204, Parts 1 and 2 Type WBP for all external work and Type BR for internal work.

6.4

ROUGH HARDWARE AND FRAME CRAMPS

6.4.1

General

1

This Part specifies fasteners and fastening systems used for Structural Timber construction and within some framing with Architectural woodwork.

6.4.2

Products

1

Cramps to be mild steel size 2 x 25 x 250 mm girth, galvanised after fabrication to BS 729, turned up at one end and drilled twice for 3 mm diameter screws and fishtailed at the other end for building in.

2

Furnish rough hardware, except nails, with a standard plating, applied after punching, forming and assembly of parts. Galvanised anchors and bolts (with nuts and washers), straps, and hangers except bolts may be cadmium plated, or zinc-coated by electro-galvanising process. Aluminium-alloy nails, plated nails, or zinc-coated nails, for nailing woodwork exposed to weather are to be used. Bolt heads and nuts bearing on wood should be fitted with washers. For work exposed to the weather, washers of cast iron, or zinc or cadmium coated steel are to be used. Special nails as required for use with ties, anchors, framing connectors, joint hangers and similar items are to be used in accordance with the item manufacturers instructions or as directed by the Engineer.

3

Joist Ties: Are to be mild steel flats, 5 mm by 32 mm size with ends bent 30 degrees from horizontal, and extending at least 40 mm onto the framing. Each end to be punched for three spikes.

4

Wall anchors for Joists and Rafters: Provide a mild steel strap, 5 mm by 32 mm with wall ends bent 50 mm, or provide 9.5 mm by 127 mm pin through the strap and build into masonry. Provide anchors parallel to framing long enough to extend at least 406 mm onto framing and punch for three spikes. Provide anchors at right angles to framing; long enough to extend onto three joists or rafters, punched for spiking at each bearing.

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6.2.3

END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 1

7

IRONMONGERY ........................................................................................... 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2

Scope References

7.2

PRODUCTS ................................................................................................... 2

7.2.1 7.2.2

General Finish

7.3

FITTING AND TESTING ................................................................................ 3

7.3.1


7.4

STANDARD IRONMONGERY FOR INTERNAL DOORS ............................. 3

7.4.1


7.5

ELECTROMAGNETIC LOCKING SYSTEMS ................................................ 4

7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8

Scope Quality Assurance Submittals Delivery and Storage Warranties System Description Locking Devices Power Supply and Control Unit

2 2 2 3

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7

IRONMONGERY

7.1

GENERAL

7.1.1

Scope

1

This Part deals with the specification of ironmongery items.

2

Related Sections are as follows: Section 1 Section 17 Section 21

Page 2

General Metal Work Electrical Works

References

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BS 3621 ......................Specification for thief resistant locks

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BS 5725 ......................Emergency Exit Devices BS 6462 ......................Casement stays

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BS 6459 ......................Door closers BS 7036 ......................CP for powered doors

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BS 7352 ......................Specification for metal hinges BS EN 60730 ..............Electrically operated door locks

PRODUCTS

7.2.1

General

1

The Contractor is to provide and fix ironmongery required by the Project Documentation complete, including all necessary screws, bolts, plugs and other fittings. The use of nails for fixing ironmongery will not be permitted. The Contractor to hand over all work in a finished state and to the satisfaction of the Engineer.

2

All ironmongery is to be of first quality and be obtained form an approved manufacturer. Butt hinges are to be aluminium alloy, stainless steel or brass as specified with double stainless steel washers to BS 7352.

3

The Contractor will be required to submit for approval samples of all items of ironmongery that he proposes to use.

4

All doors are to be provided with an approved floor stop plugged and screwed to the floor or wall and all opening areas of aluminium work (louvered doors) are to be provided with appropriate stays (friction type to plant room or service area doors opening out) to BS 6462. The size, materials, finishes, type and quality of ironmongery will be as described in the Project Documentation.

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Page 3

Finish

1

The finish of the various items of ironmongery is to be as described in the Project Specification or shown on the Drawings.

2

Ironmongery not obtainable from the same range and/or manufacturer as the general ironmongery for the Works is to match the general ironmongery as closely as possible.

3

Ironmongery to metal windows and doors is generally to match the general framing and is to be supplied and fixed with matching metal fixing screws and bolts and additional plates.

7.3

FITTING AND TESTING

7.3.1


1

All screws used for fixing ironmongery are to be of the correct type, material, finish, size and shape to the approval of the Engineer.

2

The hinges on which doors, windows, flyscreen doors, etc., are hung are to be carefully housed or let into the door, window, flyscreen doors, etc., and to the frames.

3

All fittings are to be removed before commencing any painting operations and are to be refixed in place after all painting works are completed and approved by the Engineer.

4

All ironmongery is to be carefully wrapped and protected until the completion of the work and any items or parts which are damaged or defaced or found to be defective are to be replaced at the Contractor’s expense before handing over.

5

On completion of all locks, catches and similar items of ironmongery they are to be properly cleaned, tested and oiled, and all keys are to be clearly labelled with metal tags approximately 50 x 20 mm and securely fixed to the keys and handed to the Engineer. Thief resistant locks are to BS 3621.

6

Door closers are to be fitted a maximum of two weeks before handover. Power door closers are to BS 7036 and other standard closers to BS 6459 as applicable.

7

All floor and door springs are to be fully charged with oil and their operation checked to the satisfaction of the Engineer.

8

Hinges are to be fitted in a standard position 250 mm from the top or bottom edge of the door to the centre of the hinge. Where a third hinge is fitted it is to be located centrally between the top and bottom hinges.

9

Locks are to be fitted so that the centre of the handle is at height of 1020 mm from the bottom of the door and to BS 3621 as applicable.

7.4

STANDARD IRONMONGERY FOR INTERNAL DOORS

7.4.1


1

Each door leaf is to be fitted with 1½ pairs of 100 x 75 mm satin anodised aluminium, stainless steel or brass, double stainless steel washered butts unless otherwise noted in the Particular Project documentation and drawings.

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Page 4

Where a supplier cannot offer the particular required ironmongery the Contractor is to produce samples of other supplier’s items most nearly matching the general ironmongery and/or produce alternative ironmongery by the main supplier most closely conforming with the specification for the approval of the Engineer and to BS 7352.

3

All locks are to be provided with 2 keys on a key ring neatly labelled.

4

‘Master Key’ locking systems are as stated in the Project Documentation.

5

All knob sets are to include for the appropriate mortise latch or lock with a 70 mm backset and with standard face-plates and roses unless otherwise noted.

7.5

ELECTROMAGNETIC LOCKING SYSTEMS

7.5.1

Scope

1

This Part covers the furnishing and installation of a complete low-voltage electromagnetic locking device door control and monitoring system. Specified for all new or existing exterior doors as designated on drawings by a hardware set number.

2

Supply and install all electric hardware devices, mounting brackets, power supplies, switches and controls, monitoring console and other components of the system as specified and to BS 7036.

3

Supply templates, wiring diagrams and installation instructions necessary for the coordination of the work and for proper installation, connection and operation of the system.

4

Provide all outlets, junction boxes, conduit, connectors, wiring, and other accessories necessary to complete the system installation. Requirements to be in accordance with Section 21, Electrical Works.

5

Requirements for conduit, wiring, devices, boxes and other items required to provide line current (110V-AC to 125V-AC) to refer Section 21, Electrical Works.

7.5.2

Quality Assurance

1

Manufacturer's Qualifications: Approval of the Engineer is required for products or services of proposed manufacturer, supplier and installer and will be based upon the following criteria:

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2

(a)

Locking devices, power supplies, controls and monitoring system to be products of a single manufacturer regularly and currently engaged in production of electromagnetic security locking systems.

(b)

The manufacturer's products to have been in satisfactory operation on at least three similar installations for not less than three years..

(c)

The installer to be a permanent organisation approved by the manufacturers, having facilities and employing trained personnel with technical qualifications and experience to prepare the installation, to install the required system and to provide periodic maintenance. The installer is to maintain a parts inventory and employ trained personnel at a location within a 100 mile radius of the project. The installer should have been installing security systems for a period of not less than three years.

QCS 2014


Page 5

2

Door and frame components, including locking device, are to have been tested by an approved independent testing laboratory.

7.5.3

Submittals

1

In accordance with procedures of Section 1, General, the Contractor is to furnish manufacturer's literature and product data including, but not limited to the following: (a)

complete descriptive data and details for each component, including dimensions, finishes, wiring diagrams, test reports, operation, and installation instructions.

(b)

details for the complete system, including colour-coded wiring diagrams, interface with other systems, specific locations of all concealed components, operation, maintenance procedures, and information concerning requirements not included in printed data.

Delivery and Storage

1

Components of the system are to be delivered to the job site in their original cartons, labelled with complete information for identification and containing installation instructions, screws and mounting accessories.

2

Store equipment in a dry storage facility and in an orderly manner, protected from the damage by weather and construction operations.

7.5.5

Warranties

1

A written manufacturers warranty for a period of not less than five years from the date of final acceptance against manufacturing defects in principal components of the system, including the control console, electromagnetic locks and power-control units to be provided. Components under warranty which prove to be defective are to be satisfactorily repaired or replaced without additional cost to the Client.

2

A written service contract for a period of two years from the date of final acceptance providing for periodic inspection and call-back service and prompt adjustment, repair or replacement of malfunctioning components without additional cost to the Client is to be provided.

7.5.6

System Description

1

The locking system is to be a "fail-safe open" system so that all doors will fail unlocked in the event of a power failure. The electromagnetic locking system should not be connected to the emergency power supply.

2

Electromagnetic locks are to release immediately (authorised exit) if one of the following occurs, without setting off alarms.

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7.5.4

(a)

fire alarm is activated by sprinkler system

(b)

power fails

(c)

key operated switch is activated

(d)

console release switch is activated

(e)

other authorised release is activate

QCS 2014

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Page 6

Electromagnetic locks are to release after 30 seconds (field adjustable 10 to 30 seconds) unauthorised exit but immediately notify central console if one of the following occurs and shall set off local alarms: (a)

exit device push bar is activated

(b)

push plate operator is activated

(c)

pull station operator is activated

(d)

other unauthorised release is activated

Electromagnetic locks are to be controlled by time devices and be wired through the console to allow locks to be unlocked or locked as required during certain time of day. Field programmable time clocks are to be provided so that each exit can be individually controlled.

5

Each lock is to be wired through a separate power supply and be controlled and monitored by a central control console and additionally monitored by a second console.

6

The lock control wiring is to be supervised so that any break between lock and console will cause a notice at the console.

7

Manual Doors: Pushing on the cross bar of either exit device shall activate an irreversible 30 second time delay device (field adjustable 10 to 30 seconds) and set of an alarm (unless authorised exit device has been activated first in which case the alarm will not sound), and in 30 seconds electromagnet will release and allow the door to open in accordance with BS 5725.

8

Automatic Doors: A push plate wall switch or other method to operate automatic doors should to conform to BS EN 60730 Section 2.12, and wired through a 30 second time delay (field adjustable 10 to 30 seconds) so that the switch will not open the doors until the delay release of electromagnet has occurred. When the electromagnet is deenergised, normal switches to operate the automatic doors will be operable.

9

An Exit device is to be installed on each exterior door equipped with an electromagnetic lock to accomplish activation of 30 second time delay.

7.5.7

Locking Devices

1

Locks are to be electromagnetic type, without a mechanical linkage utilising no moving parts, and securing the door to its frame solely by electromagnetic force. For a pair of swinging doors, the two electromagnetic devices are to be mounted in a common housing. For bi-parting sliding doors the unit is to be designed with an electromagnetic component mounted in stile of one leaf and the armature in the other.

2

The lock are to have an internal, replaceable voltage kick-back protection.

3

A door status switch, single pole double throw adjustable for sensitivity, is to be semi or fully concealed within the lock housing to prevent tampering and attempts to defeat the system.

4

The door-mounted armature is to have provisions for adjusting alignment to compensate for normal door wear and tear.

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Page 7

7.5.8

Power Supply and Control Unit

1

The power supply-control unit is to power and control the electromagnetic lock. One unit to be provided for each entrance and be capable of supplying and controlling a pair of doors. If located more than 12 m from the lock, the wire size will be increased for the additional voltage drop.

2

The unit will have provisions for interfacing with a panic hardware exit switch.

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END OF PART

QCS 2014

Section 19: Pluming work Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

REGULATIONS AND STANDARDS ............................................................. 2

1.2.1 1.2.2

Qatar General Electricity & Water Corporation Compliance with Standards

1.3

CONTRACTOR’S RESPONSIBILITY ............................................................ 2

1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6

General Approval to Carry Out Plumbing Works Registration of Plumbers and Plumbing Contractors Notice of Intent Existing Services Maintenance Period Requirements

1.4

CRAFTSMEN................................................................................................. 3

1.4.1 1.4.2

Workmanship Qualifications

1.5

MATERIALS .................................................................................................. 3

1.5.1

General

1.6

DRAWINGS ................................................................................................... 4

1.6.1 1.6.2 1.6.3 1.6.4

Explanation of Project Drawings Shop Drawings Co-ordination Drawings Record Drawings

1.7

SITE WORKS ................................................................................................ 5

1.7.1 1.7.2 1.7.3 1.7.4 1.7.5

Openings Painting Co-operation with other Trades. Protection of Finish Clean-Up

1.8

OPERATION AND MAINTENANCE MANUALS ............................................ 6

1.8.1


2 2

2 2 3 3 3 3 3 3 3 4 4 4 5

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Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for the construction and installation of all works associated with the supply, storage and distribution of potable water, with the exception of those works normally undertaken by the Qatar General Electricity & Water Corporation (QGEWC).

1.1.2

References

1

Related Sections are as follows:-

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Section 1 Section 9

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REGULATIONS AND STANDARDS

1.2.1

Qatar General Electricity & Water Corporation

1

The Contractor shall conform to all the requirements of the “Rules and Regulations for Plumbing Works” as prepared by QGEWC.

1.2.2

Compliance with Standards

1

It is required that certain products, components and materials covered in this Section comply with the provisions of particular standards (e.g. British Standards). Where there is a conflict between a particular referenced standard and the requirements of QGEWC, the latter shall prevail.

2

The Contractor shall conform to any requirements QGEWC may have with respect to ensuring that products, components and materials comply with any referenced standard. Such requirements may include, but not be limited to, samples, test results and supporting documentation.

1.3

CONTRACTOR’S RESPONSIBILITY

1.3.1

General

1

The Contractor is responsible for obtaining all necessary approvals and permits required to complete the Works.

1.3.2

Approval to Carry Out Plumbing Works

1

Approval to carry out plumbing works must be obtained from QGEWC for new installations and extensions or alternations to existing installations.

2

All approval procedures shall be as required by QGEWC.

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Page 3

Registration of Plumbers and Plumbing Contractors

1

All plumbers and plumbing contractors shall be approved by QGEWC.

2

All QGEWC water supply works shall be carried out by a contractor or sub-contractor prequalified and approved by the QGEWC. Proof of such approval shall be required in writing prior to the Works commencing on Site and the name of any sub-contractor to be used shall be entered in the appropriate forms when the tender is submitted.

1.3.4

Notice of Intent

1

The Contractor shall notify QGEWC in writing at least 14 days prior to the commencement of any plumbing works.

2

During the course of the Works, QGEWC or its nominated representative shall have full access to the Works.

1.3.5

Existing Services

1

The Contractor is responsible for locating and identifying all existing services in the area of the work or likely to be affected by the Work.

1.3.6

Maintenance Period Requirements

1

The Contractor is responsible for all the maintenance period requirements for all parts and components of the Works covered in this Section. Such requirements shall include, but not be limited to, the requirements of the Project Documentation and the manufacturer’s recommendations.

1.4

CRAFTSMEN

1.4.1

Workmanship

1

Construction of each part of the Works covered in this Section shall be undertaken by experienced craftsmen capable of performing the tasks allocated to them in a professional and competent manner.

2

If required by the Engineer, the Contractor shall instruct craftsmen to demonstrate their ability to perform tasks allocated to him.

1.4.2

Qualifications

1

Where the Project Documentation specifies that specialist craftsmen are required to undertake a specific work task, the Contractor shall furnish the Engineer with copies of qualifications pertinent to performing such work tasks for those craftsmen who will be undertaking the work.

1.5

MATERIALS

1.5.1

General

1

All materials, components and products shall comply with the relevant provisions of Section 1, General, subject to the provisions of Clause 1.2.2 of this Part.

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1.3.3

QCS 2014


Page 4

All materials, components and products shall be supplied by experienced and approved manufacturers as designated in the Project Documentation and to the written approval of the Engineer.

1.6

DRAWINGS

1.6.1

Explanation of Project Drawings

1

For purposes of clearness and legibility, the Project Drawings are essentially diagrammatic, and although size and location of equipment are drawn to scale where possible, the Contractor shall make use of all data in all of the Contract Documents and shall verify this information prior to and during construction.

2

Scale and figure dimensions are approximate and are for estimating purposes only. Before proceeding with any part of the Work, the Contractor shall assume all responsibility for the fitting of his materials and equipment to other parts of the Works.

3

All work not shown in complete detail shall be installed in conformance with accepted standard practice and manufacturer’s recommendations.

4

All items shall be installed in a manner and in locations avoiding all obstructions, preserving headroom and keeping openings and passageways clear. Changes shall be made to the location of equipment and materials as may be necessary in order to accomplish this.

5

The drawings are essentially diagrammatic to the extent that many offsets, beds, traps, special fittings and exact locations are not indicated. The Contractor shall carefully study the drawings and premises in order to determine the best methods, exact locations, route, building obstructions, etc., and shall install all apparatus and equipment in the available locations.

6

Work indicated on drawings, but not mentioned in Specifications, or vice versa, shall be performed as if specifically mentioned or indicated by both. Any supplementary labour or materials required for a complete, approved, and properly operating installation shall be furnished by the Contractor.

1.6.2

Shop Drawings

1

The Contractor shall prepare shop drawings for all parts of the Works to be installed or constructed under this Section and submit them to the Engineer for approval. The shop drawings shall include diagrams, illustrations, schedules, general arrangements of equipment and appurtenances in relation to buildings and structures, method statements and details of specialised installation and construction work.

1.6.3

Co-ordination Drawings

1

These shall be prepared by the Contractor to show how interdisciplinary work will be coordinated. The location, size and details of fixings, box-outs, ducts, holes, pipe chases and plinths shall be shown on the detailed layout drawings which are co-ordinated with all other work disciplines.

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Record Drawings

1

The Contractor shall prepare Record Drawings of all works constructed or installed under this Section. These shall be prepared as work proceeds. They shall provide a record of any modification to materials and equipment, and to the layout, arrangement and installation of the Works.

1.7

SITE WORKS

1.7.1

Openings

1

The Contractor shall co-operate with all trades in obtaining information as to openings required in walls, slabs and footings for all piping and equipment. Sleeves shall be accurately located and placed in forms before concrete is poured. Where several pipes pass through floors in close proximity, the Contractor may provide a single framed opening in lieu of individual sleeves. Framed openings shall be to the approval of the Engineer and shall be provided with 100 mm high curbs, on all sides. The Contractor shall pay all extra costs for cutting of holes as a result of incorrect, delayed or neglected locations of sleeves or frame openings.

1.7.2

Painting

1

All finished painting shall be done as specified in the Project Documents. All apparatus and equipment, not specified otherwise, shall be provided with a shop prime coat. All exposed ironwork, tanks pipes, and fittings without factory finish, including pipe hangers and rods shall be primed and painted with one coat of black asphalt varnish suitable for hot surfaces. Exposed pipe threads in bare or insulated piping shall be thoroughly cleaned and painted with two coats of metallic paint or red lead.

1.7.3

Co-operation with other Trades.

1

The Contractor shall so organise work progress to harmonise with the work of all trades so that work may proceed as expeditiously as possible. The Contractor shall be responsible for the correct placing of the Works and the connection thereof to the work of all related trades.

1.7.4

Protection of Finish

1

The Contractor shall provide adequate means for, and shall fully protect, all finished parts of materials and equipment against damage from whatever cause during the progress of the work and until final completion. All materials and equipment in storage and during construction shall be covered in such a manner that no finished surfaces will be damaged or marred and all moving parts shall be kept perfectly clean and dry. All damaged or defective work shall be replaced prior to applying for final acceptance.

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1.6.4

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Page 6

Clean-Up

1

During the progress of work, premises shall be kept reasonably free of the debris, waste materials and rubbish resulting from work carried out under this Section. Upon completion and before final acceptance of the Works, all debris, temporary protective coverings, rubbish, left-over materials, tools and equipment shall be removed from the Site. Exposed piping, machinery and other apparatus shall be thoroughly cleaned of cement, plaster, paint and other materials; grease and oil spots shall be removed with cleaning solvent. Surfaces shall be carefully wiped and all cracks and corners scraped clean. Chromium or nickel plated materials and equipment shall be thoroughly polished. The entire installation shall be left in a neat, clean and usable condition.

1.8

OPERATION AND MAINTENANCE MANUALS

1.8.1


1

The Contractor shall prepare Operation and Maintenance Manuals for all mechanical, electrical and electronic equipment installed under this Section.

2

Operation and Maintenance Manuals shall conform to the requirements of Clause 1.1.4 of Section 9.

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1.7.5

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END OF PART

QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 1

2

WATER DISTRIBUTION ............................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References Quality Assurance

2.2

WATER SYSTEMS........................................................................................ 3

2.2.1 2.2.2 2.2.3 2.2.4

General Requirements Cold Water Systems Hot Water Systems Pressurised Systems

2.3

PUMPS .......................................................................................................... 5

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

General Requirements Lift Pumps Circulation Pumps Pipework Connections Control

2.4

WATER DISTRIBUTION PIPEWORK ........................................................... 6

2.4.1 2.4.2 2.4.3

General Requirements Pipe Materials Pipework Jointing

2.5

PIPE FIXINGS ............................................................................................... 7

2.5.1 2.5.2

General Requirements Spacing of Pipe Fixings

2.6

TAPS, VALVES AND PROTECTION DEVICES ............................................ 9

2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6

Draw-off Taps Drain Taps Ball Float Valves Servicing Valves Stopvalves Backflow Protection Devices

2.7

PIPE INSTALLATIONS ................................................................................ 12

2.7.1 2.7.2 2.7.3 2.7.4

General Requirements Pipework Expansion Pipe Sleeves Concealed Pipework

2.8

INSULATION OF WATER PIPES ................................................................ 13

2.8.1 2.8.2

General Application

2.9

MISCELLANEOUS ...................................................................................... 14

2.9.1 2.9.2

Electrical Work Related to Plumbing Works Water Meter Cabinet

2

2 2 3

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3 3 4 4 5 5 5 5 6 6 6 7 7 7 9 10 10 10 11 11 12 12 12 12 13 13 14 14

QCS 2014


Page 2

WATER DISTRIBUTION

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements for the installation, testing and commissioning of services supplying water for use within buildings. It covers the system of pipes, fittings and connected appliances installed to supply any building with water for ablutionary, cleaning, sanitary and laundry purposes.

2


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General Mechanical and Electrical

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Section 1 Section 9

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General Cold Water Storage Hot Water Storage Commissioning of Systems

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.

2

References

1


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2.1.2

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BS 864 .......................Capillary and compression fittings for copper tubes and copper alloy.

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BS 1010 ......................Specification for draw-off taps and stopvalves for water services (screw-down pattern). BS 1212 ......................Specification for float operated valves (excluding floats).

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BS 1394 ......................Stationary circulating pumps for heating and hot water service systems. BS 1968 ......................Specification for floats for ballvalves (copper).

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BS 1972 ......................Specification for polythene pipe (Type 32) for above ground use for cold water services. BS 2456 ......................Floats (plastics) for float operated valves for cold water systems. BS 2494 ......................Specification for elastomeric joint rings for pipework and pipelines. BS 2580 ......................Specification for underground plug cocks for cold water services. BS 2871 ......................Specification for copper and alloy tubes. BS 2879 ......................Specification for draining taps (screw-down pattern). BS 3505 ......................Specification for unplasticized polyvinyl chloride (PVC-U) pressure pipes for cold potable water. BS 3958 ......................Thermal insulating material. BS 4127 ......................Specification for light gauge stainless steel tubes. BS 4346 ......................Joints and fittings for use with unplasticized PVC pressure pipes. BS 4991 ......................Propylene copolymer pressure pipe. BS 5114 ......................Specification for performance requirements for joints and compression fittingsfor use with polyethylene pipes.

QCS 2014


Page 3

BS 5154 ......................Specification for copper alloy globe, globe stop and check, check and gate valves. BS 5163 ......................Specification for predominantly key-operated cast iron gate valves for waterworks purposes. BS 5412 ......................Specification for the performance of draw-off taps with metal bodies for water services. BS 5413 ......................Specification for the performance of draw-off taps with plastics bodies for water services. BS 5422 ......................Method for supplying thermal insulating materials on pipes, ductwork and equipment BS 5433 ......................Specification for underground stopvalves for water services.

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BS 6144 ......................Expansion vessels using an internal diaphragm, for unvented hot water supply systems.

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BS 6281 ......................Devices without moving parts for the prevention of contamination of water by backflow.

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BS 6282 ......................Devices with moving parts for the prevention of contamination of water by backflow. BS 6283 ......................Safety devices for use in hot water systems.

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BS 6437 ......................Specification for polyethylene pipes (type 50) in metric diameters for general purposes.

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BS 6572 ......................Specification for blue polyethylene pipes up to nominal size 63 for bellow ground use for potable water.

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BS 6700 ......................Specification for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

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BS 7671 ......................Requirements for electrical installations. DIN 8079 ....................Pipes made of chlorinated PVC

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DIN 8080 ....................Pipes made of chlorinated PVC Quality Assurance

1

Items and equipment specified in this Part shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation or to the written approval of the Engineer.

2.2

WATER SYSTEMS

2.2.1


1

Internal hot and cold water supply installations shall be constructed so that water delivered is not liable to become contaminated to the extent that it is hazardous to health or is unfit for its intended use.

2.2.2

Cold Water Systems

1

Cold water systems shall be capable of providing cold water at the locations and in the quantities required and specified in the Project Documentation.

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2.1.3

QCS 2014


Page 4

All cold water draw-off points shall be served via a cold water storage tank. The cold water storage tank will be served directly from the Qatar General Electricity & Water Corporation (QGEWC) supply mains.

2.2.3

Hot Water Systems

1

Hot water systems shall be capable of providing hot water at the locations, in the quantities and at the temperatures required and as specified in the Project Documentation.

2

To promote maximum economy of fuel and water the hot water distribution system should be designed so that hot water appears quickly at the taps when opened. To this end, dead legs should be as short as possible. The hot water pipe feeding a spray tap for hand washing should not exceed 1 metre in length. When draw-off points are situated at a distance from the hot water storage vessel, consideration should be given to the use of a separate water heater installed close to those draw-off points. When this is impracticable a secondary circuit with flow and return pipes to the storage vessel should be considered. Secondary circuits inevitable dissipate heat and should be avoided where possible

2.2.4

Pressurised Systems

1

Whether hot or cold water is involved, it shall be ensured that no part of the system bursts due to the hydraulic pressures to which it is subjected. The pressures in the system shall never exceed the safe working pressures of the component parts. The maximum working pressure in a sealed primary circuit shall not exceed 3 bar but it shall be capable of passing a test at 1.5 times the working pressure at the working temperature. The maximum working pressure in an unvented hot water storage vessel or secondary circuit shall not exceed 6 bar.

2

Where necessary the supply pressure shall be controlled by using an atmospheric break tank or pressure reducing valves. If the supply to a storage type water heater is through a pressure reducing valve of the type that permits backflow, the working pressure in the system shall be assumed to be the maximum pressure upstream of the valve. Where reliance is placed on pressure reducing valves to limit the maximum working pressure, these shall comply with BS 6283: Part 4.

3

Provision shall be made to accommodate expansion of water by one of the following alternative methods:

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(a)

allow the expansion water to travel back along the cold feed pipe, provided that heated water cannot reach any communication pipe or branch feeding a cold water outlet

(b)

where reverse flow along the cold feed is prevented by a stopvalve a with loose jumper, replace this valve by one with a fixed jumper

(c)

where reverse flow along the cold feed is prevented, provide an expansion vessel in accordance with BS 6144 to accommodate expansion water. This vessel shall be sized in accordance with the volume of water heated and the water temperature rise so as to limit the pressure to the maximum working pressure for the system. The expansion vessel shall accommodate an expansion equal to 4% of the total volume of water heated. Any discharge from relief valves shall be readily visible and disposed of safely.

QCS 2014


Page 5

PUMPS

2.3.1


1

The installation of a pumped system should be undertaken by competent specialists experienced in such work.

2

Pumps shall be installed in accordance with the manufacturer’s recommendations and in an accessible location such that they may be readily maintained.

3

All pumps and associated equipment shall be capable of continuous operation in ambient 0 temperatures of up to 50 C.

4

Pumps shall be low speed and quiet in operation.

5

Pumps shall be firmly mounted. Measures to prevent vibration shall be taken where necessary.

6

No pump, required to increase pressure in or rate of flow from a supply pipe or any fitting or appliance connected to a supply pipe, shall be connected unless prior written approval from QGEWC is obtained.

7

Pumps located externally shall be provided with a suitable sun shade.

2.3.2

Lift Pumps

1

Centrifugal pumps with electric motors shall be used.

2

The pumps may be either the vertical type or horizontal type and shall be directly coupled to their electric motors.

3

Pump capacity shall be as stated in the Project Specification.

4

Where the pumping system has duty and standby pumps, the pumps shall be used alternately.

2.3.3

Circulation Pumps

1

Circulating pumps shall comply with the relevant provisions of BS 1394: Parts 1 and 2.

2

Circulating pumps shall be suitably suppressed to prevent radio and television interference.

3

Pump capacity shall be as stated in the Project Specification.

2.3.4

Pipework Connections

1

Flexible connections shall be used so as to prevent the transmission of pump and motor noise via pipework.

2

All pipework connections to and from the pump shall be adequately supported and anchored against thrust.

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2.3

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Page 6

Inlet and outlet pipework connections to lift pumps shall be fitted with gate valves complying with the relevant provisions Clause 2.10 of this Part.

4

Inlet and outlet pipework connections to circulating pumps shall be fitted with servicing valves complying with the relevant provisions Clause 2.9 of this Part.

2.3.5

Control

1

Pump control shall be as described in the Project Documentation.

2.4

WATER DISTRIBUTION PIPEWORK

2.4.1


1

Every pipe, pipe joint and connected fitting shall be capable of withstanding, without damage or deterioration, sustained temperatures of up to 40C for cold water installations and up to 70C, with occasional short-term peaks of up to 100C for heated water applications.

2

Pipes, pipe joints, pipe linings and connected fittings shall be made of materials that do not impart taste, colour, odour or toxicity to the water nor promote or foster microbial growth under the conditions where they are going to be installed.

3

If pipes, pipe joints or fittings are of dissimilar metals, measures shall be taken to prevent corrosion. Dissimilar metals shall be avoided in below ground installations.

2.4.2

Pipe Materials

1

Copper pipework shall comply with the relevant provisions of BS 2871: Part 1; underground pipes shall be to Table Y with a coating of seamless continuous PVC sheeting and above ground pipes shall be to Table X. Copper and copper alloy tube fittings should comply with the relevant provisions of BS 864: Part 1, Type B or BS 864: Part 2, Type A.

2

The use and installation of polyethylene pipework shall comply with the relevant provisions of BS 1972 (above ground use), BS 6437 (general purposes) and BS 6572 (below ground use). Copper alloy tube fittings for polyethylene pipes shall comply with the relevant provisions of BS 864: Part 3. Joints for polyethylene pipes shall comply with the relevant provisions of BS 5114 and BS 3505.

3

The use and installation of polypropylene pipework shall comply with the relevant provisions of BS 4991 and shall be Series 1.

4

The use and installation of unplasticized PVC (PVC-U) pipework shall comply with the relevant provisions of BS 3505. Solvent welded joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 1. Mechanical joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 2. PVC-U pipework shall only be used for cold water applications.

5

The use and installation of chlorinated PVC (CPVC) pipework shall comply with the relevant provisions of DIN 8079 and DIN 8080.

6

Stainless steel pipework shall comply with the relevant provisions of BS 4127.

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Page 7

Pipework Jointing

1

Jointing of pipes shall be in accordance with the relevant provisions of BS 6700

2

All proprietary joints shall be made in accordance with the manufacturer’s instructions.

3

Care shall be taken to establish satisfactory jointing techniques for all water service pipework. All burrs shall be removed from the ends of the pipes and any jointing materials used shall be prevented from entering the water system

4

All piping and fittings shall be cleaned internally and be free from particles of sand, soil metal filings and chips etc.

5

Jointing systems using elastomeric sealing rings shall be Type W, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer.

2.5

PIPE FIXINGS

2.5.1


1

Copper and stainless steel piping shall be secured by clips or brackets made from copper or copper-alloy.

2

Steel piping shall be secured by clips or brackets made from steel, copper alloy or suitable plastic. Copper clips or brackets shall not be used for fixing steel piping.

3

PVC-U, polyethylene, polypropylene and CPVC piping shall be secured by clips or brackets made from suitable metal or plastic. Allowance shall be made for free lateral movement within the clips and brackets.

4

Piping that is insulated shall be secured on clips or brackets that allow sufficient space behind the back of the pipe and the batten or wall to which the pipe is fixed for the insulation to be properly installed.

2.5.2

Spacing of Pipe Fixings

1

The spacings for fixings for internally located piping shall be in accordance with Table 2.1, 2.2, 2.3 and 2.4 as applicable. The figures given are based on an ambient temperature of 20C. For other temperature ranges the pipe manufacturer should be consulted.

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2.4.3

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Page 8

Table 2.1 Maximum Spacing of Fixings for Internal Piping Nominal size of pipe

Spacing on horizontal run

Spacing on vertical run

(mm)

(metres)

(metres)

Copper (light gauge) and

15

1.200

1.800

stainless steel complying with

22

1.800

2.400

BS 2871: Part 1 or BS 4127:

28

1.800

2.400

Part 2

35

2.400

3.000

42

2.400

3.000

54

2.700

3.000

76

3.000

3.600

108

3.000

3.600

3.000

3.600

3.600

4.200

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Type of Piping

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Table 2.2 Maximum Spacing of Fixings for Internal Piping Nominal size of pipe



(mm)

(metres)

(metres)

15

1.800

2.400

22

2.400

3.000

28

2.400

3.000

35

2.700

3.000

42

3.000

3.600

54

3.000

3.600

76

3.600

4.500

108

3.900

4.500

133

3.900

4.500

159

4.500

5.400

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Copper (heavy gauge)

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Page 9

Table 2.3 Maximum Spacing of Fixings for Internal Piping Type of Piping

Nominal size of pipe



(inches)

(metres)

PVC-U complying with BS 3505

0.530

1.060

and CPVC complying with DIN

1

0.610

1.220

8079 and 8080

3

/4

0.685

1.370

1

0.760

1.520

1

1 /4

0.840

1.680

1

1 /2

0.915

1.830

2

1.065

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3

2.130

1.370

2.740

1.525

3.050

1.830

3.660

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(metres)

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Tables 2.4 Maximum Spacing of Fixings for Internal Piping

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Type of Piping

Polyethylene and polypropylene

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complying with BS 1972 or

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BS 4991 respectively

Nominal size of pipe



(inches)

(metres)

(metres)

/8

0.300

0.500

½

0.400

0.800

/8

0.400

0.800

1

0.400

0.800

1 /4

1

0.450

0.900

1

1 /2

0.550

0.900

2

0.550

1.100

2 /2

1

0.600

1.100

3

0.700

1.200

4

0.700

1.400

3

3

2.6

TAPS, VALVES AND PROTECTION DEVICES

2.6.1

Draw-off Taps

1

Metal bodied draw-off taps shall conform to the relevant provisions of BS 5412: Parts 1-5.

2

Plastic bodied draw-off taps shall confirm to the relevant provisions of BS 5413: Parts 1-5.

QCS 2014


Page 10

Taps not fixed directly to an appliance shall be screwed into a suitable pipe fitting.

4

The fitting, or the pipe immediately adjacent to the tap, shall be firmly secured to a suitable support so as to prevent strain on the pipe and its joints when the tap is operated.

2.6.2

Drain Taps

1

Draining taps shall comply with the relevant provisions of BS 2879.

2

Draining tap shall be of the screwdown type with a removable key and shall be fixed over a drain or have provision for discharging the water to the nearest convenient point for disposal.

2.6.3

Ball Float Valves

1

Except for interconnected tanks arranged to store water at the same level, every pipe supplying water to a storage tank shall be fitted with a float operated valve or some other equally effective device to control the inflow of water and maintain it at the required level. The inlet control device shall be suitable for the particular application, taking into account the supply pressure and the temperature of the water in the cistern.

2

When a float operated valve is used it shall either:

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comply with BS 1212: Part 2 or 3 and be used with a float complying with BS 1968 or BS 2456 of the correct size corresponding to the length of the lever arm and the water supply pressure; or

(b)

where any other float operated valve or other level control device is used, it shall comply with the performance requirements of BS 1212 where applicable to the circumstances of its use and shall be clearly marked with the water pressure, temperature and other characteristics for which it is intended to be used.

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(a)

Every float operated valve shall be securely fixed to the cistern it supplies and where necessary braced to prevent the thrust of the float causing the valve to move and so alter the water level at which it shuts off. This water level shall be at least 25 mm below the lowest point of the warning pipe connection or, if no warning pipe is fitted at least 50 mm below the lowest point of the lowest over flow pipe connection

4

Every pipe taking water from a cistern of capacity exceeding 18 litres shall be fitted with a servicing valve close to the storage cistern, tank or cylinder.

5

Every ball float valve shall be so placed that it is readily accessibly for examination, maintenance and operation.

2.6.4

Servicing Valves

1

Servicing valves shall be located in accessible positions so as to enable the flow of water to individual or groups of appliances to be controlled and to limit the inconvenience caused by interruption of supply during repairs.

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A servicing valve shall either comply with the requirements for stopvalves as specified in Clause 2.13 of this Part or shall be capable of withstanding a static pressure 1.5 times the maximum pressure it will be subjected to in use, be leaktight when closed against the latter pressure and, when installed on any pipe pressurised from the mains or on any pipe under a static pressure exceeding 1 bar, shall be operable only by means of a key, screwdriver or coin inserted into a slot on the valve. Screwdown servicing valves shall not be of loose jumper design. Copper alloy gate valves complying with the relevant provisions of BS 5154 may be used as servicing valves.

3

A servicing valve shall be fitted upstream of, and as close as practicable to, every float operated valve connected to a supply pipe.

4

Pipes taking water from a storage tank of capacity exceeding 18 litres shall be fitted with a servicing valve. The valve shall be fitted as close to the storage tank as practicable. Pipes taking water from storage tanks with a capacity that does not exceed 18 litres shall not be fitted with servicing valves.

2.6.5

Stopvalves

1

The use and installation of stopvalves shall comply with the relevant provisions of BS 6700.

2

Stopvalves fitted to service pipes shall comply with the relevant provisions of the British Standards referenced in Table 2.5.

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Table 2.5

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Nominal Size of Pipe

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Stopvalves Fitted to Service Pipes

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50 mm or smaller

Above Ground

Below Ground

BS 1010: Part 2

BS 2580

BS 2580

BS 5433

BS 5433 BS 5163

BS 5163

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50 mm or larger

Standard

3

Stopvalve components of fittings incorporating stopvalves shall comply with the requirements for stopvalves.

4

Stop valves shall be so placed that they may be readily inspected, operated and maintained.

5

When a stopvalve is installed on an underground pipe it shall be enclosed in a pipe guard or chamber under a surface box of the correct grade for the traffic loading relevant to the location.

2.6.6

Backflow Protection Devices

1

Every pipe through which water is supplied to a point of use or draw-off where backflow or backsiphonage is likely to occur shall be fitted with a backflow protection device.

2

Pipe interrupters for backflow protection shall comply with the relevant provisions of BS 6281: Part 3.

QCS 2014


Page 12

Vacuum breakers for backflow protection shall comply with the relevant provisions of BS 6282: Part 2 and 3.

4

Check valves for backflow protection shall comply with the relevant provisions of BS 6282: Part 1. Any additional installation instruction issued by the manufacturer or supplier of the check valve shall also be complied with.

5

Combined check valve and vacuum breaker for backflow protection shall comply with the relevant provisions of BS 6282: Part 4.

6

Double check valve assembly for backflow protection shall comply with the relevant provisions of BS 6282: Part 1, with a draining tap complying with the relevant provisions of BS 2879 connected between them.

2.7

PIPE INSTALLATIONS

2.7.1


1

Pipe runs within buildings should not be laid exactly horizontal but to a slight fall to reduce the risk of air locks forming.

2.7.2

Pipework Expansion

1

In installations with limited straight runs and many bends and offsets, thermal movement is accommodated automatically. In installations that do not have limited straight runs and many bends and offsets, allowance for expansion and contraction of the pipes shall be made by forming expansion loops, by introducing changes of direction to avoid long straight runs or by fitting proprietary expansion joints. This is particularly important where temperature changes are considerable and where the pipe material has a relatively large coefficient of expansion.

2

The maximum length of a straight run for each different pipe material to be used shall be detailed in the Project Specification or shown on the Project Drawings.

2.7.3

Pipe Sleeves

1

Where a pipe enters a building it shall be accommodated in a sleeve that has previously been solidly built-in and the space between the pipe and the sleeve shall be filled with nonhardening, non-cracking, water-resistant material for a minimum length, of 150 mm at both ends to prevent the passage of water, gas or insects.

2.7.4

Concealed Pipework

1

Concealed pipework shall be housed in properly constructed builders work ducts or wall chases and have access for maintenance and inspection.

2

Ducts and chases should be constructed as the building structure is erected and should be finished smooth to receive pipe fixings.

3

No pipe or joint in or under a building shall be embedded in any wall or solid floor or in any material below a solid floor at ground level except for the following:

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the enclosing of any pipe and associated pipe joints in a purpose made duct or chase in a solid floor in such a way that the pipe and pipe joints can be exposed for purposes of examination, repair or replacement without endangering the structural integrity of the building

(b)

the enclosing of any pipe and associated pipe joints in a purpose made chase in a solid wall (but not within the cavity of a hollow wall) in such a way that the pipe and pipe joints can either be capped off and isolated or be exposed for purposes of examination, repair or replacement without endangering the structural integrity of the building

(c)

the enclosing of any pipe and associated pipe joints in any internal wall that is not a solid wall

(d)

the enclosing of any pipe within a purpose made pipe sleeve or duct in or under any solid floor in such a way that the pipe may be removed and replaced; for pipes laid in such a way, there shall be an inspection access point at each joint.

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(a)

No pipe or pipe joint shall be located under floorboards or a suspended floor, at ground floor level unless every pipe and pipe joint is accessible for examination.

5

Where access panels are formed in floor panels of structural chipboard or plywood, the structural stability of the building shall not be affected.

6

All pipe laid in ducts shall be adequately supported by clipping as specified in Table 2.1.

2.8

INSULATION OF WATER PIPES

2.8.1

General

1

Thermal insulating materials shall comply with BS 5422 and BS 3958 where applicable.

2

Thermal insulating materials shall be applied in accordance with the manufacturer’s recommendations. They shall be kept dry before, during and after application, except for water which may be required for the purpose of mixing. Gaps shall not be left at the joints of the insulating materials.

3

Where necessary, the insulating material shall be resistant to, or protected by a suitable covering against, mechanical damage, rain, moist atmosphere, groundwater and vermin.

4

Examples of suitable materials of insulating purposes are:

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(a)

polyurethane foam

(b)

foamed or expanded plastics

(c)

corkboard

(d)

amoliated vermiculite.

2.8.2

Application

1

While insulating material shall be continuous over pipes and fittings, it shall be finished in such a manner as to allow access to valves for operation.

2

Where cold water pipes pass through areas of relatively high dew point, e.g. habitable areas, they shall be insulated to prevent condensation forming on them.

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Page 14

Pipes in hot water supply systems that exceed the maximum lengths given in Table 2.6 shall be thermally insulated in accordance with BS 5422. Table 2.6 Maximum Permissible Lengths of Uninsulated Hot Water Pipes Maximum length

(mm)

(m)

12

20

Over 12 up to and including 22

12

Over 22 up to and including 28

8

Over 28

3

.

Outside diameter of pipes

MISCELLANEOUS

2.9.1

Electrical Work Related to Plumbing Works

1

Electrical works related to plumbing works shall be done in accordance with the relevant provisions of BS 7671 and the requirements of QGEWC.

2.9.2

Water Meter Cabinet

1

Water meter cabinets shall comply with the Rules and Regulations Guide for Plumbing Works prepared by QGEWC.

2

Water meter cabinets shall be located in an easily accessible place as approved by QGEWC.

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END OF PART

QCS 2014

Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 1

3

PLUMBING PIPEWORK IN TRENCHES ...................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

PIPES AND FITTINGS .................................................................................. 3

3.2.1 3.2.2

General Requirements Pipe Materials

3.3

PIPEWORK JOINTING .................................................................................. 3

3.3.1


3.4

PIPE LAYING ................................................................................................ 4

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

General Bedding Concrete Protection to Pipes Completion of Pipe Surround Backfilling Protective Coatings Pipes under Buildings Avoidance of Contamination Restraint of Pipes Testing of Pipework Surface Boxes

2 2 3 3

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PLUMBING PIPEWORK IN TRENCHES

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for pipes and fittings for below ground plumbing works.

2


Section 1 Section 5

General Concrete

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References

1


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BS 743 ........................Materials for damp-proof courses. BS 864 .......................Capillary and compression fittings for copper tubes and copper alloy.

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BS 882 ........................Aggregates from natural sources for concrete

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BS 1142 ......................Fibre building boards BS 2494Specification for elastomeric joint rings for pipework and pipeline.

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BS 2871 ......................Specification for copper and alloy tubes.

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BS 3505 ......................Specification for unplasticized polyvinyl chloride (PVC-U) pressure pipes for cold potable water.

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BS 4127 ......................Specification for light gauge stainless steel tubes. BS 4346 ......................Joints and fittings for use with unplasticized PVC pressure pipes.

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BS 4772 ......................Ductile iron pipes and fittings. BS 4991 ......................Propylene copolymer pressure pipe. BS 5114 ......................Specification for performance requirements for joints and compression fittings of use with polyethylene pipes. BS 6076 ......................Tubular polythene film for use as a protective sleeving for buried iron pipes and fittings. BS 6572 ......................Specification for blue polyethylene pipes up to nominal size 63 for bellow ground use for potable water. BS 6700 ......................Specification for design, installation, testing and maintenance of services supplying water supplying water for domestic use within buildings and their curtilages.

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Page 3

PIPES AND FITTINGS

3.2.1


1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system. Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water.

2

Every pipe, pipe joint and connected fitting shall be capable of withstanding, without damage or deterioration, sustained temperatures of up to 65C when operating under normal working pressures.

3

Pipe materials, fittings, linings and jointing materials shall impart no taste, colour, odour or toxicity to the water nor promote or foster the microbial growth under the conditions where they are going to be installed.

4

If pipes, pipe joints or fittings are of dissimilar metals, measures shall be taken to prevent corrosion. Contact between pipework components of dissimilar metals shall be avoided in below ground installations.

3.2.2

Pipe Materials

1

Copper pipework shall comply with the relevant provisions of BS 2871: Part 1, Table Y, coated with seamless continuous PVC sheeting. Copper and copper alloy tube fittings should comply with the relevant provisions of BS 864: Part 2.

2

The use and installation of polyethylene pipework shall comply with the relevant provisions of BS 6572. Copper alloy tube fittings for polyethylene pipes shall comply with the relevant provisions of BS 864: Part 3, Joints for polyethylene pipes shall comply with the relevant provisions of BS 5114 and BS 3505.

3

The use and installation of polypropylene pipework shall be in accordance with the relevant provisions of BS 4991 and shall be Series 1.

4

The use and installation of unplasticized PVC pipework shall comply with the relevant provisions of BS 3505. Solvent welded joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 1. Mechanical joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 2.

5

Ductile iron pipework shall comply with the relevant provisions of BS 4772.

6

Stainless steel pipework shall comply with the relevant provisions of BS 4127.

3.3

PIPEWORK JOINTING

3.3.1


1

Jointing of pipes shall be in accordance with the relevant provisions of BS 6700.

2

All proprietary joints shall be made in accordance with the manufacturer’s instructions.

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Page 4

Care shall be taken to establish satisfactory jointing techniques for all water service pipework. All burrs shall be removed from the ends of the pipes and any jointing materials used shall be prevented from entering the water system

4

All piping and fittings shall be cleaned internally and be free from particles of sand, soil metal filings and chips etc.

5

Jointing systems using elastomeric sealing rings shall be Type W, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer.

3.4

PIPE LAYING

3.4.1

General

1

Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint holes shall be formed in the bedding material or final excavated surface to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to made.

2

Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.

3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving. Where rock is encountered, the trench shall be cut at least 150 mm deeper than other ground and made up with well compacted selected fill material.

4

No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing, shall be examined for damage and the joint surfaces and components shall be cleaned immediately before laying.

5

Suitable measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent flotation or other movement before the Works are complete.

6

Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above the pipe.

3.4.2

Bedding

1

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the whole width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipe, and where practicable, this shall be done in sequence with the removal of the trench supports.

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Page 5

Unless otherwise detailed in the Project Documentation, bedding material shall be in accordance with Table 3.1 Table 3.1 Bedding Material Pipe Diameter

Bedding Sand

65 - 100 mm

10 mm single sized aggregate

100 - 200 mm

10 or 14 mm single sized or 14-15 mm graded aggregate

Over 200 mm

10, 14 or 20 mm single sized or 155 or 20-5 mm graded aggregate.

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up to 65 mm

Nominal single sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.

4

Sand for bedding material shall comply with the relevant provisions of BS 882.

5

Bedding systems other than those specified above may be allowed upon approval of the Engineer or as recommended by the pipe manufacturer.

3.4.3

Concrete Protection to Pipes

1

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete setting blocks. The top face of each block shall be covered with two layers of compressible packing complying with BS 743.

2

Concrete provided as a protection to pipes shall be Grade C20, placed to the required depth in one operation.

3

Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 3.2.

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Table 3.2 Thickness of Compressible Filler Nominal bore of pipe (mm)

Thickness of compressible filler (mm)

up to 300

13

Over 300 and up to 600

25


38

4

Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.

5

Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being surrounded by concrete.

QCS 2014


Page 6

Concrete work shall comply with the relevant provisions of Section 5, Concrete.

3.4.4

Completion of Pipe Surround

1

Fill material shall, where required, be placed and compacted over the full width of the trench in layers not exceeding 150 mm before compaction, to a finished thickness of 250 mm above the crown of the pipes.

3.4.5

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the parts of the Works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

2

Backfilling around existing structures shall be undertaken in such manner as to avoid uneven loading or damage.

3

Filling material to excavations shall be deposited in layers not exceeding 250 mm unconsolidated thickness and compacted to 95% modified proctor.

4

Where the excavations have been supported and the supports are to be removed, these, where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimise the danger of collapse. All voids formed behind the supports shall be carefully filled and compacted

3.4.6

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuous before trench excavations are backfilled.

3.4.7

Pipes under Buildings

1

Where a pipe has less than 300 mm of cover under a load bearing slab, it should be surrounded with concrete as an integral part of the slab. Where possible, the concrete surround shall be poured at the same time as the slab. The surround shall be tied to the slab with nominal steel reinforcement placed vertically with turned over ends.

2

No provision for pipe flexibility along the concrete surround shall be made, unless an expansion joint is included in the slab. A construction joint should be included in the surround at that point which must also coincide with a pipe joint.

3

In normal, stable ground conditions, and with 300 mm or more of cover to the pipeline beneath the slab, a total granular surround can be used as a pipe bedding. Refer to Clause 3.4.2 for bedding specification.

4

Flexibility shall be incorporated into the pipeline as it leaves any concrete surround.

5

Where plastic pipes are to be surrounded in concrete, Clause 3.4.3 of this Part shall be complied with.

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Avoidance of Contamination

1

No pipe shall be laid or installed near a sanitary manhole, cesspool, septic tank, soakaway, refuse pit or other feature likely to cause the water to become contaminated and/or cause deterioration to the pipe material.

2

Any pipe that crosses over a sewer shall be laid so that there is at least 600 mm clearance between the pipe barrels. Any pipe that lies adjacent to a sewer shall be laid so that there is at least 3m between the barrels. Plumbing pipes shall not be laid below sewers.

3

Where the above criteria cannot be met, and with the approval of the Engineer in writing, the pipe shall be encased in concrete. The limit of the concrete encasement shall be determined on site by the Engineer. No breaks in the concrete encasement shall be made at joints. If the concrete encasement extends over one or more joints it shall be treated as a beam and reinforced appropriately; in such cases, the Contractor shall prepare reinforcement details with supporting calculations and submit them to the Engineer for approval.

4

Where it is necessary to determine the extent of contamination, the Contractor shall arrange for soil samples to be taken and tested. The locations at which soil samples are taken and the number of samples to be taken shall be determined by the Engineer.

3.4.9

Restraint of Pipes

1

Except where the method of jointing and normal trench backfill are adequate to prevent longitudinal movement, Grade C20 concrete thrust blocks cast in contact with undisturbed ground shall be constructed at changes in direction, junctions and blank ends.

2

Any additional excavation required to accommodate thrust blocks shall be carried out after the bend or branch is in position and the thrust face shall be trimmed back to remove all loose or weathered material immediately prior to concreting.

3

Thrust blocks shall be required to develop adequate strength before any internal pressure is applied to the pipeline.

4

Where plastic pipes are to be surrounded in concrete, Clause 3.4.3. of this Part shall be complied with.

3.4.10

Testing of Pipework

1

Pressure tests shall be carried out on below ground plumbing pipes. Test procedures are detailed in Part 6 of this Section.

3.4.11

Surface Boxes

1

Surface boxes shall be provided to give access to operate valves.

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3.4.8

END OF PART

QCS 2014

Section 19: Plumbing Work Part 04: Cold Water Storage

Page 1

4

COLD WATER STORAGE............................................................................. 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope System Description Submittals Quality Assurance

4.2

TANK CONSTRUCTION ............................................................................... 4

4.2.1


4.3

FILTERS ........................................................................................................ 4

4.3.1


2 2 3 3

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4

COLD WATER STORAGE

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for cold water storage systems.


Section 1

General

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System Description

1

Cold water storage tanks shall impart no taste, colour, odour or toxicity to the water nor promote or foster microbial growth under the conditions where the tank is going to be installed.

2

The tank shall be supported on a firm level base capable of withstanding the weight of the tank when filled with water to the rim.

3

Where possible and practicable, tanks shall be positioned in locations where they can be easily accessed for inspection, cleaning and maintenance.

4

Tanks positioned outside buildings shall be provided with a suitable shade.

5

Where two or more tanks are coupled together in series, the inlet and outlet shall be at opposite ends of the series.

6

Tanks shall not be buried or sunk in the ground without the prior approval from the Qatar General Electricity & Water Corporation (QGEWC).

7

Each tank shall be fitted with a 25 mm diameter outlet for connection to a washout pipe. The outlet shall be flush with the bottom of the tank. The floor of tank shall be laid at a slight fall towards the outlet. A washout pipe and a stop-tap shall be fitted to the outlet. The washout pipe shall be run to a point as detailed in the Documentation.

8

Every pipe supplying water to a cold water tank shall be fitted with a float operated valve or some other equally effective device, as detailed in Part 2 of this Section, to control the inflow of water and maintain it at the required level. The float valve shall be securely fixed to the tank and be installed so that the level of water in the tank when full under normal conditions is not less that 25 mm below the level of the warning or overflow pipe. A stopvalve complying with the relevant provisions of Part 2 of this Section shall be fitted to the pipework immediately upstream of the float valve to shut off supply of water to that valve.

9

Distribution pipes for tanks shall be connected so that the lowest point of the outlet is not less than 50 mm above the bottom of the tank.

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Page 3

Connections to distribution pipes feeding hot water apparatus shall be set at a level of at least 25 mm above connectors to pipes feeding cold water outlets.

11

Any tank with an effective capacity of up to 4500 litres shall be fitted with a warning type overflow pipe. Tanks with an effective capacity exceeding 4500 litres shall be fitted with one or more overflow pipes. For capacities exceeding 4500 litres, either the lowest pipe will be a warning type overflow pipe, or a device shall be fitted that gives an audible or visual alarm when water in the tank reaches a level at least 50 mm below the lowest point of the lowest overflow pipe.

12

The invert level of the overflow pipe shall be not less than 75 mm below the invert level of the inlet pipe.

13

Overflow pipes shall be made of a rigid corrosion resistant material. No overflow or warning pipe shall rise in level outside the cistern.

14

Warning type overflow pipes shall discharge water immediately the water in the tank reaches the overflow level and shall discharge to a conspicuous position; these shall be outside the building where appropriate.

15

The overflow pipe or pipes should be able to convey water away from the tank at a rate equal to or greater than the rate of flow of water into the tank. Notwithstanding, warning type overflow pipes shall be not be less than 20 mm in diameter.

4.1.3

Submittals

1

The Contractor shall provide manufacturers’ specifications for all items to be supplied under this Part.

2

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of sectional type storage tanks, unless otherwise detailed in the manufacturer’s data sheets.

3

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of tank support assemblies unless otherwise detailed in the manufacturer’s data sheets.

4

The submittal shall include catalogue pages, erection descriptions and manufacturer data.

5

Unless the positions of the discharges for the overflow pipes are described in the Project Documentation, the Contractor shall submit his proposals for their positioning to the Engineer for approval.

4.1.4

Quality Assurance

1

Fabricated cold water storage tanks and associated equipment shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation and to the written approval of the Engineer.

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Page 4

4.2

TANK CONSTRUCTION

4.2.1


1

Cold water storage tanks shall be constructed in accordance with the Rules and Regulations for Plumbing Works as prepared by QGEWC.

2

The tanks shall be constructed with one of the following materials/methods:

(a) (b) (c)

fibre glassed reinforced plastic GRP sectional panel reinforced concrete (underground storage).

Tanks smaller than 6m in length shall have a removable close-fitting vermin proof cover. Tanks greater than 6m in length shall have two or more securable manhole covers.

4.3

FILTERS

4.3.1


1

Filters shall be of a type as detailed in the Project Documentation.

2

As a minimum, filters shall be able to remove the following:

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(b)

giardia cysts

(c)

chlorine tastes and odours

(d)

sediment to 1 micron.

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Filters shall have the following characteristics: (a)

inhibit the growth of bacteria and other micro-organisms clean and maintain.

Filters shall not unduly affect distribution rates.

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3

END OF PART

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 1

5

HOT WATER STORAGE ............................................................................... 3

5.1

GENERAL ...................................................................................................... 3

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7

Scope References System Description Identification Plate Submittals Safety Quality Assurance

5.2

HOT WATER STORAGE TANKS .................................................................. 5

5.2.1 5.2.2

Tank Construction Pressure and Non-Pressure Hot Water Storage Tanks

5.3

LOW CAPACITY ELECTRIC IMMERSION HEATER SYSTEMS .................. 5

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8

System Description Immersion Heaters Heating Element Pressure Relief Pipework Temperature and Temperature Control Electric Control Pilot Light

5.4

CALORIFIER SYSTEMS ............................................................................... 6

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11

System Description Storage Tank Construction Heat transfer System Tube Batteries Electric Heating Elements Calorifier Mountings Thermometers Altitude or Pressure Gauges Pressure Relief Valve Combined Pressure and Vacuum Gauges Vacuum Breaker

5.5

CISTERN TYPE WATER HEATERS ............................................................. 9

5.5.1


5.6

PRESSURE CONTROL ................................................................................. 9

5.6.1


5 5

5 5 6 6 6 6 6 6

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6 7 7 7 8 8 8 8 8 9 9

9

9

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5.7

VENTILATION ............................................................................................. 10

5.7.1 5.7.2

Storage Tanks Indirect Calorifier Systems

5.8

EXPANSION VESSEL ................................................................................. 10

5.8.1


5.9

INSULATION ............................................................................................... 11

5.9.1

General

10 10

10

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5

HOT WATER STORAGE

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for hot water storage systems.

2

Related Sections and Parts are as follows: This Section:

Section 1

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General

References

1


qa

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5.1.2

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BS 21.......................... Pipe threads for tubes and fittings where pressure tight joints are made on threads (metric dimensions)

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BS 417........................Galvanized mild steel cisterns and covers, tanks and cylinders BS 699........................Specification for copper direct cylinders for domestic purposes

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BS 759........................Valves, gauges and other safety fittings for applications to boilers and to piping installations for and in connection with boilers

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BS 853........................Calorifiers and storage vessels for central heating and hot water supply

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BS 1566......................Copper indirect cylinders

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BS 1780......................Bourdon tube pressure and vacuum gauges BS 1894......................Design and construction of electric boilers of welded construction

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BS 2871......................Copper and copper alloy. Tubes BS 3198......................Specification for copper hot water storage combination units for domestic purposes BS 3274......................Tubular heat exchangers for general purposes BS 3456......................Specification for safety of household and similar electrical appliances BS 3599......................Electrical controls for domestic appliances BS 4213......................Cold water storage and combined feed and expansion cisterns (polyolefin of olefin copolymer) up to 500 litres capacity for domestic purposes BS 4504......................Circular flanges for pipes, valves and fittings (PN designated) BS 4814......................Expansion vessels using an internal diaphragm, for sealed hot water systems BS 6144......................Expansion vessels using an internal diaphragm, for hot water unvented supply systems

QCS 2014


Page 4

BS 6282......................Devices with moving parts for the prevention of contamination of water by backflow BS 6283......................Safety devices for use in hot water systems System Description

1

Storage-type water heaters shall be used for the provision of hot water services.

2

The hot water storage tank shall be constructed so that water delivered is not liable to become contaminated to the extent that it is hazardous to health or unfit for its intended use.

3

The capacity of the storage tank shall be as stated in the Project Documentation.

5.1.4

Identification Plate

1

All hot water storage tanks shall have an engraved or cast-metal identification plate clearly showing the following: manufacturer’s name and address

(b)

date of manufacture

(c)

hydraulic test pressures

(d)

maximum working pressure

(e)

rated capacity and output

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(a)

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5.1.3

Submittals

1

The Contractor shall provide manufacturers’ specifications for all items to be supplied under this Part.

2

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of tank support assemblies (free standing or wall mounted), unless otherwise detailed in manufacturer’s data sheets.

3

The submittal shall include catalogue pages, erection descriptions and manufacturer’s data.

5.1.6

Safety

1

All safety requirements specified by the Qatar General Electricity & Water Corporation, the standard to which the hot water storage tank is constructed and the manufacturer shall be strictly adhered to. If the requirements specified by any of these three parties differ or conflict in any respect, the most stringent requirement, as defined by the Engineer, shall be followed.

5.1.7

Quality Assurance

1

Fabricated hot water storage tanks and associated equipment shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation and to the written approval of the Engineer.

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5.1.5

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Page 5

HOT WATER STORAGE TANKS

5.2.1

Tank Construction

1

Hot water storage tanks constructed of copper shall comply with the relevant provisions of BS 699, BS 853, BS 1566 and BS 3198, as applicable.

2

Hot water storage tanks may be constructed of materials other than copper provided that they are corrosion resistant, glass lined or porcelain lined and provided that they are approved by the Qatar General Electricity & Water Corporation. Appropriate British Standards, or equivalent, specifying the construction of storage tanks covered in this paragraph shall be supplied by the Contractor to support the required approval.

3

Tanks shall incorporate replaceable, sacrificial magnesium anodes for cathodic protection if directed in the Project Documentation.

5.2.2

Pressure and Non-Pressure Hot Water Storage Tanks

1

The hot water tanks shall be non-pressure or pressure as directed in the Project Documentation.

2

Non-pressure hot water storage tanks shall have ventilation systems as described in Clause 5.7 of this Part.

3

For non-pressure hot water storage tanks, no hose or other connection shall be made to the outlet of a non-pressure, storage type, water heater and under no circumstances shall the outlet be controlled by a tap or valve.

4

For pressure systems it shall be verified that the heater is suitable for the proposed supply pressure.

5

Suitable arrangements to accommodate expansion of the heated water shall be made for pressure hot water storage tanks. See Clause 5.8.

5.3

LOW CAPACITY ELECTRIC IMMERSION HEATER SYSTEMS

5.3.1

System Description

1

A low capacity (domestic) electrical immersion heater system involves an electric heating element placed within a hot water storage tank. Such heaters shall be used for the provision of hot water services for applications where the demand for hot water is small (i.e. kitchens and bathrooms, etc.).

2

Electric immersion heaters shall be of the vented or unvented type, as directed in the Project Documentation.

3

Tank construction shall be in accordance with Clause 5.2 of this Part.

5.3.2

Immersion Heaters

1

Electric immersion heaters shall comply with the relevant provision of BS 3456.

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Heating Element

1

The material of the heating element shall be a high-grade stainless steel. Other materials with high corrosion resistance may be used if approved by the Engineer.

5.3.4

Pressure Relief

1

An expansion relief valve shall be fitted in the cold feed to the hot water storage tank and no valves (other than a drainage tap) shall be fitted between the expansion relief valve and the storage tank. The expansion or pressure relief valve setting shall be the maximum working pressure plus 0.5 to 1.5 bar.

5.3.5

Pipework

1

For tanks with a capacity of 25 litres or greater, the size of the hot water outlet pipe shall be smaller than the cold water inlet pipe.

5.3.6

Temperature and Temperature Control

1

Unless otherwise detailed in the Project Specification, the temperature of the stored water shall never exceed 65°C.

2

Every hot water storage tank shall be fitted with a thermostat acting on the heat input. In addition, every hot water storage tank of capacity greater than 150 litres shall be fitted with an automatic control capable of stopping and starting the heat input to the stored water at pre-set times.

5.3.7

Electric Control

1

All electrical controls, including thermostats, cut-outs and switches, shall comply with the relevant provisions of BS 3599.

5.3.8

Pilot Light

1

The heater shall incorporate a clearly visible pilot light.

5.4

CALORIFIER SYSTEMS

5.4.1

System Description

1

Calorifier systems shall be used for hot water applications with a high hot water demand (hospitals, schools, etc.).

2

Calorifier systems shall be storage type systems and shall be the direct or indirect type.

3

Direct systems involve directly heating the water that will enter the hot water distribution system. This is done by circulating the water in the hot water storage tank through a heat transfer system (boiler). When inside the boiler, the water is directly exposed to the heat source.

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Direct type systems shall be designed for gravity circulation. Flow and return pipes between the boiler and the storage tank shall run as directly as possible and shall be not less than 25 mm diameter. The storage tank shall be located at a sufficient height above the boiler to give adequate circulation.

5

Indirect systems involve heating water by means of routing steam or hot water through the hot water storage tank via a tube battery. A heat transfer system (boiler) heats up the water or generates the steam that is conveyed through the tube battery that runs through the water storage tank. On exiting the hot water storage tank, the tube returns to the boiler. The hot water/steam does not come into contact with the water that will enter the hot water distribution system.

6

Indirect systems shall incorporate a sealed or vented primary circuit as directed in the Project Documentation. Primary circuits comprise the boiler, the primary heat exchanger in the hot water storage tank and the interconnecting and associated pipework.

7

Calorifiers shall incorporate electrical immersion heaters if required by the Project Documentation.

5.4.2

Storage Tank Construction

1

Storage tank construction shall be in accordance with Clause 5.2 of this Part and shall be horizontal or vertical type.

2

The storage tanks shall comply with the relevant provisions of BS 853 Grade B for shell operating pressures not exceeding 4.5 bar and temperatures not exceeding 90 oC.

3

They shall be supported on fabricated feet attached to the shell or on separate cradles or frames. Sheet lead pads shall be fitted between shell bearing surfaces and any separate supports.

4

They shall have screwed and/or flanged connections complying with the relevant provisions of BS 21 and BS 4504.

5

They shall be delivered with all connections capped or blanked-off.

5.4.3

Heat transfer System

1

Boilers shall comply with the relevant provisions of BS 1894 unless otherwise specified in the Project Documentation.

5.4.4

Tube Batteries

1

Tube battery shall be design shall comply with the relevant provisions of BS 3274 Type 2.

2

Tubes batteries shall be of solid drawn copper to BS 2871 Part 3.

3

Tube batteries shall be fixed or removable, as stated in the Project Documentation. If fixed type tube batteries are to be used, the storage tank shall include an access opening for battery maintenance purposes.

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Electric Heating Elements

1

Electric immersion heaters shall be complete with an integral thermostatic controller.

2

A minimum of two heating elements shall be provided in each calorifier. The first shall be at low level and the second one approximately two thirds from the base. The ratings of the elements shall be such that the lower heating element shall provide a minimum heat-up time of two (2) hours. The higher heating element shall be equivalently rated for a heat up time of four (4) hours.

3

The material of the heating element shall be a high-grade stainless steel. Other materials with high corrosion resistance may be used if approved by the Engineer.

5.4.6

Calorifier Mountings

1

The calorifiers shall have connections for hot water system controls and for open systems, a vent pipe connection.

2

The calorifiers shall also have an emptying/drain cock of the bronze gland pattern with hose union connection and malleable iron lever handle. The cock shall be fitted to the calorifier shell lowest point to ensure complete removal of water content and shall be of adequate size (25 mm diameter minimum).

5.4.7

Thermometers

1

The calorifier shall incorporate a stainless steel dial type mercury thermometer. The dial shall be 100 mm diameter (minimum), white faced with a black figured scale calibrated from 0 oC to 120 oC with divisions at 1 oC intervals and numbered at 10 oC intervals with bold figures. The thermometer shall be complete with an integral vertical or centre stem and separate pocket to suit the immersion position.

5.4.8

Altitude or Pressure Gauges

1

The calorifier shall incorporate a stainless steel dial type altitude or pressure gauges. The dial shall be 100 mm diameter (minimum), white faced with a black figured scale, calibrated both in bar and metre head, to approximately twice the working pressure, complete with lever handle gauge cock and adjustable red dial pointer set at normal working pressure or head of the system. The gauge shall generally to comply with the relevant provisions of BS 1780 Part 2.

5.4.9

Pressure Relief Valve

1

The calorifier shall incorporate an enclosed spring loaded pattern pressure relief valve fitted with a padlock. The valve shall incorporate a copper discharge pipe running clear of any insulation and terminating 150 mm from floor level adjacent to a drain gully position. The pressure relief valve shall comply with the relevant provisions of BS 759.

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5.4.5

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Combined Pressure and Vacuum Gauges

1

The calorifier shall incorporate a stainless steel dial type combined pressure and vacuum gauge. The dial shall be 100 mm diameter (minimum), white faced with a black figure scale, calibrated to suit steam chest pressure, complete with U pattern siphon and lever handle gauge cock. The gauge shall generally to comply with the relevant provisions of BS 1780 Part 2.

5.4.11

Vacuum Breaker

1

Vacuum breakers shall comply with the relevant provisions of BS 6282 Part 2 or 3.

2

Every vacuum breaker valve shall be of the same nominal size as the pipe on which it is connected.

3

Each vacuum breaker shall be installed at a height of not less than 150 mm above the overflowing level of the receiving cistern tank or appliance, when the later is fixed or not less than 300 mm above the outlet of the fitting in all other cases.

5.5

CISTERN TYPE WATER HEATERS

5.5.1


1

Cistern type water heaters shall comply with BS 417, BS 4213 and BS 4814, as appropriate.

2

The cistern shall comply with all the requirements for a cold water storage cistern.

3

The feed cisterns shall have a capacity at least equal to that of the hot water storage tank.

4

The feed cistern shall be situated at a height that will ensure a satisfactory flow of water at the highest point of discharge.

5.6

PRESSURE CONTROL

5.6.1


1

Whether hot or cold water is involved, it shall be ensured that no part of the system bursts due to the hydraulic pressures to which it is subjected. The pressures in the system shall never exceed the safe working pressures of the component parts. The maximum working pressure in a sealed primary circuit shall not exceed 3 bar but it shall be capable of passing a test at 1.5 times the working pressure at the working temperature. The maximum working pressure in an unvented hot water storage tank or secondary circuit shall not exceed 6 bar.

2

Where necessary the supply pressure shall be controlled by using break cisterns or by pressure reducing valves. If the supply to a storage type water heater is through a pressure reducing a valve of the type that permits backflow, the working pressure in the system shall be assumed to be the maximum pressure upstream of the valve. Where reliance is placed on pressure reducing valves to limit the maximum working pressure, these shall comply with BS 6283, Part 4.

3

Where unvented storage type water heaters are used, an expansion relief valve shall be fitted in the cold feed to the heater or hot water cylinder and no valves (other than a draining tap) shall be fitted between the expansion relief valve and the heater or hot water cylinder.

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In every case, including sealed primary circuits, the expansion or pressure relief valve setting shall be maximum working pressure plus 0.5 bar to 1.5 bar. This also applies to combined temperature and pressure relief valves.

5.7

VENTILATION

5.7.1

Storage Tanks

1

With ventilated hot water storage tanks, an open vent pipe shall run from the top of the hot water storage tank to a point above the cold water storage tank, into which it shall discharge. No valves shall be fitted to any vent pipe. The vent pipe shall rise continuously from its point of connection to the hot water storage tank to its point of discharge. The vent pipe shall be 19mm diameter or greater.

5.7.2

Indirect Calorifier Systems

1

Indirect calorifier systems incorporating vented primary circuits shall have vent route connecting the flow connection on the calorifier to the vent pipe above the expansion cistern and a feed water route from a point near the bottom of the expansion cistern to the return connection on the calorifier. These routes shall be independent.

5.8

EXPANSION VESSEL

5.8.1


1

An expansion vessel shall be connected to the cold feed supply pipe to unvented hot water storage vessels. There shall be no valve on the pipe between the expansion vessel and the storage vessel.

2

On indirect systems incorporating sealed primary circuits, an expansion vessel shall be connected to the section of pipework routing the water from the storage tank and boiler.

3

Provision shall be made to accommodate expansion water by one of the following alternative methods. allow the expansion water to travel back along cold feed pipe, provided that heated water cannot reach any communication pipe or branch feeding a cold water outlet.

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(b)

where reverse flow along the cold feed is prevented by a stopvalve with a loose jumper, replace this valve by one with a fixed jumper.

(c)

where reverse flow along the cold feed is prevented, e.g. by a check valve, some types of pressure reducing valve or a stopvalve with a loose jumper, provide an expansion vessel in accordance with BS 6144 to accommodate expansion water. This vessel shall be sized in accordance with the volume of water heated and the water temperature rise so as to limit the pressure to the maximum working pressure for the system. The expansion vessel shall accommodate expansion equal to 4% of the total volume of water heated. Any discharge from relief valves shall be readily visible and disposed of safely.

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5.9

INSULATION

5.9.1

General

1

The storage tank shall be supplied complete with a factory applied layer of high density, CFC free polyurethane foam insulation. The dimensions and properties of the polyurethane insulation shall be sufficient to ensure that heat loss under normal operating conditions does not exceed 90 watts per square metre of surface area.

2

The polyurethane shall be protected against mechanical damage and moist atmosphere by an outer shell.

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END OF PART

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 1

6

COMMISSIONING OF SYSTEMS ................................................................. 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4

Scope System Description Submittals Connection to Water Supply System

6.2

PIPELINE IDENTIFICATION ......................................................................... 3

6.2.1

Tags and Colour Coding System

6.3

TESTING AND INSPECTION ........................................................................ 3

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7

General Requirements Timing of Tests Inspection Leakage Test for Underground Pipelines Testing of Installation Within Buildings Back-Siphonage Mechanical and Electrical Equipment

6.4

DISINFECTION.............................................................................................. 6

6.4.1 6.4.2 6.4.3

General Requirements Installations Outside buildings Installation Inside Buildings

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COMMISSIONING OF SYSTEMS

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirements for identification markings for components of plumbing installations, testing of plumbing installations and disinfection of plumbing installations.

2

Related Sections and parts are as follows:

Section 1

General

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System Description

1

Where possible and practicable, the parts of all Works covered in this Section shall be split into sections for interim testing purposes. Final testing shall be done when the installation is complete.

2

Disinfection shall not be undertaken until all tests and inspections have been completed to the satisfaction of the Engineer.

6.1.3

Submittals

1

The Contractor shall prepare a detailed testing and inspection programme, including method statements, and submit it to the Engineer for approval. This programme shall identify each item to be tested, the type of test to be performed and the date and time of the test.

2

The Contractor shall prepare test record sheets for all tests undertaken. The format of the test record sheet shall be to the approval of the Engineer. On successful completion of a test, the test record sheet shall be signed and stamped by all parties. The Engineer shall retain the original test record sheet.

3

The Contractor shall prepare a detailed disinfection programme, including method statements, and shall submit it to the Engineer for approval. This programme shall identify the date and time at which each item is to be disinfected.

4

The Contractor shall prepare disinfection record sheets for all disinfections undertaken. The format of the disinfection record sheet shall be to the approval of the Engineer. On completion of disinfection, the disinfection record sheet shall be signed and stamped by all parties. The Engineer shall retain the original disinfection record sheet.

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Connection to Water Supply System

1

Connection to the Qatar General Electricity & Water Corporation (QGEWC) water supply system shall not take place until all tests and inspections have been successfully completed and the system has been disinfected.

2

The Contractor shall comply with all the requirements of the QGEWC with respect to making the connection to the water supply system.

6.2

PIPELINE IDENTIFICATION

6.2.1

Tags and Colour Coding System

1

Marker tape shall be laid above all underground water mains. The marker tape shall be blue PVC or polyethylene mesh or ribbon at least 50 mm wide, incorporating a corrosion resistant tracing system. The tape shall be clearly marked “WATER” in both English and Arabic in black print.

2

Where aesthetically acceptable, above ground piping shall be clearly and indelibly marked “WATER” in both English and Arabic. Pipes solely for the use of fire fighting purposes shall be distinguishable from other water pipes.

3

Every valve in hot and cold water service pipework installed above ground shall be provided with an identification label. The label shall be secured by either non-corroding, incombustible means to the valve or fixed to a permanent structure near the valve. Labels secured to valves shall be of a non-corroding and incombustible material and clearly marked, by stamping or engraving, with a reference number for the valve. The reference numbers for the valves shall be as stated in the Project Documents. Labels fixed near valves shall comply with the requirements for labels secured to valves except that they need not be incombustible.

4

Surface boxes shall have “WATER” in both English and Arabic cast on. They shall be painted blue with a durable epoxy paint.

6.3

TESTING AND INSPECTION

6.3.1


1

The Contractor shall notify the Engineer at least two clear working days before hand of his intention to test any section of the Works.

2

Unless otherwise agreed by the Engineer, both interim and final tests shall be undertaken on each section of the Works.

3

The Contractor shall also carry out any further testing or inspections specifically requested by QGEWC.

4

Unless otherwise provided in the Project Documentation, the Contractor shall be responsible for providing all equipment and materials for testing purposes and for their removal and proper disposal on completion of testing.

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6.1.4

QCS 2014


6.3.2

Timing of Tests

1

The timing of tests shall be arranged as follows:

Page 4

(a)

interim test shall be undertaken as soon as practicable after completion of a particular section; particular attention shall be made to work which will be concealed

(a)

final tests shall be carried out on completion of all work on items included in this Section and prior to handing over

(b)

items failing any test shall be corrected immediately and re-tested before further work proceeds.

The Contractor shall note that satisfactory completion at an interim test does not constitute a final test.

6.3.3

Inspection

1

Visual inspection shall be carried out at both interim and final testing in order to detect faults in construction or materials not shown up under testing but which could lead to premature failure. A careful record shall be kept of such inspections.

2

On external pipelines, the following shall be visually inspected:

(b)

pipe line and level

(c)

joints

(d)

air valves

(e)

washout valves

(f)

gate valves

(g)

thrust blocks

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3

Trenches shall be inspected to ensure that excavation is to the correct depth to guard against mechanical damage due to traffic loading.

4

No part of the pipe trench shall be backfilled until the above are satisfactory completed and approved by the Engineer.

5

All internal pipework shall be inspected to ensure that it has been securely fixed.

6

Before testing takes place, all cisterns, tanks, hot water cylinders and water heaters shall be inspected to ensure that they are properly supported and secured, that they are clean and that cisterns are provided with correctly fitting covers.

7

Before testing takes place, all electrical and mechanical items shall be inspected in accordance with Section 9, Mechanical and Electrical Equipment.

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Page 5

6.3.4

Leakage Test for Underground Pipelines

1

After satisfactory visual inspections have been completed, hydraulic pressure testing shall be carried out on the installation. The testing procedure shall be as follows: gauges used for testing pressure pipelines shall either be of the conventional circular type, not less than 200 mm diameter, calibrated in metres head of water, or shall have a digital indicator capable of reading increments of 0.1m head. Before any gauge is used, the Contractor shall arrange for it to be checked independently and a dated certificate of its accuracy shall be provided

(b)

before testing, valves shall be checked and sealed, the sections of pipe filled with water and the air released. After having been filled, pipelines shall be left under operating pressure for the period described in the Project Documentation or as directed by the Engineer, so as to achieve conditions as stable as possible for testing

(c)

the pressure in the pipeline shall then be raised steadily by pumping in water until the specified test pressure, as given in the Project Documentation or as directed by the Engineer, is reached in the lowest part of the section. The pressure shall be maintained at this level, by pumping if necessary, for a period of one hour. The pumps shall then be disconnected, and no further water shall be permitted to enter the pipeline for a further period of one hour. After the one hour test period, the pressure in the pipe shall be recorded. At the end of this period the original test pressure shall be restored by pumping in water and the loss measured by drawing off water form the pipeline until the pressure as recorded at the end of the one hour test period is again reached

(d)

the permissible loss shall not exceed 2 litres per metre nominal bore per kilometre length per metre head (calculated as the average head applied to the section) per 24 hours. This relationship in equation format, with the leakage measured in litres, can be written as follows:

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Permissible leakage per day = 2 x D x P x L

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For the one hour test period, this equation can be rewritten as follows:

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Permissible leakage = (2 x D x P x L) / 24 Where: D = pipe diameter (m) P = test pressure (m) L = length of test section (km)

2

(e)

in addition to the tests on separate sections, the whole pipeline shall be tested on completion to the same pressure and by the same procedures as that outlined for individual sections

(f)

where a new pipeline is to connect to an operational pipeline the final connection shall be inspected visually under normal operating pressure and there shall be no visible leakage.

To avoid the risk of contamination, water used for testing shall be obtained from a potable supply.

QCS 2014


Page 6

3

Before accepting a pipeline, a check shall be made that valve boxes are properly aligned, that suitable operating keys are provided which can be easily fitted to the valves and in the case of deep valves, that adequate extension spindles are installed.

6.3.5

Testing of Installation Within Buildings

1

When the installation is complete and visual inspection has been satisfactorily completed, it shall be slowly filled with water, with the highest draw-off point open to allow air to be expelled from the system. The installation, including all cisterns, tanks cylinders and water heaters, shall then be inspected for leaks.

2

The system shall be hydraulically tested in the following way: subject the pipes, pipe fittings and connected appliances to a test pressure at least 1.5 times the maximum working pressure for a period of at least 24 hours

(b)

check the installation for leaks; including all cisterns, tanks, cylinders and water heaters.

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Each draw-off tap, shower fitting and float-operated valve shall be checked for flow against specified requirements. Performance tests shall also be carried out on any specialist items to show that they meet the requirements detailed in the Project Documentation.

6.3.6

Back-Siphonage

1

It shall be verified that the appropriate back-flow prevention devices have been selected and that they have been installed correctly.

6.3.7

Mechanical and Electrical Equipment

1

Mechanical and electrical equipment shall be tested and commissioned in accordance with Section 9, Mechanical and Electrical Equipment.

6.4

DISINFECTION

6.4.1


1

All hot water systems and cold water systems installed shall be disinfected before being taken into use.

2

Where chlorinated water that has been used to disinfect an installation is to be discharged into a sewer, the Drainage Department shall be informed.

3

Unless otherwise stated in the Project Documentation, the Contractor is responsible for providing water for disinfection purposes.

6.4.2

Installations Outside buildings

1

At the time of laying, large bore pipes shall be brushed clean and sprayed internally with a strong solution of sodium hypochlorite.

2

At the time of laying, small bore pipes shall be swabbed with a polyurethane foam plug soaked in a strong solution of sodium hypochlorite. A water jet may be used to push the plug along the pipe.

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Page 7

Following the disinfection process, the pipe shall be regarded as operational and the Contractor shall not open or close any valves or take any other action which might interfere with the use of the pipe.

6.4.3

Installation Inside Buildings

1

All visible dirt and debris shall be removed from the cistern.

2

The cistern and distributing pipework shall be filled with clean water and then drained until empty of all water. The cistern shall be filled again and the supply closed.

3

A measured quantity of sodium hypochlorite solution of known strength shall be added to the water in the cistern to give a free residual chlorine concentration of 50 mg/litre in the water.

4

The cistern shall be left to stand for 1 hour. Then each draw-off fitting shall be successively opened working progressively away from the cistern. Each tap or draw-off fitting shall be closed when the water discharged begins to smell of chlorine. The cistern shall not be allowed to become empty during the operation; if necessary it shall be refilled and chlorinated as detailed above. Should refilling be necessary, the cistern and pipes shall be left for a further hour before continuing the disinfection procedure.

5

The tap furthest from the cistern shall be opened and the level of free residual chlorine in the water discharged from the tap shall be measured. If the concentration of free residual chlorine is less than 30 mg/l the disinfecting process shall be repeated.

6

Finally, the cistern and pipes shall remain charged with chlorinated water for at least 16 hours and then thoroughly flushed out with clean water until the chlorine concentration at the taps is no greater than that present in the clean water from the QGEWC supply main.

7

For installation with more than one cistern, all cisterns shall be cleaned and chlorinated, in accordance with paragraph 1 to 4 above, simultaneously.

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END OF PART

QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 1

7

PLUMBING FOR GASES .............................................................................. 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

Scope References Compliance Quality Assurance

7.2

MATERIALS .................................................................................................. 3

7.2.1 7.2.2

Gas System Accessories Compressed Air System Accessories

7.3

EXECUTION .................................................................................................. 5

7.3.1 7.3.2

Hangers and Supports Execution Requirements

2 2 2 2

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7

PLUMBING FOR GASES

7.1

GENERAL

7.1.1

Scope

1

The work covered in this Part consists of providing all plant, labour and materials and performing all operations in connection with gas and compressed air supply in buildings.

7.1.2

References

1


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ASME B 31.9 ..............Building Services Piping NFPA 99 .....................Health Care Facilities Compliance

1

Installation and testing of gas system shall be in accordance with NFPA 99.

2

Gas pressure vessels and relief valves shall be in accordance with the relevant ASME codes.

3

Fabrication and installation of gas systems shall be in accordance ASME B 31.9.

4

Electrical components for compressed air systems shall be listed and labelled by Underwritten Laboratories.

7.1.4

Quality Assurance

1

Manufacturers of gas and compressed air system products shall have been regularly engaged in the manufacture of such products, of the type and size specified in the Project Documentation, that have been in satisfactory use in similar service conditions for not less than five years.

2

Installation of gas and compressed air system shall be carried out by specialists with at least three years of successful installation experience of gas and compressed air systems similar to the type specified in the Project Documentation.

3

Upon completion and prior to acceptance of the installation, the contractor shall carry out operating and pressure tests at not less than 1.5 times the operating pressure, checked at half hour intervals to demonstrate satisfactory functional and operational efficiency. Such operating tests shall take place over a continuous period of not less than 8 hours for each system and shall include the following information in a report with a conclusion as to the adequacy of the system:

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7.1.3

(a)

a description of the test method including references to standard testing procedures if appropriate

(b)

time, date and duration of the test

(c)

compressed air pressure readings of the compressor at each outlet.

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Page 3

MATERIALS

7.2.1

Gas System Accessories

1

Gas cocks shall be bronze with a square head and shall have distinctly marked ON-OFF indications. They shall be pressure rated for 900 kPa (9.0 bar). The units shall conform with SSA 119 and shall be provided with an identification label. Labels shall be visible after installation. Where quick-type couplers are furnished, they shall be of the noninterchangeable type. The connector shall lock firmly into position and shall have a fingertype quick release.

2

A wrench shall be provided and attached to each cock.

3

Pressure regulators shall be in accordance with SSA 121 and shall have an adjustable diaphragm actuated by a spring-loaded pressure reducing valve, designed for liquid petroleum gas (LPG) systems. Pressure regulators shall be provided with a relief valve, and the diaphragm chamber shall be piped to the outside of the building. Pressure regulators shall be approved and marked by authorised officials recognised by a Qatari authority.

4

Shut-off valves shall be wafer type ball valves with bronze body, ball and stem, non-stick seats, seals, O-ring packing and lever handle. Shut-off valves shall have socket ends or threaded socket adapters.

5

Check valves shall be of the threaded bronze spring type with composition disc and bronze spring or of the silent double-centre guided conical spring type.

6

Safety relief valves shall have a spring-loaded shuttle with a pressure adjustment corresponding to the highest permissible working pressure of the cylinder.

7

Pipe failure valves shall have a spring-loaded shuttle suitable to shut off the flow of the gas if the rate of flow is too high.

8

Pressure gauges shall be a black enamel cast iron or cast aluminium case, chromium plated brass ring with a heavy glass, phosphor bronze bushed rotary precision movement, and a dial with a suitable pressure range.

7.2.2

Compressed Air System Accessories

1

Air compressors shall be of the reciprocating air cooled type.

2

Compressors shall consist of replaceable finned cast iron cylinders, flanged cast iron or cast aluminium heads, cast iron or cast aluminium pistons with rings made of carbon or non-stick and forged steel, bronze or aluminium connecting rods. Crank cases shall be made of cast iron. Each compressor shall have an automatic unloader system for no-load start up, a positive pressure lubricating system and stainless steel strip valves

3

Compressors and motors shall be direct-connected or operated by means of a V-belt drive, and provided with guard for flywheel and belts.

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Motors shall be of the single-phase type or the three-phase type. Motors shall be standard open frame, drip proof, ball bearing 40ºC rise NEMA standard design “B” induction type. Single-phase motors shall have grease lubricated ball bearings and built-in overload. Threephase motors shall have rigid base mounting with slide rails for belt adjustment. Motor voltage shall be as given in the Project Specification.

5

Air receivers shall be suitable for the specified system working pressure, designed and constructed in accordance with the relevant ISO Standards.

6

Air receivers shall be provided with condensate drain trap, relief valve, pressure gauge, and welded steel supporting feet.

7

The outside of air receivers shall either be galvanised or supplied with a commercial enamel finish.

8

Air dryer units shall be of the package assembled type with a cabinet enclosing refrigeration unit, hot bye-pass valve, heat exchanger, moisture separator, chiller section with replaceable type cartridge filter, temperature and pressure gauges, controls and condensate drain trap.

9

Refrigeration units shall be of the hermetically sealed compressor type with air cooled condenser.

10

The cabinets shall be made of steel and finished with commercial enamel, and provided with top-hinged access door and front panel for easy access.

11

Control valves shall be of the top entry or wafer type ball valve with bronze body, ball and stem, non-stick seats, and lever handles with socket ends or threaded socket adapters.

12

Check valves shall be of the threaded bronze spring type with composition disc and bronze spring or of the silent double-centre guided conical spring type.

13

Pressure regulating valves shall be of the adjustable, direct-acting, single-seat, springactuated diaphragm type, or of the double-seated valve plug type, the body shall be made of cast iron, die cast zinc or bronze.

14

The regulator shall be provided with an adjustment device for adjusting pressure differential, and shall be of the same size as the pipe.

15

The filter regulator units shall consist of a bronze or die cast zinc body, actuated by an adjustable direct-acting single-seat spring diaphragm type regulator.

16

The filter regulator units shall be provided with filter units, suitable to filter the supply air of particles down to fine micron size, and pressure gauges.

17

Pressure gauges shall have a black enamel cast iron or cast aluminium case, a chromium plated brass ring with a heavy duty glass cover, a phosphor bronze bushed rotary precision movement, and a dial with a suitable pressure range.

18

Drains shall be the brass pre-cock type in low points of the compressed air system, or the automatic drain type.

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EXECUTION

7.3.1

Hangers and Supports

1

Hangers in contact with copper tubing shall be electrolytically coated and shall be sized to suit the outside diameter of the pipe.

7.3.2

Execution Requirements

1

For gas systems only copper tubing shall be used. Joints shall be made either by soldering or welding. Jointing material shall be suitable for soldering and welding gas pipes.

2

No gas piping shall be installed under any building or structure and all exposed gas piping shall be kept at least 150 mm above the ground.

3

When stand-by gas is connected to the gas piping system, an approved three-way, two-part valve or other adequate safeguard shall be installed to prevent backflow into either supply system.

4

An accessible shut-off valve shall be installed in the gas piping system near each appliance and the head of the union connection thereto, and in addition to any valve on the appliance. Shut-off valves shall be within 1.0 m of the appliance. Shut-off valves may be located immediately adjacent to and inside or under an appliance when placed in an accessible and protected location and when such appliance may be removed without removal of the valve.

5

Appliance connections shall, at no time, have a diameter less than that of the inlet connection to the appliance as provided by the manufacturer.

6

Compressed air piping shall be copper steel, installed free of traps and graded to low points with condensate drain pet-cocks, or automatic condensate drain traps, as required in the Project Specification or shown on the Project Drawings.

7

Compressors shall start unloaded and shall start and stop automatically by means of an enclosed diaphragm-type pressure switch mounted on the unit.

8

Guards shall be provided for all exposed moving parts.

9

After cooler and moisture separator shall be installed between the compressor and the air receiver to remove moisture and oil condensate before the air enters the receiver, except where air dryers are installed.

10

Vacuum cleaning piping shall be made of plastic or steel and shall slope to the separator free of traps. Changes in the direction of piping shall be made by using 45 degree bends or long turn tees or bends, and shall be slip jointed.

11

Drop lines shall be connected from side or top of horizontal lines only.

12

Cleanout plugs shall be provided at all changes in direction and/or as indicated in the Project Specification or shown on the Project Drawings.

13

Floor mounted vacuum inlet valves shall be flush with floor finish.

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Page 6

The vacuum producer unit shall be provided with rubber inlet sleeve and stainless steel clamps for connecting unit to piping.

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END OF PART

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QCS 2014

Section 20: Drainage Works for Buildings Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

REGULATIONS AND STANDARDS .............................................................. 2

1.2.1

Public Works Authority

1.3

CONTRACTOR’S RESPONSIBILITY ............................................................ 2

1.3.1 1.3.2 1.3.3

General Existing Services Maintenance Period Requirements

1.4

CRAFTSMEN................................................................................................. 2

1.4.1 1.4.2

Workmanship Qualifications

1.5

MATERIALS................................................................................................... 3

1.5.1

General

1.6

DRAWINGS ................................................................................................... 3

1.6.1 1.6.2 1.6.3

Shop Drawings Co-ordination Drawings As-Built Record Drawings and Survey Drawings

1.7

SITE WORKS ................................................................................................ 4

1.7.1

Co-operation with other Trades

2 2

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Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for the construction and installation of drainage works for buildings. It does not include highway drainage.

2

Related Sections are as follows: Section 1

General

References

1


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BS 8000......................Workmanship on building sites

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1.1.2

REGULATIONS AND STANDARDS

1.2.1

Public Works Authority

1

The Contractor shall carry out his work in accordance with the relevant requirements of the Public Works Authority.

1.3

CONTRACTOR’S RESPONSIBILITY

1.3.1

General

1

The Contractor is responsible for obtaining all necessary approvals and permits required to complete the parts of the Works included in this Section.

1.3.2

Existing Services

1

The Contractor is responsible for locating and identifying all existing services that may affect, or be affected by, the construction of the parts of the Works included in this Section.

1.3.3

Maintenance Period Requirements

1

The Contractor is responsible for all the maintenance period requirements for all parts and components of the Works included in this Section.

1.4

CRAFTSMEN

1.4.1

Workmanship

1

Workmanship shall comply with the relevant provisions of BS 8000.

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Page 3

Construction of each part of the Works covered in this Section shall be undertaken by experienced craftsmen capable of performing the tasks allocated to them in a professional and competent manner.

3

If required by the Engineer, the Contractor shall instruct craftsmen to demonstrate their ability to perform tasks allocated to him.

1.4.2

Qualifications

1

Where the Project Documentation specifies that specialist craftsmen are required to undertake a specific work task, the Contractor shall furnish the Engineer with copies of qualifications pertinent to performing such work tasks for those craftsmen who will be undertaking the work.

1.5

MATERIALS

1.5.1

General

1

All materials, components and products shall comply with the relevant provisions of Section 1, General.

2

All materials, components and products shall be supplied by experienced manufacturers as designated in the Project Documentation or to the written approval of the Engineer.

1.6

DRAWINGS

1.6.1

Shop Drawings

1

The Contractor shall prepare shop drawings for all parts of the Works to be installed or constructed under this Section and submit them to the Engineer in accordance with the relevant provisions of Section 1, General. The shop drawings shall include diagrams, illustrations, schedules, general arrangements of equipment and appurtenances in relation to buildings and structures, method statements and details of specialised installation and construction work.

1.6.2

Co-ordination Drawings

1

These shall be prepared by the Contractor to show how interdisciplinary work will be coordinated. The location, size and details of fixings, box-outs, ducts, holes, pipe chases and plinths shall be shown on the detailed layout drawings which shall be fully co-ordinated with all other work disciplines.

1.6.3

As-Built Record Drawings and Survey Drawings

1

The Contractor shall prepare Record Drawings of all works constructed or installed under this Section in accordance with the relevant provisions of Section 1, General. These shall be prepared as work proceeds. They shall provide a record of any modification to materials and equipment, and to the layout, arrangement and installation of the Works.

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1.7

SITE WORKS

1.7.1

Co-operation with other Trades

1

The Contractor shall so organise work progress to harmonise with the work of all trades so that work may proceed as expeditiously as possible. The Contractor shall be responsible for the correct placing of the Works and the connection thereof to the work of all related trades.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 1

2

INTERNAL DRAINAGE WORKS ................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8

Scope Reference Contractor’s Responsibility System Description Site Work Fixing Sealants Inspection

2.2

INTERNAL DRAINAGE PIPEWORK ............................................................. 4

2.2.1 2.2.2

General Materials

2.3

LABORATORY DRAINAGE SYSTEMS ......................................................... 4

2.3.1

General

2.4

GULLIES ........................................................................................................ 5

2.4.1

Floor Gullies

2.5

ACCESS TO DRAINS .................................................................................... 5

2.5.1

General

2.6

ROOF TERMINATION ................................................................................... 5

2.6.1

Ventilating Pipes and Stack Vents

2.7

PUMPING FACILITIES .................................................................................. 6

2.7.1

Sump Pumps

2.8

SANITARYWARE INSTALLATIONS ............................................................. 6

2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7 2.8.8 2.8.9 2.8.10 2.8.11

General Pedestal WC Pans Squat Type Toilet Flushing Cisterns for Toilets Slab Urinals Bowl Urinals Wash-basins Sinks Showers Taps Traps

4 4

4

5

5

5

6

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Page 2

INTERNAL DRAINAGE WORKS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements for internal drainage pipework, internal drainage systems and sanitary appliances.

2


General Sewerage Mechanical and Electrical

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General Commissioning of Systems

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Reference

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BS 416........................Discharge and ventilating pipes and fittings, sand-cast or spun in cast iron BS 437........................Specification for cast iron spigot and socket drain pipes and fittings

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BS 539........................Dimensions of fittings for use with clay drains and sewer pipes

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BS 1010......................Specification for draw-off taps and stopvalves for water services (screw-down patterns) BS 1125......................WC flushing cisterns

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BS 1184......................Specification copper and copper alloy traps

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BS 1188......................Ceramic wash basins and pedestals BS 1206......................Fireclay sinks. Dimensions and workmanship

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BS 1212......................Float operated valves BS 1244......................Metal sinks for domestic purposes BS 1254......................Specification for WC seats (plastics) BS 1255......................WC seats (plastics) BS 2456......................Specification for floats (plastics) for ballvalves for hot and cold water BS 3402......................Quality of vitreous china sanitary appliances BS 4514......................Unplasticized PVC soil and ventilation pipes, fittings and accessories BS 5254......................Polypropylene waste pipe and fittings (external diameter 34.6 mm, 41.0 mm and 54.1 mm) BS 5255......................Thermoplastics waste pipe and fittings BS 5503......................Specification for vitreous china washdown WC pans with horizontal outlet BS 5572......................Sanitary Pipework BS 5889......................One-part gun grade silicone-based sealants

QCS 2014


Page 3

BS 8313......................Code of Practice for accommodation of building services in ducts Contractor’s Responsibility

1

The Contractor is responsible for checking the dimensions of all internal drainage works to be installed against the availability of space at their intended installation location.

2.1.4

System Description

1

Internal drainage systems shall generally conform to the relevant provisions of BS 5572.

2

Internal drainage systems shall comprise the minimum pipework necessary to carry away the discharges from sanitary appliances in buildings quickly and quietly.

3

Drainage pipework installations shall be such that there is no leakage of contaminated water or foul air into the building.

4

Drainage systems, including materials, joints, supports and fixings shall be durable under the expected operating conditions.

5

Pipework and fittings in drainage systems shall be installed so that defective parts can be replaced without undue difficulty.

2.1.5

Site Work

1

A check should be made to ensure that all holes, chases and ducts required for pipework have been properly provided in accordance with the relevant provisions of BS 8313.

2

Where several pipes pass through floors in close proximity, the Contractor may provide a single framed opening in lieu of individual sleeves. Framed openings shall be to the approval of the Engineer and shall be provided with 100 mm high curbs, on all sides.

2.1.6

Fixing

1

Water supply and discharge pipes should be installed before sanitary appliances are fixed. Before fixing an appliance into position, the Contractor shall ensure that the discharge pipe is clear of obstruction. Joints between appliances and traps and/or pipes should be of the union or detachable type.

2

Sinks and baths should be installed so that they drain to the outlet by gravity.

3

Cistern overflow pipes should be arranged to give a visible warning of discharge.

2.1.7

Sealants

1

Sealants shall comply with the relevant provisions of BS 5889, type B (high modulus sealant) with a fungicide incorporated. The sealant should be applied using a purpose made gun or devise.

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Page 4

Inspection

1

Upon completion of the work, all appliances, materials and workmanship should be carefully examined for defects and for faults in installation. Any defects or faults shall be corrected before the appliances are handed over for use.

2.2

INTERNAL DRAINAGE PIPEWORK

2.2.1

General

1

Pipes and fittings used shall be suitable for their purpose.

2

If pipes, pipe joints and pipe fittings are of dissimilar metals, measures shall be taken to prevent electrolytic corrosion.

3

The Contractor shall comply with all the recommendations of manufacturers when jointing pipes of different materials.

2.2.2

Materials

1

Soil, waste and ventilating pipes, fittings and accessories for above ground drainage systems shall comply with the relevant provisions of the appropriate standard, as set out in Table 2.1.

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2.1.8

Material

Standard

Cast Iron

BS 416, Parts 1 and 2

PVC-U (soil and ventilating)

BS 4514

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Table 2.1 Standards for pipes, fittings and accessories for above ground drainage systems

BS 5254

Plastic (waste)

BS 5255

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Internal drainage pipes and fittings for below ground applications shall comply with the relevant provisions of Section 8, Sewerage.

2.3

LABORATORY DRAINAGE SYSTEMS

2.3.1

General

1

The chemical resistance properties of pipes, fittings, jointing systems and any other drainage accessory shall be suitable for conveying all solutions expected to be discharged to the drainage system. Where possible, technical advisory services provided by manufacturers shall be used to ascertain the suitability of products to be used in the drainage system. A full list of the solutions expected to be discharged to the drainage system is given in the Project Documentation.

QCS 2014


Page 5

Drainage systems for the collection of solutions which are not permitted to be discharged to existing drainage facilities shall be kept totally separate form other drainage systems.

3

Drainage systems to which grit, gravel, sand or other granular material shall be discharged shall have sufficient abrasion resistance properties and be fitted with suitable traps and catch basins.

2.4

GULLIES

2.4.1

Floor Gullies

1

Floor gullies shall comply with the requirements of the following paragraphs unless otherwise detailed in the Project Documentation.

2

Floor gullies shall be coated cast iron and comply with the relevant provisions of BS 539. They shall have a 90 mm diameter trapped outlet and be fitted with a galvanised flat grating of an approved type.

3

Floor drains shall be selected with sufficient grate free area to pass the anticipated flow. The grate free area is defined as the total area of the drainage openings in the grate and shall be not less than 1.5 times greater than the pipe to which the grate is draining.

4

With the exception of those located in toilets, all floor drains fitted with traps shall incorporate a removable bucket.

5

The gully should be installed on a firm base and located relative to the floor finish. The method of fixing shall be as detailed in the Project Documentation.

2.5

ACCESS TO DRAINS

2.5.1

General

1

Sufficient and suitable access should be provided to enable all pipework to be tested and maintained effectively. Access covers, plugs or caps should be sited so as to facilitate the insertion of testing apparatus and the use of equipment for cleaning and/or for the removal of blockages. The use of apparatus or equipment should not be impeded by the structure or other services.

2

Access points should not be located where their use may give rise to nuisance or danger if spillage occurs.

2.6

ROOF TERMINATION

2.6.1

Ventilating Pipes and Stack Vents

1

Ventilating pipes and stack vents shall terminate with a domical cage or other cover that does not restrict air flow. They shall be positioned so that foul air does not cause a nuisance or health hazard.

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Page 6

PUMPING FACILITIES

2.7.1

Sump Pumps

1

Sump pumps shall comply with the relevant provisions of Section 9, Mechanical and Electrical Equipment.

2.8

SANITARYWARE INSTALLATIONS

2.8.1

General

1

Sanitary fittings shall, unless otherwise stated in the Project Documentation, be as described in the following Clauses.

2

Where screws are used to fix sanitary appliances to concrete, blockwork or brickwork they shall be rust-proofed steel and plugged.

2.8.2

Pedestal WC Pans

1

Pedestal WC pans shall be of white glazed fireclay and shall comply with the relevant provisions of BS 5503. They shall have P, Q or S traps as required. WC seats shall be black plastic and shall comply with the relevant provisions of BS 1254. The traps shall be provided with antisyphonage outlets, where required

2

Where pans are fixed to timber floors they shall be jointed to the drain pipe with hemp gaskin and red lead putty. Where pans are fixed to concrete floors, they shall be jointed to the drain pipe with cement/sand mortar mixed in a 1:2 ratio. The pans shall be screwed to the floor.

2.8.3

Squat Type Toilet

1

Squat type toilets shall comprise a closet of white vitreous china complying with the relevant provisions of BS 3402 for sinking into the floors and integral or separate tread plates in a matching material. They shall have P, Q or S trap as required. The traps shall be provided with antisyphonage outlets, where required.

2

The closets and tread plates shall be set into a concrete bed with the top surface level with the floor finish.

2.8.4

Flushing Cisterns for Toilets

1

Flushing cisterns shall be black plastic or white vitreous china complying with the relevant provisions of BS 1125 and shall be the single flushing type. They shall be fitted with a nylon or brass ball valve complying with the relevant provisions of BS 1212 with a plastic float complying with the relevant provisions of BS 2456. They shall have connections for 12 mm diameter supply and 20 mm diameter overflow pipes. Flush pipes complying with the relevant provisions of BS 1125 shall be provided and shall be of galvanised mild steel.

2

Flush pipes shall be jointed to the bottom of the cisterns by means of watertight unions which allow for easy removal and shall be jointed to WC pans by means of approved rubber cone connectors. The cisterns shall be fixed to walls with screws.

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Page 7

High level cisterns shall be provided with chromium plated chains with rubber pull handles. They shall be fixed a height of 1500 mm from finished floor level to the underside of the cistern. Flush pipes shall be 30 mm diameter and shall be fixed with pipe clips which shall be screwed to walls.

4

Low level cisterns shall be provided with chromium plated lever flushing handles. They shall be fixed at a height of 600 mm from finished floor level to the underside of the cistern. Flush pipes shall be 35 mm diameter.

2.8.5

Slab Urinals

1

Urinal slabs shall be white glazed fireclay and shall have end screens. All urinals shall have a white glazed fireclay floor channel and white glazed fireclay fluted treads set flush with the floor finish. The channel shall have a 40 mm diameter chromium plated brass outlet with hinged grating.

2

The urinal slabs, channel and floor treads shall be bedded in cement mortar and jointed and painted with white cement. The flushing cistern shall be a white glazed fireclay automatic flushing cistern, complete with cover, and shall be fixed on white porcelain enamelled cast iron brackets which shall be screwed to the wall.

3

Flush pipes and spreaders shall be chromium plated and shall be fixed to walls with chromium plated holderbats. A 40 mm diameter trap with 40 mm or 75 mm deep seal as necessary shall be provided.

2.8.6

Bowl Urinals

1

Urinals bowls shall be white glazed fireclay with lipped basin and flushing rim. Urinal bowls shall be screwed to the wall. Flushing cisterns, flushing pipes and spreaders shall be as described for slab urinals. The bowl urinals shall be complete with chromium plated brass outlet and trap.

2.8.7

Wash-basins

1

Wash-basins shall be white glazed fireclay size 625 mm x 450 mm overall and shall comply with the relevant provisions of BS 1188. Each basin shall be provided with a 30 mm diameter chromium plated waste outlet and rubber plug with a chromium plated chain and stay.

2

A 30 mm diameter trap shall be fixed to each basin having a 40 mm deep seal and one or two 12 mm pillar taps shall be fixed as required. Where only one tap only is required, the basin shall be provided with a tap hole stopper to match the basin. Unless otherwise specified, each wash-basin shall be fixed on two cast iron brackets complying with the relevant provisions of BS 1255 which shall be screwed to the wall. If required the pedestal WC pan shall match the basin.

2.8.8

Sinks

1

Ceramic sinks shall be white glazed fireclay size 600 mm x 450 mm x 250 mm deep and shall comply with the relevant provisions of BS 1206.

2

Metal sinks shall be stainless steel or aluminium to the sizes stated in the Project Documentation and shall comply with the relevant provisions of BS 1244.

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Page 8

Each sink shall be provided with a 40 mm chromium plated brass waste outlet, outlet grating, overflow and rubber plug with chromium plated chain and stay. A 40 mm diameter trap shall be fixed to each sink having a 40 mm or 75 mm deep seal as necessary. Each sink shall have one or two 12 mm diameter pillar or bib taps, as required. Where only one tap is required, a tap hole stopper to match the sink shall be provided. Pillar taps shall have 150 mm raising pieces and bib taps shall have extension pieces of adequate length.

4

Sinks shall be supported and fixed on brackets or legs unless otherwise specified in the Project Documentation. Two cast iron brackets shall be used for sinks supported and fixed on brackets. The brackets shall comply with the relevant provisions of BS 1255 and shall be screwed to the wall. Legs for supporting sinks shall be of cast iron or galvanised steel with a painted finish. Sinks shall be fixed at a height of 550 mm from the outlet grating to finished floor level.

2.8.9

Showers

1

Shower fittings shall comprise a 100 mm diameter adjustable chromium plated brass inclined shower head with rose and 12 mm diameter supply pipe(s) with 12 mm diameter stop valve(s) to control the water supply.

2

The shower head shall be fixed a height of 1800 mm above the finished floor level. All exposed pipework and fittings serving the showers within the shower area shall be chromium plated and fixed with chromium plated holderbats.

2.8.10

Taps

1

All taps shall comply with the relevant provisions of BS 1010. Taps shall be of the following type as appropriate and, where necessary, shall be provided with extension pieces.

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pillar taps shall be 12 mm diameter chromium plated brass with cross heads. bib taps, unless otherwise stated, shall be 12 mm diameter chromium plated brass with cross heads, complete with backplate elbow or wall flange. Bib taps to stand pipes shall be 12 mm diameter unplated brass, and shall have an extended nozzle suitable for hose connections.

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Traps

1

Traps shall be of the following types:-

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2.8.11

(a)

(b)

(c)

traps for sinks, lavatory basins and baths shall be copper, brass, or aluminium complying with the relevant provisions of BS 1184, complete with cleaning eye. Traps to sinks, baths shall have an overflow connection. traps for urinals with suspended drains shall be 75 mm diameter cast iron complying with the relevant provisions of BS 416, Table 14. They shall be fitted with cast iron connectors and threaded to receive the outlet from the urinal. traps for urinals with buried drainage shall be 75 mm diameter cast iron complying with the relevant provisions of BS 437. They shall be fitted with cast iron connectors and threaded to receive the outlet from the urinal. END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 03: External Drainage Works

Page 1

3

EXTERNAL DRAINAGE WORKS .................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3


3.2

PIPEWORK.................................................................................................... 3

3.2.1 3.2.2 3.2.3 3.2.4

General Vitrified Clay Pipework Unplasticized Polyvinyl Chloride (PVC-U) Pipework Testing of Pipework

3.3

ACCESSORIES ............................................................................................. 3

3.3.1

Gullies and Gully Gratings

3.4

CONNECTION TO EXISTING PIPELINES .................................................... 4

3.4.1

Connections to Existing Government Mains

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Page 2

EXTERNAL DRAINAGE WORKS

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for pipework and accessories for external drainage works in building areas. External drainage works includes foul water sewerage and surface water sewerage.

2



General Concrete Roadworks Sewerage

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References

1


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3.1.2

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BS 2494......................Elastomeric seals for joints in pipework and pipeline BS 4346 .....................Joints and fittings for use with unplasticized PVC pressure pipes.

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BS 4660......................unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal sizes 110 and 160 for below ground drainage and sewage

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BS 5481......................Unplasticized PVC pipe and fittings for gravity sewers BS 6209 .....................Solvent cement for non-pressure thermoplastic pipe systems

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BS EN 295 .................Vitrified clay pipes and fittings and pipe joints for drains and sewers

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ISO 4633 ....................Rubber Seals -Joints rings for supply, drainage System Description

1

Pipes and fittings to be used for foul sewerage shall be suitable for carrying sewage at temperatures of up to 45C with hydrogen sulphide concentrations up to 400 mg/l.

2

Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting the following characteristics unless otherwise specified:

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3.1.3

SO3 Content CI Content pH Conductivity 3

: : : :

1.7 g/l 1.07 g/l 8.6 4000 s/cm

The Contractor shall be responsible for providing a jointing system as recommended by the pipe manufacturer that enables the installation and use of the designated pipeline systems.

QCS 2014


Page 3

PIPEWORK

3.2.1

General

1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system.

2

Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water and the ingress of effluent when subject to ground movement and settlement.

3.2.2

Vitrified Clay Pipework

1

Vitrified clay pipes and fittings for drains and sewers shall comply with the relevant provisions of BS EN 295.

2

Pipes shall have spigot and socket joints complying with the relevant provisions of BS EN 295. Joints shall have elastomeric joint seals. Complying with the relevant provision of ISO 4633 or, BS 2494 (Type D) and shall be obtained from the pipe manufacturer. For pipes up to 150 mm diameter, push-fit (sleeve type) polypropylene flexible couplings may be used in place of spigot and socket joints.

3

All other requirements related to the manufacture, inspection and testing of vitrified clay pipes shall be in accordance with the relevant provision of Section 8, Sewerage.

3.2.3

Unplasticized Polyvinyl Chloride (PVC-U) Pipework

1

PVC-U pipe joints and fittings for gravity drains and sewers shall comply with the relevant provisions of BS 4660 or 5481.

2

Joints shall have elastomeric joint seals complying with the relevant provisions of ISO 4633 or BS 2949 (Type D) and shall be obtained from the pipe manufacturer.

3

Solvent cements for jointing PVC-U pipes shall comply with BS 4346. For pipes and fittings complying with BS 4660, solvent cement may alternatively comply with BS 6209.

4

All other requirements related to the manufacture, inspection and testing of PVC-U pipes shall be in accordance with the relevant provisions of Section 8, Sewerage.

3.2.4

Testing of Pipework

1

Internal and external pressure tests shall be carried out on external drainage pipes. Test procedures are detailed in Part 6 of this Section.

3.3

ACCESSORIES

3.3.1

Gullies and Gully Gratings

1

Gullies and gully gratings shall comply with the relevant provisions of Section 6, Roadworks.

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CONNECTION TO EXISTING PIPELINES

3.4.1

Connections to Existing Government Mains

1

Connections to existing Government mains shall comply with the relevant provisions of Section 8, Sewerage, and the following clauses.

2

Where possible and practicable, connections shall be made to future connection ports in existing Government manholes. The caps on future connection ports to which connections are made shall be cleaned and delivered to the government stores in accordance with he relevant provisions of Section 1, General.

3

Where it is not possible of practicable to utilise future connection ports in existing manholes, connections shall be made by either breaking into existing manholes or constructing new manholes on existing mains.

4

If it is necessary to break into an existing manhole, the Contractor shall break into the manhole wall, insert pipework, break out the existing benching, construct benching to suit new connection and make good. If necessary, the Contractor shall relocate the access ladder and the cover slab to suit the new benching layout.

5

Manholes built on an existing Government mains shall be constructed in accordance with Clause 6 of this Part. On completion, such manholes shall become the property of the government.

6

The Contractor shall be responsible for all over-pumping operations associated with making connections to Government mains.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 1

4

DRAINAGE PIPES IN TRENCHES ............................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2

Scope References

4.2

LAYING OF DRAINAGE PIPES IN TRENCHES ........................................... 2

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9

System Description General Bedding Protective Coatings Concrete Protection to Pipes Completion of Pipe Surround Backfilling Protective Coatings Pipes under Buildings

4.3

ACCESS TO DRAINAGE PIPES IN TRENCHES .......................................... 5

4.3.1 4.3.2 4.3.3

General Rodding Eyes Provision of Access to Drains

4.4

TESTING ....................................................................................................... 6

4.4.1

Testing of Pipework

2 2 3 3 4 4 4 5 5

5 5 5

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Page 2

DRAINAGE PIPES IN TRENCHES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for trenches and bedding for drainage pipes constructed internally and externally.

2



General Concrete Sewerage

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References

1


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4.1.2

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BS 743........................Materials for damp-proof courses. BS 882 Aggregates from natural sources for concrete

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BS 1142......................Fibre building boards BS 2494 Specification for elastomeric joint rings for pipework and pipeline

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BS 6076......................Tubular polythene film for use as a protective sleeving for buried iron pipes and fittings

LAYING OF DRAINAGE PIPES IN TRENCHES

4.2.1

System Description

1

The laying of drainage pipes in trenches shall generally be in accordance with the relevant provisions of Section 8, Sewerage.

4.2.2

General

1


2


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Page 3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding for the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving. Where rock is encountered, the trench shall be cut at least 150 mm deeper than other ground and made up with well compacted selected fill material.

4


5


6


4.2.3

Bedding

1

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the whole width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipe, and where practicable, this shall be done in sequence with the removal of the trench supports.

2

Bedding material shall be in accordance with Table 4.1 unless otherwise specified in the Project Documentation.

3

Nominal single sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.

4

Sand for bedding material shall comply with the relevant provisions of BS 882.

5

Bedding systems other than those specified in this Clause may be allowed upon approval of the Engineer or as recommended by the pipe manufacturer.

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Table 4.1 Bedding Material

Pipe Diameter

Bedding

up to 65 mm

Sand

65 - 100 mm

10 mm single sized aggregate

100 - 200 mm

10 or 14 mm single sized or 14-15 mm graded aggregate

Over 200 mm

10,14 or 20 mm single sized or 15-5 or 20-5 mm graded aggregate.

4.2.4

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuos before trench excavations are backfilled.

QCS 2014


Page 4


1


2


3

Where pipes with flexible joints are used, the concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 4.2.

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Table 4.2 Thickness of Compressible Filler

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4.2.5

Thickness of Compressible Filler (mm)

Up to 300

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6

Concrete work shall comply with the relevant provisions of Section 5, Concrete.

4.2.6


1


4.2.7

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the parts of the Works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

2


3

Filling material to excavations shall be deposited in layers not exceeding 250 mm unconsolidated thickness and compacted to 95% modified proctor.

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Page 5


4.2.8

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuos before trench excavations are backfilled.

4.2.9

Pipes under Buildings

1

Where a pipe has less than 300 mm of cover under a load bearing slab, it should be surrounded with concrete as an integral part of the slab. Where possible, the concrete surround shall be poured at the same time as the slab. The surround shall be tied to the slab with nominal steel reinforcement placed vertically with turned over ends.

2

No provision for pipe flexibility along the concrete surround shall be made, unless an expansion joint is included in the slab. A construction joint should be included in the surround at that point which must also coincide with a pipe joint.

3

In normal, stable ground conditions, and with 300 mm or more of cover to the pipeline beneath the slab, a total granular surround can be used as a pipe bedding. Refer to Clause 4.2.3 of this Part for the bedding specification.

4

Flexibility shall be incorporated into the pipeline as it leaves any concrete surround.

5

Where plastic pipes are to be surrounded in concrete, Clause 4.2.5 of this Part shall apply.

4.3

ACCESS TO DRAINAGE PIPES IN TRENCHES

4.3.1

General

1

Access is required to drainage installations for testing, inspection, maintenance and removal of debris.

4.3.2

Rodding Eyes

1

Rodding eyes shall be constructed in pipework of the same diameter as the drains it serves and should connect to the drain at an angle not steeper than 45 from the horizontal.

4.3.3

Provision of Access to Drains

1

Every drain length should be accessible for maintenance and rodding without the need to enter buildings. Access should be provided at the head of each run of a drain and at changes in direction, gradient or pipe diameter.

2

Table 4.3 indicates the recommended maximum distance between rodding eyes, inspection chambers and manholes.

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QCS 2014

3


Page 6

Where a branch drain joins another drain without the provision of an inspection chamber or manhole at the junction, access should be provided on the branch drains within 12 m of the junction. Table 4.3 Maximum Spacings of Access Points from Junction or Branch

from Inspection Chamber

from Manhole

-

22 m

45 m

rodding eye

22 m

45 m

45 m

inspection chamber

22 m

45 m

45 m

manhole

45 m

45 m

90 m

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start of external drain

.

Distance to

TESTING

4.4.1

Testing of Pipework

1

Pressure tests shall be carried out on below ground plumbing pipes. Test procedures are detailed in Part 6 of this Section.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 05: Structures Related to Drainage Work

Page 1

5

STRUCTURES RELATED TO DRAINAGE WORK ....................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3 5.1.4

Scope References Concrete Work Pipes built into structures

5.2

CONSTRUCTION OF MANHOLES, CHAMBERS AND SOAKAWAYS ........ 2

5.2.1 5.2.2

General Soakaways

5.3

PRECAST CONCRETE MANHOLES ............................................................ 3

5.3.1 5.3.2

General Jointing of Precast Manholes

5.4

TESTING OF STRUCTURES RELATED TO DRAINAGE WORK ................. 3

5.4.1

General

2 2 2 2

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5

STRUCTURES RELATED TO DRAINAGE WORK

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for the construction of manholes, chambers and soakaways for drainage works.

2

Related Section and Parts are as follows: This Section

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General External Drainage Works Commissioning of Systems

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References

1


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PWA Developer’s Drainage Guide

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5.1.2

Concrete Work

1

Concrete for manholes, chambers and soakaways shall comply with the relevant provisions of Section 5, Concrete.

5.1.4

Pipes built into structures

1

Where pipes are built into concrete, they shall be rigidly secured in position to prevent movement and shall be free from external coatings which might adversely affect the bond.

5.2

CONSTRUCTION OF MANHOLES, CHAMBERS AND SOAKAWAYS

5.2.1

General

1

The construction of manholes and chambers for drainage works for foul sewage and surface water sewage shall comply with the relevant provisions of the following:

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5.1.3

(a)

Section 8 of this Specification, Sewerage

(b)

PWA - Developer’s Drainage Guide

5.2.2

Soakaways

1

Soakaways for surface water sewage shall comply with the relevant provisions of Section 6, Roadworks, except as amended in this Part.

QCS 2014


Page 3

Soakaways shall not be constructed closer than 5 m from a building or in a position where the ground below foundations is likely to be affected.

3

Precast concrete soakaways shall be dry jointed.

5.3

PRECAST CONCRETE MANHOLES

5.3.1

General

1

Precast concrete manholes shall comply with the relevant provisions of the PWA, except as amended in this Part.

5.3.2

Jointing of Precast Manholes

1

The jointing material for precast manholes shall be mortar or a proprietary bitumen or resin mastic sealant, with the concrete surfaces primed with an appropriate sealant. The jointing material which is extruded inside the manhole shall be trimmed off and joints pointed on completion.

2

Units which bed onto bases shall be manufactured so that imposed vertical loads are transmitted directly via the full wall thickness of the unit.

3

For joints between units and the underside of slabs, joint profiles shall be capable of withstanding applied loadings from such slabs. Spigot ended sections shall only be used where the soffit of the slab is recessed to receive them.

5.4

TESTING OF STRUCTURES RELATED TO DRAINAGE WORK

5.4.1

General

1

Testing of structures related to drainage work shall be done in accordance with the relevant provisions of Part 6 of this Section.

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END OF PART

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 1

6

SURFACE WATER DRAINAGE .................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6

Scope References Submittals Pipe Marking Handling and Storage Quality Assurance

6.2

PIPEWORK.................................................................................................... 4

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

General Vitrified Clay Pipework Unplasticized Polyvinyl Chloride (PVC-U) Pipework Reinforced Concrete Pipes Testing of Pipework

6.3

PIPE LAYING................................................................................................. 5

6.3.1 6.1.1 6.3.2 6.3.3 6.3.4

General Pipe Bedding Concrete Protection to Pipes Completion of Pipe Surround Backfilling

6.4

GULLIES AND DRAINAGE CHANNELS ....................................................... 7

6.4.1 6.4.2 6.4.3

Gullies Pre-formed Gullies Drainage Channels

6.5

SOAKAWAYS ................................................................................................ 8

6.5.1


8

6.6

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QCS 2014

MANHOLES AND CATCH PITS .................................................................... 8

6.6.1


8

6.7

CONNECTION TO GOVERNMENT MAIN .................................................... 9

6.7.1


4 4 5 5 5 5 6 6 6 6 7 7 8

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Page 2

SURFACE WATER DRAINAGE

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirement for pipework, gullies, manholes, catch pits, soakaways and other items related to surface water drainage.

2


Section 5

Concrete

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References

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BS 65.......................... Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for use solely with surface water pipes and fittings BS 497........................Manhole covers, road gully grating and frames for drainage purposes

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BS 743........................Materials for damp-proof courses

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BS 1142......................Fibre building boards BS 1247......................Manhole steps

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BS 2494......................Elastomeric seals for joints in pipework and pipelines

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BS 4660......................unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal sizes 110 and 160 for below ground gravity drainage and sewerage BS 6076......................Tubular polythene film for use as protective sleeving for buried iron .................................. pipes and fittings

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6

BS 5481......................unplasticized PVC pipe and fittings for gravity sewers BS 5911......................Precast concrete pipes, fittings and ancillary products BS EN 124 .................Gully tops and manhole tops for vehicular and pedestrian areas BS EN 295 .................Vitrified clay pipes and fittings and pipe joints for drains and sewers.

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Page 3

6.1.3

Submittals

1

The Contractor shall order materials to suit the construction programme and obtain the Engineer’s approval of submittals before placing orders. The Contractor shall submit two copies of the following documents for the approval of the Engineer.

originals of catalogues and engineering data sheets for manufactured items; each item and option to be provided shall be clearly marked and each item not to be provided shall be deleted

(ii)

literature to show that products provided meet the requirements for material, construction, operation, and testing

(iii)

information on the following items as a minimum: pipes; pipe jointing systems, manhole covers and frames and gully covers, gratings and frames.

(iv)

manufacturer’s installation instructions for all items

(v)

certified reports for all tests and inspections designated herein, signed and sealed, showing full compliance with referenced standards

(vi)

maintenance requirements and procedures

(vii)

period of guarantee for products.

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Shop Drawings showing the following:

profiles of each pipe system including chainage, ground levels, invert levels, critical clearances and position of pipework structures.

(ii)

material, class, grade, joint type, pressure rating, dimension, location and identification number of each pipe and pipe fitting to be furnished and installed.

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(b)

Product Data

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(a)

procedures for building pipes into concrete structures.

(iv)

procedures for encasing pipes in concrete.

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(iii)

(v)

class, dimensions, location and identification of each manhole cover and frame to be furnished and installed.

(vi)

procedures for placing and fixing manhole covers and frames.

(vii)

class, dimensions, location and identification of each gully cover, grating and frame to be furnished and installed.

(viii) procedures for placing and fixing gully covers, gratings and frames. (ix)

details for handling and storage of pipes, manhole covers and frames and gully covers, gratings and frames.

(x)

all other miscellaneous details required for complete installation.

QCS 2013

QCS 2014


6.1.4

Pipe Marking

1

Each pipe and pipe fitting shall be marked with the following: (a)

serial number

(b)

class of pipe

(c)

nominal diameter

(d)

name or trademark for manufacturer

(e)

date of manufacture.

Page 4


1

Each item to be provided under this Part shall be stored and handled in accordance with the recommendations of the manufacturer of the item.

2

Products susceptible to ultra violet degradation shall be stored under cover and out of direct sunlight.

3

Pipes and fittings shall be subject to visual inspections after off-loading at the site and before installation.

6.1.6

Quality Assurance

1

Pipes, pipe fittings, manhole covers and frames and gully covers, gratings and frames shall be supplied by approved manufacturers as designated in the Project Specification. Production facilities shall be quality assessed in accordance with ISO 9000 or equivalent.

6.2

PIPEWORK

6.2.1

General

1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system. Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water.

6.2.2

Vitrified Clay Pipework

1

Vitrified clay pipes and fittings for surface water drainage shall comply with the relevant provisions of BS EN 295.

2

Pipes and pipe fittings shall be extra strength class.

3

All pipes and pipe fittings shall have flexible mechanical joints. Pipes with diameters larger than 150 mm shall have spigot and socket joints complying with the relevant provisions of BS EN 295. Spigot and socket joints shall have elastomeric joint seals, Type D, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer. Push-fit (sleeve type) polypropylene flexible couplings may be used in place of spigot and socket joints for pipes up to 150 mm diameter.

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6.1.5

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Page 5

Unplasticized Polyvinyl Chloride (PVC-U) Pipework

1

PVC-U pipes and fittings for surface water drainage shall comply with the relevant provisions of BS 4660 and BS 5481.

2

All pipes and pipe fittings shall have spigot and socket joints complying with the relevant provisions of BS 4660 and BS 5481. Spigot and socket joints shall incorporate Type D elastomeric joint seals complying with the relevant provisions for BS 2494 and shall be obtained from the pipe manufacturer.

6.2.4

Reinforced Concrete Pipes

1

Reinforced concrete pipes and fittings and flexible or ogee joints shall comply with the relevant provisions of BS 5911: Parts 100 and 110 respectively.

2

All pipes and fittings shall have gasket type joints of spigot and socket or rebated form, unless otherwise described in the Project Specification or shown on the Project Drawings.

6.2.5

Testing of Pipework

1

Pressure tests shall be carried out on surface water drainage pipes. Test procedures are detailed in Part 6 of this Section.

6.3

PIPE LAYING

6.3.1

General

1


2


3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving.

4


5


6


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6.2.3

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Page 6

Pipe Bedding

7

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the full width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipes, and where practicable, this shall be done in sequence with the removal of the trench supports.

6.3.2


1


2


3

Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 6.1.

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Table 6.1 Thickness of Compressible Filler

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Nominal bore of pipe (mm)

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Less than 450

Thickness of compressible filler (mm) 18 36

Exceeding 1200

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450 to 1200


5


6.3.3


1


6.3.4

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

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Page 7


3

Filling material to excavations shall be deposited in layers not exceeding 250mm unconsolidated thickness and compacted to 95% modified proctor.

4


6.4

GULLIES AND DRAINAGE CHANNELS

6.4.1

Gullies

1

Gullies shall incorporate rodding eyes. Rodding eyes shall be fitted with rubber stoppers during normal operation.

2

All gullies shall be trapped to prevent unwanted odours escaping from the drain.

3

All gullies shall incorporate aluminium silt buckets.

4

The Contractor shall ensure that the gully outlet and the outlet pipework are compatible.

5

Gully covers, gratings and frames shall comply with the relevant provisions of BS 497: Part 1 or BS EN 124.

6

The class of gullies covers, gratings and frames shall be as described in the Project Specification or as shown on the Project Drawings.

6.4.2

Pre-formed Gullies

1

Precast concrete gullies shall comply with the relevant provisions of BS 5911: Part 2 and Section 5 - Concrete.

2

Vitrified clay gullies shall comply with the relevant provisions at BS EN 295: Part 1 or BS 65.

3

Polypropylene gullies shall be of a type detailed in the Project Specification or shown on the Project Drawings and shall be obtained from a reputable manufacturer as approved by the Engineer.

4

Cast iron gullies shall be of a type detailed in the Project Specification or shown on the Project Drawings and shall be obtained from a reputable manufacturer as approved by the Engineer.

5

Pre-formed gullies shall be bedded and surrounded with Grade C20 concrete to the thickness described in the Contract Documentation.

6

Frames shall be bedded in mortar on two courses of Class B engineering brickwork or precast concrete gully cover slabs. Precast concrete gully cover slabs shall comply with the relevant provisions of BS 5911: Part 2 and Section.

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Page 8

Drainage Channels

1

Precast concrete drainage channels shall comply with the relevant provisions of BS 5911: Part 2 and Section 5 - Concrete.

2

Drainage channel gratings and frames shall comply with the relevant provisions of BS EN 124.

6.5

SOAKAWAYS

6.5.1


1

Soakaways shall not be constructed closer than 10 m from a building or in a position where the ground below foundations is likely to be adversely affected.

2

Excavation round the soakaway shall be backfilled with a band of 40mm nominal single size stone to provide a permeable surround to the soakaway. The permeable surround shall be fully wrapped in a geotextile fabric. The dimensions of the band shall be as shown on the Project Drawings.

6.6

MANHOLES AND CATCH PITS

6.6.1


1

Bases and walls to manholes and catch pits shall be cast in situ using Grade C30 concrete.

2

Cover slabs to manholes shall be precast using Grade C40 concrete and shall incorporate an integral GRP liner with a minimum thickness of 3.5 mm. The vertical sides of the

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6.4.3

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openings of cover slabs shall be formed of filament would GRP pipe and soffits shall be formed of GRP sheet. The Contractor shall provide the Engineer with a seven year unconditional guarantee against failure of all GRP linings whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed over to the Engineer before the issue of the Final Completion Certificate.

4

Unless otherwise stated in the Project Specification or shown on the Project Drawings, manhole inverts and benching shall be formed in Grade C20 concrete. Where there is no change of diameter, the invert of the benching shall follow the same gradient as the outgoing pipe.

5

Where a high strength concrete topping (granolithic finish) is required, the invert and benching shall be formed in Grade C20 concrete, and the topping shall be applied as soon as practicable thereafter.

6

All concrete works, including benching, shall comply with the relevant provisions of Section 5 - Concrete.

7

Step irons shall comply with the relevant provisions of BS 1247:Parts 1, 2 and 3.

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Covers and frames shall comply with the relevant provisions of BS 497:Part 1 and have a minimum clear opening of 600 mm diameter if circular or 600 x 750 mm if rectangular. All covers shall have closed keyways.

9

The Contractor shall prepare a standard record sheet for every manhole and catch pit to the approval of the Engineer.

10

Testing of manholes and catch pit chambers shall be as detailed in Part 6 of this Section.

6.7

CONNECTION TO GOVERNMENT MAIN

6.7.1


1

Connection to government mains shall be done at manholes. Pipe saddles and oblique junctions will not be permitted.

2

Where possible and practicable, connections shall be made to future connection ports in existing Government manholes. The caps on future connection ports to which connections are made shall be cleaned and delivered to the government stores on completion of the work.

3

Where it is not possible or practicable to utilise future connection ports in existing manholes, connections shall be made by either breaking into existing manholes or constructing new manholes on existing mains.

4

If it is necessary to break into an existing manhole, the Contractor shall break into the manhole wall, insert pipework, break out the existing benching, construct benching to suit new connection and make good. If necessary, the Contractor shall relocate the access ladder and the cover slab to suit the new benching layout.

5

Manholes built on an existing Government mains shall be constructed in accordance with Clause 6 of this Part. On completion, such manholes shall become the property of the government.

6

The Contractor shall be responsible for all over-pumping operations associated with making connections to Government mains:

7

When a connection is made to an existing manhole in an area with high groundwater levels, the Contractor shall undertake the following if instructed to by the Engineer.

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(a)

undertake a CCTV survey and deflection test between the manhole immediately upstream and the manhole immediately downstream of the manhole to which the connection is to be made before commencing dewatering operations.

(b)

construct two mass concrete stanks round the base of the manhole to prevent groundwater from flowing into the excavation. The stanks shall be positioned each side of the proposed connection and shall extend across the full width of the excavation. The stanks shall be in place before any dewatering takes place.

(c)

undertake a CCTV survey and deflection test between the manhole immediately upstream and the manhole downstream of the manhole to which the connection has been made when work is complete and groundwater levels have returned to their natural levels.

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Page 10

(d)

the Contractor shall submit all CCTV survey data and deflection test data to the Engineer. Such data shall be used to determine whether any damage has been caused to the existing main by the Contractor while carrying out his work.

(e)

the Contractor shall be responsible for rectifying any damage caused as a result of his work.

(f)

the Contractor shall submit his proposals for carrying out remedial works to the Engineer for approval prior to starting such work, should it be necessary.

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END OF PART

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Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 1

7

COMMISSIONING OF SYSTEMS ................................................................. 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

Scope System Description Submittals Connection to Existing Mains

7.2

CLEANSING OF PIPES, MANHOLES AND CHAMBERS ............................. 2

7.2.1

General

7.3

TESTING ....................................................................................................... 3

7.3.1

General

7.4

TESTING AND INSPECTION EXTERNAL DRAINAGE PIPELINES ............. 3

7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6

General Inspection Water Test Air Test CCTV Inspection Infiltration

7.5

TESTING AND INSPECTION INTERNAL DRAINAGE PIPELINES .............. 5

7.5.1 7.5.2 7.5.3

Air Test Leak Location Water test

7.6

TESTING OF SANITARY APPLIANCES ....................................................... 6

7.6.1 7.6.2 7.6.3

General Self-Siphonage and Induced Siphonage in Branch Discharge Pipes Induced Siphonage and Back Pressure in Discharge Stacks

7.7

TESTING OF DRAINAGE STRUCTURES .................................................... 7

7.7.1

Manholes and Chambers

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Page 2

COMMISSIONING OF SYSTEMS

7.1

GENERAL

7.1.1

Scope

1

This Part specifies the requirements for the testing and cleaning of drainage installations.

2


Section 1

General

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General Internal Drainage Works External Drainage Works Trenches for Drainage Pipework Surface Water drainage

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System Description

1

Inspections and tests should be made during the installation of the discharge system as the work proceeds, to ensure that the pipework is properly secured and clear of obstructing debris and superfluous matter and that all work which is to be concealed is free from defects before it is finally enclosed.

2

Prefabricated units should be tested at the works or place of fabrication, and inspected on delivery at the Site.

7.1.3

Submittals

1

The Contractor shall prepare a detailed testing and inspection programme and submit it to the Engineer for approval. This programme shall identify each item to be tested, the type of test to be performed and the date and time of the test.

2

The Contractor shall prepare test and inspection record sheets for all tests and inspections undertaken. The format of the test record sheets shall be to the approval of the Engineer. On successful completion of a test/inspection, the test record sheet shall be signed and stamped by all the Contractor and the Engineer. The Engineer shall retain the original test record sheet.

7.1.4

Connection to Existing Mains

1

Connection to existing mains shall not take place until all tests and inspections have been successfully completed and the system has been cleaned.

7.2

CLEANSING OF PIPES, MANHOLES AND CHAMBERS

7.2.1

General

1

On completion, the discharge system should be meticulously inspected to ensure that the requirements of the Contract Documentation have been observed.

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Page 3

The Contractor shall ensure that no cement droppings, rubble or other objects are left in or on the pipes and that no jointing material projects into the pipe bore.

3

Manholes and chambers shall be thoroughly cleansed to remove all deleterious matter, without such matter being passed forward to existing mains.

4

Sanitary appliances shall be thoroughly cleansed. Any chromium plated or other metallic surfaces forming part sanitary appliances that exposed to view shall be polished.

5

All parts of the Works included in this Section shall be maintained in a clean and serviceable condition by the Contractor until completion of the Contract.

7.3

TESTING

7.3.1

General

1

The Contractor shall notify the Engineer at least two clear working days prior to his intention to test a section of pipeline.

2

Items failing any test shall be corrected immediately and re-tested before further work proceeds.

3

Unless otherwise stated in the Project Documentation, the Contractor is responsible for providing materials and apparatus required for testing purposes and for their removal and proper disposal on completion at testing.

7.4

TESTING AND INSPECTION EXTERNAL DRAINAGE PIPELINES

7.4.1

General

1

Unless otherwise agreed by the Engineer, both interim and final test shall be undertaken on each section of the Works. The Contractor shall note that the satisfactory completion of an interim test does not constitute a final test.

2

Non-pressure pipelines laid in trenches shall be tested after they are jointed and before any concreting or backfilling is commenced, other than such as may be necessary for structural stability whilst under test.

3

The pipelines shall be tested by means of an air or water test or by a visual or closed circuit television (CCTV) examination, in lengths determined by the course of construction.

4

A further test shall be carried out after the backfilling is complete.

7.4.2

Inspection

1

Visual inspection shall be carried out before backfilling in order to detect faults in construction or material not shown up under test but which could lead to premature failure. A careful record shall be kept of such inspections.

2

On external pipelines, the following shall be visually inspected:

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(a)

pipe bed

(b)

pipe line and level

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(c)

joints

(d)

pipe protective coating

(e)

any pipeline appurtenance.

Page 4

Trenches shall be inspected to ensure that the excavation is to the correct depth to guard against mechanical damage due to traffic loading.

4

No part of the pipe trench shall be backfilled until the above are performed to the satisfaction of the Engineer.

7.4.3

Water Test

1

The test pressure for external drainage pipelines up to and including 750 mm nominal bore shall be not less than 1.2m head of water above the pipe soffit or groundwater level, whichever is the higher at the highest point, and not greater than 6m head at the lowest point of the section. Steeply graded pipelines shall be tested in stages in cases where the maximum head, as stated above, would be exceeded if the whole section where tested in one length.

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The pipeline shall be filled with water and a minimum period of 2 hours shall be allowed for absorption after which water shall be added from a measuring vessel at intervals of 5 minutes and the quantity required to maintain the original water level noted. Unless otherwise specified, the length of pipeline shall be accepted if the quantity of water added over a 30 minute period is less than 0.5 litre per linear metre per metre of nominal bore. This relationship in equation format, with water added measured in litres, can be written as follows:

L = pipe diameter (m) D = Length of test section (m)

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Where:

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Maximum volume of water added over a 30 minute period = 0.5 x L x D

Air Test

1

Non-pressure pipelines to be air tested shall have air pumped in by suitable means until a pressure of 100 mm head of water is indicated in a U-tube connected to the system. The pipeline shall be accepted if the air pressure remains above 75 mm head of water after a period of 5 minutes without further pumping following a period for stabilisation. Failure to pass the test shall not preclude acceptance of the pipeline if a successful water test, ordered by the Engineer, can subsequently be carried out in accordance with Clause 7.3.3.

7.4.5

CCTV Inspection

1

Where internal inspection of pipelines by CCTV is required, the Contractor shall provide all necessary equipment, including suitable covered accommodation for viewing the monitor screen, together with personnel experienced in the operation of the equipment and interpretation of results.

2

The intensity of illumination within the pipe and the rate of draw of the camera shall be such as to allow a proper examination of the inside of the pipe. Provision shall be made for the movement of the camera to be stopped and its position recorded and for permanent photographs to be taken at any point requested by the Engineer.

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7.4.6

Infiltration

1

External drainage pipelines shall be tested for infiltration after backfilling. All inlets to the system shall be effectively closed, and any residual flow shall be deemed to be infiltration.

2

The pipeline shall be accepted as satisfactory if the infiltration, including infiltration into manholes, in 30 minutes does not exceed 0.5 litre per linear metre per metre of nominal bore. This relationship in equation format, with water infiltration measured in litres, can be written as follows: Maximum volume of infiltration over a 30 minute period = 0.5 x L x D L = pipe diameter (m) D = Length of test section (m)

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Where:

Notwithstanding the satisfactory completion of the above test, if there is any discernible flow of water entering the pipeline at a point which can be located either by visual or CCTV inspection, the Contractor shall take such measures as are necessary to stop such infiltration.

7.5

TESTING AND INSPECTION INTERNAL DRAINAGE PIPELINES

7.5.1

Air Test

1

The water seals of all sanitary appliances should be fully charged and test plugs or bags inserted into the open ends of the pipework to be tested.

2

To ensure that there is a satisfactory air seal at the base of the stack, or at the lowest plug or bag in the stack if only a section of the pipework is to be tested, a small quantity of water sufficient to cover the plug or bag can be allowed to enter the system.

3

One of the remaining test plugs should be fitted with a tee piece, with a cock on each branch, one branch being connected by means of a flexible tube to a manometer. Alternatively, a flexible tube from a tee piece fitted with cocks on its other tow branches can be passed through the water seal of a sanitary appliance. Any water trapped in this tube should be removed and then a manometer can be connected to one of the branches as described above.

4

Air shall be pumped into the system through the other branch of the tee piece until a pressure equal to 38 mm water gauge is obtained. The air inlet cock is then closed and pressure in the system should remain constant for a period of not less than 3 min.

7.5.2

Leak Location

1

The use of smoke to detect leaks shall only be permitted if approved in writing by the Engineer. A smoke producing machine may be used which will introduce smoke under pressure into the defective pipework. Leakage may be observed as the smoke escapes. Smoke cartridges containing special chemicals should be used with caution, taking care that the ignited cartridge is not in direct contact with the pipework and that the products of combustion do not have a harmful effect upon the materials used for the drainage system. Smoke testing of plastics pipework or systems with rubber jointing components is not permitted.

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Page 6

With the pipework subjected to an internal pressure using the smoke machine or air test method, a soap solution can be applied to the pipes and joints. Leakage can be detected by the formation of bubbles.

7.5.3

Water test

1

There is not justification for a water test to be applied to the whole of the plumbing system. The part of the system mainly at risk is that below the lowest sanitary appliance and this may be tested by inserting a test plug in the lower end of the pipe and filling the pipe with water up to the flood level of the lowest sanitary appliance, provided that the static head does not exceed 6 m.

7.6

TESTING OF SANITARY APPLIANCES

7.6.1

General

1

To ensure that adequate water seals are retained during peak working conditions the tests described below should be carried out. After each test a minimum of 25 mm of water seal should be retained in every trap.

2

Each test should be repeated at least three times, the trap or traps being recharged before each test. The maximum loss of seal in any one test, measured by a dip stick or small diameter transparent tube, should be taken as the significant result.

7.6.2

Self-Siphonage and Induced Siphonage in Branch Discharge Pipes

1

To test for the effect of self-siphonage the appliance should be filled to overflowing level and discharged by removing the plug; WC pans should be flushed. The seal remaining in the trap should be measured when the discharge has finished.

2

Ranges of appliances, connected to a common discharge pipe, should also be tested for induced siphonage in a similar way. The number of appliances which should be discharged together is given in Table 6.1. The seal remaining in all the traps should be measured at the end of the discharge. Only those appliances included in Table 6.1 shall be tested under simultaneous discharge conditions.

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Table 6.1 Number of Sanitary Appliances to be Discharged for Performance Testing

Number of appliances of each kind on the stack

Number of appliances to be discharged simultaneously WC

Wash Basin

1 to 9

1

1

10 to 18

1

2

19 to 26

2

2

27 to 52

2

3

53 to 78

3

4

79 to 100

3

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Page 7

Induced Siphonage and Back Pressure in Discharge Stacks

1

A selection of appliances connected to the stack should be discharged simultaneously and the trap and seal losses due to positive or negative pressures in the stack should be noted. These selected appliances should normally be close to the top of the stack and on adjacent floors, as this gives the worst pressure conditions. Table 6.1 shows the number of appliances which should be discharged simultaneously. Only those appliances included in Table 6.1 shall be tested under simultaneous discharge conditions.

7.7

TESTING OF DRAINAGE STRUCTURES

7.7.1

Manholes and Chambers

1

Manholes and chambers shall be tested for infiltration after backfilling. Where appropriate, they shall be inspected for water tightness before placing cover slabs.

2

Manholes and chambers shall be substantially water tight, with no identifiable flow of water penetrating the structure. Manholes and chambers which are not substantially water tight shall be corrected immediately.

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END OF PART

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QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 1

GENERAL PROVISIONS FOR ELECTRICAL INSTALLATION .................... 2

1.1

GENERAL ...................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16 1.1.17 1.1.18 1.1.19 1.1.20 1.1.21 1.1.22 1.1.23 1.1.24 1.1.25 1.1.26 1.1.27

Scope Regulations Existing Services Contract Drawings Shop Drawings Progress Drawings As built drawings Builders Work Programme Equipment and Materials Approval Fire and Safety Precautions Protection Quality of Staff/Personnel Climatic Conditions Samples Quality of Materials Equipment Duties and Ratings Workmanship Labels/Circuit Lists/Cable Identification Segregation of Services Electricity Supply Polarity Safety Interlocks Spare Parts Protection of Excavation Supply of materials Special Requirements

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2 2 3 3 4 5 5 6 6 6 7 8 8 9 9 9 10 10 11 12 13 14 14 14 16 16 16

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Page 2

1

GENERAL PROVISIONS FOR ELECTRICAL INSTALLATION

1.1

GENERAL

1.1.1

Scope

1

The Electrical Installation Contractor, herein referred to as the 'Contractor' within this part and all other Section 21 parts of this specifications shall carry out all electrical works complete in accordance with the requirements of the Project Documentation.

2

The scope of work shall include but not be limited to: (The supply and installation of all services, equipment, components, accessories and fittings required for the operation of the facility to the extent specified and detailed on the Drawings and Specifications including 400 days maintenance or as stipulated in the contract specification and all extended warranties after provisional handover

(b)

Builder's work in connection with the Electrical Installations, including supply, necessary inserts sleeves and making good.

(c)

Any work which can be reasonably inferred as necessary for the safe, satisfactory operation of each system, whether such work is specified or shown on drawings or not

(d)

The supply and installation of cables, conduits, boxes and termination points, for the motors, starters, controls and the like for the Process Equipment, Heating, Ventilation and Air-conditioning and Plumbing services

(e)

(Arranging for installation of permanent Electrical supply by the Qatar General Electricity and Water Corporation (QGEWC), including submission of all necessary documents to the QGEWC, and carrying all necessary approvals and obtaining consumption meters Moreover, the Contractor shall allow in his tender and be responsible for the payment of all charges by way of examination, certification, depositing or connection fee to any Statutory Authority. (I.e. Electricity, Water, Drainage, Telephone, Fire, etc).

(f)

Supply and installation of permanent electrical supply equipment and cables in compliance with QGEWC requirements and approvals. The electrical equipment is required for the implementation of the of the new facilities as well for the supply of new loads,. The supply includes EHV cables, HV/MV substations, HV and MV cables and accessories, consumption meters, and all related civil works, and including submission of all necessary documents to QGEWC, and carrying all necessary approvals Coordinating with QGEWC regarding outage schedule, attending upon the Supply Authority installing mains power supply and carrying out primary and secondary injection tests and any other tests as directed by QGEWC.

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(a)

(h)

Arranging and carrying out all necessary approvals with Telecom Provider for the Telephone System

(i)

Arranging and carrying out all necessary approvals with the Qatar Civil Defence Department for the Fire Alarm System, extinguishing and protection systems.

1.1.2

Regulations

1

All supplies and services offered in response to this specification shall conform to the latest standards.

2

The design, equipment and installation requirements shall comply with the standards and recommendations laid down by the following : (a)

Regulations for Electrical Installations as issued by the Qatar General Electricity and Water Corporation (QGEWC) Qatar

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Page 3

(b)

Regulations for Electrical Installations as issued by the Institution of Electrical Engineers (I.E.E.), London (for points not included in QGEWC Regulations)

(c)

Recommendations for Lighting Installations as issued by QGEWC and the Chartered Institute of Building Services, London

(d)

Standards relating to Electrical Installations and equipment as issued by International Electrotechnical Commission (I.E.C.) and British Standards Institute (BSI)

(e)

Regulations for telephone system installation as issued by Q-TEL

(f)

National Electrical Code issued by National Fire Protection Association (NFPA), Boston, U.S.A

(g)

Rules of the Qatar Civil Defence Department for Fire Alarm Installations.

Where two or more applicable standards and/or the Specifications are in conflict, the most stringent shall apply.

1.1.3

Existing Services

1

The Contractor is deemed to have visited and inspected the site to familiarise himself with the existing site conditions and services at tender stage.

2

The Contractor shall obtain the existing services record drawings from QGEWC and various utility services departments (i.e. Q-TEL, CDD etc).

3

Co-ordination between shop drawings, work on site and existing services shall be carried out by the Contractor.

4

The Contractor shall be fully responsible for any damages to the existing services including repairs, and penalties imposed by the concerned parties etc and for removing any site obstacles such as underground cables, pipes, civil works etc. which is obstructing his work on site.

5

The Contractor shall also be responsible for liaison with QGEWC, Q-TEL and all other government utility departments to disconnect or divert the existing services supply to the existing site prior to demolishing.

1.1.4

Contract Drawings

1

The indication and/or description in any of the Contracts documents, unless otherwise specifically stated, implies an instruction to supply and fix such items.

2

Notes on Drawings referring to individual items of work take precedence over the Specification.

3

Drawings show the general run of cables, raceways, etc. and the approximate location of equipment and utilities; symbols and schematic diagrams are of no dimensional significance. Obtain from the Engineer dimensions not shown on, or which cannot be determined from Drawings. Do not scale drawings to obtain locations.

4

Notify the Engineer of conflicting requirements. Where departures from the drawings are deemed necessary, details of such departure and reasons thereupon shall be submitted to the Engineer for approval.

5

No such departure shall be made without prior written approval of the Engineer.

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The design specifications and criteria shall not relieve the Contractor from continuously following up with the respective authorities to obtain up-to-date requirements and instructions.

1.1.5

Shop Drawings

1

The term 'shop drawings' includes fabrication, erection, layout and setting out drawings; manufacturer's standard drawings, schedules; descriptive literature, illustrations, catalogues and brochures; performance and test data; wiring and control diagrams and other drawings and descriptive data pertaining to materials, equipment, raceway systems, control systems and methods of construction as required to show that materials, equipment and systems and position thereof, conform to the Contract Documents. The term 'manufactured' applies to standard units usually mass produced. The term 'fabricated' means items specifically assembled or made out of selected materials to meet individual design requirements.

2

Shop drawings shall establish actual detail of all manufactured or fabricated items, indicate proper relation to adjoining work, amplify design details of electrical equipment in proper relation to physical spaces in the structure, and incorporate minor changes of design or construction to suit actual conditions.

3

The Contractor shall submit for approval, and obtain in due time to conform to the Contract Program, all shop and installation drawings based on the design drawings approved by the QGEWC and all other relevant Municipality and Government Authorities.

4

The Contractor, immediately after being awarded the said Contract, shall prepare and submit shop drawings. Shop drawings shall be submitted with such promptness as to cause no delay in his own work nor to any other Contractor. No extensions of time will be granted because of failure to have shop drawings submitted in ample time to allow for processing, in accordance with the submittals schedule outlined in Section 9, Part 1, Clause 1.1.4.

5

Provide shop drawings, to a scale not smaller than the corresponding layout drawings, showing the following and obtain approval before commencing work:

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exact runs and sizes of conduits, ducts, cables, cable trays and trunking

(b)

layout drawings for each separate electrical installation showing the actual locations of points, suitably identified, the locations of switchgears, switchboards, motor control centres and distribution boards, details and types of fittings plans showing the equipment assembly, space requirements, clearances and locations for cable entrances and anchor bolts

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(d)

elevations showing all parts, devices, components and nameplates, positions and arrangements of the equipment. Show as many elevations as necessary to clearly depict component and device arrangements

(e)

schedules of points, indicating how the various outlets are connected to the distribution boards, size of circuit wiring, the rating of the protective device and the type and size of appliance of fitting

(f)

schematic diagram of connections of distribution boards, and equipment to main switchboards showing sizes of feeders, etc

(g)

schematic and elementary wiring diagrams, of each unit of each equipment, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

(h)

connection wiring diagrams, of each unit of each equipment, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

(i)

complete catalogue information of all parts and components of electrical equipment

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Page 5

(j)

all cable routings and layouts for the different electrical services, feeders and branch circuits showing routes, sizes and types of cables

(k)

any other data necessary for the proper maintenance of the installations.

Drawings shall be ISO standard size A1. Lettering shall be stencilled. Shop drawings and samples shall be properly identified with the name of the Project, the Contractor, the SubContractor and the date, and signed by Contractors Authorised Engineers.

7

Final co-ordination of electrical works with mechanical, structural and architectural work shall be carried out from complete shop drawings and sufficient time shall be allowed for coordination and checking of shop drawings and calculations after shop drawings are submitted.

8

Individual shop drawings shall be submitted following the distribution of the co-ordination drawings and shall bear a stamp indicating that the work has been co-ordinated with other trades.

9

The Engineer's review and approval of shop drawings submitted by and approved by the Contractor is for general conformance with the design concept and information given in the Contract Documents and shall not relieve the Contractor from responsibility for any deviations from the requirements of the Contract Documents. The Engineer's review and approval shall not be construed as a complete check nor shall it relieve the Contractor from responsibility for error of any sort in shop drawings or schedules, or from the necessity of furnishing any work required by the Contract Documents which may have been omitted on the shop drawings. The Engineer's review and approval of a component item shall not indicate review and approval of the complete assembly in which it functions.

10

The Engineer or the supervising consultant shall forward electrical drawings and specifications which are to be submitted for approval to QGEWC, when appropriate. However, it shall be the Contractors responsibility to obtain written approval from QGEWC for all such drawings and specifications appertaining to the work carried out under the contract. QGEWC approvals may take a considerable time to obtain and the Contractor should make allowance for this and be available for liaising with and pursuing approvals with QGEWC.

1.1.6

Progress Drawings

1

Provide and keep on the job at all times, one complete and separate set of blackline prints of the electrical work on which shall be clearly, neatly and accurately noted, promptly as the work progresses, all architectural and electrical changes, revisions and additions to the work. Whatever work is installed otherwise than as shown on the Contract Drawings, such changes shall be noted.

2

Indicate daily progress on these prints by colouring in the various conduit, ducts, trunking, cable trays, fixtures, apparatus and associated installation works erected.

1.1.7

As built drawings

1

The Contractor shall provide the as built drawings, as approved by the Engineer, in DXF format or AutoCAD DWG format, either in floppy diskettes or in CD-ROM, as per the Project Documentation requirement. The drawings shall be submitted not later than 2 months after completion of the Project, or putting into operation, whichever is earlier. An addition, 3 sets of hard copy of all relevant drawings, which will be required for operation and maintenance, shall be supplied in bound book forms immediately after the commissioning of the Project. The quality of these drawings shall be consistent with the standard of QGEWC. Diary sheets for Work completed shall not be authorised until such records have been presented to the Engineer and accepted.

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The Contractor shall supply, 3 sets of all operation and maintenance manuals in original, from the manufacturer in bound book forms, at least 2 weeks prior to commissioning of the equipment. These shall also be supplied, in computer diskettes, based on popular Microsoft window based publishing software programmes, along with the as built drawings as mentioned above, as specified in the Project Documentation or as directed by the Engineer.

1.1.8

Builders Work

1

Lay electrical works in advance of pouring concrete slabs and construction of walls. Obtain Engineer's approval before commencing builder's work in connection with electrical installation. Related co-ordinated shop-drawings shall be submitted for approval as per the related clause 1.1.5 of this section. Materials approval shall be obtained as per procedure detailed in clause 1.1.9 below. The Contractor shall make it certain that drawings properly coordinated with other works are submitted immediately after signing of the contract and approval of drawings and the materials are obtained at least one month prior to the commencement date of the construction.

2

Check with other trades to ensure equipment and material can be installed in space provided.

3

Provide other trades with information necessary for them to execute their work.

4

Details on drawings which are specific regarding dimensions and locations, are for information purposes. Co-ordinate with other trades to ensure work can be installed as indicated.

1.1.9

Programme

1

The Contractor shall produce a work programme based on CPM or Bar-chart form or as directed by the Engineer indicating the time required for various operations to complete the Project in time. The following points shall be highlighted in the programme:

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mobilisation

(b)

drawings/submittals

(c)

approvals

(d)

equipment deliveries including delivery periods from supply sources external to the State of Qatar

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cabling

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(a)

(g)

main/sub-main distribution equipment

(h)

second fix

(i)

fixing of light fittings

(j)

testing

(k)

commissioning and handing over.

2

The Contractor is responsible for all liaison with QGEWC in respect of programming the installation and commissioning of complete electrical system. The Contractor shall ensure that QGEWC are at all times kept informed of the current progress of the electrical works on site and that his approved electricity supply subcontractor programs the cable laying works in the specified sequence in accordance with the approved programme.

1.1.10

Equipment and Materials Approval

1

Approval of materials and equipment shall be based on latest manufacturer's published data.

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Complete and detailed information of all materials and equipment to be incorporated in the work shall be submitted. Submit detailed description and specifications, catalogues cuts, installation data, diagrams, dimensions, controls and any other data required to demonstrate compliance with the Contract Documents. Each item submitted shall be referenced to the applicable paragraph in the Specification.

3

At the request of the Engineer, submit a sample of any equipment or material for further study before approval. Where samples are required by the Engineer, the period required to obtain the sample will be taken into account when scheduling approvals.

4

Only approved materials shall be employed at the site. All materials installed which are not approved shall be removed and reinstated by approved ones.

5

Time periods for equipment and materials approvals shall be as outlined in Section 9, Part 1, Clause 1.1.4.

1.1.11


1

Establish from Architectural Drawings where fire and smoke barriers exist, and make adequate provision of fire and smoke barriers in and around trunking, conduits, cables, etc., where they pass through floors and fire rated walls, and where protection systems are installed pack space between wiring and sleeve full with Fire Retardant Material and seal with caulking.

2

The Contractor shall ensure that this work is carried out such that the integrity of any such fire barrier is properly maintained where pierced by electrical services.

3

For each switchboard the Contractor shall supply the following equipment:

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1 no. electrical grade rubber mat to BS 921 1000 mm wide extending the full length of the switchboard

(b)

1 no. pair of electrical grade rubber gloves to BS 697. The hand glove should have the date of test stamped on it.

(c)

1 no. notice in English and Arabic advising treatment for a person suffering from electrical shock.

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The Contractor shall put the notice for electrical shock treatment in details with sketches and instructions as per standard procedures. The notice shall comply with the requirement of the QGEWC in content and format. However, this should include the following as a minimum,

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(a)

(b)

ACT IMMEDIATELY (i)

Safeguard Yourself

(ii)

Switch off current or break electric circuit

(iii)

Use or stand on some dry non-conducting material to remove the CASUALTY from cable or source of electricity.

(iv)

Start artificial respiration and call for Medical Aid

TREATMENT FOR ELECTRIC SHOCK ARTIFICIAL RESPIRATION (KISS OF LIFE, MOUTH TO MOUTH METHOD) (i)

Lay the casualty on back and if possible on a table

(ii)

Kneel or stand near to the casualty‟s head

(iii)

Remove any obstruction from the mouth

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Page 8

(iv)

Support the nape of the neck and press top of the head so that it is tilted backwards

(v)

Open your mouth and take a deep breath, pinch the casualty‟s nostrils with your fingers. Seal your lips round his mouth and blow into his lungs until the chest rises.

(vi)

Remove your mouth and watch the chest falls

(vii)

Repeat and continue inflation at your natural rate of breathing. Continue to give artificial respiration until natural breathing is restored or until the medical aid arrives

(viii)

When the casualty is breathing, place in recovery position, lying and resting on the side. Remain with and watch casualty closely.

Protection

1

The Contractor shall be responsible for his work and equipment until finally inspected, tested, accepted and handed over. Materials and equipment which are not immediately installed after delivery to site shall be stored carefully. Close open ends of work with temporary covers or plugs during construction to prevent entry of obstructing material.

2

Protect work and material of other trades from damage that might be caused by his work or workmen and make good damage thus caused.

3

Protect exposed live equipment during construction for personnel safety.

4

Shield and mark live parts "LIVE 240 VOLTS" or with appropriate voltage in English and Arabic.

5

Arrange for installation of temporary doors for room containing electrical distribution equipment. Keep these doors locked except when under direct supervision of an electrician.

1.1.13

Quality of Staff/Personnel

1

The electrical services installation shall be carried out in a professional manner by experienced and qualified personnel.

2

Electrical Contractor shall be to the classifications required by QGEWC and shall carry a valid licence.

3

Prior to the commencement of works the Contractor shall notify the Engineer of his intended site staffing levels.

4

The Contractor shall appoint one graduate Electrical Engineer full time with 5 years experience in similar works and qualified staff/personnel for the supervision of the Electrical Installation Works.

5

The name, qualifications and experience of the nominated engineers shall be submitted to the Engineer for approval within 15 days of the receipt of the order to commence the works.

6

An Electrical Foreman of 10 years experience in similar projects should be full time available on site for direct follow up and implementation of the electrical works.

7

Qualified and Experienced Electricians shall be available on site to carry out the works in accordance with the programme.

8

The Engineer reserves the right to require the Contractor to provide information and documentation as may be necessary to establish the validity of any individual persons proficiency and effect their removal from site should they prove to be unsatisfactory.

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1.1.12

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1.1.14

Climatic Conditions

1

The climate in Qatar in the summer months is hot and humid and a humidity of 100 % at 30 °C has been recorded. (a)

violent sand and dust storms of several hours duration occur and even on comparatively still days, fine dust is carried in suspension in the atmosphere.

(b)

all apparatus and equipment shall, therefore, be so designed and constructed that they operate satisfactorily and without any deleterious effect for prolonged and continuous periods in the conditions stated above and at the following ambient temperature conditions: maximum sun radiation temperature in summer

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84 °C

(ii)

maximum ambient temperature in summer

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52 °C

(iii)

average max. ambient temperature in summer

-

(iv)

minimum ambient temperature in winter

(v)

the altitude of Qatar may be taken as sea level.

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(i)

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0 °C

The temperatures quoted above make no allowance for heat generated from equipment itself or from any other equipment in the vicinity

3

The capacity and ratings of all electrical equipment and materials given are, unless otherwise indicated, for Qatar climatic conditions. Provide the basis of the derating factors applied in each case

4

Where specific sizes are indicated e.g. cable sizes, due allowances have been made in the design for the climatic conditions of Qatar and derating has been applied

5

Where no ratings or sizes are indicated for components and other accessories, supply equipment which will give trouble free service in the ambient conditions stated above.

1.1.15

Samples

1

The term „samples‟ includes natural materials, fabricated items, equipment, devices, appliances, or parts thereof as specified and other samples as may be required to determine whether kind, quality, construction, workmanship, finish, colour and other characteristics of materials conform to requirements of the Contract Documents.

2

Samples shall establish kind, quality and other required characteristics of various parts of the work. Indicate details of construction, dimensions, capacities, weights and electrical performance characteristic of equipment or material.

3

Samples and sample board should be prepared and identified by the manufacturer and stamped/engraved with make, type, Cat No. and size marking should be indelible and legible.

1.1.16

Quality of Materials

1

Manufacturers shall provide their standard guarantees for products furnished under this Contract. However, such guarantees shall be in addition to and not in lieu of all other liabilities which manufacturers and the Contractor may have by law or by other provisions of the Contract Documents.

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All materials, items of equipment and workmanship furnished under this Contract shall carry standard warranty against all defects in materials and workmanship. Any faults due to defective or improper material, equipment, workmanship or Contractor's design which develop shall be made good, forthwith, by and at the expense of the Contractor, including all other damage done to areas, materials and other systems resulting from this failure.

3

Guarantee that all elements of the systems are of sufficient capacity to meet the specified performance requirements as set forth herein or as indicated.

4

Upon receipt of notice from the Engineer, of failure of any part of system or equipment during the period of maintenance, the affected parts shall be replaced.

1.1.17

Equipment Duties and Ratings

1

Power ratings shown for the proposed equipment are in accordance with the best information available to the Engineer and are to be considered as minimum ratings. In the event equipment items proposed by the Contractor should require motors with different power rating than shown, it shall be the Contractor‟s responsibility to furnish circuit breaker, starting equipment, feeder and branch circuits, conduits, and accessories etc. as required to comply with the electrical code and prevent excessive voltage drop without added cost to the Client.

2

Where equipment to be furnished is installed in an existing enclosure or adjacent to existing equipment, the Contractor shall field check the dimensions of existing equipment, location of conduits, etc., and shall familiarise himself with all existing conditions and difficulties to be encountered in performing such work.

3

Degree of protection for all electrical equipment shall be as follows:

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IP 54, for indoor equipment IP 55, for outdoor equipment IP 68, for submersible equipment

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All external equipment to be of metallic construction.

5

The equipment shall be located generally as indicated on the drawings and the Contractor shall ensure that the equipment is suitably constructed to permit installation as shown. The equipment shall where necessary be constructed in modular form to permit access into the buildings and facilitate ease of erection at site.

6

The equipment arrangements and single line diagram are for guidance only and show a practical arrangement that would be acceptable. The Contractor may propose an alternative arrangement which meets the requirements of the specification.

7

All equipment performing similar duties shall be of a single type and make and be fully interchangeable in order to limit the stock of spare parts required. This is to apply particularly to such items as motors, switchgear, instruments, controls, relays, etc.

1.1.18

Workmanship

1

The entire work provided in this specification shall be constructed and finished in every respect in a workmanlike and substantial manner. The Contractor shall provide the system in accordance with the best trade practice and to the satisfaction of the Engineer.

2

Keep others fully informed as to the shape, size and position of all openings required for apparatus and give full information sufficiently in advance of the work so that all openings may be built in advance. Provide and install all sleeves, supports, etc., hereinafter specified or required.

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Obtain detailed information from the manufacturers of apparatus as to the proper method of installing and connecting same. Obtain all information from others which may be necessary to facilitate work and the completion of the whole Project.

4

Provide the services of an experienced foreman, who shall be continuously in charge of the erection of the electrical work, together with all necessary skilled workmen, helpers and labourers, required to properly unload, transfer, erect and connect up, adjust, start, operate and test the system.

5

Before installing any work, verify that it does not interfere with clearance required for other work. Notice of adverse conditions shall be forwarded in writing to the Engineer before any work in question is installed. If notification is not made, and work installed causes interference with the contemplated design, make such changes in his work as directed by the Engineer to permit the installation of all work of the Project, at no additional cost to the Client.

6

Raceways shall be run as straight and direct as possible in general forming right angles with or parallel with walls or piping and neatly spaced, with risers erected plumb and true, maintain a clearance of at least 25 mm between finished coverings and adjoining work. Approved ceiling height shall be obtained from Architectural Drawings.

7

All equipment and accessories shall operate without objectionable noise or vibration. Should operation of any of the equipment or systems produce noise or vibration which is, in the opinion of the Engineer objectionable, make change in equipment and do all work necessary to eliminate the objectionable noise or vibration at no additional cost to the Client.

8

Wherever possible services shall not cross expansion joints. Where this is unavoidable the services shall accommodate the design movement without damage, by use of approved expansion couplings/flexible conduit arrangement.

9

All MV, HV and EHV works shall be carried out by a contractor or sub-contractor pre-qualified and approved by QGEWC. Proof of such approval shall be required in writing prior to the works commencing on site and the name of any sub–contractor to be used shall be entered in the relevant form of tender when the tender is submitted. All cable jointers to be used on the Contract shall be required to undertake and pass a trade test conducted by QGEWC at the Contractor‟s expense.

1.1.19

Labels/Circuit Lists/Cable Identification

1

For substations, switchgears, switchboards, motor control centres and panel boards:

2

engraved lamacoid name plates, black with minimum 10 mm high white lettering.

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For Distribution Boards and Circuit Breakers: (a)

where individually enclosed or in substations, switchgears, switchboards, motor control centres and panel boards without doors : engraved lamacoid nameplates, black with minimum 8 mm high white lettering.

(b) 3

in panel boards with doors : directories mounted inside transparent plastic covers in metal frames.

Wiring Identification: (a)

identify wiring with permanent indelible, identifying markings, either numbered or coloured, heat shrinkable tube or ferrules, on both ends of phase conductors of feeders and branch circuit wiring.

(b)

maintain phase sequence and colour coding throughout

(c)

colour code to standards above as specified elsewhere

(d)

use colour coded wires in communication cables, matched throughout system.

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Conduit and Cable Identification: (a)

colour code conduits and metallic sheathed cables

(b)

code with plastic sleeve or paint end points where conduit or cable enters wall, ceiling or floor and also at 15 m intervals along its length.

(c)

colours to be 25 mm wide prime colour and 20 mm wide auxiliary colour to standards above

(d)

number code, per Circuit Schedule, all feeder and branch circuit cables at both connection points and in manholes, handholes, pull-boxes and junction boxes with fibre or non-ferrous metal tags, fastened with non-ferrous wire.

Device Plates: for Device Plates of local toggle switches, toggle switch type motor starters, pilot lights and the like, whose junction is not readily apparent : plates to be engraved with 3 mm high letters describing equipment controlled or indicated.

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phase identification letters shall be stamped into the metal of the busbars of each phase of the main buses in each substation, switchgear, switchboards, motor control centre and panel board in addition to colour identification

(b)

Letters shall be visible without disassembling current carrying supporting elements.

(c)

busbars shall be sleeved for phase identification by using high temperature grade heat shrinkable coloured PVC sleeving throughout its length. In no circumstances will any kind of wrapping tape be accepted on busbars.

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For Busbars:

For Doors:

where switchboard rooms, cable chambers, metal screened spaces and the like contain electric power cables, bus bars or equipment operating at voltages exceeding 600 V : enamelled sheet metal, red on white, reading "Danger - High Voltage".

For Rooms:

Languages:

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to switchboard rooms, electric closets, metal screened spaces assigned to electrical equipment, and the like : enamelled sheet metal, red on white, reading "Electrical Equipment Room - No Storage Permitted".

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(a)

nameplates with directional, operational or warning labels shall be in Arabic and English.

1.1.20

Segregation of Services

1

Electrical services shall be segregated as specified throughout the installation to obviate the following; (a)

electrical interference from one circuit to another

(b)

a fault on one circuit affecting another

(c)

unnecessary fire damage

(d)

difficulties in circuit identification

(e)

voltage limits for general safety

(f)

difficulties in removal and/or maintenance.

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2

All raceways shall be kept clear of other services except where intentionally earthed or bonded. Generally, raceways shall be kept 150 mm away from and above hot water and 75 mm away from other services.

3

Unless specifically indicated otherwise, normal, emergency, low voltage cables and wiring shall be segregated throughout the installation generally in the following manner:

(b)

insulated conductors: Insulated conductor circuits shall, where possible, be segregated throughout by enclosing in separate conduits, trunking or trunking compartments.

.

armoured and sheathed cables: Where more than one tray has been specified or is necessary to accommodate the number of cables on a run, where practical, segregation shall be achieved by dedicating each tray to either normal or emergency services. Where normal and emergency cables have to run together in trays, ducts or trenches, they shall be formed in two groups, one normal and one emergency

(a)

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Fire Alarms:

fire alarm cables shall be segregated from other services throughout and be either armoured and sheathed cable, or insulated conductors enclosed in conduit or trunking, as indicated on the drawings.

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(a)

Electricity Supply

1

The Supply Authority will make available, at the incoming terminals of each Main Switchboard (Medium Voltage Panel) a 3 phase + Neutral, 4 wire, 415 V, 50 Hz supply of adequate capacity and having the following tolerances:

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1.1.21

voltage

415 6 %

(b)

frequency seconds)

50Hz± 0.1 Hz (short term ± 0.15 Hz for a duration of only a few

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(a)

Phase rotation of supply to BS 158.

3

Neutral: Solidly earthed at transformer location

4

Earthing system: TNS

5

Obtain fault level and fault duration time from the Supply Authority (QGEWC).

6

Obtain confirmation from the Supply Authority of the size and number of cables they will provide to Main Switchboards. Allow for adequate and appropriate cable glands, lugs and boxes.

7

After inspection and approval of the Contractor‟s installation, QGEWC will permit energisation of the feeder cables to the installation.

8

QGEWC will only inspect the Contractor's installation and permit energisation of the power supply after receiving a written request to do so from the Contractor.

9

The Contractor will be responsible for any delay caused by omission to make the request in good time.

10

The Contractor shall provide a generator of adequate capacity to carry out all precommissioning tests. Per-commissioning tests may be carried out using mains electricity if this is available.

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1.1.22

Polarity

1

The polarity of all apparatus used for the Works specified shall be arranged as follows when apparatus is viewed from the front: (a)

for two pole apparatus the phase or “live” pole at the top (or left hand side) and the '“neutral or earthed” pole at the bottom (or right hand side). On plug and socket outlets the polarity shall conform to BS 196, BS 546, or BS 1363 as appropriate

(b)

for three or four pole apparatus the phases in order red, yellow, blue and neutral reading from top to bottom or left to right in the case of vertical and horizontal layouts respectively.

All cables shall be so connected between main switchboards, distribution boards, plant and accessories so that the correct sequence of phase colours is preserved throughout the system.

3

All cable cores shall be identified with phase colours. Where more than one phase is incorporated on a common system in one room then the live cores shall be red, yellow, blue, as appropriate, and fittings and switch accessories shall be permanently labelled and segregated in accordance with I.E.E. Regulations.

1.1.23

Safety Interlocks

1

A complete system of interlocks and safety devices shall be provided as necessary for the safe and continuous operation of the plant in order to provide for the following:

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safety of personnel engaged on operation and maintenance of the plant

(b)

correct sequence of operation of the plant during start up and shut down

(c)

safety of the plant when operating under normal or emergency conditions.

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(a)

Interlocks shall be preventive and not corrective

3

The Contractor shall be responsible for the preparation of interlocking schemes for the approval of the Engineer.

4

Locks for interlocking purposes shall be of the figure lock type.

5

No spare or master key shall be provided, unless specified.

6

Device items are to be arranged to ensure that there is no danger of interchange with existing locks on other units.

1.1.24

Spare Parts

1

General:

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(a)

provide sufficient spare parts for all the electrical items included within the scope of works. Submit to the Engineer a list of all spare parts to be required for a further two years operation from the date of issue of the Maintenance Certificate

(b)

spare parts required include but not necessarily limited to those listed below, provided specified in the Project Documentation or where quantities for each item or equipment is recommended by the manufacturer

(c)

spare parts to be delivered to central stores.

Main Low Tension Boards: (a)

2 % spare moulded case circuit breakers of all different frame sizes, but in any case not less than 2 nos. circuit breaker of each size

QCS 2014


(b)

5 % spare indicating lamps for each indicating lamp in the switchgear

(c)

one set of tools required for switchgear maintenance

(d)

provide complete spare parts as recommended by the manufacturer for different sizes of ACB.

5 % spare combination magnetic motor starters

(b)

5 % spare circuit breakers for each rating of each MCCB

(c)

5 % spare HRC fuses for each rating

(d)

5 % spare of load break switch (isolators) of each size

(e)

5 % spare of current operated ELCB of each size

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5 % spare switch of each size.

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Circuit Accessories:

plug fuses - furnish ten percent (10%) of the number of each size and type of fuses installed, but in any case not less than six fuses of each sizes

(b)

wall switches - provide five percent (5%) of the number of each size and type of wall switch installed

(c)

socket outlets - provide five percent (5%) of the number of each size and type installed

(d)

lamps - provide five percent (5%) lamps of each size and type for indicating panels and pilot lights installed for different systems.

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Disconnecting Switches: (a)

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(a)

Lighting Fixtures: (a)

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Switchboards, Motor Control Centres and Distribution Boards:

for lighting fixtures provide the following spare parts: 2 % of the total quantity of each type of lighting fixture. This quantity shall not be less than one fixture of each type

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(iii)

10 % spare lamps of each wattage of different type

(iv)

5 % of the total quantity of control gear (ballast) of each type and size but in no case less than (6) ballast of each size and type.

Emergency Generating Sets: (a)

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additional diffusers for 5 % of the total quantity of each type of lighting fixture provided with acrylic, plastic or glass enclosures. Diffusers shall be identical to those of the installed fixtures. This quantity shall not be less than two diffusers of each type

complete itemised list of different spares to be included and priced by the tenderers. For emergency generator, furnish by the generator supplier to maintain it for two years.

The tenderer shall submit with his offer detail prices of the spare parts he is required to provide under the Contract indicating the quantity and the unit rate of each item.

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Protection of Excavation

1

The Contractor shall comply with all requirements of the Police Department for marking, lighting and protecting excavations. It is the responsibility of the Contractor to ascertain the requirements of Police Department and to comply fully with these requirements. No additional payments will be authorised under any circumstances for marking, lighting or protecting excavations.

2

Where carriageway works and road crossings are performed the Contractor shall provide steel plates of sufficient size and quality to permit the safe passage of traffic and the plate shall be so placed (if necessary fixed) to permit reasonable traffic flow.

3

All doorways, gates and entrances shall be kept clear with full access. Where excavations impede pedestrian access, crossings boards shall be provided. Crossing boards shall be 1250mm wide with a hand rail on both sides 1 metre high and guard rails on both sides at vehicular access to premises etc. Ducts will not be installed at entrances to premises unless instructed by the Engineer.

4

Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not possible, the material shall be removed from site and returned for backfilling on completion of cable laying at the Contractor‟s expense. In cases where the excavated material is not to be used for backfilling trenches it must be removed from site on the same day as it is excavated. Surplus material shall only be disposed of at Government approved sites. At the time of Contract award the Contractor shall contact the Ministry of Municipal Affairs and Agriculture to ascertain the approved sites and route.

1.1.26

Supply of materials

1

Where materials are to be supplied by the Contractor, the following shall apply:

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1.1.25

Materials shall be ordered in accordance with the Specifications issued by QGEWC.

(b)

Specifications and details of the proposed supplier shall be submitted to QGEWC before a firm order being placed.

(c)

On delivery of materials from outside of Qatar, QGEWC inspectors shall be given the opportunity to inspect the materials prior to their use.

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1

The Contractor shall consult the public utility authorities not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the Contractor shall make all necessary arrangements with the public utility authorities to safeguard the installation.

2

The Contractor shall give at least one week‟s notice in writing to the public utility authorities of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the public utility authorities: such operations of work shall only be carried out in the presence of the public utility authorities unless notice has been obtained in writing from the public utility authorities that they do not require to be present.

3

The public utility authorities may require work to be executed on their installation during the period of the Contract: the Contractor shall afford all facilities to the public utility authorities‟ contractors or workmen until their diversion work is complete. The Contractor shall co ordinate the work of the public utility authorities and his own activities and when necessary shall amend his programme of working to suit all requirements of the department in connection with their diversion work and shall keep the Engineer informed of all arrangements made.

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The Contractor shall locate and mark with suitable posts all the public utility authorities underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times; the Contractor shall advise the public utility authorities of any installation not found where shown on the Drawings, or found but not shown or found damaged or subsequently damaged.

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END OF PART

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Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 1

10

WIRING ACCESSORIES AND GENERAL POWER ..................................... 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4

General Reference References Description of Work Submittals

10.2

PRODUCTS ................................................................................................... 3

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10.2.1 General 10.2.2 Outlet Boxes 10.2.3 Switches 10.2.4 Ceiling Roses 10.2.5 Socket Outlets 10.2.6 Shaver Socket Outlets 10.2.7 Cooker Control Units 10.2.8 Disconnect Switches and Switch Fuses 10.2.9 Fused Connection Units 10.2.10 Junction, Pull and Terminal Boxes 10.2.11 Timer 10.2.12 Time clocks

.

2 2 2 2 3 3 3 4 4 5 6 6 6 7 7 7

INSTALLATION ............................................................................................. 8

10.3.1 10.3.2 10.3.3 10.3.4 10.3.5

Mounting Heights Installation of Outlet Boxes Installation of Switches Installation of Junction, Pull and Terminal Boxes Testing

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10.3

8 8 8 8 8

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WIRING ACCESSORIES AND GENERAL POWER

10.1

GENERAL

10.1.1

General Reference

1

The work of this Section is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2

Co-ordinate the work with all other services affecting the work of this Section.

3


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General Provisions for Electrical Installation Cables and Small wiring Conduits and Conduits Boxes Trunking

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10

References

1


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10.1.2

BS 88..........................HRC Fuses

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BS 546........................Specification Two pole and earthing-pin plugs, socket-outlets and socket-outlet adapters

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BS 800........................Specification for radio interference limits and measurements for household appliances, portable tools and other electrical equipment causing similar types of interference

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BS 1363......................13A Plugs, Switched and Un-switched Socket Outlets and connection units

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BS 3456......................Specifications for safety of household and similar electrical appliances

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BS 3676......................Part 1 Switches for household and similar fixed electrical installations BS 4177......................Cooker Control Units rated 30 Amp. and 45 Amp. 250 volts single phase supply

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BS 4343......................Industrial Plugs, Socket Outlets and Couplers BS 4662......................Boxes for enclosure of electrical Accessories BS 5419......................Fuse Switches and Switch Fuses BS 5733......................General requirements for electrical accessories BS 6972......................General requirements for luminaire supporting couplers 10.1.3

Description of Work

1

This Section shall include all labour, materials, equipment, appliances and accessories necessary for the complete performance of all switches, socket outlets etc. In accordance with the Specifications and Drawings.

10.1.4

Submittals

1

Submit shop drawings, equipment list, relevant samples etc. as mentioned under Section Part 1.

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10.2

PRODUCTS

10.2.1

General

1

All individual items of materials shall be of the same make throughout the Project unless specifically approved by the Engineer.

2

Unless otherwise indicated in the sections to follow, the faceplate of all devices shall be polycarbonate.

10.2.2

Outlet Boxes

1

Outlet Boxes: galvanized one piece pressed steel, sizes and designs shall suit devices to be fitted with a minimum wall thickness of 1.0 mm.

(B)

In all hazardous areas specified and/or shown on drawings: explosion proof.

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(a)

Outlet boxes mounted externally or in damp locations shall be totally sealed to ensure water tightness.

10.2.3

Switches

1

Lighting Switches

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(b)

to be rated 10, 15 or 20 amps depending on connected load, as stipulated in the QGEWC regulations

(c)

recessed with concealed conduit, surface pattern elsewhere

(d)

quick make and break type

(e)

single pole, double pole, one way, two way or intermediate as indicated

(f)

surface mounted switches to be either poly-carbonate, or metallic and as indicated in the Project Documentation

(g)

flush mounted switches to be of the grid fixing type with finish as noted in the Project document.

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switches shall be certified for AC-23A duty

Waterproof Switches: (a)

to be watertight IP 56 or as indicated in the Project Documentation

(b)

to be made of poly-carbonate for indoor application in damp and wet areas.

(c)

to be metallic suitable for AC-23A duty and have sunshades fitted where exposed to direct sunlight.

(d)

to be provided with rear entry for outdoor use to avoid the exposure of conduit/cables to the harmful effects of the sun.

Switch Plates (a)

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to BS 3676

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(a)

(h) 2

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2

where two or more switches are grouped together and connected to the same phase, multi-gang devices and common plates shall be used.

Double Pole Switches: (a)

the double pole switches shall be with neon indication lamps and shall be rated 20, 30 or 45 Amps. as indicated on the drawings

QCS 2014

(b)

the face plate shall be of matt chrome, unless specified otherwise in the Project Documentation and shall be engraved „WATER HEATER‟, „WATER COOLER‟ etc. as required.

(c)

switches shall be certified for AC-23A duty.

Push switches for lighting contactor control: push to make momentary contact switch

(b)

suitable for inductive load

(c)

surface mounted type shall be either poly-carbonate, metallic, protected to IP 56 or as indicated in the Project Documentation

(d)

where two or more switches occur in one position they shall be contained in one case and each shall be appropriately labelled to indicate its function

(e)

switches shall be certified for AC-23A duty and contactors shall be certified for AC-3 duty.

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Dimming Switches:

where indicated on the Project Drawings, dimming switches shall be provided, complying with BS1155

(b)

dimming switches shall be interference suppressed to conform with BS588

(c)

all dimmer units shall be sized to give a 40% margin above the connected load.

(d)

switches shall be certified for AC-23A duty

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Ceiling Roses

1

Ceiling roses shall be of the all insulated type conforming to BS76 with a white finish.

2

Ceiling roses shall be provided with insulated terminals for the switched live, neutral and protective conductors; loop-in facilities shall be provided.

3

Plug-in ceiling roses shall be used in large buildings, with extensive false ceiling systems, as detailed in the particular specification.

10.2.5

Socket Outlets

1

General purpose Socket Outlets:

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10.2.4

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3

(a)

to BS 1363

(b)

3 rectangular pin (2P+E) shuttered, with combined switch, rated 13A, 250 V

(c)

to be supplied with plug complete with fuse

15A Socket Outlet: (a)

to BS 546

(b)

3 round pin (2 P + E) shuttered switched pattern complete with plugs.

(c)

Neon indicator lamp, unless specified otherwise in the Project Documentation.

Weather proof Sockets: (a)

13A Sockets: to BS 1363

(b)

3 rectangular pins, Un-switched type to be complete with weather proof plugs

(c)

plugs: 13 Amps

QCS 2014


(d)

sockets: fused type with single pole cartridge fuse link of same rating as plug

(e)

sockets and plugs:

Page 5

(i)

to have minimum IP 55 grade protection

(ii)

housing parts: brass or pressure die-cast finished in grey hammered stove enamel

(iii)

plugs:

 

(f)

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Industrial Sockets:

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to be a combined unit comprising two sockets, rated 16A, 240V, 1 phase and 32A, 415V, 3 phase

(ii)

to be equipped with 16A SP and 32A TP MCBs, or as indicted in the Project Documentation

(iii)

three phase socket to be 5 pin type, single phase socket to be 3 pin type

(iv)

plugs of the same manufacturer to be provided

(v)

sockets and plugs to conform to BS 4343

(vi)

to have minimum IP 55 ingress protection.

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(i)

plugs and sockets for hazardous area:

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(b)

Combined Socket

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socket outlet face plates shall be finished as indicated in the Project Documentation.

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(a)

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Socket Outlet Plates:

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cable grips shall have rubber compression rings there shall be rubber gasket between plug and socket to ensure weather tightness. sockets shall have screw on caps that close tight on socket when plugs are not inserted.

to be suitable for zone 0, zone 1 or zone 2 applications, as relevant, and indicated on the Project Drawings and/or Project Documentation

(ii)

to conform to IEC 309-3

(iii)

to be corrosion resistant

(iv)

ingress protection to IP 66.

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(i)

10.2.6

Shaver Socket Outlets

1

All shaver socket outlet units shall comply with BS 3456 and IEC 335.

2

Shaver units shall be flush pattern with white moulded insert in matt chrome plate engraved „Shaver Only‟ and be suitable for installation in bathrooms, incorporating a double wound isolating transformer to provide an earth free supply.

3

Units shall incorporate primary winding circuit protection in the form of a self-resetting thermal overload device.

4

Units shall incorporate an „ON/OFF‟ switch with red neon indicator together with a selector switch for 20 VA load capacity at 240 Volts and 115 Volts

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Page 6

Units shall incorporate two pin shuttered outlet configuration and have terminals to accept 2.5 2 mm conductors.

6

Unit outlet boxes shall be a minimum of 45 mm deep, rustproof by galvanising of equal finish and complete with a brass earthing stud secured to the back of the box.

10.2.7

Cooker Control Units

1

Cooker control units shall incorporate a 32 Amp. double pole switch and 13A, 3 pin switched socket outlet and neon indicator lights for both cooker and socket

2

The cooker control unit shall be flush mounted.

10.2.8

Disconnect Switches and Switch Fuses

1

Generally

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(b)

switch shall have “ON/OFF” indication and provision for locking in “OFF” position

(c)

utilisation category AC 23A

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to be metal clad with front operated handles interlocked with switch fuse case to prevent opening switch in the “ON” position

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Fuse switch and switch fuses to BS 5419

(b)

fuses: to BS 88 bolted type, class Q1, certified for 415V and AC 80 Duty, rated as indicated

(c)

fused switch carriages: withdrawable type

(d)

fuse switches: ASTA certified to 50 KA.

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Disconnect switches

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(a)

(a)

same design as switch-fuses, with solid copper links in place of fuses

(b)

single pole and neutral, or triple pole and neutral

(c)

ratings, as indicated.

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Outdoor Equipment

equipment intended for outdoor use shall be certified by the manufacturer as being weatherproof and suitable for use outside in the prevailing conditions and shall be in compliance with the requirements of Part 28, clause 28.2.6 of this Section.

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(a)

10.2.9

Fused Connection Units

1

240 V fused connection units shall be switched, shall comply with BS1655 and shall be fitted with a fuse complying with BS5571 with a rating as specified.

2

All fused connection unit shall be fitted with a neon indicator.

3

Live contacts shall not be exposed under normal operating conditions when replacing a fuse.

4

240 V fuse connection units in plant areas, workshops etc., shall be surface mounted, metalclad and shall comply with BS5575 .

5

The type of fused connection unit, particularly relating to the flex outlet, shall be authorised by the Engineer prior to the ordering of accessories.

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Page 7

10.2.10 Junction, Pull and Terminal Boxes 1

The Junction Box shall be completed with a terminal block suitable for connecting up to 10 2 mm copper conductor (phase, neutral and earth) and an all insulated moulded white cover plate with removal covers.

2

The cover plate shall be raised for connecting outgoing cable.

10.2.11 Timer Timers shall be electronic type, unless specified otherwise in the Project Documentation.

2

Timers shall be suitable for operation from supply voltage of 240V, 1-phase, 50Hz system.

3

Timer output contacts shall be suitable for both a.c. and d.c. control circuits. The contacts shall be suitable for duty of AC-2 or DC-3 utilisation category. The rating of output contacts shall be co-ordinated with the application requirements.

4

Timers shall be provided with 2 independent timing scales with sets of change-over output contacts:

(b)

0.10 ................ 20 seconds

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10 ................... 200 seconds

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(a)

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ON/OFF indicator shall be provided to monitor the circuit status.

6

Timers shall be either:

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delay on energisation or

(b)

delay on de-energisation type, as per the application requirements

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Upon supply of rated voltage to the input terminals, the timer shall start, the output relay remains in rest position. After the set time, the output relay pulls in. The relay resets after the input supply has been cut-off. Timers shall be suitable for minimum 10 million operations.

8

The timer shall require a pozi-drive screw driver for changing of the settings.

9

Degree of protection shall be minimum IP 20.

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10.2.12 Time clocks 1

Time clocks to control circuits depended on time and hours of the day, may be either (a)

Synchronous motor operated, or

(b)

Quartz controlled motor operated, as per Project Documentation.

2

Time clocks shall be suitable for operation from supply voltage of 240V, 1-phase, 50Hz system.

3

Output contacts shall be suitable for both AC and DC control circuits. The contacts shall be suitable for duty of AC-2 or DC-3 utilisation category. The rating of output contacts shall be co-ordinated with the application requirements.

4

The no. of output contacts and the duration of contact closing shall be decided as per the application requirements.

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Page 8

Time clocks shall be provided with a time dial setting for 24 hours and 7 days program.

6

Each time clock shall be provided with a minimum running reserve energy for 1 day.

7

Accuracy of clocks shall be better than 1 second per day.

10.3

INSTALLATION

10.3.1

Mounting Heights

1

The mounting heights of wiring accessories shall be as stipulated in the QGEWC Regulations, or as otherwise approved by the Engineer.

10.3.2

Installation of Outlet Boxes

1

Location of Boxes:

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determine exact location of boxes on site and obtain the Engineer‟s approval before commencing installation

(b)

make allowance for overhead pipes, ducts, variations in arrangement, thickness of finish, window trim, panelling and other construction when locating boxes.

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Fixing: (a)

fix outlet boxes securely

(b)

fix exposed outlet boxes to permanent inserts or lead anchors with machine screws.

Installation of Switches

1

Lighting Switches:

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10.3.3

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located at the strike side of the door, approximately 150 mm from the edge of door frame

(b)

plates shall be installed with all four edges in continuous contact with finished wall

(c)

plates shall be installed with an alignment tolerance of 1.5 mm

(d)

all switch assembly louvered plates shall have their earthing terminal connected to 2 the earth terminal attached to the switch box by an insulated 2.5 mm protective conductor.

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(a)

10.3.4

Installation of Junction, Pull and Terminal Boxes

1

Generally:

2

(a)

fix junction, pull and terminal boxes where indicated and where required to facilities pulling of wires and cables and connection of future appliances

(b)

locate boxes as inconspicuously as possible, but accessible after work is completed.

Pull Boxes: (a)

fix at maximum 10m spacing and to limit the number of bends in conduit to not more than two 90° bends.

10.3.5

Testing

1

Test all switches, socket outlets etc. for correct polarity and continuity of conductors in the presence of and to the entire satisfaction of the Engineer.

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Page 9

2

Carry out live phase to earth loop impedance tests at all switches and socket outlets with an approved earth loop impedance tester to the entire satisfaction of the Engineer. Ensure that all device plates have satisfactory earth continuity to the protective conductor system.

3

Test all socket outlets for instantaneous tripping of associated distribution board current operated earth leakage circuit breaker using testing equipment, approved by the Engineer.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 11: Light Fittings

Page 1

11

LIGHT FITTINGS ........................................................................................... 2

11.1

GENERAL ...................................................................................................... 2

11.1.1 11.1.2 11.1.3 11.1.4

General Quality Assurance References Submittals

11.2

PRODUCTS ................................................................................................... 3

11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6

Lamps Luminaires Termination/Earthing Ceiling System Noise and Interference External Lighting

11.3

INSTALLATION ............................................................................................. 7

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11.3.1 Lighting Installation 11.3.2 Installation of Lamps

3 4 5 6 6 6 7 7

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Page 2

11

LIGHT FITTINGS

11.1

GENERAL

11.1.1

General

1

This section includes the supply and installation of lighting fittings as shown on the drawings, and as specified.

11.1.2

Quality Assurance

1

Design Criteria: lighting fittings shall be of first class quality, made by approved manufacturers and shall be suitable for trouble free operation on the system voltage at the site

(b)

lighting fittings shall be complete with internal wiring between lamp holder and termination point. Wiring shall be in silicone rubber insulated heat resistant flexible cables

(c)

the Contractor shall be responsible for co-ordinating the light fitting installation with any other components of the ceiling systems

(d)

all lighting fittings shall be complete with accessories and fixing hardware necessary for installation whether so detailed under fixture description or not

(e)

outdoor lighting fittings shall be installed at mounting heights as specified or instructed on site by the Engineer

(f)

all outdoor lighting fittings shall be suitably constructed and protected to withstand the corrosive atmosphere and high ambient temperatures of the site, whether indicated under the fittings description or not

(g)

lighting fittings shall have power factor not less than 0.9.

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(a)

References

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11.1.3

BS 800 ........................Limits and methods of measurement of radio interference characteristics of household electrical appliances, portable tools and similar electrical apparatus BS 3677 ......................High pressure mercury vapour lamps BS 4533 ......................Luminaires BS 5225 ......................Photometric data for luminaires BS 60400 ....................Lamp holders for tubular fluorescent lamps and starter holders BS EN 60081 ..............Tubular fluorescent lamps for general lighting service BS EN 60238 ............Edison screw lamp holders BS EN 60529 ............Degrees of protection provided by enclosures BS EN 60662 ...........(IEC 662), High pressure sodium vapour lamps BS EN 60947-1 ........General rules for low voltage switch gear and control gear BS EN 61167 ............Metal halide lamps


11.1.4

Submittals

1

Products Data:

full technical details of the fittings, including the control gear, indicating the type and size of materials used in construction

(ii)

relevant sheets of manufacturer’s catalogues and dimensional drawings of the fittings, clearly showing the location of the component

(iii)

wiring diagram of internal connections indicating colour, size and type of wiring

(iv)

confirmation that control gear is suitable for prolonged and continuous service in the ambient conditions described in Part 1

(v)

the power factor under operating conditions and illumination data sheets.

(vi)

type and quality of any plastic materials used in the fittings.

.

(i)

Other lighting fittings, submit:

full technical details of the fittings, with relevant manufacturer’s catalogues and illumination data sheets

(b)

type and quality of all metal finishes

(c)

size and quality of all glassware.

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(a)

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Fluorescent fittings and other electrical discharge lamp fittings, submit:

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QCS 2014

At least one piece of each of the lighting fixtures originally specified and quoted shall be submitted and displayed at the site office, including the alternative items for comparison in the event an alternate make is offered.

11.2

PRODUCTS

11.2.1

Lamps

1

General:

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lamps shall be furnished and installed in all luminaires covered under the Contract

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(b)

lamps used for temporary lighting services shall not be utilised in the final use in fixture units

(c)

lamps for permanent installation shall not be placed in the fixtures until so directed by the Engineer, and this shall be accomplished directly before the building areas are ready for occupancy by the Employer

(d)

lumen output of lamps shall be in accordance with BS EN 5225

(e)

generally, high output, low consumption, tri-phosphorus lamps shall be used, unless otherwise indicated.

Fluorescent Lamps: (a)

(tubular fluorescent lamp, to BS EN 60081. Lengths/diameters as indicated in the Project Documentation

(b)

tube colour: cool white, unless otherwise indicated

(c)

fittings shall comply with BS 800, for suppressing radio frequency interference.

QCS 2014

wattage as indicated in the Project Documentation

(b)

colour: deluxe white

(c)

lumen output of lamps shall be in accordance with BS 3677

(d)

burning position: universal.

High Pressure Sodium Lamps wattage as indicated in the schedule of luminaires

(b)

lamps with a high colour rendering index of 80 shall be used as indicated, suitable for indoor applications

(c)

lumen output of lamps shall be in accordance with BS EN 60662.

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Metal Halide Lamps (a)

wattage as indicated in the schedule of luminaires

(b)

lumen output of lamps shall be in accordance with BS EN 61167

Control Gear For Fluorescent Lamps: (a)

high frequency electronic ballast not less than 25 kHz to IEC 928, unless specified otherwise

(b)

when specified, conventional type low loss ballast with electronic starters shall be used and shall provide flicker free operation, as indicated in the Project Documentation

(c)

glow starters shall not be used

(d)

capacitors shall be supplied with discharge resistors and shall be housed in aluminium canister.

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Lamp Holders: (a)

SBC, BC GES, Bi-pin, etc. as necessitated by the lamp cap Edison screw lamp holders, to BS EN 60238, to be designed so that the lamp cap only makes electrical contact when fully screwed home, and to have means to prevent the unscrewing of the lamp due to vibration or similar cause

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(a)

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High Pressure Mercury Vapour Lamps:

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(c)

Lamp holders for fluorescent lamps, shall be the spring loaded rotary type, to BS 6702.

11.2.2

Luminaires

1

Luminaires shall be manufactured to BS 4533 with an appropriate IP classification to BS EN 60529.

2

All lighting fittings shall be supplied complete with appropriate control gear where necessary, lamps, mounting and fixing accessories etc. whether explicitly mentioned in the description of each light fitting or not. All the fittings shall have the same appearance, material, technical details and approximate dimensions.

QCS 2014


Page 5

Luminaires shall be connected to the main circuit wiring with heat resistant flexible cables of 2 a minimum conductor size of 1.5 mm insulated with silicon rubber.

4

Break joint rings shall be used in conjunction with batten holders, ceiling roses or back plates mounted onto a flush installation.

5

Standard fluorescent luminaires shall have two suspension or fixing points. The thickness of the luminaries body shall not be less than 0.6 mm.

6

All lamp-holders for flexible pendants shall be of the all insulated skirted pattern with code grips and for batten or wall mounting shall be of similar pattern. All lamp holders shall be of the bayonet cap pattern.

7

The point box suspensions and other parts of the lighting fittings shall be provided to be erected at festival time to suit the building programme for decoration as per the requirements of the Project Documentation.

8

The glassware diffusers, shades and lamps shall not be fitted until all building work is complete.

9

All fittings shall be easy to clean inside and outside, when mounted.

10

All fluorescent fittings shall be suitable for instant start irrespective of any catalogue or list numbers quoted.

11

Diffusers on fluorescent luminaires shall be poly-carbonate unless otherwise specified in the Project Documentation.

12

All fittings that are mounted in areas accessible to the public shall be provided with vandal proof high strength diffusers and shall be additionally provided with a galvanised steel mesh security guard.

13

All luminaires shall be certified by the manufacturer for use in an ambient temperature of 50°C.

14

All luminaires intended for use in hazardous areas shall be certified to be zone 1 or 2 as required at 50°C ambient temperature.

15

Wet well luminaries, fixtures and cabling shall conform to ingress protection IP67,shall be PTFE coated and shall be provided with tungsten halogen lamps i.e. no run up or re-strike time for safety reasons.

16

All wet well luminaries, fixtures and cabling shall conform to ingress protection IP67.

11.2.3

Termination/Earthing

1

Fused terminal blocks shall be fitted and be of sufficient capacity for the wiring involved. 2 Each terminal shall be capable of accommodating two 2.5 mm conductors.

2

Connector strip terminals shall have a current rating not less than the rating of the circuit protective device and shall be encapsulated in self-extinguishing grade polyethylene.

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Page 6

Where connector strips are provided in boxes behind heat producing appliances, porcelain connectors shall be used where temperatures in excess of 70 °C are likely.

4

Conductors shall be clamped between metal surfaces such that no screws make direct contact with the conductor. The metal used in construction of the connector shall be at least 85 °C copper alloy such that good conductivity and electrolytic compatibility are maintained at all times.

5

All light fittings shall be provided with an earthing terminal which shall be connected to the earth continuity lead of the final sub-circuit.

6

The earthing of all pendant or semi-pendant fittings shall be by a separate core in the connecting flex or cable securely bonding the earth terminal on the fitting to the glanded joint of interconnecting cables. In no case shall pendant chains or conduit support tubes be used as a means of earthing.

11.2.4

Ceiling System

1

In false ceilings, luminaires whether surface or recessed mounted shall not be supported by the false ceiling construction. Separate independent supporting systems shall be provided for each luminaire, comprising drop rods, chains or similar.

2

Luminaires installed in false ceilings shall be connected to the lighting circuit using mechanically coupled plug-in ceiling roses.

3

Luminaires shall be positioned to provide ease of access for maintenance, cleaning etc., while not impairing the distribution of light.

4

The Contractor shall ensure that the luminaire manufacturer has the correct details of the ceiling system, including suspension, tiles, etc. He shall ensure that the luminaires are supplied with the correct trim, suspension system and are fully compatible with the ceiling system.

11.2.5

Noise and Interference

1

The noise level from control gear, obtained from the average of sound pressure levels each measured at 2000 mm from the control gear in at least five positions (on each side and below), shall not exceed 30 dB Scale “A” (Noise Rating Number).

11.2.6

External Lighting

1

General:

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3

(a)

external lighting system shall consist of supply and installation of lighting columns, foundation and fixing of the columns, underground cabling, high pressure sodium vapour lamps or as specified, and control equipment as required

(b)

contactor units, where specified incorporating a controlling photo-cell and time switch, shall be provided within the external lighting distribution board for the control of external lighting

(c)

underground lighting cabling shall be XLPE or PVC/SWA/PVC or as detailed in in the Project Documentation.

QCS 2014

Page 7

Lighting Columns (a)

columns shall be hot-dip galvanized steel of either tapered or tubular construction complete with luminaire fixing arms or brackets, as per design.

(b)

all columns shall be externally painted with 2 coats of aluminium paints, internal surface including the studs inside the cable connecting box with red lead anticorrosive paints, the finishing shall be micaceous iron oxide paint pigmented with aluminium

(c)

the column shall be equipped with auxiliary control gear and a 15 amp. single pole and neutral cut-out (with a three phase and neutral terminal block), two cable glands and two entry slots in the base of the pole for incoming and outgoing cables

(d)

a two core and earth 2.5 mm sq. butyl rubber insulated heat resistant flexible cable shall connect the lantern to the cut-out

(e)

columns shall be provided with base plates having fixing holes and anchor bolts for foundations

(f)

unless specified otherwise, the column length shall be 5m including buried part or 4m when plinth mounted. The diameter at the bottom shall not be less than 120 mm.

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All external lighting fittings shall be adequately earthed.

4

Control gear shall form an integral part of the lighting fittings except where specified, or where this is not possible, it shall be totally enclosed in a housing to suit the installation location.

5

All external fittings shall be dust-tight and waterproof to IP 65.

6

The particular requirements for road lighting and high mast floodlighting are specified in Section 6, Part 12.

11.3

INSTALLATION

11.3.1

Lighting Installation

1

Terminations:

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3

(a)

general fluorescent fittings mounted direct to conduit outlet boxes shall have the circuit wiring run direct to the fittings terminal position. Flexible conduit pigtail shall be provided for all fixtures to J-boxes

(b)

terminations for recessed, or semi-recessed pattern fittings fitted in false ceilings, shall have the circuit wiring terminal above the ceiling in a ceiling rose Outlets shall be mounted adjacent to the fitting.

11.3.2

Installation of Lamps

1

Generally install new lamps in all luminaires at substantial completion of work. END OF PART

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 1

12

EMERGENCY LIGHTING .............................................................................. 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 12.1.2 12.1.3 12.1.4

Scope Reference Standards Quality Assurance Warranty

12.2

PRODUCTS ................................................................................................... 3

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

General Central Battery Units Self Contained Emergency Battery Packs Luminaries and Lamps Obstruction / Beacon lights

12.3

INSTALLATION ............................................................................................. 6

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2 2 2 2

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12.3.1 Wiring 12.3.2 Installation of Batteries 12.3.3 Luminaries and Lamps

3 3 4 5 6 6 6 7

QCS 2014


Page 2

EMERGENCY LIGHTING

12.1

GENERAL

12.1.1

Scope

1

This Part specifies the general requirements for emergency lighting and accessories both maintained and non-maintained. It shall be read in conjunction with other parts of the Specifications and the Project Drawings.

2


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General Provisions for Electrical Installations Wiring Accessories and General Power Light Fittings Testing

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12

Reference Standards

1

The following standards and documents of other organisations are referred to in this Part, and shall be complied with:

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12.1.2

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BS 4533 .....................General requirements and tests

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BS 4533 ......................Luminaires for emergency lighting

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BS 5225 ......................Method of photometric measurement of battery operated emergency lighting luminaires BS 5266 ......................Emergency lighting

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BS 7671 .....................Requirements for electrical Installations

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BS EN 60529 ..............Degrees of protection provided by enclosures (IP code)

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ISO 9000 ....................Quality management and assurance standards QGEWC .....................Qatar General Electricity & Water Corporation Regulations.

12.1.3

Quality Assurance

1

The supplier‟s manufacturing facility shall be certified to ISO 9000 or equivalent.

12.1.4

Warranty

1

Battery units, luminaires and accessories shall be warranted for a minimum of 5 years by the manufacturer. The battery shall have minimum 10 years useful life.

QCS 2014


Page 3

PRODUCTS

12.2.1

General

1

Emergency lighting installations shall be complete with emergency batteries, chargers, luminaires and wiring, all as described in Specifications and as indicated on the Project Drawings, complying with BS 5266 Part 1.All emergency lighting shall be Non-maintained type except for the EXIT lights where it shall be maintained unless otherwise explicitly specified in the project documentation.

2

Non-maintained luminaires shall be supplied directly from the battery system. Maintained exit luminaires etc., shall be supplied from a separate supply via an independent transformer and shall only operate from batteries during mains failure.

3

The operation of the system shall be such that on loss of one or all phases of the main electricity supply, a set of central batteries or individual battery packs shall provide power for 3 hours to illuminate emergency luminaires throughout the building. On restoration of the

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12.2

1

Battery chargers:

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Central Battery Units

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12.2.2

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mains supply the batteries shall be charged by an integral charger such that the system supplies not less than 85 % of its rated voltage after a period of 12 hours.

battery chargers shall be installed in purpose-made metallic enclosures with an index of protection IP 31 in accordance with BS EN 60529 suitable for wall or floor mounting, depending on size

(b)

battery charger enclosures may house the system batteries providing the design of the enclosure ensures safe operation with the batteries specified. This arrangement should normally be restricted to smaller systems e.g. for circuit breaker tripping supplies for power supply to emergency lighting system, central battery units shall be wall or floor mounted as required, conforming to BS 4533 Section 102.22, and be of robust, high quality construction. Enclosures shall be metal, with hinged lockable doors and with suitable ventilation provided battery charger shall operate from a 415 V, three phase or 240 V, 50 Hz single phase

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(a)

supply, unless otherwise specified

(d)

battery charger shall be rated to supply trickle charge and any standing loading plus any additional recharging load that may be imposed

(e)

battery charger shall use an uncontrolled bridge as the input stage to minimise harmonic generation on the supply system. The characteristics of each charger shall match the requirements of the specific batteries selected and the duty cycle

(f)

battery charger shall be suitable for fully automatic charging of the appropriate battery and shall be provided with: (i)

Mains „ON‟ lamp

(ii)

Main ON/OFF switch

(iii)

Charge Ammeter Discharge Ammeter

(iv)

Battery voltmeter

QCS 2014


Page 4

(v)

Test switch facilities

(vi)

Contactor/relays to BS 5266 Part 3

(vii)

fault protection

(viii)

output current limitation

(ix)

lamp indication for appropriate faults e.g. charger fail, low volts etc., with lamp colours in accordance with BS EN 60073

(x)

common fault contact for use with a central alarm system or BMS.

units shall be provided with composite output distribution boards of the sizes and types indicated on the Project Drawings

(h)

units shall be installed complete with all necessary fixings, maintenance equipment and instructions.

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Batteries: (a)

batteries shall be suitable for the discharge duty they will be required to perform. Batteries shall be of the lead acid, sealed re-combination type or Nickel Cadmium depending on the duty requirements and as indicated on the Project Drawings. The contractor shall submit calculation to justify the Ampere-Hour capacity of the batteries for approval to the Engineer

(b)

battery system shall be provided with a suitably rated switch disconnector

(c)

Batteries shall be mounted on suitable tiered galvanized steel shelving with moulded plastic trays to contain any leakage from the battery cells and, to allow safe easy access for maintenance

(d)

battery terminals shall be coated with the battery manufacturer‟s approved grease, and shrouded if not enclosed.

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(g)

Self Contained Emergency Battery Packs

1

Where a central emergency battery unit is not installed, individual emergency luminaries shall consist of individual power packs installed within or remote to the luminaries.

2

Battery pack units shall consist of converter/inverter devices, with nickel-cadmium batteries to provide 3 hours operation under mains failure, unless the main supply is restored prior to this.

3

Luminaries with self contained battery packs shall be connected to the „live side‟ of the local lighting circuit and lamps shall operate automatically under mains failure conditions.

4

Units shall have the capability of sustaining high temperature so that they can be accommodated in fittings with high internal temperatures. However, if the internal temperature of the fittings exceeds 50 °C, the battery unit shall be mounted remote to the

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12.2.3

luminaries. In the case of remote mounting, a purpose made remote mounting box shall be provided. 5

Key operated switches shall be provided, at the locations indicated on the Project Drawings, for all self contained emergency pack unit luminaries, to control the operation of the luminaries manually for testing purposes. Test key switches shall be clearly labelled “Emergency Lighting”.

QCS 2014


Page 5

12.2.4

Luminaries and Lamps

1

Clauses of Part II relating to luminaries and lamps shall also apply to emergency luminaries and lamps.

2

Slave luminaries shall comply with BS 4533 Section 102.22 and BS

Part 3 and be as

specified. 3

Exit sign luminaries lettering shall be both in Arabic and English. The Arabic text shall be above the English text. Maximum viewing distance for minimum legend height shall be guided as follows:

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H > L/200 H = Height of Legend L = Distance of viewer from the sign

Self contained emergency luminaries shall have a red light emitting diode installed on the luminaries so that the red light is visible.

5

With the central battery unit system, emergency luminaries shall be installed with an engraved label fixed to the outer case of the luminaries, so that it is readily identified. The label shall detail the lamp wattage and rated voltage.

6

Generally, marking of emergency luminaries shall comply with BS

7

The following illumination level shall be considered for designing the number of luminaries for emergency lighting: (refer to BS 5266, Part 1)

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4

first aid and safety equipment exit doors fire alarm call points fire fighting equipment exit and safety signs changes of direction corridor intersection adjacent areas of final exit points

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5 lux for vital positions:

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Space to Height Ratio for luminaries shall be 4:1

1 lux for normal working spaces:

on the centreline of escape route toilets lift cars and moving ways plant rooms covered car parks

Part 1.

QCS 2014

8


Page 6

Fluorescent lamps shall be provided for both slave and self contained type luminaire installations. The lamp wattage ratings shall be chosen from the following table: Slave Self contained

: 4 watts or 8 watts : 8 watts, 18 watts, 36 watts or 58 watts

Total quantity of luminaries shall be calculated based on the illumination level requirement as per item 7 above, the type of luminaries and lamp lumens. Obstruction / Beacon lights

1

This regulation is mandatory by International Civil Aviation Organization (ICAO).

2

Where a building height is 45m or more, then the contractor shall install permanent obstruction lights as required by ICAO.

3

The contractor shall obtain local navigation authorities requirements and approval for this type of installation..

12.3

INSTALLATION

12.3.1

Wiring

1

Where the emergency lighting system installation is via a central battery unit, the wiring to emergency luminaries shall be carried out in MICC, PVC sheathed cables, unless specified otherwise.

2

Where the emergency lighting scheme is self-contained emergency packs, the wiring system shall either be in MICC Cables as above or in PVC insulated single core wires in conduits.

3

Generally, cables shall be 2.5 mm cross-sectional area unless specified otherwise.

4

The Contractor shall pay careful attention to cable routings so as to keep cable runs to the shortest possible length and ensure the overall volt drop on any circuit is within the tolerances of the luminaries connected and within the limits specified in the QGEWC regulations.

12.3.2

Installation of Batteries

1

The manufacturer‟s recommendation/instructions shall always be followed.

2

Insulated tools shall be used.

3

Personnel erecting battery banks shall remove metallic objects from their person i.e. watches, rings etc.

4

Eye and hand protection shall be provided.

5

Batteries shall not be left on site for prolonged periods without being trickle charged to maintain their condition i.e. if delivery is some weeks before commissioning of the charger.

6

Due care shall be observed when handling acidic substances.

2

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12.2.5

QCS 2014


Page 7

12.3.3

Luminaries and Lamps

1

Luminaries and lamp installation shall comply with the requirements stipulated in Part 11 for general light fittings.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 13: Telephone Installations

Page 1

13

TELEPHONE INSTALLATIONS .................................................................... 2

13.1

GENERAL ...................................................................................................... 2

13.1.1 Scope 13.1.2 Reference Standards 13.2

2 2

PRODUCTS ................................................................................................... 2

13.2.1 General 13.2.2 Telephone Outlets

2 2

INSTALLATION ............................................................................................. 3

13.3.1 13.3.2 13.3.3 13.3.4

Incoming Line/Site Services Conduits and Trunking Telephone Outlets Special Requirements

13.4

RECORD DRAWINGS .................................................................................. 4

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3 3 3 3

QCS 2014


Page 2

TELEPHONE INSTALLATIONS

13.1

GENERAL

13.1.1

Scope

1

This Part specifies the general requirements for telephone installations carried out as part of a contract for other works. It shall be read in conjunction with the other Parts of the Specifications and the Project Drawings.

2


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General Provisions for Electrical Installations Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Wiring Accessories and General Power Structured Cabling Systems Testing

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 10 Part 14 Part 23

.

13

Reference Standards

1

The following standards and documents of other organisations are referred to in this Part, and shall be complied with.

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BS 13631....................3A plugs, socket outlets, adapters and connection units

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Telecom Provider .......Regulations

PRODUCTS

13.2.1

General

1

Telephone cabling and equipment supply and installation shall be carried out by an approved Ooredoo contractor specialising in telephone installations.

2

All telephone related installations carried out by the Contractor shall conform to the Ooredoo standard specifications and regulations together with this specification and the Project Drawings.

3

3 The Contractor shall supply and install cable ways, empty conduits with draw wires and/or trunking, telephone points and outlets, PVC ducts, telephone junction boxes, and manholes as required and shown on the Project Drawings unless otherwise Specified.

13.2.2

Telephone Outlets

1

The Contractor shall supply and install telephone points and the associated mains power outlets which shall conform to BS .

2

The telephone outlets shall be jack type and from the same manufacturer, and finish as for the lighting and general power outlets, unless specified otherwise.

3

Telephone outlets shall be of the type approved by Ooredoo.

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QCS 2014


Page 3

13.3

INSTALLATION

13.3.1

Incoming Line/Site Services

1

The Contractor shall supply and install the incoming line underground through Ooredoo approved PVC-u pipe ducts with draw wires, together with the manholes/draw pits as indicated on the drawings.

2

The works shall be carried out in co-operation with Ooredoo Engineers.

3

Standard Ooredoo type manhole and manhole covers shall be utilised, appropriate to the manhole location.

4

External ducts shall be installed in a 775 mm deep trench, on 75 mm of dune sand, covered

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with 75 mm of dune sand, and completed with selected filling materials. Trenches for Q-Tel ducts through rockfill shall be lined with geotextile filter fabric material as specified in Section 6 Clause 14.9.4.

6

Contractor shall arrange with Ooredoo for inspection of the installation during execution stage and on completion, all costs are deemed to be included in his price.

13.3.2

Conduits and Trunking

1

The Contractor shall if required by the Project Specification or on the Project Drawings, allow for the supply and installation of an empty conduit system complete with draw wires and/or a trunking system between the outlet points and the telephone equipment area.

2

Conduit installations shall be concealed within the building fabric and/or concealed in suspended ceiling voids.

3

Conduit and trunking installations shall conform to the requirements of the Specifications and Ooredoo requirements.

4

Unless otherwise specified, the minimum size of the conduit installed shall be 25 mm

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The Contractor shall be responsible for liaison with the specialist telephone installer and/or Ooredoo engineers to ensure that:

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diameter and telephone underground duct 50 mm diameter as subscriber duct.

(a)

the proposed conduits and trunking are adequate to accommodate cables

(b)

the specialist installer is provided with the programme requirements and that his work is carried out in accordance with the Contractor’s main programme.

13.3.3

Telephone Outlets

1

Outlets shall be installed at locations indicated on the drawings and at the same heights as the general power socket outlets, unless otherwise specified in the Project Documentation.

13.3.4


1

The Contractor shall consult the Ooredoo not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed works, in which event the Contractor shall make all necessary arrangements with Ooredoo to safeguard the installation.

QCS 2014


Page 4

The Contractor shall give at least one week’s notice in writing to Ooredoo of the dates upon which it is intended to operate plant or equipment or carry out work for which permission has been given in writing by Ooredoo; such operations of work shall only be carried out in the presence of Ooredoo unless notice shall be obtained in writing from Ooredoo that they do not require to be present.

3

Ooredoo may require work to be executed on their installations during the period of the Contract; the Contractor shall afford all facilities to Ooredoo’s contractors or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of Ooredoo and his own activities and when necessary shall amend his programme of work to suit all requirements of Ooredoo in connection with their diversion work and keep the Engineer informed in writing of all arrangements made.

13.4

RECORD DRAWINGS

1

The Contractor shall keep accurate record drawings of the arrangement, positions and details of all works constructed by him. These drawings will be of forms and to scales approved by the Engineer and his designated representative.

2

As soon as each drawing has been completed, two prints shall be submitted to the Engineer and his designated representative for approval.

3

If the Drawings or documents are not approved, one copy shall be returned to the Contractor with marked indications of the alterations required. Upon final approval one copy of the drawing or document shall be stamped "Approved" by the Engineer or his designated representative and returned to the Contractor forthwith.

4

After such approval is given, the Contractor shall supply to the Engineer two prints of the finalised drawings, and the digital files in CAD format on CD, for the use of the Engineer.

5

All record drawings shall be completed within 30 days of the commencement of the Maintenance Period.

6

Record drawings will show accurately the exact locations of all road crossings, ducts, joint boxes, etc., fully dimensioned and triangulated.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 1

14

STRUCTURED CABLING SYSTEMS ........................................................... 2

14.1

GENERAL ...................................................................................................... 2

14.1.1 Scope 14.1.2 Reference Standards

2 2

PRODUCTS ................................................................................................... 2

14.2.1 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6

General Copper Cables Optical Fibre Cables Patch Panels Patch Cords/Line Cords Outlets

14.3

INSTALLATION ............................................................................................. 5

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14.2

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14.3.1 Containment Systems 14.3.2 Testing and Commissioning

2 2 3 4 4 5 5 5

QCS 2014


Page 2

STRUCTURED CABLING SYSTEMS

14.1

GENERAL

14.1.1

Scope

1

This Part specifies the general requirements for structural cabling system used in data transmission applications for buildings or sub-systems thereof.

2


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General Provisions for Electrical Installations Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Uninterruptible Power Supply Systems Testing

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 18 Part 23

.

14

Reference Standards

1


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14.1.2

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BS EN 60950.............. Safety of information technology equipment, including electrical business equipment

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EN 50173 ...................Information Technologies: Generic Cabling Systems

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ISO/IEC 11801 ...........Generic Cabling for Customer Premise Cabling EIA/TIA SP-2840

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ANSI/EIA/TIA 455-30,46,51,53,61 ANSI/EIA/TIA 568A

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ANSI/EIA/TIA 592-AAAA

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ANSI/ICEA S-83-569 (Ref. B.1.40) Bellcore TR-TSY-000020

PRODUCTS

14.2.1

General

1

The Contractor shall provide structured cabling installations for telephone and computer networks, including distribution frames, patch panels, racking systems (cabinets), patch cords, outlets, adaptors, conduits, PVC ducts and junction boxes, in accordance with the Project Specification and Drawings.

2

Wiring for cabling systems shall be carried out by a Specialist Contractor approved by the Engineer and Ooredoo, who has 5 years experience in Qatar.

14.2.2

Copper Cables

1

Copper cables shall be 24 AWG, 4 pair 0.170 mm diameter, polymer alloy jacket, category 5, unshielded twisted pair (UTP), suitable for extended multi-media transmission distance over frequency range up to 100 MHz, with extremely low noise characteristics.

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QCS 2014


Page 3

2

Cables shall conform to ANSI/EIA/TIA 568A, Category 5 and EIA/TIA SP-2840 horizontal UTP.

3

Cables shall conform to the following performance data:

14.2.3

NEXT (dB) worst pair at 100 MHz

:

38 dB

Attenuation (dB/100 m)

:

22.0 dB/100 m

Impedance ±7 % (Typical)

:

100 ohms ±7 %

Optical Fibre Cables There are two types of optical fibre cables, one is multi-mode, graded index optical fibre and another is Single Mode optical fibre.

.

Multi-mode, graded index optical fibre.The multimode graded index optical fibre cables with nominal 62.5/125 µm core/cladding diameter, which are optimized for use in both wave lengths 850 nm and 1310 nm.

(b)

Fibres shall comply with ANSI/EIA/TIA 592-AAAA (Ref. B1.18) and also with ANSI/EIA/TIA 568A Paragraph 12.5.1 on mechanical terminations.

(c)

Outdoor optical fibres shall be used to connect buildings to the main distribution frame.

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(a)

Outdoor optical fibres shall comply with the same specifications, however cables shall also be, jelly filled, rodent proof specifically made for outdoor applications and shall be used for installation in ducts and shall be flexible and resistant to pulling and torsion forces, with 12 strands ,unless otherwise specified in the project specification. Optical fibres shall meet the graded-index multi-mode performance specified in Table 14.1. Table 14.1 Graded-Index 62.5/125 µm Multi-mode Cable Characteristics 850 nm 1300 nm

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Multi-mode, Graded Index Optical Fibre.

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1

3.75

0.4

Bandwidth - MHz. km

160

500

Attenuation shall be measured in accordance with EIA fibre optic test procedure ANSI/EIA/TIA 455-46, 61, or 53 (Ref. B1.39). Information transmission capacity shall be measured in accordance with the ANSI/EIA/TIA 455-51, or 30 (Ref. B1.39).

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Attenuation - dB/km

(c)

3

Mechanical and environment specifications for indoor fibre optical cables shall be in accordance with ANSI/ICEA S-83-569 (Ref. B1.40). Outdoor fibre optic cables shall be in accordance with Bellcore TR-TSY-000020 (Ref. B1.36).

Single Mode Optical Fibre. (a)

The Single mode optical fibre cables which are optimized for use in both wave lengths 1310 nm and 1550 nm.

(b)

The optical fibre cables shall meet the requirements stated in ITU-T Rec. by international telecommunication Union, BS EN 50173-3 standard.

(c)

The fibre utilized in these cables have maximum attenuation at 1310 nm of 0.4 dB/km, at 1550 nm of 0.3 dB/km or less. If used for outdoor, then the fibre cable must be loose-tube non-dielectric type.

QCS 2014

(d)


Page 4

Outdoor optical fibres shall comply with the same specifications, however cables shall also be jelly filled, rodent proof specifically made for outdoor applications and shall be used for installation in ducts and shall be flexible and resistant to pulling and torsion forces, with 12 strands ,unless otherwise specified in the project specification.

The single mode fibre shall be used for fibre optic network more than 300 m distance data transmission, unless otherwise justified by the manufacturer.

5

The above specified cables shall be new, unused and of current design and manufacture. Suitable optical fibre cables shall be selected based on the distance travel, bandwidth, indoor and outdoor application and shall be approved by the Engineer .The material of the fibre shall be silica glass fibre.

14.2.4

Patch Panels

1

Patch panels shall be type RJ45, 16 port, 1U type in rows of three with extension possible of up to six patch panels.

2

Patch panels shall be housed inside racking system (19” preferred) cabinets with hinged doors on either side and lockable front doors.

3

Ventilation slots shall be provided in both sides.

4

Rack size shall suit patch panels.

14.2.5

Patch Cords/Line Cords

1

Patch cords, shall be 2 metres long with adapters at both ends suitable for connection to RJ45 16 port IU patch panels.

2

Patch cords shall be Category 5 and be flexible enough to bend without loosing any performance.

3

Patch cords shall be the flexible stranded type.

4

Line cords shall have the same specifications as patch cords, however these shall be the solid type, used at wall outlets to connect computers or terminals to distribution cabling systems.

5

Cables shall comply with the performance data specified in Table 14.2.

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4

Table 14.2 Specifications for Category 5 solid/stranded line cords or patch cords Frequency Attenuation Next (MHz)

(Max. dB/305 m)

(Min Loss dB/305 m)

1.00

6.80

62.0

4.00

14.0

53.0

10.0

22.4

47.0

16.0

28.3

44.0

20.0

31.7

42.0

25.0

35.9

41.0

31.25

40.9

40.0

62.5

59.3

35.0

100.0

76.1

32.0

QCS 2014


Page 5

14.2.6

Outlets

1

These shall be twin outlet type RJ45 to EN 60950 IBS 7008 having white moulded plastic plates with black shutters for computer outlets and white shutters for telephone outlets.

2

Outlets shall conform to the following specifications: (a)

Attenuation (dB)

:

<-0.12

(b)

Return loss (dB)

:

<-21.54

(c)

Bulk resistance (milli-ohm)

:

21.85

(d)

Voltage rating

:

>1050 V DC for 1 minute

INSTALLATION

14.3.1

Containment Systems

1

90 mm diameter or as approved by the Engineer, HDPE ducts and draw-pits shall be provided from external boundary walls to main distribution frame (MDF) positions and from the MDF to other buildings, as indicated on the Project Drawings.

2

Conduits, trunking and cable trays shall be provided for structured cabling installations, complying with Parts 7, 8 and 9 respectively of Section 21. The minimum conduit size shall be 25mm.

3

The computer wiring shall be laid from the user outlets up to the computer room (server) without any joints in between. Moreover the maximum length of a single run shall not exceed 90 meters, otherwise amplification of signal shall be provided.

4

All public offices and buildings shall be equipped with a complete wireless access points through the building.

14.3.2


1

General

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certificates shall be supplied by the Specialist Contractor to certify efficient working of the networks.

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(b)

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(a)

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14.3

2

Copper Cable and Connectors: Each RJ-45 Jack connector shall be tested to ensure Category 5 performance. Each RJ-45 Jack shall be tested for Point to Point connectivity, by utilising hand held time domain reflectometers (TDR), capable of generating pulses of 100 MHz, and of testing that the following parameters are in accordance with EIA/TIA 568A: (a)

Wire mapping for correct polarity

(b)

Length for point to point connectivity under 90 metres

(c)

Near end cross talk (NEXT)

(d)

Resistance

(e)

Impedance

(f)

Capacitance

(g)

Noise

(h)

Attenuation

QCS 2014

Page 6

Optical fibre cable shall comply with the following: (a)

certificates of compliance with EIA/TIA specifications, and manufacturer’s test certificates attached to the reels/drums

(b)

white light tests shall be performed to confirm end to end connectivity on delivery to site, after installation and prior to field termination

(c)

after field termination point to point connectivity shall be tested on each cable by a hand held optical time domain reflectometer, (OTDR), or optical power light meter and light source, capable of reading and measuring signal loss by generating wave lengths of 950 mm and 1300 mm. This shall check the field termination loss and that no damage has occurred from macro/micro bending.

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END OF PART

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QCS 2014

Section 21: Electrical Works Part 15: Electric Motors

Page 1

15

ELECTRIC MOTORS .................................................................................... 2

15.1

GENERAL ...................................................................................................... 2

15.1.1 Submittals 15.1.2 References 15.2

2 2

PRODUCTS ................................................................................................... 2

15.2.1 Motor Enclosures 15.2.2 Induction Motors 15.3

2 4

INSTALLATION ............................................................................................. 8

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15.3.1 General 15.3.2 Factory Tests 15.3.3 Field Checks

8 8 8

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15

ELECTRIC MOTORS

15.1

GENERAL

15.1.1

Submittals

1

Submit for QGEWC/Engineer approval, shop drawings, factory test reports, manufacturer‟s certified reports and technical data for motors supplied with driven equipment to the extent required in this Section and the Specification Sections for mechanical equipment.

2

Shop Drawings. In addition to information to be included in the shop drawings as specified in Part 1, shop drawings shall include the following: motor locked rotor and full load currents

(b)

power factors and efficiencies at full load, three quarters load and half load

(c)

motor housing material, winding material, ambient temperatures and maximum elevations in which motor is designed to operate continuously, service factor, insulation Class, temperature rise, type of enclosure, voltage, bearing life and dynamic balance; all of which shall comply to the requirements of the specifications

(d)

nameplate data

(e)

dimensions, weights and mounting details of motors

(f)

motor construction details

(g)

speed torque/current at 100 % volts

(h)

wiring diagrams, internal and typical external connections.

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(a)

Current Data. Submit eight copies to the Engineer of field recorded current data. The data shall indicate the full load current for each motor, and current rating for the overload relay in each motor starter and controller.

15.1.2

References

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BS 2048 ......................Dimensions for fractional horse-power motors

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BS 4999 ......................Winding terminations BS 5000 ......................Rotating electrical machines of particular types or for particular applications BS EN 60034 BS 2757

15.2

PRODUCTS

15.2.1

Motor Enclosures

1

Motor enclosures shall be selected from BS EN 60034-5 as follows:-

QCS 2014


Page 3

for submersible applications the enclosure shall be IP68 and be capable of being continuously submersed to a depth of at least 2 metres greater than the maximum immersion depth of the application. Where such motors are to be installed in an area designated as potentially explosive then it shall have the appropriate BASEEFA/CENELEC or other similar National Testing Organisation Certification. Copies of the Certificates shall be submitted. Motors to be used in sewage wet wells shall be certified for use in a Zone 2 area and Certificates shall show that the motors o were tested at an ambient temperature of 50 C. They shall be certified in accordance with BS 4683 Parts 1 and 2 classification Ex d IIA T3.

(b)

motors shall be of the submersible squirrel cage rotor induction type suitable for operating in the specified medium (sewage, effluent etc.).

(c)

motors shall be suitable for continuous operation when immersed in the specified medium and when the motor is above the specified medium in an ambient temperature o of 50 C.

(d)

the motors shall be entirely waterproof and provided with adequate cooling facilities which shall be achieved either by the surrounding liquid in the sump or by providing a motor jacket cooling system supplied with liquid from the pump volute.

(e)

terminal boxes shall be watertight and the motor shall be supplied with an adequate length of multi-core heavy duty flexible cable with tough rubber outer sheath.

(f)

the cable shall pass through a watertight gland on entry into the motor body.

(g)

the rotor and impeller assembly shall be dynamically balanced at the duty speed.

(h)

for indoor applications the enclosure shall be to IP54 of BS EN 60034-5. Submersible motors that are to be installed in dry wells shall be to IP 68 of BSEN60034-5. The cooling method shall be exactly the same as if the motor was installed in a submerged condition. Under no circumstances will an external cooling fan be permitted on dry installed submersible motors.

(i)

for outdoor application the enclosure shall be to IPW55 of BS EN 60034-5. A certificate shall be issued by the manufacturer certifying the motor suitability for the outdoor application, in the service conditions as described under the general section of this specification.

(j)

for high voltage motors the enclosure shall be protected to IP55 of BS4999 Part 105

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Unless stated otherwise, stator frames shall be of cast iron, foot and flange mounted as required by the Contract. Aluminium frames are permitted for 2.2 kW motors and smaller only. Ductile stainless steel frames shall be used, when specified in the particular specification, for aggressive sewage conditions, and shall be of grade 316L minimum.

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(a)

(a)

lifting facilities shall be provided on all motors

(b)

submersible motors shall be protected by a tandem mechanical seal arrangement. Lip seals are not permitted. The Contractor shall provide complete data on the seal materials, seats, faces etc., and ensure suitability for the medium being sealed i.e. oil chamber, oil and supernatant.

(c)

on pumps greater than 2.2 kW the mechanical seal performance shall be monitored by monitoring equipment to detect the following:- (alarm indication shall be transmitted on Motor starter panel.) (i)

moisture within the oil chamber.

(ii)

moisture/water or oil within the motor casing.

(iii)

temperature rise of the hydraulic driven end bearing.

(iv)

loss of oil from the oil chamber.

QCS 2014

(d)


Page 4

motors installed outdoors shall be protected from direct sunlight. Fan covers and cooling fans shall be metallic. Plastic fan covers and/or fans shall not be permitted on motors installed outdoors. Sunshades on motors/machinery should be sized such that cable entry points and the ends of cable trays are protected from sunlight. Sun/weather protection shades shall be manufactured from welded mild steel, hot dip galvanised after manufacture, or stainless steel. There shall be no sharp edges or dangerous protrusions on any sun/weather protection shades.

15.2.2

Induction Motors

1

General: motors shall be supplied by the manufacturer of the driven equipment as specified in this section, and specifically outlined in the driven equipment specifications

(b)

all motors shall be suitable for operation on a 415V or 690V, 50 Hz 3 phase supply. Different voltage levels may be used as indicated in particular specifications or drawings

(c)

All motors shall be capable of starting 10 times per hour. The stalled motor current shall not exceed 6 times full load current

(d)

All motors shall be commercially silent in operation and run free from vibration and the rotors shall be perfectly balanced both statically and dynamically and shall be tested and adjusted for dynamic balance in an approved manner

(e)

All motors shall be fitted with anti-condensation heaters of a size to maintain the temperature of the windings 5 °C above ambient. Each heater shall be provided with a switch and automatic control to disconnect it when its motor is in operation

(f)

Terminal Boxes

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(a)

Terminal boxes shall be cast iron and shall be designed to accept XLPE or PVC armoured cable as detailed in the Contract. On non-submersible motors, terminal boxes shall be mounted on the right hand side when viewed from the driving end of the motor, unless otherwise required by the Contract.

(ii)

The motor stool base where appropriate shall be drilled at works vertically below the terminal box gland for the passage of the cables and the edges of the hole slightly countersunk or the hole bushed.

(iii)

Motor terminals shall be stud-type, substantially designed, anchored to a carrier terminal block and insulated from the motor frame. Terminals shall be identified in accordance with BS 4999 Part 108 or equivalent. A separate earth stud shall be included on each terminal box. Heater terminals shall be shrouded and prominently labelled.

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(i)

(iv)

Adequate space and glanding arrangements shall be provided, particularly on smaller motors requiring glanding and terminating of steel wire armoured cable for star/delta starting, anti-condensation heating and thermistor winding protection devices.

(v)

Where a common terminal box is used for main, heater and thermistor cable terminations, a permanent warning label shall be fixed to the terminal box cover. In addition, heater and thermistor cable terminations shall be clearly marked to identify their separate functions and operating voltages.

(vi)

Terminal box covers shall be gasketed to provide a degree of protection equivalent to or better than that of the motor.

(vii)

For Ex 'd' flameproof motors, terminal boxes may employ Type 'e' increased safety protection, utilising indirect cable entry to the flameproof enclosure. However, this must be of the same type used to obtain the potentially explosive hazardous area motor certification.

QCS 2014

Section 21: Electrical Works Part 15: Electric Motors (viii)

3.3kV motor cable termination boxes shall be high fault level type, with segregated phases, pressure relief diaphragm and sealing chamber.

(g)

arrangements shall be made with the manufacturer so that the Engineer shall witness motor tests for motors with power larger than 75 kW as specified in the FAT testing paragraph.

(h)

the motors shall run in ball and/or roller bearings and the weight of the motor shall be carried by thrust bearings incorporated in the motor body

(i)

bearings shall be grease lubricated using hydraulic type nipples which are freely accessible without any dismantling, or otherwise piped out to a readily accessible location

(j)

“Sealed for Life” bearings shall not normally be used. However, for small motors the Engineer may allow the use of sealed for life bearings.

The efficiency and power factor of the motors shall be high over a wide range of load conditions. The motors shall be designed, manufactured and tested in accordance with BS 4999 and BS 5000 (or BS 2048 and BS 5000 in the case of small horsepower motors) for continuously rated industrial electric motors and Class “F” insulation but limited to Class „B‟ temperature rise. This shall be in addition to any adjustments necessary for high ambient temperatures at site. The maximum continuous rating (MCR) of each motor shall be as set out in Table 15.1 and shall be rated and designed to suit the climatic conditions at site. This reserve power requirement shall be added to the calculated power prior to any other adjustments e.g. high ambient temperatures at site Table 15.1 MCR Ratings

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(a)

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Motor Ratings:

Up to 75 kW drive

Above 75 kW drive

All pump motors (excluding positive displacement type)

10% above that required under all conditions of operation

5% above that required under all conditions of operation

Positive displacement pumps and compressors

25% above maximum duty requirements

12.5% above maximum duty requirements

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Application

motor starters shall be selected from the following to satisfy the stipulated performance requirements and comply with QGEWC starting current restrictions:-

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(i)

motors up to 11 kW (15 hp) shall be squirrel cage suitable for DOL starting having a starting current not greater than 6 x full load current (FLC)

(ii)

motors between 11 kW (15 hp) and 37.5 kW shall have their starting current restricted to 4 x FLC and shall use one of the following starting methods; as indicated in the Project Drawings or the Project Documentation: 

(iii)

Solid State Reduced Voltage (Soft) Start with torque characteristics suitable for the application Star - Delta

motor over 37.5 kW shall have their starting current restricted to 2.5 FLC and shall use one of the following starting methods:  

Solid State Reduced Voltage (Soft) Start with torque characteristics suitable for the application VFD

QCS 2014

Section 21: Electrical Works Part 15: Electric Motors (iv)

(c)

motors shall be suitable and certified for the zone of hazard in which they are to be installed

(d)

where flywheels are fitted to the main pump set, the motors shall be capable of starting and driving the pumps under these conditions.

Motor Cooling (a)

non-submersible motors shall be air cooled to IC 41 of BS EN 60034-6.

(b)

cooling of submersible motors shall be an efficient system to the manufacturer's design.

.

Motor Windings (a)

motor windings shall be copper and treated to render them impervious to moisture, saline atmospheres, acid/alkaline fumes, oil and grease. They shall be adequately braced to prevent movement of coils during all conditions of service and be insulated throughout to Class F of BS 2757 or equivalent with a temperature rise limit of Class B. This provision shall be in addition to any adjustments necessary for ambient o temperatures at site of 55 C

(b)

motor operating voltage and connection type shall be clearly stated on the motor nameplate.

(c)

for high voltage motors, the stator windings shall use a modern synthetic resin insulation system based on mica glass tape continuously wound on the coils to give a void-free homogeneous structure. The end windings shall be securely braced to prevent harmful movement arising from electro-magnetic and mechanical forces. The rotor bars shall be securely keyed into the rotor. The rotor shall be shrunk and keyed onto the shaft.

Thermal Protection

all motors rated at 11 kW and above shall be equipped with thermostatic contact elements in accordance with QGEWC Regulation 801. Six thermostats shall be provided (3 in use, 3 spare) to BS 4999 Part 111 to give Class 1 protection. Thermostats shall be of the normally closed (break on temperature rise) type. They o shall operate at 160 C on rising temperature and shall be complete with leads and terminals.

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(a)

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submersible pump motors because of inherent design are to generally comply with the foregoing. The starting method is to be restricted to DOL/ Star-delta starting or soft start according to rating.

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(b)

when thermistors are specified six shall be provided (3 in use, 3 spare) to BS 4999 Part 111 to give Class 1 protection. Thermistors shall be PTC type P160 and shall be complete with control units for motor tripping.

(c)

when embedded resistance thermometers are specified six shall be provided (3 in use, 3 spare) either in the stator slots or end windings. They shall be of the platinum wire o type compensated for 0 C at 100 ohms (Pt. 100). They shall be complete with evaluating unit and remote temperature indicators with set points for over temperature alarms.

(d)

when motor winding thermocouples are specified six shall be provided (3 in use, 3 spare) either in the stator slots or end windings. They shall be complete with remote temperature indicator with set points for over-temperature alarm.

(e)

When motor winding RTD‟s (Resistance Temperature Detectors) are specified six shall be provided (3 in use, 3 spare) either in the stator slots or end windings.

(f)

when bearing temperature indicators are specified the sensors shall be Pt. 100 resistance thermometers installed as close as possible to the bearing and complete with remote temperature indications with set points for alarm.

QCS 2014

Page 7

(g)

when cooling air temperature indicators are specified two shall be provided to monitor both the warmed air and the fresh air. The sensors shall be Pt. 100 resistance thermometers installed in the air passage and complete with remote temperature indications with set points for alarms.

(h)

where thermostats or thermistors are used in explosion proof designs, the devices must be of the same type used to obtain the potentially explosive hazardous area motor certification.

Submersible motor cables (a)

submersible motors shall be complete with lengths of black PTFE covered flexible cable for Power, Signalling and Protection purposes.

(b)

each cable shall be a minimum of 20 metres long or as otherwise required by the Contract, and shall be rated in accordance with the cable routing details. As a minimum cables shall be continuously rated to carry the motor full load current when laid in a classified area to the approval of QGEWC. The cable shall be factory fitted according to the connection of the motor winding.

(c)

flexible cables for use in potentially explosive atmospheres shall be identical to those types used to obtain the potentially explosive hazardous area combined motor/cable certification. Where protection cables are part of an intrinsically safe circuit the outer sheath shall be coloured blue.

(d)

jointing of cables is not acceptable.

(e)

cables shall be laid such that there is no fouling of the submersible pump whilst lifting or lowering. The extra length of cable shall be relaxed and not coiled.

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Bearings

the motors shall run in ball and/or roller bearings and the weight of the motor shall be carried by thrust bearings incorporated in the motor body.

(b)

maximum life bearings with oil seals shall be fitted to both drive end and non-drive end bearing housings to prevent ingress of solid particles and liquids. Bearings shall be in accordance with BS 292 or equivalent.

(c)

bearings that are not sealed for life shall be grease lubricated and shall be fitted with a means for replenishing the grease and a relief device for disposal of excess grease. Hydraulic button head grease nipples in accordance with BS 1486 Part 2 or equivalent shall be provided and shall be extended, where necessary, such that they are located at the top of the frame. Re-greasing points shall be located for ease of access.

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bearing temperature monitoring facilities shall be provided on submersible motors over 75 kW and on non-submersible motors over 100kW.

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(e)

8

Noise Levels (a)

9

All VFD controlled motors shall be provided with insulated bearings to prevent bearing failure due to circulating rotor currents. Confirmation from Motor manufacturer shall be provided that the motors are suitable for VFD (Variable speed Drive) continuous operation

unless otherwise required by the Contract, the noise levels (Sound Power Levels dB(A)) of the motors shall be in accordance with BS EN 60034-9.

Paint finish (a)

the paint finish shall be entirely compatible with the environment to which the motors will be subjected. This shall consist of an anti-corrosion primer/undercoat with a 2 part heavy duty epoxy resin paint or such other paint finish determined by the application, and as detailed in the specification for Corrosion Protection.

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Page 8

15.3

INSTALLATION

15.3.1

General

1

Provide all the equipment installations and wiring installations, including connections as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces as shown on the Drawings.

2

Motor: provide power, control, alarm and earthing installations for all motors as indicated and required

(b)

check the connections to provide correct rotation for all motors

(c)

record the full load current to each motor, and the overload relay rating in each motor starter for the certified data submittal

(d)

provide the wiring for heaters in the motor frames and the required controls to deenergise the heater when the motor operates (if applicable)

(e)

provide the required wiring for all equipment that shall be furnished and installed according to other relevant Sections of the Specifications

(f)

install the control stations and/or emergency stop units on steel stanchions or building structures near motors, if specified and as shown on the Drawings. Control stations, where required in accordance with the particular specification, shall incorporate a “Local/Remote” switch, “On/Off” switch and the emergency stop unit

(g)

field damaged factory finish on equipment shall be touched-up with paint that is equal in quality and colour to the original factory finish.

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(a)

Factory Tests

1

Factory tests shall be carried out as follows

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(c)

No load current High voltage on windings and auxiliary Windings resistance Vibration Full load heat run and temperature rise Efficiency at 100 %, 75 %, 50 % and 25 % load Power factor at 100%, 75%, 50% and 25% load Noise Momentary overload shall be provided for all motors to cover as a minimum the

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(b)

All motors:

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15.3.2

Locked rotor current Locked rotor torque Saturation curves Percent slip

2

The Contractor shall provide calculations to demonstrate motor power rating and bearing life with derating factors taken into account.

15.3.3

Field Checks

1

Motor Installations shall be complete and correct.

2

Operation tests shall be performed to observe that motors start, run and stop satisfactorily under design load. END OF PART

QCS 2014

Section 21: Electrical Works Part 16: Power Factor Correction Capacitors

Page 1

16

POWER FACTOR CORRECTION CAPACITORS ........................................ 2

16.1

GENERAL ...................................................................................................... 2

16.1.1 16.1.2 16.1.3 16.1.4 16.1.5 16.1.6 16.1.7

General Description References Quality Assurance Submissions Delivery, Storage and Handling Co-ordination

16.2

PRODUCTS ................................................................................................... 3

2 2 2 2 2 2 2

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16.3

.

16.2.1 General 16.2.2 Capacitors 16.2.3 Control and Protection

INSTALLATION ............................................................................................. 4

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16.3.1 Installation

4

TESTS ........................................................................................................... 5

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16.4

3 3 3

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16.4.1 Factory and Field Tests

5

QCS 2014


Page 2

POWER FACTOR CORRECTION CAPACITORS

16.1

GENERAL

16.1.1

General

1

This specification section covers the supply and installation of power factor correction equipment operating on electrical power systems up to 600 V ac 50 Hz.

2

The work of this part is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

3


4


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General Provision for Electrical Installation HV & MV Factory Built Assemblies (FBA’s) Protective Devices Cables and Small Wiring Electric Motors

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Description

1

Provide all labour, materials, equipment, services and accessories necessary to furnish and install the work of this Part, complete and functional, as indicated in the Project Documentation and as specified herein.

16.1.3

References

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16.1.2

BS 88 ..........................Cartridge fuses for voltage up to 1000 V ac

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BS EN 60949.................Control gear for voltage up to 1000 V ac Quality Assurance

1

Reference standards as detailed under Part 1 and this Part Clause 17.1.4.

16.1.5

Submissions

1

Reference Part 1

16.1.6


1

Deliver, store and handle materials and products in a manner to prevent damage.

2

Reference Part 1

16.1.7

Co-ordination

1

The work of this Section shall be completely co-ordinated with the work of other services.

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16.1.4

QCS 2014


Page 3

PRODUCTS

16.2.1

General

1

Power factor improvement equipment shall be provided in LV (415 V) Main Distribution Board. Correction shall be automatic and be capable of correcting the power factor to within range 0.9 lagging to unity as required by the design. The power factor setting shall be adjustable.

2

Individual power factor capacitors shall be provided for the larger motorised drives, as indicated on the single line diagrams.

3

All capacitors must be arranged so that they are connected in minimum 4 stages and subject to the Engineer’s approval. These stages shall be sized to prevent system over-voltage during light loads conditions.

16.2.2

Capacitors

1

Capacitors shall comply with BS 1650 and shall be of a dry metalised film construction, containing no liquid and must have low losses (typically 0.5 Watts/kVA).

2

Each capacitor shall be housed in a sealed container and be fitted with a fail-safe, pressure sensitive disconnect device.

3

Each capacitor shall be equipped with suitable discharge resistors to reduce the voltage to less than 50V in one minute, or less, after supply disconnection.

4

The capacitors shall be housed in a metal enclosure, forming part of the Main Distribution Board. The enclosure size should allow enough space and cabling etc., for at least one additional capacitor unit to be fitted at a later date.

5

Provision shall be made to ensure that a connection point is available for a series connected, de-tuning reactor in case of problems with harmonics.

6

The equipment must comply with BS 800 with respect to electrical interference.

7

The capacitors shall be protected by a fused switch-disconnector or circuit breaker on the LV motor control centre.

8

The capacitor manufacturer must recommend the maximum fuse or circuit breaker that will ensure the protection of each capacitor bank.

9

All power and control cables used within the capacitor bank enclosure must be in accordance with BS 6231 Type BK.

10

Detuned reactor/harmonic filters

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16.2

(a)

anti-resonance reactor detunned or filters deemed necessary to reduce the harmonic content.

(b)

total Harmonic Distortion (THD) of voltage at point of common couplings shall adhere to IEEE Harmonic Standard 519-1992 and ER G5/4.

16.2.3

Control and Protection

1

Power Factor Regulator

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Page 4

(a)

The minimum number of capacitor switching steps shall be four (4) as far as practically possible for smaller rating capacitor banks and between 6 to 12 steps for others. The capacitors’ KVAr shall be so chosen to provide maximum programming flexibility such as switching sequence 1:2:2:2, 1:1:1:1 etc. in order to maintain the power factor within the set limits for most of the operating time.

(b)

an alphanumerical LCD, micro-processor based automatic power factor correction regulator shall be provided to control steps and display measurement of the following:-

(iii)

step connection and disconnection time

(iv)

actual current

(v)

reactive current

(vi)

active power

(vii)

reactive power

(viii)

THD voltage

(ix)

alarm conditions as listed below

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no. of steps connected

(ii)

abnormal power factor

(iii)

leading power factor

(iv)

overcurrent

(v)

overtemperature

(vi)

overvoltage

(vii)

THD high

(viii)

capacitor overload etc.

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low power factor

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the regulator shall have built-in alarm relay for remote indication and following alarm conditions locally:-

the regulator shall provide facility to manually energize/denergise capacitor steps for the purpose of testing and verification of required/set power factor. switching contactors shall have a minimum duty category AC4 to BS EN 60947 and a minimum current rating of 1.3 x the current consumed by the capacitor bank (see BS 1650).

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(d)

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(c)

(i)

(f)

Each capacitor “stage” connection shall be indicated on the panel door by an indicating lamp.

16.3

INSTALLATION

16.3.1

Installation

1

Documentation shall be provided detailing: (a)

Type test certificate

(b)

Routine test certificate

(c)

Maintenance requirements

(d)

Fault diagnosis

(e)

Parts list with part numbers and recommended spares

(f)

Commissioning instructions

QCS 2014


Page 5

16.4

TESTS

16.4.1

Factory and Field Tests

1

The PFCC assembly shall be tested at the factory and at site during commissioning. The results so obtained shall be verified with the actual requirements and QGEWC regulations. Modifications if any shall be carried-out at no extra cost to the Owner.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 17: Standby Diesel Generator Set

Page 1

17

STANDBY DIESEL GENERATOR SET ........................................................ 2

17.1

GENERAL ...................................................................................................... 2

17.1.1 17.1.2 17.1.3 17.1.4 17.1.5 17.1.6

General Reference Description of Work References Quality Assurance Submittals Period of Maintenance

17.2

PRODUCTS ................................................................................................... 5

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17.2.1 Diesel Generator Set 17.2.2 Control Panel 17.2.3 Automatic Transfer Switch (A.T.S.) 17.2.4 System Operation and Performance 17.2.5 Manual Operation 17.2.6 System Responsibility 17.2.7 Installation 17.2.8 Paint Work 17.2.9 Site Quality Control 17.2.10 Commissioning 17.2.11 Training of Operation and Maintenance Personnel 17.2.12 Reference Data Sheet

.

2 2 2 2 3 5 5 14 15 16 16 16 16 17 17 17 18 19

QCS 2014


Page 2

STANDBY DIESEL GENERATOR SET

17.1

GENERAL

17.1.1

General Reference

1

The work of this Section is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2


17.1.2

Description of Work

1

The Contractor shall supply, install, commission, test and handover in good operable manner including 400 days guarantee and maintenance of 415 V mains failure, standby diesel generator set and 5 years guarantee for electric motors, as per the Project Documentation. The set shall be arranged for either automatic or manual start on mains failure, as indicated on the Project Drawings. The set shall be complete with diesel engine, generator, control panel, batteries, starting motor, built-in air cooled radiator, main fuel storage tank, daily fuel storage tank, fuel transfer pumps and all other accessories as specified and mentioned in the BOQ.

2


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General Provisions for Electrical Installation Cables and Small Wiring Conduits Trunking Cable Trays Earthing and Bonding

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 22

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17

References

1

The following standards or revised/updated are referred to in this Part

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BS 4999 ......................Alternators

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Quality Assurance

1

Manufacturer's Qualification: (a)

The Diesel Generator Set shall be designed and manufactured complete by a manufacturer regularly engaged as a manufacturer of such equipment.

(b)

The Diesel Generator Set Manufacturer shall have a proven manufacturing experience of minimum 10 years in this field. Reference of previous approvals in similar applications and environmental conditions shall be provided for Engineer’s review and approval.

(c)

The DG set manufacture shall have an approved ISO 9001 QA/QC procedure for design, manufacturing and testing of complete DG set. The DG set Manufacturer shall provide minimum the following documents as a part of submittal approval. (i)

Quality policy

(ii)

Quality Policy manual

(iii)

Manufacturing and storage facilities.

QCS 2014

(d)

2

Section 21: Electrical Works Part 17: Standby Diesel Generator Set (iv)

Traceability of components.

(v)

Design facilities.

(vi)

Testing facilities.

Page 3

The Diesel Generator Set manufacturer shall have full Load testing facilities in his premises for testing the full range of his products at full load as per the relevant BS/ ISO standards.

Installer's Qualification: all the Diesel Generator installation work shall be carried out by a Diesel Generator sub-contractor. Diesel Generator sub-contractor shall be one who is normally an agent representing one or more of the approved makes of D/G sets. Diesel Generator installation shall be supervised, checked and tested by a qualified representative of the manufacturer and handover the works in perfect running order to the satisfaction of the Engineer.

Source Quality Control:

The Diesel Generator Set Manufacturer shall test the complete Diesel Generator set at the manufacturing facilities. The test shall be performed as per the latest BS/IEC standard and the Factory Acceptance Procedure shall be approved by the Engineer/Client. Any additional test required by the Engineer during the FAT shall be performed by the Diesel Generator Manufacturer in his cost. The Diesel Generator set shall not be shipped from the manufacturing facilities until the test reports have been submitted and approved by the Engineer.

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3

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(a)

Local Agent:

the manufacturer should have an agent in Qatar who is well experienced in installation and maintenance of diesel generators of the size specified herein. The agent should have been associated with the manufacturer for a minimum period of five years.

ov

Design Criteria:

all materials and equipment shall comply with relevant IEC and BS specifications as regards quality of materials, performance and proving tests.

(b)

the emergency power supply system and its components shall be such as may be properly maintained and serviced without the necessity of carrying expensive spare part stocks, or being subjected to interrupted service due to the lack of spare parts

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(a)

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(c)

emergency generator set shall be designed to allow easy replacement of major items subject to wear.

17.1.5

Submittals

1

Shop Drawings: (a)

Submit shop drawings for approval in accordance to Part 1

(b)

Shop drawings shall be complete, as to be record drawings, not general outline drawings used for sales and guide layouts

(c)

Submit a complete wiring diagram for the generator set, drawn on a single standard size sheet, showing the following: (i)

all components of: 

engine starting control



engine alarm



generator control

QCS 2014

Section 21: Electrical Works Part 17: Standby Diesel Generator Set battery



battery charger



earthing



transfer switch control relays

(ii)

interior wiring, terminals and interconnecting wiring

(iii)

certified dimensions and weights.

(d)

submit a composite wiring diagram of the entire emergency transfer system showing all wiring between the engine starting panel, engine generator set and the automatic transfer switches

(e)

wiring diagrams shall clearly show: main current conductors, in heavy lines

(ii)

control conductors, with colour and/or number coding

(iii)

location of relays and apparatus

(iv)

description of function, type and catalogue, of all components.

.l. l

rw

submit a schematic line diagram showing: Interlocks



Protection



Instruments

qa



submit general arrangement drawings of the generator installation and the generator building layout.

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(g)

ta

alternator Control Panel: (i)

.

(i)

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(f)

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Product Data submitted in accordance to Part 1. submit curves showing the actual performance of a similar engine (same model, stroke, etc.) to that proposed, superimposed on the standard published performance curves for continuous, and maximum operation

(b)

submit the detailed information together with manufacturer's catalogues for the following:

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(a)

(i)

generating set manufacturer

(ii)

name and Address

(iii)

generating set Model No.

(iv)

diesel Engine

(v)

radiator

(vi)

fuel System

(vii)

alternator

(viii)

exciter

(ix)

starting Battery

(x)

control Panel

(xi)

service Facilities

m

2

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Page 4

(c)

test certificates

(d)

list of spare parts

(e)

certified factory test reports

QCS 2014


(f)

instruction manuals for operation and maintenance

(g)

parts catalogue with manufacturer address.

Page 5

Period of Maintenance

1

During the maintenance period of 400 days the sub-contractor shall repair and replace directly, at his own expense, any of the plant, material or work performed or furnished under the respective works in the Project which may develop under the conditions provided for by the Project and under proper use in the works or that portion thereof taken over by the Engineer. The guarantee period for all electric motors shall be 5 years.

2

The sub-contractor shall obtain and submit to the Engineer all guarantees or certificates or warranty available from the manufacturers, but only as supplementary to the sub-contractor's own liabilities under the Project and in no way invalidate them.

3

The D/G sub-contractor shall be responsible for the satisfactory operation of the D/G installation during the Maintenance and Guarantee Period. He shall carry out necessary inspection, preventive maintenance and testing to keep the set ready all the time. The set shall function satisfactorily during power failures. The D/G sub-contractor shall carry out routine testing of the installation once in every month throughout the Maintenance and Guarantee Period. The testing shall be carried in presence of Engineer. The sub-contractor shall himself provide all electrical and mechanical spare parts, grease, lubricating oils, touchup paints, etc., required for the maintenance of the D/G installation. The owner shall be responsible only for providing diesel oil as and when required. The D/G sub-contractor shall prepare log-books listed full details of maintenance work and each log-book entry shall be countersigned by the Engineer.

17.2

PRODUCTS

17.2.1

Diesel Generator Set

1

The Diesel Generator Set shall be of rugged reliable design and built for long trouble free service under the worst specified climatic conditions and made by an approved reputable manufacturer.

2

Rating:

et it

The Diesel Generator Set output shall be design for prime rating as specified elsewhere. Detailed design calculations for Engine, Alternator, Cooling system, battery, etc shall be provided for Engineer’s approval for the proposed Diesel Generator set.

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(a)

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17.1.6

(b)

3

The rated output shall be as specified elsewhere or as indicated on the drawings, 415/240 Volts, 3 phase, 4 wire and 50 Hz or different voltage level as indicated elsewhere in the Contract specifications (690 V or 3.3 KV).. The rated output shall mean the net full continuous derated output in Qatar at an ambient temperature up to 50°C at a relative humidity of 95%. The set shall also be capable of 110% load for one hour under these conditions at the rated speed without undue heating of the engine or alternator and without mechanical or electrical troubles.

Diesel Engine: (a)

The diesel engine shall be of the stationary heavy duty, turbo charged compression/ignition, multi cylinder 4 stroke operation. The steel base frame shall be provided with spring type vibration isolators. The engine shall be able to deliver full load in the shortest possible time after start. The engine speed shall not exceed 1500 r.p.m. The engine construction shall be in such a way as to allow for dismantling of any engine component for inspection or repair without undue complication i.e. without dismantling of other non-defective parts. The crank case shall be provided with inspection windows

QCS 2014

(b)


starting system: The diesel engine shall be equipped with starting system detailed hereunder and as per Engineer's approval. (i)

Battery Starting System: 

batteries for starting shall be of the nickel cadmium type, 24 Volt, heavy duty diesel starting type and of sufficient capacity to allow 6 consecutive start attempts each of 15 seconds with 1 minute intervals. It shall be possible by means of a selector to alter the starting sequence to provide a single start attempt of 1 minute before lockout and alarm. The battery used for starting may also be used to energise the diesel plant control system but shall have enough capacity remaining after 3 engine start attempts to energise the system continuously for 24 hours. The control system shall be suitable to continue operating correctly during the voltage dips occurring on the battery during the engine starts.

.

Cooling System: radiator : built-in type with sufficient capacity to dissipate the total joules per hour rejected by the engine cooling system at 110 % full load

(ii)

blower fan: to have sufficient pressure to circulate required quantity of air for engine cooling. The fan shall be provided with a suitable guard. D/G room o inside temperature should not exceed 56 C

(iii)

jacket water heaters: to be provided on engine to facilitate quick starting under low ambient conditions

(iv)

the cooling system shall be capable of keeping the temperature of cooling water at safe limits at all conditions of load required in the specifications. Maximum temperature of cooling water after 10 hours of continuous running at full load at worst Qatar climatic conditions shall not exceed the maximum temperature limits of the diesel engine

(v)

the cooling system shall include an engine shaft driven circulating water pump. The water jacket of the engine cylinder shall be so constructed that the water in the jacket can be drained completely

(vi)

the radiator finned tubes shall have a common inlet and common outlet headers

(vii)

drain valve and a filling valve shall be provided to the radiator for flushing and quick filling

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(i)

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(c)

Page 6

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(viii)

(ix)

(d)

Cooling water piping, complete with all necessary supports; control valves, flanges and fittings, thermometers, pressure gauges, relays etc., shall be supplied and installed to form a complete engine water cooling line. Piping shall be as of BS 1387 the water pump discharge valve shall preferably be a globe valve, the other valves shall be (sluice) gate valve.

Fuel System (i)

The engine shall be suitable for running on diesel oil as described below: Specific gravity at 60F distillation : 0.834 (P.P. 123/40) IBM : 219 C 10% : 250 C 50% : 276 C 90% : 314 C F.E.P. : 342 C Flash Point PME : 189 C Sulphur : 1.1%

QCS 2014

Section 21: Electrical Works Part 17: Standby Diesel Generator Set -

: : :

19750 62 34

Fuel supply to the engine shall be maintained by a separate day tank located in the room. Daily fuel tank shall be sufficient capacity for continuous run of 8 hours at full load, unless otherwise specified in the Project Documentation. The daily service tank shall be manufactured from mild steel to a rectangular shape in accordance with BS 799 and shall be complete with the following minimum equipment and facilities:-



Inspection cover



vent/breather pipe



filler pipe connection



overflow connection



drain valve and sump drain



emergency dump valve operated by the fire alarm system and by a fusible link mounted over the diesel engine



dial type contents gauge calibrated in gallons and litres



level switches to control fuel transfer pump



level switches to operate high and low fuel level alarm circuits in the diesel alternator set control panel



lifting lugs.



the Contractor shall provide and install an external dump sump of sufficient capacity to contain the contents of a full day tank and all pipework necessary to carry the dumped fuel quickly by gravity, to a safe location in the event of a fire being detected in the generator house. The sump shall be constructed to contain the fuel without leakage to the surrounding ground and shall be provided with a lockable cover. Provision to allow emptying of the sump by portable pump shall be provided.

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(ii)

Calorific value BTU/lb. gross carbon residue. 0.01/wt diesel index Viscosity redwood seconds at 100F Daily Fuel Tank:

Page 7

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(iii)

Main Fuel Storage Tank: 

The Contractor shall supply and install a cylindrical diesel oil storage tank with a capacity to operate the associated diesel generator set continuously on full load for a minimum of 7 days, unless otherwise specified in the Project Documentation.



the tank shall be welded mild steel construction suitably protected from corrosion in accordance with BS. 2594 and shall be installed in the location indicated on the drawings.



The storage tank shall be complete with pipes, fittings, feed lines, vents.etc. The tank shall be of the approved type located outside the diesel engine room. The tank shall be provided with 600 mm inspection manhole with cover, 50 mm filling pipe with cooped filling terminal, 50 mm air vent pipe with screen outlets, isolating valve, valved drain etc.



Electronic fuel indicator with an audio/visual alarm shall be provided for main fuel storage tank



Also the storage tank and its accessories must comply with the Qatar.Civil Defence Regulations for generator installations.

QCS 2014

Section 21: Electrical Works Part 17: Standby Diesel Generator Set (iv)

Page 8

Duplex Diesel Oil Pumping Set: 





rw

qa

Tank Gauges: 

Provide as shown on the Drawings. Each gauge is to be provided with an aluminium case and calibrated to indicate level of fuel in the tank. Mounted on gauges shall also be a high/low level alarm switch. The switches and gauges shall be designed for operation from a 24 Volt DC, loop powered system. Locate indicating gauges as shown on the Drawings or required



Tank fittings and pressure fittings shall be made of solid bar stock to prevent leak possibilities.

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ov

Diesel Oil Piping: Provide all diesel oil piping from storage tank to day tank fill lines, water tight fill boxes, vents, vent caps, tank foot valves, and accessories

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

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(vi)

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(v)

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 

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

Provide packaged type duplex, self priming, fuel oil pumping and straining set with a capacity of four times the total fuel consumption of engine at full load for each individual Diesel Generator Set. Pump sets shall be factory assembled, piped, wired and tested. Pumps shall be activated by a switch in the day tank automatically. All pumps installed in the D/G room shall be flame-proof and fire-resistant as per NFPA Regulations Piping shall be complete to suction, discharge and return line connections. Provide gate valves and unions arranged to permit removal of either pump while the system is in operation. Install check valves and relief valves on pump outlet and gate valves prior to pressure gauges Suction strainer shall be flanged connection, duplex type, one-piece, cast-iron body, ASTM A48 Class 30, with 1.2 mm perforation brass baskets Oil pump set shall be factory assembled on a structural steel channel beam base to include pumps, motors, flexible couplings and guards. Pump set shall be suitable for diesel oil Suitable manually operated pump shall be provided. The installation of Diesel transfer pump set shall be subject of the Engineer’s approval. There shall not be any possibility of flooding of the diesel transfer pumps.

(e)



Provide swing check valves and gate valves at pump inlets. Provide approved anti-siphon valves at high points of suction lines. Provide whatever additional valves that may be required by local regulations



All piping shall be provided with ground joint unions at piece of apparatus to facilitate connecting and disconnecting



All piping, unless otherwise specified, shall be schedule 40 standard weight black wrought iron pipe



Steel vent pipelines shall run from the fuel oil storage tanks, carried to the proper height within building construction and terminating with vent fittings. Fittings shall be "Bronze Ventilating Brick" with thickness of 20 mesh bronze wire gauge in front of louvered opening.

Lubricating System (i)

The lubricating oil system shall be forced fed type. The details of the system shall be included in the offer. The shaft bearing lubricating shall be directly fed from the lubricating oil pump and not through the main bearings

(ii)

The lubricating oil shall be of a type readily available internationally

Page 9

The lubrication system shall be positive displacement type. By-pass arrangement should be provided in case of filter clogging

(iv)

A heat-exchanger shall be provided for cooling the lubricating oil and this shall be of long-life type i.e. the system shall not require constant cleaning or other maintenance work. A valve for taking oil sample shall be provided. The coolant for the above shall be jacket water of the engine. That is, the cooling system of the engine and the lube-oil heat-exchanger cooling system shall work in parallel or in series. If the lube-oil pressure reaches low value, the engine shall be shut down automatically and also immediately should give audible alarm together with visual indication. The lube-oil system shall be provided with means to monitor pressure at important points at the engine-monitor panel

(v)

a large capacity oil sump shall be provided and incorporated in the construction of the bed plate

(vi)

the system of lubrication shall ensure that adequate oil is pumped to all rotating parts

(vii)

The system shall incorporate a level dipstick, filler cap and tube and crankcase breather pipe or outlet

(viii)

the capacity of the lubricating oil system shall be sufficient to enable the engine to run continuously for 12 hours at any load without replenishment.

(ix)

Suitable manual-pumping arrangement for easy draining of the whole quantity of lube-oil into a drum shall be provided.

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(iii)

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Exhaust System:

Exhaust pipes shall be of Schedule 40 black steel and of adequate size to ensure that back pressure does not exceed the value specified by the manufacturer

(ii)

The exhaust pipe shall be connected through airtight flexible coupling to the engine

(iii)

Exhaust pipes shall be adequately lagged with 75 mm thick (minimum) rock wool covered with aluminium sheaths of minimum thickness 1.5 mm so that to 0 take care of exhaust gas temperature in pipes exceeding 500 C. When exhaust pipes pass through walls or roof a suitable weatherproof sleeve or thimble shall be provided to isolate exhaust pipe from the building. A silencer of heavy duty residential type shall be provided in the exhaust system and it shall also be lagged. The operation of casting the sleeves in the concrete, if required, will be carried out by a civil contractor

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(i)

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(f)


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QCS 2014

(g)

(iv)

Exhaust pipes and silencers shall be supported from the ceiling by special vibration isolating hangers and the pipe shall be slanted away from the engine and a condensate trap fitted at the lowest points. Approved rain caps shall be installed at the discharge end of the exhaust pipes on the roof.

(v)

Suitable flexible expansion joints shall be provided along the pipe run to take care of expansion requirements

(vi)

the completed exhaust system shall be capable of limiting the noise level at the external outlet to 65 dB (A) at three metres from the end of the exhaust pipe

(vii)

suitable guards shall be provided with the exhaust pipe to prevent small animals/reptiles from entering.

Filters: Cleanable/replaceable elements should be provided. (i)

Fuel Oil System The system shall have the following filters fitted before the fuel injection pumps:

QCS 2014


(ii)

Page 10



A primary fuel filter of ample capacity to prevent all particles of 10 microns size or smaller.



A secondary filter to prevent all particles down to 3 microns size or smaller.

Lubricating Oil System This system should have full flow filters of sufficient capacity

(iii)

 Tenderers shall give full particulars of the filters used. It shall be mentioned in if filter elements are cleanable for replaceable, in which case, the working hours after which the element and the Lubricating oil is to be replaced should be stated. Intake and Exhaust System Air is inducted to the engine manifold through



Large capacity air cleaner



Both filters are required due to severity of dust storms and dust suspensions in the air



The engine exhaust line shall be fitted with flexible fitting efficient silencer to give efficient silencing with minimum back pressure and terminated outside the engine room.

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Ventilation:

The following ventilation works are required for the diesel engine generator room.

as

(i)

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Precleaner

Aluminium inlet louvres with washable metal filters shall be provided for outside air intake into the engine room. Filters shall be sized to perform their duty with a face velocity not more than 1 metre per second when the engine is running. Filters shall be installed in an appropriate arrangement on the generator room walls. The total filter area shall consider air for engine intakes and radiator cooling requirements. Filters with handles and easily operated retaining latches shall be provided. The radiator shall be provided with a motorised louvre, interlocked with the generator, so that the generator will shut down in the event of the louvre not opening on start up. The louvre shall be capable of being manually opened in the event of drive motor failure. Gravity louvres shall not be allowed for the radiator exhaust.

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

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(h)



(i)

(j)

Governing System: (i)

the engine shall run steadily at any load within its rating at its rated speed, and the changes in speed due to change in load shall comply with BS 5514/77 for Class A1 or with ISO 3067

(ii)

the governor should be of the electronic type to comply with BS 5514/77 Class A1.

Coupling and Common Bed: (i)

the engine and the alternator shall be suitably coupled directly without interposing gear arrangement

(ii)

the common bed shall be provided with spring type anti-vibration mountings devices for fixing to the floor

Section 21: Electrical Works Part 17: Standby Diesel Generator Set (iii)

the engine vibration shall be the minimum possible and shall comply with the relevant BS. The vibratory force induced as the engine passed through resonance revolutions during starting and stopping period shall not cause any damage to the whole system

.

Engine Control Panel: The engine-generator control panel shall be of rigid and robust construction and rust-proof and shall be of the electronic modular type utilising environmentally sealed, solid state, micro-processor based modules for engine control and AC metering. The panel shall be capable of operating under the operating temperature range of 0 degrees to + 70 degrees Celsius. Metering accuracy shall be 0.5% true RMS. The electronic control system shall employ solid-state transducers for constant monitoring of oil pressure and coolant temperature through a Single Sire Serial Data Link. Unless otherwise specified in the Project Documentation, the control panel shall provide the following features: automatic start/stop engine control with programmable safety shutdowns and associated flashing LED indicators for low oil pressure, high coolant temperature, overspeed overcrank and emergency stop

(ii)

adjustable 1 to 60 second cycle cranking with rest periods

(iii)

cool-down timer, adjustable between 0 and 30 sec.

(iv)

LCD digital readout for:

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(i)

engine oil pressure (N/mg)



lubricant oil pressure gauge (N/mg)



cooling temperature ( C)



exhaust gas temperature gauge ( C)



exhaust turbo-blower pressure gauge (N/mg)



engine RPM

 

0

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0

system DC Volts engine run hours eight system diagnostic codes

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(k)

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QCS 2014



generator AC Volts



generator AC Amps



Generator frequency

The system diagnostic codes shall be designed to enhance the system protection and to allow for trouble shooting by untrained personnel. These signals shall be: -loss of engine speed -invalid engine control switch -internal circuit fault -loss of coolant temperature -loss of data sending unit -unscheduled engine shutdown -invalid programming switch position -loss of failure of programme setting These panels shall be provided with the following control switches: -engine control switch

QCS 2014


Page 12

-ammeter -voltmeter phase selector -emergency stop -indicator/display test switch -voltage adjust potentiometer Alternator and Exciter the alternator shall be able to withstand the stresses caused by the sudden application of the loads Type

:

Self excited, self ventilated, air cooled, splashproof, synchronous alternator

(ii)

Output

:

As per Project Documentation, at Qatar Climatic Condition

(iii)

Voltage

:

415V(Or as indicated in Project documents)

(iv)

Frequency

:

50 Hz

(v)

No. of poles

:

4

(vi)

No. of phases

:

3, (ungraded neutral to be brought out)

(vii)

Power factor

:

80% lagging

(viii)

Commercial efficiency not less than 90 % (including excitation and field losses)

(ix)

Voltage regulation

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(i)

: Automatic and static.

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(a)

Class F insulation shall be provided for the alternator and exciter windings with the temperature rise as Class B and de-rated for the ambient conditions.

(c)

the alternator shall be suitable for continuous running duty type S1, BS 2613 (latest edition)

(d)

the alternator unit shall be capable of giving 110% of nominal rated output for one hour under site conditions. The rotor shall be capable of withstanding an over-speed test of 15% for 5 minutes

(e)

distortion of no-load voltage wave form at alternator terminals shall be within 5 % from the sinusoidal wave form

(f)

voltage adjustable range of the output voltage by adjusting the exciter shall be not less than 3 % of rated voltage at rated load and not less than ± 5 % of rated voltage under no-load conditions. This adjustment shall be able to be performed from panel

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(b)

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(g)

mounted handle or knob

(h)

the voltage of the alternator shall be automatically controlled by electronic static circuits

(i)

the alternator shall not be switched on the load until terminal voltage has reached at least 90 % of the nominal value. It is essential that the voltage regulation equipment shall have sufficient fast response time so that the alternator is ready to accept load in the shortest possible time

(j)

the voltage regulator shall be designed to maintain the alternator terminal voltage constant within ± 1 % of the nominal value from no load to full load within normal variations of engine speed with change in load

(k)

the exciter shall be brushless, self excited, rotor mounted type. The rectifying elements shall be silicon. The silicon diodes of the three phase rectified bridge assembly shall be protected against surges and overloads such that the generator will continue to run with a diode failure. Diodes shall have heat sinks suitable for the ambient conditions described. Means shall be provided to indicate exciter diode failure on the remote control panel

QCS 2014


Page 13

the unit shall be suitably protected so that when there is a sudden variation of load, the sudden increase of field current in the rotor shall be curtailed and thus the speed build up of the engine and the voltage build up of generator shall vary proportionately

(m)

alternator protection. The alternator shall be provided with protection against over speed, over voltage, over current, short circuit, reverse power, single phasing earth fault and any other found necessary. The neutral points of alternators shall be solid by connecting to earth

(n)

terminals with cable end boxes shall be provided respectively for the alternator and exciter

(o)

the cooling air for alternator and exciter shall be drawn through openings at the nondrive end and exhausted sideways at the driving end

(p)

the alternator shall be fitted with anti-condensation heater to keep the winding in good, dry and safe condition. The anti-condensation heater shall be automatically cutoff when the machine is running. Necessary on-off switches shall be provided on the control panel and the operation status of the heater shall be indicated

(q)

temperature Rise: Alternator components shall be sound electrically mechanically in continuous operation lasting over 24 hours at the rated output

(r)

insulation Resistance: Insulation resistance of the machine at strategic points shall be provided along with the submission

(s)

dielectric Strength: The Dielectric strength, the voltage of testing and test procedure at various points of the machine shall be submitted with the shop drawings

(t)

radio and television interference suppression devices shall be provided in accordance with the requirements of BS. 800. Components used for suppression shall be to BS 613

(u)

vibration at the fixed components of the alternator under excited no-load operation shall be as per relevant BS.

(v)

terminal symbols requirements

(w)

panel Wiring:

and

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.l. l

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(l)

the

alternator

shall

be

in

accordance

with

BS

all wiring of battery charger, exciter and control panel shall be P.V.C tropical grade of adequate current carrying capacity to prevent over-heating under worst climatic conditions

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(i)

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for

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(ii)

(x)

all wiring shall conform to the relevant BS and at least 50 % derated with 2 minimum size of 2.5 mm or its equivalent.

terminal Board (i)

terminal boards shall have pairs of terminals for Incoming and Outgoing wires and not more than two wires shall be connected to any one terminal

(ii)

insulating barriers shall be provided between adjacent connectors. Labels for wiring designation marks shall be provided on the fixed portion of the terminal boards as well as wires. No live metal shall be exposed at the back of the terminal boards

(iii)

terminal boards having pressure type terminal lusts or equivalent shall be used so that no terminal clamp is necessary. 10 % spare terminals shall be provided for each terminal board assembly.

QCS 2014

Guards (a)

Suitable guards with brackets and securing arrangements of substantial construction shall protect all exposed rotating or moving parts. All guards shall be mechanically fixed to the generator set. Special attention shall be given to guarding the flywheelcoupling and the radiator fan drive.

17.2.2

Control Panel

1

Cabinet heavy gauge, 2.5 mm thick, sheet steel construction, totally enclosed, dust and water protected and vermin proof to IP 55

(b)

a hinged, lockable door shall give access to control and instruments

(c)

"live" parts shall be secured to prevent inadvertent contact with them

(d)

controls for diesel engine, alternator, exciter, meters and alarm device shall be positioned to give ample space for removing and installing components.

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(a)

Control Panel Equipment and Instrumentation

ta

control panel shall include: (unless otherwise specified in the Project Documentation) 3 pole air circuit breaker with over-current, short circuit and earth fault protection as specified in this specification. (unless part of a main switchboard, as indicated on the drawings)

(ii)

busbar system as specified in this specification (unless part of a main switchboard, as indicated on the drawings)

(iii)

voltmeter (0-500V) with selector switch to read phase to phase and phase to neutral voltages

(iv)

ammeters of suitable range 3 Nos.

(v)

frequency meter of range 45 - 55 Hz

(vi)

duty selector switch OFF/TEST/MANUAL/AUTO key operated

(vii)

solid state voltage and frequency sensing relays

(viii)

microprocessor control unit incorporating, but not limited to the following:

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

30 sec engine warm-up with override



engine minimum run time of 10 minutes



engine cool down time of 10 minutes



return to mains time delay of 30 sec.



80% stand-by voltage setting before load transfer



80% stand-by frequency setting before load transfer



auto exerciser of seven days from initial command that allows operation



with or without load transfer



controls for remote operation and alarm signalling to remote SCADA/PLC

(ix)

current transformer for measuring and protection devices

(x)

watt meter for unbalanced phases

(xi)

voltage trimmer

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Page 15

(xii)

visual and audible alarm for engine starting, engine running overspeed, high water temperature, low oil pressure, failure to start, engine stalling or shut down, low fuel level in tanks, overvoltage and alternator overload.

(xiii)

indicator lamps for supply available, battery charger and cooling water heater

(xiv) manual start, stop, emergency OFF and lamp test push-buttons (xv)

manual and automatic service push-buttons

(xvi) control switch for alternator circuit breaker, ON and OFF (xvii) mimic diagram with moving coil indicator for position of air circuit breaker (xviii) battery charger, automatic type, nominal current 10 Amps. for charging 24 volts nickel cadmium starter battery and all required instruments

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(xix) all other accessories, fuses, terminal boards, small wiring, etc. Automatic Transfer Switch (A.T.S.)

1

he A.T.S. shall consist of 4 pole, 3 phase, break before make except for the neutral, ted as shown on the Drawings in accordance with QGEWC regulations

2

with the A.T.S. provide manual change-over switches to by-pass the A.T.S. in case of emergency, maintenance or repair

3

the arrangement, wiring and components shall satisfy the requirements of the Diesel generator Manufacturer. His written approval shall be submitted

4

control voltage of A.T.S. shall be normally fed from the main supply, in case of failure of the main supply it shall be fed automatically from the emergency supply.

5

in addition to transfer switches the A.T.S. arrangement shall be equipped with the following:

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17.2.3

a selector switch to control the operation of A.T.S. on normal, emergency, automatic and OFF

(b)

adjustable - 3 phase voltage sensing relays sense failure in a phase/phases and voltage drop below 70 % of the normal voltage (pick-up and drop-out

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(a)

voltages and adjustable within the range 70 - 100 % of the normal voltage) visual Mechanical Indicator for transfer switch position

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(c)

(d)

indicator lamps to show transfer switch position normal, emergency and OFF.

(e)

an adjustable time delay relay of 1 - 3 seconds for starting signal to the Generator set after cutting of main supply

(f)

an adjustable time delay relay of 0 - 3 minutes which allows A.T.S. from Normal to Emergency after the voltage build up relay of the generator has sensed 90 % rated voltage when frequency within 90 % rated of rated frequency

(g)

an adjustable time delay relay of 1 - 10 minutes to allow A.T.S. from Emergency to Normal

(h)

an adjustable time delay relay of 0.5 - 5 seconds to prevent instantaneous transition from EMERGENCY to NORMAL i.e. the delay allows time sufficient For the residual motor voltage to decay to a safe switching level.

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Page 16

System Operation and Performance

1

The normal mode of system operation shall provide for unattended automatic transfer of load for the emergency power system. Emergency power shall be supplied to the system emergency loads within 10 seconds after interruption of the normal service. Upon receiving a signal from the ATS indicating a failure or normal power from transformer, the system control unit will signal engine generator to start. Generator circuit breakers are open at this time and the emergency busbar is dead. The generating set to reach approximately 90% of rated frequency and voltage signals to start sensor. The sensor then inhibits the operation of sensors and initiates a closing signal to circuit breaker, connecting this generating set to the emergency busbar. The priority control then initiates operation of the designated transfer switch, applying load up to the total kW rating of the generating set.

2

If the generating set fails to start after cranking for the suitable cranking period, it shall be locked off the busbar and the overcrank light on its switchboard shall light and the alarm sound. The control prevents critical transfer switch from operating. The generating set may receive troubleshooting signals after placing its engine control function switch in the "OFF" position. When the generating set is operational, it may again be placed into automatic operation by returning its function switch to the "remote" position.

3

If a generating set stalls and shuts down during normal operation, its respective switchboard circuit breaker shall open, removing it from the busbar. The appropriate failure light operates and the alarm sounds. The load shedding contacts in the control close, tripping a breaker in the load circuits, reducing system load to the rating of the remaining available generating capacity. After the generating set is made operable, it can be automatically reconnected to the busbar by resetting the load shed switch and engine control switch.

4

After normal power has been restored and the time delay on stop has expired, it shall be possible to manually shut down the generator and restore the mains power.

5

Under circumstance or condition operation of an emergency stop push button shall immediately shut down the engine.

17.2.5

Manual Operation

1

The manual operation of the Diesel Generator Set shall have the following features:

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the emergency power system shall have the capacity of being manually operated. The generator may be started by engine control switch located on the engine control unit. Once started and stable, the generator may be manually connected to the emergency busbar through generator circuit breaker

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17.2.4

(b)

the generator control unit shall be equipped with a generator breaker control switch, engine speed adjusting potentiometer and a generator voltage adjust thermostat and facilitate.

17.2.6

System Responsibility

1

The generating set, switchboard and automatic transfer switches shall be interconnected according to building load requirements and to manufacturer's recommendations, to prevent the emergency generating system from stalling or faltering due to momentary or temporary overloads beyond system rating, from distribution faults, motor starting loads.

17.2.7

Installation

1

Product Delivery, Storage Handling: (a)

lift all generator equipment using eyes, yokes and skids provided by the manufacturer

(b)

do not store equipment assemblies exposed to weather

QCS 2014

Page 17

(c)

physically protected all generator equipment against damage from work of other trades

(d)

cover all generator equipment with suitable material to avoid damage to finish.

(e)

Contractor shall submit the calculation to prove the adequacy of capacity of the crane he intends to use for installation of the D-G set

Installation: (a)

the engine and generator shall be properly aligned and mounted on a common steel base through resilient mountings to prevent vibrations. The whole set shall be fixed on the concrete slabs through suitable number of adjustable spring type vibration isolators. Foundation and other builder's work shall be as recommended by the manufacturer and approved by the Engineer

(b)

except as may be described in this Section or shown on the drawings carry out installation strictly in accordance with the manufacturer's recommendation.

Control Boards:

Record Print: (a)

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run all outgoing cables from the generator to the control boards in the floor trench as indicated on the Project Drawings.

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(a)

fix record print of each generator set, framed behind non-glare plexiglass, on a wall near the generator control room.

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Paint Work

1

Paint work of each set shall be of the highest quality to withstand the worst weather conditions specified. All steel works such as tanks, pipes, frames, louvers, ladders, platform, etc. shall be given two undercoats of anti-rust paint and two enamel finishing.

2

The diesel generator set, day tank internal metalworks and control panel shall be finished to BS 4800, shade 14E53.

17.2.9

Site Quality Control

1

Final Testing:

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testing shall be carried out at full load after completion of installation by the Engine manufacturer's qualified representative in the presence of the Engineer

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17.2.8

(b)

if the above cannot be done then testing shall be done at the manufacturer/supplier's premises at full load in the presence of the Engineer. All arrangements and costs incurred by such a test shall be responsibility of the sub-contractor.

17.2.10 Commissioning 1

Simulated Power Failure Test: (a)

2

engine-generator shall be made ready for automatic operation and started by means of the test transfer switch on the automatic transfer switch. Unit shall run for the duration of all time delays and then automatically shut-down. This test shall be made with unit operating, and twice with unit simulated for a starting failure.

Testing of the Set: (a)

Engine: (i)

the engine shall be tested at site before and after erection to BS 649 and amendments or equivalent including items which are said to be subject to

QCS 2014


Page 18

mutual agreement. The test shall include inspection, after testing the following parts subsequent running test of eight hours shall be carried out of the set

(iii)

the engine shall be subjected to vigorous performance tests at site to the satisfaction of the Engineer and the main items shall include: Output characteristics



Temperature rise



Checking of valve clearance, fuel pump setting, governor setting, pipeline connections, exhaust piping and flexible connections



Checking the base and set are level in all directions, checking alignment of engine and generator and vibration isolators location and proper installation



Checking of proper operation of engine safety devices



Checking of fuel pipelines, fuel pumps, tank level gauges and level control switches operation.

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

Alternator and Exciter:

the alternator and exciter shall be tested to BS 5000, P.99 amendments thereof

(ii)

tests at site before erection and after erection prior to handing over shall be carried out to the satisfaction of the Engineer. The main items of tests deemed necessary by the Engineer shall be carried out at the expense of the Contractor. The performance test shall be for 24 hours under the worst climatic conditions prevailing in Qatar

(iii)

the Contractor shall be fully responsible to provide all the necessary facilities for the test at his own expense.

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(b)

(ii)

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17.2.11 Training of Operation and Maintenance Personnel The Contractor shall train a number of persons who will be selected by the Engineer for the operation and maintenance of all the works within the Project before these works are handed over to the Engineer.

2

The training has to be carried out by qualified staff of the Contractor for each specified service and shall be provided for a one month period following the certificate of completion.

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17.2.12 Reference Data Sheet This Form or similar is to be completed by the Electrical sub-contractor as Well as D/G subcontractor and to be submitted for approval to the Engineer unless otherwise Specified.

--------------------------------------------------------------------------------------------------------------------------1. Name and Address of D/G sub-contractor Detail of work in hand now with proposed D/G sub-contractor --------------------------------------------------------------------------------------------------------------------------Name of Government Amount of D/G Project Installation Works --------------------------------------------------------------------------------------------------------------------------a. ---------------------------------------------------------------------------------------------------------------b. ---------------------------------------------------------------------------------------------------------------c. ---------------------------------------------------------------------------------------------------------------d. ---------------------------------------------------------------------------------------------------------------e. ----------------------------------------------------------------------------------------------------------------

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We confirm that the Statements given above are true, to the best of our knowledge and it is known to us that Engineer reserves the right to refuse to award sub-contract to us if the above Statements are found to be incorrect.

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Name of Electrical Contractor

Signature

Name of D/G sub-contractor

Signature

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Position in company of person signing

Position in company of person signing

END OF PART

QCS 2014

Section 21: Electrical Works Part 18: Uninterruptible Power Supply Systems

Page 1

18

UNINTERRUPTIBLE POWER SUPPLY SYSTEMS ..................................... 2

18.1

GENERAL ...................................................................................................... 2

18.1.1 18.1.2 18.1.3 18.1.4

Scope Description References Submissions

18.2

PRODUCTS ................................................................................................... 3

18.2.1 18.2.2 18.2.3 18.2.4 18.2.5 18.2.6 18.2.7 18.2.8

System Rectifier/Charger Battery Static Switch Monitoring and Control Test Procedures Environment Protective Devices, Controls and Monitors

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QCS 2014


18

UNINTERRUPTIBLE POWER SUPPLY SYSTEMS

18.1

GENERAL

18.1.1

Scope

1

This Part specifies the requirements for uninterruptible power supply systems.

2

Related Parts and Sections are as follows: This Section Part 2 Part 3 Part 6 Part 7 Part 8 Part 9 Part 10

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FBA Protective Devices Cables and small wiring Conduits Trunking Cable trays Accessories and General Power

Page 2

Description

1

A single UPS System shall be provided for the Main Control Room (MCR) Data Communication system (DCS), and peripheral equipment, essential field instruments and essential equipment subject of Engineer approval

18.1.3

References

1


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18.1.2

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IEC 157 ......................Low Voltage Switchgear and Control gear

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IEC 158 ......................Low Voltage Control gear Submissions

1

Submit in accordance with Part 1

2

Shop Drawings

submit dimensional drawings elevations, showing the following:

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(a)

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18.1.4

3

the

UPS,

(i)

sizes and positions of components

(ii)

positions and method of fixing cable and boxes

(iii)

location of terminal boards

(iv)

Internal wiring diagram

(v)

Power and control diagrams

(vi)

External connection drawing

(vii)

Component parts lists

(viii)

Other pertinent data.

(ix)

Spare parts list

Project Data (a)

of

Submit:

including

sections

and

QCS 2014


Page 3

(i)

full specifications of the enclosure and the components of the equipment with relevant sheets of manufacturer’s catalogues

(ii)

confirmation that the equipment complies with the relevant specifications.

(iii)

Detailed UPS and battery and rectifier size calculation

(iv)

Previous approval in similar applications

18.2

PRODUCTS

18.2.1

System

1

The UPS system shall be comprise of single rectifier, battery charger and inverter modules: the UPS system shall be designed in such a way that any spare part, printed circuit board, sub-assembly or component, can be replaced without any adjustment

(b)

it shall supply clean, uninterrupted power to the critical loads and meet the specifications

(c)

transformers shall be manufactured using vacuum pressure impregnated insulation.

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(a)

The Contractor shall assess the electrical load capacity of the UPS taking into account derating for non-linear loads and worst case ambient temperature conditions.

3

The UPS cabinet shall be designed such that all components are removable from the front and cable entry by floor mounted gland plates.

4

UPS shall be designed and manufactured “standalone” for automatic operation and as such circuit connections; protection devices and the like shall comply with BS EN 60950, BS EN 50091-3 and BS EN 60439.

5

The UPS shall be designed to supply clean, uninterrupted power to the loads.

6

The design of UPS shall take account of continuous load capacity, de-rating for non-linear loads and ambient temperature conditions. The UPS shall be sized to supply all instrumentation and control equipment including but not limited to control and computer room hardware, mimic, annunciation, telecommunication systems and emergency lighting etc. where applicable.

7

Main Features

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2

The UPS shall consist of fully controlled rectifier charger, battery bank, inverter, static bypass and manual bypass capable to providing safe and secure power supply for a minimum period of 8 hours. The UPS shall include the following features as minimum:(a)

optimal quality of the output voltage

(b)

transient over-voltages and spike protection

(c)

voltage variations and mains failures protection

(d)

frequency variations protection

(e)

true single phase regulation

(f)

low noise

(g)

low THD (Not to exceed BS G5/4 limits)

(h)

PC connectivity for parametering as described under particular requirements.

(i)

serial communication 100100 by employing industry standard modbus, fieldbus, NP etc protocol as described under particular requirements.

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Page 4

18.2.2

Rectifier/Charger

1

The rectifier/charger shall be of solid-state type with fully controlled 6-pulse thyristor bridge and anti-harmonic chokes. It shall have 10 sec walk-in ramp for input current, adjustable battery current and voltage. It shall recharge a fully discharge battery in 24 hours. A boost charge facility shall be provided. A normally open contact rated at 240 Vac, 2A, close on boost charge, shall be provided for remote monitoring. Input voltage ratings are as follows:

(c)

.

(b)

Mains 1 (input to rectifier/charger) Voltage : 415 volts AC ± 10% Wiring : 3-phase, 4 wire + Earth. Frequency : 45 to 55 Hz. Mains 2 (input to static switch) Voltage : 415 volts AC (± 15%) Wiring : 3-phase, 4 wire + Earth. Frequency : 50 Hz Synchronisation Range: ± 0.75 HZ

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(a)

Battery

1

Unless otherwise specified in the Project Documentation, the batteries shall be of sealed nickel cadmium maintenance free type and sized for the pre-selected time with the UPS operating at rated load. The battery bank shall be sized to maintain full load for a period of 8 hours

2

The inverter shall be of transistorised PWM type, for the specified UPS rated power at 0.8 p.f. Output rating shall be as follows:

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Harmonic distortion Efficiency Audible noise

: 3-phase, 4 wire and earth. : 415/240 volts (± 1%), 50 Hz (± 0.25 Hz). : Voltage transients shall not exceed ± 5 % for a 100 % load step change and the return to steady state value shall be in less than 20 milliseconds. : Less than 4% THD : For 100% load 92% & For 50% load 91% :  65 dBA @ 1.5m

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Wiring Voltage Transient Voltage Regulation

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18.2.3

3

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Output synchronised in amplitude, phase & frequency to mains 2 when mains 2 is within tolerance limits. Phase difference between inverter output and mains 2 held below 3‫؛‬ (electrical) in such condition so that the maximum gap while transfer to UPS from Mains 2 and vice versa occurs shall be less than 167 micro seconds. Overload Capabilities: (a)

inverter shall sustain 125 % overload for at least 10 minutes and 150 % overloads for 1 minute. After delay, if overload persists, the load shall be transferred to bypass supply without break if Mains 2 voltage is within tolerance limits. The UPS shall check the load and if the load is below overload threshold, inverter shall restart automatically and load shall be transferred back to inverter. Facility to inhibit automatic re-transfer shall be provided.

4

The automatic retransfer to the inverter shall be blocked if a transfer to the mains was initiated six times within one minute or in case of non-synchronization of the inverter with the mains.

18.2.4

Static Switch

1

The static switch shall have anti-parallel connected thyristor bank for instantaneous load transfer between the inverter and the mains 2 supply.

QCS 2014

Maintenance manual By Pass: Manual bypass switch system of full UPS shall be integrated into the UPS so that load can be transferred to mains supply WITHOUT break for maintenance of UPS. Procedure for transfer to maintenance bypass and back to UPS shall be controlled by the bypass menu of the UPS, thus eliminating possibility of causing disturbance of load by operator who is unaware of correct procedures.

18.2.5

Monitoring and Control

1

Monitors: the following status information shall be monitored by indicating lights on the front panel of the UPS: rectifier-charger on

(ii)

load on inverter

(iii)

load on Mains 2 bypass

(iv)

alarm

(v)

inverter shutdown imminent

(vi)

boost charge

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(i)

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(a)

an audible alarm shall warn the user of faults or operating problems. The system shall be equipped with an alarm off button. Metering values displayed on an alpha-numeric display.

(c)

The following measurements shall be available:

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(b)

inverter output voltage (L-L)

(ii)

inverter output frequency

(iii)

inverter output currents

(iv)

voltage across battery terminals

(v)

battery current (charge/discharge)

(vi)

mains 1 (rectifier/charger) input voltages (L-L)

(vii)

rectifier/charger input currents.

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(i)

Remote Control And Monitoring:

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(a)

Remote transmission shall be provided for all controls, monitors and measurement indication on the UPS unit to the site PLC/SCADA.

18.2.6

Test Procedures

1

For UPS larger than 75 KW the Contractor shall provide a Works Test Report. The integrated functional test shall be conducted at manufacturer’s works to ensure satisfactorily functioning of the equipment.

2

The Assembly shall not leave the manufacturer’s works until the works test sheets have been duly approved and stamped by the Engineer and written permission is obtained for their dispatch to site.

3

The UPS manufacturer shall provide proof of a stringent Quality Assurance Program. In particular the main equipment manufacturing stages sanctioned by appropriate tests such as: incoming components inspection, discrete sub-assembly tests and complete functional checks on the final product. Equipment shall undergo on-load burn-in leaving the factory. Final inspection and calibration operations shall be documented in a report drawn up by the supplier’s Quality Inspection department.

QCS 2014

18.2.7


Page 6

Environment (a)

Ambient temperature

(b)

Maximum relative humidity :

0

:

0

0 C to + 50 C 95 %

18.2.8

Protective Devices, Controls and Monitors

1

The UPS shall be built on modular basis.

2

Main Protections - The UPS shall include the following protections as minimum:-

(b)

Load short circuit

(c)

Over temperature

(d)

Surge protection

(e)

Noise protection

(f)

Battery deep discharge protection

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Input over voltage

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Controls shall be micro processor based and the following main controls shall be possible: rectifier/charger on/off

(b)

inverter on/off

(c)

forced shutdown

(d)

forced transfer upon forced shutdown of inverter when the (mains 2) is outside tolerances

(e)

self-test

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(a)

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(a)

END OF PART

bypass power supply

QCS 2014

Section 21: Electrical Works Part 19: Sound and Call Systems

Page 1

19

SOUND AND CALL SYSTEMS ..................................................................... 2

19.1

GENERAL ...................................................................................................... 2

19.1.1 19.1.2 19.1.3 19.1.4

Scope Reference Standards Quality Assurance Submittals

19.2

PRODUCTS ................................................................................................... 3

19.2.1 19.2.2 19.2.3 19.2.4

Public Address Systems Farash Call Systems Intercom Systems Auto Class Change Over Systems

19.3

INSTALLATION ............................................................................................. 8

19.3.1 19.3.2 19.3.3 19.3.4

Wiring and Wiring Facilities Testing and Commissioning Maintenance and Guarantees Training

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SOUND AND CALL SYSTEMS

19.1

GENERAL

19.1.1

Scope

1

This Part specifies the general requirements for sound and call systems, including amplification and tone selection/control equipment, input stations, loudspeakers, power connections, cables and terminations.

2


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General Provisions for Electrical Installations Cables and small wiring Conduits and Conduit Boxes Trunking Cable Trays Telephone Installation Structured Cabling Systems Testing

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 13 Part 14 Part 23

.

19

Reference Standards

1

The following standards are referred to in this Part, and shall be complied with:

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19.1.2

Sound system equipment Requirements for electrical installations

ISO 9000

Quality management and assurance standards

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BS 6840 BS 7671

Quality Assurance

1

Manufacturer‟s qualifications: the equipment and accessories to be furnished for the sound and call systems shall be the products of one internationally reputed manufacturer regularly engaged in producing such systems for a minimum of ten years. Manufacturers shall be certified to ISO 9000 or equivalent.

2

Installer‟s qualifications: Installations shall be executed by the manufacturer‟s personnel. Installations may be executed under the supervision of the manufacturer‟s personnel, with the Engineer‟s approval, provided the installer has three years previous experience of such installations and has completed three similar projects within Qatar.

3

Mixing of major components from different manufacturer, to make one system, shall not be permitted. All components shall by supplied from a single source/manufacturer.

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19.1.3

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Page 3

Submittals

1

The Contractor shall include a detailed list of all equipment and materials proposed

2

The Contractor shall include a complete set of catalogues, illustrations, diagrams and any other descriptive literature sufficient to present complete information about systems for the Engineer's approval.

3

The Contractor shall include in detail the maintenance programme of equipment and system capacity to accept future expansions.

4

The Contractor shall include a detailed list of recommended spare parts required for 2 years.

19.2

PRODUCTS

19.2.1

Public Address Systems

1

General

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19.1.4

the Contractor shall provide and install complete intercommunication systems with hand-free operation, electronic centralised microprocessor controls and full functionality as specified, to BS 6840 where applicable

(b)

systems shall include central exchange controllers, disk stations, surface mounted wall stations, privacy hand-sets, wall receptacles, cables, terminals and strips as specified to provide a complete working system

(c)

equipment shall be reliable, long life, maintenance free and have low power consumption

(d)

when specified for a large installation having multiple microphone stations, it shall be possible to automatically isolate remaining microphone input stations or other auxiliary input terminals as soon as one is activated. Stations shall be activated by push button action.

(e)

multiple channel input and zone selector modules shall permit flexible arrangements for selecting the input channels on priority basis. Stations with higher priority shall override announcements activated by others with lower priority order systems shall permit announcement on individual zones, any combination of zones and simultaneous announcements on all zones

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(a)

(g) 2

system layouts shall be according to the Project Drawings.

Amplifiers (a)

master module amplifiers shall incorporate a master volume control, a sliding control for both treble and bass, a built-in limiter plus and LED indicator and headphone socket to permit input signal monitoring

(b)

amplifiers shall incorporate a push button ON/OFF switch with indicator lamps to define unit status

(c)

amplifiers shall incorporate a power supply section, mains transformer, output transformer and printed circuit boards to provide necessary amplification of input signals. Amplifier outputs shall have voltage tappings of 100, 70 and 50 volts

(d)

amplifiers shall be accommodated in racks (19" rack is preferred) with sliding facilities.

(e)

for multiple zones, one amplifier shall be assigned to each zone. Systems shall include an additional amplifier to be used as common standby with switching facilities

QCS 2014

(f)

to connect the standby instead of the faulty amplifier

(g)

technical performance (i)

Rated Output Power

:

refer to Project Documentation

(ii)

Max. Power Consumption :

refer to Project Documentation

(iii)

Frequency Response

:

60 Hz - 16 kHz

(iv)

Distortion at 1 kHz

:

< 0.5% THD

(v)

Operating Temp. Range

:

0 C to 45 C

(vi)

Relative Humidity

:

95%

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Channel Input Modules: shall be programmed so that inter-channel priority forms can be achieved via an interconnection block on main printed circuit boards as follows: mixing mode : all input channels shall have the same priority and signals may be mixed together

(b)

serial/cascade priority mode : Channel 1 has priority over 2, 2 over 3, and so on

(c)

first served priority mode : The first channel switched on shall block the input for other channels.

(d)

technical performance

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(a)

Input Level

:

(ii)

Frequency Response

:

60 Hz - 16 kHz

(iii)

Distortion

:

< 0.2 % THD

(iv)

S/N

:

> 65 dB

(v)

Cross-talk Attenuation

:

> 60 dB

(vi)

Operating Temp. Range

:

0 oC to 45 oC

(vii)

Relative Humidity

:

95 %

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(i)

500 mV - 8V max.

Active zone selectors: zone selectors shall have the capability of switching ON and OFF loudspeakers in various zones by means of electronic built-in facilities. Switching shall be based on pre-programmed cascaded order to permit selection of one of the following modes:

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(a)

manual operation : Loudspeakers shall be selected by means of push button switches. Each switch corresponds to one zone

(b)

zone programming : in conjunction with input modules to provide the facilities for connecting any of the zones with any of the input channels

(c)

remote control from microphone station : selection of any of the loudspeaker zones shall be achieved by operating the appropriate switches on the microphone control unit. It shall be possible by operating a switch in the microphone control unit to access all the channels at the same time for common announcements

When specified in the Project Documentation, facility for switching to alarm mode shall be provided. When an alarm signal is initiated, all loudspeaker zones shall be automatically switched and prepared to receive any common announcement. The alert/alarm signal Input Units shall be coupled to amplifier units to perform the following functions: (a)

two tone alert signal

:

550 Hz tone followed by 440 Hz tone

(b)

alarm signal

:

continuous repetition of the alert signal

QCS 2014


Page 5

(c)

time signal

:

550 Hz tone

(d)

priority

:

microphone input channel

(e)

pre-set control of microphone

: independent of master volume control.

Various modes of initiating attention signals shall be by pressing a switch on the unit front panel, or remotely by the microphone „ON' switch on the microphone control unit attached to the unit, or any other microphone stations. Central Equipment Assemblies (a)

when specified, free standing racked shelf assemblies shall be provided suitable for accommodating all amplifiers, input modules, zone selector modules and alarm units

(b)

when specified, central equipment shall include AM/FM radio tuners and tape playback set. Units shall be integrated and connected to systems through switching and control units

(c)

central equipment racks shall be rack type (19” preferred) accessible from back and with removable side panels. Racks shall be provided with mounting facilities to permit sliding in and out of units with facilities to fix units to racks by screws to the front side

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Loud Speakers : Loud speakers shall comply with IEC 268, Parts 5 and 14 wall speakers: these speakers shall be provided with a resonating board and an aluminium grille for universal application for flush or surface-mounted enclosures. The speaker shall be a high performance type and shall be provided with auto-transformer with taps for 1/4, 1/2 and 1/1 output. The normal rated capacity shall be 4-5 W, if not otherwise specified in the Project Documentation. A volume control shall be incorporated. The sound pressure shall be approximately 100 dB

(b)

ceiling speakers: these speakers shall be designed, including their accessories, for recess installation in various suspended ceiling types. The grille shall be aluminium. The speaker shall be of the same type as wall speakers

(c)

sound column speakers : these shall be designed for interior installation or in weatherproof design for exterior installation. The enclosure shall be of aluminium and shall be for wall or pole mounting, with suitable accessories. They shall be provided with adjustable cast aluminium fixing arms, which allow sound columns to be adjusted through 20o vertically and 75o horizontally and shall include multiple loud speakers of 8 Ohms nominal impedance, symmetrically positioned within sound columns. An autotransformer with taps for 1/4, 1/2 and 1/1 capacity shall be built in. The normal rated capacity shall be 10, 20, 30 or 40 W as indicated in the Project Documentation. The Column boxes shall accommodate multiple speaker systems depending on capacity, which may be as follows (preferably as per manufacturer‟s standard design):

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(i)

10 W - 3 speakers

(ii)

20 W - 4 speakers

(iii)

30 W - 6 speakers

(iv)

50 W - 8 speakers

(d)

horn speakers : these speakers shall be designed weatherproof for exterior installation. The enclosure shall be of aluminium, impact-resistant and coated with weatherproof paints. They shall be provided with swivel brackets for fixing. An autotransformer with taps for 1/8, 1/4, 1/2 and 1/1 capacity shall be built in. The normal rated capacity shall be 10, 20, 30 or 40 W as indicated in the Project Documentation

(e)

the speaker systems may be any of the above or their combinations, according to requirements in the Project Documentation.

(f)

unless otherwise specified, the paint finishing shall be white when mounted on walls.

QCS 2014

(g)

Page 6


Sound pressure level at 1 kHz Octave, 1 m, at 1 W in accordance with IEC : refer to Project Documentation

(ii)

Power handling capacity : refer to Project Documentation.

(iii)

Frequency response

:

60 Hz to 16 Hz

(iv)

Input Voltage

:

100/70 Volts as per driving amplifier.

(v)

Environment conditions

:

0 oC to 45 oC.

Microphone Stations (a)

microphone input stations shall consist of swan-necked microphones on table stands, incorporating zone selector switches for remotely controlling loudspeaker zones. If specified in the Project Documentation, adjustable height microphone, floor stands with collapsible type boom shall be provided

(b)

microphones shall be dynamic cardoid type or condenser type with balanced line level output and suitable for use with unscreened cable.

(c)

table stands shall incorporate the following features :

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microphone switch and LED indicator

(ii)

colour-coded switches for switching ON/OFF zones.

(iii)

one `ALL CALL' switch for switching `ON' all loudspeaker zones for common announcements.

(iv)

LED indicators shall operate in parallel with indicators on corresponding amplifier input channels. The Contractor shall submit details of the proposed provisions to confirm the normal conditions of the system and the perfect selection of zones and input channels, before the operator executes the feed message of feed in the required signal.


Frequency Range

:

60 Hz - 16 kHz

Rated output Impedance

:

200 Ohms

Sensitivity

:

2 mV/Pa

(iv)

Operating temp. Range

:

10 oC to +45 oC

(v)

Relative humidity

:

95%

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microphone input stations shall be complete with microphone accessories and 10m length microphone connections. Provisions shall be made for stations to avoid the possibilities of feedback.

Cassette decks shall have a sequencer which will accept 2 music cassettes, with audio sensing and auto reverse playback features, to provide truly continuous back-ground music. Cassettes shall auto-eject on power-off or jammed tape. (a)


Frequency

:

60 Hz to 16 kHz

(ii)

Distortion at 1kHz

:

< 3 % THD

(iii)

Signal to Noise Ratio

:

< 49 dB

(iv)

Wow & Flutter

:

0.35 % WRMS

QCS 2014

10


Page 7

(v)

Tape Speed

:

4.75 cm/sec.

(vi)

Power Supply

:

240 volts, 50 Hz

FM/AM Tuners shall be 6 channel radios with digital display and a provision of six pre-set stations. (a)


Characteristics

:

FM/AM tuner section

(ii)

Sensitivity

:

3 mV for FM channel, 20 mV for AM channel

(iii)

Normal Output

:

100 mV at ± 100 mV at 50 % modulation 27.5 kHz deviations

Freq. Response

:

To European standard

(v)

Distortion

:

Less than 1 % THD of 1 kHz @ 30 %

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1 kHz @ nominal modulation output.

Farash Call Systems

1

Farash call systems shall be provided and installed in the areas indicated on the Project Drawings. Systems shall comprise call control panels with audible and visual indications initiated by call push buttons located in the various areas indicated. Call control panels shall have a resetting facility, for visual (sound ends when finger removed from button), after the call is attended. Systems shall be wired with low voltage wiring independent of other standard wiring systems.

2

Door strike: When specified and as per the Project Drawings, door strike system shall be provided to open, close and latch the entry doors by remote control push-buttons

19.2.3

Intercom Systems

1

System Operation

calls shall be placed from any master station to any other station in the system unless specifically blocked. Calling parties shall touch-dial the appropriate digit numbers of desired stations, at which time a „connection tone” shall be heard and an LED illuminated at both stations to signify completion of connections. Voice communications may then begin. Connections may be cancelled by either party by pressing a cancel button

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(b)

master stations shall be equipped with a privacy/open facility to permit any user to place his station in the “privacy” mode. When calling a station that is in “privacy” mode, a unique “privacy tone” shall be heard at both stations for a pre-determined time interval as pre-set at the central exchange

(c)

upon completion of conversation and cancellation by either party, the “private” station shall be restored to “privacy” without further control manipulation

(d)

should calls be placed to stations already in use, the interrupted “busy tone” shall be heard by the calling party

(e)

slide-type volume controls to adjust incoming volumes shall be included on each desk master station. Control settings shall be clearly visible. Stations shall contain continuously adjustable volume controls.

Control Exchange Controllers

QCS 2014


Page 8

central controllers shall provide all control, switching logic, signalling and operating features listed throughout this specification

(b)

circuitry and components shall be arranged on slide-in printed circuit boards of the highest quality

(c)

central controllers shall not require external devices to program system functions and features

(d)

central exchanges shall be equipped with the required number of subscriber boards necessary to accommodate the quantity of stations required

(e)

expansion to ultimate cabinet capacity shall require addition of the requiredquantity of plug-in type subscriber boards. One plug-in board shall be required to increase exchange capacity

(f)

station wiring connections to central controllers shall be by means of screw terminals. Soldering, wire wrap and pressure connectors shall not be used. Interwiring between circuit board receptacles shall be by master printed circuit lines

(g)

central controllers shall be powered by closely regulated power supplies at maximum 24 Volt. Power supply mains transformers shall be mounted within or adjacent to exchange cabinets.

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Master Stations

intercom stations shall be the master type capable of receiving and initiating calls

(b)

intercom stations shall either be the desk-mounted type as used in commercial offices or a wall-mounted industrial type in workshop and plant areas, as indicated on the Project Drawings

(c)

stations shall have handsets for confidential conversations. Lifting handsets shall switch off microphones and loudspeakers to provide fully telephonic facilities

(d)

master stations installed in workshop areas shall comprise of heavy duty waterproof units for use in dusty and/or damp environments.

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(a)

System cabling shall comprise individual twisted pair telephone cables connected to the central controller from each of the stations.

19.2.4

Auto Class Change Over Systems

1

Auto-class change over systems for the automatic ringing of class change bells shall be provided located at different places within school buildings as shown on the Project Drawings. The system shall be microprocessor controlled and programmable.

2

Systems shall include the following salient features:

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19.3

(a)

7 days a week programming

(b)

override to silence the alarm on week ends i.e. Friday

(c)

minimum time adjustable to 5 minutes

(d)

over ride switch to operate the bells in the event of timer failure or wrong time

(e)

(easy system to programme the timing throughout the week and also separate selection through a two way switch for summer/winter schedules

(f)

DC backup using nickel cadmium batteries for 24 hours spring reserve

(g)

selector switch to select the operation mode in Manual/Auto/Off positions.

INSTALLATION

QCS 2014


Page 9

Wiring and Wiring Facilities

1

Wiring shall be executed to provide a complete and satisfactory functional system in all respects.

2

Wiring shall be carried out using multi-core and twisted pair conductors as indicated on the drawings. Wires/cables shall be enclosed in conduits and/or trunking. Vertical cable distribution cabling shall be on cable ladders. Cabling, conducting and trunking shall be in conformity with the relevant Specifications.

3

Cable terminations, components and junction boxes shall have identification tags, indicating polarity and function in a consistent manner throughout the system so that it can be crossreferenced with the as-built drawings and manufacturer's diagrams.

4

Signalling cables shall be electrically and physically separated and isolated from the mains voltage cables. Microphone cables shall be separated from the loudspeaker cables in a separate conduit.

19.3.2


1

After the installations are completed, the Contractor shall conduct acceptance tests to confirm the compliance of the systems with the Specifications. The Contractor shall present a list of the acceptance test items to be performed for Engineer's approval.

2

The test instruments and personnel to conduct the test shall be provided by the Contractor.

19.3.3

Maintenance and Guarantees

1

The Contractor shall be responsible for the system maintenance and repair of any fault for a period of 400 days starting from the provisional handing over. During this period the Contractor shall replace and/or repair any fault with all spare parts without any cost to the Employer.

2

The Contractor shall guarantee the system for a period of 400 days. During this period the Contractor shall clear any failure due to design problems or poor installation and workmanship.

19.3.4

Training

1

Training of personnel designated by the Engineer shall be carried out to enable to take over, operation and maintenance of the sound and call systems in the shortest time.

2

The Contractor shall submit a detailed training program which shall include theoretical and practical training for 1 month for personnel to be deputed by the Employer, at the end of the guarantee period, in addition to the Employer‟s personnel participation in the installation and testing stages as specified earlier, and maintenance during the guarantee period of 400 days.

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19.3.1

END OF PART

QCS 2014

Section 21: Electrical Works Part 02: MV Factory Built Assemblies (FBA‟s)

Page 1

2

MV FACTORY BUILT ASSEMBLIES (FBA‟S) ................................................ 2

2.1

GENERAL ....................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5

Scope General Reference References Submissions Quality Assurance

2.2

PRODUCTS .................................................................................................... 5

2.2.1 2.2.2 2.2.3 2.2.4

Cubicle Switchboards Motor Control Centres MCCB Panel Boards Distribution Boards

2.3

INSTALLATION ............................................................................................ 29

2.3.1

General Earth Bonding 29

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2 2 2 3 4 5 23 27 28 29 29

QCS 2014


Page 2

MV FACTORY BUILT ASSEMBLIES (FBA’S)

2.1

GENERAL

2.1.1

Scope

1

This Part shall include all labour, materials and accessories for the complete performance of all MV Cubicle Switchboards, Main Switchboards, Submain Switchboards, Motor Control Centres, MCCB panel boards, distribution boards in accordance with the Specifications and Drawings.

2


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General Provisions for Electrical Installation Protective Devices Motor Starters VFD Cables and Small Wiring Conduits Trunking Cable Trays Power factor correction capacitors

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This Section Part 1 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 16

.

2

Factory built assemblies of switchgear and control gear (MCCs) shall be suitable for operation under the ambient and service conditions specified. They shall comply with all local regulations and requirements. The Contractor shall be responsible for making himself aware of any special conditions which apply to the installation.

4

The Contractor shall be responsible for ensuring that all details relating to the construction and protection systems are fully compliant with the latest requirements of QGEWC and construction shall not commence until QGEWC approval has been obtained. The Contractor shall provided all protection relays, interlocks and devices deemed necessary by QGEWC.

2.1.2

General Reference

1

The work of this Part is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2

Co-ordinate the work with all other services affecting the work of this Part.

2.1.3

References

1

The following standards or updated/amended/revised versions are referred to in this Section:

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BS 37 Pt. 1 ................Electricity meters general BS 89, IEC 51 ............Direct acting indicating electrical measuring instruments BS 142 .......................Electrical protective relays BS 4794, Pt. 2 IEC 337-2

Control devices

BS 5685, IEC 521 ......Electric meters BS 6231 .....................PVC insulated cables for switchgear BS 7626, IEC 185 ......Current transformers BS EN 60073..............Basic and safety principles for man-machine interface, marking and identification coding principles for indicators and actuators BS 88, BS EN 60127 .Cartridge fuses

QCS 2014


Page 3

BS 159, IEC 61439.....Busbar and connection IEC 61439, IEC 439 ..Factory built assemblies LV BS EN 60947-4 IEC-1 & 1A Contactors BS EN 60529, IEC 529

Degree of protection of enclosures

BS EN 60947-3, IEC 408

Air break switches

BS 4752, IEC 157-1, IEC 61439

Switchgear and control-gear

BS 5472, IEC 61439 ..Low voltage switchgear and control-gear BS 7354, IEC 61439, .BS EN 6094 Electrical power switchgear 2.1.4

Submissions

1

Shop Drawings: All submittals in accordance with Part 1:

.

submit dimensional drawings of all the switchgears, switchboards and motor control centres, including sections and elevations, showing the following:

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(a)

arrangement of dimensions busbars

all components, instruments, indication and of all

(ii)

positions and method of fixing cables and boxes

(iii)

location of terminal blocks

(iv)

single line diagram of the circuits showing the rating of all components, the type and size of the incoming and outgoing feeders

(v)

schematic and elementary wiring diagrams, for each control unit, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

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connection wiring diagrams, for each control unit, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

(vii)

complete catalogue information for all components

(viii)

a complete list of parts, with prices, that would be necessary to maintain and/or modify the equipment

(ix)

Protection coordination studies for all types of MCC/MV panel breakers.

(x)

other relevant data.

Product Data: (a)

full specifications of the enclosures and the components of the switchgear, switchboards and motor control centres, with relevant sheets of manufacturer‟s catalogues

(b)

type test certificates of all components fully type tested and whole assembled MCCs from an internationally recognised testing authority or from independent testing lab in accordance with IEC 61439 or updated/revised/amended version.

QCS 2014

Section 21: Electrical Works Part 02: MV Factory Built Assemblies (FBA‟s) (c)

Page 4

confirmation that the switchgears, switchboards and motor control centres comply with the relevant specification as mentioned in this Section.

2.1.5

Quality Assurance

1

The switchgear manufacturer must have a previous record of satisfactory service in Qatar for at least 3 years in similar applications.

2

All new and refurbished Motor Control Centres shall be subject to routine tests to detect faults and workmanship in accordance with IEC 61439 or revised/updated version. Standard assemblies and/or products used within the assembly shall also be subject to tests at the manufacture‟s works who supplied the products. Routine tests shall include: the effectiveness of mechanical actuating elements, interlock, locks etc. shall be checked. The conductors and cables shall be checked for proper laying and the devices for proper mounting. A visual inspection is also necessary to ensure that the prescribed degree of protection, creepage and clearances are maintained.

(b)

all termination types and connections especially screwed connections shall be checked for adequate contact and torques.

(c)

factory built assemblies such as motor control centres for pumping stations and treatment plants, unit mounted stand alone control panels etc. shall be inspected thoroughly and tested at the manufacturer's works to verify the electrical operation in accordance with the control philosophy by simulating the site conditions.

(d)

the manufacturer shall submit the process flow diagram together with cause and effects for the assemblies involving complex control schemes and complicated interlock, sequence controls, etc.

(e)

the tests so conducted on the assembly at manufacturer's works shall be repeated as integrated tests on site with all field devices and interfaces present.

(f)

the manufacturer shall submit in advance, the testing procedure to the Engineer for approval prior to conducting the tests.

(g)

Motor Control Centres shall be subjected to dielectric tests as described in IEC 614391 and 2or latest /updated version of the standard.. All electrical components of the assembly shall be connected for the test, excluding those designed for lower test voltage and currents e.g. measuring instruments.

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(a)

anti-interference capacitors installed between the live and exposed conductive parts shall be capable of withstanding the test voltage without being disconnected from the circuit.

(i)

the protective measures with regard to protection against direct and indirect contact shall be checked as per IEC 61439 or latest /updated version of the standard.

(j)

Motor Control Centres shall be Totally Type Tested to IEC 61439-1 and 2 ASTA/KEMA type test certificate together with test report including reports/terms under (k) shall be submitted to the Engineer for approval.

(k)

following is a list of verifications and tests to be performed on a Totally Type Tested Assembly according to IEC 61439-1 A type test report shall be submitted to the Engineer.

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(h)

(i)

Strength of material and parts 10.2 Not required as “Type test” but as “Design and construction” rules on paragraph 7 or on subsidiary standard


Page 5

Resistance to corrosion 10.2.2



Properties of insulating materials 10.2.3



Thermal stability 10.2.3.1



Resistance of insulating materials to normal heat 10.2.3.2



Resistance to abnormal heat and fire due to internal electric effects 10.2.3.3



Resistance to ultra-violet (UV) radiation 10.2.4



Lifting 10.2.5



Mechanical impact 10.2.6



Marking 10.2.7

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Degree of protection of enclosures 10.3 8.2.7

(iii)

Clearances and creepage distances 10.4 8.2.5

(iv)

Protection against electric shock and integrity of protective circuits 10.5-8.2.4

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Effective continuity between the exposed conductive parts of the Assembly and the protective circuit 10.5.2



Effectiveness of the Assembly for external faults 10.5.3

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Incorporation of switching devices and components 10.6 Not required as “Type test” but as “Design and construction” rules on paragraph 7 or on subsidiary standard

(vi)

Internal electrical circuits and connections 10.7

(vii)

Terminals for external conductors 10.8

(viii)

Dielectric properties 10.9

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QCS 2014

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Power -frequency withstand voltage 10.9.2 8.2.2

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Impulse withstand voltage 10.9.3

(ix)

Temperature rise limits 10.10 8.2.1

(x)

Short-circuit withstand strength 10.11 8.2.3

(xi)

Electromagnetic compatibility (EMC) 10.12 + Annex J 8.2.8 + Annex H

(xii)

Mechanical operation 10.13 8.2.6

2.2

PRODUCTS

2.2.1

Cubicle Switchboards

1

General: (a)

M.V. cubicle switchboards shall be of indoor construction, purpose made, floor standing, totally enclosed, cellular cubicle type, dust protected, vermin proof and of clean and modern appearance containing the main components shown on the Drawings and/or specified


Page 6

(b)

the switchboards shall be fabricated, assembled, wired, checked, tested and coordinated at the factory by one manufacturer using the same make for all internal switchgear components and shall be constructed in accordance with IEC 61439 or latest /updated version of the standard..

(c)

the switchboard shall be equipped with Air Circuit Breakers, moulded case circuit breakers, relays, instruments, transformers, ancillary devices necessary for operation protection or measurement purposes and Automatic Transfer control with Manual operation bypass arrangement as indicated on the Drawings

(d)

the normal components, fittings and accessories required for safe and proper operation of switchgear shall be provided, whether specifically mentioned herein or not

(e)

to withstand thermal and mechanical stresses set up by short circuit conditions in accordance with the fault through current of the feeding transformer. In general fault breaking capacities for main switchboards shall be as stipulated in QGEWC regulations minimum 44KA for 3 Seconds.

(f)

spare ways indicated on the Single Line Diagram shall be fully equipped

(g)

all FBA‟s should have a manufacturers name plate indicating minimum; Manufacturer name, address, project No. busbar rating, fault current, year of manufacture, serial no. IP, etc.as per Engineer approval.

(h)

the MCCs shall be designed, manufactured and tested to IP54 in compliance with the requirements of IEC 60529.

(i)

equipment such as Variable Frequency Drives (VFD), UPS and others with large watt loss, if specifically mentioned in the particular requirements to be included in the MCC, that require forced ventilation by employing external fan and louvers as recommended by the manufacturer, the degree of protection (IP rating) shall be reduced to IP43 from IP54.

(j)

the MV/MCCs panels shall be designed and type tested to withstand a fault current of 44 kA for 3 seconds symmetrical. Additionally the MCCs shall be type tested for safe containment of an internal arcing fault, which will check the capability of the steel structure to withstand the forces associated with the arc, and ensure safety and integrity of the assembly for continuous use. This is to establish that the enclosure of MV/MCCs together with internal partitions and/or barriers withstands the pressure and temperature arising from internal arcing with short circuit current and thus provides protection for persons in front of or within the close proximity of the MCCs in the event of internal arcing.

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QCS 2014

(k)

the test certificate must show that the neutral bar has been tested with the full fault current and for the full time specified.

(l)

the MCCs shall be designed and equipped with properly sized circuit breakers and/or fused disconnect switches, having a minimum factor of safety of capacity 1.5 taking into account the connected load and its diversity, with provision for selective short-circuit co-ordination so that faults are cleared without disturbing other circuits.

(m)

the MCCs shall be designed for indoor installation except where specified for outdoor installation.

(n)

the MCCs shall be designed to operate satisfactorily in an ambient air temperature of +50° C and RH exceeding 90%.

(o)

unless otherwise specified temperature up to +70° C and RH up to 100% shall apply during transport, storage and installation. Equipment subjected to these extreme service conditions without being operated shall not suffer irreversible damage when operated under normal specified conditions.


Page 7

(p)

the altitude of the site installation shall not exceed 100 meters.

(q)

the MCCs shall normally be located indoors in service conditions as specified above. However some parts of the MCCs such as sensors, field instruments and pilot devices may require installation in highly corrosive gaseous environments. Gases such as hydrogen sulfide and methane may adversely affect the functions of the components and devices. In such application environments, special measure shall be adopted to prevent corrosion and the subsequent rise in resistance leading to temporary or permanent interruption in control or power circuits.

(r)

the temperature rise in MCCs shall not be allowed to damage the components, connectors, wires, terminals etc. With the equipment in normal service condition, no live part shall become subjected to high temperature causing overheating that increases the risk of internal arcing accidents.

(s)

extreme care shall be taken while designing the MCCs to ensure external surface temperature is maintained within the specified limits.

(t)

the clearances and creep age distances in the MCCs shall be based on rated impulse withstand voltage in accordance with IEC 61439to ensure that the equipment designed is capable of withstanding the specified voltage without failure under specified test conditions.

(u)

the equipped MCC must confirm to the clearance and creepage distances and withstand voltages explicitly by taking into account the specified service conditions.

(v)

the maximum height of assemblies shall be 2400 mm above the finished floor level.

(w)

site consideration including safety and maintenance shall be taken into account in the design of assemblies. These considerations shall include: clear floor space of at least 2000 mm shall be provided in front of the MV/MCC panel from the free edge of the doors in the open position. Clear floor space of 900mm shall be provided behind the MCC when the doors are in the open position if the MCC is less than 4000mm long. If the MCC is 4000mm or longer the space provided shall be 1200mm. The clear floor space behind the MCC is not required when a true front access assembly is provided.

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QCS 2014

(ii)

in order to provide an unobstructed exit route a clear path of not less than 1000mm shall be provided at each end of the MCC.

(iii)

provision of sufficient space to allow for doors to open fully without fouling other items of equipment or other open doors.

(iv)

limiting the size and weight of assembly sections to those imposed by transportation, site access and permitted levels of site floor loading.

(v)

clear floor space of at least 1000 mm shall be provided from the sides of all MCCs in order to allow possible future extension.

(vi)

Provide a 2 m clear opening, cable basement access room below the MV/MCC rooms for cable access including the required fire alarm, ventilation, earthing and lighting requirements as listed elsewhere and as per Qatar UPDA Municipality requirements.

(vii)

All cable penetrations from MCC basement to MCC trough the MCC floor shall be sealed with 2 hours fire rated spray compound, subject of Engineer‟s approval.

(viii)

50% standby capacity Air Conditioning (minimum one unit) shall be provided for the MCC/MV room.

QCS 2014

Page 8

Construction: unless specified otherwise in the Project Documentation, main FBA switchboards and MCC for general purpose indoor uses shall be constructed to comply with the requirements of IEC 61439 –Form 4b or Form 4 Type 7 conform with GAMBICA

(b)

switchboard shall be factory built, totally enclosed, and have provision for rear access. Size, rating arrangements shall be as indicated on the Drawings

(c)

the switchboard shall consist of standard cubicles assembled together on continuous base channels to form a rigid in line flush fronted free standing continuous switchboard assembly. For small installations where particularly specified, true front access MCCs must be provided. For all other cases front and rear access MCCs must be provided. MCCs shall be constructed such that doors and covers are flush with one another and aligned to a common vertical plane; manufactured out of mild steel coated with Alu Zinc having the following thickness: Plinth/bed frame

- 3.00 mm

(ii)

Frames

- 2.00 mm

(iii)

Covers and Doors

- 2.00 mm

(iv)

Mounting plate

- 3.00 mm

(v)

Gland Plate

- 3.00 mm

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(a)

a separate cubicle section shall be provided for the main incoming circuit breaker and cable glands shall be provided for the incoming cables in accordance with the QGEWC regulations.

(e)

each cubicle shall be divided into segregated busbar section and circuit section. The circuit section shall be further divided into segregated compartments for housing main and emergency circuit breakers and other devices. Access to internal components of any compartment must be feasible by isolating its particular switch. The hinged door shall be mechanically interlocked with the switch in such a manner that the door can be opened only in the „OFF‟ position

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(f)

the switchboards shall be totally enclosed, all hinged doors, covers shall be gasketed to provide protection against dust

(g)

cabinet shall have adequate means of lifting and shall be capable of being rolled or moved into the installation position and bolted directly to the floor

(h)

the switchboards shall be provided with suitable cable glands to suit the type, size and number of cables as indicated on the Drawings. The cable glands or bracket where required shall be adequately mounted inside the switchboard. The switchboards shall be provided with the proper cable fixing clamps and terminal lugs for incoming and outgoing cables as well as earth bonding connections


Page 9

(i)

after fabrication, steel work shall be cleaned, zinc sprayed and stove enamelled with one prime coat, two under-coats and one finishing coat, the surface being rubbed down after each coat or epoxy coated subject of Engineer‟s approval.

(j)

the finish of all parts shall be entirely suitable for the climatic conditions on site.

(k)

the equipment shall be finished with at least two coats of undercoat and two coats of high grade acrylic stove enamel or epoxy coated subject of Engineer‟s approval. Cubicle interiors shall be completely painted white, however this is not essential for the rear of the door. The height of the switch board shall be limited to 2200mm unless specifically required to meet the site constraints and approved in writing by the Engineer.

(l)

any damage caused to the finish during transportation and erection shall be returned to the manufacturer for repair if it cannot be perfectly repaired on site. The structure shall be protected from rust and oxidization. The paint shall be applied to rust and grease free surface of metal. The steel shall be electro – zinc plated (ZINTEC) and must have a minimum of priming coat, undercoat and finishing coat or epoxy coated subject of Engineer‟s approval. The undercoat and finishing coat shall be stove enamelled.

(m)

The exterior shall be green to BS 4800, shade 14E53. The switchboard degree of protection shall be IP 54 to BS EN 60529.

(n)

all plastic parts used within the assembly shall be of flame-retardant, self extinguishing type and halogen free.

(o)

MCCs shall have internal separation by means of metallic or non-metallic partitions or barriers.

(p)

all internal components within the compartment /cubicle shall be provided with the degree of protections to IP 2X as minimum whereas the degree of Protection to IP4X shall be provided to adjacent functional units preventing contact with live parts.

(q)

electrical continuity between the exposed conductive parts of MCCs and protective circuits of the installation shall be ensured to provide protection against indirect contact by using protective circuits.

(r)

the protective circuits throughout the installation shall be so designed that it is impossible to break the protective path with the removal of any component from the MCC.

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QCS 2014

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(s)

all outgoing circuit‟s protective conductors shall have a separate terminal of adequate size duly identified in accordance with the Identification Section explained elsewhere in QCS.

(t)

MCCs must be designed by giving highest importance to accessibility especially when in service/fully powered, allowing easy viewing for inspection and operation, replacement of fuses and extension of additional functional units etc.

(u)

floor mounted assembles shall either be provided with an integral plinth or a separate rolled mild steel channel bed frame, at least 50 mm high. Fixing shall be by not less than four holding down bolts per assembly/column section, located around the periphery of the section. The fixing shall not be visible from outside the section, but shall be readily accessible from within.

(v)

fixings for wall and pole mounted enclosures shall be provided outside the enclosure. The back of the enclosure shall not be drilled to accept fixings.

(w)

the type of cubicle construction shall be multi-compartment type unless specified otherwise.


Page 10

compartments containing switchfuses, starters, control sections, distribution boards, busbars, downdroppers and similar equipment shall be fully segregated. There shall be no aperture large enough to admit a 5mm diameter wire between any two adjacent compartments. Each cubicle/compartment shall have its own door.

(y)

interconnecting cables between adjacent compartments shall not proceed directly from one to the other but shall pass through a vertical wall into a cabling compartment before re-entering. Holes for interconnecting cables shall be of the minimum size necessary. All such holes shall be filled with insulating grommets.

(z)

all cubicles shall be provided with a means of ensuring that equipment can be adequately isolated for maintenance purposes without interrupting essential loads which may continue to operate whilst maintenance is being undertaken.

(aa)

distribution sections shall be fully insulated to allow safe operation by nonengineering personnel.

(bb)

doors shall be adequately sized to accommodate readily and neatly all mounted equipment, open at least 120 degrees, be rigidly constructed, suitably braced and provided with at least two substantial hinges which shall be captive when the door is closed. Doors shall be provided with stays to prevent over opening.

(cc)

each door shall be provided with non-rusting metalic ‘T’ type handles at least one of, which shall be lockable.

(dd)

the doors shall be fixed to the frame by substantial single knuckle non-rusting type, or internal concealed type hinges. Hinges shall be on the left hand side of the door. Hinges shall not be welded to either the door or frame. Substantial continuous stainless steel type hinges over the whole height of the door may be considered if the manufacturer can provide evidence of long continuous service of this type of hinge on his product.

(ee)

locking combinations shall be provided as specified. Three keys for each key type shall be provided on individual key rings having a nametag showing identify details.

(ff)

where the need of padlocking facilities is identified by the engineer/employer, the padlocks shall be supplied and fitted.

(gg)

equipment shall not be mounted on covers. Covers shall not weigh more than 30 kg, and any cover over 7.5 kg shall be provided with a means of supporting the lower edge when its securing bolts are being inserted or removed.

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(x)

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QCS 2014

removable back covers shall be provided.

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(hh) (ii)

each door shall be provided with an internal welded earthing stud, and shall be bonded to the assembly main earth bar.

(jj)

every incomer, starter, feeder, etc. shall have an individual terminal/gland box. Control compartments and small power and lighting distribution boards must also have independent gland boxes but these may be common to more than one circuit.

(kk)

terminal/gland boxes may be externally mounted on the rear of the MCC or internal. Terminal/gland boxes shall not inhibit access to or maintenance of any part of the MCC.

(ll)

outgoing main and control cables shall be glanded at the compartment so as to ensure a full earth screen to each compartment and shall also be glanded at plinth level to make the complete MCC vermin-proof. Compartment gland plates shall be a minimum of 300mm above the plinth level gland plate.

(mm) gasket material used for sealing panel doors and covers and for door mounted instruments shall be of highest quality and should not be subject to deterioration by temperature, UV, hydrogen sulphide and methane.


Page 11

(nn)

doors and covers giving access to potentially live conductors shall be provided with prominent warning labels, in English and Arabic.

(oo)

doors on outdoor assemblies shall be retained in the open position by the provision of adequately fixed stays.

(pp)

each cubicle/compartment shall be provided with a removable steel components mounting plate located clear of the cubicle rear panel.

(qq)

all components, other than door mounted, shall be located on the component mounting plate by bolting into tapped holes or by using self-tapping screws. Nuts used for securing components shall be captive.

(rr)

rail type fixings may be used where appropriate. mounted on any other surface.

(ss)

no components shall be located within the assembly at a height greater than 2000 mm or less than 500 mm above finished floor level.

(tt)

it shall be possible to replace and maintain any component without first removing other components.

(uu)

bolts and nuts for cover fixing shall be captive and provided with protective washers to prevent damage to paintwork.

(vv)

unless specified otherwise control supplies shall be 110V a.c. derived from a transformer within the control compartment or in a separate compartment, fused on its primary circuit. Neutral shall be earthed with a removable link. Individual compartments shall be fed through a fused tapping next to the main 110v bus adjacent to the transformer. Proper fuse coordination to be achieved to avoid one section fault from affecting the other section. Transformer shall be rated for at least 150% of the maximum loading for long service life.

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Components shall not be

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(ww) auxiliary supplies such as 24 V AC/DC, 240 V AC etc. are specified in the relevant individual component‟s specifications. each compartment shall be provided with a separately fixed compartment heater rated 110 Volts AC. Apart from those in motor starter compartments the heaters shall be controlled by means of individual “OFF/AUTO” switches. Auto operation shall be by means of adjustable panel mounted humidistat covering the range of humidity envisaged.

(yy)

MCCs shall be designed for ready extension at each end.

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(zz)

all terminals for outgoing connections shall be located at a low level in the compartment adjacent to the cable gland trays. Adequate space shall be provided the installation and dressing of site cables. It should be noted that site cables are frequently oversized to allow for high ambient temperatures and long cable routes. Direct termination on equipment such as Distribution Board Fuses or Miniature Circuit Breakers (MCB‟s) shall not be permitted.

(aaa) all main switches shall be arranged such that a minimum distance of 700mm exists between the glandplate and the bottom of the circuit breaker or terminals, whichever is the less. (bbb) all live terminals, bus bar joints, main incoming and DG cables lugs/joints with the Busbar ACB terminals (or similar cases) shall be fully shrouded by using removable jointing caps high-grade high temperature material subject of Engineer‟s/client approval. (ccc) all cable entries shall be affected using brass cable glands to IP rating as specified. (ddd) all cable glands shall be provided with earth tags. (eee) cables shall enter assemblies through detachable steel or aluminum/brass (for single core cables); gland plates fitted at least 200 mm above finished floor level.

QCS 2014

Section 21: Electrical Works Part 02: MV Factory Built Assemblies (FBA‟s) (fff)

Page 12

gland plates shall be rust proofed and provided with a welded and bonded earthing stud, and adequately sized to accommodate present and known future cabling requirements. Access to both sides of each gland plate when it is in position shall be possible from within the assembly. Cables shall enter at the top or bottom of assemblies as specified and/or as shown on the relevant drawings where applicable.

(ggg) cableways shall be provided to ensure that apart from inter-connections no cable routed to one cubicle shall pass through any other cubicle. 2

(hhh) for cable sizes 300mm and above insulated glands shall be fitted. provision for accommodation of rising armored cables shall be provided with adequate cable supports and a form of cable entry via approved cable glands secured to a steel glanding plate.

(jjj)

space shall be provided to accommodate cable glands of appropriate size for incoming and outgoing circuits. All gland plates and trays shall be adequately earthed.

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within each assembly, all metal parts of equipment supplied, other than those forming part of an electric circuit, shall be bonded to the earth bar. Metalwork may be used for this purpose provided that earth continuity conductors are fitted at all joints and other discontinuities and those connections to metal work are made using a welded or bolted stud.

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(kkk) cable disconnecting links shall be provided where specified and shall be used for maintenance purposes only. The links shall be fitted to the bus bar risers immediately before the cable terminations and shall be easily accessible. The links shall be labeled „ISOLATING LINK‟ and the circuit or cable reference shall be quoted.

gland plates

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(mmm) the following metal parts must be provided with equipotential bonding connected to an earth busbar system by using yellow/green earth cable of at least 6.0 mm square.

gland covers

(iii)

side sheets

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(iv)

top barriers

(v)

intermediate barriers

(vi)

top covers

(vii)

end covers

(viii)

rear Covers

(ix)

front covers

(x)

cable Boxes

(xi)

doors and bolted front covers

(xii)

horizontal busbar barriers.

(nnn) Where specified in contract document, each compartment shall be provided with a smoke detector. In addition to this, a heat sensitive cable shall be run throughout the MCC passing through each compartment. Both shall be connected to the fire alarm panel and shall additionally be arranged to open the main supply circuit breaker and inhibit the start up of the standby generator.

QCS 2014


Page 13

(ooo) Where specified in contract document, MV/MCC panel shall be provided with capsular type fire extinguishing system using FM 200 clean agent as described in section 23. One cylinder for maximum 2 columns shall be provided. The system shall be connected to the fire alarm panel and shall be arranged to open the main supply circuit breaker and inhibit the start up of the standby generator. No objection letter shall be provided by the FBA manufacturer for installation of Capsular Fire Extinguishing system in the FBA panel.. (ppp) The height of the switch board shall be limited to 2200mm unless specifically required to meet the site constraints. Proposal shall be approved in writing by the Engineer. (qqq) Provide carriage/Lifting Truck if an ACB exceeded 25kg in weight (One carriage only for each site/project regardless of number of breakers provided).

.

Supply incoming ACB/MCCB including Electricity Supply Authority metering.

(ii)

Diesel generator ACB/MCCB incoming.

(iii)

Pump starters (current pump installation-if existing)

(iv)

Pump starters (future pumps) –

(v)

Miscellaneous feeders / valve actuators, etc.

(vi)

PLC

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InstrumentationLabels:

Provide identification on all equipment e.g. control panels, MCC, controllers, raceways, boxes and conductors, devices etc in accordance with BS 61346, BS 61666, BS 61175 and BS 60445 standards or latest edition of other applicable standards to the approval of the Engineer.

(b)

All labels shall be permanent, and be machine generated. NO HANDWRITTEN OR NON-PERMANENT LABELS SHALL BE ALLOWED.

(c)

Prior to making any label or nameplate for the purpose of identification, submit a detailed schedule indicating nameplate size, lettering size, color, material and actual nameplate information for the Engineer's review and approval.

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(d)

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The different panel compartments shall be arranged in the following order when facing the front of the MCC and reading from left to right:

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(rrr)

All external labels, nameplates, operational and warning signs shall be provided in English.

(e)

Material used in making the engraved labels shall be of highest quality suitable for the environmental and climatic conditions as specified in the relevant section.

(f)

Critical devices such as disconnect switches; service feeders and branch circuit protective feeders shall be legibly labeled to indicate its purpose and point of origin. The legibility distance shall not be less than 2.0 meters.

(g)

Identification nameplates shall be provided in addition to the manufacturer's equipment nameplates as required by NEMA, BS, IEC or UL.

(h)

Warning signs and instruction labels wherever needed shall be provided in accordance with all applicable local regulations.

(i)

The Contractor shall clearly show locations and fixing arrangements of nameplates and labels on layout drawings.

(j)

The Contractor shall comply with the following requirements for labels: (i)

Provide equipment identification labels for all electrical equipment including, but not limited to switchgear, control panels, switchboards,

QCS 2014


Page 14

transfer switches, disconnect switches, transformers, generators, power factor capacitors, fixed equipment, motor starters, MCCs etc. Provided sub-classification label for all emergency power system, junction boxes and pull boxes.

(iii)

External labels:3mm thickness minimum, Clear Perspex back engraved, in black letters on white backgorund in English with chamfered edges fixed with stainless steel screws with nuts and flat & lock washers. The letters should be filled in white and the rear surface painted black.

(iv)

Internal labels: Multi-layered plastic to an approved design engraved in English, and fixed with stainless steel screws. Alternatively special purpose made DIN rail may be used for fixing labels as approved by the engineer.

(v)

All labels shall be screw or rivet fixed and adhesive labels shall not be permitted under any circumstances.

(vi)

Internal components labels shall have circuit designations correlated with the drawings.

(vii)

Labels shall not be attached to trunking covers or other readily removable items.

(viii)

electrical equipment enclosures, vaults, doors and fences shall be provided with "DANGER KEEP OUT" warning sign, showing proper voltage.

(ix)

disconnect switches and emergency devices shall have "CAUTION" warning signs as directed by the Engineer.

(x)

fuse and MCB distribution boards shall be provided with internal, screw fixed, engraved circuit labels. Ink on paper, ink on plastic, printed paper, printed plastic, plastic film or any kind of adhesive labels shall not be permitted.

(xi)

Provide a main Title Label all for electrical distribution and all other control equipment, panels etc.

(xii)

Provide a Function Label for door mounted components.

(xiii)

Every internal component - Identification Label.

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(xiv) Provide a Identification Label for Protective devices - ( e.g. fuse/mcb type, rating). (xv)

Provide a Title Label for Communication equipment.

(xvi) Compartments with doors and covers not electrically interlocked to an isolator, external label - “ DANGER, LIVE TERMINALS ” with flash and voltage in red letters on white background in Arabic and English. (xvii) Provide a function description Label for group of terminal blocks. (xviii) Letter size shall be to the approval of the Engineer (xix) Removable rear cover shall be provided with identification and the location on the Switchgear panel shall be provided with identification label. 4

Switchboard Wiring:


Page 15

(a)

Wiring shall generally be of the multi-stranded high temperature to minimum 105° C flexible PVC insulated, 600/1000V single core stranded copper type cable to BS EN 6231. Where it is proposed to use alternative high temperature, double insulated or other special cable or insulated flexible laminated bus bar this should be brought to the attention of the Engineer for his approval.

(b)

Wiring shall be supported in insulated cleats or cable trunking. Adhesive type cleats or mounts shall not be used unless augmented by screw fixings.

(c)

Busbar chambers shall not be used as trunking for small wiring.

(d)

Wiring shall be neatly laid and run in limited compression insulated cleats, insulated straps or, where more than ten wires follow the same route, in plastic slotted-sided trunking with clip-on covers. Where trunking is used, the effective overall cross-sectional area of cables shall not be greater than 70% of the trunking cross sectional area.

(e)

Wiring to items of equipment mounted on hinged doors or subject to movement shall run in plastic sleeving or flexible conduit, being securely anchored at both ends; leaving ample slack to prevent wiring strain, arranged so that they are subject to torsion rather than bending.

(f)

Holes in steelwork through which cables pass shall be protected using grommets or bushes, suitable for the size of hole.

(g)

Cables used for control, extra low voltage and instrument signal transmission, likely to be affected by interference, shall be screened and/or spaced from each other and from heavy current power cables. The separation distance shall ensure that the resultant electrical noise is insufficient to cause any form of malfunction of associated equipment or give false readings.

(h)

A sufficient number of terminal connections including 15 % spare terminals shall be provided for all control and instrument wiring.

(i)

All wiring shall be identified at each end by means of glossy plastic ferrules showing the wire number as on the schematic diagrams. Ferrules shall be color coded, ‘Z‟ type and indelibly marked.

(j)

Where single core cable is to be accommodated, a non-magnetic gland plate shall be provided. For cable size 300 mm Sq. and above insulated glands shall be fitted.

(k)

Undrilled gland plates shall be provided for the reception of conduits and threaded glands. Boxes and glands shall be within the cubicles except where otherwise approved.

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(l)

Single strand wire shall not be used. The minimum cross sectional area of the 2 2 wire used shall be 1.0 mm (multi strand flexible) for control circuit and 2.5 mm for power circuit. Both ends of every wire shall be fitted with a white cable marker as described above. Clip on type cable markers shall not be used. Color-coding shall be:  Red - Red phase  Yellow - Yellow phase  Blue - Blue phase  Black - Neutral  Green and Yellow - Earth/Protective conductors  Grey - 110V a.c  White - 60 D.C  Purple - <50V a.c  Brown - Current Transformers Identification of conductors and auxiliary circuit shall be in accordance with BS EN 60445 and BS EN 60446 (m)

Terminations shall be as follows:-


Page 16

All wiring shall have crimped terminations, only one wire being held by any one crimp. Crimped lugs shall be of the insulated type without conductor exposure between the crimp and wire insulation.

(ii)

The type of crimp used shall be appropriate for the type of terminal to which it connects. The crimping shall be tubular when the tightening screw sits directly above it, or fork type if the tightening screw passes through the lug.

(iii)

Terminations shall be neatly arranged leaving adequate length for one termination.

(iv)

All terminal blocks for the connection of small wiring shall comprise shrouded anti-tracking molding of melamine phenolic or comparable material with provision for securing conductors either by high tensile screws and clamps or alternatively in the case of small telephone type conductors by solder tag connection.

(v)

Terminal blocks shall be arranged to facilitate easy access to both terminals and wiring ends. Connections for outgoing circuits to auxiliary pilot cables shall be provided with test links.

(vi)

Removable rail terminals shall be provided for all wiring, mounted at an angle to provide ease of access. Centre-disconnecting link type terminals shall be provided for analogue signal circuits, external control devices and all alarm/telemetry signals. Sufficient, suitably sized earth terminals and end stops shall also be provided.

(vii)

The gap between gland plates and associated terminals shall be such that conductors can be safely manipulated and connected without damage. Terminals shall face the door of a cubicle for ease of connection.

(viii)

Barriers shall be provided on all terminal banks, to group terminals into logical divisions. Power terminals of different phases shall be barriered from each other and separated from control terminals.

(ix)

In all cases care shall be taken to ensure that terminals are easily accessible after all wiring and plant cabling has been installed and terminated. All connections shall be made on the front of terminal blocks.

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No more than one conductor shall be connected to one side of a terminal. Where several conductors are to be connected, shorting bars shall be provided across multiple terminals. Outgoing cables shall be wired so that all assembly wiring is connected to one side only.

(xi)

The terminal numbers, voltage grouping and terminal block layout shall correspond precisely with wiring diagrams so that quick and accurate identification of wiring can be made.

(xii)

All terminals shall show the circuit wire number reference.

(xiii)

A separate dedicated telemetry/RTU section shall be provided in the MCC cubicle equipped with all terminals duly wired and located in the side or on the top of the compartment interior leaving maximum room for free issued fully wired and tagged RTU complete with all associated hardware‟s on a mounting plate. When a PLC control system is provided the PLC should be suitable for telemetry communication and shall be configured to communicate with the SCADA master station.

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(x)

(xiv) The MCC vendor shall co-ordinate with the RTU vendor through the Contractor to confirm the size of free issued duly wired RTU on a

QCS 2014


Page 17

backplate. The MCC vendor shall install and complete interconnection wiring between the RTU and the MCC accordingly. (n)

Safety Measures. (a)

circuit breakers shall be provided with suitable means to prevent unauthorised and accidental operations. Interlocks to prevent dangerous operations shall be provided wherever necessary. High voltage parts shall be protected to prevent accidental human contact. Warning signs of durable type fixed on visible place shall be provided on high voltage parts. Earthing of metal parts shall be provided.

(b)

mechanical interlocking shall be provided where required. All electrical interlocking shall be of the double interlocked type having separate permissive and prohibitive interlocks. Thus to allow a device to operate there must be an absence of prohibitive signals and a presence of permissive signals from the remaining devices in the interlocked system i.e. fail safe.

(c)

suitable equipment shall be provided mechanically to prevent a device being manually operated when a prohibitive signal from another part of the interlocked system is present.

(d)

when the MCC includes a standby generator incomer in addition to the QGEWC incomer, mechanical and electrical interlocks shall be provided in accordance with QGEWC regulations.

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The Contractor shall submit for the Engineer's approval, samples of wires, numbered ferules, and terminal pins or lugs which he proposes to use.

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Pilot Devices:

pilot devices shall confirm to BS EN 60947-5.1. These shall be circular, 22 mm dia suitable for mounting on the cubicle door. The pilot devices shall have two main parts the operator and the Snap-On contact block. The mounting between the cubicle door and the operator shall be done through Snap-On flange. Pilot devices shall be designed to provide IP65 as a minimum protection when installed in the enclosures. Terminals shall be protected to IP2X.

(b)

push buttons shall comply with the following specifications unless specified otherwise in particular requirements: -

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(a)

(i)

standard design

(ii)

mushroom/stayput/lockable type where specified

(iii)

non illuminated

(iv)

anodized Aluminum Bezel

(v)

1NO+1NC configuration minimum

(vi)

RED button for STOP function

(vii)

GREEN button for START function [Recessed type]

(viii)

mushroom RED for Emergency STOP function

(ix)

BLACK button for manual RESET

(x)

WHITE button for lamp test

(xi)

push buttons for other functions where applicable shall be subjected to the approval of engineer.

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(c)

selector switches shall comply with the following specifications unless specified otherwise in particular requirements: (i)

standard design

(ii)

lever type cam operated

QCS 2014

Section 21: Electrical Works Part 02: MV Factory Built Assemblies (FBA‟s) (iii)

Twist Release/Push-Pull/KEY type where specified and/or approved by engineer.

(iv)

non illuminated

(v)

anodized aluminum bezel

(vi)

No. of positions as per logic diagram

(vii)

BLACK color

(viii)

1NO+1NC configuration minimum

indicators shall comply with the following specifications unless specified otherwise in particular requirements: (i)

low voltage transformer latch type 110V/50Hz primary

(ii)

bulbs shall be long life neon types rated at least 10% higher than the operating voltage.

(iii)

GREEN colour for RUN/ON indication

(iv)

WHITE/Grey colour for STOP/OFF indication

(v)

AMBER colour for TRIP/FAULT indications

(vi)

BLUE colour for equipment selected „On-Auto‟ indication

(vii)

WHITE color for SUPPLY AVAILABLE / ENERGISED

(viii)

RED colour for DANGER (in operation) indication

(ix)

indicators for other conditions where applicable shall be subjected to the approval of the Engineer.

(x)

the pilot light operator shall be designed to facilitate removal of bulb from the front of the unit without requiring any tool.

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(d)

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LEDs shall be allowed.

(f)

emergency and safety switches where specified shall confirm to BS EN 609473, Utilization Category AC23 and comply with the following specifications: -

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(i)

(ii)

visible operating handle with marking OFF/ON position

(iii)

lockable in Off position by using padlocks

(iv)

suitable for base/wall mounting

(v)

the breaking capacity shall be more than the largest circuit it breaks

(vi)

the emergency switch shall have red handle on a yellow background

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IP65 metal/thermoplastic enclosure suitable for installation in nonsafe areas involving Methane and H2S gases.

Busbars: (a)

the busbars shall be electro-tinned hard drawn, high conductivity 99.9 % purity, suitably sleeved for phase identification to BS 158

(b)

all busbars shall extend through the length of the board with same cross section throughout unless indicated otherwise

(c)

a copper Earth Busbar sized at least 50 % of the phase busbars or 300 mm , whichever is greater, shall be provided along the full length of the board

(d)

busbars shall be adequately supported by porcelain or moulded insulators spaced on suitable centres so that the complete assembly can withstand the maximum mechanical stresses to which it may be subjected to under fault conditions

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Page 19

(e)

unless otherwise stipulated in the particular specification or drawings busbars shall be housed in separate adequately ventilated compartment which shall not contain any wiring or apparatus other than that required for connections for busbars

(f)

rating : As indicated on the drawings.

(g)

the mechanical and dielectric strength of bus bars and supports shall be capable of withstanding the worst conditions of electrical surge, which can occur in the installation

(h)

bus bars shall be sleeved for phase identification by using high temperature grade heat shrinkable colored PVC sleeving throughout its length. In no circumstances will any kind of wrapping tape be accepted on busbars.

(i)

all three phases and the neutral busbar shall be of same size enclosed in a common separate chamber.

(j)

the mains horizontal busbars shall be housed in a separate chamber located on the top of the assembly. Busbars located elsewhere not on the Top shall be accepted at the discretion of the Engineer after verifying the certification, site location, available space and considering other factors necessary for ease in operation and maintenance of the assemblies. Insulation barriers shall be provided at each cubicle division.

(k)

vertical busbars shall be fully enclosed in a separate chamber.

(l)

bus bars connections shall be identified by phase color marking and adequately supported by suitable supports designed to withstand the full fault capacity as specified herein.

(m)

connections from the main bus bars to MCCB‟s controlling main motor starters and outgoing distribution feeder shall be via solid copper bus bars.

(n)

Connections to busbars shall take the form of rigid bolted copper strips. Caliper sliding connections or similar movable contacts shall not operate directly onto the busbars or down-droppers.

(o)

The utilization of “Fault Free Zones” will be permitted for the connection between the busbar risers and functional units rated 32 amps or below. These may be of copper conductors of solid rigid manufacture or double-insulated flexible conductors provided that they are securely fastened, provided in both cases that under normal operating condition an internal short circuit is only a remote possibility. For all functional units the connections between the busbar and the functional units should be sized to the frame rating of the short circuit protection device in the functional unit and an ASTA/KEMA certificate for their short circuit 2 let though (I T) capability shall be provided.

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QCS 2014

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(p)

bolted copper bus bar links shall be provided where specified and shall be used for maintenance purposes only. The link section shall be easily accessible from the front or top of the board and shall have a lockable cover. Provision for storing the links nuts and bolts shall be made in the switchboard.

(q)

the temperature rise of busbars shall be limited to that which will not cause damage to the insulating material when carrying their rated current at the site ambient temperature and shall in any case not exceed 60°c reduced by the amount the site ambient temperature exceeds 40°c.

(r)

The neutral shall be solidly earthed at the MCC. The neutral-earth link shall be adjacent to the incomer, externally labeled and be easily accessible.

Instruments:

Section 21: Electrical Works Part 02: MV Factory Built Assemblies (FBA‟s) (a)

the Measuring Instruments shall include ammeters, voltmeters, kWh meters, selector switches and associated accessories as indicated on the Drawings and described herein as follows: (i)

the measuring instruments shall be moving iron vane type, flush pattern with dust and moisture proof enclosure. Anti-glare glass front, anti-parallax scales and white faces with black numerals and marking shall be used. All instruments shall be of long scale 240 degree with full load indicating approximately at 180°



the dial size shall be 10 x 10 cm2.



accuracy shall be one percent of full scale values



moving elements shall be provided with zero adjustments located at face of



dial.



the ammeter shall be capable of withstanding twice of rated current for 10



minutes and overload sustained under fault conditions without damage or loss of accuracy.



voltmeter shall have a measuring range from 0 to 500 V and shall withstand



twice the rated full scale voltage for 1.0 minute without damage



three ammeters or a single ammeter with selector switch shall be provided to



read the current of each phase, as indicated on the Drawings



the voltmeter selector switch shall be of the rotary type with cam operated



contactor and shall have (7) positions off, R-Y, Y-B, R-B, R-N, Y-N, B-N



single and poly phase power factor meters with associated current and



potential transformers shall be provided as required and specified herein



ammeters shall have maximum demand pointers.

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

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Current Transformers:

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Ammeter, Voltmeter and Power Factor Meter:

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QCS 2014

current transformers shall be of the bar primary type, air cooled and suitably insulated. The current transformers shall be of Class X accuracy for restricted earth fault protection and Class 1 accuracy for metering purposes, as stipulated in the QGEWC Regulations

(ii)

current transformers shall be rated not less than 5 VA and shall have thermal and mechanical rating at least equal to those of the main circuit breakers.

(iii)

following are the approved ratings of the current transformers (CTs) as approved by QGEWC.

 100/5  200/5  500/5  800/5  1200/5  1600/5  2000/5  2500/5 (iv) removable links shall be located on the main busbars of each phase and neutral to enable easy maintenance and replacement.


Page 21

(v)

current transformers shall comply with BS 3938 and should be suitably rated and designed to carry out the appropriate function as indicated.

(vi)

The rated burden of the current transformers shall be 30% in excess of the sum of burdens of all relays, instruments and related loads.

(vii)

the short time rating shall not be less than 44kVA for 3 seconds.

(viii)

identification labels giving type, ratio‟s, rating output, manufacturer and serial numbers shall be fitted. Duplicate rating labels are to be fitted on the exterior of the mounting chambers suitably located to enable reading without removal of Any cover. Labels shall be supplied for multi ratio current transformers indicating the connection required for alternative ratios.

(ix)

bar type current transformers shall be provided in preference to those with wound primaries. Short time current factors shall relate to the full fault level for three seconds. For overcurrent protection the product of VA rated burden and rated accuracy limit factor shall be 150 unless otherwise agreed with the Engineer.

(x)

one secondary terminal of each current transformer shall be earthed through a removable link.

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kWh Meters:

the kWh meters shall be suitable for operation on 415/240 Volt, 3 phase, 4 wire, 50 Hz supply and shall conform to BS 37 Part 1 and BS 5685

(ii)

the meters shall be dust-proof and vermin proof, protected from corrosion due to high humidity and compensated against the effect of temperature up to 55 °C

(iii)

the meters shall maintain their accuracy over many years service under Qatar climatic conditions. The counter shall be of the cycle meter type with six figures, the lowest figure being unit. Pointer type counters are not acceptable

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QCS 2014

(d)

(iv)

the meter cover and cases shall be of metal

(v)

meters shall not have less than 5 mm diameter terminal holes and shall be operated through three current transformers and the counter of the meter should be calibrated to read the primary kWh. The current transformers shall be selected from the standard sizes stipulated in QGEWC Regulations

(vi)

all meters shall be handed over to the Qatar General Electricity & Water Corporation for calibration prior to final installation and connection.

power monitoring Unit(PMU): (i)

power monitoring (PMU) shall be a true RMS digital instrument, with LCD display, capable of controlling and measurement highly nonlinear loads accurately and able to detect voltage based disturbances.

(ii)

the LCD unit combined with function keys, minimum IP54, shall be mounted locally on the Incomer cubicle door.


Page 22

(iii)

PMU shall be CE marked and confirm to BS EN 61010-1

(iv)

the Power Monitoring Unit shall register all measured values and log current and previous measured values for reporting and printing purposes.

(v)

the Power Monitor shall be supplied with software, user manual and associated interconnecting cables.

(vi)

PMU shall be provided with user friendly software minimum windows 2000 based communication (fully supported by Latest Edition of Windows Based Operating System) program allowing easy access to all features with pull down menus

(vii)

true RMS measurement of current and voltage

(viii)

control and measurement of highly nonlinear loads

(ix)

capable to detect voltage based disturbances

(x)

interface capability with PLC/RTU/Circuit breaker

(xi)

provide load shedding capabilities

(xii)

provide interface with Power Factor Correction Control equipment

(xiii)

RS-485 port

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(xv)

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(xiv) modbus communication protocol

DNP3.0 Communication protocol

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(xvi) web enabled Ethernet capability (xvii) measurement of Harmonics

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(xviii) monitoring of disturbances in the power supply network

(xx)

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(xix) continuous sampling at 128 times per cycle trending analysis for historical data collection

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(xxi) sequence of events

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(xxii) RMS current of each phase

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(xxiii) RMS voltage L1-L2-L3-N (xxiv) average system voltage (Vav)

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(xxv) average system current (Iav) (xxvi) real power (KW) (xxvii) reactive power (KVAr) (xxviii)apparent power (KVA) (xxix) power factor (cos phi) (xxx) peak demand (xxxi) frequency (HZ) (xxxii) temperature (T) (xxxiii)THD current (%Ithd) (xxxiv) THD Voltage (%Vthd) (xxxv)

9

K-factor100

Restricted Earth Fault Protection.

QCS 2014

Page 23

(a)

Restricted earth fault protection shall be provided for main switchboards in accordance with the QGEWC Regulations.

(b)

30 DC supply is required for tripping of the LV ACBs through D.C. shunt trip for restricted earth fault relay. Contractor to provide for this unit a trickle charger and long life nickel cadmium batteries. The unit shall be designed to operate on 240 volts, 1 phase & 50 Hz A.C. Supply and for continuous duty at an ambient temperature of 50 ºC and 98% relative humidity. The capacity of the unit is to be determined by the manufacturer and based on number of trip unit , all to the approval of the Engineer and KAHRAMAA.

Anti-Condensation Heaters. (a)

anti-condensation heaters shall be provided inside each compartment in strategic positions. These shall be controlled by an internally mounted humidistat and an external overriding ON/AUTO switch

(b)

heaters shall be of sufficient size to maintain the air temperature inside compartment o at least 10 C above the outside ambient.

Motor Control Centres

1

General:

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provide the metal enclosed motor control centres as indicated, specified and required

(b)

the motor control centres shall be switchboard type construction as described for M.V. cubicle switchboards except as modified herein

(c)

the motor control centres shall be front access only

(d)

shipment shall be made in sections to facilitate field handling, and the shipped sections shall be joined together to form a complete back-to-wall or back-toback unit assembly as indicated

(e)

the motor control centres shall be free-standing or wall-mounted, as indicated in the Project Drawings.

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Construction

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(a)

(a)

vertical sections shall contain adequate space for connecting the incoming power supply circuits, outgoing branch circuits, motor circuits and control circuits to terminals, horizontal and vertical power bus bars, horizontal earth bus, circuit breakers, magnetic starters, contactors, control stations, pilot lights, timers, terminals, transformers, panels, relays, ammeters, voltmeters, meter switches, earth leakage protection, space heaters, thermostats, fans, vents, screens, filters and switches

(b)

the vertical sections shall be fabricated from heavy gauge steel (minimum thickness of 1.5 mm), with uniform surfaces

(c)

unless otherwise indicated, the standard section shall be 800 mm wide (600 mm for equipment and components, 200 mm for vertical wire way) by 600 mm deep


Page 24

(d)

holes shall be provided in the structural base of each section for anchor bolts

(e)

sections shall contain wireways, brackets, supports, plates, trims, barriers, gaskets, doors, base channels, lifting angles and hardware

(f)

horizontal wireways (top and bottom) shall extend through the width of each section

(g)

wire way openings shall be provided between sections with closing plates on the end sections

(h)

each vertical section shall contain its own individual full height vertical wire way separated from the vertical bus by a metal barrier, and also separated from the individual control units by the side pan of the control unit.

(i)

wire ties shall be furnished in the vertical wireways to group and securely hold the conductors in place

(j)

a separate cover shall be provided on the vertical wire way

(k)

control units shall be isolated from one another by horizontal steel barriers

(l)

front to rear bracing shall not interfere with the cable entrance areas

(m)

hinged doors shall be equipped with screwdriver operated quarter-turn latches that catch automatically when the door is pushed closed. Large doors shall be equipped with additional latches

(n)

provision shall be included to add a vertical section on either end of the line up in the future

(o)

the power supply compartment shall be sized to accommodate the incoming power conductors. The compartment shall be located at the top or bottom of the vertical section as shown on the Drawings. The power compartment shall be covered by a hinged door and shall be held closed with quarter-turn pawl type latches

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(p)

(q)

busbars shall be provided for the power and earth systems. When shown on the Drawings, provide full length full capacity and insulated neutral bus and cable connectors. Bus joints shall be connected with bolts, nuts and spring washers. The main horizontal power bus shall be located in the centre or near the top of each section, joined together to form a continuous bus for the full length of the motor control centre. The horizontal power bus shall be copper and the current rating shall be as shown on the Drawings. The vertical power buses shall be copper full height and rated for the section total load. The minimum current rating for the vertical power buses shall be 300 amperes or as specified in the Project Documentation. Small openings in the vertical barriers shall permit the plug-on control unit contacts to pass through and engage with the vertical bus bars. Unused plug-on openings in the vertical barriers shall be equipped with plastic snap-in closing plugs. each MV/MCC Incomer Section shall consist of: in addition to KAHRAMAA requirements


Page 25

4 Pole ACB/MCCB (For Generator Incomer)

(ii)

3 Pole ACB/MCCB with solid neutral link (For Mains Incomer)

(iii)

1X Voltmeter 96X96, 240 degree scale for mains bus voltage live indication (For Mains Incomer)

(iv)

3X Voltmeter 96X96, 240 degree scale for generator bus voltage live indication (For Generator Incomer)

(v)

1X Voltmeter Selector Switch 7 Position (For Mains Incomer)

(vi)

1X Ammeter 96X96, 240 degree scale (For Mains Incomer)

(vii)

3X Ammeter 96X96, 240 degree scale (For Generator Incomer)

(viii)

6X Maximum Demand Indicator 96X96 (May be included with ammeter)

(ix)

1X Ammeter selector switch 5 position (For Mains Incomer)

(x)

Power Monitoring Unit (PMU) for Main and Generator Incomers

(xi)

phase failure/phase sequence relay for sensing the main incomer, generator incomer and busbar voltage.

(xii)

2X IDMTL overload relay (may be included in the circuit breaker)

(xiii)

2X IDMTL earth fault relay (may be included in the circuit breaker)

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QCS 2014

(xiv) 2X IDMTL restricted earth fault relay 1X Frequency meter (45-55)Hz

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(xvi) 3X Supply available and 3x supply on indicator lamps (for each phase for Main and Generator incomers)

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(xvii) auto/manual changeover for MCC with two or more Incomers (See Metering Section below)

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(xviii) trip circuit healthy test facility in case of a circuit breaker designed to trip on fault through externally mounted protection devices e.g. IDMT (Inverse Definite Minimum Time relay), UV relay etc.

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(xix) control fuses

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(xx)

open/close/trip indicating lamps

(xxi) terminals etc.

the changeover function shall be fully automatic mains Generator on failure of power and vice versa.

(s)

a separate metering section shall be included in order to accommodate analogue meters, Power Monitoring Unit (PMU), control relays, timers, PLC, selector switches, push buttons, indicating lamps etc. as necessary for interlocking scheme for the incomers.All informations available in PMU shall be transferred to PLC/SCADA for monitoring.

(t)

an auto/manual changeover scheme shall be included unless specified otherwise, as a definite requirement for two or more incomers, fully wired and factory tested.

(u)

detailed drawings shall be prepared during the design stage and the same to be submitted to the Engineer for approval prior to the manufacturing.

(v)

installations requiring a mobile generator shall be provided with an appliance inlet socket outlet or junction box.

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Page 26

the appliance inlet shall be used for generators up to 125 A and be housed in a weather proof box fixed and located outside the MCC Room as shown on plant and equipment drawing. The junction box shall have detachable gland plate at the bottom facilitating easy connection and disconnection of the generator cable. For higher capacity generator ratings above 125 A, a weatherproof junction box shall be provided with solid copper links and ample space for terminating cables.

(x)

a separate section shall be provided to house the QGEWC kWh meter. The kWh meter compartment shall be provided with a 300mm X 300mm X 12mm thick plywood mounting board and a ten way terminal block in accordance with QGEWC regulations.

(y)

the kWh meter shall be CT operated for loads exceeding 100A.

(z)

each outgoing starter, feeder or other functional unit shall be enclosed within its own section providing Form 4 type 7 (Gambica) segregation (or Form 4b as per IEC).

(aa)

Tree spare equipped feeder section (MCCB only) per MCC shall be provided as minimum. The rating shall be subject to the approval of the engineer.

(bb)

the Common Control section shall consist of the following controls and instruments as minimum for guidance purpose only subject to the approval of the engineer:

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(w)

non door interlock MCCB

(ii)

24 V DC regulated power supply

(iii)

24 V DC Ni Cd battery

(iv)

24 V DC Ni Cd battery charger

(v)

power distribution MCBs for field instruments

(vi)

programmable Logic Controller (PLC) – Refer to Instrumentation & Control Section for specifications

(vii)

Video Display Unit where specified - Refer to Instrumentation & Control Section for specifications

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(viii) (ix)

sounder complete with auto cut-off time and mute pushbutton as specified in the particular requirements.

(x)

flashing Beacon Light (mounted outside building) as specified in the particular requirements.

(xi)

local/remote selector switch

(xii)

float/level selector switch

(xiii)

pumps Duty-Standby selector switch

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pressure & level indicators - Refer to Instrumentation & Control Section for specifications

(xiv) push buttons for lamp test, fault-reset etc. (xv)

status Indicating Lamps

(xvi) control relays, timers and control fuses as required according to the logic + 20% as spares wired to the terminals. (xvii) zener barriers (xviii) hygrostatically controlled Anti-condensation heater (xix) standard and special terminals to suit the applications requirement (xx)

terminal kiosk (A separate partitioned terminals arrangement clearly labelled identifying IN/OUT). [All wires to field devices and telemetry section must be routed through terminal kiosk].

QCS 2014


Page 27

(xxi) 240V, 13 amp AC single phase 3 pin (flat) standard socket the telemetry section shall consist of the following controls as minimum for guidance purpose only subject to the approval of the engineer: Non door interlock MCCB

(ii)

24 V DC Ni Cd battery

(iii)

24 V DC Ni Cd battery charger

(iv)

Remote Terminal Unit (RTU) – Refer to Instrumentation & Control Section for specifications

(v)

Interposing relays

(vi)

Hygrostatically controlled Anti-condensation heater

(vii)

Terminals, control fuses and surge protection etc.

MCCB Panel Boards

1

General.

MCCB panel boards shall be manufactured to IEC 61439, factory assembled and type tested certified by an internationally authorising testing body

(b)

the panel board shall be suitable for operating on a 3 phase, 4 wire, 415 V supply

(c)

the symmetrical through fault rating shall be 25 kA for a duration of 3 seconds

(d)

if necessary, the panel board shall include a suitable hardwood backboard to accommodate the QGEWC metering equipment.

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(a)

Construction.

the panel board shall be of robust construction, fabricated from heavy gauge folded steel angles strengthened by horizontal and vertical folded channels

(b)

the frame work shall be enclosed in self-supporting, screw -on front, rear and top covers of sheet steel with gaskets

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the doors shall be lockable and have concealed hinges provided with gaskets

(d)

thickness of the steel sheet shall be not less than 1.5 mm

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(c)

3

4

(e)

the panel shall be suitable for wall mounting.

(f)

the structure shall be protected from rust and oxidisation before being given a coat of primer and finishing coats

(g)

the finished paint colour shall be to Engineer‟s approval selected from BS 381.

Busbars (a)

the bus bars shall be of high conductivity, rectangular section, hard drawn copper, electrolytically tined suitably marked and colour sleeved coded in accordance with BS 158/159

(b)

the short circuit ratings of the bus bars shall be as stated above

Components (a)

the switch boards shall comprise of the following components:

QCS 2014


Page 28

(i)

incoming: suitably rated isolator/MCCB as indicated on the tender drawings and to comply with relevant Clauses of this specifications

(ii)

outgoing: Moulded Case Circuit Breakers of 25 kA fault level with ratings as per the tender drawings and de rated for 50 ºC ambient temperature.. All MCCB of rating 100 Amps and above shall have adjustable thermal and magnetic facilities

(iii)

meters: 3 ammeters with dead pointer to indicate the maximum reading and 1 No. 0-500 Volt voltmeter with Off/ph-ph/ph-N selector switch, for incoming supply.

Distribution Boards

1

Distribution boards shall be provided to serve lighting, fans, socket outlets, and other appliances. Board shall be arranged in banks of ways as indicated on the schedule of points.

2

The Distribution Board shall be a part of the MCC cubicle assembly unless otherwise indicated in the project Documentation

3

Where there is Distribution Board stand alone, then:

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2.2.4

Distribution Boards shall be flush mounted type, or surface mounted type and shall be mounted separately from motor control centres or switchboards. The boards shall be totally enclosed, dust protected, vermin proof type. Distribution boards installed in all plant rooms and other process areas shall be corrosion resistant.

(b)

Enclosure shall be fabricated from robust galvanised sheet steel fully rustproofed, stove enamelled, of minimum thickness of 1.5mm and shall be protected to IP 32 for internal use with neoprene gaskets for the doors.

(c)

The distribution boards shall be provided with fixed cover and a hinged door with padlock which can be opened without any obstruction about 120 degrees and conduit knockouts from the top and bottom. The hinged door with a lock and key shall be integral part of the fixed cover.

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The cabinet shall be constructed so that it is necessary to open the door to operate Miniature Circuit Breakers or ELCB. Access to interior components and internal wiring shall be gained by removing a separate barrier within the enclosure.

4

All distribution boards shall be controlled by an adequately rated on-load main isolator or circuit breaker to interrupt the supply to the entire distribution board. This main isolator or circuit breaker shall be double pole for single phase DBs and triple pole for three phase DBs. Moreover, it shall be connected to the busbar directly without links whatsoever.

5

A circuit label shall be provided to indicate the area served by each MCB.

6

Busbars shall: (a)

be of appropriate current carrying capacity at least equal to the rating of the main incoming isolator or circuit breaker.

(b)

be of high electrical conductivity copper.

(c)

Where the main isolator or circuit breaker is connected to bus bars then these bus bars shall be shrouded.

QCS 2014


Page 29

Each DB shall have separate earth and neutral bars having the same number of connection as there are for phase connections. A cable connection shall be made from earth bar to the incoming cable gland earth tag. All phase and neutral bars shall be sized to carry the full load current of the controlling breaker which shall be of flat tinned copper rigidly mounted, supported on shock-resisting, non-hygroscopic, high grade insulators with high resistance to tracking, not subject to mould growth or termite attack with adequate spacing and clearance.

8

Connection from the bus bars to the breakers shall be made by using solid circular insulated conductors or insulated and tinned copper strip neatly set and formed. Each connection to or from a phase or neutral bar shall have its own brass fixing screws, washers, butts and locknuts.

9

Each distribution board shall be fitted with an identification label on its front cover. The label shall be suitably inscribed stating the distribution boards reference number/letter, rating in volts & amperes and the number of ways in English and Arabic. In addition to the above a reference card shall be fitted inside the distribution board giving details of each circuit, MCB size, cable size and location. The reference card shall be affixed to the inside of the distribution board‟s door via a transparent envelope.

10

Distribution Boards (DB) located remote from the main switch boards shall be mounted at a height of not less than 1200mm from finished floor level to bottom of the DB and maximum height of this DB shall be 2200mm from finished floor level to top of DB.

11

All live terminals of parts and bus bars shall shrouded with insulating materials to ensure that it is impossible for any live metal to be touched while withdrawing or replacing MCBs.

12

The correct rating of breakers shall be fitted in each way to conform to the size of the final circuit conductor and its connected load in conformity with KAHRAMAA.

13

All breakers and DBs shall be of one make throughout the whole of the works.

2.3

INSTALLATION

2.3.1

General

1

The M.V./MCC cubicle switchboards shall be supplied and installed in the building or in a separate services building or in substations as indicated on the Drawings.

2

The Contractor shall submit details of proposed equipment and method of installation to the Engineer and QGEWC for approval prior to commencement of installation work.

3

Provide all the motor control equipment installations, wiring installations and tests, including connections and interconnections for the electrical controls as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces shown on the Drawings.

4

Equipment shall be installed level and securely attached to the concrete foundations and walls with expansion anchors. The sections shall be joined together with bolts, nuts and washers to form a complete unit assembly. Floor standing equipment shall be installed on concrete plinths as shown on the Drawings.

2.3.2

Earth Bonding

1

Each MV/MCC switchgear panel or section shall be individually connected (at both end of the panel earthing bar) to two separate earthing pits trough the main earth bar located in the electrical or cable basement rooms. Calculation for the earthing cable size shall be provided using professional dedicated, international recognized approved software subject of Engineer‟s approval.

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2

Each panel section shall be cross bonded to adjacent panel section earthing terminal.

3

MV/MCC panel earthing conductor to earthing bar and earthing pit is to be sized for maximum earth fault current for 5 seconds with final conductor temperature not exceeding 160 °c or sized not less than 20 mm² per 100 KVA of transformer rating, and with a minimum of 95 mm².

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END OF PART

QCS 2014

Section 21: Electrical Works Part 20: Elevators/Escalators

Page 1

20

ELEVATORS/ESCALATORS ........................................................................ 2

20.1

GENERAL ...................................................................................................... 2

20.1.1 20.1.2 20.1.3 20.1.4 20.1.5

Scope References Submittals Quality Assurance Warranty

20.2

PRODUCTS ................................................................................................... 4

20.2.1 20.2.2 20.2.3 20.2.4

Description Electric Traction Passenger Lifts Electro-Hydraulic Passenger Lift Escalators

20.3

INSTALLATION ........................................................................................... 15

20.3.1 20.3.2 20.3.3 20.3.4 20.3.5 20.3.6 20.3.7 20.3.8 20.3.9

Site Condition Inspection Preparatory Work Installation Field Quality Control Field Adjustments Acceptance Inspection and Tests Clean Up Manufacturer's Services Maintenance and Guarantees

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2 2 3 3 3 4 4 8 11 15 15 16 17 17 17 18 18 18

QCS 2014


Page 2

ELEVATORS/ESCALATORS

20.1

GENERAL

20.1.1

Scope

1

This Part specifics the general requirements for elevators and escalators used only for passengers

2



Concrete Structural metal work Metal work

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General Provisions for Electrical Installations Motor Starters Cables and Small wiring Conduits and Conduit Boxes Trunking Cable Trays Wiring Accessories and General Power Light fittings Electric Motors Earthing and Bonding Testing

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This Section Part 1 Part 4 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 15 Part 22 Part 23

.

20

References

1


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BS 476 ........................ Fire tests on building materials and structures

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BS 5655 (EN 81) .......Lifts and service lifts BS 5656 (EN 115) ......Safety rules for the construction and installation of escalators and passenger conveyors BS 6977 ...................... Insulated flexible cables for lifts and for other flexible connections BS 7255 ...................... Code of practice for safe working in lifts BS EN 9000 ................ Quality management and assurance standards Qatar General Electricity & Water Corporation Regulations for passenger and goods lifts.

QCS 2014


20.1.3

Submittals

1

Manufacturer’s product data and samples. (a)

submit three 75 x 300 or 300 mm length samples of each required finish, excluding those intended for painting after installation, for the Engineer’s approval

(b)

catalogues shall be provided of signal equipment units to show push buttons, lights, graphics and mounting provisions.

Shop Drawings: drawings for all main components including the pit, hoistway, and the machine room general arrangements, foundations and installations, sectional elevations of the hoistway, car and entrance details, and signal details

(b)

component specifications and preventative maintenance charts

(c)

electrical schematics and one copy of the approved master electric schematic and approved lubrication chart shall be framed with a clear plastic cover and mounted on the machine room wall

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(a)

manufacturer

(b)

minimum guaranteed efficiency

(c)

power factor under all load conditions

(d)

locked rotor current

(e)

motor speed

(f)

mounting details

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Motor data including:

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Certificates of Compliance.

5

Certified Test Reports.

6

Operation and Maintenance Manuals.

7

Training Programme.

20.1.4

Quality Assurance

1

Products shall be from an experienced manufacturer who can demonstrate equal or larger capacity installations using similar equipment, installed and successfully operating for at least 5 years, with names and phone numbers of contacts at installations to verify performance. The manufacturer shall comply with ISO 9000 or equivalent.

20.1.5

Warranty

1

All components shall be free of defects in materials or workmanship.

2

The Contractor shall remain responsible for routine maintenance for 400 days from the date of acceptance of the installation by the Engineer. During this period the Contractor shall promptly replace and/or repair any fault with supply of all spare parts without any cost to the Client.

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QCS 2014


Page 4

Motors shall have 5 year warranties.

4

Individual warranties by component manufacturers in lieu of single source responsibility by the elevator manufacturer shall not be acceptable.

5

Items which fail during the warranty period, excluding expendable items, shall be replaced without cost to the Employer.

6

Manufacturer’s guarantee and warranty certificates shall be provided prior to equipment startup.

20.2

PRODUCTS

20.2.1

Description

1

Equipment shall be provided by a single manufacturer who shall design, fabricate, and test all components of the elevators as well as supervise, install and commission the units.

2

Elevators shall be complete in all respects and shall include but not necessarily be limited to the following components:

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machine room equipment

(b)

hoistway equipment

(c)

elevator entrance ways

(d)

door opening and closing devices

(e)

elevator cars

(f)

car control stations

(g)

landing control stations

(h)

appurtenances

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(a)

The Contractor shall make all modifications, adjustment, and improvements to the elevator system necessary to meet the performance requirements specified. The elevator shall provide safe, smooth operation, complying with all building and elevator codes required by the authorities.

20.2.2

Electric Traction Passenger Lifts

1

Machine Room Equipment

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(a)

general: shall be provided with manufacturer’s standard pre-engineered elevator system in accordance with the specification. Manufacturer’s may provide custommanufactured elevator systems that meet specified requirements. Where components are not specified, components shall be provided as for manufacturer’s standard pre-engineered elevator systems, or as necessary to produce a safe and fully operational elevator system

(b)

motor control: solid-state power converter/inverter with line filters or chokes to prevent peaks or spikes from feeding back into building power systems

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Page 5

(c)

hoisting machine: variable voltage variable frequency (VVVF) thyristor, traction-type, geared hoisting machine with squirrel cage motors designed specifically for elevators. Unless specified otherwise, variable voltage variable frequency AC drives shall be used. Refer to part 5 of this section for general specification

(d)

selector: microprocessor solid-state, integrated controller with durable cabinet, lockable doors and adequate ventilation to dissipate heat, wired to identified terminal block studs, with identifying symbols or letters identical to those on wiring diagrams, permanently marked adjacent to each component on the controller

(e)

The microprocessor based controller shall include the facility to interface with Remote Elevator Monitoring (REM) and Elevator Management Service (EMS) as a part of Building Management System through the data network system.

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Hoistway Equipment guide rails and brackets: T-section cold drawn (not fabricated) guide rails and brackets suitable for travel, car weight and support locations at structural floors, with backing as EN 81

(b)

buffers: energy dissipation type with blocking and supports

(c)

normal terminal stopping devices: in accordance with EN 81

(d)

electricity wiring: copper conductors with 600 volt insulation throughout with individual wires coded, with 10 % spare capacity. All connections shall be identified on studs or terminal blocks, rated 75 °C minimum. Splices or similar connections in wiring are not permitted except at terminal blocks, control cabinets or junction boxes. Flexible heavy-duty service cord to BS 6977 may be used between fixed car wiring and car door switches

(e)

conduit and duct shall be PVC jacketed or galvanised steel 20 mm minimum diameter. Flexible conduit shall not exceed 450 mm in length and shall be as in Part 7

(f)

entrance equipment:

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door hangers: shall use two-point suspension with upthrust rollers

(ii)

door tracks: replaceable bar or formed cold drawn steel with smooth hanger contact surface

(iii)

interlocks: operable without retiring cam, with interlocks that are visible and conspicuous when doors are open, painted matt black

(iv)

closures: spring or aspirator type

(v)

pit stop switches to BS EN 81

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(i)

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Hoistway entrances shall be fire rated in accordance with BS 476 Part 8, with frames as follows: (a)

floor entrances, jambs and heads shall be fabricated steel with a 304 stainless steel cladding

(b)

frames shall be hollow metal, bolted to form a one-piece unit

(c)

jamb and head depth and profiles shall be as indicated on the Project Drawings, fabricated from mild steel not less than 1.2 mm thick, steel pan construction, with side-opening doors, rubber bumpers to cushion closing impact, and finished faces as specified. Each door panel shall include gibs. The trailing door gib shall be in the sill groove throughout the length of travel

QCS 2014

Page 6

(d)

sills: extruded hard aluminium

(e)

fascia toe guards, dust and fascia width hanger covers: 1.5 mm galvanised steel with door open bumpers on entrances equipped with vertical struts.

Door Opening and Control Devices (a)

safety edge devices shall be full height, infra red, non contact, door edge safety devices to detect obstruction in the doorway and reverse

(b)

nudging action : in the event that the safety edge is operated for a pre-determined time interval (15-20 seconds) after automatic door closing has been initiated, a buzzer shall sound, and the doors shall close with a maximum of 0.35 Kg-meters kinetic energy

(c)

Microprocessor based Variable Voltage Variable Frequency (VVVF) drive operational control shall be extended for door control as integral with the car movement.

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Car Equipment car frames: welded or bolted steel channel construction

(b)

platforms: isolated type, steel, construction fire proofed on the underside

(c)

guide shoes: nylon sliding type

(d)

car sills: hard aluminium type sill

(e)

toe guards: in accordance with EN 81

(f)

car door hangers and tracks: as specifications on hoistway entrance hangers and tracks

(g)

headers: minimum 1.2 mm thick steel shaped to provide stiffening flanges

(h)

car door electrical contacts shall operate in conjunction with the car doors so that elevators cannot operate unless doors are closed, or within tolerances allowed by EN 81

(i)

door operators : shall be microprocessor based a.c./d.c. capable of opening doors at no less than 60 m/min and accomplishing reversal in no more than 65 mm of door movement

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(a)

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car finishes front return, side & rear wall, door, handrail, floor, ceiling panels, and light fixtures shall be finished as detailed in the Specifications

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(k)

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removable panels shall be provided as specified for side and rear wall panels at elevators with facings glued to plywood, full-height between top of base and ceiling of car. Panel joints shall be flush with panel surfaces in accordance with manufacturer’s standard layouts. Elevator car suspended ceiling panels shall have suitable strong backing in the ceiling frame to prevent sagging, without exposed screws or bolts.

Car Control Stations (a)

car control stations shall have durable vandal resistant face plates and micro-Touch Buttons located no higher than 1620 mm above the car floor (875 mm for alarm buttons) floor buttons, alarm buttons, door open buttons shall be identified by engraved or painted letters or symbols in accordance with EN 81

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Page 7

car floor buttons shall have 16 mm numbers on the face of buttons corresponding to the floors served for registration of the car stops. Call registration lights, located within or behind the buttons, shall illuminate the floor number corresponding to the call registered

(c)

alarm buttons at the bottom of stations shall be provided to ring bells located on the car doors. Open and close buttons shall be provided to stop motion of doors and cause them to return automatically to their fully open or closed position respectively. Buttons shall be effective while cars are at landings and until cars start into motion, regardless of any special operational features

(d)

car top control stations shall be in accordance with EN81, mounted on car tops, accessible from landings

(e)

work lights and plug receptacles shall be provided top of elevator car with on-off switches and bulb guards

(f)

car position indicators shall be provided in elevator car operating panels with digital indicators representing floors served and direction of car travel

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(b)

when cars leave or pass a floor, the numeral representing the floor shall be displayed, thereby indicating the position of the car in the hoistway at all times

(ii)

proper direction arrows shall be continuously illuminated to indicate the direction of travel

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flush-mounted vandal resistant durable faceplates and buttons for each direction of travel, illuminated to indicate call registration

(ii)

A fire recall station shall be provided at the main access level in addition to the call button

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(i)

signal fixtures shall be provided at each entrance to indicate the intended direction of travel of the elevator to waiting passengers, with the following features: (i)

display numerals for car level, arrow and a gong mounted in the box fastened in the wall. Up or down arrows shall be illuminated and a gong sounded (once for up direction travel and twice for down direction travel) prior to the car’s arrival at the floor. The light shall remain illuminated until shortly before the elevator doors start to close

(ii)

hall lanterns shall be provided, of impact resistant plastic lenses and with satin stainless steel finish.

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(b)

micro-touch buttons stations shall be provided adjacent to door jambs of each entrance with the following features:

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(a)

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Landing Control Stations

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(i)

Performance. The elevator shall: (a)

speed to within plus or minus 10 % of the specified speed under any loading condition

(b)

safely lower, stop, and hold up to 125 % of the rated load

(c)

stop the elevator within plus or minus 10 mm of the design landing elevation under any loading condition.

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Page 8

9

Unless otherwise specified in the Project Documentation, operation shall be "Selective Down Collective Automatic Operation" as defined in EN 81. Doors shall open automatically when a car arrives at the main floor to permit egress of passengers, whether or not the main floor call has been registered in the car. When the car has arrived at the landing it shall have its doors open until the car is dispatched, or on expiration of a timed loading interval with no demand.

10

Emergency Features shall comply with EN 81 for Emergency Firemen’s Service, and the following: emergency operation: the elevator shall be equipped with a control system to operate

(b)

and recall the car in fire or other emergency condition.

(c)

terminals shall be provided on the controller for connection of signals from the sensors. Operation shall be similar on all elevators and visual/audible signals shall operate until return is complete or automatic operation restored

(d)

standby lighting and alarm: during power failure, car lighting and car alarm shall be supplied with standby power via a car-mounted battery unit, including solid state charger, with testing means, installed in common metal container. Batteries shall be rechargeable with 10 year minimum life expectancy. Car mounted units shall operate alarm bell and light only

(e)

emergency landing device: in the event of normal power failure, an emergency evacuation power supply shall drive the lift to a nearby floor. This controller shall be operated by sealed batteries which will be kept automatically charged for use by the unit:

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(a)

standby power shall be provided by 24/12 V battery units mounted in the machine room, including solid-state chargers with testing means installed in common metal containers

(ii)

upon arrival at floor landings, elevator doors shall open automatically and remain open until the regular door time has expired. Elevators shall then become inactivated

(iii)

upon restoration of normal power supply to the building, elevators shall automatically resume normal operation.

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(i)

Protection of electrical work: boxes and enclosures shall be provided with gasket covers. Doors and motors shall be totally enclosed.

20.2.3

Electro-Hydraulic Passenger Lift

1

General: materials and equipment associated with electro-hydraulic passenger lifts shall comply generally with the requirements stipulated for electric traction lifts above, with specific requirements stipulated below.

2

Lift Machines

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(a)

hydraulic pumps shall of the high efficiency type of either vane or screw type design. Means shall be provided where pumps may be coupled to the driving motors without the effect of eccentric loading on the pump bearings

(b)

if pumps/motors of monoblock construction are offered, access shall be provided for inspection/replacement of coupling systems, thrust bearings, etc.

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Page 9

(c)

pump/motor assemblies shall be mounted on rigid mild steel bedplates and suitably insulated, to absorb vibration of pump/motor assemblies

(d)

direction of rotation of pumps shall be clearly indicated on pumps where they can be readily seen

(e)

pumps shall be clearly marked to indicate inlets and outlets, related to a specified direction of rotation if external to power systems. Inlet sides to pumps shall be fitted with renewable fine mesh filters

(f)

data plates with manufacturer’s name, part model and serial number shall be permanently displayed on or adjacent to pump/motor assemblies.

Drive Motor. Motors shall be suitable for operation for 415 V 50 Hz 3 Phase (a)

motor drive: solid-state power converter/inverter with line filters or chokes to prevent peaks or spikes from feeding back into building power systems

(b)

pump drive: variable voltage variable frequency(VVVF) thyristor controlled, geared machine with squirrel cage motors designed specifically for elevators. Unless specified otherwise, variable voltage variable frequency a.c. drives shall be used. Refer to part 5 of this section for general specification

(c)

control: microprocessor solid-state, integrated controller with durable cabinet, lockable doors and adequate ventilation to dissipate heat, wired to identified terminal block studs, with identifying symbols or letters identical to those on wiring diagrams, permanently marked adjacent to each component on the controller

(d)

The microprocessor based controller shall include the facility to interface with Remote Elevator Monitoring (REM) and Elevator Management Service (EMS) as a part of Building Management System through the data network system

(e)

shall run with the minimum of noise and vibration, capable of a continuous duty cycle of at least 60 motor starts per hour. Contractors shall submit full test certificates in triplicate for all tests. Refer to part 5 of this section for motor starter general specification and part 15 for electric motor general specification.

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Anti-creep devices shall be provided which shall automatically limit the car movement within 75 mm of the landing, from any point within the interlock zone, irrespective of handling doors. Devices shall only operate in landing level interlocked zones, and shall operate cars in the ‘UP’ direction only. Operation may depend on the availability of the electrical power supply provided that:

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(a)

main switches are kept in closed positions at all times except during maintenance, repairs and inspections

(b)

electrical protective devices shall not cause electrical power to be removed from the anti-creep mechanism, except when such a device operates in consequence of motor failure.

5

Mufflers: High pressure systems shall be suitably muffled. Flexible pipes shall be included to prevent the hydraulic pulse attenuation from being transmitted to cars.

6

Cylinders and rams (a)

Cars shall be directly supported by one side-acting steel ram turned true parallel, fine polished, and of sufficient diameter and strength to raise the Contract load at Contract speed

QCS 2014

Page 10

(b)

ram attachments to car platforms shall be of sufficient strength to support ram weight with a safety factor of 4

(c)

rams shall not be subjected to bending stresses or eccentric loading. Eccentric loading shall be taken by car frames and guide shoes

(d)

Rams shall be provided with solid metal stops at limits of stroke, or other means to prevent rams travelling beyond limits of cylinders

(e)

multi stage rams, shall only be used if approved by the Engineer

(f)

cylinder interconnections shall incorporate flow restriction ram descent speed, should supply pressure lines fracture

(g)

suitable trays shall be fitted to ram heads to collect leakage from ram seals.

valves

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Pipes and Pipe Supports

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all necessary pipework and supports shall be provided between cylinder and valve block assemblies. Pipes shall be supported such that undue stresses are eliminated at all joints, bends and fittings, particularly at sections of systems subject to vibration

(b)

cross-sectional areas of pipework shall be sufficient to prevent cavitation and starvation and not to induce turbulence or rise in temperature of oil.

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(a)

Oil Storage Tank

oil storage tanks shall be constructed of heavy gauge sheet steel provided with tight fitting covers, oil level gauges and protective vents. Suction inlets shall be provided with filters to prevent ingress of foreign matter to systems. Means of completely draining oil storage tanks shall be provided.

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Valves

check valves shall be provided and shall be installed so that they hold the lift car with the Contract load at any point in the lift well, when the pump stops, or the pressure drops below the minimum operating pressure

(b)

check, relief and other auxiliary valves shall withstand a static pressure equal to twice the normal operative pressure without damage

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(a)

valve gear/blocks shall be fitted with gradual restriction/release of hydraulic fluid to provide smooth acceleration and slowing of cars

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(a)

(d)

main pressure supply restrictions shall be diverted back to oil reservoirs and not to pump outlets

(e)

relief valves shall be located between pumps and check valves and shall be of such types and so installed in by-pass connections that valves shall pass oil directly to tanks and not to pump suction sides

(f)

main controlling valves shall be constructed such that they will remain closed to supply when pressure is shut off

(g)

electrically controlled valves shall remain safe in the event of power supply failure.

QCS 2014


20.2.4

Escalators

1

Escalator Trusses

(b)

truss design shall ensure that the maximum deflection is less than D/880 of the distance between end supports with a calculated passenger load of 500 N/m2.

(c)

oil tight welded 5 mm sheet steel bottom plate shall be welded over the full length and width of the bottom of the trusses

(d)

prior to welding, profiles shall be sand blasted, and after welding shall be protected against corrosion by minimum 40 µm thick primer coat

(e)

a maintenance room shall be provided at the end of the lower landing to EN 115

(f)

truss support angles welded to the truss at the ends of both landings shall be capable of carrying the weight of the escalator and the load transmitted by the passengers (5000 N/m2)

(g)

teflon sliding supports shall be used at the lower landing and if an expansion joint of the building is located between upper and lower landings

(h)

anti vibration rubber pads shall be provided to ensure that escalator support angles are isolated from building structures. Pads shall be used at both landings.

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escalator trusses shall be of welded construction, fabricated from warm rolled standard ST 52 steel profiles. Sides of trusses shall be of frame work design

Track System

closed track systems shall be provided to guide and support step chains and steps as they cycle around trusses

(b)

track holders shall be welded to the framework of the trusses in order to fasten the individual tracks

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(a)

Main Drive (a)

main drives shall be located in upper landings and shall consist of a rigid solid shaft to eliminate tension with self-aligning spherical roller bearings main drive shaft bearings shall be replaceable without dismantling balustrades

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(c)

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main drives shall provide smooth operation and power transfer from drives to moving steps.

Tension carriage (a)

tension carriages shall be located at lower landings of escalators for tensioning step chains

(b)

step chains shall be guided laterally by sliding block guides and constantly tensioned by two compression springs

(c)

reversal tracks shall be fabricated from 3.5 mm sheet steel

(d)

special openings shall be provided to remove steps for maintenance or replacement

(e)

correct chain tension shall be monitored by safety switches at each side of the tension carriages.

QCS 2014

(a)

step chains shall be made of flat steel links, provided with wheels and interconnected by pins made of hardened ground steel

(b)

the breaking strength per stand shall be 150 kn. The safety factor shall be 5 for the maximum rise. Step chain pins shall allow a maximum pin pressure of 32.3 N/mm2 at maximum rise

(c)

both sides of step chains shall be linked by solid axles to optimise performance

(d)

step chain wheels shall be provided at both ends of step axles between step chain links and shall have sealed bearings and oil resistant rubber tyres.

Steps steps shall be one piece die-cast aluminium design with cleated treads and rises, ensuring maximum safety as each step meshes with the adjacent step

(b)

step rollers shall have polyurethane tyres

(c)

step tread pitches shall be 8.47 mm. Riser pitches shall be 16.94 mm

(d)

steps shall be fastened to step chain by means of spring loaded pins providing a positive fixing to the axle, allowing the steps to be easily removed for maintenance

(e)

step systems shall be designed such that step removal does not require dismantling of skirting or balustrade parts

(f)

steps with yellow demonstration lines or yellow plastic inserts may be required, as specified.

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(a)

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Handrail drive system

handrail drive systems shall be driven directly from step chains via drive sprockets and reinforced toothed belts

(b)

handrail drive units shall be located on both sides of the escalator in the incline section close to upper landings

(c)

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syncronisity between steps and handrails shall be assured to within EN115 recommendations

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(d)

design and positioning of drive systems shall be such that components can be inspected without need for step removal

(e)

handrails shall be provided as endless vulcanised loops. Handrails shall have endless inner steel cord members to make handrails free of elongation, eliminating the need for frequent retensioning

(f)

handrail guides shall be made from extruded aluminium profiles, having special polymer covers throughout the length to reduce friction between guides and handrails to a minimum

(g)

passenger lines shall have tensioned spring clamps located between aluminium profiles and glass panels

(h)

return lines shall have aluminium profiles fastened to trusses using screws.

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Page 13

Balustrades, decking and skirting (a)

balustrade heights above finished floors shall be 1000 mm or 930 mm in upper and lower landing areas

(b)

inclined sections heights shall be 842 mm at right angles to step nose lines

(c)

material and finishes for balustrades, decking and skirting profiles shall be as specified

Combs, Comb Plates and Floor Plates (a)

combs, comb plates and floor plates shall be designed for maximum passenger loads in accordance with EN 115

(b)

combs shall be made of die cast aluminium, screwed to comb plates for ease of replacement if necessary. Comb teeth shall have intentional rupture points, allowing them to break easily in the event of objects getting trapped between steps and combs, thereby preventing serious damage

(c)

comb plates shall be made from extruded aluminium profiles with laterally extending grooves preventing passengers from slipping. Grooves shall be powder coated black and the surfaces finished as stated in the particular specification

(d)

fixed floor plates shall be made from extruded aluminium profiles with laterally extending grooves to match the comb plate. The grooves shall be powder coated black and surface finished as specified

(e)

removable floor plates shall be provided, allowing access to both machine rooms and maintenance rooms. Removable floor plates shall be constructed from low weight extruded aluminium profile sections allowing ease of the removal by one service mechanic. Standard removable floor plates shall be recessed by 7 mm, allowing for infill materials as specified.

Drive Machinery and Brakes

(b)

star delta starting shall be provided for motors > 5 kW motor insulation Class F, protection class IP 55

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(c)

drives, motors and gearboxes shall be designed to ensure quiet and smooth operation of the escalator

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(d)

operational brakes located between motor and gear boxes shall have an AC commercial magnets and shall use asbestos free brake linings. Double acting shoe brakes shall be fail safe and shall operate automatically via springs in the event of power failure or on safety switches tripping

(e)

a hand winding devices shall be provided with machines in order to move step bands by hand

Electronic Controllers (a)

protection class controller cabinet shall be IP 54

(b)

control voltages shall be < 50 V

QCS 2014

(c)

Page 14

cabinets shall have an industrial enamel triple corrosion resistant coating with the following layers: (i)

phosphate layer

(ii)

primer coating, minimum 25 µm layer thickness

(iii)

final coating, colour RAL 5019 (blue), minimum 35 µm layer thickness, or as otherwise specified

controllers shall be equipped with modular electronic boards. Mother boards shall cover all basic functions

(e)

interface capabilities shall be provided for remote monitoring by volt free contacts

(f)

controllers shall include the following functions:

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(d)

directional settings

(ii)

supervision of power supply voltage

(iii)

full motor protection against overheating

(iv)

fault indicator by means of display

(v)

control of safety contacts

(vi)

asymmetric relays

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Operation Panels

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(i)

operation panels shall be installed at upper landings and at lower landings

(b)

panels shall be located in steel panels next to handrail entry guards

(c)

operational panels at the lower landings shall be equipped with key switches and stop buttons only

(d)

operation panels at upper landings shall be equipped with key switches, key boards, displays and stop buttons

(e)

displays shall have 8 digits, using 5 x 7 dot matrix for alpha numeric indicators with text shown in plain language

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after setting of passwords via the key board, displays shall show maintenance and fault finding information, including but not limited to:

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(i)

memory of faults (50 messages deep) e.g. amount of faults within a definite period of time

(ii)

operating hour counter (total and per week)

(iii)

start counter (total and per week)

(iv)

stopping distance and deceleration indicator

Electrical Safety Devices (a)

the escalator shall be equipped with all safety devices required by EN 115 including, but not limited to: (i)

emergency stop buttons and key switches at landings

(ii)

handrail entry devices


Page 15

(iii)

broken step chain devices

(iv)

comb plate safety devices

(v)

broken step and chain wheel control contacts

(vi)

step chain roller monitoring switches

(vii)

non reversal devices (electronic device, located in the controller)

(viii)

operational brakes

(ix)

motor thermal devices

(x)

sockets for manual inspection

(xi)

main and secondary circuit breakers

(xii)

earthing contacts

(xiii)

asymmetric relays (inside controllers)

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QCS 2014

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(xiv) hand lamps

INSTALLATION

20.3.1

Site Condition Inspection

1

Before the commencement of installation of equipment the hoistway and machine room areas shall be examined to verify that no irregularities exist that would effect the execution of the work, particularly:

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20.3

the hoistway size, plumpness and wellway lengths

(b)

the support areas for bracket and beams etc.

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(a)

Installation shall not commence until previous work conforms to Project requirements.

20.3.2

Preparatory Work

1

Legal Hoistways and Pit Enclosures. The following shall be provided: clear plumb hoistway with variations not exceeding 25 mm at any point

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(b)

bevel cants (15 degrees from vertical) over any rear or side wall ledges or beams that project 50 mm or more into the hoistway

(c)

provisions for guide rail bracket supports in concrete in place as required, with necessary supports provided by elevator installer as indicated on shop drawings walls and floors cut and patch as necessary

(d)

blockouts or cutouts for push button stations, hall lanterns and position indicators

(e)

front hoistway wall, erected after entrances have been installed

(f)

pit ladders, cars and counterweight buffers, and rail load supports

(g)

waterproof pits and 600 x 600 x 600 mm deep sump pit

(h)

barriers at open hoistways and entrances during construction

(i)

cars, entrances, and special metal finishes protected from damage after installation

(j)

hoistways vented to outside air.

QCS 2014

Machine Rooms. The following shall be provided: (a)

facilities conforming to EN 81 and requirements of authorities having jurisdiction

(b)

concrete on metal deck machine room floors

(c)

fire-rated, self-closing, and lockable machine room access doors installed

(d)

machine room ventilation

(e)

machine room floor slab, smoke venting grates, dampers, and ducts installed

(f)

machine room walls, ceiling and floor painted and monocoat beam fireproofing sealed to prevent flaking.

Electrical Services. The following shall be provided: pit and machine room lighting and convenience outlets in accordance with EN 81

(b)

conduits run from elevator hoistways to ground level control consoles. Sizes and locations as indicated on elevator installation drawings

(c)

415 V, 3-phase, 50 Hz main power feeders to terminals of each elevator controller unit, including protected lockable "OFF" disconnect switch (copper conductors to terminals)

(d)

240 V a.c., single-phase, 50 Hz, power feeders to each car controller available for lighting and exhaust blowers, including individual 20-amp circuit breakers at locations shown on elevator shop drawings

(e)

suitable power feeders and branch wiring circuits as required to elevator control panels in machine rooms as designated by elevator installer.

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Installation

1

The elevator installer shall supervise and co-ordinate the preparation of all shop drawings, the selection and furnishing of all materials included in the specifications, and the installer shall also install the cars. Installation work shall be to BS 7255. The elevator installer shall also be responsible for the supply and installation of the following:

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20.3.3

(c)

headers, tracks and thresholds

(d)

hangers and gibs on car doors and hang doors

(e)

communications system as specified

(f)

basic car construction of 1.2 mm steel, with vent slots in accordance with EN 81, and wall panels as specified

(g)

exhaust blowers, isolated from steel canopies on rubber grommets.

electrical controls and signal fixtures and wires complete conduit and wiring to lighting and ventilating fixtures, with temporary power and lighting as required

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(a)

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Each equipment item shall be installed in accordance with accepted manufacturer's directions, referenced codes and specifications, with clearances complying with the same.

3

Items shall be installed so that they may be removed by portable hoists or other means for maintenance and/or repair, and so that access for maintenance is safe and readily available, in accordance with BS 7255.

QCS 2014


20.3.4


1

Inspection

Page 17

(a)

work at job sites will be checked during the course of installations. Full co-operation with inspections is mandatory

(b)

corrective work required shall be accomplished prior to performing further installations dependent upon, or related to, required corrections.

Acceptance. The Engineer’s and Employer’s acceptance inspections shall be performed, before acceptance of the works. Verification will be required that tests have been completed, corrective work accomplished and installation approved for issuance of a permit to operate.

20.3.5

Field Adjustments

1

Guide rails shall be aligned vertically within a tolerance of 1.5 mm in 30 m. Joints shall be secure without gaps and irregularities filed to a smooth surface.

2

Cars shall be balanced to equalise pressure of roller guide shoes on rails

3

Equipment shall be lubricated in accordance with manufacturer's instructions.

4

Motors, controller, levelling switches, stopping switches, door operators, interlocking, and safety devices shall be adjusted to achieve required performance levels.

20.3.6

Acceptance Inspection and Tests

1

Acceptance of installations shall be made only after all field quality control and tests are complete, all submittals and certificates have been received, and the Engineer is satisfied that the following have been satisfactorily completed. The Contractor shall supply, labour, materials and equipment necessary for tests:

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2

workmanship and equipment comply with specifications

(b)

speed, capacity, and floor-to-floor performance comply with specifications

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performance of the following are satisfactory: (i)

starting, accelerating, running

(ii)

decelerating, stopping accuracy, stopping

(iii)

door operation and closing pressure

(iv)

equipment noise levels.

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(c)

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(a)

(d)

in all test conditions, speed and performance times specified shall be met, stopping accuracy shall be maintained without re-levelling, and general ride quality shall be acceptable to the Engineer.

Temperature tests may also be required, at the Engineer’s discretion. 2

Should tests detect any defects or poor workmanship, or non-compliance with or variance from the specification requirements, the following work and/or repairs shall be completed at no expense to the Employer: (a)

replace all equipment that does not meet specification requirements

QCS 2014


Page 18

(b)

perform all work and supply all labour, materials, and equipment necessary to complete specified operation and/ or performance

(c)

perform all retesting required by the authorities and the Engineer to verify specified operation and/ or performance.

Clean Up

1

Areas shall be kept orderly and free from debris during Project progress.

2

Loose materials and filings resulting from work on hoistway surfaces and truss interiors shall be removed.

3

The machine room equipment and floor shall be cleared of dirt, oil and grease.

4

Hoistways, cars, car enclosures, entrances, operating and signal fixtures, handrails, and trim shall be cleaned of dirt, grease, and finger marks.

20.3.8

Manufacturer's Services

1

The manufacturer's representative shall inspect the final installation and supervise initial operation. Manufacturer’s certificates shall be provided prior to field testing equipment.

2

The manufacturer's representative shall instruct and train plant personnel for at least one 8 hour day on proper operation and maintenance procedures.

20.3.9

Maintenance and Guarantees

1

The Contractor shall be responsible for the system maintenance and repair of any fault for a period of 400 days starting from the provisional handing over. During this period the Contractor shall replace and/or repair any fault with all spare parts without any cost to the Client.

2

The Contractor shall guarantee the system for a period of 400 days. During this period the Contractor shall clear any failure due to design problems or poor installation and workmanship.

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20.3.7

END OF PART

QCS 2014

Section 21: Electrical Works Part 21: Lightning Protection

Page 1

21

LIGHTNING PROTECTION ........................................................................... 2

21.1

GENERAL ...................................................................................................... 2

21.1.1 21.1.2 21.1.3 21.1.4

Scope References Quality Assurance Submittals

21.2

PRODUCTS ................................................................................................... 2

2 2 2 2

21.2.1 Materials 21.3

2

INSTALLATION ............................................................................................. 4

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Page 2

21

LIGHTNING PROTECTION

21.1

GENERAL

21.1.1

Scope

1

This Part specifies the requirements for lightening protection.

2

Related Parts and Section are as follows: This Section General Provisions for Electrical Installation Conduit Cable Trays Cables and Small Wiring Trunking HV and MV Factory Built Assemblies (FBA’s)

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Part 1 Part 7 Part 9 Part 6 Part 8 Part 2

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(a)

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QCS 2014

References

1


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21.1.2

Code of practice for protection of structures against lightning.

BS 7430

Code of practice for earthing

Quality Assurance

1

Design Criteria:

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the lightning protection system shall be in accordance with QGEWC Rules and Regulations.

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(a)

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21.1.3

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BS 6651

Submittals

1

Shop Drawing and product Data per Part 1.

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21.1.4

(a)

submit full technical details and conductor size calculations of each type of cable or wire proposed

(b)

submit exact route of each cable or wire proposed.

21.2

PRODUCTS

21.2.1

Materials

1

Generally: (a)

(products used in the lightning protection system shall be copper or an approved copper alloy, unless otherwise specified, and specifically manufactured for the purpose.

QCS 2014

2


Page 3

Air Termination Conductors and Down Conductors: (a)

lightning air terminals and down conductors for lightning air terminals shall be provided as indicated on the drawings. Where vertical air terminations are used, they shall be min of 15 mm diameter tinned copper (air termination rod) 0.8 meter long with top spike, unless otherwise specified in the Project Documentation

(b)

generally, roof conductors and down conductors shall be of PVC sheathed 3 x

mm

(minimum) copper tape. PVC colour to be approved by the Engineer. However, bare copper tape may be unless indicated otherwise on the Project Drawings or Specification air termination rods shall be securely anchored and welded

(d)

down conductors shall be run along the outer surface of the wall or column of the building

(e)

down conductors shall be as short as possible, protected and directly connected to earthing system through test links (refer to item 7 below)

(f)

anchoring bolts shall be used to hold roof conductors and down conductors in firm position

(g)

lightning conductor connectors shall be provided for conductor splice connections and conductor terminal connections

(h)

the connectors shall be heavy duty, cast metal and shall have hex-head screws in the bodies and holes in the tongues for bolts

(i)

TV antenna, HVAC equipment, handrails and structures in the vicinity of the lightning protection system, if any, shall be bonded to the system by 3x20 sq. mm (minimum) PVC sheathed copper tape.

Main Earth Loops: (a)

25 x 3 mm tinned copper tape, unless otherwise indicated on the Project Drawings or

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(c)

Earth Electrodes:

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Specification.

(a)

shall be of the earth rod type

(b)

earth rod electrodes: 16 mm diameter steel core copper jacketed type, comprising a high strength steel alloy core with a molten welded copper covering, minimum 0.25 mm thick

(c) 5

Earth Connectors: (a)

6

to be not less than 3.6 m long, in 1.2 m sections coupled by strong bronze couplers.

shall connection of rod electrodes: bolted type.

Removable Earth Links: (a)

to comprise a bolted copper link fixed on porcelain insulators and complete with studs, nuts and washers to take the earth tape and a bolted lug adequately sized for the final connection of the earth electrode.

QCS 2014

Bolts, Washers And Nuts In Bolted Connections: (a)

high copper alloy or silicone bronze. Ferrous hardware is not acceptable.

Earth Pit Cover shall be of heavy duty construction

(b)

shall have a recessed lifting hook

(c)

shall have a brass plate, engraved “Electrical Earth Below”.

INSTALLATION

21.3.1

Installation

1

Removable Earth Links

(b)

install in an accessible position, above ground as close as possible to the earth electrode.

multiple bolt type

(b)

where bare copper is bolted in connections contact surfaces shall electroplated.

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(a)

be silver

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Brazed Connections:

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where earthing terminal connections are to be brazed to equipment, thoroughly clean metal prior to brazing and repaint impaired surfaces to prevent corrosion.

Connections Between Dissimilar Metals: protect by: (i)

painting with a moisture resistant bituminous paint or compound, or

(ii)

wrapping with protective tape to exclude moisture.

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Bolted Connections:

(a)

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fix in every main earth lead to enable the electrode system to be disconnected for testing

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(a)

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Earth Rod Electrodes: (a)

extensible rods of the same diameter shall be installed in holes drilled into the ground. If ground conditions permit, rods may be driven into the ground either manually or mechanically. The earth electrode shall be installed at such a depth that it penetrates the summer water table by a minimum of 2 metres. Under no circumstances shall lightning protection electrodes be connected to any QGEWC earthing electrode. A minimum distance of 7 metres shall be provided between any lightning earth electrode and a QGEWC earth electrode.

(b)

weld earth connectors to the top of the rods, in sufficient number to make connection with all incoming cables.

QCS 2014

6


Page 5

Earth Pit: (a)

provide a concrete/PVC pit complete with a heavy duty concrete, cast iron or PVC cover with recessed lifting hook to the Engineers written approval, at the head of the earth rod, to protect the rod and allow access to connections for testing.

Testing

1

Testing earthing systems by the earth megger test.

2

The resistance of any one point in the lightning protection earth continuity system to the main earth electrode shall not exceed 10 ohms, unless allowed otherwise by QGEWC, without taking account of any bonding to other services.

3

Install additional earth electrodes in parallel, if these figures are not met.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 22: Earthing and Bonding

Page 1

22

EARTHING AND BONDING .......................................................................... 2

22.1

GENERAL ...................................................................................................... 2

22.1.1 22.1.2 22.1.3 22.1.4

Scope References Quality Assurance Submittals

22.2

PRODUCTS ................................................................................................... 2

2 2 2 2

22.2.1 Materials 22.3

2

INSTALLATION ............................................................................................. 3

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22

EARTHING AND BONDING

22.1

GENERAL

22.1.1

Scope

1

This Part specifies the requirements for earthing and bonding.

2

Related Parts and Sections are as follows: This Section Part 1 Part 2 Part 6 Part 7 Part 8 Part 9 References

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BS 7430 ......................Code of practice for earthing

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22.1.2

General Provisions for Electrical Installations HV and MV Factory Built Assemblies (FBA’s) Cables and Small Wiring Conduit Trunking Cable Trays

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QCS 2014

Quality Assurance

1

Design Criteria: the earthing system shall be in accordance with QGEWC Rules and Regulations.

22.1.4

Submittals

1

Shop Drawing and product data per Part 1.

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submit full technical details and conductor size calculations of each type of cable or wire proposed

(b)

submit exact route of each cable or wire proposed.

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(a)

PRODUCTS

22.2.1

Materials

1

Generally:

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22.2

(a) 2

3

products used in the earthing system shall be copper or an approved copper alloy, unless otherwise specified, and specifically manufactured for the purpose.

Earth Continuity Conductors: (a)

sizes shall be as specified by QGEWC, unless otherwise indicated, but in no case shall size be less than half that of the associated phase conductors

(b)

insulation shall be of the same material as insulation in associated sub-circuits.

Main Earth Loops: (a)

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22.1.3

25 x 3 mm tinned copper tape, unless otherwise indicated.

Rod Electrodes: (a)

shall be of the earth rod type

QCS 2014

5

6


Page 3

(b)

earth rod electrodes: 16 mm diameter steel core copper jacketed type, comprising a high strength steel alloy core with a molten welded copper covering

(c)

Length as required, in 1.2 m sections coupled by strong bronze couplers.

Earth Connectors: (a)

Connection of rod electrodes: shall be bolted type.

(b)

All connection of earth electrodes with conductor/tape in earth pit shall be provided with clamps. Two connection clamps shall be provided for each individual connection.

Removable Earth Links: to comprise a bolted copper link fixed on porcelain insulators and complete with studs, nuts and washers to take the earth tape and a bolted lug adequately sized for the final connection of the earth electrode.

Bolts, Washers And Nuts In Bolted Connections:

ta

Earth Pit Cover (a)

shall be of heavy duty construction

(b)

shall have a recessed lifting hook

(c)

shall have a brass plate, engraved “Electrical Earth Below No.XXX”. Including identification No. as per the approved drawings.

INSTALLATION

22.3.1

Installation

1

Circuit Wiring

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shall have a green/yellow coloured insulated earth continuity cable connecting the earth bus or earth terminal in switchboards, switchgears, motor control centres and panel boards to the motor, equipment, outlet and other device by earthing lugs. All hand rails and other metal works within 2 m of a potentially live metal surface shall be earthed.

Main Earth Loops

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high copper alloy or silicone bronze. Ferrous hardware is not acceptable.

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(a)

3

(a)

Fix in mechanical equipment rooms and other areas indicated on the drawings, in convenient locations, allowing two return paths to earth

(b)

Fix copper tape to structure with copper or brass saddles and/or screws. Make tees and straight joints by riveting and seating

(c)

Make branch connections between main loop and major equipment, such as switchboards, switchgears, motor control centres and large motors, with copper tape of same size as main loop tape

(d)

Make other branch connections to equipment with copper conductors of size not less than half that of the relative phase conductor.

Removable Earth Links (a)

Fix in every main earth lead to enable the electrode system to be disconnected for testing

(b)

Install in an accessible position, above ground as close as possible to the earth electrode.

QCS 2014

Exposed Earth Cables (a)

(a)

Multiple bolt type

(b)

Where bare copper is bolted in connections contact surfaces shall be silver/tin electroplated.

Brazed Connections: (a)

where earthing terminal connections are to be brazed to equipment, thoroughly clean

(b)

metal prior to brazing and repaint impaired surfaces to prevent corrosion.

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(ii)

wrapping with protective tape to exclude moisture.

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(a)

connect all non-current carrying metallic parts of the electrical/mechanical installation to the earthing system

(b)

non-current carrying metallic parts of the electrical installation include: (i)

metal conduit, cable armour, raceways, outlet boxes, cabinets, and the like

(ii)

exposed metal parts of apparatus

(iii)

enclosures, doors, grills, barriers and the like protecting or shielding electrical equipment from direct access

o

series earthing of one piece of equipment to another is not acceptable. Each item shall be individually connected to earth system

Fire Fighting Equipment: (a)

earth on a separate ring system.

Motors Earthing:

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10

painting with a moisture resistant bituminous paint or compound, or

Equipment Earthing:

(c) 9

(i)

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8

protect by:

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(a)

.

Connections Between Dissimilar Metals:

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Bolted Connections:

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6

Install and locate in a manner to provide maximum mechanical protection, utilising ceiling corners, suspended ceiling and webs of beams as much as possible.

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4


(a)

connect the motor terminal box to the relative earth loop. The terminal must be mechanically connected to the frame or, where this is not feasible

(b)

extend the earthing conductor through an insulated bushed opening in the connection box and connect to the frame.

Main Switchboards, Switchgears and Motor Control Centres Earthing: (a)

connect the special earthing lug or busbars inside the cabinet to the main earth copper tape.

(b)

connect all parts of the switchboards, switchgears and motor control centres other than “live” parts, to the earth bar in the board in an approved manner.

(c)

The MV /MCC panel shall be connected at both end of the MV/MCC to a two separate Earthing pits, (directly or through intermediary Earthing bar installed in MV/MCC basement) or as approved by the Engineer. The earthing cable calculation shall be performed with approved professional international recognised licensed software, Subject to the Engineer’s approval.

QCS 2014

Distribution Boards Earthing: (a)

Bus-Duct Feeders Earthing: (a)

Cable Armour Earthing: (a)

16

Connect steel armour to the earthing system Coordinate with QGEWC regarding any specific earthing requirements for the EHV cable sheaths.

.

Earth Rod Electrodes: (a)

extensible rods of the same diameter shall be installed in holes drilled into the ground. If ground conditions permit, rods may be driven into the ground either manually or mechanically. The earth electrode shall be installed at such a depth that it penetrates the summer water table by a minimum of 2 metres.

(b)

bolt earth connectors to the top of the rods, in sufficient number to make connection with all incoming cables.

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connect the green/yellow coded earth busbar directly to the earth bus-bar in main switchboard with earth copper tape

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14

connect an earthing conductor from the main distribution earth busbar to an earth connector welded to the cabinet and earthing bushings on the incoming and outgoing feeder conduits.

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Earth Pit:

Provide a concrete/PVC pit complete with a heavy duty concrete, cast iron or PVC cover with recessed lifting hook to the Engineers written approval, at the head of the earth rod, to protect the rod and allow access to connections for testing.

Transformer and MCC/MV Panel Earthing: Transformer Earthing Terminals are to be connected to MV main earthing bar by bare copper earthing conductor not less than 30 mm² per 100 kVA of transformer rating, with a minimum of 120 mm².

(b)

Transformer Neutral (Star Point) is to be connected by insulated conductor (colour black) to MV/MCC panel as per QGEWC rules and regulations.

(c)

MV/MCC panel earthing conductor to earthing bar and earthing pit , is to be sized for maximum earth fault current for 5 seconds with final conductor temperature not exceeding 160 °C or sized not less than 20 mm² per 100 kVA of transformer rating, and with a minimum of 95 mm².

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(a)

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(a)

22.3.2

Testing

1

Testing earthing systems shall be done by the earth megger test. The electrical resistance value of the earthing system shall not exceed 1 ohm, unless approved otherwise by QGEWC

2

The resistance of any point in the earth continuity system to the main earth electrode shall not exceed 1 ohm, unless approved otherwise by QGEWC.

3

Install additional earth electrodes if these figures are not met. END OF PART

QCS 2014

Section 21: Electrical Works Part 23: Inspection and Testing

Page 1

23

INSPECTION AND TESTING ........................................................................ 2

23.1

GENERAL ...................................................................................................... 2

23.1.1 Inspection and Tests at Manufacturer's Place 23.1.2 Inspection and Tests at Site

2 3

ELECTRICAL INSTALLATION TESTING...................................................... 4

23.2.1 23.2.2 23.2.3 23.2.4 23.2.5 23.2.6 23.2.7 23.2.8 23.2.9

General Verification of Polarity Earth Electrode Resistance Insulation Resistance Ring Circuit Continuity Phase Rotation Continuity of Protective Conductor Earth-fault Loop Impedance Operation Tests

23.3

ELECTRICAL EQUIPMENT TESTING .......................................................... 6

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23.2

23.4

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23.3.1 General

4 5 5 5 5 6 6 6 6 6

COMMISSIONING ......................................................................................... 7

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23.4.1 General

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Page 2


23.1

GENERAL

23.1.1

Inspection and Tests at Manufacturer's Place

1

The Engineer shall be authorised to inspect, examine and test at any reasonable time and in the premises of the manufacturer, the quality of the material used for the equipment to be supplied. These work inspections shall include but not be limited to the following equipment, lighting fixtures, emergency power equipment, switchgears, switchboards, motor control centres, main and sub-main distribution boards, Pumps (>75 KW), Motors (>75 KW), Blowers, Compressors, VFDs / AHF(>75 KW), Diesel Generators Sets, GT sets, MV/FBA/MCCs/Switchgears, SCADA/PLCs, 11/3.3 kV Switchgears, HV Transformers, HV/EHV cables, UF equipment, UV systems, Chlorination equipment. He shall also be authorised to verify the qualifications of the staff employed by the manufacturer.

2

Should part of the equipment be subcontracted to another manufacturer, the Contractor shall ensure that the Engineer is authorised to inspect, examine and test the equipment in the premises of the Sub-Contractor.

3

These inspections, examinations and tests shall not relieve the Contractor, in any case, from the contractual responsibility and commitments.

4

Factory Inspection. The Engineer and his representative shall inspect the Mechanical and Electrical / I&C equipment listed in the tender documents at the manufacturing facilities after the completion of manufacturing process. The Contractor shall notify the Engineer in writing of the Factory Acceptance Test (FAT) schedule dates, 30 calendar days before commencement date of Factory Acceptance Test (FAT) in order that the factory inspection can be arranged. Factory inspections will be made at any reasonable time after the completion of internal testing by the Manufacturer and prior to shipment. Approval of equipment at the factory only allows the manufacturer to ship the equipment to the Site and does not constitute final acceptance. Where specified, the Contractor shall include in the Contract Price for all the costs of the Engineer and his representative. The equipment will be released from the manufacturing facilities only after written FAT witness test reports are accepted in writing by the Engineer/Client.

5

Factory Acceptance Witness Tests and Test Certificates. Factory Acceptance Witness tests shall be carried out as specified in the Project Specification at manufacturing facilities places, and as required by international standards and industry norms. Detailed Factory Test Procedures shall be provided by the Contractor and submitted for Engineer’s approval minimum 60 days before the proposed inspection date, and shall be subject of Engineer’s approval. The FAT test procedure shall be approved by the Engineer 30 days before the FAT witness date is proposed.

6

The Contractor shall ensure that the manufacturer provides all labour, materials, electricity, fuel, stores, apparatus and all instruments as are requisite and as may reasonably be required to carry out the test efficiently. The Engineer and his representative will witness the FAT tests.

7

The Contractor shall submit from the equipment manufacturer, a certified internal written test certificate in accordance with the requirements/international standards of the relevant test procedure before the FAT witness testing date.

8


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QCS 2014


Page 3

Wherever possible, Site conditions shall be simulated at the manufacturing facilities during FAT witness, or the tests shall be extended to allow for Site conditions. Where the pumps are driven by VFD equipment, the complete Motor VFD shall be FAT witness tested in the presence of the Engineer.

10

Should the Contractor provide for tests to be made in the premises of the Contractor or any Sub-Contractors or suppliers, the Contractor shall afford any assistance, labour, materials, electricity, fuel supplies, equipment and instrument required and which can be reasonably requested for these tests.

23.1.2

Inspection and Tests at Site

1

This specification defines the tests to be made on electrical equipment, distribution systems and installations at site to establish compliance with the specification and to ensure they are entirely suitable for the intended purposes.

2

For all tests a minimum of 30 days notice in writing shall be given by the Contractor to the Engineer to enable the tests to be witnessed.

3

All electrical tests, unless otherwise specified, shall be made either in a manner prescribed in the relevant:

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British Standard Specification and Code of Practice

(b)

IEE Regulation (latest edition)

(c)

QGEWC regulation

(d)

Civil Defence Department regulation

(e)

or where no Standard/Code/Regulation exists, in a manner approved by the Engineer.

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(a)

A pre-closing Inspection shall be carried out on all items of Electrical equipment, cables and conduit to be permanently concealed i.e. underground cables and ducts, conduit in screed or plastered into walls, above ceiling etc.

5

The Contractor shall provide the Engineer with 3 clear working days notice of his intention to cover the works. Failure to comply with this requirement shall result in the re-exposure. Engineer's inspection and re-exposure of the works being carried out shall be at the Contractor's expense.

6

The inspection and tests specified herein do not supersede but are supplementary and complimentary to the tests called for in Project Specifications and clauses for equipment, systems and installation.

7

The Contractor shall supply all necessary instruments, apparatus, consumable stores, connection, skilled and unskilled labours and services with proper, reasonable and safe facilities required for the tests. Any costs which may be involved in the tests shall be included in the tender. The Contractor shall satisfy the Engineer that the instruments and the equipment to be used for any test are adequate as regards accuracy and calibration for the tests to be undertaken.

8

Workmanship shall be checked during work in progress and completed work inspections. Any work not to the satisfaction of the Engineer during such inspection shall be replaced to a standard approved by the Engineer at the Contractor’s expense, and prior to any subsequent inspection.

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Page 4

9

A complete written record shall be made by the Contractor of all inspections and tests. These records shall be made at the time of the tests and shall be countersigned by the Engineer, if present, as a true record. A copy of each record sheet shall be included with the operation and maintenance manual. Inspection or approval of tests, acceptance of test certificate and waiving of tests, by the Engineer, of any equipment, works or installation shall not relieve the Contractor from the obligation to supply the complete equipment and complete work and installations in accordance with the Project Specification and suitable for the purpose intended.

10

Certificates of tests shall contain or have attached to them, the following information:the job name and number as designated by the Engineer

(b)

the name, address and contract or order number of the Contractor

(c)

a description of the item, component, equipment, system or installation tested including any fabrication, block or production number

(d)


(e)

environmental conditions including weather, if relevant

(f)

the testing party (if other than the Contractor) and signature of the Engineer

(g)

the properties to be tested and the source of the parameters for such properties, i.e. British Standard, Codes of Practice, QGEWC Regulation, Specifications, etc

(h)

the results of the tests and any divergence from the specification, production drawings or statutory requirements

(i)

the detail of any works to be completed but which is outside the scope of this test.

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(a)

The Engineer shall have discretion to waive inspection/testing for either any part or of the complete installation.

23.2

ELECTRICAL INSTALLATION TESTING

23.2.1

General

1

On completion of the entire electrical installation work or any separate or distinct part thereof, notify the Engineer, in writing, that the complete part of the electrical work is ready for inspection and testing. Before doing so, perform initial trial tests. Test, correct, adjust, balance, regulate, etc., the section concerned as necessary until required conditions are obtained.

2

The results and readings obtained for tests shall be equal or better than the requirements of the IEE and the QGEWC Regulations and these shall be recorded on Forms similar to the ones described in the IEE Regulations. The tests shall be carried out in a manner as described in these regulations.

3

The Contractor shall supply all instruments and tools required for carrying out the tests.

4

In case the tests specified below are satisfactory and no errors or faults appear in the installation, submit the necessary test forms, duly filled out, to QGEWC to repeat, if necessary, the tests in the presence of QGEWC inspectors.

5

Upon Completion of testing, the Contractor shall follow-up and make all necessary arrangements with the QGEWC and Telecom Provider for the purpose of providing permanent electricity supply and telephone services to the new facilities. Also provide all facilities and attendance to QGEWC for any other tests to be carried out before energising the installation.

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Page 5

The testing of the installations shall comprise of the following but not limited to:-

23.2.2

Verification of Polarity

1

Verification of polarity shall be made to ensure that all fuses and single pole control devices are connected only on the live phase conductor. The neutral must not be connected through any of these devices.

2

The centre contact of Edison type screw lamp holder shall be connected to the phase conductor, the outer threaded metal part shall be connected to the neutral conductor.

3

Wiring to plugs and socket outlets should be such that that they are connected with phase conductor on the right pole when viewed from the front.

4

A suitable type of testing device shall be used to confirm the above.

23.2.3

Earth Electrode Resistance

1

Upon installation of earth electrode, test shall be carried out to ensure that the installation of electrode has reduced the earth fault impedance effectively to the required value.

2

Resistance to earth of all earthing rods, each earth termination network, continuity of conductors and all bends and joints shall be tested by means of a Wenner test. The electrode resistance shall not exceed 1 ohms requirement or as specified in the QGEWC regulation.

23.2.4

Insulation Resistance

1

Insulation resistance test shall be carried out before a completed installation is permanently connected to the supply. Large installations may be divided into groups. A DC voltage not less than twice the normal supply voltage (RMS value of AC system voltage) shall be applied for the measurement of the insulation resistance. For low voltage installations, where apparatus voltage rating does not exceed 55 V, shall be tested applying 500 V DC only.

2

When measured with all fuse links in place, all switches (including, if possible, the main switch) closed, the insulation resistance for whole installation shall not be less than 1 meg ohm.

3

When measured between one phase conductor and other conductors connected together to earth, in turn for all phases, the insulation resistance shall be not less than 1 mega ohm.

4

Wherever possible, so that all parts of the wiring may be tested, all lamps shall be removed, all current using apparatus disconnected, all local switches shall be closed; where removal of lamps or disconnection of current using apparatus is not practicable, respective control switches shall be opened.

5

Where apparatus is disconnected for the tests, the insulation between the enclosure or frameworks and all the live parts (phase) of the apparatus shall be measured separately and shall comply with the requirements as per BS for the corresponding apparatus, where such standard is not available, the insulation resistance shall not be less than 0.5 meg ohm.

23.2.5

Ring Circuit Continuity

1

A test shall be carried out to verify the continuity of all conductors (including the earth continuity conductor) of every ring circuit and all readings shall be tabulated.

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Phase Rotation

1

The complete installation shall be tested to ensure that all distribution boards are connected to give correct phase rotation for the corresponding apparatus as required.

23.2.7

Continuity of Protective Conductor

1

A test shall be carried out to verify that all protective conductors are connected correctly and are electrically sound, before power supply is connected to an installation.

2

When the protective conductor is a core in multi-core cable or a separate protective conductor, a DC ohmmeter may be used to measure the resistance. Where steel conduits or other metallic structure is used as protective conductor, the test shall be carried out by current injection at a voltage not exceeding 50 V AC or DC and current about 1.5 times the normal circuit current but not exceeding 25 Amps. When using DC source, it must be ensured that inductors are not connected in the test path.

3

A portable hand generator is preferable to use for this test so that the disconnected phase conductor can be connected to the consumer earth terminal and tests can be made between phase conductor and the protective conductor at each outlet point.

23.2.8

Earth-fault Loop Impedance

1

Each completed installation shall be tested for effectiveness of the earthing by means of an earth fault loop impedance test. The test shall be carried out by using earth loop impedance test instrument

23.2.9

Operation Tests

1

This clause applies to relays, Interlocks and any other protective and control device, viz., residual current devices, to ensure correct functioning.

2

Suitable test pro forma shall be prepared, as per the recommendation of the manufacturer for protective relay tests and submit to the Engineer for approval. Logic diagram for control and interlocks shall be prepared, based on the requirement for functional tests, and shall be submitted to the Engineer for approval. Tests shall be carried out according to the approved form and all results shall be tabulated.

3

The RCDs shall be tested by external supply to check for instantaneous operation. The testing device shall be single phase double wound continuously variable type transformer (variac) with maximum output voltage 50 V and loading resistors to control current. While rated current applied, the device shall operate instantaneously or within a time delay as per manufacturer data sheet. The test current to be applied shall be as per manufacturer recommendation.

23.3

ELECTRICAL EQUIPMENT TESTING

23.3.1

General

1

The Contractor shall fully test and commission the whole of electrical installation in accordance with QGEWC and IEE regulations, as per requirements of the Project Documentation and as outlined in this section.

2

The following equipment will be inspected and tested on site after installation. Any omission or defects, or faults raised by the Engineer are to be remedied or corrected by the Contractor and re-testing made at the direction of the Engineer at the Contractor’s expense:

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23.2.6

(a)

415V switchgears and MCC, VFD

Mains cable

(c)

Motors

(d)

Starters and control gear

(e)

Control and starter panels

(f)

Small wiring etc.

(g)

Elevator, walkway system

(h)

Radio and TV interference

(i)

Fire alarm and detection system

(j)

Public address system

(k)

HV switchgear

(l)

HV cables

(m)

Power transformer

(n)

EHV cables

(o)

Main telephone installations

(p)

Diesel Generators

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Following functional tests shall be carried out to ensure proper functioning of the plant and all apparatus. All protective circuits, interlocks, control and alarm shall be tested for correct operation

(b)

All lighting circuits shall be energised and checked to ensure that they are operational

(c)

All motors, plants and electrical equipment connected with mechanical services shall be checked to ensure that they run freely in the correct direction/rotation and in correct sequence

(d)

Fire alarm system, fire fighting system, SCADA/PLC, etc, elevator system and building management system (if applicable) shall be tested for correct operation.

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(e)

(f)

All major authority related testing requirements shall be witnessed by the relevant authority representative (QGEWC, Qatar Civil Defence, or Telecom Provider). The Contractor shall give a minimum of one-week advance notice prior to performing any major tests The Contractor shall obtain all relevant testing requirements from QGEWC and Telecom Provider and make available all necessary testing apparatus.

4

The testing requirements and procedures for the various items of electrical equipment is specified in the other relevant specification parts for electrical works and relevant standards.

23.4

COMMISSIONING

23.4.1

General

1

This specification deals with the Contractor’s work involved in commissioning to energise the electrical distribution systems, installations and plants after inspections and tests to ensure safety and proper operation; and the evaluation of performance by means of further inspection and tests to ensure the works operate in conformity with the design specification.

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2

Commissioning works shall be carried out by the Contractor using trained, experienced commissioning engineers. The commissioning engineer shall perform switching operations and also must be in charge for the opening and closing of circuits, interlocks and safety devices.

3

The Contractor in conjunction with the Engineer shall prepare a commissioning schedule. This shall show a time scale and the extent of power or other services requirements for setting the plant to work. The following information shall be made available to the Engineer: (a)

Specification of work

(b)

Test certificates from works test at manufacturers facilities

(c)

Test results from site progress tests.

(d)

Notes from pre-commissioning meetings.

The method statement shall be submitted to the Engineer and get it approved at least 1 month before the commencement of commissioning tests.

5

After commissioning, the plant shall operate for the guarantee period as per the requirements of the Project Documentation, from the date of practical completion certificate issue in accordance with normal requirements without defect of any kind. Any defect which appears shall be remedied forthwith by the Contractor without any cost to the contract and reliability run shall start after re-commissioning. The guarantee period shall be calculated from the latest date of such re-commissioning.

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END OF PART

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Section 21: Electrical Works Part 24: Documentation Format

Page 1

24

DOCUMENTATION FORMAT ....................................................................... 2

24.1

GENERAL ...................................................................................................... 2

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24.1.1 Scope 24.1.2 General Requirements 24.1.3 Document format 24.1.4 Time Scale 24.1.5 Approval 24.1.6 Record Drawings 24.1.7 As-Built Drawings 24.1.8 Scales 24.1.9 Scale Bar 24.1.10 Presentation of Drawings 24.1.11 Manuals 24.1.12 Instrumentation Documentation

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24

DOCUMENTATION FORMAT

24.1

GENERAL

24.1.1

Scope

1

This Part specifies the general requirements and standards required for the compilation of paper and electronic documents.

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1

Documents will be presented both electronically and on paper. Documents from an electronic source shall, when printed, conform to the requirements for documents presented on paper. The number of hardcopy manuals shall be determined by the contract documentation.

2

The final approved documentation shall be reproducible in the following sizes. These sizes are defined to ensure that the provided documentation can be easily read and understood.

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24.1.2

A4 size paper for manuals

(b)

A3 size for system diagrams

(c)

A1 size for instrument location and plant drawings

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Document format

1

Drawings shall be compiled in AutoCAD DWG or Microstation DGN file format or similar approved with Engineer. Word processed documentation should be presented in Adobe Acrobat PDF format or similar approved with Engineer. Scanned copies of the „as built‟ drawings showing all of the required approval signatures and official stamps shall be provided in TIFF format. The files should be presented on optical disc containing a readme.txt file containing an index of the disk.

24.1.4

Time Scale

1

The time scale for delivery of manuals shall be as stated in the contract documentation, with the final versions of the manuals being available before hand over.

24.1.5

Approval

1

During the construction phase of the project, the drawing and manuals status shall be monitored and discussed. These discussions form part of the project meetings / site meetings and are part of the approval process. All documents shall be approved prior to hand over.

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Record Drawings

1

This specification defines the production of drawings so they are provided in a consistent way that shall make the drawings easy to use. This section refers to record drawings that relate to the as built product. Documents from an electronic source shall, when printed, conform to the requirements for documents presented on paper.

24.1.7

As-Built Drawings

1

Drawings produced by suppliers/Vendors shall be of appropriate size as below. Documents from an electronic source shall, when printed, conform to the requirements for documents presented on paper.

2

Drawing information shall be handed over in 'As Constructed‟ form and marked-up accordingly in the information panel.

24.1.8

Scales

1

As few scales as possible shall be used and each scale used shall be recorded in the title panel. The scale shall be large enough to permit easy and clear interpretation of the information and ensure clarity of prints of all sizes reproduced. The recommended scales are listed in Table 24.1.

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Table 24.1 Scale Recommendations

Recommended ratios of scale

50:1 5:1

20:1 2:1

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Full Size

1:1 1:5 1:50 1:500 1:5000

1:10 1:100 1:1000 1:10000

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1:2 1:20 1:200 1:2000

10:1

24.1.9

Scale Bar

1

The original scale shall be indicated by means of a relevant numbered scale bar. A warning against scaling the drawing shall be given.

24.1.10 Presentation of Drawings 1

Title panel and information panel shall contain the following information:(a)

client

(b)

contractor

(c)

supervisory consultant

(d)

designer/manufacturer

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project title

(f)

name of site/s

(g)

name and type of installation/s

(h)

drawing title/description

(i)

sheet number in the series

(j)

drawing status

(k)

identity of persons carrying out the draughting and checking

(l)

date of drawing

(m)

drawing scale/s

(n)

drawing no. with provision for revision suffix (Year/Contract/Number/ /Revision)

(o)

contents of information panel

(p)

The nature and date of each revision and the identification of the person approving it shall be recorded in the information panel, starting next to the title panel. General notes shall commence at the opposite end of the information panel

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(e)

All text and drawings shall be in black unless otherwise stated.

3

Amendment of Drawings

as

After receipt by the Client of (draft) 'As Constructed' drawings, the Contractor shall notify the Client of any changes by re-issuing a complete draft, with further revision suffix to title and information panel.

(b)

Each section shall clearly indicate the status of the information in the form of amendment notes.

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4 Electrical Schematics

The legend for naming and symbols used shall be clearly displayed on the drawing.

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Electrical schematics shall be complete with cross references for all contact elements of all components used.

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24.1.11 Manuals 1

A contents page shall be provided for each Volume listing the contents of that particular Volume. It shall be entitled “Contents of Volume No XXX”. Where there are two or more volumes to a manual then there shall be a complete index to the set of volumes with each Volume.

2

The manual(s) shall be formed containing operational information in the first part of the manual and maintenance information in the latter part.

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The manual shall be split into the following sections: (a)

Section 1.0 - Introduction (i)

Section 2.0 - Technical Description (i)

process descriptions

(ii)

plant description

(iii)

schedule of equipment commencing with a complete data sheet specific to the equipment used detailing Make, Type or Model No.. Rating, Order No., Quantity used etc.

(ii)

hazardous area zoning

(iii)

confined spaces

(iv)


(v)

site security description

(vi)

warning labels, etc

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Section 4.0 - Operating Information plant settings

(ii)

operating procedure

(iii)

start up/shut down/power failure

(iv)

routine check procedure

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(v)

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The introduction shall describe the purpose of the operating manual. This shall include how to start up and shut down the installation and/or process and/or plant as appropriate and maintain it at its optimum performance. The following details shall be included in the body of the manual.

replacement of consumable items

Section 5.0 - Control Philosophy

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Functional Design Specification (FDS) to include the following as minimum:(i)

description of mechanical plant

(ii)

description of electrical plant

(iii)

description of instrumentation, control and field devices

(iv)

process & instrumentation diagrams (P&ID's)

(v)

plant start up sequence for both manual and automatic mode

(vi)

plant shut down sequence for both manual and automatic mode

(vii)

power fail and restart sequences

(viii)

normal process sequences

Section 6.0 - Maintenance Instructions including:(i)

safety precautions

(ii)

routine maintenance schedules

(iii)

spare parts listing and agreed spares list

(iv)

lubrication

(v)

plant strip down/assembly

(vi)

fault finding instructions

Section 7.0 - Suppliers

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(ii)

electrical diagrams

(iii)

cable schedules

(iv)

valve schedules

(v)

instrument loop diagram

(vi)

vendor manuals (original manuals only-photocopies shall not be acceptable)

(vii)

vendor test certificates

(viii)

instrumentation loop test certificates

(ix)

plant description forms

(x)

hazardous area zoning drawings

(xi)

a general description of each plant and how it operates, shall be included at the beginning of each of the M&E sections. The description shall explain the function of the equipment. It shall be sufficiently detailed to enable the reader to understand how the works operates before using the operating instructions.

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Supplier‟s/Vendor‟s names, contact person and his title, addresses and telephone numbers, email etc.

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a complete set of data sheets providing specific details of the equipment used with Order No., Serial No., and specific technical details etc. If a comprehensive spare parts list is not attached to the individual equipment catalogue section, the same shall be compiled by the Contractor and attached to this section.

(xiii)

a complete list of all components used for Order No., Motor Control Centres detailing Make, Model No., Rating, Quantity used etc.

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24.1.12 Instrumentation Documentation The instrumentation documentation shall be according to the following specification. (a)

(b)

For the instrumentation the contractor shall supply the following information: (i)

instrument loop diagrams

(ii)

manufactures literature

(iii)

certificate of calibration

(iv)

certificate of conformity

RTU Documentation For the RTU system, the contractor shall supply the following information:

(ii)

GA and wiring diagram

(iii)

isagraph program (disk)

(iv)

RTU configuration (disk)

(v)

RTU user manual

(vi)

RTU programming software user manual

(vii)

licensed and latest version of the programming software original with all end user license agreements.

PLC Documentation

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RTU I/O schedules

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(c)

(i)

For the PLC system, the contractor shall supply the following information:system architecture drawing

(ii)

rack layouts

(iii)

PLC I/O schedules (printed sheet + Excel format disc)

(iv)

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(v)

PLC hardware listing

(vi)

annotated PLC ladder logic (printed sheet + disc)

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(vii)

PLC user manual

(viii)

PLC programming software user manual

(ix)

licensed and latest version of the PLC programming software original with all end user license agreements.

HMI Documentation For the Man Machine Interfaces, the contractor shall supply the following information: (i)

system architecture drawing

(ii)

graphic copy and description of all mimics

(iii)

description of all trends

(iv)

alarm handling and schedules

(v)

operator control functions

(vi)

HMI database listing with disc, if applicable

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SCADA Documentation For the SCADA system, the contractor shall supply the following information: system architecture drawing

(ii)

software user manuals

(iii)

SCADA database listing and discs

(iv)

alarm handling and schedules

(v)

description of all trends

(vi)

graphic copy and description of all mimics

(vii)

database point allocation table (disk

(viii)

application software source code

(ix)

SCADA latest version of the programming software and IO Drivers with all end user license agreements.

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END OF PART

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Section 21: Electrical Works Part 25: Electrical Identification

Page 1

25

ELECTRICAL IDENTIFICATIONS ................................................................. 2

25.1

GENERAL ...................................................................................................... 2

25.1.1 25.1.2 25.1.3 25.1.4 25.1.5 25.1.6

General Nameplates and Labels Wire and Cable Markers Interconnecting Cabling Identification “ICA” Under ground Warning Tape Installation

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ELECTRICAL IDENTIFICATIONS

25.1

GENERAL

25.1.1

General

1

Provide identification on all equipment e.g. control panels, FBA, controllers, raceways, boxes and conductors, devices etc in accordance with BS 61346, BS 61666, BS 61175 and BS 60445 standards or latest edition of other applicable standards to the approval of engineer.

2

All labels shall be permanent, and be machine generated. NO HANDWRITTEN OR NONPERMANENT LABELS SHALL BE ALLOWED.

3

Prior to making any label or nameplate for the purpose of identification submit a detailed schedule indicating nameplate size, lettering size, color, material and actual nameplate information for Engineer's review and approval.

4

All external labels, nameplates, operational and warning signs shall be provided in Arabic and English.

5

Material used in making the engraved labels shall be of highest quality suitable for the environmental and climatic conditions as specified in the relevant section.

6

Critical devices such as disconnect switches; service feeders and branch circuit protective feeders shall be legibly labeled to indicate its purpose and point of origin. The legibility distance shall not be less than 2.0 meters.

7

Identification nameplates shall be provided in addition to the manufacturer's equipment nameplates as required by NEMA, BS, IEC or UL.

8

Warning signs and instruction labels wherever needed shall be provided in accordance with local regulations of QGEWC, Civil defence etc.

9

Contractor shall clearly show locations and fixing arrangements of nameplates and labels on layout drawings.

25.1.2

Nameplates and Labels

1

Nameplates:

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(a)

Provide equipment identification labels for all electrical equipment including, but not limited to Switchgear, control panels, switchboards, transfer switches, disconnect switches, transformers, generators, power factor capacitors, fixed equipment, motor starters, FBA etc.

(b)

Provided sub classification label for all emergency power system, junction boxes and pull boxes.

(c)

External labels: Clear Perspex, back engraved in black letters on white background, in Arabic and English with chamfered edges fixed with stainless steel screws with nuts and flat and lock washers.

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Internal labels: Multi-layered plastic to an approved design engraved in Arabic and English, and fixed with stainless steel screws. Alternatively special purpose made DIN rail may be used for fixing labels as approved by the engineer.

(e)

Adhesive labels shall not be permitted.

(f)

Internal components labels shall have circuit designations correlated with the drawings.

(g)

Labels shall not be attached to trunking covers or other readily removable items.

(h)

Electrical equipment enclosures, vaults, doors and fences shall be provided with "DANGER KEEP OUT" warning sign, showing proper voltage.

(i)

Disconnect switches and emergency devices shall have "CAUTION" warning signs as directed by the engineer.

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Provide Title Label for electrical distribution and all other control equipment, panels etc.

(b)

Provide Function Label for door mounted component.

(c)

Every internal component - Identification Label.

(d)

Provide Identification Label for Protective device - (e.g. fuse/mcb type, rating).

(e)

Provide Title Label for Communication equipments.

(f)

Compartments with doors and covers not electrically interlocked to an isolator, external label - “DANGER, LIVE TERMINALS” with flash and voltage in red letters on white background in Arabic and English.

(g)

Provide Function description Label for group of terminal blocks.

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Letter Size is to be approved with Engineer.

25.1.3

Wire and Cable Markers

1

Description: Interlocking ferrules of white insulating material engraved in black. Letters and symbols to IEC 446 shall be used for control wiring and Flameproof Cable tags for appropriate cable group.

2

Locations:

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(a)

Conductor at pull boxes outlet, junction boxes and each load connection.

(b)

Cable laid in trenches, duct, raceways etc.

Legend: (a)

Power and Lighting Circuits: Branch circuit or feeder number indicated on drawings.

(b)

Control Circuits: Control wire number indicated on schematic and interconnection diagrams on drawings.

25.1.4

Interconnecting Cabling Identification “ICA”

1

Each horizontal cable from instruments, transmitter, controller etc. termination blocks or patch panel if any to an outlet box shall be labelled at both ends.

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Tags shall be consecutively numbered so that no two (2) cables have the same identification number.

3

In addition the cable tag shall indicate the reference of location where the associated outlet is located and the device is installed.

25.1.5

Under ground Warning Tape

1

Description: 100 mm wide plastic tape, detectable type, coloured yellow with suitable warning legend describing buried electrical lines e.g. 0.6/1KV, 11KV etc.

25.1.6

Installation

1

Degrease and clean surfaces to receive nameplates and labels.

2

Install nameplate and label parallel to equipment lines.

3

Secure nameplate to equipment front as specified.

4

Secure nameplate to inside surface of door on panelboard that is recessed in finished locations.

5

Identify underground conduits using underground warning tape. Install one tape per trench at 150 mm below finished grade.

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END OF PART

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Section 21: Electrical Works Part 26: Electromagnetic Compatibility

Page 1

26

ELECTROMAGNETIC COMPATIBILITY ................................................................. 2

26.1

REGULATIONS ....................................................................................................... 2

26.1.1 26.1.2 26.1.3 26.1.4 26.1.5 26.1.6 26.1.7

General EMC: Electromagnetic Compatibility The CE Marking EMC Directive and Standards EU Product Directives Harmonized European Standards CE Marking Vs ISO 9000

26.2

Recommendations for reducing interference ........................................................... 4

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ELECTROMAGNETIC COMPATIBILITY

26.1

REGULATIONS

26.1.1

General

1

Ensuring electrical components, equipment and systems supplied are safe and does not interfere with the normal operation of other equipment is the basis for Electromagnetic Compatibility regulation.

2

Low Voltage Directive 73/23/EEC; shall apply to electrical equipment designed for use at a rated voltage of 50 to 1000 V for alternating current and 75 to 1500 V for direct current. Rated voltage shall refer to the input or output voltage of the equipment and not voltages which are generated internally.

3

The electrotechnical product shall also meet the requirements of other applicable directives in addition to the Low Voltage Directives. The compliance of individual components with the requirements of appropriate European Norms (EN) does not imply compliance of the end product. End product testing ensures that interconnections as well as manufactured CE marked components are performing to what is formally stated in their declaration of conformity.

26.1.2

EMC: Electromagnetic Compatibility

1

EMC is the ability of different items of electrical equipment to work together without suffering the effects of interference. All equipment shall operate without interfering with broadcast and communications signals and be immune to normal levels of such signals.

2

EMC implies that equipment shall not generate unacceptable levels of interference, which affect the performance of other products designed to operate in the same environment. Also, equipment shall have sufficient immunity to electrical interference, such that the equipment continues to operate in an acceptable manner.

3

The contractor shall submit a certificate issued by the manufacturer that the electrical equipment's supplied against the contract under execution complies with the requirements of the EMC Directive.

26.1.3

The CE Marking

1

All electrical products shall have CE Marking as an EU recognised certification mark that confirms the product has been tested and complies with the European Union Electromagnetic Compatibility Directive and other relevant directives, standards or norms.

26.1.4

EMC Directive and Standards

1

The electrotechnical products shall be designed and constructed that do not cause excessive electromagnetic interference and are not duly affected by electromagnetic interference. Electrical products shall carry a CE mark and manufacturers 'Declaration of Conformity'.

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There are four generic standards: (a)

EN 50081-1 1992 EMC - Generic emission standard - Part 1. Residential commercial and light industry.

(b)

EN 50081-2 1993 EMC - Generic emission standard - Part 2. Industrial environment.

(c)

EN 50082-1 1997 EMC - Generic immunity standard - Part 1. Residential commercial and light industry.

(d)

EN 61000-6-2 1999 EMC - Part 6-2: Generic standards - Immunity for Industrial Environments.

EU Product Directives

1

The EU product directives deal with large families of products or horizontal risks such as those addressed in the Electromagnetic Compatibility Directive. The manufacturer and exporter are responsible for ensuring the product meets the requirements for all applicable directives.

2

The following directives (with the reference between brackets) have been adopted:

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26.1.5

low voltage (73/23/EEC)

(b)

simple pressure vessels (87/404/EEC)

(c)

safety of toys (87/378/EEC)

(d)

construction products (89/106/EEC)

(e)

electromagnetic compatibility (EMC) (89/336/EEC)

(f)

machine safety (89/392/EEC)

(g)

personal protection equipment (89/686/EEC)

(h)

new hot-water boilers (92/42/EEC)

(i)

gas appliances (90/396/EEC)

(j)

explosives for civil uses (93/15/EEC)

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recreational craft (94/25/EC) non-automatic weighing machines (90/384/EEC)

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(a)

(m)

active implantable medical devices (90/385/EEC)

(n)

equipment for explosive atmospheres (94/9/EEC)

(o)

telecommunications terminal equipment (91/263/EEC)

3

Most of the above-mentioned directives are amended by Directive 93/68/EEC, "Rules for the Affixing and Use of the CE Conformity Marking."

26.1.6

Harmonized European Standards

1

EU product directives are limited to essential safety, health or other performance requirements in the general public interest. The technical details of how to meet these requirements are to be certified by the three regional European standards organisations, CEN, CENELEC, ETSI, and government appointed product certification bodies.

QCS 2014


Page 4

Products that meet the essential technical standards developed by CEN, CENELEC and ETSI are presumed to conform to the requirements of EU directives

3

For many products, however, a manufacturer can choose not to comply with CEN, CENELEC, ETSI standards, but must then demonstrate that the product meets the essential safety and performance requirements of the directives.

26.1.7

CE Marking Vs ISO 9000

1

Manufacturer having a quality management certificate that demonstrates an efficient organisational confirming low failure rate shall not be acceptable as a substitute to CE marking.

2

The quality system makes no reference to the quality of the product. The quality certificate is only a recommendation for customers that their order will be processed correctly and on time.

3

The CE marking indicates that the product complies with the essential requirements relating to safety, health, environment and consumer protection of the user.

4

Some directives explicitly make use of a quality management system (ISO 9000) as part of the conformity assessment. If a manufacturer wishes to provide the customer with assurance about the functional quality of the product, the manufacturer can then obtain a voluntary quality inspection mark that guarantees the products conform to safety and functional requirements over the long term.

26.2

RECOMMENDATIONS FOR REDUCING INTERFERENCE

1

The contractor shall exercise the manufacturer's recommendation for reducing interference. Following is basic guidelines for ready reference that helps reduce radiated interference by screening of the equipment and cables. The conducted interference can be reduced by filtering of the mains supply.

separate power cables and signal cables from each other and from different equipment

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(c)

shield the mains cable to the welding equipment if any

(d)

apply earthing and equipotential bonding to the welding installation

(e)

connect the equipment to a separate mains supply spur or using a different phase

(f)

physically separate welding equipment from other equipment

(g)

weld at times, which cause minimum disruption. END OF PART

QCS 2014

Section 21: Electrical Works Part 27: Battery and Battery Charger

Page 1

27

BATTERY AND BATTERY CHARGER ......................................................... 2

27.1

GENERAL ...................................................................................................... 2

27.1.1 27.1.2 27.1.3 27.1.4


27.2

PRODUCTS ................................................................................................... 3

2 2 2 2

27.2.1 General 27.2.2 Batteries 27.2.3 Battery Chargers

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QUALITY CONTROL AND TEST PROCEDURES ........................................ 5

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3 3 3

27.4

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27.3.1 General

5

ENVIRONMENT ............................................................................................ 5

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27

BATTERY AND BATTERY CHARGER

27.1

GENERAL

27.1.1

Scope

1

This Part specifies the requirements for battery and battery charger.

2

Related Parts and Sections are as follows: This Section Part 2 Part 3 Part 6 Part 7 Part 8 Part 9 Part 10

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FBA Protective Devices Cables and small wiring Conduits Trunking Cable Trays Accessories and General Power

Description

1

A single battery and battery charger shall be provided for each FBA of motor control centre, control desk or control panel.

27.1.3

References

1


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27.1.2

EIC 157 ......................Low Voltage Switchgear and Control gear

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EIC 158 ......................Low Voltage Control gear Submissions

1

Submissions shall be in accordance with Part 1 of this Section and Part 7 of Section 1.

2

Shop Drawings submission shall include dimensional drawings of the battery and battery charger, including sections and elevations, showing the following: sizes and positions of components

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(b)


(c)


(d)

Internal wiring diagram

(e)

Power and control diagrams

(f)

External connection drawings

(g)

Component parts lists

(h)

Other pertinent data.

(i)

Spare parts list

Submission of project data shall be as follows: (a)


(b)


QCS 2014


(c)

Detailed battery and battery charger size calculation

(d)


Page 3

PRODUCTS

27.2.1

General

1

The batteries and chargers shall be used as back-up power source for uninterruptible and bumpless operation of controls, instrumentation, alarm and monitoring equipment, but not for switchgear tripping/closing or other special function batteries.

2

Where alternate a.c. supplies are available, provide for taking the supply to the battery charger from either source (e.g. from either side of the bus-section switch) with facilities for automatic changeover from one source to the other in the event of failure of the supply system.

3

The battery and charger unit shall be housed in the common control section of the MCC provided that the battery is of the sealed type and shall not release any corrosive media. If the battery is not sealed it shall be mounted in a separate compartment.

4

A separate sheet steel floor standing cubicle having adequate ventilation and separate compartments for the batteries (lower compartment) and chargers (upper compartment) with associated control and protection devices and accessories may be used as a stand-alone unit for large capacities where it is difficult to accommodate within a dedicated section of the MCC and in case of all other applications wherever specified.

5

When used as a stand-alone unit, the access to the batteries shall be via lockable, hinged doors, and to the chargers via removable covers.

6

Batteries and charger units shall be suitable for the intended service under the prevailing climate and environments conditions and Tropical use.

7

Unless specified elsewhere the, the battery charger shall confirm to the specification herein.

8

Form 4 panels when equipped with battery and charger shall be provided with fully segregated/shrouded arrangement for the batteries within the cubicle, ensuring proper ventilation. Alternatively batteries may be located in a separate enclosure installed within the close proximity of the control panel.

27.2.2

Batteries

1

Nickel Cadmium sealed batteries shall be used confirming to BS EN 60623.

2

The batteries shall be maintenance free long life Nickel Cadmium sealed type with a nominal output of 24 volts, and shall be of adequate capacity to maintain full operation of the relevant load equipment’s’ plus an additional 20 per cent, for a period of 8 hours during mains failure, assuming a normal charge condition at the start of the mains failure.

3

All batteries shall be protected from mechanical damage and any accidental electric shorting. All batteries shall be supplied in banks sized for easy handling, and all interconnections shall be included. Batteries shall not be housed above charger units or any other equipment and shall be so ventilated that gases do not permeate into adjacent equipment.

27.2.3

Battery Chargers

1

Battery Chargers shall confirm to BS EN 60146-1.

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Page 4

Battery chargers complete with associated controls shall be provided and mounted on its own chassis and housed in one of the section of the FBA, stand-alone panel or in a separate enclosure as applicable. (a)

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The front panel for each charger unit shall include:1 No. “ON/OFF” Mains switch 1 No. Lamp to indicate “A.C. Supply On” (white) 1 No. Charger Ammeter 1 No. Lamp to indicate “Boost Charge” (Red) 1 No. Lamp to indicate “Float Charge” (White) 1 No. Lamp to indicate “Charger Failed” (Amber) 1 No. Lamp test push button Each charger unit shall also be provided with:1 No. “Float/Boost” selector switch, mounted internally 1 No. Set of a.c. supply fuses 1 No. volt-free contact for charger failed alarm 1 No. volt-free contact for low d.c. output voltage alarm 1 No. volt free contact for loss of d.c. output voltage alarm

.

2


The chargers shall protect the batteries from deep discharge and over charging.

4

Volt free contacts shall operate in fail-safe mode and be wired to terminal block.

5

The Charger unit shall also be equipped with the following:-

6

1 No. DC output voltmeter, scaled to indicate regions of “Low”, “Normal” and “High” output voltages, by the use of different colored sectors.

7

1 No. D.C. output switch

8

1 No. D.C. output Ammeter

9

The charger unit shall also be provided with one set of full capacity rated output d.c. terminals and fuses.

10

In the event of failure of the charger, the batteries shall ensure operation of controls, instrumentation, alarm and monitoring equipment for at least 6 hours. A separate relay contact shall be provided to indicate “Critical Alarm Condition – Charger Fail".

11

The chargers shall be of the constant potential type, and shall be designed to regulate the charger output voltage to within +/- 1 percent.

12

A suitable means shall be provided to the approval of Engineer to protect the batteries from deep discharge. Alarm shall be provided for this condition.

13

The D.C. terminal voltage shall be regulated such that under “Float” or “Boost” charge condition the DC voltage does not rise to more than 10 percent above the nominal.

14

The charger unit shall also be provided with both short circuit and reverse polarity functions.

15

The charger when selected to “Float” shall be capable of restoring the battery to 75 percent capacity within 7 - 8 hours.

16

Under “Boost” condition the charger shall be capable of restoring a fully discharged battery to 75 percent capacity within 4 - 5 hours.

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Page 5

Fix inside the cubicle a wiring diagram indicating and identifying all outgoing terminals, components and fuses, and also a warning label in Arabic and English giving maintenance and safety instructions.

18

The Battery Charger shall be connected to PLC/SCADA control room and all the information’s available in the charger shall be transmitted to SCADA for battery chargers larger than 50 KW.

27.3

QUALITY CONTROL AND TEST PROCEDURES

27.3.1

General

1

The manufacturer shall provide proof of a stringent Quality Control Program or Inspection Test Plan (ITP). In particular the main equipment manufacturing stages sanctioned by appropriate tests such as: incoming components inspection, discrete sub-assembly tests and complete functional checks on the final product. Equipment shall undergo on-load burn-in leaving the factory. Final inspection and calibration operations shall be documented in a report drawn up by the supplier’s Quality Inspection department and/or qualified Third Party Agency (TPA).

2

Complete charge and discharge tests on each battery and combined battery and charger shall be conducted and results recorded so as to permit verification of the ampere-hour capacity of the battery. During these tests five reference cells shall be selected at random and the voltage curves thereof shall be checked when the battery is discharged over three and ten hour periods. The automatic control feature of the charger shall be demonstrated over the specified load range.

3

The integrated functional test shall be conducted at manufacturer’s works to ensure satisfactorily functioning of the equipment.

4


27.4

ENVIRONMENT

27.4.1

General

1

Environmental conditions shall be in accordance with Section 1 Part 1 unless specified herein.

2

Minimum ambient temperature shall be 0C.

3

Maximum relative humidity shall be 95%.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 28: Small Enclosures

Page 1

28

SMALL ENCLOSURES ................................................................................. 2

28.1

GENERAL ...................................................................................................... 2

28.1.1 28.1.2 28.1.3 28.1.4


28.2

PRODUCTS ................................................................................................... 3

28.2.1 28.2.2 28.2.3 28.2.4 28.2.5 28.2.6

General Hinged Cover Enclosures for use Indoors Cabinets and Junction Boxes for use Indoors Terminal Blocks Weatherproof Cabinets for use Outdoors Small outdoor Enclosures for Pushbutton Stations, Local Isolators, Local Starter or Control Gear etc.

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Environment ................................................................................................... 7

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28.5

3 3 4 4 4

INSTALLATION ............................................................................................. 6

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2 2 2 2

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Page 2

28

SMALL ENCLOSURES

28.1

GENERAL

28.1.1

Scope

1

This Part specifies the requirements for small enclosures.

2


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FBA Protective Devices Cables and small wiring Conduits Trunking Cable Trays Accessories and General Power

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This Section Part 2 Part 3 Part 6 Part 7 Part 8 Part 9 Part 10 Description

1

The use of small enclosures, cabinets and junction boxes shall be limited to enclosing terminal blocks and low voltage (not exceeding 415 Volts) electrical field devices e.g. transmitters, sensors, switches, sockets, local starters and control stations, etc. excluding main motor control and switchgear.

28.1.3

References

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28.1.2

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BS 6220 .....................Junction Boxes

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BS 7671, ....................Requirements for Electrical Installations NEMA 250

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IEE, UK., BS EN 60947-4-1

NFPA 70 - ..................National Electrical Code, U.S.A

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...................................or other approved equivalent standards as applicable. 28.1.4

Submissions

1


2

Shop Drawings submission shall include dimensional drawings of the battery and battery charger, including sections and elevations, showing the following: (a)


(b)


(c)


(d)

other pertinent data.

(e)

Component part list

(f)

Single line diagram

(g)

Three line diagram

QCS 2014

3


(h)

Wiring diagram

(i)

Spare parts list

Page 3



(b)


(c)


PRODUCTS

28.2.1

General

1

The specification shall be in accordance with latest edition of local and International regulations e.g QGEWC.

2

The product selected and proposed shall include manufacturer's Instructions that Indicate application conditions and limitations of use stipulated by Product testing agency specified under Regulatory Requirements.

3

The Contractor shall select the product only from manufacturer’s specializing in manufacturing products specified in this Part with minimum five years documented experience of the products being satisfactorily in use in a similar service and climatic conditions.

4

The Contractor shall ensure proper co-ordination with related civil and other project associated activities prior to the selection of the equipment.

5

The Contractor shall clearly show locations and fixing arrangements on the drawings.

6

IP ratings are based on short laboratory tests and are not an indication of an enclosure’s suitability for use outdoors or in a harsh environment. All such enclosures need considerable interpretation for each installation.

7

Any enclosure installed in the wet well of a pumping station or in any area where the change of flooding exists shall be rated for IP68 classification.

8

Any enclosure installed the wet well of a pumping station shall be rated for Zone 2 hazardous area classification.

28.2.2

Hinged Cover Enclosures for use Indoors

1

Construction: Galvanized steel with minimum sheet steel thickness of 2 mm with panel fronts of thickness 2.0 mm minimum.

2

Covers: Lift-off hinge held closed by lockable T type handles. Doors shall close on to neoprene or soft rubber sealing strips held in place mechanically.

3

Provide interior metal panel for mounting terminal blocks and electrical components; finish with white enamel.

4

Enclosure Finish: Green to BS 4800, shade 14E53.

5

Enclosure Protection: Dust and vermin proof. Environmental protection to IP 54 or as applicable depending on the application.

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Page 4

Cabinets and Junction Boxes for use Indoors

1

Boxes: Galvanized steel with minimum sheet steel thickness of 2 mm with panel fronts of thickness 2.0 mm minimum.

2

Box Size: To suit equipment requirements.

3

Provide interior metal panels for mounting terminal blocks and electrical components; finish with white enamel.

4

Fronts: Lift-off hinge held closed by lockable T type handles. Doors shall close on to neoprene or soft rubber sealing strips held in place mechanically.

5

Junction boxes enclosing small quantity of terminals with bolted cover shall however be permitted to be used as per the approval of the Engineer.

6

Glandplates shall be provided to suit cable, conduit and circuiting arrangements.

7

Provide metal barriers to form separate compartments wiring of different systems and voltages.

8

Provide accessory feet, pedestal or pillar for free-standing equipment.

9

Enclosure Finish: Green to BS 4800, shade 14E53.

10

Enclosure Protection: Dust and vermin proof. Environmental protection to IP 54 or as applicable depending on the application.

28.2.4

Terminal Blocks

1

Terminal Blocks: IEC 947-7-1 or BS EN 60947-7-1: Terminal blocks for copper conductors.

2

Power Terminals: Unit construction type with closed back and tubular pressure screw connectors, rated 600 volts.

3

Signal and Control Terminals: Modular construction type, suitable for channel mounting, with tubular pressure screw connectors, rated 600 volts.

4

Provide earth bus terminal block, with each connector bonded to the enclosure.

5

Special terminals e.g. disconnect type, diode type, bridging type, fuse type etc. according to the applications requirements or as directed by the Engineer shall be provided.

6

All terminal assemblies shall be provided with dividers as necessary and end plates. Where included in the manufacturers’ inventory, locking wire shall be installed on every terminal assembly.

28.2.5

Weatherproof Cabinets for use Outdoors

1

Weatherproof cabinets shall be provided for all electrical, control, instrumentation, distribution, etc. equipment which is to be used externally.

2

Outdoor equipment shall be weatherproof and designed to prevent the collection of water at any point. Metal to metal joints will not be permitted and all external bolts or screws shall be provided with blind tapped holes where a through hole would permit the ingress of moisture. The insides of outdoor cubicles shall be coated with an approved anti-condensation finish.

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28.2.3

QCS 2014


Page 5

Confirmation must be provided from the manufacturer of any equipment intended for use outdoor that the equipment is suitable for use outdoors in the local climatic conditions, in situations where minor accidental damage, e.g. chipping, is likely to occur.

4

All kiosks and cubicles shall be fitted with door operated internal lights and shall be ventilated.

5

All instrumentation and control cubicles, kiosks etc. designed for use outside shall be manufactured having walls of double skinned, resin bonded fibreglass, with a totally encapsulated infill of rigid weather and "boil" proof plywood to DD ENV 12038 between the two skins.

6

The roof section shall have a totally encapsulated infill of end grain balsa instead of plywood. The end grain balsa shall have a minimum thickness of 18mm.

7

They shall be fully wind, dust and water tight and suitable for the prevailing climatic conditions and be of robust vandal proof construction.

8

The cabinets shall have a single door or two or more hinged non-overlapping doors fitted with a double locking bar, with a waterproof lever handle and cylindrical lock. Doors shall have an all round channel recessed gasket of non-fatigue, oil and age resistant material. Hinges shall be strong, smooth action and non-corrodable which allow the door to be easily removed. Doors shall be fitted with a suitable fixing bar to hold in the open position.

9

Box section steel shall be encapsulated into door edges and door frames.

10

All door catches and locks shall latch onto steel reinforced surfaces. The door sill shall be protected by a non-corroding alloy material.

11

Door mounted meters and transparent windows shall be of wired glass, which shall be protected from harmful direct sunshine by orientation or other approved means.

12

The cabinet shall be stiffened and/or reinforced when required for additional rigidity.

13

The cabinet shall have an easily removable rear mounting plate on moulded spacers.

14

All internal equipment shall be mounted on supports built into the fiberglass structure. Fixing bolts through the skin will not be accepted.

15

If required by the internal components, encapsulated thermal insulation shall be included.

16

The laminate material shall have flame retardant characteristics in compliance with BS 476 Part 7 Class 2, and shall retain "stability, integrity and insulation" for 30 min. when tested in accordance with BS 476 Part 8. An indicative fire test report shall be provided with the tender.

17

Colour impregnated gel coats backed by coloured resin shall be used to ensure maintenance free and "colour fast" finishes.

18

The cabinet shall be light grey in colour. The finish shall be colour fast and maintenance free.

19

The cabinet shall be constructed to provide environmental protection to IP 55.

20

The cabinet shall have a suitable shade canopy.

21

Ventilation via louvres with efficient sand traps and vermin screens will be permitted.

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Page 6

The cabinet shall be floor mounted suitable for bolting down to a concrete base.

23

The locking arrangement shall be suitable for the Master Lock & Key System used by the Employer.

28.2.6

Small outdoor Enclosures for Pushbutton Stations, Local Isolators, Local Starter or Control Gear etc.

1

All push button stations for use outdoors shall be of cast alloy, galvanised iron or stainless steel, heavy duty construction, specifically made for outdoor use and certified by the manufacturer as weatherproof.

2

Stop push buttons shall be of the auto-latch turn-to-release type. Push buttons shall not be prone to U.V. degradation.

3

Clearly visible legend plates to indicate the motor controlled shall be fitted at each push button or control station.

4

Isolator enclosures shall be of similar construction, lockable in the off position and fitted with auxiliary contacts for alarm purposes.

5

A robust factory manufactured and galvanised steel or stainless steel floor standing support shall be supplied and fixed for mounting the enclosure at a convenient height. These shall be pipe mounted with cabling running up inside the pipe, to protect the cables from mechanical damage and sun or fabricated from substantial angle iron and channel. Enclosures shall not be attached to handrailing. Under no circumstances shall enclosures be mounted on channel type supports of the unistrut type. Unistrut will not be accepted as any part of a welded support.

6

Where enclosures are installed in direct sunlight sunshades of an approved design shall be provided.

7

Hinged doors shall have a rain trap all round the opening and enclosures shall be fitted with a separate weather protection canopy.

8

Under no circumstances will painted sheet steel enclosures or enclosures with knock-outs for conduit or glandplates be acceptable for use outdoors unless they are mounted inside a heavy duty GRP enclosure and weather canopy.

28.3

INSTALLATION

28.3.1

General

1

Install in accordance with NECA "Standard of Installation" and other standards as directed by the Engineer.

2

Remove dirt and debris from enclosure

3

Install enclosures and boxes plumb. Anchor securely to wall and structural supports at each corner under the provisions of Section "supporting Devices".

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Page 7


28.4.1

General

1

The manufacturer shall provide proof of a stringent Quality Control (QC) plan or Inspection Test Plan (ITP). In particular the main equipment manufacturing stages sanctioned by appropriate tests such as: incoming components inspection, discrete sub-assembly tests and complete functional checks on the final product. Final inspection and calibration operations shall be documented in a report drawn up by the supplier’s Quality Inspection department.

2


3


28.5

ENVIRONMENT

28.5.1

General

1


2


3


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END OF PART

QCS 2014

Section 21: Electrical Works Part 29: Underfloor Ducts

Page 1

29

UNDERFLOOR DUCTS ................................................................................ 2

29.1

GENERAL ...................................................................................................... 2

29.1.1 29.1.2 29.1.3 29.1.4


29.2

PRODUCTS ................................................................................................... 2

29.2.1 29.2.2 29.2.3 29.2.4

General Underfloor Ducts Trench Ducts Service Fittings

29.3

INSTALLATION ............................................................................................. 5

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2 3 4 4

6

ENVIRONMENT ............................................................................................ 7

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29

UNDERFLOOR DUCTS

29.1

GENERAL

29.1.1

Scope

1

This Part specifies the requirements for underfloor ducts.

2

Related Parts and Sections are as follows: This Section Part 6 Part 7 Part 8 Part 9 Part 10

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Cables and small wiring Conduits Trunking Cable Trays Accessories and General Power

Description

1

Underfloor ducts shall be provided as specified and shown on the drawings.

29.1.3

References

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29.1.2

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1


2

Shop Drawings submission shall include dimensional drawings, including sections and elevations, showing the following: sizes and positions of components

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(b)


(c)




(b)


29.2

PRODUCTS

29.2.1

General

1

Underfloor ducts shall confirm to requirements as specified in BS 7671, NFPA 70 - National Electrical Code, U.S.A or other equivalent standard as applicable.

QCS 2014


Page 3

Underfloor duct specification shall be in accordance with QGEWC regulations and IEE latest edition as applicable.

3

The product selected and proposed shall include manufacturer's instructions that indicate application conditions and limitations of use stipulated by the product testing agency specified under Regulatory Requirements.

4

The contractor shall select the product only from a manufacturer specializing in manufacturing products specified in this Part with minimum five years documented experience of the products being satisfactorily in use in a similar service and climatic conditions.

5

The contractor shall ensure proper co-ordination with related civil activities prior to the selection of the equipment.

6

The contractor shall clearly show locations of ducts, service fittings, junction boxes, and branch circuiting arrangements on the drawings

29.2.2

Underfloor Ducts

1

Sheet metal raceway shall be designed to be embedded in concrete slab.

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concealed underfloor duct - Type of underfloor duct, which has concrete topping over cover, which shall have inserts for installation of service fittings.

(b)

flush duct - Type of underfloor duct, which has cover, installed flush with concrete slab. Cover shall have openings for installation of service fittings

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Steel duct shall be provided with a corrosion-resistant finish.

3

The ducting shall be Underfloor or Flush as specified

4

Configuration of the ducting shall be one or two level systems as specified using ducts in parallel runs as shown on Drawings.

5

Services shall include, 240 volt power - standard size, telephone - extra width size, computer data - extra width size, 415 volt power - standard or extra width size as specified.

6

Underfloor ducting shall be selected from the standard range of the manufacturer. The nominal size shall be 38 x 76 mm or as specified.

7

Underfloor ducting where required for larger width application shall be 38 x 152 mm or as specified.

8

Fabricate distribution lengths with standard height preset inserts on 610 mm centers or provide precut 32 mm diameter holes on 610 mm centers as specified. Close with flat metal screw plugs.

9

Rectangular or round cover and trim single level junction boxes or as specified with adjustable height shall be used. Provide internal barriers, conduit and duct entrances, and extension rings as required.

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10

Rectangular or round cover and trim Two Level Junction Boxes or as specified with adjustable height shall be used. Provide separate enclosures for each service to allow feeder ducts to cross under distribution ducts. Provide conduit and duct entrances and extension rings as required.

11

Junction Box Cover Plate shall conform to one of the following as specified: (a)

tile trim plate flush with finished floor.

(b)

smooth cover plate flush with concrete floor

(c)

carpet trim holders of proper depth.

Supports shall be adjustable type and to be adjusted before concrete topping placement.

13

Service Fittings shall be provided in conjunction with wiring devices.

14

Duct Markers shall be corrosion resistant marker screws, with escutcheon.

15

Manufacturer's standard range of fittings and accessories shall be used as much as is practically as possible.

29.2.3

Trench Ducts

1

Underfloor raceway where specified shall be provided with a removable cover flush with the concrete slab.

2

Steel trench duct shall be provided with corrosion resistant finish. The duct shall be of closed or open bottom type as specified

3

The duct sizes shall be as specified or indicated on the Drawings.

4

Provide adjustable compartment dividers.

5

Supports shall be adjustable type and to be adjusted before and after concrete topping placement.

6

Coverplates shall conform to one of the following as specified:

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(a)

6.4 mm thick steel removable Coverplates with gasket joints

(b)

smooth cover plate flush with concrete floor

(c)

recessed coverplate with tile trim.

7

Manufacturer's standard range of fittings and accessories shall be used as much as is practically as possible.

29.2.4

Service Fittings

1

Pedestal Convenience Receptacle shall have satin aluminum housing with stainless steel device plate in one duplex, two duplex or back to back configurations or as specified.

2

Flush Cover Convenience Receptacle shall be of aluminum or brass in duplex with flap or threaded opening or as specified.

QCS 2014


Page 5

Pedestal Communication Outlet shall have satin aluminum housing with stainless steel device plate having One bushed opening 25 mm inside diameter or as specified.

4

Flush Cover Communication Outlet shall be of aluminum or brass with stainless steel device plate having 54 x 25-mm combination threaded opening or as specified.

5

Pedestal Communication Fitting shall have satin aluminum housing with stainless steel device plate having one duplex convenience receptacle with one bushed opening, 25 mm inside diameter or as specified.

6

Flush Cover Communication Fitting shall be of aluminum or brass with stainless steel device plate having 54 x 25-mm combination threaded opening or as specified.

29.3

INSTALLATION

29.3.1

General

1

Install Products in accordance with the manufacturer's instructions.

2

Locate duct in structural slab or concrete topping as specified.

3

Provide expansion fittings with suitable bonding jumper where duct crosses building expansion joints.

4

Terminate ducts for power service in bottom of panelboard or wireway as specified using suitable fittings. Terminate in junction box for extension of conduit to panel board where specified. .

5

Terminate ducts for telephone service 50 mm above floor in telephone closet or in bottom of telephone cabinet using suitable fittings as specified.

6

Terminate ducts for data services in bottom of data services cabinet using suitable fittings.

7

Level cover plates flush with finished concrete floor.

8

Place rectangular plates square with wall lines.

9

Securely hold junction boxes and ducts in place during installation to avoid floating or other movement.

10

Close unused duct or conduit entrances to junction boxes. Seal duct terminations at junction boxes.

11

Earth and bond duct under provisions of Part "Earthing and Bonding".

12

Install underfloor duct with tops of preset inserts as specified or indicated on the Drawings below finished floor line. Locate ducts on centers as specified or as indicated on Drawings.

13

Install flush duct flush with finished floor.

14

Place schedule on the inside of coverplate of each junction box indicating distance to first insert in each direction, measured from the center of the box. Use self-adhesive labels for schedule.

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Page 6

Use blank duct in permanent corridors, passages, lobbies, for connecting parallel ducts less than 1.8 m apart, for feeder duct from cabinet or panelboard to first junction box, and where indicated.

16

Join duct lengths using combination support couplers where practical. Provide additional supports at intervals of not over 1.5 m, within 750 mm each side of junction boxes, and as close as practical to elbows, bends, and terminations.

17

Install insert within 30 mm of edge of junction box. Align inserts on same centers for all services.

18

Do not extend inserts into special floor finishes, such as terrazzo, marble, or wood.

19

Install a duct marker in each insert adjacent to junction box, at end of each duct run, on both sides of permanent partitions, and on both sides of change of direction of duct. Install markers flush with finished floor material. In carpeted areas, install marker screws level with carpet backing.

20

Install surface service fittings after installation of floor finishes. Cut floors as necessary, following duct manufacturer's recommendations. Replace damaged floor construction and finish.

21

Install trench duct trims flush with coverplates. Maintain covering of factory-applied tape for protection.

22

Terminate ducts for X-ray circuits at wall; interface with wall duct provided under Part "Surface Raceway Trunking".

23

Clean ducts and fittings of debris and dust before installing wire and cable.

24

Pull wire and cable from outlet insert toward junction boxes.

25

Install branch circuit conductors continuous between junction box and farthest fitting. Do not cut conductor to make connections to receptacle devices.

26

Clean finished surfaces before and after the installation in accordance with manufacturer's instructions.

29.4


29.4.1

General

1

The manufacturer shall provide proof of a stringent Quality Control (QC) Plan or Inspection Test Plan (ITP). In particular the main equipment manufacturing stages sanctioned by appropriate tests such as: incoming components inspection, discrete sub-assembly tests and complete functional checks on the final product. Final inspection and calibration operations shall be documented in a report drawn up by the supplier’s Quality Inspection department.

2


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29.5

ENVIRONMENT

29.5.1

General

1


2


3


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END OF PART

QCS 2014

Section 21: Electrical Works Part 03: Protective Devices

Page 1

3

PROTECTIVE DEVICES ............................................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7

Scope General Reference Ratings Standards Overcurrent Protective Device Co-ordination Quality Assurance Manufacturers

3.2

PRODUCTS ................................................................................................... 3

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.2.12 3.2.13 3.2.14 3.2.15 3.2.16 3.2.17 3.2.18

Air Circuit Breakers Moulded Case Circuit Breakers Miniature Circuit Breakers MCB/ELCB Earth Leakage Circuit Breakers (ELCB) Overload Relays Fuses Fuse Switches Isolating Switches Stop Lock-off Push Buttons Control Relays/Auxiliary Relays/Interposing Relays Protection Relays Alarm System Padlocks Hours Run Meters Thermistor relay Moisture and mechanical seal leakage protection Timers

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2 2 2 2 2 3 3 3 6 7 7 7 8 10 11 12 12 12 13 13 14 14 14 15 15

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Page 2

PROTECTIVE DEVICES

3.1

GENERAL

3.1.1

Scope

1

This Part shall specify the requirements for protective devices.

3.1.2

General Reference

1

The work of this Part is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2


3.1.3

Ratings

1

The ratings of the various overcurrent protective devices shall be, in general, as indicated on the Project Drawings. However, the protective device ratings shall be confirmed based on the equipment and items being provided by the Contractor. Contractor shall provide calculation and justification for proposing any change in the rating.

3.1.4

Standards

1

The following standards shall be followed:

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BS EN 60255-6, IEC 255 Electrical relays

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BS EN 60269, IEC 269 Cartridge fuses for voltages up to and including 1000VAC and 1500 V AC BS EN 60898, IEC 157-1A

Miniature and Moulded Case Circuit Breakers

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BS EN 60947, IEC 947-2 Low Voltage circuit breakers BS EN 61008-1 ..........Earth Leakage circuit breakers

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BS EN 61810-1 ..........Electrical Relays BS88...........................

Cartridge fuses

3.1.5

Overcurrent Protective Device Co-ordination

1

The Contractor shall carry out and provide an overcurrent protective device. Co-ordination study as part of his material submission, as outlined below:

2

Properly co-ordinated automatically operated overcurrent protective devices shall be provided for this Project. The overcurrent protective devices shown on the Drawings shall be coordinated for adequate continuous current and interrupting capacity to assure proper overcurrent protective devices operation under normal and fault conditions in the system.

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Page 3

3

All overcurrent protective devices on this Project and the first upstream device of the existing electrical system shall be co-ordinated so that they will perform as follows. When two or more overcurrent protective devices (including the first upstream protective device of the existing system) in series with each other experience current flow greater than their rated current, the device with the lowest rated current shall trip and/or open the circuit first and thereby prevent the higher rated devices from operating.

4

The Supplier of the overcurrent protective devices shall prepare a co-ordination study to verify the above stated performance requirements. The study shall be documented by the Supplier and the documents shall include but not be limited to the following: a composite drawing or drawings (on full size, reproducible, log-log paper) showing the entire new electrical system (including the first upstream protective device of the existing system) showing all protective device curves (including motor overloads), short circuit duties, motor starting curves and damage curves for motors, equipment and conductors. This drawing or drawings shall show that all protective devices are properly co-ordinated to perform as stated above

(b)

manufacturer‟s overcurrent operating curves (on full size, reproducible, log-log paper) for each overcurrent device. In the case of fuses, both minimum melt and maximum clearing time curves shall be included

(c)

reproducible copies of all Project single line diagrams so marked to show short circuit duties at all switchboards and motor control centres, and which operating curve applies to each overcurrent device on the diagram (the operating curves shall also be correspondingly marked)

(d)

a tabulation of the short circuit duties at all switchboards and motor control centres, sizes and ratings of all overcurrent protective devices and the required settings of all of the adjustable overcurrent protective devices so that the performance requirements are met. Protective devices which have earth fault protection features are specifically required to meet this performance requirement.

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(a)

This documented co-ordination study shall be submitted for review before the overcurrent devices are supplied for the Project.

3.1.6

Quality Assurance

1

The suppliers manufacturing facility shall be certified to the ISO - 9001 series of standards from the International Standards Organisation.

3.1.7

Manufacturers

1

Preference will be given to one manufacturer of ACB, MCCB and MCB to ensure proper coordination in accordance with Clause 3.1 above.

3.2

PRODUCTS

3.2.1

Air Circuit Breakers

1

To IEC 947-2 or BS EN 60947-2, suitable for triple pole service and shall have breaking capacity of 50 kA symmetrical for 3 seconds at 415 Volts.

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ACBs shall be of the horizontal withdraw able, load making and breaking type with the contacts being of the double break pattern with arcing chutes, shutters etc. The main arcing contacts shall be of the high pressure butt type with wipe and roll action on opening and closing. The main contacts shall be of silver alloy.

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Page 4

Removable arc chutes shall be fitted together with an air circuit breaker. ACB shall be complete with a mechanical ON/OFF position indicator, pad-lockable. ACB shall conform to B.S. En 60947-2 (EN 60947-2, IEC 947-2) and B.S. En 60664-1. Each circuit breaker shall be enclosed in sheet steel and provided with three phase manual and automatic isolating devices suitably interlocked so as to prevent isolation except when the circuit breaker is in open position. It shall be arranged in such a manner that it will not be possible to withdraw the breaker or remove the front cover unless the ACB is in the isolated position. Provision shall be made for locking the ACB in this position (isolated position).

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Shutters shall be provided to protect the live terminals against accidental touch when the ACBs are in a fully withdraw able position. The ACB shall have solid sate overload and short circuit protection devices along with earth fault trip mechanism. The solid state circuit shall be provided with proper LED indication to indicate the trip status of the ACB. The ACBs shall be equipped with shunt trip of 30V DC trip mechanism for tripping the breaker with restrictive earth fault relay to be provided separately with suitable size of CTs. The Air Circuit Breakers (the conventional type and not moulded case circuit breaker) shall be 500 V, 50 Hz, triple pole with neutral link for incoming and outgoing ACB or four poles for bus tie ACB only with ratings as shown on the Drawings. They shall be air break, trip free, draw-out type with mechanical and electrical ON/OFF indicators.

3

Where air circuit breakers are to be electrically operated by automatic motor wound spring mechanism, a standby manual operating handle shall be provided for operating the circuit breaker in case of power or motor failure.

4

The air circuit breaker shall be provided with built-in overcurrent, short circuit and Earth fault protection having the following characteristics:adjustable long time delay current setting between 50 – 200% with variable tripping time characteristics.

(b)

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instantaneous tripping for heavier over current applications adjustable from 400 – 1600% of the base current.

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(c)

adjustable short time delay current setting 200 – 800% with variable tripping time characteristics.

(d)

adjustable earth fault trip current setting 20 – 80% with variable tripping time characteristics.

5

The circuit breaker shall have three position on the draw-out mechanism, namely service position where all main and auxiliary contacts are made, test position where main contacts are open but auxiliary contacts are closed and isolated position where all contacts are open. An indicator shall clearly show these positions and provisions shall be made for locking the breakers in any position. ON/OFF indicator shall be provided.

6

Mechanical Interlocks shall be provided to prevent withdrawing or inserting of the breaker when it is „ON‟. Any attempt to do so shall trip the breaker automatically.

7

The withdrawable part of the circuit breaker shall be effectively connected to earth through scraping contacts that shall make before and break after the main and auxiliary contacts.

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Page 5

8

The moving contacts comprising the main and arcing contacts shall be of the spring loaded, self aligning type. The arc contacts shall be arranged to make before and break after the main contacts.

9

The air circuit breaker shall include but not limited to the following as minimum:8NO/8NC auxiliary contacts

(b)

arc chutes

(c)

folding extension rail

(d)

charging handle

(e)

open and close push buttons

(f)

trip indicator

(g)

spring charge motor

(h)

spring charge indicator

(i)

breaker position indicator mechanically and electrically.

(j)

micro-processor based protection and management unit that provides the following control and monitoring features:-

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overcurrent protection

(ii)

short circuit protection

(iii)

earth fault protection

(iv)

neutral protection

(v)

thermal memory

(vi)

alarm logging

(vii)

field selectable Manual or Auto reset

(viii)

microprocessor malfunction watch dog

(ix)

programmable input/outputs

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load monitoring

(xi)

operation counter

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(x)

(xii)

serial communication.

(k)

carriage/Lifting Truck for ACB exceeding 25 Kg in weight [One carriage for each site/project regardless of number of breakers provided

(l)

shunt trip and under voltage release

10

The Main Incoming Circuit Breakers shall be provided with cable terminal boxes to suit the incoming cables from the transformer/source supply. The gland plate for the incoming cables shall be non-ferrous material brass compression type glands, earthing tags and shrouds. In case single core PILCA/PVC cables are used, the clamping arrangement is to supplied as per the sketch nos. 9 & 10 shown on pages 144/145 of KAHRAMAA regulations.

11

Circuit breakers shall be tropicalised to operate continuously in an ambient temperature of 55 °C and high relative humidity.

12

Type test certificate for each size of circuit breakers and MCCB from an internationally recognised testing authority acceptable to the Engineer shall be provided.

QCS 2014

Page 6

The ACB shall have adjustable settings and the following facility: Long time current setting and tripping delay.

(b)

Overload signal.

(c)

Short time pick up and tripping delay.

(d)

Instantaneous pick-up.

(e)

Earth leakage test button.

(f)

Long time rating plug screw.

(g)

Test connector

(h)

Lamp test, reset and battery test.

(i)

Indication of tripping cause.

(j)

Digital display.

(k)

Three phase bar graph and power display.

(l)

Setting / programmable buttons.

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The ultimate breaking capacity (ICU) shall be minimum of 44KA. The rated service breaking capacity (ICS) and rated short time withstand current (ICW) shall be equal to or greater than ICU.

15

The ACB section of the switch board shall be in separate cubicle separated from other parts of the switch board. This section shall not have any outgoing feeders.

3.2.2

Moulded Case Circuit Breakers

1

Shall have a combination of thermal and magnetic tripping giving an inverse time delay protection against sustained overloads and instantaneous tripping under heavy overloads and short circuits. Unless otherwise stated in the particular specification or drawings, MCCB shall have a minimum short circuit rating of 25 kA.

2

Breakers shall have a quick make, quick break over-centre switching mechanism that is mechanically trip free from the handle so that contacts cannot be held closed against short circuits and abnormal current.

3

Tripping due to overload or short circuits shall be clearly indicated by the handle assuming a position mid-way between the manual ON and OFF position.

4

Latch surfaces shall be polished.

5

Poles shall be constructed to open, close and trip simultaneously.

6

Ampere ratings shall be clearly visible.

7

Breakers shall be completely enclosed in a moulded case to IEC No. 157 - 1A, suitable for installation inside switchboards.

8

Non-interchangeable trip breakers shall have the trip unit sealed.

9

Breakers with earth leakage relay protection shall be provided with shunt trips.

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Page 7

Frame sizes shall be as per manufacturer‟s standard size and as approved by the Engineer.

11

The magnetic trip shall be adjustable type for rating 200 Amp. and above, with 8 settings from 1.5 to 10 times the rated current of the circuit breaker.

12

Each MCCB shall be housed in a separate Compartment with the operating handle door interlocked when used as an Incomer, feeder or motor starter isolator, so that access can only be gained to the Compartment with the MCCB in the OFF position. Padlocking shall be provided in the OFF position only. When the MCCB is used for control transformers, distribution or ICA compartments the handle shall be internally mounted with appropriate shrouding and warning labels.

13

Each MCCB shall be complete with 2 N/O and 2 N/C spare auxiliary contacts (10A, 240v rating) in addition to those required for the Contract.

14

Each MCCB used as an Incomer or feeder shall have facilities for electrical as well as mechanical interlock.

15

All incoming circuit breakers shall be provided with electrical & mechanical interlocking scheme to ensure that only one incoming supply can be energized at any one time where more than one supply is available.

3.2.3

Miniature Circuit Breakers

1

These shall be type C for general purpose uses, suitable for the load they feed, and shall have short circuit rating of 9 kA, unless specified otherwise in the Project Documentation.

2

They shall be fault rated so that fuse backup protection is not required.

3

They shall be rated in accordance with BS EN 60898, IEC 898.

4

They shall include the following minimum features: (a)

magnetic and thermal trip elements

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locking of facilities with detachable proprietary brackets and clearly marked ratings.

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(c)

trip-free mechanisms

5

RCBO shall comply with BS EN 61008-1 & BS EN 61009-1

3.2.4

MCB/ELCB

1

Combined MCB/ELCB units shall be provided for final circuits supplying socket outlets, water heaters and water pumps.

2

The units shall have a trip sensitivity of 30 mA.

3.2.5

Earth Leakage Circuit Breakers (ELCB)

1

Current operated earth leakage circuit breakers shall provide accident protection by interrupting dangerous contact with voltage which may be present in faulty electrical equipment as a result of frame faults, insufficient insulation or misuse.

QCS 2014


Page 8

The ELCB shall also provide high degree of protection against earth leakage, fire and electric shock. It shall withstand at least 10 kA or as specified in the project documents. The breakers shall comply with BS EN 61008-1 and the recommended specification CEE 227 of the IEC on rules of approval of electrical equipment.

3

The breaker shall consist of a core balance transformer, a tripping coil with contact assembly, main supply contacts, ON/OFF switch, a test button and a trip free mechanism all enclosed in a robust body of all insulated material.

4

Degree of Protection against earth leakage throughout the electrical installation shall be as indicated on the Drawings. Unless otherwise indicated, ELCB shall have 30 mA trip settings.

5

The breaker protecting lighting and or power circuits shall be mounted in the panel board enclosure.

3.2.6

Overload Relays

1

Thermal Overload Relay

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thermal overload relay where specified shall be of Bi-metallic inverse time-lag type, which shall be used with a contactor in the starter circuit enabling switching device to open both control and power circuit (fully isolating the power to the motor terminal box) when the current in the relay exceeds a predetermined value.

(b)

the thermal overload relay shall fully comply with the requirement of BS EN 60255-8

(c)

the thermal overload relay shall be simple and robust suitable for direct contactor mounting or if to be mounted separately shall be used with manufacturer supplied links and associated attachment.

(d)

the thermal overload relay shall be designed to include ambient temperature compensation feature from – 20 Deg C to + 65 Deg C eliminating the need of any calibration in the field during operation.

(e)

the thermal overload relay shall provide the following protections:over-current/Overload

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single phasing/Phase failure

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(f)

the thermal overload relay shall have MAN/AUTO field convertible Reset button located on top of the relay for resetting of the relay after trip. Additionally a facility shall be provided on the door of starter compartment to reset the relay if so required/specified.

(g)

the thermal overload relay shall have two characteristics, the one when the relay bimetals are in cold state that will break the contacts of the relay within 8-10 seconds and the other when in hot state the contacts breaking shall be reduced to approximately one third of the tripping time as indicated for the cold characteristics. The tripping time may be allowed to vary depending upon the starting of the motor such as normal/heavy-duty.

(h)

the thermal overload relay shall have been type tested and ASTA certified to achieve Type 2 co-ordination in accordance with BS EN 60947.

(i)

thermal overload relays shall be used for motors rating up to and including 11 kW.

Electronic Motor Protection Relay (a)

General


Page 9

the Motor Protection shall be an intelligent electronic device that is user friendly and user configurable, capable of controlling the motor manually or automatic.

(ii)

EMPR shall be CE marked and confirm to BSEN 60947-1

(iii)

EMPR with LCD display shall be provided in the MCC for each sewage pump motor starter regardless of the rating of the pump and non-sewage pump drives above 11.0 KW. The LCD unit combined with function keys, minimum IP54, shall be mounted on the cubicle door

(iv)

non sewage pump drives upto 11.0 KW inclusive may be provided with ambient compensated bi-metal type thermal overload relay.

(v)

EMPR shall have built-in RS485 communication port utilizing Modbus RTU protocol for serial communication with other devices on the network.

(vi)

EMPR shall be supplied with software, user manual and interconnecting cables.

(vii)

EMPR shall be provided with user friendly software minimum windows 2000 based communication (fully supported by Latest Edition of Windows Based Operating System) program allowing easy access to all features with pull down menus.

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(i)

the protection features shall include the following as minimum:over load protection

(ii)

over current protection

(iii)

over voltage protection

(iv)

under voltage protection

(v)

under current protection

(vi)

phase sequence

(vii)

phase imbalance

(viii)

phase loss

(ix)

earth leakage

(x)

earth fault

(xi)

thermistor broken

(xii)

open contactor

(xiii)

locked rotor

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QCS 2014

(c)

motor current sensing shall be through external 5 A or 1 A current transformer. The following measured values shall be displayed on the LCD mounted on the starter compartment door. (i)

RMS current of each phase

(ii)

RMS voltage

(iii)

earth leakage current

(iv)

continuous monitoring of thermal capacity of the motor

(v)

thermal capacity used

(vi)

power factor of the motor

(vii)

motor kW

QCS 2014

Section 21: Electrical Works Part 03: Protective Devices (viii)

phase unbalance

(ix)

parameter settings

(x)

percentage of FLC of the motor

(xi)

adjustable delayed start/stop

(xii)

maintenance Log

Page 10

(d)

EMPR shall be capable of registering all trip commands and log trip and pre-trip metering values for reporting and printing purposes.

(e)

Programmable Ranges overload – shall be based on the calculation of accumulated I²t value and selected thermal capacity curve. The tripping time shall be 0-10 Sec. Adjustable.

(ii)

locked rotor – To trip the motor within 1 to 5 Sec. when the running current exceeds the stalled rotor trip level of 1.5 to 5.0 x FLC.

(iii)

phase unbalance – Should there be a phase current unbalance of greater than 15% lasting for 5 seconds an alarm shall be generated. If the condition prolonged for 10 seconds or more a trip shall occurs.

(iv)

earth fault – The earth fault shall be measured as a percentage of primary range of current transformer. The setting range for the ground current shall be 0.1 to 1.0 x ground fault CT primary current. An adjustable delay time of 0-30 seconds shall allow preventing nuisance alarm from momentary surges. It should be possible to make the alarm setting below the trip level to indicate early warning insulation breakdown.

(v)

thermistor/over temperature – EMPR shall be capable of accepting PTC and NTC sensors. Thermistor level shall be selectable for both alarm and trip conditions with an adjustable time delay of 0-5 seconds.

(vi)

under current – 10 – 100% of motor FLC with a time delay of 0-30 seconds.

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(i)

Fuses

1

These shall be selected according to the application and be suitable for the type of load they feed, for example motor starting, cable protection, protection for the semi conductor devices, control transformer protection etc.

2

Fuses shall be sized according to the condition under which they will operate such as normal, small sustained overload, heavy overload etc. in order to consider the operating characteristics accordingly.

3

The fuse shall either include a suitable fuse carrier or it shall be capable of isolation. If the fuse carrier is included it shall be such that when it is being withdrawn normally or when it is completely withdrawn the operator is completely protected from accidental contact with any live metal of its fuse link, fuse contacts and fixed contacts.

4

Fuse/links shall be fixed inside cubicles with sufficient spacing to facilitate easy fuse/link withdrawal.

5

If the fuse is capable of isolation it shall be so interlocked with the switch that isolation is complete before the fuse enclosure can be opened further. The switch shall be prevented from closing while the fuse-cover is open.

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3.2.7

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All fuses shall be of HBC/HRC cartridge type to BS 88/BS EN 60269.

7

Fuse holders and fittings shall be made of molded plastic insulating material of an approved make. Ceramic materials will not be accepted. Fuse fittings shall be fully shrouded and it shall be possible to change the fuses without danger of contact with live metal. Fuse holder terminals shall be of the clamp type where the screw does not directly tighten onto the conductor.

8

Fuse fittings shall have basic sizes of 16, 32, 63, 100 and 200A and the fuse holders shall be able to accept fuse links of that rating on any BS rating down to the next basic size.

9

A mechanical indication device shall be built into the fuse to indicate operation/fail status.

10

All small wiring for voltmeters etc. from the busbars shall be via busbar mounted fuse holders containing 20 amp fuse links. The fuse holders shall be solidly bolted to the busbars.

3.2.8

Fuse Switches

1

Fuse switches where specified shall comprise flush/surface mounted heavy duty composite air break switches and fuse units complying with BS EN 60947-3 and fitted with fuses to BS EN 60269 and shall be rated and equipped as detailed. Composite units shall be contained within an enclosure of metal and shall be fitted with an earthing terminal or equivalent to enable the enclosures to be earthed irrespective of any means of connection such as is provided for attaching armoring or other metallic covering of the cable supplying the composite unit.

2

Fuse switch shall be capable of making, carrying and breaking current under normal circuit condition, which may include specified operating overload conditions and also carrying for specified time currents under specified circuit conditions such as those of short circuit.

3

The switch breaking capacity shall be related to AC 23 utilization category or other approved equivalent standard for 415 V 3 phase 50 Hz 4 wire operation for use on specified fault level and for service and site climatic conditions as described in section 16480 Factory Built Assembly (FBA).

4

BS EN 60269 complied HRC fuses shall be provided as a mean of overcurrent/overload protective device to protect the switch. The maximum rated current of the fuse with regard to the prospective short circuit current in the actual circuit shall be mentioned.

5

The fuse shall be connected after the switch so that a short circuit will not occur in the fusecombination, thus for an expected fault to take place after the combination fuse switch unit

6

In the event of a fault this combination shall provide protection, permitting switching without, for example contact welding and preventing separation of main contacts in case of fault occurring during running.

7

The combination fuse switch unit shall be housed in an enclosure so constructed that the cover cannot be opened until the switch is fully opened and the construction shall be such that when the cover is opened a competent examiner can override the interlock and operate the switch. After such operation the cover shall be prevented from closing with the switch position indicator in a false position.

8

Switches shall be provided with mechanical ON/OFF indicators and operating handles.

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Means shall be provided for locking the switch in the OFF position only.

10

The combination fuse switch unit shall be fitted with 2NO + 2 NC auxiliary contacts wired to the terminals.

3.2.9

Isolating Switches

1

The switch when used alone as explained above as an Isolator shall confirm to the utilization category AC23 and shall fully comply with the requirement specified for isolating functions specially the isolating distance in accordance with the applicable standard.

2

An Isolator shall be capable of opening and closing the circuit ON-LOAD with full voltage applied across the terminals.

3

The Isolator shall be capable of carrying currents under normal circuit conditions and carrying for specified time currents under abnormal conditions such as those of short-circuit.

4

All other features of the Isolator shall be same as specified above for combination fuse switch unit.

3.2.10

Stop Lock-off Push Buttons

1

Stop lock-off push buttons for motors shall be the mushroom headed red stay-put type with automatic latching, the units having to be key operated to be released.

2

Push buttons shall be housed in a surface mounting weatherproof enclosure to IP 65.

3

Push buttons shall be UV stabilised.

3.2.11

Control Relays/Auxiliary Relays/Interposing Relays

1

All auxiliary relays shall mainly comply with BS EN 116000 and BS EN 116205-7.

2

Where similar relays have different operating voltages and/or different contact configurations, they shall be non-interchangeable.

3

Voltage at nominal operating temperature and shall not „drop-out‟ at greater than 60 % of the nominal coil voltage.

4

Relays shall be continuously rated and capable of sustaining a voltage 10 % in excess of the nominal coil voltage.

5

Relays shall be fully encapsulated and be of the plug-in type, with terminals protected to a minimum of IP2X.

6

Plug-in relays shall be fitted with transparent dust-proof covers. External connections shall be screw clamp terminals, which are easily accessible with the relay in position.

7

Relays shall include the provision for manual operation.

8

The pin configuration of the relay shall be printed on the casing and on the bases in order to ensure correct pin alignment.

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Relays shall be suitable for operation at plus 10% and minus 20% of their nominal rated voltage.

10

The contacts configuration shall be either normally open/normally closed or changeover contact combinations.

11

The contact material used in the Relay for general logic design shall be AgCdO. Specific applications requiring extra low switching current shall have GOLD Flash contacts for minimal voltage drop across the contacts.

12

It will not be permitted to use mixed voltages on the different contacts of a particular relay. If necessary additional relays shall be used by employing good engineering practices such as operation of add-on relay through auxiliary contact of main relay.

13

Relays Coil shall be vacuum impregnated ensuring satisfactorily operation for the adverse climatic conditions as specified.

14

The relays shall be mounted on DIN Rail.

15

Relays shall be secured to their bases by retaining bar or clip to prevent malfunction due to the relay being loosened in its base.

16

Care shall be taken to ensure that relay contacts and associated wiring are suitably fused protected.

17

All type of relays shall have a means of visual indication e.g. light emitting diode (LED) or neon bulb mounted within their clear covers connected directly across the relay coil to indicate when the relay is energized. These indicators shall be easily seen when the relay compartment door is opened.

18

A permanent means of identification shall be affixed to both relay and base in line with the circuit diagram reference.

19

Where remote supply voltages are used, a warning label engraved in English and Arabic shall be fitted, clearly identifying the source of supply.

20

The relay shall be designed for minimum 1 Million mechanical operation and 200,000+ electrical operations at rated load.

3.2.12

Protection Relays

1

Protection relays shall comply with BS EN 60225-6, BS EN 61810-1, IEC 255.

2

Secondary injection shall be easily possible by means of purpose-made voltage and/or current plug-in type test terminal blocks which automatically open circuit or short circuit the integral voltage transformers or current transformers respectively and provide termination‟s for the test supply. Disconnection of any permanent wiring will not be acceptable.

3.2.13

Alarm System

1

Auxiliary relays and auxiliary contacts and circuit breakers shall be provided as necessary and if indicated to transmit alarm signals to remote control buildings.

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Alarms shall be as indicated on the Contract Drawings and shall be selected from: (a)

circuit breaker tripped

(b)

power failure

(c)

standby generator failed-to-start.

Padlocks

1

Padlocks shall be provided for all handle operated circuit breakers, fuse-switches, isolators and the like.

2

Padlocks and keys shall be housed inside a safety key box located in the relevant electrical switch rooms, including padlocks and keys for lockable field equipment supplied from the switch-room.

3

Safety key boxes shall also be lockable using a master key.

3.2.15

Hours Run Meters

1

There shall be two counters provided for each motor. The one counter shall be nonresettable hour run meter, rotating disc type for measuring total operating period (accumulative) of a motor. The minimum size shall be 48 x 48 mm. The counting capacity shall be 99,999.99 hours. The color of the decimal digits shall be red while the color of other digits shall be white.

2

The second counter shall be provided for counting total (accumulative) number of start of motors 75kW and above. This shall be non-resettable, electronic type with permanent memory retention arrangement and LCD display to indicate Number of start of a motor.

3.2.16

Thermistor relay

1

All motors where recommended by the manufacturer or 30 kW and above shall be protected against excessive temperature, poor cooling, high ambient temperature, high starting frequency etc. by providing thermistors unless otherwise specified.

2

Thermistors shall be of PTC (Positive Temperature Coefficient) type made of platinum wire Pt100 having resistance of 100 ohms at 0 degree C. These shall be embedded in the stator winding/slot and the leads of the elements shall be brought out to a separate terminal block located within the junction box of the motor.

3

Thermistors shall have a tamper proof pre-set point and fast response time.

4

Thermistors shall be designed to include the following features:-

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3.2.14

(a)

tamperproof

(b)

rapid responding

(c)

UL/CSA recognized component

(d)

eliminates nuisance trips

(e)

field-proven Klixon design

(f)

requiring no field adjustment

(g)

allows full use of motor rating

QCS 2014

(h) 5


Page 15

directly senses winding over-heating

Thermistors shall protect the motor against the following conditions:(a)

locked rotor

(b)

running overload

(c)

single phasing

(d)

voltage unbalance

(e)

high motor ambient temperature

(f)

blocked ventilation

Thermistors have to be connected to a separate control unit that enables tripping of the motor through the starter contactor upon change of resistance of elements in the thermistor circuit beyond pre-determined value.

7

The wiring of the relay module shall be so done, that inhibit the starting of the pumps automatically even after the temperature limit sensors have cooled and reclosed the circuit. The facility shall be provided in the motor control centre to reset the control circuit manually, ensuring that a proper cause of overheating has been determined and corrected prior to the restart of the pumps in auto mode.

8

Additional to the sensing of winding temperature by the thermistor, means shall be provided to monitor the bearing temperature wherever possible and as recommended by the motor manufacturer.

3.2.17

Moisture and mechanical seal leakage protection

1

All submersible sewage pump motors shall be provided with a dedicated moisture and mechanical seal leakage protection relay.

2

The moisture sensing probes extended into the oil chamber located between the lower (outer) and upper (inner) seals to detect the presence of moisture in case of failure of outer seal.

3

The probes shall also detects water in the motor chamber and provide a warning prior to the water reaching the bearing or wound stator assemblies. The sensor leads must be connected to a moisture relay equipped with alarm contacts for indication.

4

The moisture detection relay shall be supplied by the pump motor manufacturer and to be free issued by the contractor to the Motor Control Centre Vendor together with detailed schematic diagrams and work instructions pertaining to the mounting and location of the relay.

5

The Motor Control Centre vendor shall strictly adhere to the wiring practices and works instructions as provided by the manufacturer.

3.2.18

Timers

1

Timers shall be plug-in or surface-mounting types; solid state microprocessor based employing CMOS IC technology.

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Timers shall be suitable for operation on a nominal 240 V AC, 110V AC, 24 V AC/DC or other voltage as specified or deemed necessary for the safe operation.

3

Timers shall have linearly calibrated scales, in units of time, each scale division being a maximum of 5% of full scale. Repeat accuracy shall be within 0.5% of full scale.

4

Timers shall be provided with “energized” and “timed out” indicators.

5

Plug-in timers shall be fitted with transparent dust-proof covers. External connections shall be screw clamp terminals which are easily accessible with the timer in position

6

Timers shall be secured to their bases by retaining bar or clip to prevent malfunction due to the relay being loosened in its base.

7

The pin configuration shall be printed on the casing of the timer and on its associated bases in order to ensure correct pin alignment.

8

Timer shall be provided with 10 Amps. Rated output relay with DPDT contacts.

9

Unless specified otherwise, timers shall be provided for circuits that require delay on operate, delay on release, and star-delta starting of a 3-phase induction motor.

10

Multifunction timing relay programmable where specified shall be provided to the satisfaction of the engineer.

11

The use of pneumatic timers, motor driven timers and other special timers shall be avoided unless specifically mentioned in the particular requirements and the same shall be subjected to the review and approval by the engineer.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 30: Duct bank and Manholes

Page 1

30

DUCT BANK AND MANHOLES..................................................................... 2

30.1

GENERAL ...................................................................................................... 2

30.1.1 Scope 30.1.2 Description 30.1.3 Submissions

2 2 2

PRODUCTS ................................................................................................... 2

30.2.1 30.2.2 30.2.3 30.2.4 30.2.5 30.2.6 30.2.7 30.2.8

General Rigid Steel Conduit Plastic Conduit Plastic Duct Reinforced Resin Conduit Pre-Cast Concrete Manholes Accessories Cast in Place Manhole Accessories

30.3

INSTALLATION ............................................................................................. 5

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30.4.1 General

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ENVIRONMENT ............................................................................................ 8

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30.3.1 Duct Bank Installation 30.3.2 Pre-Cast Manhole Installation 30.3.3 Cast in Place Manhole Installation

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30.2

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DUCT BANK AND MANHOLES

30.1

GENERAL

30.1.1

Scope

1

This Part specifies the requirements for duct bank and manholes.

2

Related Parts and Sections are as follows: This Section Part 6 Part 7 Part 8 Part 9 Part 10

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Cables and small wiring Conduits Trunking Cable Trays Accessories and General Power

Description

1

Duct bank and manholes shall be provided as specified and shown on the drawings.

30.1.3

Submissions

1


2

Shop Drawings submission shall include dimensional drawings of the duct bank and manholes, including sections and elevations, showing the following:

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(b)

duct routing

(c)

location of entry to buildings

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(a)

Submission of the project data shall be as follows:

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(a)


(b)


30.2

PRODUCTS

30.2.1

General

1

Duct Banks and manholes shall confirm to requirements as specified in relevant standard as applicable.

2

The specification shall be in accordance with latest edition of local and International regulations e.g. QGEWC, NEMA, ASTM, IEE etc.

QCS 2014


Page 3


4

The contractor shall select the product only from the manufacturer specializing in manufacturing products specified in this Part with minimum five years documented experience of the products being satisfactorily in use in a similar service and climatic conditions.

5

The contractor shall ensure proper co-ordination with related civil and other project associated activities prior to the selection of the equipment.

6

The contractor shall clearly show locations and arrangements of fittings on the drawings.

7

To ensure that field measurements are as indicated.

8

Provide detail routing and termination locations of duct bank prior to excavation. for rough in.

9

Provide locations of manholes prior to excavating for installation.

30.2.2

Rigid Steel Conduit

1

Rigid Steel Conduit: ANSI C80.1 or other approved standard.

2

Fittings: NEMA FB 1 or other approved standard, steel.

30.2.3

Plastic Conduit

1

Rigid Plastic Conduit: NEMA TC 2, Schedule 40 or 80 PVC or as specified, with fittings and conduit bodies to NEMA TC 3 or other approved standard.

2

Rigid Plastic Underground Conduit: UL 651A, Type A PVC; UL 651A, Type EB PVC; Highdensity polyethylene, Schedule 40 or Fibreglass-reinforced epoxy as specified or indicated.

30.2.4

Plastic Duct

1

Plastic Utilities Duct: approved standard.

2

Plastic Utility Duct Fittings: NEMA TC 9 or other approved standard.

3

Plastic Communications Duct and Fittings: NEMA TC 10, Type EB or DB as specified or other approved standard.

30.2.5

Reinforced Resin Conduit

1

Conduit and Fittings: standard.

2

Joining Method: specified.

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NEMA TC 6; PVC or ABS Type EB or DB as specified or other

NEMA TC 14, Type SW or HW as specified or other approved

Tapered bell and spigot joints, threaded joints or saw-cut system as

QCS 2014


Page 4

30.2.6

Pre-Cast Concrete Manholes

1

Pre-cast concrete manholes shall be as specified as follows: Description: Precast manhole designed in accordance with ASTM C858, comprising modular, interlocking sections complete with accessories or as specified.

(b)

Loading: ASTM C857, Class A-16, A-12, A-8 or A-0.3 as specified.

(c)

Shape: Square or rectangular with truncated corners or as indicated.

(d)

Nominal Inside Dimensions: Specified or indicated mm x mm.

(e)

Corner Panel Dimensions: Specified mm wide.

(f)

Inside Depth: Specified mm.

(g)

Wall Thickness: Specified mm.

(h)

Base Section: Include 75 or specified mm deep x 350 or specified mm round sump with cast sleeve, and two 25 mm ground rod openings where specified

(i)

Top Section: Include 1000 mm diameter or other approved size and shape grooved opening for frame and cover.

(j)

Riser Casting: 150 or 300 mm as specified or indicated, with manhole step cast into frame.

(k)

Frames and Covers: ASTM A48; Class 30B gray cast iron, 686 or 762 mm size as specified or other approved standard and size, machine finished with flat bearing surfaces. Provide cover marked ELECTRIC, TELEPHONE or as directed by the Engineer to indicate utility.

(l)

Duct Entry Provisions: Single duct knockouts, window knockouts or windows with plastic duct terminators and diaphragms as specified.

(m)

Duct Entry Locations: As specified or indicated.

(n)

Duct Entry Size: 100 or 150 mm as specified.

(o)

Cable Pulling Irons: Use galvanised rod and hardware. Locate opposite each duct entry. Provide watertight seal.

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Cable Rack Inserts: Minimum load rating 365 kg or as specified. Locate at specified or indicated distance on centre.

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(a)

(q)

Cable Rack Mounting Channel: 38 x 19 mm or approved size steel channel, 1.2 m or specified length. Provide cable rack arm mounting slots 38 mm or at standard centres.

(r)

Cable Racks: Steel channel, 38 x 19 x 350 mm or other approved size, with fastener to match mounting channel.

(s)

Cable Supports: Porcelain, Maple or other approved type clamps and saddles.

(t)

Manhole Steps: Polypropylene plastic manhole step with 13 mm steel reinforcement, Cast steps at 300 mm on centre vertically or as specified or indicated or Ladder: Aluminium rung, approved length, with top hook to engage manhole step in riser casting. Provide one ladder for each manhole.

(u)

Sump Covers: ASTM A48; Class 30B gray cast iron or other approved standard.

(v)

Source Quality Control: Inspect manholes in accordance with ASTM C1037 or other approved standard.

QCS 2014


Page 5

Accessories

1

Underground Warning Tape: 100 mm wide plastic tape, detectable type, coloured yellow with suitable warning legend describing buried electrical lines.

30.2.8

Cast in Place Manhole Accessories

1

Frames and Covers: ASTM A48; Class 30B gray cast iron, 686 or 762 mm size as specified or other approved standard and size, machine finished with flat bearing surfaces. Provide cover marked ELECTRIC, TELEPHONE or as directed by the Engineer to indicate utility.

2

Cable Pulling Irons: Use galvanised rod and hardware.

3

Cable Rack Inserts: Minimum load rating of 365 kg or as approved.

4

Cable Rack Mounting Channel: 38 x 19 mm or approved size steel channel, 1.2 m or specified length. Provide cable rack arm mounting slots 38 mm or at standard centres.

5

Cable Racks: Steel channel, 38 x 19 x 350 mm or other approved size, with fastener to match mounting channel.

6

Cable Supports: Porcelain, Maple or other approved type clamps and saddles.

7

Manhole Steps: Polypropylene plastic manhole step with 13 mm steel reinforcement, Cast steps at 300 mm on centre vertically or as specified or indicated or Ladder: Aluminium rung, approved length, with top hook to engage manhole step in riser casting. Provide one ladder for each manhole.

8

Sump Covers: ASTM A48; Class 30B gray cast iron or other approved standard.

30.3

INSTALLATION

30.3.1

Duct Bank Installation

1

Install duct to locate top of ductbank at depths as indicated on drawings or install duct to locate top of ductbank minimum specified or indicated mm below finished grade.

2

Install duct with minimum slope of 100 mm per 25.4 m (0.33 percent) or as specified or indicated. Slope duct away from building entrances.

3

Cut duct square using saw or pipe cutter; de-burr cut ends.

4

Insert duct to shoulder of fittings; fasten securely.

5

Join non-metallic duct using adhesive as recommended by manufacturer.

6

Wipe non-metallic duct dry and clean before joining. Apply full even coat of adhesive to entire area inserted in fitting. Allow joint to cure for 20 minutes, minimum.

7

Install no more than equivalent of two 90-degree bends between pull points.

8

Provide suitable fittings to accommodate expansion and deflection where required.

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30.2.7

QCS 2014


Page 6

Terminate duct at manhole entries using end bell.

10

Stagger duct joints vertically in concrete encasement 150 mm minimum.

11

Use suitable separators and chairs installed not greater than 1200 mm on centres.

12

Band ducts together before backfilling or placing concrete.

13

Securely anchor duct to prevent movement during concrete placement.

14

Place concrete under provisions of relevant section. Use mineral pigment to colour concrete where specified.

15

Provide minimum 75-mm or other specified concrete cover at bottom, top, and sides of ductbank.

16

Provide specified or indicated steel reinforcing bars in top of bank under paved areas.

17

Connect to existing concrete encasement using dowels.

18

Connect to manhole wall using dowels.

19

Provide suitable pull string in each empty duct except sleeves and nipples.

20

Swab duct. Use suitable caps to protect installed duct against entrance of dirt and moisture.

21

Backfill trenches under provisions of relevant section.

22

Interface installation of underground warning tape with backfilling specified in relevant section. Install tape 150 mm below finished surface.

30.3.2

Pre-Cast Manhole Installation

1

Excavate for manhole installation under the provisions of relevant section.

2

Install and seal precast sections in accordance with ASTM C891 or other approved standard.

3

Install manholes plumb.

4

Use precast neck and shaft sections to bring manhole cover to finished elevation.

5

Attach cable racks to inserts after manhole installation is complete.

6

Where specified or indicated, install drains in manholes and connect to site drainage system or provide DN100 pipe terminating in 1/4 cu m crushed gravel bed under provisions of relevant section.

7

Damp proof exterior surfaces, joints, and interruptions of manholes after concrete has cured 28 days, under provisions of relevant section.

8

Backfill manhole excavation under the provisions of relevant section.

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Page 7

Cast in Place Manhole Installation

1

Excavate for manhole installation under the provisions of relevant section.

2

Formwork: Form inside and outside manhole surfaces in accordance with provisions of relevant section.

3

Reinforcing: Install reinforcing under the provisions of relevant section.

4

Concrete: Provide air-entrained, 2000 psi (20 mPa) compressive strength at 28 days under the provisions of relevant section or as specified.

5

Shape: As specified or indicated.

6

Nominal Dimensions: As specified or indicated.

7

Inside Depth: As specified or indicated.

8

Wall Thickness: As specified or indicated.

9

Base: Include 350 mm drain opening and two 25 mm ground rod openings where specified. Slope to drain at 6.35 mm per m (2 percent).

10

Top: Include 1000-mm diameter or other approved size and shape opening; cast 13-mm rod in opening to accept ladder hook.

11

Duct Entry: Cast ducts openings in walls as indicated.

12

Cable Pulling Irons: Locate opposite each duct entry.

13

Cable Rack Inserts: Locate at specified mm on centre.

14

Construct brick collar with 760-mm or approved size clear opening to bring cover to proper elevation.

15

Manhole Steps: Cast steps at 300 or specified mm on centre vertically or install ladder in each manhole.

16

Attach cable racks to inserts after manhole construction is complete.

17

Install drains in manholes and connect to site drainage system or provide 100 mm pipe terminating in 0.25 cu m crushed gravel bed under provisions of relevant section where specified or indicated.

18

Dampproof exterior surfaces, joints, and interruptions of manholes after concrete has cured 28 days, under provisions of relevant section.

19

Backfill manhole excavation under the provisions of relevant section.

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30.3.3

QCS 2014


Page 8


30.4.1

General

1


2


30.5

ENVIRONMENT

30.5.1

General

1


2


3


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END OF PART

QCS 2014

Section 21: Electrical Works Part 31: Power Distribution Transformers

Page 1

31

POWER DISTRIBUTION TRANSFORMERS ................................................ 2

31.1

GENERAL ...................................................................................................... 2

31.1.1 31.1.2 31.1.3 31.1.4


31.2

PRODUCTS ................................................................................................... 3

2 2 2 2

31.2.1 General 31.3

3

INSTALLATION ............................................................................................. 4

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31.3.1 General 31.3.2 Earthing

4 4


31.4.1 31.4.2 31.4.3 31.4.4 31.4.5

General DELIVERY, STORAGE AND HANDLING Testing and Commissioning Final Adjustments General

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4 4 5 6 6

QCS 2014


Page 2

POWER DISTRIBUTION TRANSFORMERS

31.1

GENERAL

31.1.1

Scope

1

This Part specifies the requirements for Power Distribution Transformers.

31.1.2

Description

1

Power Distribution Transformers shall be provided as specified.

31.1.3

References

1

Power Distribution Transformers shall be provided in accordance with QGEWC latest specifications and the International Standards referred to here below: Power Distribution transformers shall be submitted for QGEWC approval.

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Hot Dip Galvanized Coatings on Iron and Steel Articles.

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BS EN ISO 1461:2009

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BS 381C 1980 ............Specification for Colours for Identification, Coding, and Special Purposes.

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BS 3692......................ISO Metric Precision Hexagonal Bolts, Screws and Nuts. BS 4190......................ISO Metric Black Hexagonal Bolts, Screws and Nuts.

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BS 7079, BS EN ISO 8501, BS EN ISO 8503------Surface Finish of Blast Cleaned Steel for Painting.

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BS 2562 1979 ...........Specification for Cable Boxes for Transformers and Reactors.

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BS EN ISO 12944, BS EN ISO 14713------Code of Practice for Protective coating for Iron and Steel Structures against Corrosion

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BS 6435 1984 ............Specifications for Unfilled Enclosures for the Dry Termination of HV Cables for Transformers and Reactors. BS Code of Practice 1010. ESI Standard 98-1.

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BS IEC 60076, BS IEC 60078----Power Transformers IEC 296/BS 148 .........Insulating Oil for Transformers and Switchgear. IEC 529/BS 5420 ....... Specification for Degrees of protection Provided by Enclosures. BS EN 60076. IEC 60076 Method of Measurement of Transformer and Reactor Sound Levels. IEC 726 ......................Cast risen transformers QGEWC

latest requirements for Power distribution transformers.

31.1.4

Submissions

1

Tender information and drawings shall be submitted to QGEWC through the supervising consultant. Submissions shall be in accordance with the requirements of the latest QGEWC specifications.

2

The following documents to be submitted to QGEWC for approval:

QCS 2014


Page 3

Product data and catalogue for each product specified, detailed description of construction, including dimensioned plans, sections, and elevations. Show minimum clearances and installed devices and features, weight and bearing forces, incoming and outgoing terminals and provisions for feeder terminations.

(b)

Wiring diagrams of transformers and accessory components, differentiating between manufacturer-installed and field-installed wiring and cabling.

(c)

Type tests, Routine Tests And Special Tests are to include measurement of noise level, winding resistance, voltage ratio, check of polarity/vector group, impedance voltage, load loss, no-load loss, no-load current, induced overvoltage withstand test and separate source voltage withstand test.

(d)

Qualification data for firms and persons specified in the "Quality Assurance" Article to demonstrate their capabilities and experience. Include a list of relevant completed projects with project names and addresses, and names and addresses of the respective Engineers and Government.

(e)

Shop and construction drawings including foundation details, grouting holes, base frames and installation details. All civil works are to be approved by END, Civil Section (EWD).

(f)

Operation and maintenance data for materials and products.

(g)

Undertaking form signed by the Supervisory consultant, supplier, manufacturer in original form.

(h)

Spare parts list

(i)

KAHRAMAA/QGEWC Scheme number and Building Permit number.

(j)

Any additional information as required by QGEWC.

(k)

It is the Contractor responsibility to provide al QGEWC/KAHRAMAA requirements in time in order to obtain the approval in time.

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(a)

PRODUCTS

31.2.1

General

1

The Contractor shall supply, install, test and commission Power Distribution Transformers as specified.

2

The transformers shall be ONAN outdoor, mineral oil filled, in compliance with QGEWC latest standards.

3

The Contractor shall be responsible for obtaining the latest version of QGEWC specification for Power Distribution Transformers and shall be responsible for obtaining QGEWC approval.

4


5

The Contractor shall provide full technical details of the proposed transformers together with a copy of all relevant standards for review and comment by the Engineer, prior to submission to QGEWC for approval.

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QCS 2014


Page 4

INSTALLATION

31.3.1

General

1

Comply with QGEWC electrical safety codes and the manufacturer's written installation instructions.

2

A contractor who is currently approved by QGEWC must carry out installation. The written approval of QGEWC for the contractor to carry out the work must be forwarded to the Engineer, and be acknowledged by him, before any installation work commences.

3

Equipment Bases: ensure that concrete bases and foundations provided for installation of equipment are constructed in accordance with approved shop and construction drawings and equipment manufacturer’s drawings and that holes for fixings bolts and provisions for passage of cables etc. are provided as required.

4

Cable Trenches: ensure that trench construction and covers provided for installation of power and control cables are in accordance with approved shop and construction drawings.

5

Cabling and Wiring: install cables, wires, raceways, supports, cable ends and termination fittings in accordance with the appropriate sections of the Specification and/or as shown on the Drawings. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values.

31.3.2

Earthing

1

Earth transformers shall be in accordance with Part 22.

31.4


31.4.1

General

1


2


3

Installer Qualifications: Engage an experienced Installer (approved by QGEWC) of high voltage electrical distribution equipment to perform the installation specified in this Section.

4

Standards: Comply with IEC 76, 354, 726 - Power Transformers and IEC 296 - Insulating Oil.

31.4.2

DELIVERY, STORAGE AND HANDLING

1

Spare Parts: provide spare parts as recommended by the manufacturer, for one year maintenance as expected under local conditions, and to allow for emergency replacement due to accidental breakage or failure.

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31.3

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Spare Parts for Oil Filled Transformers are to include, but are not limited to, one set of 11 kV bushings, drain plug, fragile parts which are subject to external damage and suitable quantity of make-up insulating oil.

3

Tools and Instruments: provide tools and instruments required for normal routine inspection, testing, operation and maintenance, recommended by the manufacturer.

31.4.3


1

Transformer to be tested in accordance with QGEWC requirements.

2

Schedule tests and provide notification at least one week in advance of test commencement.

3

Report: Submit a written report of observations and tests. Report defective materials and workmanship.

4

Tests: Include the following minimum inspections and tests according to the manufacturer's instructions. For test method and data correction factors, conform to applicable Standards.

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2

Inspect accessible components for cleanliness, mechanical, and electrical integrity, for presence of damage or deterioration, and to ensure removal of temporary shipping bracing. Do not proceed with tests until deficiencies are corrected.

(b)

Inspect bolted electrical connections for tightness according to manufacturer's published torque values or, where not available, those of applicable Standards.

(c)

Insulation Resistance: Perform megohmmeter test of primary and secondary windingto-winding and winding-to-ground according to the following:

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(a)

MINIMUM TEST VOLTS (d.c.)

MINIMUM INSULATION RESISTANCE (MEGOHMS) FOR LIQUID FILLED

601 – 5.000

2.500

1.000

5.000 – 35.000

5.000

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WINDING RATING (VOLTS)

Duration of Each Test

:

10 minutes.

(ii)

Temperature Correction

:

correct results for test temperature, deviation

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(i)

from 20 C standards.

5

(d)

Turns Ratio: Measure between windings at each tap setting. Measured ratios deviating more than 0.5 per cent from the calculated ratio or the measured ratio for adjacent coil are not acceptable.

(e)

Winding Resistance: Measure for winding at nominal tap setting. Measured resistance deviating more than 1 per cent from that of adjacent winding is not acceptable.

Test Failures: Compare test results with specified performance or manufacturer's data. Correct deficiencies identified by tests and retest. Verify that transformers meet specified requirements.

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31.4.4

Final Adjustments

1

After completing installation and cleaning, touch up scratches and mars on finish to match original finish.

2

Adjust transformer taps to provide optimum voltage conditions at utilization equipment throughout the normal operating cycle of the facility. Record voltages and tap settings to submit with test results.

31.4.5

General

1

Environmental conditions shall be as specified in Section 1 Part 1 and/or QGEWC specifications as applicable.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 32: 11 kV Switchgear

Page 1

32

11 KV SWITCHGEAR .................................................................................... 2

32.1

GENERAL ...................................................................................................... 2

32.1.1 32.1.2 32.1.3 32.1.4


32.2

PRODUCTS ................................................................................................... 2

2 2 2 2

32.2.1 General 32.3

2

INSTALLATION ............................................................................................. 2

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32.3.1 General


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32.4.1 General

3

ENVIRONMENT ............................................................................................ 3

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2

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11 KV SWITCHGEAR

32.1

GENERAL

32.1.1

Scope

1

This Part specifies the requirements for 11 kV Switchgear.

32.1.2

Description

1

11 kV Switchgear shall be provided as specified.

32.1.3

References

1

11 kV Switchgear shall be provided in accordance with QGEWC latest specifications and the International Standards referred to therein.

32.1.4

Submissions

1

Tender information and drawings shall be submitted to QGEWC through the supervising consultant. Submissions shall be in accordance with the requirements of the latest QGEWC specifications.

32.2

PRODUCTS

32.2.1

General

1

The contractor shall supply, install, test and commission 11 kV Switchgear as specified.

2

The 11 kV Switchgear complete with metering and instrumentation, special tools, accessories, test equipment, etc, shall be in compliance with QGEWC latest standards.

3

The contractor shall be responsible for obtaining the latest version of QGEWC specification for 11 kV Switchgear and shall be responsible for obtaining QGEWC approval.

4


5

The contractor shall provide full technical details of the proposed 11 kV Switchgear together with a copy of all relevant standards for review and comment by the Engineer, prior to submission to QGEWC for approval.

32.3

INSTALLATION

32.3.1

General

1

Install Products in accordance with the manufacturer's instructions.

2

A contractor who is currently approved by QGEWC must carry out installation. The written approval of QGEWC for the contractor to carry out the work must be forwarded to the Engineer, and be acknowledged by him, before any installation work commences.

3

Earth and bond duct under provisions of Part "Earthing and Bonding".

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32.4.1

General

1


2


32.5

ENVIRONMENT

32.5.1

General

1

Environmental conditions shall be as specified in Section 1 Part 1 and/or QGEWC specifications as applicable.

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32.4

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END OF PART

QCS 2014

Section 21: Electrical Works Part 33: Actuators

Page 1

33

ACTUATORS .......................................................................................................... 2

33.1

GENERAL ............................................................................................................... 2

33.1.1 33.1.2 33.1.3

Scope Description Submissions

33.2

PRODUCTS ............................................................................................................ 2

33.2.1 33.2.2

Electric Actuators Pneumatic

33.3

QUALITY CONTROL AND TEST PROCEDURES ................................................... 5

33.3.1

General

33.4

ENVIRONMENT ...................................................................................................... 5

33.4.1

General

2 2 2 2 5

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ACTUATORS

33.1

GENERAL

33.1.1

Scope

1

This Part specifies the requirements for valve/penstock actuators.

33.1.2

Description

1

Electric or penstock actuators shall be provided for valves and penstocks where specified.

33.1.3

Submissions

1


2

Shop Drawings submission shall include dimensional drawings of the actuator, including sections and elevations, showing the following:

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(b)


(c)


(d)

wiring diagrams

(e)


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Project data submission shall contain the following: full specifications of the enclosure and the components of the equipment with relevant sheets of manufacturer’s catalogues

(b)


(c)

the torque-speed requirement calculations / data sheet done for this selection.

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PRODUCTS

33.2.1

Electric Actuators

1

Where specified valves or penstocks shall be provided with electric motorised actuators.

2

As far as possible, the actuators shall be the standard product of a well known specialist manufacturer such as Rotork or Auma, which shall be approved by the Engineer.

3

Valve actuators shall be directly mounted onto and supported by the valves/penstocks which they control unless the valve/penstock is underground where the actuator shall be mounted at coping level. They shall be suitable for remote Automatic control and shall also incorporate means for local manual operation using a handwheel or lever. Actuators shall have integral starters and control equipment, unless the actuator motor is of a size that necessitates a panel mounted starter, in which case it will be specified in the particular specification.

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Page 3

The output shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the ball or roller type.

5

The design shall permit the gear case to be opened for inspection or disassembled without releasing the stem thrust or taking the valve out of service.

6

Valves stems and threads shall be provided with grease lubrication, rising spindle valves being protected with a totally enclosed grease packed cover tube.

7

The actuator shall be fitted with a drive bushing which is easily detachable for machining to suit the valve stem or gearbox input shaft. Bushing shall be fitted in the base of the actuator to enable standard length valve stems to be used.

8

Only two categories of sealing are permitted:

.

4

UK BASEEFA certified for EExdIIBT4 CENELEC Norm EN50018, BS5501 for defined hazardous locations; or

(b)

Watertight, dust-tight complying with the requirements of BS 5490 IP67 or better.

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Actuators shall be suitable for pedestal mounting and interchangeable without removal of the associated valve, penstock, pedestal, etc.

10

Sealing of static joints shall be by 'O' ring on moving components to prevent leakage of lubricant from the machine.

11

The actuator shall provide Double Sealing between the terminal compartment and the internal electrical elements of the actuator, fully protecting the motor and all other internal electrical elements of the actuator from ingress of moisture and dust when terminal cover is removed on site for cabling.

12

For control purposes limit switches shall be fitted to the actuator at both the closed and open positions of the valve. Limit switches shall also be fitted for signalling purposes. All these shall be fitted internally. Limit switches contacts shall be volt-free. The switch contact rating shall be 5 amps, 250 volts AC, 30 volts DC. Valve position shall be clearly marked externally on the actuator.

13

The actuators shall be sized so that they develop sufficient torque to reliably seat/unseat the valve or penstock off its seat, and to provide adequate torque throughout its operating range. The torque output must be at least 20% more than is required under maximum operating conditions (i.e. maximum differential head). The drive shall incorporate a lost motion hammer blow feature.

14

Adequate overload protection shall be provided to prevent actuator motor damage in the event of seizure. This shall either be in the form of torque switches, or over-temperature thermostats. The torque switch shall latch out on operation, and to be reset by driving in the opposite directions. A mechanical latch shall be provided to prevent the open torque switch tripping while the initial unsealing hammer blow is applied.

15

The setting of the torque and limit switches shall be able to be carried out without the need to remove any electrical compartment covers.

16

Adjustable mechanical limit stops shall be provided for open and closed positions of actuators.

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Actuators supplies shall be 110 volts Single Phase or less for quarter-turn and 415V three phase for multi-turn. Motors shall have Class F insulation, with a time raring of 15 minutes or three times the open/close stroking time whichever is the longer. Motors shall be capable of operating at the sun radiation temperature and certification shall be provided to this effect. Nevertheless, sun/weather canopies shall be provided for all externally installed actuators. These shall give complete shading from the sun during the hottest part of the day and should not restrict maintenance or operational access.

18

Certain valve actuators will require fail safe operation in the event of an electricity mains failure. The Contractor may achieve this either by using fail-safe actuators, or by providing standby power supplies for the affected actuators. There should be no tendency for any actuator to "creep" either open or closed, both in normal operation or under mains failure conditions.

19

Anti-condensation heaters for use on 110 volt a.c. shall be provided for all actuator motors.

20

The actuator motor gearbox shall be of the totally enclosed oil bath lubricated type suitable for operation at any angle and provided with appropriate filling and drain plugs.

21

A hand wheel shall be provided for manual operation of the valve. This hand wheel shall not operate during powered actuator movement by reason of a positive means of disconnection from the motor driven mechanism. The wheel shall be maintained in its engaged position once this is selected until powered movement takes place when it shall automatically disconnect and "free wheel". The hand wheel gearing shall be selected to allow valve operation without undue effort i.e. not exceeding 25 kg.

22

It shall be possible to secure hand or powered operation by means of padlocking in the selected mode.

23

Where necessary to present the actuator hand wheel at a convenient operating height, flange mounted pillars shall be provided which fully enclose the necessary valve stem extension spindles. Supplementary support of the extension spindle within its pillar shall be provided for long shafts.

24

The open/close direction of rotation shall be clearly indicated on the hand wheel.

25

A visual position indicator shall be provided within the actuator complete with a pointer showing open/closed and in travel positions, and a sealed potentiometer to transmit continuous remote position. Where specified in the particular specification, this indicator shall be illuminated.

26

Electrical and mechanical disconnection of the motor should be possible without draining the lubricant from the actuator gear-case.

27

The colour code for actuator push button shall be:

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(a)

“Start” actuation

Green

(b)

“Stop” actuation

Red

(c)

“Re-set” actuation

Black

(d)

“Test” actuation

White

(e)

“Emergency Stop”

Red (mushroom style, latching on depressing, release on turning).

QCS 2014


Page 5

Pneumatic

1

Where specified valves/penstocks shall be provided with pneumatic actuators.

2

Air actuators shall only be used where specified in the particular specification and shall be of the double acting type and be field interchangeable without the necessity of removal of the valve or penstock.

3

Where a pneumatic actuator is used for modulating control it shall be fitted with integral feedback.

33.3


33.3.1

General

1

The manufacturer shall provide proof of a stringent Quality Control (QC) Plan or Inspection Test Plan (ITP). In particular the main equipment manufacturing stages sanctioned by appropriate tests such as: incoming components inspection, discrete sub-assembly tests and complete functional checks on the final product. Equipment shall undergo on-load burn-in leaving the factory. Final inspection and calibration operations shall be documented in a report drawn up by the supplier’s Quality Inspection department.

2

Combined operational lists shall be carried out at the valve/penstock manufacturers works and list certificates provided confirming limit switch and torque settings.

3


4


33.4

ENVIRONMENT

33.4.1

General

1


2

Minimum ambient temperature shall be assumed as 0C.

3

Sun radiation temperature shall be assumed as 70C.

4

Maximum relative humidity shall be assumed as 95%.

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33.2.2

END OF PART

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 1

34

HIGH VOLTAGE VARIABLE FREQUENCY DRIVE (>1000 V) ..................... 2

34.1

GENERAL ...................................................................................................... 2

34.1.1 Scope 34.2

2

SYSTEM DESCRIPTION............................................................................... 2

34.2.1 Description 34.3

2

STANDARDS ................................................................................................. 3

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34.4.1 Ratings 34.4.2 Design Characteristics 34.4.3 Control System 34.4.4 Controller Keypad 34.4.5 Communications Interface 34.4.6 Fault Detection 34.4.7 Protection Features 34.4.8 Emergency Stop Control 34.4.9 Drive Enclosures 34.4.10 Factory Witness Inspections

4 5 6 8 8 8 9 11 11 12

INSTALLATION ........................................................................................... 12

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34.5

3 4 4

PRODUCTS ................................................................................................... 4

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34.4

.

34.3.1 Codes and Standards 34.3.2 Quality Assurance 34.3.3 Warranty

12 13 13

QCS 2014


Page 2

HIGH VOLTAGE VARIABLE FREQUENCY DRIVE (>1000 V)

34.1

GENERAL

34.1.1

Scope

1

This Specification defines the requirements for High Voltage Variable Frequency Drive Systems (VFDs) for the operation of pump motors. The system shall consist of the following main components: Isolation breaker, Drive Isolation Transformers, High voltage Variable Speed Drives (VFDs), Output Sine Filter, and any necessary power factor correction or harmonic filter components if required to meet this Specification.

2

The Manufacturer shall prepare a complete compliance with the Specification. Any exception shall be included in the compliance statement with an explanation, clearly indicating the paragraph of the Specification to which the exception applies, and concisely stating the reasons.

3

Unless clearly identified as an exception, the Specification shall have precedence where there is conflict between Manufacturer descriptive information and the Specification.

4

The drive manufacturer shall have a proven operation for the proposed drive and active harmonic filter/if provided in the sewage treatment plants or sewage pumping stations (or similar applications –subject to Engineer‟s approval) for more than 10 years.

34.2

SYSTEM DESCRIPTION

34.2.1

Description

1

The VFD System (VFDS) shall consist of the following main components: Isolation breaker, Drive Isolation Transformers, High voltage Variable Speed Drives (VFDs), Output Sine Filter, and any necessary power factor correction or harmonic filter components if required to meet this Specification.

2

The VFD manufacturer shall provide a dedicated fused contactor or circuit breaker (Hereto called Input Isolation Switchgear); rated to protect the VFD from specified short-circuit levels. The Input Isolation Switchgear shall be controlled by the VFD. The VFD doors shall be interlocked to prevent opening when main power is available.

3

The VFD shall be supplied with 11 kV, 3 phase, 50 Hz power and shall be able operate with +/-6% voltage variation.

4

Auxiliary power 415V, 3 phase, 50 Hz and safe-line power 240V, single phase, 50 Hz will be provided on site from a separated UPS. Alarm of missing Auxiliary power supply shall be provided in the VFD and an indication lamp shall be provided on the VFD door.

5

The variable frequency drive shall control a 3-phase squirrel cage induction motor

6

The drive will be suitable for the motor(s) rated 3300V, 3 phases, 50 Hz and above.

7

The power capacity of the converter shall meet the speed-load curve of the application, even at minimum mains supply voltage. An additional service factor or over-dimensioning of the VFD is not required.

8

The VFD shall be suitable for use with a new or an existing standard squirrel cage motor with 1.0 service factor and standard High voltage insulation and have dv/dt 10 to 50µsec.

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9

The VFD shall control the speed by employing advanced torque control techniques and auto tuning that measure and set all constant and critical parameters of the motor automatically.

10

It will be necessary to conduct field tests to measure the harmonics with all VFDs regardless of whether filters, reactors, chokes etc. are installed or not, running at 100 percent and 50 percent loads for the duration of at least 3 hours under each load condition. If drives don‟t meet the specified performance, the Contractor shall provide an acceptable solution at no extra cost.

11

The VFD shall be selected based on the following as the main advantages:User friendly allowing the operator to configure the VFD at site with ease.

(b)

Uniform motor running at all speeds.

(c)

Power factor close to unity regardless of the speed of the motor.

(d)

High overall system efficiency

(e)

No increase of noise in the motor.

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(a)

The VFD shall be arranged to prevent nuisance tripping due to failure of supply for a short duration (transient disturbances).

13

The following indication LED lamps with labels as per the relevant QSC Section 21, shall be provided on the VFD door.

(b)

VFD General fault.

(c)

Run/Stop.

(d)

Local/Remote.

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STANDARDS

34.3.1

Codes and Standards

1

The specified Variable Frequency Drive System shall be designed and materials shall be furnished in accordance with the latest revisions of applicable sections of the following Codes and Standards.

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IEEE 519 ....................Guide for Harmonic Control and Reactive Compensation of Static Power Converters. IEEE 995 ....................Recommended Practice for Efficiency Determination of AC Adjustable Speed Drives. IEEE C57.12.00-2000 General Requirements for Liquid-Immersed Distribution Power and Regulating Transformers. IEEE C57.12.01-1989 General Requirements Transformers.

for

Dry-Type

Distribution

and

Power

ANSI C57.12.10-1988 Transformers – 230 kV and Below 833/948 through 8333/10417 kVA, Single-Phase, and 750/862 Through 60000/80000 kVA with load TAP Changing – Safety Requirements. ANSI C57.12.51-1981 Requirements for Ventilated Dry-Type Power Transformers, 501 kVA and Larger, Three-Phase with High-Voltage 601 to 34500 volts, LowVoltage 208Y/120 to 4160 Volts. ANSI C57.12.70-1978 Terminal Markings and Connections for Distribution and Power Transformers.

QCS 2014


Page 4

IEEE C57.12.90-1999 Test Code for Liquid-Immersed Distribution, Power and Regulating Transformers. IEEE C57.12.91-1995 Test Code for Dry-Type Distribution and Power Transformers. IEEE C57.18.10-1998 Practices and Requirements for Semiconductor Power Rectifier Transformers. IEEE C57.124-1991 ...Detection of Partial Discharge and the Measurement of Apparent Charge in Dry-Type Transformers. ENV 50141 .................Radio frequency common mode. EN55011 ....................Suppression of Radio disturbances caused by electrical appliances and systems. EN 50081-2 ................Electromagnetic compatibility (EMC) IEC 146-1-1 ................Semiconductor Converters

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IEC 529 ......................Degrees of protection provided by enclosures (IP Code)

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NFPA-70.....................National Fire Protection Agency (NFPA) –70 National Electric Code (NEC), latest adopted edition.

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ICS7.1 ........................NEMA Safety standard for construction and guide to selection, installation and operation of Adjustable Frequency Drive Systems.

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OSHA .........................Standard No. 29 CFR 1910.147 – The standard for control of hazardous energy (Lockout/Tagout). IEC1000-4-2 ...............Electrostatic immunity test

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IEC1000-4-4 ...............Fast transient immunity test

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IEC1000-4-5 ...............Surge immunity test

IEC61800 ...................Adjustable speed electrical power drive systems

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UL 347 ........................High Voltage Industrial Control Equipment. UL 508C .....................Power Conversion Equipment

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UL 467 ........................Safety Standard for Grounding Equipment

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NEMA .........................National Electrical Manufacturer‟s Association Standard MG1 (1987) Quality Assurance

1

The VFD manufacturer shall have ISO 9001 certification.

2

The VFD manufacturer shall be able to provide start-up service, 24 hour/day emergency call service, repair work, maintenance and troubleshooting training of customer personnel.

3

VFD converter shall be UL listed/EC certified.

34.3.3

Warranty

1

The drive shall be warranted by the manufacturer for a minimum of three years from the date of commissioning in PWA name.

34.4

PRODUCTS

34.4.1

Ratings

1

The VFD shall convert 11k V - 3 Phase - 50 Hz, power to an adjustable voltage and frequency for controlling the speed of the pump. The output voltage shall vary proportionally with the output frequency to maintain a constant volts/hertz value up to a nominal frequency. Above nominal frequency, the output voltage shall remain constant.

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QCS 2014


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The drive shall be designed to operate in ambient temperature between 0°C and 50 °C with a relative humidity of up to 95 % (non-condensing).

3

The drive shall be capable of being stored at a temperature between -0 °C and 70 °C.

4

The drive shall be capable of operating at altitudes up to 200 meters above sea level.

5

The drive shall be capable of operating at a minimum efficiency of 95% at full load and full speed

6

The incoming line power factor shall range between 1.0 and 0.95, lagging, over the entire operating speed range.

34.4.2

Design Characteristics

1

VFD

Converter shall be offered with minimum 18 Pulse or higher to mitigate Harmonics generated at the line side and shall confirm to IEEE 519-1992 standards

(b)

The VSD shall have a fixed and alternatively variable V/f curve characteristic suitable for the required application.

(c)

The VSD shall be capable of varying the motor speed from a maximum speed at full load and at any intermediate speed down to 10% full load speed.

(d)

The drive shall be designed to be selectable for variable or constant torque. When selected for constant torque, the drive shall supply 150% of rated current for up to one minute. When selected for variable torque the drive shall supply 110% of rated current for one minute every 10 minutes.

(e)

The rectifier shall make use of three phase Rectifier Bridge consisting of diodes for power conversion from AC to DC. The inverter section shall use latest IGCT or nontransistor based modules for minimal loss, high speed switching and very low harmonics.

(f)

The VFD shall be trouble free operation.

(g)

The VFD shall have a fuse less design, which detects failures and acts within 25 microseconds. The device should be non-rupture type.

(h)

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2

The manufacturer shall not use any control or power components that require replacement before 50,000 hours of operation minimum.

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(i)

VFDs, using electrolytic high voltage capacitors or fuses, are not acceptable.

(j)

The Mean Time Between Failure (MTBF) of the VFD shall be greater than 50,000 hours minimum. All components of the VFD shall be considered for MTBF calculations.

(k)

The calculated Availability of the VFD shall be greater than 99.95%. The Availability shall be calculated based on the expected downtime due to corrective and preventive maintenance.

(l)

The VFD shall be capable of continuous operation (“ride-through”) in the event of a power loss of up to 1 second or more. The time limit shall be defined by the load inertia and not by the VFD‟s capability.

(m)

The VFD shall be able to safely operate, without tripping, at down to 30% under voltage of the mains supply.

(n)

The FVD drive shall be a high voltage VFD system. All power semiconductors and passive power components in both the rectifier and inverter part shall be high voltage rated components. Low voltage components are not acceptable in the power part sections

QCS 2014

Page 6

(o)

The drive must be capable of switching on to a motor already rotating in either direction.

(p)

The starting arrangement must include a ramp speed control, to achieve starting currents not exceeding normal full load current.

Drive Isolation Transformer (a)

A drive isolation transformer shall be furnished to provide power conversion from the 11 KV line voltage to the required VFD voltage and to isolate the line from harmonics and common mode voltages. The transformer shall conform to ANSI/IEEE C57.

(b)

The transformer shall be designed to withstand a short circuit. It shall maintain electromagnetic symmetry when only one secondary winding is in short circuit in order to minimize the resulting short circuit forces. The transformer shall be capable of thermally withstanding a short circuit for 2 seconds.

(c)

Transformers shall be of a high efficiency type with full load losses of less than 2%.

(d)

Transformer winding material shall be copper.

(e)

Suitable vibration dampers shall be provided with the transformer and its enclosure in order to attenuate mechanical resonance and to reduce the operational sound level.

(f)

The cable distance between the VFD and Drive Isolation transformer shall be designed for up to 50 m minimum.

(g)

The transformer shall include electrostatic shielding between the windings to carry high frequency capacitive currents to ground.

(h)

Transformer designs shall be indoor / outdoor, mounted dry type /ONAN type.

(i)

Only Rectifier grade K-factor transformers shall be utilized, with K-Factor of 6 for diode rectifiers. VFD manufacturers providing SCR type rectifiers shall include K Factor of 12 transformers for variable torque applications and K Factor of 20 for constant torque applications.

(j)

Dry type transformers shall be protected with an over-temperature protection, and any other protections as per the relevant standards, device with alarm and trip contacts and subject of Engineer‟s approval

(k)

Liquid cooled transformer / ONAN shall be equipped with an oil level indicator, an overpressure device (Buchholz or overpressure relay) and a top oil thermometer with alarm and trip contacts and subject of Engineer‟s approval. Each primary winding shall be provided with taps, adjustable in a range of +/-2.5% and +/-5% above and below nominal voltage. All taps shall be full capacity, no load type lockable type.

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(m)

If a dry type transformer is provided, the transformer shall be of Temperature Class 180C and average winding temperature rise of 115C.

(n)

If a liquid cooled transformer / ONAN is provided, the transformer shall have an average temperature rise of 60C for the oil and 65°C for the windings.

34.4.3

Control System

1

The VFD shall have a sensorless vector torque control or Direct torque control algorithm with static speed error of less than 0.2% and open loop torque step rise time under 10 milliseconds

2

Unless specified, the VFD shall not require the use of a tachometer.

3

The VFD shall be able to catch and take control of a spinning load if started while rotating equipment is already spinning. Appropriate safeguards shall be included in this operation to prevent damaging torque excitations, voltages or currents from impacting any of the equipment. The user shall have the option of employing this feature or disabling it.

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The VFD to provide an automatic current limit feature to control motor currents during startup and provide a “soft start” torque profile for the motor-load combination. Current and torque limit adjustments shall be provided to limit the maximum VFD output current and the maximum torque produced by the motor.

5

The VFD shall accept a start/stop command and speed reference from a local VFD panel, or from a remote panel.

6

The VFD shall have the capability to avoid up to five critical operating ranges. The critical operating ranges (skip frequencies) shall have selectable bandwidth, configurable via the operator interface

7

Upon restoration of power following a power loss, if the VFD status is healthy, the VFD shall be capable of re-starting upon receiving a start signal from the main processor.

8

The VFD shall be capable of passing through a momentary power outage of 3 cycles without causing the drive to trip.

9

The modulating control scheme shall closely approximate actual sine wave current throughout the speed range of the drive. The frequency resolution of the VFD shall be 0.01Hz.

10

Each VFD shall be equipped with a front mounted operator control panel consisting of a back lighted alphanumeric display and a keypad with the functions:

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Run/Stop command including indication lamps on the door.

(b)

Local/Remote command including indication lamps on the door.

(c)

Increase/Decrease command

(d)

Forward/Reverse command

(e)

Menu navigation and parameter selection

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(a)

All parameter names, fault messages, warnings and other information shall be displayed in plain text to allow the user to understand what is being displayed without the use of a manual or cross-reference table. A display contrast adjustment shall be provided to optimize viewing at any angle.

12

During normal operation, the speed reference, and run/stop forward/reverse and local/remote status shall be displayed. At least 3 additional user selectable analogue values shall be available for display including the following values as a minimum:

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(a)

Motor speed, current and power.

(b)

Output frequency, voltage and torque

(c)

DC bus voltage.

(d)

Cooling air or water temperature.

(e)

Status of discrete inputs and outputs.

(f)

Values of analog input and output signals.

13

Password protection shall be provided for prevention of unauthorized parameter access.

14

If specified, hardware inputs and outputs shall be provided to interface with external operator and supervisory control and monitoring equipment. The following galvanically isolated I/O points shall be included: (a)

Analogue inputs shall be 4 - 20 mA. Analogue input signals processing functions shall include scaling adjustments, adjustable filtering and signal inversion. Analogue signal functions shall include speed reference signals.

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Page 8

(b)

Discrete (binary) inputs shall be designed for 24 VDC. Discrete input functions shall include „run/stop‟ and „remote reset‟.

(c)

Analogue outputs shall be 4 to 20 mA signals. Analog outputs shall be programmable to provide signals proportional to at least output motor speed and current.

(d)

Relay contact outputs shall be rated to switch in minimum 6 A at 24 VDC or 250 VAC. Function selections shall include „VFD ready‟, „running‟, „alarm‟ and „trip‟ indications.

The VFD output frequency shall be controllable between 0 – 66 Hz.

16

The VFD memory shall retain and record, run and fault status with a minimum of 8 last fault conditions.

17

The VFD cubicle shall be provided with additional control and accessories if any are deemed necessary to meet the operating logic as described in the particular requirement.

18

The VFD shall include any additional protective features not detailed in the specification but recommended by the manufacturer in order to avoid damage to the VFD or Motor.

34.4.4

Controller Keypad

1

The VFD shall be provided with a unit mounted but detachable LCD display unit, provided with a three meter length of cable, suitable for mounting on the cubicle door. The VFD shall allow the program stored in one drive to be copied to another drive by using the display unit and supplied software. Interconnecting cables and associated accessories together with a user manual must accompany the VFD.

2

The VFD shall include any additional protective features not detailed in the specification but recommended by the manufacturer in order to avoid damage to the VFD or Motor

3

All parameters shall be password protected to prevent tampering and unauthorised changes.

34.4.5

Communications Interface

1

The drive shall incorporate an RS 485 serial communications interface to allow full drive control, programming, monitoring and diagnostics, including access to history record.

2

The VFD shall be provided with communication interface and facility to integrate the operation of the system. The facility employing communication protocols e.g. profibus, modbus etc. shall be compatible with other system equipments such as the PLC, RTU etc.

3

The Contractor shall provide a suitably sized programming device (laptop) complete with all necessary connection cables, software and licenses for configuration and maintenance of the VFD‟s.

34.4.6

Fault Detection

1

The drive shall keep a record of the last ten trips, plus a 100 sample history record of up to ten pre-defined parameters to enable fast diagnosis and minimum down time. Automatic printout of history record to a serial printer shall be an available feature.

2

The VFD shall have a programmable fold back function that will sense a controller/motor overload condition and fold back the frequency to avoid a fault condition.

3

A dedicated microprocessor based electronic motor protection system to be provided for the protection of the motor.

4

The VFD shall be protected against short circuit between output phases and ground, analogue outputs and logic circuit.

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For each programmed warning and fault protection function, the VFD shall display a message in complete English words or Standard English abbreviations. At least 40 time tagged fault messages shall be stored in the drive‟s fault history

6

In order to guarantee correct fault indications and trip sequence in the event that auxiliary power source feeding the drive is lost, the drive system processor shall be connected to an uninterrupted Power supply source (either within the drive or provided externally) to supply control power for display and signals.

34.4.7

Protection Features

1

For personal safety reasons all power capacitors have to be hard grounded (mechanical interlock), before accessing any MV section of the VFD. The grounding has to be mechanically and electrically interlocked with the cabinet doors. It shall be only possible to open the doors when the capacitors are grounded.

2

For each programmed warning and fault protection function, the VFD shall display a message in complete English words or Standard English abbreviations. At least 40 time tagged fault messages shall be stored in the drive‟s fault history.

3

An Emergency-stop push button (E-Stop) shall be provided on the VFD door and one additional remote located near the motor shall be provided.

4

The VFD shall provide input phase loss protection.

5

The system offered shall incorporate adequate protection and alarms properly coordinated by the Vendor for the drive control and for motor but not limited to the following :

6

The drive shall be protected against supply-phase loss and mains discontinuity.

7

The drive shall have a selectable auto-restart after trip.

8

The drive shall be designed to shut down with no component failure in the event of any of the above fault conditions arising. Main Drive Motor & Supply Cables The Motor Phase Loss

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Short Circuit in the Rectifier Bridge

(iii)

Supply Phase Loss

(iv)

Overload of the Inverter.

(v)

Short Circuit of the Inverter

(vi)

Battery Test if applicable

(vii)

Communication Fault

(viii)

External Motor Protection Trip

(ix)

External Transformer Protection Trip

(x)

Process Stop

(xi)

External Emergency Off

(xii)

Overcurrent (through current control limiter)

(xiii)

Overvoltage

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(ii)

(xiv) Phase unbalance/Single phasing (xv)

Earth fault

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(xvi) Locked Rotor (xvii) Overspeed – 105% / Under speed – 95% (xviii) Over temperature in stator through Motor model (xix) Line breaker tripped (xx)

Cooling medium temperature high

(xxi) Loss of one cooling system in case of redundant cooling system

(iii)

Raise/lower

(iv)

Forward/Reverse

(v)

Auto/Manual mode

(vi)

Local/Remote.

(vii)

Emergency stop

.

Speed control

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Start/stop

Drive on

(ii)

Drive off

(iii)

Motor over speed

(iv)

System ready to start

(v)

Remote breaker trip

(vi)


(vii)

VFD General fault.

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The system shall monitor the status of the following and provide indications.

Fault Annunciation Display of forty maximum previous faults shall be provided with a minimum of the these features (i)

Inverter overload

(ii)

Inverter high temperature

(iii)

No cooling of panel/motor

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Following minimum control are envisaged on front of the panel unless otherwise specified.

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(b)

(e)

Following control / metering shall be provided on local control panel.

(i)

ON/OFF push button

(ii)

Speed Raise/Lower push button

(iii)

Emergency stop push button

(iv)

Local/remote selection indication

(v)

Speed indicator

(vi)

Ammeter

(vii)

ON/OFF indication

(viii)

Drive ready to start indication

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34.4.8

Emergency Stop Control

1

An Emergency-stop (E-Stop) shall be provided on the VFD door in addition to inputs for customer supplied E-Stop command to ensure effective direct stopping of the drive if dangerous situations arise. The means provided should include direct connection to an Breaker, arranged such that its opening on-load: (a)

does not inhibit any in-built deceleration provided by the variable speed controller

(b)

does not produce additional safety hazards

(c)

does not cause damage to the controller.

Drive Enclosures

1

The converter and inverter section shall be suitably housed in sheet steel panels and shall be fabricated with 2 mm thick cold rolled sheet steel and structural steel. The panel shall be suitable for indoor installation if not otherwise specified. The panel shall be free standing, dust and vermin proof and degree of protection IP- 4X for air cooled or for water cooled if not otherwise specified. The cabinet shall be riveted/welded type construction to provide effective protection against Electromagnetic emissions.

2

The followings minimum thickness shall apply:.

(b)

Frames

(c)

Covers and Doors

- 2.00 mm

(d)

Gland Plate

- 3.00 mm

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- 2.00 mm

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34.4.9

The VFD Converter shall require front access only.

4

The VFD Converter enclosure doors shall include an electromechanical interlocking system with a safety grounding switch. The enclosure doors can be opened only if the safety ground switch connects all DC buses to ground, to ensure all stored VFD and motor energy is discharged before opening any high voltage compartment door.

5

The Output Sine Filter, Input Harmonic Filter and Power Factor Correction filter, if required, shall be factory mounted and wired into the Converter enclosure.

6

All painted surfaces shall be (ZINTEC) and must have a minimum of priming coat, undercoat and finishing coat. The undercoat and finishing coat shall be stove enamelled. The exterior shall be green to BS 4800, shade 14E53. Interior surfaces shall be white painted or shall be bright (unpainted) galvanized steel.

7

All bus bars shall be copper and corrosion protected.

8

The enclosure must be designed to avoid harmonic and inductive heating and eliminate radio frequency interference.

9

VFD noise level shall be less than 85 dB(A) for air cooled and less than 70 dB(A) for water cooled drives at 3 feet distance.

10

Anti-condensation heaters shall be provided with a thermostat and humidistat and have OFF/AUTO control on the cubicle front door. The heater shall not be in operation when the inverter is functioning.

11

The VFD shall be of Fuse less design.

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All panels shall be same height so as to form a bank, which shall give good aesthetic appearance.

13

All the control wiring shall be enclosed in plastic channel. Each wire shall be identified at both ends by wire marker tapes or PVC ferrules.

14

Power and control wiring inside the panel shall be done with PVC insulated copper conductor.

15

All Power modules and components shall be accessible from front of panel only.

16

PCB construction shall be rigid and robust. Components shall be wave soldered to the PCBs. Each component on the board must be clearly identified.

17

Suitable lifting hooks shall be provided for lifting the panel.

18

All FVD components shall be individually provided with identification engraved label.

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34.4.10 Factory Witness Inspections

Where specified in the tender documents, the stand-alone Drive (VFDs) shall be witness tested at the manufacturing facilities in the presence of Engineer and/or his representative. The detailed and complete Factory Acceptance testing procedure including the testing sheets shall be subject of Engineer‟s approval, and shall be approved by the Engineer 30 days before FAT dates are proposed. Internal test reports shall be provided to Engineer before the FAT test is performed.

2

The VFD shall be tested at 25%, 50% and 100 % load, minimum 3 hours recording the temperature rise.

3

The VFD System shall undergo standard manufacturing testing and as approved by the Engineer.

4

Each VFD shall be factory 100% load tested with a similar induction motor size on a dynamometer test stand at manufacturing facilities.

5

The FAT inspection procedure shall be submitted to Engineer for approval, and approved 30 days before performing the FAT witness test at manufacturing facilities.

6

Internal Factory test report shall be provided before preparation of the FAT witness date.

7

It will be necessary to conduct field tests to measure the harmonics with all VFDs regardless of whether filters, reactors, chokes etc. are installed or not, running at 100 percent and 50 percent loads for the duration of at least 3 hours under each load condition. If drives do not meet the specified performance, the Contractor shall provide an acceptable solution at no extra cost.

34.5

INSTALLATION

34.5.1

Documentation

1

The following documentation shall be provided:

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(a)

load de-rating (with tender)

(b)

harmonic distortion (with tender)

(c)

circuit diagrams

(d)

maintenance instructions

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(e)

fault diagnosis

(f)

parts list with part numbers

(g)

commissioning instructions

(h)

general arrangements drawings

Page 13

A recommended spares list for two years continuous operation shall be submitted at the time of tender. Where multiple, identical units are being supplied a rationalised list, i.e. not a summation of individual drives, requirements, should be produced.

34.5.2

Commissioning

1

The manufacturer of the drive system shall have a factory trained service representative residing in the Qatar for commissioning, programming and to provide training and after sales service.

2

The representative shall be trained in the installation, maintenance and trouble-shooting of the equipment specified and shall assist the Contractor to set-up and commission the variable speed motor drives and controls.

3

System validation tests shall be performed on all VSD‟s.

4

The integrated site test on the VFD, motor and all other associated devices shall be conducted to verify the input and output current, voltage, frequency, power factor, acceleration and deceleration rate etc. in accordance with the operating characteristics as approved by the Engineer.

5

Test VFD at different operating conditions by adjusting parameters (25, 50, 75 and 100%). Record the performance and verify.

6

The power system shall be tested for harmonics, line notching and for RFI/EMI in cable circuits and in the air.

7

Tests shall be performed during normal plant operation and during operation with the emergency generator.

8

The test results so obtained shall be used to calculate the Total Harmonic Distortion (%THD) and compare the same with IEEE 519

9

The manufacturer's engineer or their trained and qualified engineer working full time with the local supplier shall conduct all tests on site.

10

Upon completion of site tests a duly signed report listing all tests and checks, together with all supporting documents and drawings where applicable, shall be submitted to the Engineer for review. The Owner‟s representative shall be invited to witness the tests.

11

Submit all test reports, drawings and supporting documents to the Engineer and obtain written approval from both prior to the system being accepted by the Owner.

34.5.3

Training

1

Site Training. The AC drive manufacturer shall provide an on-site training program for the operating personnel of minimum 7 working days. This program shall provide operating and instruction manuals, training in equipment operation, and troubleshooting of the AC drive. The training program shall include, but not be limited to:

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(a)

Instruction on the basic theory of pulse width modulation control

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(b)

Instruction on the layout of the variable frequency controller indicating the location and purpose of each component

(c)

instruction on troubleshooting problems related to controller

(d)

installation and removal of printed circuit boards

(e)

actions to take under failure of controller

(f)

necessary cleaning of component parts.

Factory training. Duration of training program shall be minimum 10 days for two client persons at the manufacturing facilities.

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END OF PART

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Section 21: Electrical Works Part 04: Motor Starters

Page 1

4

LOW VOLTAGE MOTOR STARTERS (<1000V) .......................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2

Scope References

4.2

PRODUCTS ................................................................................................... 2

4.2.1 4.2.2 4.2.3 4.2.4

Starters DOL Starters Star Delta Starters Reduced Voltage “Soft Starters”

4.3

INSTALLATION ............................................................................................. 5

4.3.2

Earth Bonding

2 2

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4

LOW VOLTAGE MOTOR STARTERS (<1000V)

4.1

GENERAL

4.1.1

Scope

1

This Part includes the supply and installation of motor starters and associated equipment.

4.1.2

References

1

The following standards or updated/revised/superseded versions shall be followed BS EN 60073..............Coding of indicating supplementary means

devices

and

actuators

by

colour

and

BS EN 60947-1, IEC 947

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BS EN 60947-4 ..........Contactors and motor Starters

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BS EN 60439, IEC 439 Specification for low-voltage switchgear and control gear assembly Low Voltage switchgear and control gear

PRODUCTS

4.2.1

Starters

1

Motor starters shall be rated to carry the full load current of its rated duty at its most severe load conditions. All starters shall be capable of at least 20 starts per hour at 100 % full load torque unless otherwise specified.

2

In accordance with the current QGEWC regulations, motors up to and including 11 kW shall be started direct on line. Motors above 11 kW shall incorporate assisted starting.

3

Motor starters shall be housed in a separate cubicle compartment of the relevant motor control centre and each starter cubicle shall contain the following components, or as otherwise indicated on the Project Drawings or Project Documentation.

1 no. starter, comprising one of the following types, as indicated on the Project Drawings:

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(b)

1 no. triple pole ACB or MCCB or fuse switch, as indicated on the Project Documents, externally operated and interlocked with the cubicle door. There shall be provision for padlocking in the OFF position.

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(i)

direct on line

(ii)

star/delta

(iii)

close transition star/delta

(iv)

reduced voltage “soft start”

(v)

VFD control as per part 5

(c)

1 no. motor protection relay, as specified in Part 3

(d)

1 no. set of auxiliary relays and timers required to provide the necessary indication and control sequence

(e)

1 no. set of main motor terminals and auxiliary terminals for remote controls and indications.

(f)

1 no. set of terminals for remote lock-off stop push buttons

(g)

1 no. control circuit transformer, where applicable

QCS 2014


Page 3

(h)

1 no. anti-condensation heater

(i)

1 no. set of power factor correction capacitors with separate fuses for all drives above 11 kW, to give a power factor of not less than 0.85.

(j)

Thermistor relays where applicable

(k)

Bearing Vibration/temperature relays where applicable.

(l)

Pump protection relays for submersible pumps>2.2kW (moisture within the oil chamber, moisture within the cable connection box, mechanical seal failure, temperature rise of the hydraulic driven end bearing, loss of oil from the oil chamber/if available).

The components of the starter shall be type tested and ASTA certified to achieve Type 2 coordination in accordance with IEC 947.

5

The following equipment shall be mounted on the door of the starter cubicle, or as otherwise indicated in the Project Drawings or Project Documentation.

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1 no. Ammeter with selector switch for Motors with P<10 KW , and 3 no. A meters for motors with P>10 KW,, 96 X 96, with 240° scale fitted with suppressed 6xFLC scale to read motor running and starting current, with an adjustable red pointer to indicate full load current. The scale range shall be such that normal full load current gives approximately 60% full scale deflection.

(b)

3 no. pilot lamps to indicate “SUPPLY ON” () and 1 no lamp to indicate “MOTOR RUNNING” (Green) and “MOTOR STOP (White)”

(c)

1 no. pilot lamp to indicate “MOTOR FAILED” (Amber)

(d)

“X” no pilot alarm indication lamps (a separate lamp for each motor fault conditions)

(e)

1 no. “Hand/OFF/AUTO” Selector switch

(f)

1 set “Start/Stop” push button

(g)

1 no. externally operated overload reset push button

(h)

1 no. motor heater and cubicle heater humidistat controlled “OFF/AUTO” control switch, .

(i)

1 no. electronic hour counter reading to 99999 hours with analogue display, memory and battery backup with reset button

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lamp test push button 1 duty label

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(l)

All motors shall have local emergency stop push buttons on MCC and near the motor. For small motors, 2.2KW & lower, local isolator shall be enough. For submersible pumps emergency stop shall be near the junction box on wet well floor.

6

All starters shall contain a totally enclosed dust proof timer, or the operation will be controlled by a timer in the automatic section, which shall prevent pump(s) starting after a power failure until after a pre-set time has elapsed. The timer(s) or contacts shall be adjustable in the range 50 to 200 percent of the anticipated maximum delay which shall be taken as twice the total time required for all pumps to start and run steadily having been started consecutively. The timer(s) or contacts shall be set to give individual sequential start after a power failure with no drive starting until its predecessor has reached full steady running.

4.2.2

DOL Starters

1

DOL starters shall consist of a TP contactor for switching direct on line in accordance with BS EN 60947-4-1 and fitted with auxiliary contacts.

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Page 4

Contactors shall be selected for category AC-3 duty.

4.2.3

Star Delta Starters

1

Star-delta starters shall be provided with contactors as for DOL starters, arranged in such a manner to ensure the star contactor opens before the delta contactor closes.

2

The period of running in star and the transition time shall be controlled by adjustable solid state type timers.

3

For closed transition type star-delta starters, further requirements shall be wire wound or pressed sheet resistor banks of sufficient thermal rating to allow three (3) consecutive starts of 30 seconds period followed by a 15 minutes rest and another 30 seconds starting period. They shall also be of sufficient thermal rating to allow 10 starts per hour in line with the pump and starter specification unless otherwise specified. Resistance values shall be chosen to give a high starting current with low transient current. A thermal cut out shall be provided for transient resistance banks. Starter cubicles incorporating resistor banks shall be well ventilated and vermin proof with ventilation louvres.

4.2.4

Reduced Voltage “Soft Starters”

1

Solid-state reduced voltage motor starters shall be closed transition, shunt duty type with isolation contactor and bypass contactor. When the motor reaches full speed, the bypass contactor bypasses the soft starter power section. The solid-state power section shall consist of six silicon controlled rectifiers (two per phase connected back to back, in reverse parallel configuration) to provide soft start. The starters shall conform to the latest IEC Standards.

2

The starters shall use the current limit method of starting with the current adjustable between 150 percent and 425 percent of full load current of the motor. At turn-on, the control ramps up to the current limit in approximately 1 second and maintains that current until the motor comes up to full speed. If a problem exists and the motor fails to reach rated speed within a predetermined period of time, the control will shutdown. The starter shall provide a smooth, stepless acceleration and deceleration of the load from start to full speed and from full speed to stop. The starter shall be equipped with metal oxide varistor type surge suppressers across the SCR to protect against voltage transients and resistor/capacitor scrubber networks to protect against false firing of the SCR. Each SCR heat sink shall have a temperature sensor that shall shut the starter down in the event of an over temperature condition. When a starter failure occurs, the actual problem shall be indicated by an LED on the control panel front.

3

There shall be a overcurrent protective device, which shall provide over current protection and main disconnect function for the control unit. The position of the operating handle shall indicate “ON” or “OFF” position of the protective device and include provision for padlocking in the “OFF” position. This protective device shall be equipped with a shunt trip and shall trip when there is a SCR or plant power failure. Motor space heaters shall be energised when the motor is not running.

4

The reduced voltage starters shall be equipped with micro-processor controlled motor protection relays to control, monitor and protect the motors. The relay shall monitor three phase current and voltage and make trip and alarm decisions based on pre-programmed motor current and voltage conditions. Control functions shall include start detection, starter transition, incomplete sequence and number of starts per hour. The relay shall monitor and display load current of each phase, percent of full load current of each phase and running time. The relay shall protect the motor against time overcurrent, instantaneous overcurrent, underload, phase unbalance, earth fault, phase loss and phase reversal.

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5

The manufacturer shall supply certified test results to confirm that the controller has been tested to substantiate designs according to applicable standards. The tests shall verify not only the performance of the unit and integrated assembly, but also the suitability of the enclosure venting, rigidity and bus bracing. In addition, the unit shall be factory tested in accordance with applicable standards.

6

Manufacturer shall be prepared to show proper evidence of having tested for noise immunity on both input and output power connections.

7

The softstarter shall be supplied factory configured ready to commission, without requiring any parametering or reconfiguration at site.

8

The softstarter shall have the following protective feature as minimum:over temperature

(b)

overload

(c)

jam

(d)

stall

(e)

phase Loss

(f)

phase reversal

(g)

shorted SCR

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(a)

The softstarter shall have the following control feature as minimum:-

10

kick start 0-85% locked rotor torque – 0 to 2 seconds

11

ramp start 0-85% locked rotor torque – 1 to 60 seconds

12

current limit start 0-85% locked rotor current – 1 to 60 S

13

soft stop 0 to 60 seconds

14

The softstarter shall be provided with high speed fuses as recommended.

4.3

INSTALLATION

1

The Contractor shall submit details of proposed equipment and method of installation to the Engineer and QGEWC for approval prior to commencement of installation work.

2

Provide all the motor control equipment installations, wiring installations and tests, including connections and interconnections for the electrical controls as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces shown on the Drawings. The starter can be installed in a separate cubicle for MCC or can be an item in the Distribution Board, as per the Project Documentation. The installation procedures as applicable for MCC and DB shall also in general applicable for motor starter items.

3

Equipment shall be installed level and securely attached to the cubicle frames. The sections shall be joined together with bolts, nuts and washers to form a complete unit assembly. Floor standing equipment shall be installed on concrete plinths as shown on the Drawings.

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4.3.2

Earth Bonding

1

Each Medium Voltage/MCC switchgear panel or section shall be individually connected (at both end of the panel earthing bar) to two separate earthing pits trough the main earth bar located in the electrical or cable basement rooms. The earthing cable size shall be provided using a professional international recognized cable size design software subject to the Engineer’s approval.

2

Medium Voltage /MCC switchgear panel earthing conductor to earthing bar and earthing pit is to be sized for maximum earth fault current for 5 seconds with final conductor temperature not exceeding 160 °C or sized not less than 20 mm² per 100 kVA of transformer rating, and with a minimum of 95 mm².

3

Each panel section shall be cross bonded to adjacent panel section earthing terminal.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 05: Low Voltage Variable Speed Controllers

Page 1

5

LOW VOLTAGE VARIABLE SPEED CONTROLLERS (VFD)(,1000 V) ........ 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3 5.1.4

Description Standards Quality Assurance Warranty

5.2

PRODUCTS ................................................................................................... 4

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9

Ratings Design Characteristics Control System Controller Keypad Communications Interface Fault Detection Protection Features Emergency Stop Control Drive Enclosures

5.3

INSTALLATION ............................................................................................. 8

5.3.1 5.3.2 5.3.3

Documentation Commissioning Training

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QCS 2014


5

LOW VOLTAGE (VFD)(,1000 V)

SPEED

CONTROLLERS

5.1

GENERAL

5.1.1

Description

1

Variable Frequency Drives (VFD) shall be of the solid state, static, low harmonic design voltage source type, using minimum 32 bits microprocessor or the latest available, digital sine wave approximation Pulse Width Modulation (PWM) type. VFD’s shall be suitable for the particular application, controlling mainly pumps with variable torque characteristics. The drive manufacturer shall have a proven operation for the propose drive (and active harmonic filter/if provided), in sewage treatment plant or sewage pumping stations(or similar applicationssubject of the Engineer’s approval) for more than 10 years.

2

The VFD and associated control equipment shall be housed within a cubicle forming part of the relevant Factory Built Assembly. A stand alone VFD panel shall be provided for VFD above 75 kW. A stand-alone control panel may however be provided depending on the design, if the application requires special ventilation arrangements, or due to space constrains within the FBA cubicles. Detailed technical proposals shall be submitted for the Engineer’s review and approval.

3

The VFD shall be of a proven design that provides high pump efficiency, high availability, minimum maintenance, substantial energy reduction and longer bearing and seal life at reduced speeds.

4

The VFD shall control the speed by employing advanced torque control techniques and auto tuning that measure and set all constant and critical parameters of the motor automatically.

5

The VFD cubicle to be considered as a starter with the only addition of VFD with display unit and keypad and therefore shall comply with the requirements as described for starters and FBA’s in QCS.

6

The Contractor shall provide a properly matched pump - motor - drive system for the specific duty operating in conjunction with VFD considering load - torque characteristics, KW rating, efficiency, thermal capacity, power factor improvement etc.

7

The driving motor speed shall be variable between maximum speed at full load and at any intermediate speed down to a tenth of full load speed by means of a variable frequency from the VFD. The VFD shall provide a constant torque availability at any speed with a starting torque of 1.5 times full load torque at maximum speed. The VFD shall be capable of supplying the motor continuously at any frequency.

8

The VFD shall utilize a full wave bridge design incorporating diode rectifiers or semicontrolled bridge consisting of diodes-thyristors or transistors combination or 6-pulse/12pulse converter (whichever satisfy regulations pertaining to reduced harmonics distortion) or the latest available technology.

9

A DC link choke-smoothing reactor shall be included to limit fault throughput.

10

The thyristors/transistors shall be chosen to have a rating of 2.5 times the normal peak working voltage. Voltage peak transients for every thyristor/transstors shall be suppressed by a capacitor/resistance network and excessively high rates of change of voltage (dv/dt) shall be limited by a "snubber" network. Voltage spikes, which may be detrimental to any solid state component or relay, shall be suppressed by suitable networks.

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VARIABLE

Page 2

QCS 2014


Page 3

The thyristors/transistors shall be capable of maintaining continuously 10 per cent in excess of the current imposed by the maximum load conditions. Thyristors/transistors shall be protected against current overloads caused by malfunction of components or circuitry within the inverter or external loads. Overcurrent protection and rate of current rise (di/dt) in the thyristors shall be controlled by electronic current limiting devices, which shall cause trip current circuits to operate.

12

Thyristor heat sinks shall be provided with thermostats, which shall effect tripping in the event of excessive temperatures occurring.

13

The printed circuit boards shall confirm to BS 4584 or other approved equivalent standard and connections by multi-way sockets suitably treated to avoid high resistances being formed between the plug and socket.

14

Anti-condensation heaters shall be provided complete with a hygrostat type switch with reasonable setting range (50-100%), which operates when the preset value of %RH is exceeded above dew point and have OFF/AUTO control on the cubicle front door. The heater shall not be in operation when the VFD is functioning.

15

It will be necessary to conduct field tests to measure the harmonics with all VFDs regardless of whether filters, reactors, chokes etc. are installed or not, running at 100 percent and 50 percent loads for the duration of at least 3 hours under each load condition. If drives don’t meet the specified performance, the Contractor shall provide an acceptable solution at no extra cost.

16

The VFD shall be selected based on the following as the main advantages:-

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User friendly allowing the operator to configure the VFD at site with ease.

(b)

Uniform motor running at all speeds.

(c)

Power factor close to unity regardless of the speed of the motor.

(d)

High overall system efficiency

(e)

No increase of noise in the motor.

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The VFD shall be arranged to prevent nuisance tripping due to failure of supply for a short duration (transient disturbances).

18

The following indication LED lamps with labels as per the relevant QSC Section 21, shall be provided on the VFD door.

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(a)


(b)

VFD General fault.

(c)

Run/Stop.

(d)

Local/Remote.

5.1.2

Standards

1

The drive shall conform to the requirements of IEC 146.

2

The drive shall comply with EMC requirements such as EC directive 89/336/EEC.

3

The drive shall conform to the guidelines outlined in the Electricity Association, London, Engineering Recommendation G.5/-4 regarding harmonic distortion. The level of harmonic distortion shall not exceed 5 %.

QCS 2014


Page 4

The Contractor shall carry out a harmonic assessment for the project and provide whatever corrective measures are necessary to ensure that the installations harmonic distortion does not cause deviations of the voltage characteristics other than those allowed by European Standard EN 5016 – Voltage characteristics of electricity supplied by public distribution systems. The Contractor shall obtain QGEWC approval of the assessment and the corrective measures proposed. The Contractor shall also provide cross-referenced confirmations from the machine/motor suppliers and the control gear/soft starter or VSD manufacturers that the equipment they are supplying is totally mutually compatible.

5

Total Harmonic distortion (THD) shall be limited to lowest level under 5% as per G5/4 in order not to create stresses and resultant problems for the plant’s distribution systems. It may therefore be necessary to provide active type a harmonic filter including automatic 100% stand-by active harmonic filter to achieve the required limits as set by QGEWC and/or IEEE519.

5.1.3

Quality Assurance

1

The suppliers manufacturing facility shall be certified to the ISO - 9001 series of standards from the International Standards Organisation.

2

Type test reports shall be provided including internal test reports for the proposed drive as per IEC/BS standards.

5.1.4

Warranty

1

The drive shall be warranted for a minimum of five years from the date of commissioning by the manufacturer. The warranty letter shall be provided direct form the Drive manufacturer in ASHGHAL –PWA name.

5.2

PRODUCTS

5.2.1

Ratings

1

The VFD shall convert 415 V or 690 V - 3 Phase - 50 Hz, power to an adjustable voltage and frequency for controlling the speed of the pump. The output voltage shall vary proportionally with the output frequency to maintain a constant volts/hertz value up to a nominal frequency. Above nominal frequency, the output voltage shall remain constant.

2

The incoming line power factor shall range between 1.0 and 0.95, lagging, over the entire operating speed range.

3

The drive shall be capable of being stored at a temperature between -0 °C and 70 °C.

4

The drive shall be capable of operating in ambient temperature between 0 °C and 50 °C continuously with a relative humidity of up to 95 % (non-condensing).

5

The drive shall be capable of operating at altitudes up to 200 metres above sea level.

6

The drive shall be capable of operating at a minimum efficiency of 95% at full load and full speed.

7

The rating of the drive unit must be sufficient for the continuous maximum rating of the motor and not its running load.

8

The modulating control scheme shall closely approximate actual sine wave current throughout the speed range of the drive.

9

The frequency resolution of the VFD shall be 0.01Hz.

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QCS 2014


Page 5

The VFD shall not be sensitive to line notching from other VFD operating nearby.

11

The VFD shall be capable of passing through a momentary power outage of 3 cycles without causing the drive to trip.

12

The VFD shall have an adjustable IR compensation (voltage boost) control capable of providing 100% starting torque from the motor. The control shall be adjustable and provide the additional voltage only at the frequency range required starting the motor.

13

Upon restoration of power following a power loss, if the VFD status is healthy, the VFD shall be capable of re-starting upon receiving a start signal from the main processor.

14

The VFD shall continuously monitor its output current and frequency. Should the drive be operating in current limit or below 10 Hz for 10 seconds (stall condition), the VFD will shut down. The VFD shall allow site configuration of the parameters to match the application requirements.

15

The VFD shall have the capability to avoid up to five critical operating ranges. The critical operating ranges (skip frequencies) shall have selectable bandwidth, configurable via the operator interface.

16

The VFD shall be capable of operating with the output open circuited.

17

The VFD shall be capable of regenerating power from the motor to the DC bus for controlled deceleration. The maximum deceleration rate shall be determined by the losses in the drive system. The deceleration rate shall be constant and independent of motor speed.

18

The VFD Drive shall be designed to operate in all four quadrants.

5.2.2

Design Characteristics

1

The VSD shall have a fixed and alternatively variable V/f curve characteristic suitable for the required application.

2

The VSD shall be capable of varying the motor speed from a maximum speed at full load and at any intermediate speed down to 10% full load speed.

3

The drive shall be designed to be selectable for variable or constant torque. When selected for constant torque, the drive shall supply 150% of rated current for up to one minute. When selected for variable torque the drive shall supply 115% of rated current for up to one minute.

4

The VSD shall employ a pulse width modulated (PWM) inverter system with insulated gate bi-polar transistors (IGBT) to minimise audible motor noise and increase overall performance.

5

The drive shall be designed to have an adjustable PWM carrier frequency with a minimum range from 2k Hz to 8k Hz to minimise audible motor noise.

6

The drive shall be optimised for 4k Hz switching frequency at 44 kW (60 HP) or less and 2 K Hz at 55 kW (75 HP) and larger.

7

The drive must be capable of switching on to a motor already rotating in either direction.

8

The starting arrangement must include a ramp speed control, to achieve starting currents not exceeding normal full load current.

9

The VFD shall be provided with a full load isolation and disconnecting device as per IEC relevant standard for the safety of Convertors.

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QCS 2014


Page 6

Control System

1

The VFD shall have self-diagnostic features on power-up to validate memory, analogue reference, communication link, dynamic breaking if any, and control power etc.

2

The VFD design shall include SCR heatsink construction for heat transfer

3

The VFD shall include semiconductor metal oxide varistors (MOVs) or other approved equivalent method to the approval of the Engineer for protection against voltage surges.

4

Other built-in features of the VFD shall be PID, auto start, multiple pump control, reverse run protection and restart after instantaneous power failure.

5

The VFD shall self configure to the main operating voltage and frequency.

6

Upon power up, the VFD shall first check availability of connected motor and then update its memory by storing the new data, compare the data, auto tune by optimizing the operating characteristics and run the motor.

7

The VFD shall be factory configured and preset requiring minimal site adjustment during commissioning.

8

The VFD output frequency shall be controllable between 0 – 120 Hz.

9

An AC pre-settable fault current limiting facility shall be provided to ensure that when a setting is exceeded voltage and frequency are automatically controlled.

10

The VFD shall facilitate field adjustment of the following parameters as minimum:-

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5.2.3

The motor acceleration 0-600 seconds

(b)

The motor deceleration 0-600 seconds

(c)

The voltage to frequency ratio boost in proportion to load torque

(d)

Compensation for motor slip from 0-5 per cent with varying load torque

(e)

Minimum frequency set control

(f)

Maximum frequency set control

(g)

Presentable current limit facility

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(a)

The VFD memory shall retain and record, run and fault status with a minimum of 8 last fault conditions.

12

The Contractor shall furnish details of specific installation and cable lengths to the manufacturer of the VFD and obtain in writing, the recommended size, type and specification of power and control cables used between the VFD and the motor.

13

The VFD cubicle shall be provided with additional control and accessories if any are deemed necessary to meet the operating logic as described in the particular requirement.

14

The VFD shall include any additional protective features not detailed in the specification but recommended by the manufacturer in order to avoid damage to the VFD or Motor.

5.2.4

Controller Keypad

1

The VFD shall be provided with a unit mounted but detachable LCD display unit, provided with a three metre length of cable, suitable for mounting on the cubicle door. The VFD shall allow the program stored in one drive to be copied to another drive by using the display unit and supplied software. Interconnecting cables and associated accessories together with a user manual must accompany the VFD.

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QCS 2014


Page 7

All parameters shall be password protected to prevent tampering and unauthorised changes.

5.2.5

Communications Interface

1

The drive shall incorporate an RS 485 serial communications interface to allow full drive control, programming, monitoring and diagnostics, including access to history record to SCADA control station.

2

The VFD shall be provided with communication interface and facility to integrate the operation of the system. The facility employing communication protocols e.g. profibus, modbus etc. shall be compatible with other system equipments such as the PLC, RTU etc.

3

The Contractor shall provide a suitably sized programming device (laptop) complete with all necessary connection cables, software and licences for configuration and maintenance of the VFD’s.

5.2.6

Fault Detection

1

The drive shall keep a record of the last ten trips, plus a 100 sample history record of up to ten pre-defined parameters to enable fast diagnosis and minimum down time. Automatic printout of history record to a serial printer shall be an available feature.

2

The VFD shall have a programmable fold back function that will sense a controller/motor overload condition and fold back the frequency to avoid a fault condition.

3

A dedicated microprocessor based electronic motor protection system to be provided for the protection of the motor.

4

The VFD shall have UL listed solid state I²t protection and class 10 or equivalent overload protection as per BSEN 60947 meeting Type 2 co-ordination. Semiconductor fuses providing the required protection may be permitted to use as approved by the Engineer

5

The VFD shall be protected against short circuit between output phases and ground, analog outputs and logic circuit.

5.2.7

Protection Features

1

The drive shall incorporate the following protective functions: active limiting of fundamental current by frequency fold back on acceleration loads and frequency hold on decelerating loads

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(b)

overcurrent protection

(c)

short circuit protection

(d)

fast acting supply fuses

(e)

DC intermediate bus undervoltage

(f)

DC intermediate bus overvoltage

(g)

power section overtemperature

(h)

earth fault protection without damage

(i)

power section faults.

2

The drive shall be protected against supply-phase loss and mains discontinuity.

3

The drive shall have a selectable auto-restart after trip.

4

The drive shall be designed to shut down with no component failure in the event of any of the above fault conditions arising.

QCS 2014


Page 8

5.2.8

Emergency Stop Control

1

The drive shall incorporate facilities to allow the connection of an Emergency Stop Pushbutton to ensure effective direct stopping of the drive if dangerous situations arise. The means provided should include direct connection to an air-break device e.g. a contactor, arranged such that its opening on-load: (a)

does not inhibit any in-built deceleration provided by the variable speed controller

(b)

does not produce additional safety hazards

(c)

does not cause damage to the controller.

Such contactors shall be to BS EN 60947-1 with utilisation category AC-3.

5.2.9

Drive Enclosures

1

Drive enclosures shall generally be fabricated in accordance with the requirements for motor control centres specified in Part 2.

2

The drive enclosure shall have a protection rating of IP 31 minimum to BS EN 60947-1.

3

Where necessary, forced cooling shall be provided incorporating a visual indication on the front of the cubicle door in the event of a cooling system failure.

4

Ventilation grills shall be fitted with sand trap filters. 100% spare filters shall be provided.

5

Anti-condensation heaters shall be provided with a thermostat and have OFF/AUTO control on the cubicle front door. The heater shall not be in operation when the inverter is functioning.

5.3

INSTALLATION

5.3.1

Documentation

1

The following documentation shall be provided:

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load de-rating (with tender)

(b)

harmonic distortion (with tender) circuit diagrams maintenance instructions

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(e)

fault diagnosis

(f)

parts list with part numbers

(g)

commissioning instructions

(h)

general arrangements drawings

2

A recommended spares list for two years continuous operation shall be submitted at the time of tender. Where multiple, identical units are being supplied a rationalised list, i.e. not a summation of individual drives, requirements, should be produced.

5.3.2

Commissioning

1

The manufacturer of the drive system shall have a factory trained service representative residing in the Qatar for commissioning, programming and to provide training and after sales service.

2

The representative shall be trained in the installation, maintenance and trouble-shooting of the equipment specified and shall assist the Contractor to set-up and commission the variable speed motor drives and controls.

QCS 2014


Page 9

System validation tests shall be performed on all VSD’s.

4

The integrated site test on the VFD, motor and all other associated devices shall be conducted to verify the input and output current, voltage, frequency, power factor, acceleration and deceleration rate etc. in accordance with the operating characteristics as approved by the Engineer.

5

Test VFD at different operating conditions by adjusting parameters (25, 50, 75 and 100%). Record the performance and verify.

6

The power system shall be tested for harmonics, line notching and for RFI/EMI in cable circuits and in the air.

7

Tests shall be performed during normal plant operation and during operation with the emergency generator.

8

The test results so obtained shall be used to calculate the Total Harmonic Distortion (%THD) and compare the same with IEEE 519 and QGEWC regulation.

9

The manufacturer's engineer or their trained and qualified engineer working full time with the local supplier shall conduct all tests on site.

10

Upon completion of site tests a duly signed report listing all tests and checks, together with all supporting documents and drawings where applicable, shall be submitted to the Engineer for review. The Owner’s representative shall be invited to witness the tests.

11

Submit all test reports, drawings and supporting documents to the Engineer and QGEWC and obtain written approval from both prior to the system being accepted by the Owner.

5.3.3

Training

1

The AC drive manufacturer shall provide an on site training program for the operating personnel. This program shall provide operating and instruction manuals, training in equipment operation, and troubleshooting of the AC drive. The training program shall include, but not be limited to:

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Instruction on the basic theory of pulse width modulation control

(b)

Instruction on the layout of the variable frequency controller indicating the location and purpose of each component

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(a)

(d)

installation and removal of printed circuit boards

(e)

actions to take under failure of controller

(f)

necessary cleaning of component parts.

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instruction on troubleshooting problems related to controller

END OF PART

QCS 2014

Section 21: Electrical Works Part 06: Cables and Small Wiring

Page 1

6

CABLES AND SMALL WIRING ..................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5

Scope References Quality Assurance Submissions Products Delivery, Storage and Handling

6.2

PRODUCTS ................................................................................................... 4

6.2.1 6.2.2 6.2.3 6.2.4

Performance Requirements for Environmental Conditions Cables Sundries Jointing 11 kV, L.V. and Pilot Cables

6.3

INSTALLATION ........................................................................................... 12

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

General Cable Trays Spacing Between Cables Trench Depth Cable tiles Removal of Existing Cables Ducts Quarry Scalping

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QCS 2014


Page 2

CABLES AND SMALL WIRING

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the general requirements for power cables and small wiring systems. It shall be read in conjunction with other parts of the Project Documentation.

2

This particular requirement is to be read in conjunction with Specification for Underground Cables in PVC-u Ducts, plus Section 21 Part 30 Duct Bank and Manholes refers (but not limited to).

3


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General Provisions for Electrical Installations Conduits Trunking Cable Trays Wiring Accessories and General Power Testing

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References

1

Cables and wires shall comply with the following standards or updated/revised amended versions as appropriate:

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BS 1442......................Galvanized mild steel wire for armouring cables

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BS 2484......................Straight concrete clay ware covers BS 2897......................Aluminium strip armour for cables

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BS 3506......................Unplasticised PVC pipe for industrial purposes BS 4066......................(IEC 332) Tests on electric cables under fire conditions

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BS 4660......................Unplasticised polyvinyl chloride (PVC-u) pipes and plastic fittings of nominal sizes 110 and 160 for below ground gravity drainage and sewerage BS 5308......................Instrumentation cables. BS 5467......................(IEC 502) Cables with thermosetting Insulation for electricity supply for voltages of up to and including 600/1000 V and 19000/30000 V BS 6004......................(IEC 227) PVC insulated cables (non-armoured) for electrical power BS 6007......................Rubber insulated cables for electric power and lighting BS 6207......................(IEC 245) Mineral insulated cables. BS 6234......................Polythene insulation and sheath for cables. BS 6346......................PVC insulated cables for electrical supply. BS 6360......................(IEC 228) Copper conductors for cables. BS 6500......................(IEC 227) Insulated flexible cords. BS 6622......................(IEC 502) Cables with extruded cross linked polyethylene Insulation, for rated voltage 3800/6000 V up to 19000/30000 V BS 6746......................PVC Insulation and sheath of electric cables BS 6746C ...................Colour chart for insulation and sheath of electric cables

QCS 2014


Page 3

BS 6899......................Rubber insulation and sheath of electric cables BS 7671......................Requirements for electrical installations QGWEC

Latest regulation

BS EN 29453..............Soft solder alloys-chemical composition and forms ISO 9000 ....................Quality management and assurance standards Cable terminations shall comply with the following specifications: BS 1858......................Bitumen based compounds for electrical purposes

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BS 4579......................Performance of mechanical and compression Joints in electric cable and wire connectors

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BS 6121......................Mechanical cable glands for elastomer and plastic Insulated cables

Low voltage electrical installations

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IEC 60364

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BS 6910......................Cold pour resin compound and heat shrink cable joints in the voltage range up to 1000 V AC and 1500 V DC

Quality Assurance

1

The Contractor shall determine the correct size of cables to be used for the equipment selected, based on current rating and voltage drop, as relevant, after taking into consideration:

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6.1.3

type of cable and wire

(b)

ambient conditions

(c)

method of installation

(d)

the disposition of each cable relative to other cables

(e)

fault power level

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protective device ratings motor circuit voltage drop during starting.

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(a)

2

Voltage drop and current ratings shall be calculated according to QGEWC Regulations or BS 7671 , IEC 60364 and IEE regulation, whichever is more stringent.

3

All cables and wires shall be suitable for installation and continuous service in the ambient conditions described in Part 1, and shall be manufactured to ISO 9000 or equivalent.

4

Approximate cable route lengths and equipment power ratings indicated on the Project Drawings shall be for calculating cable sizes for tendering purposes. The Contractor shall determine exact cable lengths from site measurements and calculate cable size from the power ratings of the actual equipment being proposed. The Contractor shall be responsible for any increase in costs or design work associated with proposed equipment which has different electrical characteristics than the equipment on which the design was based.

5

Cables from manufacturer whose product have been in satisfactory use in similar services in the state of Qatar for not less than 5 years shall be used only. Certificate of origin shall be submitted with the offer.

QCS 2014


6.1.4

Submissions

1

Shop Drawings and Product Data:

Page 4

submit full technical details including cable sizing calculations(Cable loading, voltage drop, thermal limit verification of cable under fault condition , overloading capability, protective devices ratings, motor voltage drop during starting, as a minimum) for each method of installation used on site, performed with an approved professional international recognized licensed software (Subject of Engineer’s approval), and catalogueinformation of each type of cable or wire proposed for the Engineer’s approval before ordering

(b)

submit copy of test certificates from the manufacturer or an independent testing authority confirming that cables comply with the Specifications

(c)

submit exact route of the cable runs and relevant Sections in the shop drawings,including fixing details, termination details etc.

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(a)

Products Delivery, Storage and Handling

1

Reference Part 1.

2

Each drum length of cable shall be allotted a distinct and separate reference number. This number shall appear on the test certificates covering the respective length of cable and shall also be clearly marked on the cable drum.

3

The Contractor shall advise the Engineer upon delivery to site of each drum length, quoting the reference number. The test certificates shall be handed to the Engineer for examination and approval.

4

All cables shall be delivered to site with the manufacturer’s seals, labels or other proof of origin intact. These labels and seals shall not be removed until the cable is required for use and shall be retained for inspection by the Engineer.

5

The Contractor shall be responsible for the off-loading and handling of the cables on site, and shall ensure that cables are delivered to site on drums and properly protected against mechanical damage. Where lengths are cut from cables, the open cable ends shall be sealed.

6.2

PRODUCTS

6.2.1

Performance Requirements for Environmental Conditions

1

The Contractor shall be aware of the need to supply and install all wire and cables for this Contract which are most suitable for the special environmental conditions prevailing in Qatar.

2

All conductors shall have good fatigue resistance and not be subject to breaks due to nicks or cuts when terminating.

6.2.2

Cables

1

Unless otherwise specified, cables and wires of the following specified voltage ratings shall be used as indicated.

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6.1.5

(a)

6350/11000 V rated cables

:

11kV ring and radial circuit

(b)


:

Main and sub-main distribution panels, motor control centres, circuits serving process equipment

QCS 2014


Page 5

(c)


:

Final sub-circuit supplies for lighting, socket outlets, etc.

(d)


:

Instrumentation

(e)

250 V rated cables

:

Extra low voltage wiring, communication circuits where the maximum voltage is 50 V.

(f)

Music/paging systems, Cable and TV system cable twisted pair conductors circuits

General: conductors shall be high conductivity copper, to BS 6360 (IEC 228) unless otherwise indicated

(b)

copper conductors shall be stranded

(c)

signal control cables shall have solid conductors

(d)

flexible cords shall have fine stranded conductors

(e)

conductor sizes shall be metric. Conductors with cross sectional areas smaller than those specified will not be accepted

(f)

insulation for each conductor shall be colour coded or otherwise identified as required by the Regulations. Colour coding shall be maintained throughout the installation

(g)

the current carrying capacity of conductors has been determined in accordance with the specified Regulations, the specified type of insulation and the expected conditions of installation

(h)

all cables shall be as far as practicable, of one manufacturer only. All cables shall comply with the relevant IEC/BS.

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600/1000 V rated PVC Insulated armoured cables. PVC/SWA/PVC cable: 600/1000 V Grade, to BS 6346

(b)

conductor: Annealed high conductivity copper, stranded, shaped and laid in an approved manner

(c)

armour: Single layer of galvanised steel wires for multicore cables

(d)

insulation: Colour coded to BS 6746C PVC for sheath and insulation to BS 6746

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Special screened and

(f)

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5

cables shall be terminated with compression glands as specified below, giving adequate mechanical support by locking on the armour and ensuring a high earth continuity.

PVC Insulated PVC Sheathed (PVC/PVC) Cable. (a)

to BS 6346, 600/1000V Grade, or to BS 6004, 300/500 V Grade

(b)

flat twin and three core cable shall be to BS 6004 and incorporate an earth conductor placed between the red and black cores for two core cable and between the yellow and blue cores for three core cable

(c)

conductor: annealed high conductivity copper, stranded, shaped and laid in an approved manner

(d)

insulation: Colour coded to BS 6746C

(e)

PVC for sheath and insulation : to BS 6746

Single core PVC Insulated Wires:

QCS 2014

8

(a)

(cable shall be to BS 6004, rated 450/750 V, with high conductivity copper conductors and PVC compound insulation. Colour coding shall be in accordance with table 51 A of BS 7671

(b)

wires shall be continuous from outlet to outlet and no splice shall be made except within outlet and junction boxes. A separate neutral wire shall be provided for each circuit. Wires shall be left sufficiently long enough (minimum 150 mm) to permit making final connections.

Mineral Insulated Cable: to BS EN 60702 : Part 1, rated 600/1000 V

(b)

cable shall comprise of a pressure packed magnesium oxide insulation contained within a continuous soft ductile copper sheath and copper conductors embedded in the dielectric in standard formation

(c)

cable termination kit shall comprise of conductor insulation of neoprene sleeving retained by cone shaped beads beneath a fibre sealing disc. Each conductor shall be identified with regard to phase etc., by means of sleeving placed over the neoprene insulation

(d)

cable seals shall comprise of screw-in-pot type seals, with brass ring glands designed to accommodate the pot seal.

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Terminals: 2

(a)

for cable up to 6 mm : two screw pinching type

(b)

for cable over 6 mm : grip lug type cable sockets

(c)

brass saddles: purpose made, two fixing screw type.

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Heat Resistant and High Temperature cable: to BS 6500, or BS 6004 300/500 V grade, designated EPR (ethylene polypropylene rubber) insulated HOFR sheathed, 85 °C or EPR insulated OFR sheathed, 60 °C. Conductor(s) shall be flexible class 5 tinned copper to BS 6360. Insulation shall be type GP.1 to BS 6899. Outer sheath shall be HOFR (heat, oil, fume resistant) or OFR (oil and fume resistant) sheath type RS3 to BS 6899 and flame retardant to BS 4066 Part 1, temperature rating 60 ° or 85 °C high temperature cable shall be to BS 6500 or BS 6007, designated 300/500 V grade silicone insulated glass braided, 180 °C. Conductors shall be flexible class 5 tinned copper to BS 6360. Insulation shall be silicone rubber type EI 2 to BS 6899. Outer sheath shall be treated glass fibre braid, temperature rating 180 °C.

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9

10

Flexible Cable: (a)

to BS 6007, or BS 6500, rated in accordance with manufacturer’s tables

(b)

flexible cables subject to excessive heat shall be insulated as (8) above, (a) or (b) as per the Project Documentation requirement.

600/1000V rated XLPE Insulated Cable (a)

to BS 5467, 600/1000V grade, designated XLPE/SWA/PVC for armoured multicore cable, and XPLE/PVC for unarmoured cable

(b)

conductors : plain annealed copper to BS 6360

(c)

cable shall comprise of plain copper, stranded circular conductors insulated with an adequate thickness of extruded cross linked polyethylene (XLPE)

QCS 2014


Page 7

conductors shall be laid up together and warmed circular with suitable performed fillers and warnings, bound with polythene terephthalate (PTP) tape and covered with an extruded PVC sheath, minimum 1.4 mm thick for multicore cable

(e)

armoured multicore cable shall have steel wire armouring and extruded sheath of black PVC

(f)

armoured single core cable shall have aluminium wire armouring and extruded sheath of black PVC

(g)

outer sheath of single core cables shall be at least 2.5 mm thick

(h)

conductor screen : non-metallic comprising either semi-conducting tape or a layer of extruded semi-conducting material

(i)

prevent void formation in insulation by careful control of its passage through temperature graded water baths

(j)

cable shall be terminated with compression glands as specified below, giving adequate mechanical support by locking on the armour and ensuring high earth continuity.

6350/11000V Cable

cable shall be armoured type, rated 6350/11000 Volts, and shall comply with BS 6622. Single core cable shall be designated 11 kV XLPE/AWA/PVC. Multi-core cable shall be designated 11 kV XLPE/SWA/PVC

(b)

conductors shall be stranded copper complying with BS 6360, covered with a semiconducting screen extruded on to the conductors

(c)

insulation shall be extruded cross linked polyethylene suitable for continuous operation at 90 °C, able to accept a final temperature of 250 °C in the event of a short circuit, and covered with a screen consisting of an extruded semi-conducting layer and a copper tape layer

(d)

armoured cables shall have a secure bedding, over the core or core assembly, for the armour. For single core cable, the bedding shall consist of a PVC sheath. For multi-core cable, the bedding shall consist of non-hygroscopic fillers

(e)

single core cable shall have aluminium wire armour. Multi-core cables shall have galvanised steel wire armour. Cable shall be covered with a red coloured PVC sheath

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(a)

12

electrical design stress at any point in the insulation shall not exceed 3 kV per mm

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(d)

Instrumentation Cables - Analogue Signals: (a)

to BS 5308 part 2, type 2,300-500 V

(b)

single copper conductor 1/0.8 mm

(c)

polyethylene insulation

(d)

individual screen of aluminium backed polyester tape with tinned copper stranded drain wire

(e)

collective screen of aluminium backed polyester tape with tinned copper stranded drain wire

(f)

extruded PVC bedding

(g)

galvanised steel wire armour

(h)

PVC outer sheath, gray

(i)

core identification as BS 5308 Part 2.

QCS 2014

Instrumentation Cables - Digital Signals: (a)

to BS 5308 part 2, type 2 300-500 V

(b)

single copper conductor 1/0.8 mm

(c)

polyethylene insulation

(d)

collective screen of aluminium backed polyester tape with tinned copper stranded drain wire

(e)

extruded PVC bedding

(f)

galvanised steel wire armour

(g)

PVC outer sheath, Gary

(h)

Core identification as BS 5308 Part 2.

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Pilot cables shall be PVC insulated multi core cables to be used for: (i)

Standard pilot wires protection schemes

(ii)

Telecommunication purpose.

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(a)

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Pilot cables shall comply with following requirements:

Conductors shall be stranded copper, plain annealed and in accordance with BS 6360.

(c)

Core insulation shall be PVC complying with requirements of BS 6746. It shall be applied by an extrusion process and shall form a compact, homogenous body of uniform thickness. Insulation thickness shall be in compliance with BS 6346.

(d)

Core identification shall be by one of the following:

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(b)

Number printed on the core insulation

(ii)

Colour, 4mm cores having colours Red, Blue and Black.

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(i)

(e)

Bedding shall be compliance with BS 6346.

(f)

The cables shall have a single layer of galvanised steel wire armour of diameter 1.6mm in accordance with BS 6346.

(g)

The oversheath shall be of black PVC in compliance with BS 6746 Type 1 compound. It shall have a minimum thickness of 1.7mm and shall be in general compliance with BS 6346.

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Source Tests on Cables

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(a)

16

Provide test certificates against each drum and /or cable length. These shall include:(i)

high voltage D.C. insulation pressure test, between cores, each core to earth, metallic sheath or armour as applicable.

(ii)

insulation resistance test.

(iii)

core continuity and identification.

(iv)

conductor resistance test.

Field Tests on Cables (a)

inform the Engineer prior to the testing of the cables and be responsible for liaising with any other contractor to whose equipment the cables may be terminated to ensure that all parties concerned are aware of the impending tests, to guarantee the safety of personnel and that the isolation of any equipment has been completed. Any special isolation or preparation required to be carried out before cable testing can be completed, shall be carried out by the Contractor responsible for that equipment. All tests shall be carried out by the Contractor and supervised by the Engineer.

QCS 2014


Page 9

(b)

All cables shall be tested in accordance with the latest QGEWC requirements and the relevant BS and IEE regulations for the class of cable. QGEWC shall be given the opportunity to witness the testing of high voltage cables and these shall be tested in accordance with their specific requirements.

(c)

demonstrate correct phasing of cores in all cables throughout the works and test the insulation of all cables, both between the cores and between the cores and earth, during installation with a 500-volt insulation tester.

6.2.3

Sundries

1

Cable Jointing and Termination: joints in wires and cable shall be avoided wherever possible. Joints in flexible cables and cords are not permitted

(b)

joints and terminations of all power cables shall be made by skilled cable jointers approved by the Engineer

(c)

no reduction in the number of strands of a cable core shall be allowed at a cable joint or termination

(d)

ferrules, compression connectors and bare portions of cable core resulting from a jointing or terminating process shall be insulated with an approved type of insulating tape or heat shrinkable tubing after completion of process. Such insulating tape or heat shrinkable tubing shall have equal or better electrical and mechanical properties than those of the original insulation removed, and shall be adhered to the cores etc. securely and permanently. The final thickness shall be in smooth contour throughout the whole length

(e)

every compression joint shall be of a type which has been the subject of a test certificate as described in BS 4579. When a compression joint is made, the appropriate tools specified by the manufacturer of the joint connectors shall be used.

(f)

a circuit protective conductor having adequate cross sectional area and of same material as the phase conductors shall be installed and connected to maintain the effectiveness of the earth continuity across every cable joint

(g)

all cable jointing and termination shall be witnessed by the Engineer

(h)

sufficient spare cable shall be allowed to remake the joint or termination

(i)

above ground cable joints and terminations shall be accessible

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cable cores shall pass through glands or termination boxes directly to equipment terminals, without crosses if practicable.

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(a)

Joints (a)

straight through joints for copper conductors: Where permitted by the Engineer, conductors shall be jointed by approved type compression connectors using the appropriate tools and connectors

(b)

joints shall be made core-to-core.

Joints Boxes and Termination Boxes (a)

malleable cast iron boxes for joints in all power cables shall be compound filled and of adequate size. The boxes shall be fitted with suitable armouring clamps and glands. The armouring of the cables shall be terminated at the armouring clamps and the inner sheath shall pass through the gland. Self amalgamating tapes shall be applied to give fully screening insulation reinstatement where the insulation is screened

(b)

the box and compound shall be at the correct temperature before the compound is poured to allow total adhesion between the compound and the box. The compound shall then be allowed to cool and topped up before the box is closed. No air locks shall be formed within the box

QCS 2014

Page 10

(c)

with the consent of the Engineer, plastic shells fitted with suitably sized armour bond and filled with an approved type of cold pouring encapsulating compound to BS 6910 may be used as an alternative to the compound filled cast iron joint boxes for jointing PVC-insulated power cables. In such cases, the complete jointing kit, including plastic shell, compound, insulating tape etc. shall be from the same proprietary manufacturer who is specialised in manufacturing products for this purpose. The jointing methods and procedures, as laid down by the manufacturer, shall be followed in strict accordance

(d)

MICC mains cable: joints shall be suitably sized galvanised malleable iron adaptable box with glands and fixed base mechanical clamping connectors of approved design. For external use the jointing box shall be enclosed in a second galvanised box with glands, filled with encapsulating compound

Cable Glands (a)

cable glands shall be used for terminating cables to switch gear, switch boards, motor control centres, motors and other equipment

(b)

they shall be brass compression glands and comply with the relevant part of BS 6121, except for MICC cables, which shall comply with BS 6207 Part 2.

(c)

glands for armoured or screened cables shall have suitable clamps

(d)

external compression glands shall have close fitting PVC shrouds

(e)

earthing for armouring and metallic sheaths: suitable brass or copper clamps, and copper strip conductor in accordance with QGEWC requirements, and not less than 2.5 sq. mm

(f)

cables forming part of a LAN or structured cable system shall be terminated to floor plates or wall sockets compatible with the media interface connector specified for the particular network being used.

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Cable Sockets:

shall be correct size for type of cable

(b)

shall be sweating type, or an approved crimping type used with an approved crimping tool

(c)

sweating sockets for conductors 70 sq. mm. and over shall be machined cast brass.

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Fire Barriers:

shall be purpose made, comprising a rigid fixed frame with adjustable seals and a suitable clamping device

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(a) (b)

in fire compartment separation walls and floors shall be same standard of fire resistance as wall or floor.

7

Cable Covers: shall be to BS 2484 and concrete covers exceeding 300 mm wide shall be reinforced.

8

Pipe Ducts : shall be PVC or as indicated.

9

Solder: an alloy of lead and tin to BS EN 29453 grade F or H, unless otherwise recommended by cable manufacturer.

10

Cable Sealing Compounds: shall be tropical grade to BS 1858 or BS 6910 and approved by cable manufacturer, of an oil-resisting compound where the difference in level between cable ends exceeds 6 m.

11

Cleats: shall be an approved claw type cast aluminium, gunmetal, plastic or brass of approved type, two bolt fixing for cables greater than 50 mm diameter.

QCS 2014

Cable Markers: (a)

shall be precast concrete, minimum size 300 x 300 mm x 100 mm deep

(b)

the markers shall be engraved “HV CABLE”, “ELECTRIC CABLE”, “ELV CABLE”, “EARTH PIT” or “CABLE JOINT”, as applicable

(c)

cable marker construction details and engravings shall be approved by QGEWC.

Cable Transits cable transits shall have a stainless steel frame which shall be cast into or bolted to the structural concrete.

(b)

the insert blocks shall be proofed against fire, explosion, water, rodents and gas.

(c)

the design shall be such that at a later date cables can be added or removed with minimal disturbance to the remaining cables.

(d)

the whole cable transit assembly shall be of an approved proprietary modular system which shall be certified by a recognised International Testing Authority.

(e)

full details of proposed cable transits shall be submitted for the approval of the Engineer.

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(a)

Jointing 11 kV, L.V. and Pilot Cables

1

General

All jointing shall be carried out to instructions of QGEWC and the Engineer and only by approved Jointers. All jointing shall be carried out in accordance with the QGEWC Safety Rules.

(b)

All connections to lead sheaths shall be plumbed.

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11 kV Cables

Terminations - These shall generally be of the heat shrinkable type using compression connectors although occasionally compound filled terminations shall be required. Generally crossed cores shall be avoided.

(b)

Straight Joints - Intermediate joints shall be joined in the easiest way avoiding crossed cores.

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Phasing joints - Phasing shall be in accordance with the instructions of QGEWC and the Engineer to obtain correct phasing. The joints shall be of the bituminous filled type using sweated ferrules.

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3

Pilot Cables - These shall be jointed in accordance with instructions of QGEWC and the Engineer. The joints shall be resin filled type using compression connectors for straight joints and mechanical glands for terminations.

4

600/1000 Volt Cables (a)

All jointing shall be on a colour basis such that: (i)

Core 1: Red phase

(ii)

Core 2: Yellow phase

(iii)

Core 3: Blue phase

(iv)

Core 4: Neutral

(b)

For terminations heat shrinkable techniques and compression connectors shall be used.

(c)

For straight joints heat shrinkable techniques of joints using bituminous compound or resin shall be used at the discretion of QGEWC and the Engineer.

QCS 2014

(d)


Page 12

For tee or branch joints bituminous compound or resin shall be at the discretion of QGEWC and Engineer. Mechanical or sweated connectors shall be used as decided by QGEWC and the Engineer.

6.3

INSTALLATION

6.3.1

General

1

Installing cables: pull cable into position by hand, where possible using an adequate number of operative roller guides suitably positioned along cable length

(b)

obtain approval of pulling cables by winch or similar appliance

(c)

when pulling by winch or the like, fit a suitable tension gauge into the haulage line between winch and cable. Pulling tension shall not exceed the limit recommended by the cable manufacturer

(d)

do not allow cable to twist or rotate about its longitudinal axis

(e)

lay 3 phase groups of single core cables in trefoil formation. If this is not possible obtain instructions

(f)

install cables to allow any one cable to be subsequently removed without disturbing the remainder

(g)

underground cable horizontal separation shall be a minimum of 150 mm

(h)

damaged cables shall be removed, unless the Engineer agrees to a repair.

(i)

all cables shall be neatly run in all situations. Where two or more cables are to be installed, cable tray must be provided.

(j)

where power cables are surface run on the external faces of structures or above ground level they shall be installed on cable tray. They shall be protected from radiation of the sun by means of purpose made sunshades, which shall be of an approved design, securely fixed and fully ventilated.

(k)

mechanical protection by cable tray covers shall be provided for all cable trays above ground/floor level to a height of 1000mm.

(l)

when more than one cable is to be terminated at particular items of equipment special care should be taken to ensure that all cables to that equipment are routed from a common direction and each is terminated in an orderly and symmetrical fashion. Each and every cable shall be permanently identified at each end by its cable number as noted within the schedules. The identification label shall be of adequate size and style to a pattern approved by the Engineer and shall be securely fixed to its relative cable.

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(a)

(m)

identification labels shall also be fixed on cables at each and every entry and exit point of buried ducts, exits and entry to any structure and in such other positions as are necessary to identify and trace the route of any site cable. The use of punch type adhesive labels (Dymo-tape) will not be permitted.

(n)

where cables enter or leave structures or panel plinths, the ducts including spare ducts shall be sealed at the points of entry or exit. Caulking shall be carried out with an approved asbestos compound and followed by not less than 40mm of epoxy resin two-mix cold waterproof compound or a weak sand/cement mixture as directed by the Engineer. The Contractor shall be responsible for temporarily sealing all cable ducts into structures during the installation stage to prevent accidental flooding of structures.

(o)

during caulking care should be taken to ensure that the serving and/or armouring of any cable is not damaged. Any damaged cables shall be replaced entirely.

QCS 2014


Page 13

all cables entering or leaving hazardous areas (e.g. wet well), air conditioned areas or areas protected by a fixed fire fighting installation shall do so via approved proprietary manufactured cable transits. Cables entering or leaving structures or passing between rooms of the same classification may be sealed by alternative means subject to the agreement of the Engineer.

(q)

cables shall be free from kinks and the whole installation shall present a neat appearance.

(r)

ties of PVC, nylon, plastic or similar material will not be permitted under any circumstances.

(s)

protection of cables against possible mechanical damage shall be provided wherever seen to be necessary by the Engineer. All cables are to be run with particular regard to neatness. Multiple runs are to be arranged so that cables entering or leaving the run do so in a logical order.

(t)

all power cables shall be terminated with palm type compression terminals of the correct type and size.

(u)

special terminals shall be provided where necessary. Standard terminals which have palms/holes which are oversized for the application will not be acceptable. Standard terminals which are drilled out to a larger size, reducing the area of the palm will not be acceptable.

(v)

removal of strands or shaving of conductors to enable them to be terminated at terminals which are not designed for the size of cable necessary will not be permitted at any point.

(w)

pneumatic crimping machines shall be employed with correctly sized dies. Hand crimping shall not be used.

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(p)

Bending Radius: as large as possible and cable shall not to bend to a radius less than that specified in the relevant British Standard, QGEWC regulations or manufacturer’s recommendation, whichever is largest.

3

Underground Cables in PVC-u Ducts: cables shall be installed in ducts where there is hard standing or vehicular passage. Ducts where there is vehicular passage or landscaped area shall be concrete encased

(b)

cable duct size shall be as specified in the Drawings, to BS 3506 Class B or BS 4660.

(c)

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However the minimum duct wall thickness shall be as per the following:

DUCT SIZE (mm)

DUCT WALL THICKNESS (mm)

75

3.2

100

3.4

150

3.6

200

4.2

(d)

run cables at least 300 mm clear of other services, whether the latter run parallel or transversely to cable trench. use pulling compound, or lubricant to avoid excessive stress on the cable, if required

(e)

run cables below intersecting piped services, unless the cable would be at a depth exceeding 2 m, in which case seek instructions

(f)

ducts shall not be filled with cables to more than 60 % of their capacity

QCS 2014

Page 14

(g)

nylon draw cords shall always be left in ducts

(h)

cable duct pits shall be provided at each change in direction and in any case at distances not exceeding 30 m

(i)

ducts shall be suitably sealed with polyurethane foam or proprietary cable sealing arrangements if specified

(j)

empty ducts shall be plugged with removable plugs

(k)

ducts shall have a minimum diameter of 100 mm.

Direct Buried Cables: the excavation and backfilling of cable trench work shall be carried out by the Contractor.

(b)

excavated spoil shall be removed from the route of the trench. There shall be no loose stones or other debris on either side of the trench for a distance of 1000mm.

(c)

the Contractor shall supply and lay the sand bedding, cables, sand blinding, cable cover tiles and marking tape. He shall also supply and lay cable route marker posts after the backfilling and top soiling has been carried out.

(d)

the sanding and laying of all cables shall satisfy the following requirements:

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(a)

cable depths shall be measured from the finished ground level unless otherwise directed by the Engineer.

(ii)

H.V. cables shall be laid at a depth of 1 meter.

(iii)

L.V. cables shall be laid at a depth of 0.6 meter.

(iv)

H.V. and L.V. cables may be run in the same trench but should be staggered. however where necessary to pass through ductwork, cables shall be laid vertically on top each other with the H.V. cables at the lowest level with a good sand blinding forming the sand bedding for the L.V. cables.

(v)

before laying in cables the Contractor shall inspect the trench work to ensure that the trench bottom is of a smooth and firm contour and free from any sharp materials or obstructions.

(vi)

cable bedding within the trenches shall be formed by a 200-mm sand layer.

(vii)

cables shall be laid with adequate separation and shall be “snaked” to avoid tension during backfilling operations and subsequent settlement.

(viii)

before sanding and backfilling, all laid cables shall be inspected by the Engineer, and a further inspection following sanding and tiling shall be made by the Engineer before backfilling.

(ix)

after cables have been laid, they shall be covered by a further 200-mm of sand, which shall be well tamped around the cables. Mechanical punners shall not be used for this work.

(x)

after sanding cable cover tiles shall be placed in position to overlap the cables by a minimum of 50 mm either side of the cables as per Clause 6.3.5 of this Section.

(xi)

the Contractor shall carry out backfilling and shall ensure that cable cover tiles are undisturbed and that large rocks, stones and the like (more than 20mm diameter) are eliminated from backfill spoil.

(xii)

after backfilling the Contractor shall reinstate to finished ground level. The Contractor shall lay in position the necessary cable route markers at a maximum of 10 meters apart and at entries to buildings and any change in direction.

(xiii)

cables are to be spaced in accordance with QGEWC requirements i.e. M.V./M.V. – 700mm, M.V./H.V. – 1000mm and H.V./H.V. – 1000mm.

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QCS 2014


Page 15

(xiv) the Contractor shall provide cable route markers to the approval of the Engineer and engraved “Electricity Cables”, or other suitable legend, with the appropriate voltage.

protection shall be provided where mechanical damage is possible

(b)

unarmoured cables shall be protected by conduit, ducting or trunking

(c)

cables shall be protected from direct sunlight

(d)

cable spacings and layouts shall be as table 4A of BS 7671

(e)

cables shall be run at least 150 mm from other services.

Underground Cables in trenches in areas of hard standing cables may also be installed in concrete or brick cable trenches with removable covers

(b)

cables may be laid in a single layer on the trench floor, otherwise they shall be supported on the sides of the trench on cable tray by cleats or ladders

(c)

cable spacings and layouts in the trenches shall be as table 4A of BS 7671

(d)

other services shall not be run in cable trenches.

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7

(a)

Cable Supports: (a)

cables shall be supported in accordance with the methods described in table 4A of BS 7671. Other methods shall be approved by the Engineer

(b)

cables shall be supported at regular intervals and at spacings a maximum of 400 mm

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6

Cables above Ground:

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5

for cleats for horizontal runs and 550 mm for vertical runs vertical cable runs exceeding 100 m shall incorporate tension releasing sections

(d)

structured cable management systems or ladders shall be of G.R.P or galvanised steel cable supports shall be provided at 300 mm intervals

(e)

MICC Cables:

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(c)

run on surface of walls ceilings. Where embedded, run in a PVC trough or conduit

(ii)

run cables in square symmetrical lines. Where single core cables are run in groups, bend the sheaths at maximum 50 mm centres

(iii)

fix surface run cables with saddles at maximum 300 mm centres.

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9

Heat Resistant Cables: (a)

in areas where a constant ambient temperature exceeding 55C will occur, run all final sub-circuits and distribution circuits in heat resistant cable

(b)

make conversion from PVC cable to heat resistant cable with a fixed block connector housed and fixed into a conduit box or equal, except where the conversion of cable types emanate from a switch, ceiling rose or similar fixed connector accessory.

Flexible Cables: (a)

flexible cable shall be kept to a minimum and concealed if possible

(b)

mechanical retainment shall not depend on electrical connections.

QCS 2014

Sealing Cables: (a)

seal both ends of cables immediately after tests

(b)

seal MICC cables immediately after cutting to prevent hygroscopic action by the dielectric. All cables shall give an infinity test when tested on a 1000 volt Megger immediately, and 48 hours after sealing

(c)

seal aluminium sheathed cables with a metal cap plumbed to the sheath

(d)

seal plastic sheathed cables with a plastic cap embracing the wires and outer sheath

(e)

mark cable ends in accordance with the relevant BS.

QGEWC will require to carry out inspections at the following stages: Completion of excavations

(b)

Completion of bedding of trench prior to cable installation.

(c)

Cable installation

(d)

Completion of surround over cables and installation of cable tiles etc.

(e)

Upon completion of reinstatement.

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(a)

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10


The Contractor must not progress from one stage to the next of the above without the approval of QGEWC and the Engineer. The Contractor shall be responsible for arranging inspections by QGEWC to suit his programme of Works.

13

Cable Segregation

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12

Only conductors carrying signals of the same instrumentation signal category shall be contained within any one multi-core cable.

(b)

In each instrumentation signal category, a further segregation is required to ensure that conductors forming part of an intrinsically safe circuit are contained within multicore cables reserved solely for such circuits.

(c)

High integrity signals such as data transmission or critical shut down signals shall be contained in separate cables.

(d)

ICA/Telemetry cables sharing a cable tray, duct or route with power cables shall be avoided. Power cables are defined as a.c. cables above 50 volts with a 10-amp rating. Where this is not practicable, a minimum maintained separation between cables should be provided in accordance with Table 6.1.

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Where the maximum current exceeds 100 amps or the voltage exceeds 650 volts, the minimum segregation shall be in accordance to Clause 6.3.3 of this Section.

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(e)

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(a)

(f)

Where the length of an enforced parallel run between power and ICA/Telemetry cables is greater than 500 meters, a progressive “pro-rata” increase in the segregation distance shall apply.

(g)

The segregation distances shall be maintained by positive means and shall apply to both above ground and below ground installations.

(h)

Where a crossover between power and ICA/Telemetry cables is unavoidable the cable shall be arranged to cross at right angles. The number of crossovers shall be kept to a minimum.

(i)

Where cable installations are of a restrictive nature such as entries into buildings, panels' etc. relaxation of the minimum segregation distance requirement from a power cable(s) is acceptable. The minimum segregation distance shall then be the distance, determined by the length of the parallelism at the restrictive section of the installation.

(j)

Where a manufacturer’s installation specification requires greater segregation than detailed in Table 6.1 such as for data highway cables etc. the Contractor shall comply with the manufacturer’s segregation specification.

QCS 2014


Page 17

(k)

Cables of different categories shall not be installed in the same duct

(l)

Public Telephone service (Telecom Provider) cables shall be installed in separate ducts

Table 6.1 Minimum Segregation Distance for Cables Minimum Segregation Distance Requirement in mm Distance over which parallelism exists between signal and power cables in metres Power cable

Instrumentation Signal Classification Category to BS 6739 or equivalent

0 - <3 3 - <10 10 - <100 100 - <250 250 - < 500

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Cat. 3 50 100 150 200 250 300

100 150 200 275 350

150 200 250 350 450

175 200 250 350 500

250 300 450 525 650

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Maximum current 100 amps at any phase voltage up to 650 volts a.c.

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0 - <3 3 - <10 10 - <100 100 - <250 250 - < 500

ta

Maximum current 50 amps at any phase voltage up to 650 volts a.c.

50 100 100 150 200 250

qa

0 - <3 3 - <10 10 - <25 25 - <100 100 - <250 250 - < 500

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Maximum current 10 amps at any phase voltage up to 250 volts a.c. or d.c.

.

Cat. 2

Cable Trays

1

Generally:

m

6.3.2

(a)

install cables on trays in a single layer, unless otherwise specified

(b)

use purpose made straps or saddles to maintain cables in a neat regular disposition

(c)

secure cables with load bearing cleats securely fixed to the tray, where trays do not directly support the cables

(d)

space cleats, saddles and straps at maximum centres recommended in QGEWC Regulations, as above, or by cable manufacturer

(e)

cable trays and installation shall be in accordance with Part 9 of this section, QGEWC regulations and BS 7671.

6.3.3

Spacing Between Cables

1

High Voltage Cables (a)

11,000 volt cables shall be laid with a horizontal spacing of 750mm between centres and a minimum distance of 150mm from trench wall.

QCS 2014

(b)


Page 18

Pilot cables shall be laid with a horizontal spacing of 140mm from the associated main cable in case of multiple cables trenches pilot cables shall be laid between the power cables.

Low Voltage Cables - 1000 volt main cables shall be laid with a horizontal spacing of 600mm between centres and with a minimum distance of 150m m from trench wall.

3

High Voltage and Low Voltage Cables in same trench - Where 11,000 volt and 1000 volt cables are laid in the same trench the spacing between the 11,000 volt and 1,000 volt shall be 750mm.

4

Reduction of Spacing - Any reduction from above spacing can only be permissible for lengths of 10 m or less.

6.3.4

Trench Depth

1

High Voltage - For 11,000 volt cables the trench shall be 950mm deep.

2

Low Voltage

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For 1,000 V main cables the trench shall be 850 mm deep

(b)

For 1,000 V service cables the trench shall be 650mm deep.

ta

(a)

Arrangements for Trenches with High Voltage and Low Voltage Cables - Where 11,000 volt and 1,000 volt cables are to be laid along the same route a stepped trench shall be dug with the 1,000 volt cables laid inside i.e away from the road.

6.3.5

Cable tiles

1

The Contractor shall provide and install:

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3

Concrete cable tiles over all 66 kV cables. The cable tiles shall be of the size and form shown on the drawings. Samples must be provided for approval by QGEWC and the Engineer and satisfy a test of impact strength in accordance with BS 2484: 1985.

(b)

Cable tiles over all 11,000 volt cables and MV/LV instrumentation /Control Cables manufactured from recycled polyethylene indicating cable voltage levels or similar complying with the following requirements: Minimum thickness : 12 mm Length : 1m Width : 24mm 2 Tensile : 8.40 N/mm (B S2782 Method 20C) The tiles shall be marked as specified. The cable tiles must be supplied complete with any pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC and the Engineer for approval prior to use.

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(a)

(c)

6.3.6

Removal of Existing Cables

1

The Contractor shall liaise directly with QGEWC regarding the removal of existing cables and shall not, under any circumstances, commence removal of cables until QGEWC have verified such apparatus as being redundant. Removal of cables shall only be carried out in the presence of a QGEWC Engineer.

2

The Contractor shall arrange uplift of empty cable drums from QGEWC Stores and shall return all recovered cables neatly coiled on the drums provided.

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Page 19

6.3.7

Ducts

1

Ducts are to be supplied by the Contractor. They shall be of the following type: Material Internal Diameter Minimum wall thickness

- High impact resistance PVC - 150 mm or 100 mm as specified - 3.6 mm (for 150 mm ducts) or 2.4 mm (for 100 mm ducts)

Samples shall be provided for approval by the Engineer prior to use.

6.3.8

Quarry Scalping

1

Shall comprise of quarried limestone materials having particle sizes varying from 5 mm down to dust with a homogenous mixture of all particle sizes.

2

The materials shall have specific mechanical and thermal resistive qualities as defined below:

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.

2

Thermal Resistivity - The material shall be subject to a 90 % compaction, using an amount of water equal to optimum moisture content. After subsequent drying, such that the water content does not exceed 2% of the weight of the sample, the thermal resistivity of the material shall not exceed 2.0 C M/Watt

(b)

Mechanical Qualities - The scalping material shall have mechanical qualities that meet the requirements of the QCS Roadworks Section.

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(a)

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END OF PART

QCS 2014

Section 21: Electrical Works Part 07: Conduits and Conduit Boxes

Page 1

7

CONDUITS AND CONDUIT BOXES ............................................................. 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

General Reference References Description Submissions

7.2

PRODUCTS ................................................................................................... 3

7.2.1 7.2.2 7.2.3

Rigid PVC Conduit and Fittings Rigid Steel Conduit and Fittings Flexible Conduit and Connections

7.3

INSTALLATION ............................................................................................. 6

7.3.1 7.3.2 7.3.3 7.3.4

Preparation Installation of Conduit Installation of Flexible Conduit Cleaning

2 2 2 3

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QCS 2014


Page 2

CONDUITS AND CONDUIT BOXES

7.1

GENERAL

7.1.1

General Reference

1

The work of this section is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2

Co-ordinate the work with all other services affecting the work of this section.

3


7.1.2

References

1

The following references are referred to in this Part:

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General Provisions for Electrical Installation Cables and Small Wiring

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.

7

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BS 2782......................Method of testing plastics

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BS EN 50086-1:1994 .Flexible steel conduits and adapters for the protection of electric cable. BS 4568......................Steel conduits and fittings, metric units

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BS 4607......................Non-metallic conduits and fittings for electrical installations rigid PVC conduits and conduit fittings, metric units

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BS EN 60423..............IEC 423-A, Conduit diameters and threads for conduit and fittings. Description

1

This Section to include the supply, installation and commissioning of all conduit works in accordance with the Project Documentation.

2

General:

o

conduit system shall generally be concealed and installed as indicated, unless otherwise indicated

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(b)

light and power circuits, fire alarm, telephone, signal and other low current system wiring shall be drawn in conduits unless otherwise indicated

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(a)

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7.1.3

(c)

light and power circuits, fire alarm wiring, telephone wiring, signal wiring and low current system wiring shall each be run in separate conduit and wire way

(d)

cable insulated for two different categories of circuit shall be segregated

(e)

irrespective of service, conduit and fitting used shall be: (i)

where embedded: heavy gauge rigid PVC complying to BS 4607, BS 6053 and BS 6099 Part 2, section 2.2

(ii)

where surface mounted, exposed: galvanised steel conduit as per BS 4568

(iii)

where installed above false ceilings and in voids: galvanised steel throughout the circuit

(iv)

where installed in flame proof and hazardous areas: galvanised steel

(v)

from terminal box to machine: flexible steel conduit as per BS BS EN 500861:1994.

QCS 2014


7.1.4

Submissions

1

Samples: (a)

2

cut-away samples of all sizes of conduits, conduit boxes and fittings of each type shall be fixed to a board and submitted to the Engineer.

Product Data: (a)

3

Page 3

at the time of submitting samples submit manufacturer’s details, catalogues and copies of test certificates confirming that offered types comply with the Specification.

Shop Drawings: submit drawings of proposed conduit layout and obtain approval before commencing work.

PRODUCTS

7.2.1

Rigid PVC Conduit and Fittings

1

Standards:

qa

Conduit and fittings shall comply with BS 4607: Part 1 and CEE Publication 26 or revised/amended/updated standards. In addition, conduit and fittings shall comply with this specification where requirements are more stringent

(b)

Conduit diameters shall comply with QGEWC regulations.

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(a)

Physical Properties:

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conduit and fittings shall be:

resistant to high temperatures

(ii)

non-hygroscopic

(iii)

self-extinguishing

(iv)

of adequate insulation resistance and electric strength

(v)

inert to all liquid normally discharged from residential, commercial and industrial premises

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(i)

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(a)

(vi)

suitable for installation, storage and transportation at temperature not normally below -5 ° C. or above 85 ° C. and at these temperatures shall not:  

(vii)

3

soften or suffer any structural degradation show signs of cracking, or deform so that cables cannot be easily drawn in or are likely to be damaged when drawing in, when bent, compressed or exposed to extreme temperature of adequate mechanical strength and thermal stability

(viii)

suitably and indelibly marked and identified. Markings shall include nominal size and be easily legible

(ix)

Smooth inside and outside and free from burrs and sharp edges. Surfaces and corners over which cables may be drawn shall be smooth and well rounded.

Sizes of Conduit: (a)

(minimum 20 mm, internal diameter unless otherwise indicated

QCS 2014


(b)

where size is not indicated: select in accordance with the regulations and as proper to the number and size of conductors.

(c)

The minimum conduit wall thickness shall be as per the following: CONDUIT WALL THICKNESS

CONDUIT SIZE (mm)

1.9

32

2.3

38

2.5

50

3.1

.

25

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1.8

ta

conduit entries shall be designed to ensure a watertight joint.

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Expansion fittings: type to be approved.

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(a)

PVC Conduit Boxes:

PVC Conduit Boxes can be used through PVC Conduit raceway system and shall comply with BS 4607

(b)

metallic conduit boxes as specified elsewhere in this section can be used alternatively if required for PVC conduit raceway system

(c)

all boxes shall be provided with tapped brass inserts for fixing the screws

(d)

all boxes for switches, sockets, outlets, etc., shall be rigid PVC or metallic type and their dimensions shall be suitable for fixing the switches, sockets and other accessories.

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(a)

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6

20

Fittings: (a)

5

(mm)

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Page 4

Rigid Steel Conduit and Fittings

1

Rigid Steel Conduit

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7.2.2

(a)

all metallic conduits shall comply with BS 4568 and of Class 4 rigid steel screwed type having an interior and exterior zinc coating of uniform quality and appearance throughout all surfaces

(b)

conduits shall not be less than 20 mm diameter size, and shall be complete with all necessary threaded fittings, couplings and connecting devices having galvanised equivalent finish

(c)

conduits and fittings shall be manufactured specially for electric wiring purposes. When manufactured by a continuous weld process, weld heads both inside and outside the tube shall be completely removed prior to galvanising

QCS 2014


Page 5

all conduits and fittings shall be free from rust or other defects on delivery to the site and shall be properly stored in covered racking so that it is protected from mechanical damage and damage by weather and water whilst stored on the site

(e)

all conduits shall be coupled to boxes and trunking wires using brass male bushes. All such bushes shall be hexagon headed, heavy duty long threaded type

(f)

all conduit expansion couplings used shall be fabricated from material equal or equivalent to that of the conduit with which the coupling is to be used, having factory installed packing ring and pressure ring to prevent entrance of moisture. All coupling shall be equipped with earthing ring or earthing conductor

(g)

all conduit runs shall be fixed using spacer bar pattern saddles giving not less than 3 mm clearance between the conduit and the surface to which it is fixed. Saddles shall have finish to match the conduit and saddle clips shall be secured to the bar by means of brass screws.

Metallic Conduit Boxes:

metallic conduit boxes shall be used throughout metallic conduit raceway systems, and shall comply with, or be of demonstrated equivalent quality and performance to BS 4568 requirements. All boxes and covers shall be galvanised, zinc plated or rust-proof finish equivalent to conduit finish

(b)

circular and/or rectangular boxes shall be used for pull boxes and terminating boxes, according to size and number of conduits connected to box. Boxes shall be either malleable iron or heavy duty steel construction with welded joints and tapped holes to receive metal threaded cover retaining screws. Self tapping screws will not be permitted

(c)

all boxes, other than those to which a fitting or accessory is to be directly mounted shall be fitted with covers screwed to the box by brass screws. Malleable iron covers shall be used with malleable iron boxes and heavy gauge steel covers shall be used with sheet steel boxes

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(a)

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(d)

(d)

all cover and accessory fixing provisions shall be so positioned that the fixing screws lie completely clear of cable entering the box. All fixing screws shall be of brass all boxes installed in exterior locations, plant rooms, ducts, etc., shall be fitted with approved type gaskets to provide a waterproof seal between box and cover or other items fitted to the box

QCS 2014

(e)


Page 6

all boxes provided as junction boxes where cable joints are specified or permitted, shall be provided with fixed terminal blocks. Such boxes shall be of suitable size to contain the terminal block and sufficient cable to allow neat connections to be made. The terminal blocks shall be fixed to the box by brass screws and shall comprise brass conductor connectors, with brass clamping screws enclosed in porcelain or other heat resisting insulation material which will not distort or otherwise have its properties damaged by temperatures below the highest temperature at which the insulation of any cable connected to it is destroyed.

Flexible Conduit and Connections

1

Flexible Conduit:

to BS EN 50086-1:1994or updated standard, watertight, PVC sheathed, spiralled stainless steel metal type and UV resistant plastic covered . The conduit shall be terminated at boxes and equipment by means of approved stainless steel or brass/bronze compression glands

(b)

to be of the unpacked type for normal atmospheric conditions and non-asbestos packaged for damp situations. Adapters shall be of the solid type rust resistant (Stainless steel/Brass/bronze).

(c)

flexible conduit shall be used for the final connection of rigid conduit to the terminal boxes of machines fitted with a means of drive adjustment and/or where vibrations is likely to occur.

(d)

flexible conduit for use outdoors shall be weatherproof and certified to be resistant to UV radiation.

Flexible Connections:

where connections to electrical machines are to be by multicore glands, the final termination shall be by ring type universal glands and locknuts, and adequate slack cable in the form of a loop or spiral being left to allow for the movement of motors necessitated by belt retensioning, vibration, etc.

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(a)

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(a)

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7.2.3

7.3

INSTALLATION

7.3.1

Preparation

1

Sets and Bends: (a)

conduits up to 32 mm diameter; form on site with an approved bending machine using proper formers, guides, springs, etc., taking care not to deform conduit

(b)

conduits over 32 mm diameter : use coupling fittings.

7.3.2

Installation of Conduit

1

General (a)

run conduit in square, symmetrical lines, parallel to or at right angles to walls and in accordance with the accepted practice

QCS 2014


Page 7

conduit system shall be mechanically continuous and watertight after installation. All conduit system shall be arranged wherever possible to be self draining

(c)

conduit runs between draw-in positions shall conform to QGEWC Regulations regarding no. of bends and lengths of straight run

(d)

installation shall permit easy drawing in of cables

(e)

keep conduits at least 100 mm from pipes and other non-electrical services

(f)

where conduit runs are to be concealed in the structure or are to pass through floor slabs, the Contractor shall be responsible for marking the accurate positions of all chases and holes on site. The Contractor shall arrange the conduit routing to make maximum use of any preformed conduit holes and slots provided in structural beams. Conduit installation on shear walls shall be kept to a minimum. All routings necessary on shear walls shall be agreed with the Engineer before work is put in hand

(g)

install conduits so as not to interfere with ceiling inserts, lights or ventilation outlets.

(h)

install conduit in accordance with NECA "Standard of Installation." or other national standards or Codes of Practice to the approval of QGEWC.

(i)

install nonmetallic conduit in accordance with manufacturer's instructions.

(j)

arrange supports to prevent misalignment during wiring installation.

(k)

support conduit using coated steel or malleable iron straps, lay-in adjustable hangers, clevis hangers, and split hangers.

(l)

group related conduits; support using conduit rack. Construct rack using steel channel ; provide space on each for 25 percent additional conduits.

(m)

fasten conduit supports to building structure and surfaces under provisions of Section "Supporting Devices"

(n)

do not support conduit with wire or perforated pipe straps. Remove wire used for temporary supports

(o)

do not attach conduit to ceiling support wires.

(p)

arrange conduit to maintain headroom and present neat appearance.

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route conduit parallel and perpendicular to walls. route conduit installed above accessible ceilings parallel and perpendicular to walls.

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(q)

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(b)

(s)

route conduit in and under slab from point-to-point.

(t)

maintain adequate clearance between conduit and piping.

(u)

cut conduit square using saw or pipecutter; de-burr cut ends.

(v)

bring conduit to shoulder of fittings; fasten securely.

(w)

join nonmetallic conduit using cement as recommended by manufacturer. Wipe nonmetallic conduit dry and clean before joining. Apply full even coat of cement to entire area inserted in fitting. Allow joint to cure for 20 minutes, minimum.

(x)

use conduit hubs or sealing locknuts to fasten conduit to boxes and fittings.

(y)

install no more than equivalent of two 90-degree bends between boxes. Use conduit bodies to make sharp changes in direction, as around beams. Use hydraulic one-shot bender to fabricate and factory elbows for bends in metal conduit larger than 2-inch (50-mm) size.

(z)

avoid moisture traps; provide junction box with drain fitting at low points in conduit system.

QCS 2014


Page 8

provide suitable fittings to accommodate expansion and deflection where conduit crosses seismic , control and expansion joints.

(bb)

provide suitable pull string in each empty conduit except sleeves and nipples.

(cc)

use suitable caps to protect installed conduit against entrance of dirt and moisture.

(dd)

provide supports for fittings independently of any false ceiling for sunk and concealed conduit systems.

(ee)

size conduits, draw-in boxes and junction boxes in accordance with regulations.

(ff)

swab whole of the conduit system to remove any loose matter or dirt before cables are pulled in.

(gg)

where conduits connect to switch boxes draw-in boxes and the like the conduits must have a machined faced socket screwed on to the end which when tightened is flush with the outside of the box. The conduit is then to be secured to the apparatus by means of a hexagon smooth bore brass bush screwed from the inside of the apparatus into the conduit socket in order to make a sound and tight mechanical joint.

(hh)

all horizontal runs shall be supported at no more than 900 mm. Vertical runs shall be supported at no more than 1200 mm. Where directional changes occur support shall be provided at no more than 150 mm either side of the bend.

(ii)

hot bending shall be carried out on all non-metallic conduits. A bending spring of the correct size shall be used in all cases. The heat source shall be provided by a hot air torch. When the conduit is in a pliable state it shall be bent around a suitable former and held in position until the conduit has set. No other method will be approved.

(jj)

couplers, slip type bends and spouted fittings shall be made using semi permanent mastic sealing compounds. Expansion couplers shall be used in surface installations where straight runs exceed 8 meters.

(kk)

standard junction or adaptable boxes shall be provided at all junctions and at sharp changes of direction in addition to any special positions where they are required on Site. Inspection couplers may be used in long runs to facilitate drawing in cables.

(ll)

particular care must be taken to ensure that no water is allowed to enter conduit at any time and all conduits shall be arranged with adequate ventilation and drainage where necessary as directed by the Engineer. Inaccessible junction boxes will not be allowed.

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(aa)

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(mm) only continuous lengths of buried conduit shall be installed between boxes, no joint boxes being allowed in the floor screeds. Conduits crossing expansion joints shall be fitted with couplings of approved manufacture. (nn)

the ends of conduits laid or set in formwork prior to concreting shall be temporarily sealed off with a coupler and a plug.

(oo)

fixing to surfaces of walls shall be by means of spacer bar saddles securely fixed by screws. Where conduits are concealed or laid in structural floors they shall be held in position with substantial fixings of make and pattern to be approved by the Engineer.

(pp)

adaptable boxes shall be manufactured from PVC as previously detailed for conduit boxes and sized to provide sufficient space factor.

(qq)

weatherproof boxes and accessories shall be used outdoors where agreed on Site by the Engineer or where indicated in this Specification or on the Drawings.

(rr)

conduit shall be installed such as to permit complete rewiring without the need to remove false ceiling or carry out builders work.

(ss)

no single conduit serving phase socket outlets lighting points and switches shall contain more than one phase.

(tt)

wiring shall be carried out on the looping-in system and no joints other than at looping-in points will be allowed.

QCS 2014

(uu)

where the conduit system terminates at any equipment requiring a non-rigid connection a flexible conduit shall be installed of the PVC or PVC sheathed metallic type fully watertight with purpose made connection adapters.

(vv)

each flexible connection shall include not less than 400mm length of flexible conduit and a separate earth conductor shall be run within the conduit connected to the earth terminals in the equipment and the fixed conduit run. The flexible conduit shall not be used as an earth continuity conductor.

Runs in Reinforced Concrete: obtain approval for placing PVC conduits before pouring concrete

(b)

run conduits in concrete slabs parallel to main reinforcing steel

(c)

additional openings in finished slabs, where approved, shall be made by drilling, not by breaking

(d)

conduit boxes shall not be nailed to shuttering boards.

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Surface Mounted Conduit (including conduit installed above false ceiling): (a)

fix with distance spacing saddles to allow conduits to be taken directly into accessories without bends or sets.

Concealed Conduit: (a)

fix securely to prevent movement before casting of concrete and screeds, application of plaster and the like

(b)

spacing of clips shall be not greater than as follows:

(iii)

50 mm

1000 mm

ov

900 mm

Supports for exposed conduit shall be fixed at each side of bends.

fix in conduit wherever it crosses as expansion joint in the structure to which it is fixed.

Terminations: (a)

8

32-38 mm

Expansion Fittings: (a)

7

(ii)

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6

Spacing 600 mm

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(c)

(i)

Conduit size up to 25 mm

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5

(to be avoided in partitions and side walls.

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4

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Horizontal or Cross Runs: (a)

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(a)

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3

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make with a flanged coupling, lead washer and hexagonal male brass bush, where conduit runs terminate in cable trunking, distribution boards or any sheet metal structure.

Conduit Boxes: (a)

fix at all outlet points.

7.3.3

Installation of Flexible Conduit

1

All conduits must be secured to outlet boxes, junction boxes or cabinets by placing locknuts on outside of box and locknuts and bushings on the inside of box.

QCS 2014


Page 10

2

Conduits connecting recessed fixtures and their adjacent junction boxes must be flexible metallic conduit 20 mm minimum size and shall be of sufficient length to permit dropping of the fixture below the ceiling and to gain access to the junction box.

3

Conduit to motors shall be terminated in the conduit fittings on the motors, the final connection being made with liquid tight flexible conduit and suitable liquid tight connectors.

4

A green insulated 4 mm (minimum) tinned copper earth connection shall be made between the solid conduit or cable sheath and the equipment, the copper cable being run inside the flexible conduit. Couplings fitted to removable covers or non-metallic equipment etc., shall be bonded to the earthing terminal of the equipment etc. Where changes to flexible conduits occur, a watertight outlet box with threaded entries shall be inserted and the earth connection made to an internal terminal. The cover screws shall not be used for earthing connections.

7.3.4

Cleaning

1

The conduit outlets when installed and before wiring shall be temporarily closed by means of well fitting wooden plugs, and immediately before cables are drawn in, conduit systems shall be thoroughly swabbed out until they are dry and clean

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END OF PART

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QCS 2014

Section 21: Electrical works Part 08: Trunking

Page 1

8

TRUNKING .................................................................................................... 2

8.1

GENERAL ...................................................................................................... 2

8.1.1 8.1.2 8.1.3 8.1.4

General Reference References System Description Submissions

8.2

PRODUCTS ................................................................................................... 3

8.2.1

Trunking

8.3

INSTALLATION ............................................................................................. 6

8.3.1 8.3.2

Installation Cleaning and Adjustment

2 2 2 2

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3 6 7

QCS 2014


Page 2

TRUNKING

8.1

GENERAL

8.1.1

General Reference

1


2


3


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General Provisions for Installation Cables and Small Wiring Conduits and Conduit Boxes Cable Trays

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.

8

References

1


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8.1.2

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BS 729 ........................Hot dip galvanised coatings on iron and steel articles

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BS 3382 ......................Zinc on steel components BS 4607 ......................Fittings and components of insulating materials

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BS 4678 ......................Steel surface trunking

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BS 4678 ......................Cable trunking of insulating materials

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BS EN 10142 ..............Hot dip zinc coated sheet steel

System Description

1

The Contractor shall supply and install the complete trunking system as indicated on the Drawings and specified in this Section.

8.1.4

Submissions

1

Samples: submit samples of trunking and accessories.

2

Product Data: at the time of submitting samples submit manufacturer’s details, catalogues etc.

3

Shop Drawings: submit drawings showing route of trunking system and obtain approval before commencing work.

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8.1.3

QCS 2014


8.2

PRODUCTS

8.2.1

Trunking

1

General:

Page 3

trunking, associated parts and accessories shall be fabricated from hot dipped galvanised sheet steel not less than 16 SWG

(b)

trunking shall be supplied in 3 m lengths or bigger, each length complete with lid, coupler and coupler screws and shall provide adequate earth continuity throughout the whole trunking run

(c)

shall be complete with necessary fittings and accessories. All accessories and fixing materials shall also be of galvanised sheet steel of not less than 1 mm thickness

(d)

if specified in the Project Documentation, trunking, associated parts and accessories shall be fabricated from high impact PVC-u material, having thickness not less than 1.5 mm and shall be complete with necessary fittings and accessories made from the similar material as for the trunking

(e)

trunking shall not be smaller than the minimum size stated on the Drawings or specified later and shall be so sized, if not specified, that a space factor of 35 % is not exceeded. The Contractor shall check the minimum size of trunking specified is large enough for his requirements without exceeding this space factor

(f)

trunking and accessories installed in hazardous and extremely environments shall be heavy duty GRP or 316 S31 grade stainless steel.

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Trunking and Connectors:

shall be to BS 4678: Part 1, but thickness of metal for body and cover material may not be less than those in Table 1. The PVC trunking system shall satisfy the requirement in Part 4 of BS 4678 providing smooth internal and external finishes

(b)

metal thickness for trunking and connectors exceeding 150 x 150 mm external dimensions shall be to approval and shall not be less than that specified in BS 4678 Part 1 for the largest trunking detailed

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(a)

finish for steel trunking:

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(a)

(i)

for internal use: Class 3 heavy protection internally and externally (e.g. galvanised steel to BS EN 10142; protection to BS 4678 : Part 1)

(ii)

for external use: Class 3 protection

(d)

lids shall be clipped and fixed at regular intervals not exceeding 2 m on straight runs, by quick release cam type fasteners. In PVC trunking installations the lids can be slide-in type of proper lengths

(e)

partitions shall be at least 1 mm thick, finished to same standard as trunking. The means of fixing partitions shall prevent them being misplaced and shall not cause corrosion or electrolytic action

(f)

connectors shall span the complete internal surface of the trunking. Trunking sections shall have butt joints

QCS 2014

(g)

3

4


Page 4

accessories for bends and tee-off shall be supplied from the same manufacturer and provided with lids as necessary. Reduction type tee-offs shall be provided where smaller size branch trunking is required.

Bonding links and fastenings: (a)

shall satisfy continuity conditions of BS 4678

(b)

shall not cause corrosion

(c)

separate protective conductor of size not less than 4 mm2 shall run in the PVC trunking system.

Braided Copper Tape: shall be 15 x 2 mm minimum having a resistance from fixing to fixing equal to or less than the links used in standard trunking joints.

(b)

fixings used for securing or fitting shall not cause corrosion or electrolytic action. Black screws are not acceptable

(c)

brackets, mild steel angle or channel finished to same standard as trunking.

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shall have cable support units with insulated pins at centres not exceeding 3 meters.

Horizontal Trunking:

Sizes exceeding 100 x 50 mm shall have cable separators with insulated pins at maximum centres not exceeding 2 m.

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(a)

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Vertical Trunking: (a)

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shall have a zinc coating finish to BS 729 or BS 3382 : Part 2, or equivalent

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6

Steel Screws and Fasteners:

Surface Metal Raceway

the surface metal raceway assembly shall comprise of a metal base and cover to form a raceway intended for surface mounting, except in very small sizes. The cover shall be removable to allow wire installation after the raceway has been installed as a complete system.

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(b)

the surface metal raceway shall be constructed of sheet metal channel with fitted cover.

(c)

the minimum size of the surface metal raceway shall be 50 mm x 50 mm or as specified on the layout drawings.

(d)

fittings, Boxes, and Extension Rings as practical as possible shall be chosen from the manufacturer's standard range of accessories.

(e)

all accessories shall be complete with removable covers.

Surface Nonmetal Raceway (a)

the surface nonmetal raceway assembly shall comprise of a molded or extruded nonmetallic base and cover to form a raceway intended for surface mounting.

QCS 2014

Page 5

(b)

the surface nonmetal raceway shall be constructed of heavy-duty rigid unplasticised PVC channel with fitted cover. The material shall be self-extinguishing and shall be unaffected by sunlight and/or water. The material shall be suitable for continuous ambient temperatures of 650 C.

(c)

the minimum size of the surface metal raceway shall be 50 mm x 50 mm or as specified on the layout drawings.

(d)

fittings, Boxes, and Extension Rings as practical as possible shall be chosen from the manufacturer's standard range of accessories.

(e)

all accessories shall be complete with removable covers.

Multioutlet Assembly (a)

the multoutlet assembly shall comprise of surface metal raceway with receptacles. Receptacle devices may be pre-wired in which case they are regularly spaced.

(b)

the multoutlet assembly shall be constructed of sheet metal channel with fitted cover and/or with pre-wired receptacles where specified.

(c)

the sizes of the multoutlet assembly shall be as indicated on the layout drawings.

(d)

provide covers and accessories to accept convenience receptacles in conjunction with the wiring devices.

(e)

the spacing between the receptacle shall be 150, 300 or 450 mm or as specified/indicated on the Drawings.

(f)

the Colour of receptacle shall be subject to the approval of the Engineer.

(g)

couplings, elbows, outlet and device boxes, and connectors as practical as possible shall be chosen from the manufacturer's standard range of accessories.

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the wireway shall be Narrow sheet metal enclosure, rectangular in cross section with hinged or removable covers for housing and protecting electric wires and cable and in which conductors are laid in place after the wireway has been installed as a complete system.

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Wireway

the wireway shall be general purpose, oiltight and dust-tight or rain-tight type as specified and/or indicated on the drawings.

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(c)

knockouts shall be as per manufacturer standard.

(d)

the sizes of the wireways shall be as indicated on the drawings.

(e)

the wireways shall be provided with Screw cover and full gasketing.

(f)

the fittings shall be lay-in type with removable top, bottom, and side and be provided with captive screws. Include drip shield where specified.

QCS 2014


8.3

INSTALLATION

8.3.1

Installation

1

Fixing Trunking: trunking shall be properly aligned, and securely fixed at maximum 2 meters centres on straight runs. At bends, angles and offsets fix with additional fixings at centres not exceeding 150 mm on each side of the fitting

(b)

only manufacturers bends, T-offsets and accessories shall be used. Site fabrication shall not be permitted.

Settlement and Expansion Joints: make a trunking joint where trunking crosses such joints

(b)

make connection through slotted holes allowing a 10 mm movement horizontally and vertically

(c)

earth continuity link across joints shall be braided copper tape which is long enough to allow for the maximum movement of trunking. Fold braid ends.

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(ii)

at each floor level when trunking is installed in riser ducts.

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where trunking passes through walls, floors and ceilings

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make connections to conduits, multiple boxes, switchgears, switchboards, motor control centres and distribution boards with flanged units.

Cable Retaining Straps: (a)

fix at not exceeding 1m centres.

Raceway and Wireway

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(i)

Connections: (a)

5

where specified, install non-combustible, non-metallic fire barriers

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Fire Barriers: (a)

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Page 6

(a)

install products in accordance with manufacturer's instructions.

(b)

use flat-head screws, clips, and straps to fasten raceway channel to surfaces. Mount plumb and level.

(c)

use suitable insulating bushings and inserts at connections to outlets and corner fittings.

(d)

provide steel channel for supporting the wireways.

(e)

close ends of wireway and unused conduit openings.

(f)

earth and bond raceway and wireway as described under the "Earthing and Bonding" Part of QCS.

(g)

provide circuit cable clamps at no greater than 500 mm intervals for raceways installed in vertical runs.

QCS 2014


8.3.2

Cleaning and Adjustment

1

Making Good:

Page 7

(a)

make good cutting and damages of the steel trunking systems, remove burrs and rough edges and corrosion and treat with a rust proofing agent, followed by an application of zinc epoxy

(b)

provide a coat of paint to match adjacent surface for PVC system

(c)

provide the paint after application of the zinc epoxy for steel trunking system.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 09: Cable Trays

Page 1

9

CABLE TRAYS .............................................................................................. 2

9.1

GENERAL ...................................................................................................... 2

9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7

General Reference References Description Quality Assurance Submissions Delivery, Storage and Handling Co-ordination

9.2

PRODUCTS ................................................................................................... 3

9.2.1 9.2.2

General Materials

9.3

INSTALLATION ............................................................................................. 7

9.3.1 9.3.2 9.3.3

Installation Erection Earthing

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2 2 2 2 2 2 2 3 3 7 8 9

QCS 2014


Page 2

CABLE TRAYS

9.1

GENERAL

9.1.1

General Reference

1


2

Co-ordinate the work with all other services affecting the work of this section.

3


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General Provisions for Electrical Installations Cables and Small Wiring Conduits and Conduit Boxes

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References

1


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9.1.2

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BS 729 ........................Hot dip galvanized coating on iron and steel articles

Description

1

Provide all labour, materials, equipment, services and accessories necessary to furnish and install the work of this Section, complete and functional, as indicated in the Project Documentation and as specified herein.

9.1.4

Quality Assurance

1

Reference standards as detailed under Part 1 and this Part Clause 9.1.4.

9.1.5

Submissions

1

Reference Part 1

9.1.6


1

Deliver, store and handle materials and products in a manner to prevent damage.

2

Reference Part 1

9.1.7

Co-ordination

1

The work of this Section shall be completely co-ordinated with the work of other services.

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9.1.3

QCS 2014


Page 3

9.2

PRODUCTS

9.2.1

General

1

The cable tray system shall be of one manufacturer and shall include factory-made trays, tray fittings, connectors and necessary accessories and supports to form a complete cable support system.

2

The cable tray system shall include the following factory-made tray elements: straight cable trays and ladders

(b)

fittings as horizontal and vertical bends of various angles, crosses, tees, wyes, reducers, vertical riser elements

(c)

connectors

(d)

all necessary fixing accessories.

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(a)

Manufacturer’s standard accessories shall be used and site fabrication shall not be permitted.

4

Horizontal run of cables laid on cable tray and exposed to direct sunlight shall be provided with covering at higher level to allow for ventilation. Cable tray shall be raised 15 cm from finished floor level.

5

Cable trays shall confirm to requirements as specified in BS 7671, NFPA 70 - National Electrical Code, U.S.A or other equivalent standard as applicable.

6

Cable trays specification and installation shall be in accordance with QGEWC regulations and IEE latest edition as applicable.

7

The product selected and proposed shall include manufacturer's Instructions that Indicate application conditions and limitations of use stipulated by product testing agency specified under regulatory requirements.

8

The contractor shall select the product only from manufacturer’s specializing in manufacturing products specified in this Section, with a minimum five years documented experience of the products being satisfactorily in use in a similar service and climatic conditions.

9

The contractor shall ensure proper co-ordination with related civil activities prior to the selection of the equipment.

10

The contractor shall clearly show locations of trays, service fittings, junction boxes, and branch circuiting arrangements on the drawings.

9.2.2

Materials

1

The whole of the tray work, trays, fittings, supports shall be of mild steel hot dipped galvanized after manufacture to BS 729. The thickness of the protective sheath on any element shall not be less than 55 microns.

2

Cable trays shall be constructed from mild steel hot dip galvanized and of minimum thickness of 1.5 mm.

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QCS 2014


Page 4

Insert elements, bolts, screws, pins, etc., shall be mild steel cadmium plated.

4

Tray work shall have oval perforations. Ladder type trays shall be used for vertical runs as approved by the Engineer.

5

All trays (straight and fittings) shall be welded construction and be a heavy duty returned flanged, perforated type, unless specified otherwise. The minimum thickness of heavy duty returned flanged cable trays shall be 1.5 mm.

6

Tray components shall be accurately rolled or formed to close tolerances and all edges rounded. Flanges shall have full round smooth edges.

7

Ladder racks shall be of similar construction. The rungs shall be spaced at maximum 300 mm. The system shall allow for installing additional rungs and for replacement of rungs.

8

For all trays, flanges shall be a minimum of 50 mm deep, unless otherwise specified.

9

Cable tray width and radius of curved sections shall be selected to suit the number of cables as shown on drawings and to the approval of the Engineer.

10

Cable trays and accessories installed in hazardous and extremely corrosive environments shall be heavy duty GRP or 316 S31 grade stainless steel.

11

Ladder Type Cable Tray

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definition: Two longitudinal side rails connected by individual cross members (rungs).

(b)

description: NEMA VE 1, specified Class or other approved standard, ladder type tray.

(c)

material: Steel or aluminium as specified.

(d)

finish: ASTM A 123 or other approved standard, hot dipped galvanised after fabrication for steel trays. Painted with specified colour epoxy or PVC coated as specified. The material shall be self extinguishing and non-inflammable and shall be unaffected by sunlight or water. It shall be suitable for continuous ambient temperature of 65° C.

(e)

inside Width: 150, 300, 450, 600, 750 or 900 mm as specified or indicated. inside Depth: 75, 100, 125, or 150 mm as specified or indicated.

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(g)

straight Section Rung Spacing: 150, 225, 300 or 450 mm as specified or indicated.

(h)

inside Radius of Fittings: 300, 600 or 900 mm as specified or indicated.

(i)

provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips, connectors, and grounding straps.

(j)

covers: Flanged or Non-flanged as specified, solid or ventilated and flush or raised cover as specified.

(k)

bond trays carrying LV cables to earth with 16 Sq. mm. PVC insulated copper single core cable, 25x3 mm copper tape if carrying HV cables.

Trough Type cable Tray (a)

definition: Two longitudinal side rails connected by closely-spaced rungs or ventilated bottoms.

(b)

description: NEMA VE 1, specified Class or other approved standard, trough type tray.

QCS 2014


Page 5

material: Steel, aluminium or heavy duty unplasticised PVC as specified.

(d)

finish: ASTM A 123 or other approved standard, hot dipped galvanised after fabrication for steel trays. Painted with specified colour epoxy or PVC coated as specified. The material shall be self extinguishing and non-inflammable and shall be unaffected by sunlight or water. It shall be suitable for continuous ambient temperature of 65 degrees C.

(e)

inside Width: 150, 300, 450, 600, 750 or 900 mm as specified or indicated.

(f)

inside Depth: 75, 100, 125, or 150 mm as specified or indicated.

(g)


(h)

provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips, connectors, and earthing straps.

(i)


Solid Bottom Type Cable Tray

definition: Two longitudinal side rails connected by corrugated or reinforced solid bottom.

(b)

description: NEMA VE 1, specified Class or other approved standard, solid bottom cable tray.

(c)

material: Steel, aluminium or heavy duty unplasticised PVC as specified.

(d)


(e)


(f)


(g)

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inside Radius of Fittings: 300, 600 or 900 mm as specified or indicated. provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips, connectors, and earthing straps.

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(i)

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Channel Type Cable Tray (a)

definition: Single piece formed into channel. Bottom may be solid or with ventilation openings.

(b)

description: NEMA VE 1, specified Class or other approved standard, solid bottom or ventilated bottom type cable tray as specified.

(c)

material: Steel, aluminum or heavy duty unplasticised PVC as specified.

(d)


QCS 2014

Page 6

(e)

inside Width: 75 or 100 mm as specified or indicated.

(f)

outside Depth: As specified or indicated.

(g)


(h)


(i)

covers: Flanged, solid or ventilated cover as specified.

Fiberglass Ladder Type Cable Tray (a)

description: NEMA FG 1, specified Class or other approved standard, ladder type tray.

(b)

material: Fiberglass.

(c)


(d)


(e)

straight Section Rung Spacing: 150, 225, 300 or 450 mm as specified or indicated.

(f)


(g)

provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips, and connectors.

(h)


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description: NEMA FG 1, specified Class or other approved standard, trough type tray.

(b)


(c)


(d)

inside Depth: 75, 100, 125 or 150 mm as specified or indicated.

(e)


(f)

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Fiberglass Trough Type Cable Tray


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(g)

17


Fibreglass Solid Bottom Type Cable Tray (a)

description: NEMA FG 1, specified Class or other approved standard, solid bottom cable tray.

(b)


(c)


(d)

inside Depth: 75, 100, 125 or 150 mm as specified or indicated.

(e)


(f)

provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips and connectors.

QCS 2014

(g)

Page 7


Fibreglass Channel Type Cable Tray (a)

description: NEMA FG 1, specified Class or other approved standard, solid bottom or ventilated as specified, channel type cable tray.

(b)


(c)

inside Width: 75 or 100 mm as specified or indicated.

(d)

outside Depth: As specified or indicated.

(e)


(f)

provide manufacturer's standard clamps, hangers, brackets, splice plates, reducer plates, blind ends, barrier strips, and connectors.

(g)

covers: Flanged, solid or ventilated cover as specified.

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Warning Signs

engraved nameplates shall be provided and installed along the route of the cable tray: 13-mm black letters on yellow laminated plastic nameplate, engraved with the following wording:- “WARNING! DO NOT USE CABLE TRAY AS WALKWAY, LADDER, OR SUPPORT. USE ONLY AS MECHANICAL SUPPORT FOR CABLES AND TUBING!”

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INSTALLATION

9.3.1

Installation

1

Drilling, machining or cutting shall not be carried out after application of protective coat, unless previously agreed by the Engineer. If cutting or drilling is necessary, edges shall be cleaned up and painted with zinc based paint before erection.

2

Installation of vertical runs of tray along the line of vertical expansion joints in structure of the facility shall not be allowed.

3

Cables shall be fixed to the trays by means of PVC covered saddles or straps secured with brass or cadmium plated bolts, nuts and washers.

4

20 % spare capacity shall be maintained once all cables have been installed on trays. Double banking of cables shall not be permitted. space between adjacent cables shall be not less than the radius of the bigger cable.

5

Trays shall not be smaller than the minimum size stated on the Drawings or specified later and shall be so sized; if not specified, the Contractor shall calculate the size of the tray and submit to the Engineer for approval. The Contractor shall check the minimum size as specified is large enough for his requirements and provide 20% spare capacity for future use.

6

Install metallic cable tray in accordance with NEMA VE 1 or other approved standard and local regulations as approved by the Engineer.

7

Install fibreglass cable tray in accordance with NEMA FG 1 or other approved standard and local regulations as approved by the Engineer.

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9.3

QCS 2014


Page 8

8

Support trays in conjunction with supporting devices as described under Section "Supporting Devices". Provide supports at each connection point, at the end of each run, and at other points to maintain spacing between supports of 1200 mm maximum.

9

Use expansion connectors where required.

10

Provide firestopping under provisions of relevant Section to sustain ratings when passing cable tray through fire-rated elements.

11

Ground and bond cable tray under provisions of the Earthing and Bonding Part of QCS. provide continuity between tray components.

(b)

use anti-oxidant compound to prepare aluminium contact surfaces before assembly.

(c)

provide specified cross section copper equipment grounding conductor through entire length of tray; bond to each component.

(d)

connections to tray may be made using mechanical or exothermic connectors.

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(a)

Where specified, install warning signs at 1500 mm centres along cable tray, located to be visible.

13

Where specified, install warning signs at 1500 mm centres along cable tray, located to be visible.

14

Plastic tie-wraps of any description shall not be used for fixing cables to cable tray.

15

Saddle and cleat cables in position as they are installed along the route. Cables should be neatly dressed and crossing of cables should be avoided by good detailed design of cable routing.

16

All cable tray changes in direction or level shall be made via sets and adequately sized angles to provide a support to the cables.

17

Single core cables of the same circuit shall be laid and mounted in purpose made trefoil cleats.

9.3.2

Erection

1

Cable trays arranged one above the other shall have spacing in relation to their width not exceeding a ratio of 1:2 with a minimum distance of 150 mm.

2

Supports

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12

Install fixings and supports: (a)

at 2 meter centres or as specified in project docutmentation

(b)

150 mm from bends, tees, intersections and risers

(c)

as close as practicable to joints

(d)

each side of expansion joints.

QCS 2014

3


Page 9

Supports shall be selected from the following types, to suit the site conditions: (a)

M12 steel threaded drop rods fixed to ceilings complete with GI channels or brackets

(b)

wall support brackets

(c)

cantilever arms

(d)

steel channels.

The cable trays shall be fixed in accordance with site conditions and manufacturer’s recommendations.

5

Join cable tray and accessories with hardware per manufacturer’s recommendations.

6

Avoid mid-span joints.

7

The Contractor shall submit, as required, all calculations relating to tray work and tray supports demonstrating acceptable mechanical stresses and sag.

8

Cable trays installed on roofs shall be supported using GI brackets or concrete blocks. Removable cable tray cover shall be fitted.

9

Access shall be available at all times to remove or replace cables with a minimum of 400 mm between trays and physical obstructions, A/C ductwork etc.

9.3.3

Earthing

1

Cable trays and accessories shall be electrically and mechanically continuous throughout their length.

2

The entire cable tray system shall be bonded and 12 mm x 2.5 mm tinned copper links shall be bolted across each joint in the system by means of bronze nut and bolts, complete with flat and spring washers.

3

All cable trays shall be provided with earth continuity copper tape along the whole route of cable trays which shall be bonded to the main earthing system of the facility. The earth continuity copper tape shall be fixed on cable tray by means of PVC covered saddles or by other means approved by the Engineer.

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END OF PART

QCS 2014

Section 22: Air Conditioning, Refrigeration and Ventilation Par 01: General

Page 1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1

Scope

2

1.1.2

References

2

1.1.3

Standard of Work

2

1.1.4

Data to be Supplied with Tender

3

1.1.5

Practical Completion Certificate

4

1.1.6

Air Conditioning Subcontractor

4

1.1.7

Design Data

4

1.1.8

Rating for Continuous Service and Local Ambient Condition

6

1.1.9

Quality of Materials and Equipment

6

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1.1.10 Cleaning

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1.1.11 Accessibility

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1.1.12 Cutting and Patching

7 7 7 7

1.1.14 Access Panels and Doors

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1.1.15 Flashing

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1.1.13 Inserts, Sleeves, Escutcheons and Curbs.

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1.1.16 General Welding Requirements

10 10 11

1.1.18 Testing of Welded Pipework Installation

12

1.1.19 Painting, Tags, Name Plate Identification and Colour Coding

13

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1.1.17 Testing for Welder Qualification

15

1.1.21 Construction Drawings

16

1.1.22 Shop Drawings

16

1.1.23 Record Drawings

18

1.1.24 Storage of Materials and Equipment

18

1.1.25 Inspection of Material Prior to Installation

18

1.1.26 Inspection, Testing and Adjusting

18

1.1.27 Testing

21

1.1.28 Instructions for Operation and Routine Maintenance

21

1.1.29 Maintenance

22

1.1.30 Warranty

22

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QCS 2014


Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Part details the requirements for air conditioning, refrigeration and ventilation systems. It shall apply to all mechanical and electrical systems and equipment.

2


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General Concrete Instrumentation, Control and Automation Structural Metal Work Metal Work Electrical Installations

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References

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ASHRAE.....................Standard 52.1 - 1992 Gravimetonic and Dust spot Procedures for testing air cleaning devices BS 1710 ......................Identification of building services pipework

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BS 1724 ......................Bronze welding by gas

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BS 2600 ......................Radiographic examination of fusion welded butt joints in steel BS 2640 ......................Class II oxy–acetylene welding of carbon steel pipework for carrying fluids

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BS 2910 ......................Radiographic examination of fusion welded circumferential butt joints in steel pipes BS 2971 ......................Class II arc welding of carbon steel pipework for carrying fluids

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BS 4515 ..........................Process of welding steel pipelines on land and off-shore

1.1.3

Standard of Work

1

The Contractor shall install equipment, air conditioning ducts, conduit and piping in a workmanlike manner to present a neat appearance and to function properly to the satisfaction of the Engineer. Air conditioning ducts and pipes shall be installed parallel and perpendicular to the building planes. All piping and ductwork shall be concealed in chases, behind furring, or above ceiling, except in unfinished areas. All exposed systems shall be installed neatly and be grouped to present a neat appearance.

2

All gauges, thermometers, etc., shall be installed in such a way as to facilitate easy observance.

3

All equipment and apparatus, which requires maintenance, adjustment or eventual replacement, shall be installed making due allowance for access.

QCS 2014


Page 3

Control sensors shall be installed to guarantee proper sensing. Elements shall be shielded from direct radiation and shall avoid being placed behind obstructions.

5

All panels and boards, etc., shall be installed to remit easy operation.

6

The Contractor shall include in the work all the requirements of the manufacturer’s as shown on their drawings.

7

The Contractor shall replace all work not performed to the satisfaction of the Engineer without extra cost and to the standard required by the Engineer. This applies to any item that is found to be defective in service during the maintenance period, or extended maintenance period as appropriate.

8

Where height dimensions are given, the installation shall be reasonably expected to be within 13 mm of actual position.

9

Items displaying a horizontal dimension or edge must be plumbed with a level and must be to the Engineer’s satisfaction. Any apparent discrepancy between “level” electrical and mechanical items and adjacent items MUST be reported immediately to the Engineer.

10

All work shall be co-ordinated with other works so as not to obstruct equipment and apparatus which requires maintenance, adjustment or eventual replacement.

11

Manufacturers and subcontractors shall operate an ISO 9000 approved quality system or equivalent in house system. If requested, details of the quality system shall be submitted to the engineer.

12

Equipment shall conform to the requirements of the Project Documentation and reference standards.

13

All equipment furnished shall be new, and where feasible shall be a standard product of an experienced or approved manufacturer, and assembled from standard components readily available.

1.1.4

Data to be Supplied with Tender

1

Initial technical submissions are to accompany the bid including full technical details of every item of equipment proposed for the Project, with the appropriate figures and details highlighted in marker pen or similar in standard manufacturer’s catalogues.

2

After final checking of sizing after award of contract, re-submission shall be made with any changes specifically noted.

3

Technical submissions shall be submitted for all equipment as specified in the Project Documentation.

4

In the even that the Engineer requires further information on any of the proposed items the Contractor shall arrange visits to similar units that he has installed. In an event, all equipment proposed for the Project shall be currently installed and working satisfactorily locally. The Contractor must be able to provide references of at least three satisfied Owners and Engineer with equipment of the particular size and model proposed.

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Page 4

1.1.5

Practical Completion Certificate

1

A Practical Completion Certificate for works included in this Section shall only be issued when the Engineer is satisfied that all the requirements of this Section have been met.

1.1.6

Air Conditioning Subcontractor

1

The air conditioning services subcontractor shall be responsible for co-ordination with other trades and services and shall provide all materials, labour and supervision, equipment, tools, appliances, services, etc. for the supply and installation of the following items or work: air conditioning and ventilation plant and equipment.

(b)

insulated ductwork complete with air terminals, dampers, supports, etc.

(c)

chilled water pipework complete with valves, fittings supports, etc.

(d)

controls and control panels

(e)

motor control centres and starter panels complete with cabling from the panels to the respective equipment. Power supply up to the panel shall be the responsibility of the electrical subcontractor

(f)

insulated drain piping from each air handling unit fan coil unit to the nearest drain point. The drainage subcontractor shall be responsible for provision of a floor drain in each mechanical room location to be co-ordinated with air handling units (AHU).

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(a)

The contractor shall also include all overheads at office and site, labour, sundries, plant, appliances and consumable both for the Works and for testing and commissioning, and during the maintenance period.

3

The air conditioning subcontractor shall be approved so as to meet all QGEWC regulations.

1.1.7

Design Data

1

Design parameters. Design, in general, shall be based on ASHRAE recommendation in addition to the following particular requirements:

2

Design Conditions

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(a)

external (Summer)

:

46 C Dry Bulb, 30 C Wet Bulb

(b)

Internal

:

23  1 C Dry Bulb, 50  5 % RH o

Fresh air supply. One air change - minimum quantity as indicated on drawings.

QCS 2014

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Page 5

Noise levels In general, the following noise ratings shall not be exceeded for central A/C plants:

NCLevel

General Office

40-45

35-40

Private Office

35

30

Meeting Rooms

35

30

Corridor

45

40

Library

35

Cafeteria

50

Auditorium

35

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Mosque Class Room

30

35-40

30-35

40

35

40-45

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Manned Control rooms

45

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30

Solar load. Solar loads shall be based on maximum instantaneous values in appropriate direction for consideration of the worst exposure calculations. They shall also be based on the worst cumulative block load when checked on any hourly basis from 10 AM to 6 PM over the period May to October, coincident with the maximum outside ambient as listed above. Values as listed in ASHRAE or CARRIER SYSTEM MANUAL for 20 º north will be acceptable.

6

Air Filtration

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Based on ASHRAE 52.1 - 1992 Primary filters (flat panel) Secondary filters (bag) 7

95 % Gravimetric 60 % Opacimetric

: : :

7 C o 12 C 2.43 m/s

:

2.5 m/s

Chilled water to cooling coils Chilled water inlet temperature Chilled water outlet temperature Maximum velocity of water through pipework Pipes to be sized for full flow rate of all cooling coils Maximum coil face velocity

8

: :

o

Air Distribution Duct Velocity, supply : 5 m/s Duct Velocity, return : 4 m/s Duct Velocity, Kitchen exhaust : 10 m/s Higher velocities are permissible in the ducts located in the shafts

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Page 6

Fire Philosophy. Smoke detectors shall be positioned in return air ductwork of Air Handling Units (AHU). A fire condition sensed by the smoke detectors shall shut off the relevant AHU through the fire annunciation panel. Smoke detectors installed within rooms shall be interlocked with the fan coil unit serving the respective room such that the fan coil unit will be shut off in a fire situation through the fire annunciation panel. Fire dampers shall be positioned in all ductwork crossing firewalls. Fire dampers shall be included in return and extract ductwork at each fire zone crossing. They shall be triggered from a fusible link connection sited in the damper. Note:

The above data that is mentioned in items 7 & 8 could vary subject to project specification.

Rating for Continuous Service and Local Ambient Condition

1

The design of the Plant shall be in accordance with the latest good engineering practice. All parts shall be of ample strength to withstand without failure or injury the maximum mechanical and electrical stresses to which they may be subjected in the course of operation of the plant.

2

The Works shall be designed to facilitate inspection, cleaning, and ease of maintenance and operation in which continuity of service and reliability is the primary consideration. The design shall incorporate every reasonable precaution and provision for the safety of all concerned in the operation and maintenance of the plant.

3

All plant and equipment shall be suitable for operation under the prevailing ambient conditions at site and all special requirements for thermal insulation, finish, painting and lubrication etc. shall be incorporated.

4

Except where otherwise stated, all equipment shall be constructed and sealed as to prevent damage by the ingress of wind blown sand and other matter. All equipment shall be suitable for operation over the ambient temperature range 0 C to 55 C.

5

Except where otherwise stated in the Project Documentation, the declared ratings for all equipment shall be for continuous operation in final service position for the following environmental criteria. maximum daily average ambient temperature of 50 C

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1.1.8

(b)

relative humidity of 80 %

(c)

altitude 20 m above sea level.

These criteria shall be achieved independently of any forced means of mechanical ventilation or air conditioning plant. 1.1.9

Quality of Materials and Equipment

1

All materials used on the Project shall be brand new and of high quality. Obtain approval of all manufacturers from the Engineer and Owner.

2

New is defined as newly manufactured, state of the art, tested and proven item of equipment. Items that have been held in stock for any extended period of time by either the manufacturer or the supplier will be rejected.

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Page 7

Cleaning

1

Each day as the work proceeds, and on completion, the Contractor shall clean up and remove from the premises all rubbish, surplus material, equipment, machinery, tools, scaffolds, and other items used in the performance of the work. The Contractor shall clean out dirt and debris and leave the buildings broom clean with no stains and in a condition acceptable to the Engineer.

2

Where electrical items form part of the visible finish in the rooms, the Contractor shall protect them from over-painting, etc. and shall give all items a final cleaning before handing over.

1.1.11

Accessibility

1

Each item of equipment shall be located so as to be accessible for maintenance or repair without removing adjacent structures, equipment, piping, ducts, or other ducts, or other materials. For large air handling units the Contractor shall ensure that these can be assembled on site from components taken into the area.

2

Clean outs shall be located to permit rodding of all drain lines. These shall be located wherever possible external to occupied areas, and to minimise spillage problems during rodding.

1.1.12

Cutting and Patching

1

The Contractor shall Inform all other Divisions in time concerning required openings. Obtain the approval of the Engineer before doing any cutting.

2

In existing work and in work already finished as part of this contract, all cutting and patching will be carried out at the expense of this Contractor. Where finishing work is involved, this will only be reinstated by the Contractor responsible for the original work. The Contractor shall obtain the approval of the Engineer before doing any cutting. Supporting members of any floor, wall or the building structure shall only be cut and in such a manner as approved by the Engineer. All reinstatement work must be done to the same standard as the original work.

1.1.13

Inserts, Sleeves, Escutcheons and Curbs.

1

The Contractor shall use only factory made, threaded or toggle type inserts as required for supports and anchors, properly sized for the load to be carried. The inserts shall be place only in portions of the main structure and not in any finishing material.

2

The Contractor shall use factory made expansion shields where inserts cannot be placed, but only where approved by the Engineer and for light weights.

3

The Contractor shall not use powder activated tools except with the written permission of the Engineer.

4

The Contractor shall supply and locate all inserts, holes anchor bolts, and sleeves in good time when walls, floors, and roof are erected.

5

The Contractor shall ensure that insulation is unbroken where pipe or duct is insulated. Size sleeves shall be sized to provide adequate clearance all around.

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1.1.10

QCS 2014

Page 8

The following materials shall be used for pipe sleeves: (a)

through all interior walls above grade, standard weight galvanized steel pipes, machine cut, flush with finished structure. The Contractor shall check the room finishes schedules.

(b)

through all exterior walls above grade, standard weight galvanized steel pipes machine cut, flush with finished structure inside and to suit flashing on outside

(c)

through al exterior walls below grade and all other waterproof wall use extra heavy weight cast iron sleeves, machine cut. Refer to Section 14, Roofing, for further details.

(d)

through all waterproof floors, janitor’s closets, mechanical rooms kitchens, roofs, use extra heavy weight cast iron sleeves, machine cut. As an alternative, copper DWV 2 sleeves up to and including 150 mm sleeve size and rolled 10 kg/m copper sleeves for larger than 150 mm may be used. The sleeves shall be extended 100 mm above finished floor level upwards and cut flush with underside of floor. The Contractor shall make particular reference to flashing details through waterproof floors

(e)

approved type plastic sleeves may be used as an alternative for standard weight galvanized sleeves in interior areas if approved in writing by the Engineer

(f)

the Contractor shall provide 100 mm high, 100 mm wide watertight concrete curbs with 20 mm chamfered edges around all pipes passing though waterproof floors except where furred in. Concrete works shall be done in accordance with Section 5, Concrete.

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The Contractor shall pack all sleeves between the insulated pipe and the sleeve or where uninsulated between the pipe and the sleeve with polyurethane insulation. Seal the annular space as follows:

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for all horizontal sleeves in exposed areas, the Contractor shall use a seal equal or better fire rated than the wall to be sealed

(b)

for horizontal concealed sleeves through fire walls and through walls separating areas of different air pressure, use a permanently resilient silicone based sealing compound.

8

for all vertical sleeves through roofs, janitor’s closets, equipment rooms, use permanently resilient silicone based sealing compound, non-inflammable and waterproof.

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The Contractor shall ensure that the seal is compatible with the floor and ceiling finishes. The room finishing schedules shall be checked for further details and clarified if necessary with the Engineer.

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Page 9

The following sleeving shall be used for ducts: The minimum thickness of duct material passing through a sleeve shall be 1.3 mm. For rectangular duct openings through walls and floors a removable hardwood box-out shall be provided of the required size, soft wood or plywood will not be acceptable. Through fire walls, build fire dampers into wall, or make detailed fixing in accordance with Engineer’s instruction. Through floors where ducts are not furred in or enclosed in a duct shaft, provide 100 mm high and 100 mm wide watertight concrete curbs, with 25 mm chamfered edges all around. Extend sleeves where used flush to top of curb. Concrete works shall be done in accordance with Section 5, Concrete. Through floors where duct is enclosed in a duct shaft or furred in, provide the watertight curbs at the extreme top and bottom only. Cover exposed floor and wall pipe sleeves in finished areas with satin finish chrome or nickel plated solid brass or with satin finished stainless steel escutcheons with non-ferrous set screws. Split cast plates of the screw locking type may not be used. Do not use stamped steel friction type split plates. Through roofs, provide curbs and sleeves as shown on drawings and to suit flashing requirements.

10

After ducts are installed, the openings shall be packed and sealed as follows:-

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fibreglass insulation for packing except through curbed concrete floors where a fibre proof packing must be used

(b)

fibre proof packing shall be sealed in openings through floors with permanently resilient silicone base non inflammable waterproof compound; duct supports shall be pressed firmly down into caulking before bolting it down to curb

(c)

through all vertical walls, seal the fibreglass packing using permanently resilient silicone based sealant.

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(a)

Duct sleeves and box-outs shall be braced to retain their position and shape during the pouring of concrete and other work.

12

Bracing for each duct at ever passage through structure shall be provided to prevent sagging.

13

Exposed duct sleeves and openings shall be covered in exposed areas. 100 mm long galvanized steel escutcheons shall be used in the form of a duct collar. Over curbs, the collar shall be extended 30 mm down the side of the curb, similar to counter flashing. The collar shall be fixed in place with Cadmium plated screws.

1.1.14

Access Panels and Doors

1

The Contractor shall install all concealed mechanical equipment requiring adjustment or maintenance in locations easily accessible through access panels or doors. Install systems and components to result in a minimum number of access panels. Indicate access panels on as-built drawings.

2

The Contractor shall prepare drawings showing the location and type of all access doors in co-ordination with other trades before proceeding with installation and hand these to the Engineer to obtain approval. On smaller Projects, the Contractor shall indicate on the ceiling plans access required at the discretion of the engineer.

3

All access doors shall be sized to provide adequate access commensurate with the type of structure and architectural finish. Should it be necessary for persons to enter, a minimum opening of 600 x 450 mm shall be provided.

4

Proper fire rating of access doors shall be ensured in fire separations.

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Page 10

Lay-in type ceiling tiles, if properly marked may serve as access panels.

6

The Contractor shall provide panels in glazed tile walls of 2.6 mm thick 304 alloy stainless steel, with no. 4 finish, with the recessed frame secured with stainless steel, countersunk, flush-headed screws.

7

Panels in plaster surfaces shall be provided with dish shaped door and welded metal lath, ready to take plaster. A plastic grommet shall be provided for door key access.

8

Details of other types of access doors shall be submitted to the Engineer for approval.

1.1.15

Flashing

1

The Contractor shall provide flashing to all mechanical and electrical parts passing through or built into a roof, outside wall, or waterproof floor.

2

49 kg/m sheet lead flashing shall be provided for cast iron sleeves passing through roof. Factory manufactured flange plates shall be provided to flash PVC-U pipes passing through roofs.

3

7 kg/m copper flashing shall be provided for copper sleeves passing through roof where copper sleeves are used for copper pipework

4

All flashing shall suit the roof angle and shall extend a minimum of 400 mm on all sides. The Contractor shall build the flashing into the roofing system to render a completely watertight connection.

5

Counter flashing shall be provided on all stacks, ducts, and pipes passing through roofs to fit over the flashing or curb.

6

Pipes through waterproof floors shall be flashed as per approved details.

7

Provide pipes and sleeves passing through outside walls with lead or copper flashings and as directed by the Engineer. All visual aspects of such sleeves to be approved by the Engineer. All sleeves shall be installed according to the relevant standard and shall be suitable for local ambient conditions.

8

The Contractor shall pay special attention to the waterproof conditions of basements and walls and floors that may exist. The Contractor shall ensure co-ordination at all times with the waterproofing trade to prevent damage to any water proofing seal. The Contractor shall provide piping sleeves passing through waterproof walls which shall be sealed to the satisfaction of the Engineer.

1.1.16

General Welding Requirements

1

All welding shall be generally in accordance with BS 4515. This will be modified where appropriate for other materials and may be relaxed or varied by order of the Engineer, provided that the Contractor has made a comprehensive request for an alternate.

2

Tack welds shall be performed by fully qualified welders and all tack welds shall be of a length equal to twice the pipe thickness and shall fully penetrate the pipe walls.

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Page 11

Where welding is carried out in the proximity of inflammable materials special precautions shall be taken to prevent risk of fire or other damage to the building fabric.

4

Where oxyacetylene cutting equipment or any welding plant is being used by an operative for any of part of the Works, then fire extinguishers shall be supplied and carried as part of the equipment. The operators of cutting and welding equipment shall be trained in the use of the fire extinguishers which they carry and all extinguishers shall be fully charged and ready for use. In all cases, extinguishers shall be positioned immediately adjacent to the position where cutting and welding is being carried out and shall be readily accessible for use in the event of an emergency.

5

All accommodation, benches, tools, welding plant, acetylene, oxygen or electricity, filler rods and electrodes, which are necessary for installations where welding is required, shall be provided as part of this Contract.

6

All welded pipe assemblies shall be constructed so that individual welded joints do not affect each other. The distance between the centres of adjacent welds shall be not less than twice the bore diameter of the pipe.

7

No welded joints shall be left partially completed. Any joints tacked in position must be promptly finished within the working day. The Engineer will reject all work not done in accordance with this instruction.

8

Where work is rejected, pipes must be machine cut at least 150 mm either side of rejected welds and proper weld preparation must be used on the shortened sector. Where shorter fillin sections are required because of such rejection and re-working, then new full sized lengths must be supplied by the Contractor.

9

Where pipes with longitudinal seams are specified, pipes seams shall be arranged such that adjacent seams are opposed 45 º from each side of top dead centre and branches shall be made only with weldable fittings.

10

All filler metals that are coated shall be protected from excessive moisture changes. Filler materials or fluxes that show any sign of deterioration shall not be used. If instructed by the Engineer, samples of filler rods to be used shall be submitted for approval before any work is done on site. These may be submitted, at the Contractor’s cost, to an independent testing laboratory for verification.

1.1.17

Testing for Welder Qualification

1

The purpose of the welder’s qualification tests is to determine the ability of the welders to make sound and acceptable welds. Before any site welding on the contract is allowed, each proposed welder shall carry out the tests required in the presence of the Engineer.

2

A responsible person shall keep any weld test specimens that have been suitably marked and approved on site, so that they can be produced at any time, at the request of the Engineer.

3

All accommodation, benches, tools, welding plant, acetylene, oxygen, electricity, test pieces, filler rods, electrodes, facilities for cutting and grinding, polishing, bending and examining, which are necessary for welders qualification tests shall be provided by the Contractor. In the absence of any items for inspecting the welds, the Engineer may submit the finished samples to an independent laboratory for testing at the Contractor’s expense.

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Page 12

4

Under no circumstances shall a welder be employed on the Works, either on or off the site, for welding operations other than those for which that welder is qualified.

5

Copies and records of all test reports shall be promptly given to and kept by the Engineer.

6

For tests for Qualification on Steel Pipes, each test shall be carried out in accordance with the test procedures laid down in BS 2640 and BS 2971. The test position shall be similar to the working conditions expected to be encountered and test pieces shall not be rotated to suit any individual welding procedures. Each test sample shall be subjected to the following examinations and test. Pipes up to 100 mm diameter shall undergo visual examination and normal tongue bend test and X-ray test

(b)

Pipes over 100 mm diameter shall undergo visual examination and 2 normal tongue bend tests and two reverse bend tests and X-ray tests.

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(a)

The Engineer may at his discretion require macro-etch examination in the event of any doubt. For a successful test, the weld shall conform in all respect to the requirements of the relevant British Standard. Each welder who qualifies shall be issued with a metal punch with an identifying number and shall stamp adjacent to each weld. If any test sample does not reach the required standard, two further welds shall be made and tested as detailed. Both of the retests shall be successful for the welder to qualify for the work.

8

For testing for Qualification on Copper Pipes, each test shall be carried out in accordance with the test procedures laid down in BS 1724. The test position shall be similar to the working conditions expected to be encountered and test pieces shall not be rotated to suit any individual welding procedure. Each test sample shall be subjected to the following tests and examinations.

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visual

(b)

flattening test

(c)

micro examination

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(a)

For a successful test, the weld shall conform in all respects to the requirements laid down in BS 4515. Other conditions are similar to the above for steel pipes. Testing of Welded Pipework Installation

1

Testing of welded pipework installations shall be by either destructive or non destructive test methods as detailed in the following schedules.

2

All services 75 mm and below shall have two joints per floor for destructive testing. All services above 75 mm shall have two joints per floors for non-destructive testing. If a weld fails the testing requirements, then two additional welds made by the same operative shall be tested, at no additional cost. If both additional welds are successful, then in the case of destructive testing, the cost of making good shall be at no additional cost. If either of the two additional welds fail the test requirements, then further tests on other or all of the welds made by that operative shall be carried out, at the Engineer’s discretion. All costs resulting from either of the two additional welds failing the test requirements shall be at no cost to the Contract. If either of the two additional welds fail, then the operative concerned shall not make any further welds on any service unless approved by the Engineer.

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1.1.18

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Page 13

The detailed requirements concerning testing shall be as follows: destructive testing. Destructive testing and examination shall be exactly as detailed under Tests for Welder Qualification

(b)

non-destructive testing shall consist of radiographic inspection to comply with BS 2600 and BS 2910. Non-destructive testing shall be carried out by a specialist company approved by the Engineer

(c)

the specialist company shall provide a report on the radiographic tests which have been made, including an interpretative results section. The report and films shall be handed to the Engineer

(d)

the material of the image quality indicator shall be radiographically similar to that of the filler metal under examination

(e)

the use of x-ray and gamma radiation sources shall be in strict accordance with the requirements of the Ionising Radiation (Sealed Sources) Regulations.

(f)

the required radiographic sensitivity shall not be more than two, and the required image details shall be readily seen on each radiograph

(g)

radiographs which do not comply with this requirement, whatever the cause, shall be unacceptable and the weld in question shall be re-examined at no cost to the Contract. All interested parties shall be advised well in advance where and when radiographic tests are to be conducted, in order that appropriate precautions may be taken

(h)

macro-examinations. When the Engineer requires macro examinations, these shall be carried out by a specialist company who shall present etched section photographs and a report on the tests to the Engineer. All costs for these tests are to be borne by the Contractor.

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Painting, Tags, Name Plate Identification and Colour Coding

1

All painting of plant, equipment, storage vessels, and the like, and all surfaces to be painted in the areas where such items are installed, including generator areas, condenser areas, etc. shall be carried out by an approved specialist painting contractor.

2

Painting shall be applied to all pipework and associated pipework components, valves, fittings, etc. equipment, supports of any kind, insulation, plain mild steel, copper, or cast iron surfaces. Where movement is required between adjacent surfaces, the Contractor shall request clarification from the Engineer.

3

The following items do not require site painting:

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1.1.19

(a)

Insulation having any of the following finishes: (i)

aluminium foil

(ii)

metalwork

(iii)

polyisobutylene sheeting/bitumen coating

(iv)

vinyl-glass/resin-aluminium foil laminate

QCS 2014

(b)

Page 14

equipment or plant or supports or frames delivered to site with any of the following finishes: (i)

painted finish, other than printed only, provided that the finish is not damaged in any way

(ii)

stainless steel or plastic coated steel

(iii)

stoved enamel.

All surfaces to be painted shall be prepared by thoroughly cleaning and removing all rust, grease, oil, dirt and surface corrosion, using wire brush, emery paper and/or degreasing medium as required. The paint shall be applied in accordance with the manufacturer’s instructions and the type of paint to be used shall be in accordance with the following:(a)

ferrous surface, one coat of zinc chromate primer plus wash primer as necessary, followed by 2 undercoats, and one finishing coat.

(b)

(non-ferrous surface, one coat of zinc chromate primer plus wash primers as necessary, followed by 2 undercoats, and one finishing coat.

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Approved manufacturers shall supply all paint.

For factory applied finishes, repainting or refinishing of any surfaces damaged during shipping, erection or construction shall be done using only factory supplied materials.

6

After finished painting is completed, each piped and ducted service shall be identified, and identification and flow arrows located.

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behind each access door

(b)

at each change of direction on all joining pipes and ducts

(c)

at not more than 10 m in straight runs of exposed pipes and ducts, but on both sides of sleeves

(d)

at not more than 10 m apart in straight runs of pipes and ducts behind removal

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(a)

above each floor or platform for vertical exposed pipes, preferably 1.5 m above

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enclosures such as lay-in ceiling but on both sides of sleeves

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floor or platform level.

7

PVC tape identifying bands will not be accepted.

8

Stencils and stencil paint shall be used on all piping and ductwork. letters a minimum of 30 mm high shall be Used. After completion of the Works, the Contractor shall provide to the Engineer usable stencils for each service.

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Page 15

Wherever insulation is to be painted, the paint used shall comply with all the fire resistance requirements for insulation finish, and shall be carried out by the insulation subcontractor. In all cases, the actual grade of paint to be used shall be suitable for the operating surface temperature and shall be approved by the maker for the application concerned. In certain cases, the grade of finishing coat may not require the application of undercoats in which case these may be omitted, provided that the Engineer’s approval in writing is obtained beforehand. All insulated or un-insulated pipework in concealed positions shall be identified by means of 75 mm wide identification bands, painted neatly on and at right angles to the pipe axis at intervals not greater than 3 m. In addition to the name of the service and pipe diameter shall be stencilled on in a visible position with an arrow indicating the direction of flow. Flow and returns shall have the letter “F” or “R” added to the identifying name. The identifying band colours and the finishing colour of the services to be painted shall be in accordance with the colours and procedures given in BS 1710. Ductwork shall be identified in accordance with the procedures laid down in HVAC Code of Practice No. DW 144.

10

All equipment located in concealed positions shall have a nameplates secured to the item giving the following information.

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Equipment reference number (as indicated on the record drawings). System Room/Area served Duty/output information The name plate shall be 100 x 100 mm approximately, of white plastic 3 mm thick with the above information engraved in black lettering and the plate shall be secured by screws, bolts, clips, etc. as appropriate to the item concerned. This plate is in addition to any name plate supplied by the manufacturer of the item giving detailed specification information for the equipment.

1.1.20

Contract Drawings

1

The drawings included in the Project Documentation are diagrammatic, and intended to convey the scope of work and indicate general arrangement and approximate locations of apparatus, fixtures, pipe and duct runs, etc. The drawings are not intended to indicate Architectural or Structural details, nor do they show any fabrication or installation details.

2

Do not scale drawings. Obtain accurate dimensions to structure and architectural items from drawings of those trades. Confirm by site measurement. The Contractor shall verify the location and elevation of all services (water, electrical, telephone, sanitary, storm drainage, gas, etc.) before proceeding with the work.

3

The Contractor shall install all ceiling mounted components (diffusers, grilles, detectors, light fixtures, emergency lights, fire detectors, loudspeakers, camera points, etc.) in accordance with the reflected ceiling drawings which are to be prepared by the Contractor and coordinated with all trades. These must be submitted for approval and be approved before any work commences on site.

4

Sufficient space shall be left clear to install all work to accommodate future materials and/or equipment as indicated and/or supplied by another trade. All pipe runs, conduit runs, cable trays etc. shall be installed to maintain maximum headroom and clearances, and to conserve space in shafts and ceiling spaces and under floors, and to provide adequate space for service and maintenance.

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Page 16

The exact location of outlets and fixtures shall be confirmed on the site, also the locations of outlets and fixtures provided by any other trade shall be confirmed.

1.1.21

Construction Drawings

1

The Contractor shall prepare drawings in conjunction with all trades concerned in the Works, showing sleeves and openings for all passages through the structure and all insert sizes and locations.

2

Composite construction drawings shall be prepared of piping and equipment in tunnels, shafts, mechanical equipment rooms and areas, and all other critical locations to avoid a conflict of trades that are fully dimensioned. The equipment drawings shall be based upon shop drawings and include but not necessarily limited to, all details pertaining to access, clean outs, tappings, sleeves, electrical connections, drains, location and elevation of pipes, ducts, conduits, etc. obtained from consultation with, and agreement of, all trades involved.

3

The Contractor shall prepare drawings of equipment bases, pump pits, anchors, inertia slabs, floor and roof curbs, wall openings, trenches, pertaining to mechanical work.

4

All drawings shall be prepared to scale and dimension. These shall be forwarded, after approval by the trades concerned to the Engineer for his records. Transparencies and printed copies shall be provide in the number specified in the Project Documentation, but in any case not less than four sets.

5

The Contractor shall bind one complete set of construction drawings showing “as built” conditions in each operating and maintenance instruction manual. The extent of these drawings will be indicated to the Contractor in advance by the Engineer.

1.1.22

Shop Drawings

1

The Contractor shall submit shop drawings and samples for materials and equipment as listed in this and in each subsequent section. Transparencies shall be provided wherever possible as well as printed copies in the number specified in the Project Documentation. The Engineer may retain the sample of each item at his discretion until the completion of the Works.

2

The Contractor shall submit to the Engineer a schedule of shop drawings after award of the Contract, in accordance with programme detailed in the Project Documentation. The schedule shall indicate the anticipated date when the drawings will be submitted for review. The Contractor shall be fully responsible for the timely submission of all drawings. An allowance of three weeks shall be made for the Engineer’s review period. At time of submission, the Contractor shall indicate any other constraints and associated cost implications resulting from the programme, etc. otherwise the Engineer will advise the Owner that cost and completion date will be unaffected.

3

The Engineer will only consider shop drawing bearing the stamp of the Contractor and all Subcontractors involved. The Contractor shall check the drawings for all pertinent information such as physical dimensions, make, performance, electrical characteristics, and shall use reference symbols or enumeration to correspond to the design drawings.

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Page 17

The Contractor shall assume responsibility for the accuracy of equipment dimensions related to space available, accessibility for maintenance and service and compliance with inspection authority codes. Shop Drawings shall indicate the shipping and working weights of all equipment.

5

The submission of samples will be subject to the same procedure as those of shop drawings. The materials for which samples are to be submitted shall include, but may not be limited to conduits and accessories, wiring accessories, distribution boards, cables and wires, fire alarm accessories, speakers, light fittings, sanitary fixtures and fittings, valves, Instruments, thermostats, Insulation and grilles and diffusers. One set of such samples shall be required to be brought to site and kept there after approval until substantial completion.

6

The Engineer shall mark the drawings “re-submit specified item”, “rejected”, “no exception taken”, or “make correction noted”. In the last case, all revisions will be clearly marked on the returned print and corrected prints may be issued for manufacture and construction. The Contractor shall make the revisions shown on the “make corrections as noted” prints onto the drawings as soon as practicable and forward copies to the Engineer for his records. This must be done within one month. Failure to re-submit in this time will cause the drawings to be treated as “revise and re-submit” and the contractor will be responsible for any delays so caused.

7

The Engineer is not responsible for any delays caused by the inadequacy of the Contractor’s drawings or his failure to obtain initial or subsequent approval. Any time taken by the Contractor to obtain approval after the originally scheduled date will be considered as a delay to the contract caused by the Contractor.

8

When drawings are marked “re-submit specified item”, the Contractor is to re-submit the item as originally specified or as may be determined to be equivalent by the Engineer. The Engineer is the sole arbiter of whether any item is satisfactory or equivalent.

9

When drawings are marked “rejected” a complete re-submission of the particular drawing is necessary, subject to the same conditions as outlined above.

10

The Engineer’s review shall not relieve the Contractor from responsibility for deviations from the Project Documentation, unless he has, in writing, called the Engineer’s attention to such deviations at the time of submission of drawings. The Engineer’s review shall be construed to apply to, and only to, general arrangements and shall not relieve the Contractor from the entire responsibility. Any approval by the Engineer shall be on the understanding that any item submitted shall be ordered with options and modifications to fully meet the requirements of the Project Documentation. Any fabrication, erection, setting out or other work done in advance of receipt of stamped drawings shall be done entirely at the Contractor’s risk and cost.

11

The Contractor shall furnish prints of the reviewed details to all other parties who may require them for proper co-ordination of their work, and furnish all information necessary for the work as a whole.

12

The Contractor shall obtain manufacturer’s installation directions to aid in the proper execution of the work. Two copies of such directions shall be submitted to the Engineer prior to installation, for use in inspecting the work.

13

One complete set of checked shop drawings shall be bound into each operating and maintenance manual.

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Page 18

Record Drawings

1

As the job progresses, the Contractor shall mark on one set of prints to accurately indicate the status of installed work. The white prints shall be available for inspection at the site at all times, and be presented for scrutiny at all progress meetings. All information shall be transferred onto the set of transparencies. One set of transparencies and five sets of white prints shall be submitted to the Engineer for onward transmission to the Owner.

2

The record drawings shall show the installed inverts of all services entering and leaving the building and the property. Underground services shall be dimensioned at key points of every run in relation to the structure and building. Record all elevations for underground services shall be recorded in relation to floor level of the building and give reference datums to Municipality benchmarks.

3

The exact locations of all services left for future work shall be indicated. All embedded work shall be shown and dimensioned in the structure.

1.1.24

Storage of Materials and Equipment

1

The Contractor shall protect all mechanical and electrical works from damage and shall keep all equipment dry and clean at all times.

2

All openings in equipment and materials shall be covered. all temporary openings in ducts and pipes with polyethylene sheets or caps shall be covered until the final connection is made. The quality of such cover must be determined with due regard to how long it may be until final connection.

3

The Contractor shall be responsible for and make good any damages caused directly or indirectly to any walls, floors, ceilings, woodwork, brickwork, finishes, services, roads, gardens etc.

1.1.25

Inspection of Material Prior to Installation

1

The following shall be inspected prior to Installation: pumps and fans shall be inspected to ensure there is no damage to the casings impellers or drives

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1.1.23

(b)

pipework and ductwork shall be checked for any obstructions or dirt

(c)

valves dampers set shall be checked for damage and proper operation

(d)

all material shall be inspected to ensure that it is an approved item.

1.1.26

Inspection, Testing and Adjusting

1

All the works provided as part of this Contract shall be inspected and commissioned in accordance with all relevant British Standards and to the entire satisfaction of the Engineer.

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Page 19

The electrical/mechanical subcontractor shall employ the services of a specialist testing and commissioning company approved by the Engineer. The specialist company should be regularly engaged in providing a testing and commissioning service and have been in continuous business for not less than seven (7) years. The company shall employ fully trained staff having not less than three (3) years dedicated experience. A senior experienced commissioning engineer with minimum dedicated experience of seven (7) years shall be responsible for supervising and directing the activities for the testing and commissioning team.

3

The Contractor shall carry out all tests specified any other tests required by the Engineer. Equipment shall be tested to the requirements of, and where necessary, in the presence of the manufacturer and the Engineer.

4

The Contractor shall provide all equipment, labour, instruments, loading devices, incidentals, and pay for all fuel, power and sundries required to carry out the tests.

5

All installations shall be inspected and tested in sections as the work proceeds and on completion as composite systems and it shall be noted that the Engineer or any of the other relevant Authorities may require to inspect or test any equipment during manufacture at the manufacturer’s works. All necessary arrangements shall be made as part of this Contract. This will generally not apply to specified items unless specifically noted in the Project Documentation, but may be necessary for alternate equipment, should this be considered at all.

6

All tests shall be arranged in co-operation with the Engineer and all other concerned parties and shall be subject to at least five (5) days notice in writing of the time, location and nature of the test to be performed. Not test shall be considered valid unless the Engineer is present.

7

All necessary skilled and unskilled labour shall be provided for attendance during the tests (including pre-and post-test activities) and the test media shall be provided and subsequently disposed of except where specifically stated otherwise.

8

The testing and adjusting is the contractual responsibility of the Contractor but actual performance of the tests is expected to the sole responsibility of an approved subcontractor.

9

The Contractor shall have all testing and balancing performed only by persons who are thoroughly versed in this type of testing and balancing and with proven ability. Names, complete with experience records, and references shall be submitted for the approval of the Engineer.

10

Any defects occurring at any time during the test duration shall be made good and a complete re-test shall be carried out, at no additional cost to the Contract.

11

Where failure occurs during a test, inspection or commissioning procedure which results in damage to the building fabric and/or any services not provides as part of this Contract, or requires subsequent builder’s work to be carried out, this work shall be performed to the entire satisfaction of the Engineer at no additional cost to the Contract.

12

All the test points shall be provided which are necessary to carry out the specified tests and commissioning procedures including facilities for measuring or monitoring temperature, pressure, pressure drop, volume flow, in-duct sound power or sound pressure, humidity, or other relevant conditions in both air side and water side systems. Such points shall be fitted with removable plugs, flanges, or other appropriate and approved devices.

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Page 20

13

Prepare test report forms for each test to be performed and submit these to the Engineer at least two weeks prior to the commencement of any tests.

14

Only after the system installation has been completed and the system has been put into continuous operation shall testing be carried out. The testing, adjusting, and balancing shall be performed when outside conditions are commensurate with the design conditions for the given system. Dummy loads shall be added to the system if outside conditions are less severe than the specified points.

15

The Contractor shall prepare a complete list of instruments for each test containing for each instrument.

(b)

scale and full scale accuracy

(c)

date of last calibration test

(d)

name of last calibrating company.

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All instruments and consumable, such as recording paper, necessary for conducing the tests shall be provided, including but not limited to the following:electronic anemometer

(b)

inclined tube manometer or micromanometer

(c)

pitot tubes of various lengths

(d)

digital thermometers

(e)

weekly recording thermometers

(f)

weekly recording relative humidity meter

(g)

anemometer for diffusers, with collector

(h)

ammeter, voltmeter, wattmeter

(i)

power factor meter

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tachometer

insulation tester earth loop impedance tester

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(a)

17

Duplicate signed test certificates shall be provided after each test which will be countersigned by the attending Engineer. The test certificate shall give the following particulars: (a)

apparatus or section under test

(b)

maker’s number (if any)

(c)

nature, duration and conditions of test

(d)

result of test

No test shall be valid until the test certificate is provided. 18

Duplicate copies of test certificates carried out at manufacturer’s works shall be forwarded to the Engineer for approval prior to despatch of the article to site.

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Page 21

No section of the Works shall be insulated or in any other way concealed prior to testing and inspection and subsequent concealment where applicable shall only take place following written authority from the Engineer.

1.1.27

Testing

1

All necessary facilities, measuring and recording instruments including test pumps and gauges for inspection, testing and commissioning requirements shall be provided and shall be checked or calibrated as necessary before use.

2

The Engineer reserves the right to call for a demonstration of the accuracy of any instruments provided.

3

All representatives present during inspection, testing and commissioning shall be fully conversant with the system concerned and the method of system and instrument operation.

4

Manufacturer’s of specialist subcontractors’ representatives shall attend where specifically indicated elsewhere in the Project Documentation or where necessary to ensure full service and co-operation is available to the Engineer to enable the Works to be tested and commissioned in accordance with the requirements of the Project Documentation.

5

All necessary precautions shall be taken to safeguard structures and existing equipment against damage during inspection, testing or commissioning. Any damage so caused shall be made good at no cost to the Contract.

6

All tests shall last for the minimum time period stated or longer if necessary to ensure all sections have been fully examined as required by the test.

1.1.28

Instructions for Operation and Routine Maintenance

1

The Contractor shall provide instruction to the Owner’s staff on how to make minor adjustments, carry out necessary maintenance and how to operate each system.

2

For new equipment, the Contractor shall provide the Engineer with three copies of complete operating and maintenance instruction for equipment at the time of delivery of the equipment.

3

Equipment shall be rejected unless accompanies by instructions. Such documents must be received al least one month prior to the completion date of the relative section of the Works.

4

Instructions shall be bound in a suitable loose leaf booklet or binder, and shall include prints of the following drawings:

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(a)

list of all equipment installed

(b)

general layout

(c)

wiring diagram of control panels

(d)

non-dimensional layout, showing location of all electrical devices

1

The contractor is to operate a draft for discussion with the Engineer prior to finalising the documents.

5

Portable tools and spare parts shall be correctly labelled and handed over to the Engineer.

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Page 22

The section dealing with complete systems shall be subdivided into each service with a ready means of reference and detailed index. The function and manner of operation of each system shall be clearly described together with illustrations and line diagrams in schematic form showing the location and function of control valves, items of equipment and spaces or areas which are service by these items. The colour coding and identification systems employed shall be explained.

1.1.29

Maintenance

1

Maintenance is defined as the Contractual Liability to maintain the equipment in working condition, plus the regular checks and servicing of equipment during the maintenance period to keep the equipment in best working order.

2

Regular maintenance shall be as necessary, but in any event not less frequently than monthly.

3

In the even that the Owner has his own staff, the Contractor is still to check monthly and advise on any problems and is still to assume responsibility. The Owner is to ensure that his staff do nothing to adversely affect the Contractual maintenance.

1.1.30

Warranty

1

All Warrantees for equipment suppliers will be vested in the Owner regardless of whether the Contractor who supplied the equipment is still associated with the Project or not.

2

Warranty will be full warranty and will include all overhead, profit, incidental charges and sundries.

3

Where damage is caused to any other item by any failure of the item warranted then the warranty shall also include the costs incurred in rectifying the damage.

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END OF PART

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CENTRAL REFRIGERATION & AIR CONDITIONING EQUIPMENT............ 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 Products 2 PACKAGE CHILLERS ................................................................................... 2 Air Cooled Package Chillers 2 Water Cooled Package Chillers 3 PACKAGED AIR CONDITIONERS ............................................................... 4 Air Cooled Packaged Air Conditioning Units 4 Water Cooled Packaged Air Conditioning Units 4 COMPRESSORS........................................................................................... 5 General 5 Reciprocating Compressors 7 Rotary Compressors 8 CONDENSERS.............................................................................................. 8 Air Cooled Condenser 8 Water Cooled Condenser 10 Evaporative Condensers 11 Dual Condensing 11 COOLER ...................................................................................................... 12 General 12 COOLING TOWERS ................................................................................... 12 General 12 PACKAGE COOLING TOWERS ................................................................. 14 General 14 REFRIGERATION ACCESSORIES ............................................................ 15 MISCELLANEOUS ...................................................................................... 15 Water Chemical Treatment 15 Water Softeners 16

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2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.6.1 2.7 2.7.1 2.8 2.8.1 2.9 2.10 2.10.1 2.10.2

Section 22: Air Conditioning, Refrigeration and Ventilation Page 1 Part 02: Central Refrigeration & Air Conditioning Equipment

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2

CENTRAL REFRIGERATION EQUIPMENT

&

AIR

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements of the design manufacture, construction installation testing and commissioning of central refrigeration and air conditioning equipment.

2

Related Sections and Parts are as follows: General


General Instrumentation, Control and Automation Structural Metalwork Electrical Works

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This Section Part 1

CONDITIONING

References

1

The following standards and organisations are referred to in this Part:

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ARI Standard 210 ARI Standard 450 ARI Standard 480 ARI Standard 550 ASHRAE Products

1

Materials and equipment furnished under these specifications shall be standard catalogue products of manufacturers regularly engaged in production of such materials or equipment and shall be the manufacturer’s latest standard design complying with the specification requirements and meets and capacity indicated in the Project Documentation. Where two or more units of the same class of equipment are required, these units shall be produces of a single manufacturer. However, the component parts of the system need not be the products of the same manufacturer.

2

Each major component of equipment shall have the manufacturer’s name address, and catalogue number on a nameplate securely affixed in a conspicuous place; the nameplate of a distributing agent only will not be acceptable.

2.2

PACKAGE CHILLERS

2.2.1

Air Cooled Package Chillers

1

The air-cooled packaged chillers shall be factory assembled complete with piping and wiring and shipped with refrigerant charge and oil change.

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2.1.3

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The only required field connections shall be the system water piping, electrical power supply and external control cables when required.

3

The units shall be provided with lifting lugs for easy site handling.

4

All components shall be mounted on a continuous structural steel base resting on vibration isolators. The isolators shall be proportional for the loads at all points under the unit.

5

The chiller control and starters shall be housed in a weather proof and dust proof enclosure with lockable door. The minimum rating for the enclosure shall be IP55.

6

The system shall be designed and supplied with the refrigerant as specified in the Project Documentation.

7

The power supply cables and protective devices shall be rated as recommended by the manufacturer.

8

The chiller shall be selected to meet the capacities as detailed in the Project Documentation.

9

The compressor type shall be as specified in the Project Documentation.

10

The chiller shall be in accordance with the latest QGEWC regulations.

11

The manufacturer’s details should be followed wherever possible.

12

Adequate space shall be provided for operating and maintenance purpose.

2.2.2

Water Cooled Package Chillers

1

The water-cooled packaged chillers shall be factory assembled complete with piping and wiring and shipped with refrigerant charge and oil change.

2

The associated condensor capacity shall be matched with the capacity of the chillers.

3

The only required field connections shall be the system water piping, electrical power supply and external control cables when required.

4

The units shall be provided with lifting lugs for easy handling.

5


6

The chiller control and starters shall be housed in a weather proof and dust proof enclosure with lockable door. The minimum rating for the enclosure shall be IP55.

7


8


9

The chiller shall be selected to meet the capacities as detailed in the Project Documentation.

10


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12


13


2.3

PACKAGED AIR CONDITIONERS

2.3.1

Air Cooled Packaged Air Conditioning Units

1

The air-cooled packaged Air Conditioning Units shall be factory assembled complete with piping and wiring and shipped with refrigerant charge and oil change.

2

The only required field connections shall be the system ductwork, electrical power supply and external control cables when required.

3


4


5

The Packaged Air Conditioning Units controls and starters shall be housed in a weather proof and dust proof enclosure with lockable door. The minimum rating for the enclosure shall be IP55.

6


7


8

The Packaged Air Conditioning Units shall be selected to meet the capacities as detailed in the Project Documentation.

9


10

The Packaged Air Conditioning Units shall be in accordance with the latest QGEWC regulations.

11


12


2.3.2

Water Cooled Packaged Air Conditioning Units

1

The water-cooled packaged Air Conditioning Unit shall be factory assembled complete with piping and wiring and shipped with refrigerant charge and oil change.

2

The associated condensor capacity shall be matched with the packaged Air Conditioning Units requirements.

3

The only required field connections shall be the condensor system water piping ductwork, electrical power supply and external control cables when required.

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5

All components shall be mounted on a continuous structural steel base resting on vibration isolators. The isolator shall be proportional for the loads at all points under the unit.

6

The Packaged Air Conditioning Units controls and starters shall be housed in a weather proof and dust proof enclosure with lockable door. The minimum rating for the enclosure shall be IP55.

7


8


9

The Packaged Air Conditioning Units shall be selected to meet the capacities as detailed in the Project Documentation.

10


11


12


13


2.4

COMPRESSORS

2.4.1

General

1

Compressors shall be tested and rated in accordance with ISO Standard 917 or equivalent and guaranteed to operate at published capacities.

2.1.1

Centrifugal Compressors

2

Shall be serviceable, hermetically sealed requiring no shaft seals, or required stages and consisting of the following:

3

Impeller

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(a)

shall be made of non-ferrous, cast aluminium alloy or approved alloy or approved equivalent material

(b)

shall be dynamically and statically balanced after fabrication and tested minimum 25 % overspeed

(c)

shall be sufficiently rigid to prevent any vibration at operating speed

(d)

the impeller operating speed shall be below first critical speed

(e)

two-stage impellers shall be connected to the motor by a gear train.

Casing (a)

all external parts shall be constructed of steel, high-strength ductile iron casting or approved equivalent material

QCS 2014

(b)

O-ring gaskets shall be used between casings

Lubrication System (a)

shall be of the forced-feed type and shall provide oil at the proper temperature to all parts requiring lubrication

(b)

on units providing forced-feed lubrication prior to starting, a differential oil pressure cut-out interlocked with the compressor starting equipment shall allow the compressor to operate only when the required oil pressure is provided to the bearings

(c)

the lubrication system shall be complete with the following: pressure relief valves

(ii)

oil piping

(iii)

gauges

(iv)

thermometers

(v)

oil pressure switches

(vi)

oil cooler designed for use with chilled water, condenser water or directly cooled by refrigerant

(vii)

oil filter

(viii)

oil reservoir

(ix)

oil heater, of a size to prevent oil from absorbing refrigerant during shutdown, thermostatically controlled. It shall not be required if the system is designed to prevent the refrigerant from contact with the oil and guaranteed not to absorb oil during prolonged shutdowns.

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(i)

Capacity Control

the compressor shall be provided with temperature or pressure-actuated capacity reduction to the pre-rotation vane or suction damper type to provide automatic capacity modulation from 100 to 10 percent capacity

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hot gas by-pass automatically controlled shall be provided if required to maintain stable operation.

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Gear Transmission (a)

the gear transmission shall be of the self-aligning type, having sufficient capacity to transmit the maximum compressor load under all operating conditions without objectionable noise or vibration

(b)

the gears shall be double helical type, and the teeth shall be continuously flooded with filtered oil

(c)

the bearings shall be of the pressure lubricated type, and suitable for both gears and pinions.

Motors (a)

the motors shall be of the hermetically sealed, refrigerant-cooled type, the winding specifically insulated for use with refrigerant

QCS 2014


(b)

the motors shall be designed for continuous operation at nameplate rating, provided with a load limit mechanism and solid state sensors in motor winding to provide positive thermal and current overload protection

(c)

the motor starter shall be contained in a weatherproof enclosure, completely pre-wired to the motor.

9

Lifting device (a)

An eyebolt or approved equal device to permit lifting compressor shall be included:

2.4.2

Reciprocating Compressors

1

Clarification reciprocating compressors may be of the open or semi-hermitic serviceable type, or of the welded hermetic type, with the motor and compressor contained within the same pressure vessel and the motor shall be in contact with the refrigerant

(b)

reciprocating compressors shall be capable of operating at partial load conditions a continuous operating down to the lowest step of unloading

(c)

reciprocating compressors shall be designed for use with a fluorocarbon refrigerant.

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Drivers and Starters (a)

open type compressor

open type compressor may be driven by an external motor, directly through a coupling or indirect through a belt-drive or gearbox. Starting of open type compressors shall be across the line or in accordance with the manufacturer’s recommendations.

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hermetic type compressors shall be direct driven by either a standard motor and across the line starter or a reduced voltage starter

(ii)

the motor insulation and rubber materials shall be compatible with refrigerant and oil mixtures.

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Lubrication System

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(a)

(a)

reciprocating compressors shall be provided with a forced feed lubrication system by means of eccentric gear-pump, vane pump or piston pump. The lubrication pumps shall be equipped with bleed provisions on the discharge side to vent the pump and to prevent excessive pressures, and with a strainer or oil filter in the suction line

(b)

small reciprocating compressors may be lubricated by a splash. The crankcase shall be filled with oil up to the bottom of the main bearings or to the middle of the crankshaft main bearings. At each revolution the crankshaft or the eccentric shall splash the oil around the inside of the compressor.

Features: Reciprocating compressors shall be provided with the following features:(a)

capacity control for unloaded start and noted capacity steps

(b)

suction strainer

(c)

crankcase heater

QCS 2014


(d)

hot gas muffler

(e)

replaceable bearings

(f)

suction and discharge stop valves

(g)

oil level sight-glass

(h)

suction and discharge refrigerant gas pressure gauges

(i)

high and low gas pressure adjustable safety control

(j)

vibration isolators

(k)

oil safety switch

Rotary Compressors

1

Description

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2.4.3

rotary compressors shall be designed and rated in accordance with ASHRAE recommendations or equivalent

(b)

rotary compressors used for household refrigerators using R-12 refrigerant or for window type air conditioners using R-22 refrigerants shall be of the rolling piston or rotating vane type

(c)

rotary compressors shall be designed to have a high volumetric efficiency and an acceptable sound level, particularly where they are intended for use in homes

(d)

rotary compressors shall have a rigidly constructed shaft to meet deflection allowances and cast iron bearing with a hardened, steel journal rotary compressors shall have tow blades, designed for maximum reliability, and constructed to limit the deflection under load to no more than 0.05 mm per/m of blade length. The slots shall be hardened, steel journal

(e)

the journal shall be ground round and honed or polished

(f)

rotary compressor shall be equipped with a check valve at the suction inlet to close automatically when the compressor stops to prevent high pressure gas from migrating into the evaporator.

Lubrication System

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(a)

3

(a)

rotary compressors shall be provided with a good lubricating system to circulate an ample supply of clean oil to all working surfaces, bearings, blades, slots, and seal faces

(b)

oil grooves shall have outlets to permit free flow of the excess lubricant, and to flush particles into the sump.

Drivers and Starters (a)

rotary compressors shall be equipped with a standard split-phase motor or a permanent split-capacitor motor in accordance with the manufacturer’s recommendations.

2.5

CONDENSERS

2.5.1

Air Cooled Condenser

QCS 2014


1

Air-cooled condenser shall be rated to ARI Standard 210 or equivalent and guaranteed to operate at published capacities.

2

Air-cooled condenser shall be suitable for remote installation in a weather protected casing, or for use with self-contained air conditioners.

3

The air-cooled condenser shall be a complete factory-fabricated and factory assembled unit consisting of the following:

4

Coils shall be as follows: the tubes shall be Seamless copper

(b)

the fins: shall be Aluminium

(c)

condenser coils for installation in salt air or corrosive atmosphere shall be constructed of copper tubes and fins with galvanized steel end sheets. Alternatively the condenser coils shall be provided with protective coating as specified.

7

propeller type or centrifugal type directly connected to the motor shaft or indirectly connected to the motor by means of a V-belt drive

(b)

belt drives shall be completely enclosed within the unit casing or equipped with a guard

(c)

fans shall be statically and dynamically balanced

as

qa

ta

(a)

se

The Housing shall consist of:

the frame and supports shall be constructed of galvanized angle iron

(b)

the casing shall be constructed of hot dip galvanized steel

(c)

vibration isolators

Motors

totally enclosed, fan-cooled for all installations where motor is exposed to the weather or in an air stream.

(b)

et it

(a)

er

(a)

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6

Fans

o

5

rw

.l. l

.

(a)

(c)

motor starter shall be a magnetic across the line type within a watertight enclosure

(d)

thermal protection shall be of the manual or automatic reset type

m

open drip-proof type within an enclosure to be fully protected from the weather

8

Condenser Controls. One of the following methods of controlling condensing temperature shall be provided: (a)

air volume control (i)

thermostat or pressure switch type with a control relay shall be provided to modulate fan discharge dampers and maintain adjustable pre-set refrigerant condensing temperatures

(ii)

a solid state variable speed fan motor controller may be provided in lieu of volume dampers to control the airflow over the coil

(iii)

a condenser with multiple fans may be provided with a fan cycling control to cycle one of two, or two of three fans act in response to outdoor ambient temperatures.

QCS 2014


(b)

condenser flooding. On a decrease in refrigerant discharge pressure, a head pressure sensitive valve shall start to throttle the liquid flow from the condenser outlet and thereby increase the amount of liquid in the condenser. The liquid leaving the condenser shall be reheated by hot gas to increase the temperature of the sub-cooled liquid sufficiently to maintain a balanced pressure temperature relationship in the receiver.

9

Liquid Receiver A liquid receiver of a minimum capacity of 125 % of the refrigerant charge shall be supplied and connected to the refrigerant circuit, complete with inlet and outlet service valves

(b)

charging connections

(c)

relief valve

rw

.l. l

.

(a)

ta

An air-cooled condenser may be used for refrigerant storage in lieu of separate receiver, provided that the condenser storage capacity is 20 percent in excess of the fully charged system. Water Cooled Condenser

1

Water cooled condenser shall be rated in accordance with ARI Standard 450 or equivalent and guaranteed to operation at published capacities. Fouling factor shall be a minimum of 0.000088 in accordance with ARI Standard 550.

2

Shells and Tubes

er

the welded steel shells and copper tubes shall be rolled into grooved holes in tube sheets

(b)

the tube shall be removable without affecting tube sheet or causing leakage of adjacent tubes

(c)

the tube sheets shall be made of carbon steel suitable for withstanding working pressure

et it

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(a)

intermediate tube sheet supports shall be installed prevent tube vibration.

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(d) 3

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2.5.2

Water Boxes (a)

the water boxes shall be made of high grade carbon steel or material of equivalent strength and suitable for the specified pressure

(b)

water boxes shall have the following: (i)

separable cover with eyebolt

(ii)

vent and drain connections

(iii)

connected to shell in a manner to prevent shell exposure to water

(iv)

flanged water nozzles for main piping connections

(v)

tappings for thermometers, control bulbs and gauges

(vi)

piping connections shall be arranged to permit cleaning without removing the piping.

QCS 2014

to prevent direct impingement of refrigerant gases upon tubes

(b)

to uniformly distributes gas refrigerant over length of condenser

(c)

non-corrodible baffle sheet to segregate and collect non-condensable gases for compression purging. Purge connections non-corrodible materials

(d)

purge and recovery unit connection to remove non-condensable gases and water vapour.

Condenser Controls capacity control by means of restricting water flow through condenser using one of the following two methods. two-way throttling valve to maintain applications utilising city or well water

(b)

three-way valve to direct water around the condenser as the condensing temperature is lowered. This system is most often used with a cooling tower.

pressure

in

once-through

.l. l

rw

ta

Evaporative Condensers

as

qa

draw through or blow-through type sized and installed in accordance with ASHRAE recommendations consisting of the following: (i)

galvanized steel casing and basin with overflow and drain connection

(ii)

frame made of angle iron

(iii)

removable galvanized steel eliminators

(iv)

access panels of adequate size for maintenance

(v)

make-up water float valve

(vi)

fan with adjustable pitch belt drive with belt guard and weather protection cover for motor. Fan shaft shall be epoxy coated, zinc chromatised or approved equal finish

et it

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(a)

condensing

.

(a)

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2.5.3

(a)

er

5

Baffles

ov

4


m

(vii)

condensing coil with a liquid sub-cooler made of hot-dip galvanized steel, copper tubing or iron pipe

(viii)

recirculating pump factory installed and piped to bronze non-clog spray nozzles

(ix)

galvanized steel piping

(x)

flanged collars for duct connections for indoor installations

(xi)

water bleed system

(xii)

capacity control can be obtained as a modulating discharge damper to vary air flow across the coil or a multi-speed fan motor to vary airflow across the coil.

2.5.4

Dual Condensing

1

Dual condensing systems shall consist of a heat rejection and an auxiliary heat recovery condenser to extract heat from refrigerant and reject some of that heat to a warm circuit.

QCS 2014


Heat Rejection Condenser. The heat rejection condenser shall be of the water-cooled condenser type, as described in clause 2.9 or of the air-cooled condenser type as described in the Clause 2.8.

3

Heat recovery Condenser. The heat rejection condenser shall be of the water-cooled condenser type as described in Clause 2.9.

2.6

COOLER

2.6.1

General

1

Cooler shall be designed and rated in accordance with ARI Standard 480.

2

Shell and tube type and performance is based on a fouling factor to 0.000088 for non-ferrous tubes, and 0.000176 for steel tubes, consisting of the following:-

3

Shells and Tubes see Clause 2.9.2.

4

Water Boxes

ta

rw

.l. l

.

2

water boxes made on high-grade carbon steel or material or equivalent strength suitable for specified pressure, provided at each end for an odd number of passes and one end for an even

(b)

water boxes shall have the following specifications : See Clause 2.9.3.

se

to prevent direct impingement of liquid on tubes

(b)

to distribute liquid refrigerant uniformly.

Eliminators

ov

er

(a)

(a)

non-ferrous

(b)

to prevent liquid refrigerant from entering compressor.

o

6

Baffles

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5

as

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(a)

Anti-freeze thermostat

8

Insulation with a vapour barrier

2.7

COOLING TOWERS

2.7.1

General

1

Cooling towers shall be designed, constructed and rated in accordance with ASHRAE Recommendation 21 - Equipment.

2

Field-assembled Cooling Towers. Filed assembled cooling towers shall consist of the following :

3

Framework

m

7

(a)

Steel framework bolted, reinforced and interconnected so that stresses are transmitted directly to the tower foundation

QCS 2014


(b)

Bolts, nuts, washers and corners shall be made of hot-dipped galvanized steel

(c)

Roof framing designed for additional loads of fan, fan motors, gear-reducer if required, fan-casing, and other loads during erection or normal operation.

4

Casing. Casing shall be water and-air tight made of stainless steel, galvanized steel with a zinc coating or hot-dip galvanized after fabrication, as specified in the Project Documentation. Casing fastening to frames shall be by means of stainless steel hardware.

5

Partitions full height of tower

(b)

water and air tight

Water Distribution distribution system for each cell.

(b)

header system with branches, spray arm and nozzles.

(c)

nozzles made of non-clogging cast bronze or polyethylene type.

ta

rw

(a)

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Collection Basin

made of hot-dipped galvanized steel or stainless steel one-piece, factorywelded design

(b)

overflow and cleanaout

(c)

drain connector.

as

(a)

se

7

.l. l

.

6

(a)

Access. To fan deck, gear and fan, water distribution area and basin.

9

Fans

ov

er

8

propeller or centrifugal type with adjustable pulley

(b)

gear speed reducer, if required, with a stainless steel shaft, flexible coupling and extension pipe to permit filling, draining and sampling of the oil level out-side fan housing with an oil sight-glass

(c)

et it

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(a)

(d)

removable wire screen, hot-dipped galvanized steel.

m

totally enclosed fan cooled type motor

10

Vibration Eliminators. Vibration eliminators with an isolation efficiency of a minimum of 70 percent.

11

Corrosion Protection. Interior and exterior corrosion protection coating and lining.

12

Eliminators. Removable made of asbestos neoprene honeycomb or approved equal materials, and supported by galvanized steel channel sections.

13

Fill Material. Made of polyvinyl chloride film-type or approved equal materials supported at close centres by galvanized steel structural members.

QCS 2014


Bleed-off and Make-up Water. The cooling tower shall be provided with a controlled bleed-off feature to minimise scale formation and to inhibit corrosion and with a make-up water connection controlled by a large-diameter seamless type copper float to maintain automatically the water level in the sump at a predetermined level.

2.8

PACKAGE COOLING TOWERS

2.8.1

General

1

Package cooling towers shall be factory-assembled of the counterflow through design, with centrifugal or propeller fan assemblies built completely into the pan, with all moving parts factory-mounted and aligned. The packaged cooling tower shall consist of the following:

2

Pan Section

.

14

the pan section shall consist of a steel framework and a sloped stainless steel or hot-dipped galvanized steel basin

(b)

the pan section shall be provided with access door, stainless steel strainer with perforated openings smaller than spray nozzle orifices, waste water bleed-off line with valve, and a make-up valve with a large diameter float arranged for easy adjustment.

Fan Assembly (a)

the fan shall be of the propeller or centrifugal type. The housing of the fan shall have compound curve inlet rings for efficient air entry and a discharge cover within the pan to prevent water from entering the fan

(b)

the fan shaft shall be mounted in heavy-duty, grease-packed, self-aligning ball bearings

(c)

V-belt drives shall be designed for not less than 150 percent of motor nameplate horsepower. Drives and all moving parts shall be completely enclosed by removable screens made of stainless steel or hot-dipped galvanized steel.

ov

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(a)

o

Surface Section

5

Water Distribution (a)

6

water distribution shall be evenly spread over the tower’s fill area through gravity or sprayhead tree, consisting of stainless steel header and removable branches with replaceable spray nozzles made of plastic or approved equal materials. The nozzles shall be held in place with snap-in rubber grommets to provide quick removal of individual nozzles or branches for cleaning or flushing.

Eliminators (a)

7

the heat transfer section shall be removable from the pan made of stainless steel or other approved material supported in galvanized steel frame, and waveformed or honeycomb in shape for optimum heat transfer.

m

(a)

et it

4

eliminators shall be removable in easily handled sections made of stainless steel or other approved material.

Fan Motors (a)

fan motors shall be of the encapsulated epoxy-insulated drip-proof type.

QCS 2014


REFRIGERATION ACCESSORIES

1

Combination filter with a dryer in the refrigerant line, so arranged that cartridges can be replaced when the refrigerant circuit is changed.

2

Combination sight-glass and moisture indicator.

3

Solenoid valve in the refrigerant line and in the oil bleeder lines from flooded evaporators.

4

Expansion valve on refrigerant line at coil inlet with the bulb located immediately after the coil outlet.

5

Strainer in suction line on steel piping systems to protect pressure-regulating devices.

6

Strainer in refrigerant line to protect expansion valve.

7

Refrigerant charging connection in the liquid line.

8

Liquid suction interchange in the liquid line.

9

Muffler in the hot-gas line in the downward flow risers or in the horizontal lines near the compressor.

10

Oil trap (separator) in the discharge line.

2.10

MISCELLANEOUS

2.10.1

Water Chemical Treatment

1

After preliminary design, the Contractor shall submit to the Supervising Agency a complete analysis of local water or actual water samples at the site. This information shall be accompanied by a description of each system to be treated with anticipated make-up rates and other available data.

2

Make-up rates of chemicals and water quality requirements for each system shall be in accordance with the ASHRAE recommendations and the chemical analysis.

3

Water Treatment Firm

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2.9

(a)

the Contractor shall engage a water treatment firm which shall : (i)

supervise installation and application of water treatment

(ii)

supply required treatment chemicals and instructions for application and control of initial cleaning of all piping systems

(iii)

supply testing equipment and reagent

(iv)

instruct the Contractor on installation of chemical feeding equipment before start-up

(v)

demonstrate the proper application of treatment materials to be used, operation of feeding equipment as installed and operation of testing equipment required

QCS 2014

(vi)

collect samples of each treated system for analysis at laboratory and submit result, with comments

(vii)

provide written proposals detailing services to be performed for an extended service period of one year from date of start-up.

Condenser Water System

chemical formulation to control corrosion and scale as directed by raw water analysis or sea water analysis where applicable and equipment operating conditions, is to be introduced to system through automatic treatment equipment

(ii)

this formulation shall be a non-metallic blend of corrosion and scale inhibitors capable of producing desired treatment results without supplementary acid feed

(iii)

biological fouling liquid formulation as dictated by water analysis and local environmental conditions to be slug-fed to system

(iv)

cycles of concentration are to be maintained at a level consistent with raw water analysis and operating conditions

(v)

biocides shall be added if significant amount of algae or slime are detected after system operation. Compounds of mercury, copper or arsenic are not permitted.

as

qa

ta

rw

.l. l

.

(i)

Equipment

diaphragm chemical proportioning pump shall be furnished to pump algae inhibitors. The pump shall include suction strainer, check valve and associated piping including corporation stop injection assembly

(ii)

water meter shall be located in the cooling tower make-up line and shall be sized for combined peak flow of evaporation and bleed-off

(iii)

automatic re-set timer unit and counter-unit shall be assembled as a package to modulate chemical feed and bleed in proportion to tower make-up water

se

(i)

et it

o

(b)

chemicals. Selection of treatment chemicals for the cooling tower system shall be based upon characteristics and solids content of make-up water as follows :

er

(a)

ov

4


(iv)

Chilled Water System

m

5

a solenoid bleed valve and Y-strainer shall be furnished.

(a)

Chemicals. Treatment shall consist of a buffered nitride-based product, maintained in circulating water systems at 700 - 1000 PPM sodium nitride.

(b)

Equipment. By-pass chemical pot feeders, consisting of cast iron and steel body, easy to fill.

2.10.2

Water Softeners

1

Water softeners shall be fully automatic downflow, pressure-type water softeners, having capacities as indicated in the Project Documentation.

2

Piping. Piping shall be copper tubing with brass or wrought copper solder joint fittings, or as required in the Project Documentation.

QCS 2014

3

Tank (a)

softener tank shall be made of riveted or welded stainless steel construction in accordance with the relevant ISO Standards and/or ASME Code

(b)

the shell shall be designed and tested at 50 percent greater pressure than the working pressure

(c)

the tank and both sides of false bottoms shall be lined with plastic, rubber or equivalent corrosion-resistant material

(d)

upper head and lower side of each tank shall be provided with access openings.

Collector System (a)

a suitable device shall be provided within the softener tank for collecting softened water and distributing wash water. The device shall be deflector-plate type, or falsebottom type, or other approved equal type

(b)

the underdrain system shall distribute the backwash water in a manner that will not cause channelling of the gravel and exchange material.

rw

ta

(b)

pipe connection for softened-water outlet or backwash inlet shall be on the underside between deflector and tank bottom.

se

as

qa

the deflector-plate type collector shall be made of cast iron, or corrosion-resistant steel, securely fastened to the bottom of the tank and arranged for discharge around the circumstance of the plate or through radial slots in the plate. The deflector-plate type require a gravel bed

er

False-bottom Type

the false-bottom type collector shall consist of a false bottom with strainers attached thereto and therefore does not require a gravel bed.

(b)

strainers and fasteners shall be made of corrosion-resistant metal.

ov

(a)

(a) (b)

the gravel shall be washed and free from any foreign materials

(c)

the gravel bed shall be properly graded to prevent loss of exchange material during normal operation and back-washing.

Gravel Bed

the gravel supporting bed shall be placed immediately above the underdrain system of all types except the false-bottom type collector

m

7

(a)

o

6

Deflector-plate Type

et it

5

.l. l

.

4


8

Exchange Material (a)

exchange material shall be quartz sand, washed, processed and not less than 0.35 mm in size and with uniformity coefficient not higher than 1.2

(b)

exchange material shall not require dosing or adding of any chemical mixture or solution to the water to be treated or to the water used for back-washing or regeneration other than common salt, NaCI.

QCS 2014

Brine-storage Tank (a)

one brine-storage tank shall be provided for each water softening unit, made of steel, reinforced and lined with enamel or other approved brine-resistant material, provided with an automatic, float-controlled water control valve, located in an independent float chamber, inside the tank.

et it

o

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ta

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.l. l

.

END OF PART

m

9


QCS 2014

Section 22: Air Conditioning, Refrigeration and Ventilation Part 03: Unitary Equipment

Page 1

3

UNITARY EQUIPMENT ................................................................................... 2

3.1

GENERAL ........................................................................................................ 2

3.1.1

SCOPE

3.2

AIR-CONDITIONERS ...................................................................................... 2

3.2.1

Window Air-conditioners

2

3.2.2

Split Type Room Air-conditioners

3

3.3

DOMESTIC APPLIANCES .............................................................................. 5

3.3.1

Domestic Refrigerators

5

3.3.2

Drinking Water Coolers

5

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.

2

QCS 2014


Page 2

3

UNITARY EQUIPMENT

3.1

GENERAL

3.1.1

SCOPE

1

This Part details the requirements for all types of unitary equipment as specified in the Contract.

2

Related Sections are as follows: General Electrical Installation

.l. l

.


AIR-CONDITIONERS

3.2.1

Window Air-conditioners

1

The unit offered in the tender shall be a reputed manufacturer who is represented locally and can provide an efficient maintenance and spare parts service.

2

The casing shall consist of a heavy gauge steel chassis with sheet metal casing. The minimum thickness shall be 1.2 mm. The whole unit shall be protected against corrosion and finished inside and outside with stoned primer and paint. The decorative front panel shall be of rigid plastic.

3

The unit shall be supplied completely packaged and ready for operation once connected to the suitable electrical supply.

4

The fan shall be of the forward curved centrifugal type and be made of aluminium reinforced glass fibre, rigid plastic material, aluminium or steel.

5

The air filters shall be of nylon fibre, glass fibre material or as supplied by the manufacturer and approved by the Engineer.

6

The filter shall be easily removable for cleaning without removing the unit from the wall.

7

The fan motor shall have factory lubricated bearings sealed of the sealed for life type.

8

The fan motor windings and electrical components shall be impregnated or protected to avoid problems from condensation.

9

The compressors shall be the hermetically sealed pattern complete with resilient mountings.

10

The condenser and evaporator coils shall be formed of copper primary tubes with aluminium or copper fins. If copper fins are used they shall be electro-tinned after manufacture. The fins shall be mechanically bonded to the tubes. Aluminium coils shall be guaranteed for five years.

11

The unit shall have control giving three running speeds and an off position.

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3.2

QCS 2014


Page 3

The units shall incorporate a damper adjustable from the control panel to allow a percentage of fresh air to be included.

13

The units shall meet the specified duties for air flow and cooling capacity.

14

The units shall be installed according to the manufacturer’s recommendations and installed on suitable galvanized supports where required.

15

The outlet grille shall be fully adjustable to enable the direction of airflow to be set to the desired direction.

16

The condensate drain shall be connected to the nearest floor gully or soakaway.

17

The condensate pan shall be adequately treated against corrosion, insulated and pitched for positive drainage with the unit installed level.

18

The controls shall include the following :

oil pressure protection switch

(c)

thermal overload cut-out.

rw

(b)

ta

high-low pressure switches

qa

(a)

.l. l

.

12

The air conditioners shall be quiet in operation. Sound level shall not exceed 55 dBA at low speed and 60 dBA at high speed when measured at 1 m distance in a room with normal furniture and occupancy.

20

The air conditioning unit shall be capable of handling the cooling loads when operating in ambient conditions of 35 C (Nominal load).

21

The degree of cooling shall be adjustable from maximum to minimum.

3.2.2

Split Type Room Air-conditioners

1

The unit offered in the tender shall be by a reputed manufacturer who is represented locally and can provide an efficient maintenance and spare part service.

2

The casing shall consist of a heavy gauge steel chassis with sheet metal casing. The minimum thickness shall be 1.2 mm. The whole unit shall be protected against corrosion and finished inside and outside with stoned primer and paint.

3

The casing for the inside unit shall be the same as mentioned above or of rigid plastic as supplied by the manufacturer.

4

The fan shall be of the forward curved centrifugal type and be made of aluminium reinforced glass fibre or rigid plastic material.

5

The air filters shall be of nylon fibre glass fibre material or as supplied by the manufacturer and approved by the Engineer.

6

The filter shall be easily removable for cleaning.

7

The inside unit fan and condenser fan motors shall factory lubricated bearings of the sealed for life type.

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QCS 2014


Page 4

The motor winding and electrical components shall be impregnated or protected to avoid problems with condensation.

9

The compressor in the outside unit shall be the hermetically sealed pattern complete with resilient mountings.

10

The condenser and evaporator coils shall be formed of copper primary tubes with aluminium fins or copper fins. If copper fins are used they shall be elctro-tinned after manufacture. The fins shall be mechanically bonded to the tubes. Aluminium coils shall be guaranteed for five years.

11

The unit shall have control giving three running speeds and an off position.

12

The outlet grille shall be fully adjustable to enable the direction of airflow to be set to the desired direction. Where the units are floor mounted the supply grilles shall be on the top of the unit.

13

The units shall be installed in accordance with the manufacturer’s recommendations to unit location, refrigerant piping, power and condensate piping.

14

Where the units are of the concealed type the Contractor shall ensure adequate access is provided for the removal of a complete unit.

15

The condensate pipe work shall be run to the nearest drain.

16

The units shall meet the specified duties for air flow and cooling capacities.

17

The controls shall include the following:

ta

qa

as

se

er

high-low pressure switches

(b)

oil pressure protection switch

(c)

thermal overload cut-out.

o

ov

(a)

The units shall incorporate the following accessories: electric crank case heater

m

(a)

et it

18

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.l. l

.

8

(b)

suction and discharge shut off valves

(c)

changing, relief and purging valves

(d)

gauge connections

(e)

spring mounts for compressor.

19

The fin spacing for the evaporator and condenser coils shall be in line with the latest QGEWC regulations.

20

The air conditioning unit shall be capable of handling the cooling loads when operating in ambient conditions of 50 C at the medium speed

21

The outdoor unit shall be designed to operate at outdoor ambient temperature of 50 C.

22

The sound level shall not exceed 45 dBA at low speed and 55 dBA at high speed when measured at 1 m distance in a room with normal occupancy and furnishing.

QCS 2014

Section 22: Air Conditioning, Refrigeration and Ventilation Part 03: Unitary Equipment the

compressors

shall

be

as

per

the

manufacturer’s

23

The safety devices recommendations.

3.3

DOMESTIC APPLIANCES

3.3.1

Domestic Refrigerators

1

The refrigerator offered in the tender shall be by a reputed manufacturer who is represented locally and can provide and efficient maintenance and spare parts service.

2

The refrigerator supplied shall be as close as possible to the size as detailed in he Project Documentation.

3

The refrigerator shall be installed in the allocated location with adequate ventilation for efficient operation.

4

The casing shall be plastic coated aluminium, plastic coated steel or stainless steel as detailed in the he Project Documentation.

5

The refrigerator shall be insulated with foam injected CFC free insulation.

6

The compressor shall be the hermetically sealed pattern complete with resilient mountings.

7

The coils shall be manufactured of copper tubes with mechanically bonded aluminium or copper fins. Aluminium coils shall be guaranteed for five years.

8

Where detailed in the Project Documentation the refrigerator shall incorporate a separate freezer section, which shall be constructed of plastic.

9

The temperature shall be independently adjustable in both freezer and refrigerator sections.

10

The refrigerator shall be supplied complete with all shelves drawers and dispensers as detailed in the Project Documentation.

11

The door hinges shall be convertible hinges to allow the change of door swing from the right to left or vice versa.

12

The refrigerator shall be provided with rollers to assist installation and maintenance.

3.3.2

Drinking Water Coolers

1

The drinking water coolers offers in the tender shall be by a reputed manufacturer who is represented locally and can provide an efficient maintenance and spare parts service.

2

The water coolers shall be either the free standing type or recessed type as detailed in the Project Documentation.

3

The complete casing and faucets shall be manufactured of polished stainless steel.

4

The water coolers shall be installed in the allocated location with adequate ventilation to ensure efficient operation.

5

The compressor shall be the hermetically sealed pattern complete with resilient mountings.

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for

Page 5

QCS 2014


Page 6

6

The coils shall be manufactured of copper tubes with mechanically bonded aluminium or copper fins. Aluminium coils shall be guaranteed for five years.

7

The cooling coils shall be isolated from the stainless steel water storage tank to ensure contamination cannot occur in the event of a leak.

8

The water supply to the water cooler shall be filtered by a replaceable cartridge type filter. The filter shall be installed in an accessible location within or as close as possible to the water cooler.

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.

END OF PART

QCS 2014

Page 1

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AIR HANDLING EQUIPMENT ....................................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 Quality Assurance 2 System Description 2 CONSTRUCTION OF AIR HANDLING UNITS .............................................. 3 General 3 FAN SECTION ............................................................................................... 4 General 4 Centrifugal Fans 5 Axial Fans 5 COIL SECTION.............................................................................................. 6 Coils General 6 Chilled and Hot Water Coils 7 Refrigerant Direct Expansion Air Cooling Coils 7 ELECTRICAL DUCT HEATERS .................................................................... 8 General 8 FILTERS ........................................................................................................ 8 General 8 Dry Replacement Media Type Filter 9 Regenerative Filters 10 Bag Filters 10 Automatic Fibre Roll Type Filters 10 Grease Eliminators 11 High Efficiency Filters 11 Activated Carbon Type Filters 11 HUMIDIFIER ................................................................................................ 12 General 12 Water Type Humidifiers 12 Steam Type Humidifiers 12 HEAT RECOVERY UNITS .......................................................................... 13 General 13 Static Rate Heat Exchanger 13 Rotating Matrix Heat Exchanger (thermal wheel) 13

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4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.2 4.2.1 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.7 4.7.1 4.7.2 4.7.3 4.8 4.8.1 4.8.2 4.8.3

Section 22: Air Conditioning, Refrigeration and Ventilation Part 04: Air Handling Equipment

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4

AIR HANDLING EQUIPMENT

4.1

GENERAL

4.1.1

Scope

1

This Part specifies single zone, multizone, draw through and blow through type air handling equipment.

2


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General Structural Metal Works Mechanical Works Electrical Installations

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Section 1 Section 16 Section 17 Section 21 References

1

The following standards have been referred to in this Part:

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BS 746 ........................Gas meter unions and adaptors

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BS 2831 ......................Methods of test for air filters used in air conditioning and general ventilation

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BS 3120 .....................Performance requirements of flame proof materials for clothing and other purposes

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BS 3928 ......................Method for sodium flame test for air filters (other than air supply) to i.c engines and compression

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ASHRAE Standard 52-68 Quality Assurance

1

UL compliance: Fans shall be designed, manufactured, and tested in accordance with UL705 “Power Ventilators”.

2

NEMA compliance: Motors and electrical installation shall comply with NEMA standards.

3

Electrical Component Standard: component and installation shall comply with NFPA 70 “National Electrical Code”.

4.1.4

System Description

1

The units shall be installed to allow adequate access for the withdrawal of tubes, fan shafts, coils or other items for replacement or maintenance.

2

The internal surfaces of panels and frames shall be treated to prevent migration of particles into the air stream and to minimise the possibility of damage.

3

The overall dimension and weights shall be such that the units of sub-assemblies can be moved to their ultimate position on site through existing openings or, where possible, prearranged access ways.

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4.1.3

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All pipe inlets and outlets are to be sealed to prevent ingress of air moisture and foreign bodies.

5

Checks shall be carried out to ensure the frames are not distorted or twisted on arrival and, subsequently, after each every removal to another part of site. In addition checks shall be made of individual sections of equipment.

6

All associated control systems and wiring shall be provided with adequate protection against ingress of dirt and moisture.

7

Physical checks shall be made on all bases that have been provided for all equipment and on the installation of the equipment on the bases, to ensure correct level and alignment.

8

Where air handling units have to stand for long periods prior to use, the manufacturer shall be consulted as to any precautions to be taken. This may include rotating the fan impeller by hand at regular intervals to avoid a permanent set in the fan shaft owing to deflection and complete relubrication before start-up.

9

Fresh air intakes shall be as remote as possible from concentrations of surface or roof dirt and positioned to avoid the intake of fumes and odours.

10

The fresh air inlet shall be positioned at least 1.2 m above ground level.

11

The control system and wiring shall be provided with adequate protection against ingress of dust and moisture.

4.2

CONSTRUCTION OF AIR HANDLING UNITS

4.2.1

General

1

The unit casings shall be of double skinned sectional construction with all panels fitted on a penta post frame

2

The panels should be braced to avoid vibration and druming

3

Panels shall be bolted to the sub-frame, except Panels that are required for removal for securing. Service panels shall be hinged and latched

4

All casing panels shall be insulated with at least 50 mm thick for outdoor units and 37 mm 3 thick for indoor units 48 kg/m density rigid fibre glass with a k-factor not exceeding 2 0.037 W/m /K. Injected polyurethane can be used instead, provided that the overall heat

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transfer coefficient does not exceed the above construction. 5

Panels shall be either pre-plastisized, paint finish or aluminium.

6

Frame shall be insulated such that condensation does not occur due to the formation of cold bridges under adverse ambient conditions.

7

The interior of the air handling units shall be free from dangerous obstruction and projection to facilitate cleaning and thus maintain a supply of clean air.

8

Surfaces of the units table to be affected by any free water produced shall be protected by anti-corrosion paint.

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The sealing of all panels and frames shall be made air tight by means of permanently plastic or rubber pressure sealant, and made weather proof for outdoor installation.

10

Air handing units for outside installation shall have sunshade cover and weatherproof canopy.

11

All air handling unit sections shall be produced with heavy duty lifting lugs

12

The drain pan shall be constructed no less than 1.0 mm stainless steel or heavy gage aluminium. It shall be rigidly supported by galvanized heavy duty frame.

13

The units shall include a mixing box section when required. The mixing box section shall include factory installed dampers.

14

Dampers shall be of rigid construction and should not rattle. Shut off dampers shall provide an effective seal to minimise air leakage.

15

The drain pan shall be adequately insulated to prevent sweating under adverse conditions.

4.3

FAN SECTION

4.3.1

General

1

The fans installed in all AHU shall comply with all relevant QGEWC regulations.

2

The type of fan installed in each AHU shall be as detailed in the Project Documentation.

3

Variable pitch pulleys shall be installed on all AHU drive motors on belt and pulley driven fans. The pulleys shall be sized to allow for  5 % fan speed adjustment from the design fan speed.

4

Flexible connection shall be installed on the supply, return and fresh air ducts to minimise vibration transmission to the adjacent ductwork.

5

The complete fan and motor shall be installed on a rigid frame. The frame will be supported by properly sized anti-vibration spring mounts to isolate the motor and fan from the units casing.

6

Where the fan volume or static pressure is to be variable one of the following methods of control shall be incorporated as detailed in the Project Documentation.

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(a)

Multi speed motors

(b)

variable speed frequency drive

(c)

variable pitch

(d)

variable inlet guide valves.

7

The external pressure calculations shall be submitted by the contractor along with the AHU submission on order to select the suitable motor.

8

Fan and motor drive shall be oversized by at least 20 %.

9

The fan shall be configured to minimise excessive pressure drop and air turbulence.

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The fan and motor assemblies shall be mounted on suitable bases and anti-vibration mounts.

11

The motors shall be connected with flexible electrical connections.

4.3.2

Centrifugal Fans

1

Centrifugal fans larger than 7.5 kW output shall be of the backward curved blade type having fan total efficiency of not less than 78 %.

2

Centrifugal fans below 7.5 kW may be either forward curved or backward curved type.

3

Fan casings shall be constructed of mild steel plates with angle stiffeners and base angles to ensure freedom from drumming and shall be suitable for operation at the maximum static pressure of the system. The whole assembly shall be treated for resistance to corrosion.

4

Fan casings shall be constructed so that impellers can be easily hand driven after installation.

5

A drain plug shall be fitted to the fan casing at its lowest point.

6

Impellers shall be of mild steel or other approved material of riveted or welded construction, with spiders or hubs of robust design and shall be capable of running continuously at 10 % in excess of normal speed.

7

Impellers shall be keyed to a substantial mild steel shaft.

8

Fans and shafts shall be operate well below their critical speeds. Each shaft assembly shall be statically and dynamically balanced before shipment from the manufacturer.

9

Fan bearings shall be ring oiled sleeve bearings, or ball or roller type. Where silence is important, the bearing pedestal shall not be attached to the fan casing, and ring oiled sleeve bearings shall be applied.

10

Unless otherwise indicated centrifugal fans shall be driven by electric motors through v-belt drives.

11

The maximum fan outlet velocity shall be 10 m/s.

4.3.3

Axial Fans

1

Axial flow fans shall be either single stage type of the multistage contra rotating type with each impeller mounted on an independent motor, and having an efficiency of not less than 60 %.

2

Casings shall be rigidly constructed of mild steel stiffened and braced to obviate drumming and vibration. Cast iron or fabricated steel feet shall be produced where necessary for bolting to the base of supports.

3

Inlet and outlet ducts shall terminate in flanged steel rings for easy removal.

4

The length of the duct casing shall be greater than the length of the fan(s) and motor(s) in order that the complete section may be removed without disturbing adjacent duct work.

5

Electrical connections to the motor(s) shall be through an external terminal box secured to the casing.

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The impeller shall be of steel or aluminium and the blades shall either be secured to the hub or the blades and hub shall be formed in one piece

7

The hub shall be keyed to a substantial mild steel shaft and the whole shall be statically and dynamically balanced before shipment from the manufacturer.

8

The fan blades shall be of an aerofoil section.

9

Shafts shall be carried in two bearings which may be ball, roller or sleeve type. Lubricators shall be extended to the outside of the casing.

10

Where axial flow fans are driven by a motor external to the fan casing, the pulleys and v-belts shall be provided with a guard and adequate sized access doors.

11

Where axial flow fans of the bifurcated type are indicated, the motors shall be out of the air stream. Motors may be placed between the two halves of the casing in the external air or may be placed within the fan casing provided that effective ventilation is given to the motor.

12

Where hot gasses or vapours are being handled, the motor and bearings shall be suitable for operation at the temperature they may experience.

13

Axial flow fans, which do not connect to suction duct, shall be supplied with a bellmouth inlet.

4.4

COIL SECTION

4.4.1

Coils General

1

The coil casing shall be of galvanized sheet steel not less than 1.2 mm and drilled to meet the adjacent sections of the AHU.

2

The coils shall be fabricated from heavy gauge solid drawn copper tubing expanded into the fins to give a mechanical bond.

3

The coil fins shall be aluminium or copper with the fin spacing not less than 2 mm.

4

The coils shall have a minimum of 4 rows

5

Return bends shall be die formed

6

Headers shall be heavy section seamless copper tubing and all joints shall be silver brazed

7

On systems where the static pressure exceeds 750 Pa, airtight cover boxes shall be provided over the header and bends. Provisions shall be made for draining the cover boxes.

8

The resistance to air flow shall not exceed 125 Pa and the face velocity shall not exceed 2.5 m/s.

9

The coil shall be constructed to maintain even leaving temperature across the total face area of the coil

10

Cooling coils shall be fitted with eliminator plates if the face velocity exceeds 2.5 m/s.

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Cooling coil casings shall be made to form a water tight drip tray complete with drain connection. The drain shall be fitted with a water seal to prevent the ingress and discharge of air to and from the system. The drain pipe shall return to the nearest sump or gully.

12

Cooling and heating coils for large air handling units shall be fitted with slide rails to facilitate easy removal by personnel.

4.4.2

Chilled and Hot Water Coils

1

Coils shall be arranged in a contra flow Pattern, with the flow of water entering at the leaving air side and the leaving at the entering air side.

2

The flow and return headers and connections shall be arranged to ensure an equal flow of water through all tubes.

3

All coils shall be tested at the manufacturers factory to 1½ times the working pressure or to 7 bar whichever is the greater.

4

Coil connections up to and including 65 mm bore shall be screwed or flanged. Connections 80 mm bore and above shall be flanged.

5

Isolating valves shall be installed on the inlet and outlet connections. The valves shall be arranged so as to facilitate the removal of the coil without disturbing adjacent pipework.

6

Provision shall be made for effective venting of the coil and connections and for draining of the coil header and tubes.

4.4.3

Refrigerant Direct Expansion Air Cooling Coils

1

The coils shall be provided with refrigerant distributors and the connections to the tubes shall be designed to ensure an equal flow of the refrigerant to each tube.

2

The suction connections shall be arranged so as to ensure complete drainage of any oil in the coil.

3

The coils shall be dehydrated and sealed after manufacture.

4

The coils shall be tested to 1.5 times their maximum working pressure.

5

The thermostatic expansion valve which shall incorporate an external equaliser line shall maintain the design degree of super heat at the evaporator outlet. The remote sensing bulb shall be securely fixed to the evaporator outlet piping in a position where the degree of superheat can be correctly sensed.

6

The design evaporating temperature shall not be less than -1 °C.

7

The coil shall be sized to be compatible with the associated refrigeration equipment.

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ELECTRICAL DUCT HEATERS

4.5.1

General

1

The casing shall be of galvanized sheet steel no less than 1.2 mm thick with angle framing drilled and ready to receive the counter flange on the duct work. Alternatively, the construction shall be compatible to fit within the air handling unit where appropriate.

2

The electric heaters shall consist of a number of helically coiled nickel chromium alloy heating elements of the enclosed non-corrodible type mounted in the sheet steel casing.

3

The elements shall be so installed that they can be removed for cleaning or removal with minimum disturbance to other plant items.

4

The surface temperature of the elements shall not exceed 150 °C.

5

The control of electric air heaters shall be inter locked with the fan motor starter and air flow switch so that the heater cannot operate unless the fan is running and air flow is detected.

6

The heater shall be installed with a high temperature limit device with hand re-set button.

7

The control of the heater shall be by a thyristor type fully variable controller.

8

All heaters and heater sections greater than 3 kW loading shall be balanced over three phases and the complete heater bank shall be arranged for balanced operation on a 3-phase 4-wire system.

9

The connections from each element shall be taken to readily accessible terminal box arrange for conduit entry.

10

Each heater section shall be separately fused and the neutral point of a all 3 -phase starconnected section shall be brought out to a link in the terminal box.

11

The insulation of the wiring near any hot areas shall be of the appropriate quality.

12

The total resistance of the heater to air flow shall not exceed 25 Pa and the velocity through the free area shall not exceed 6 m/s.

13

The installation of electric heaters batteries shall comply in all respects with the requirements of the Civil Defence Department and QGEWC regulations.

4.6

FILTERS

4.6.1

General

1

Filters shall operate to at least the efficiencies specified in this section and not less than 73 % average synthetic dust weight or resistance in accordance with ASHRAE Standard 52-68.

2

Filters shall be complete with holding frames sufficiently robust to ensure that no distortion occurs in operation.

3

Filters shall be installed with edge seals which shall prevent air by passing the filters. The seal shall remain effective even though the cells are periodically removed and refitted.

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Filters shall be arranged so that there is easy access for cleaning and/or removal.

5

A differential pressure gauge of the dial type or incline manometer type shall be provided for each filter bank and shall be fixed in such a position outside the AHU system that it is accessible and easily read. The gauge shall be marked to show maximum differential indicating a filter change requirement.

6

Filters shall also have a differential pressure switch installed when the system is to be monitored by a BMS system. The differential switch shall be calibrated to operate indicating a fitter change requirement.

7

The air velocity through filters shall be such that the clean resistance as indicated is not exceeded and that the filter fabric or oil is not carried over into the system.

8

Where a flame proof filter medium is specified the material shall comply with the following requirements when tested in accordance with the relevant standard.

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Duration of flaming. No test sample shall continue to flame for more than 8 seconds after the igniting flame has been removed

(b)

Extent of after-glow. After glow shall not spread beyond the area of material damaged by fire

(c)

Length of material which chars or melts. The average length of material which chars or melts on the specimen shall not exceed 85 mm and the maximum length of the charred or melted material in any one specimen shall not exceed 115 mm.

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(a)

Where washable type flame proof filters are offered or specified the filter medium shall comply with the requirements of Clause (b) above both before and after the washing treatment prescribed in BS 3120 Appendix A. Washable type filters shall not be used without prior approval from QGEWC.

10

Where the filter medium is required to be flame proof the casing shall not be less than 1.6 mm thick for at least 1.8 m upstream and 1.8 m down stream of the filter. The immediate frames of cases of the filter elements shall be of material complying with BS 746 Part 1. Clause 7 Class 1.

4.6.2

Dry Replacement Media Type Filter

1

The filter shall be of the flat panel type continued in galvanized steel front or side removal frame.

2

Each cell shall comprise a pad of glass fibre or synthetic fabric filter media, 50 mm thick and retained within a rigid frame of durable cardboard.

3

The filters shall have an efficiency of not less than 92 % based on test specified in BS 2831 with test dust No. 2.

4

The maximum face velocity shall be 2.5 m/s.

5

The initial pressure drop shall not exceed 70 Pa.

6

Sufficient spare cells shall be provided to replace all of the filter bank.

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Regenerative Filters

1

The filter medium shall be processed washable open cell foamed plastic or plastic bonded synthetic fibre.

2

The medium shall have a minimum thickness of 15 mm.

3

The element shall be supported on plastic coated steel wire formers with a metal frame.

4

The face velocity shall not exceed 2.25 m/s.

5

The initial pressure drop shall not exceed 100 Pa.

6

Fitters of this type shall have an efficiency of not less than 90 % based on the test specified in BS 2831 with test dust No. 2.

4.6.4

Bag Filters

1

The filter shall comprise of one or more 600 x 600 mm filter bag modules fitted into a purpose made galvanized steel side or front withdrawal frame.

2

Each module shall comprise a minimum of four separate bags bonded or clipped into a galvanized steel header.

3

The bags shall have a minimum length of 600 mm.

4

The medium shall be of a fine multi-layer type with high mechanical strength.

5

The maximum initial resistance shall not exceed 100 Pa.

6

Fitters of this type shall have an efficiently of not less than 99.6 % based on the tests specified in BS 2831 with test dust No. 2.

7

One complete set of spare bags shall be supplied.

4.6.5

Automatic Fibre Roll Type Filters

1

The filter shall comprise of the complete assembly of filter frame, motor and drive and filter medium.

2

The filter shall operate automatically, with provision for manual starting and stopping of filter movements.

3

Unless otherwise indicated automatic filter movement shall be controlled by the resistance across the filter.

4

Provision shall be made for visual warning that the end of the clean filter medium is approaching.

5

The driving motor shall be automatically switched off when the end of the filter medium is reached.

6

The air velocity through the fitter medium shall not exceed 2.5 m/s.

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Filters of this type shall have an efficiency of 95 % based on the tests specified in BS 2831 with test dust No. 2.

8

Where the motor and/or gearbox is mounted in the air stream the electrical insulation and/or lubricants shall be suitable for the temperature range experienced.

9

A spare roll of filter medium shall be provided for every installed roll.

4.6.6

Grease Eliminators

1

Grease eliminators shall be of the impingement type comprising of fluropolymer coated adjustable vertical baffles contained within a stainless steel casing.

2

The bottom of the casing shall comprise a grease collecting trough from which a drain shall be provided into a removable stainless steel grease collector.

3

The baffles shall be supplied in modules with a maximum size of 500 x 500 mm.

4

The baffles shall be installed in a frame and shall be readily removable for cleaning.

5

Greese eliminators shall be installed where specified in the Project Documentation.

4.6.7

High Efficiency Filters

1

High efficiency filters shall consist of asbestos cellulose of glass fibre pleated Paper media in rigidly constructed case with a completely positive seal.

2

The efficiency of the filters shall be equal to or better than that indicated and in any case shall not be more than 0.5 % penetration based on the tests specified in BS 2831 with methylene blue or the sodium flame test specified in BS 3928.

3

Where fire protection is required or the air temperature may exceed 200 C the filtering medium shall be glass fibre paper and the casing spacers and seals shall be of a fire resistant material.

4

The air velocity at the face of the filter shall not exceed 1.25 m/s.

5

Fitters changing arrangements must be such that dust is not released into the room during the changeover operation.

6

Two spare filters or 10 % of the total whichever is the greater shall be provided.

4.6.8

Activated Carbon Type Filters

1

The cell casing shall be manufactured of steel protected against corrosion.

2

The internal arrangement shall include a corrosion proof framework of supports to ensure an equal disposition of individual panels across the all.

3

There shall be seals installed between each panel.

4

Mechanical protection shall be provided on both the front and rear of the panels.

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5

The carbon shall be of uniform thickness in the panels and shall be of sufficient density to ensure that no settling down or gaps occur in use.

6

The quantity of carbon shall be 20 kg for each rated 0.5 m /s.

7

The resistance to air flow shall not exceed 125 Pa.

4.7

HUMIDIFIER

4.7.1

General

1

Humidifiers shall be in accordance with ARI 610/ASHRAE equipment.

4.7.2

Water Type Humidifiers

1

The water type humidifiers shall be pan or atomiser type as specified in the Project Documentation.

2

The humidifier shall consist of the following:

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water pan or reservoir with a water feeder valve controlled with a float box

(b)

the water pan, float box tubes, evaporator and all materials exposed to water shall be constructed of a non-ferrous corrosion resistant material

(c)

the units shall include overflow and drain connections

(d)

the water immersion heaters shall be copper sheathed

(e)

the atomiser shall be of motor driven centrifugal type with directional dome and supporting brackets.

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(a)

Steam Type Humidifiers

1

The steam type humidifier shall be of a factory assembled packaged type.

2

The humidifier shall consist of the following: packaged steam generator

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4.7.3

(b)

steam moisture separator

(c)

water feeder

(d)

pressure gauges

(e)

thermometers

(f)

controls

(g)

all materials exposed to water shall be non-ferrous

(h)

the heating element shall be copper sheathed

(i)

the steam distribution pipe shall be stainless steel.

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HEAT RECOVERY UNITS

4.8.1

General

1

Where specified in the Project Documentation heat recovery units shall be installed.

2

The heat recovery section shall be constructed to permit easy access.

3

The unit shall be equipped with a drain pan for moisture removal.

4.8.2

Static Rate Heat Exchanger

1

The static rate heat exchanger shall be of the cross flow type consisting of alternative passages.

2

The two air steams passing through the exchanger shall exchange sensible heat to achieve pre-heating or pre-cooling.

3

The heat exchanger material shall be as specified in the Project Documentation.

4.8.3

Rotating Matrix Heat Exchanger (thermal wheel)

1

The unit shall consist of a motor, rotating via a gear motor.

2

The heat exchanger material shall be as specified in the Project Documentation

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END OF PART

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CHILLED WATER PIPEWORK ...................................................................... 2 GENERAL ....................................................................................................... 2 Scope 2 Reference 2 PIPEWORK .................................................................................................... 2 General 2 Pipework Supports 3 Condensation Drain Pipework 5 PIPE INSTALLATION ..................................................................................... 5 General 5 Installation of Steel Pipework 7 Installation Copper Pipework 8 Installation PVC-U Pipework 9 Expansion Provisions and Anchor Points 9 Flanges 10 VALVES ........................................................................................................ 11 General 11 PUMPS ......................................................................................................... 13 General 13 STRAINERS ................................................................................................. 14 General 14 AIR VENTS ................................................................................................... 15 General 15 FLOW SWITCHES ....................................................................................... 15 General 15 FLOW MEASUREMENT .............................................................................. 15 General 15 CLEANING OF WATER SYSTEM TREATMENT ......................................... 16 General 16 GAUGES AND ACCESSORIES ................................................................... 16 General 16 SUBMITTALS ............................................................................................... 17 General 17

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5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.4 5.4.1 5.5 5.5.1 5.6 5.6.1 5.7 5.7.1 5.8 5.8.1 5.9 5.9.1 5.10 5.10.1 5.11 5.11.1 5.12 5.12.1

Section 22: Air Conditioning, Refrigeration and Ventilation Part 05: Chilled Water Pipework

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5

CHILLED WATER PIPEWORK

5.1

GENERAL

5.1.1

Scope

1

This Part details the requirements for chilled water pipework as specified in the Project Documentation.

2

Related Sections and Parts are as follows: Section 1

General

Reference

1


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ASTM A53 Schedule 40 Steel Pipe Specification

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5.1.2

BS 10 ..........................Flanges for bolting pipes, valves and fittings

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BS 21 ..........................Pipe threads for tubes and fittings where pressure-type joints are made on threads (metric dimensions)

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BS 916 ........................Black bolts, screws and nuts

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BS 1387 ......................Screwed and socketed steel tubes and tubulars for plain end steel tubes suitable for welding of for screwing to BS 21 pipe threads BS 1845 ......................Filler metals for brazing

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BS 1965 ......................Butt-welding pipe fittings for pressure purposes

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BS 2871 ......................Copper and copper alloys. Tubes

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BS 3505 ......................Unplastisized polyvinyl chloride (PVC-U) pressure pipes for cold potable water

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BS 3601 ......................Steel pipes and tubes for sizes of 150 mm diameter and above. BS 4504 ......................Circular flanges for pipes, valves and fittings (PN designated)

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BS 6755 ......................Testing of valves

5.2

PIPEWORK

5.2.1

General

1

All pipework shall be free from surface or general corrosion and without any signs of scaling, pitting or excess weathering. Any pipework so affected shall be replaced at no cost to the contract.

2

Each length of pipework shall have at least one coloured identification band or identifying mark, when delivered. All pipework shall be supplied in the manufacturer straight random lengths, but not less than 6m long except where shorter specific or flanged lengths between fittings are actually required.

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Page 3

In congested areas where small bore chilled water piping is required, type K copper piping to BS 2871 with cast bronze non de-zincifiable fittings may be used subject to the Engineer‟s approval, and to a test of the welding operatives who will be doing the brazing. Brazed joints are required throughout; no compression fittings will be permitted.

4

All pipework, pipework fittings, jointing materials and gaskets shall be stacked in storage sheds in accordance with the manufacturer‟s recommendations and as required elsewhere in the Project Documentation. The ends of all pipework shall be protected during transit and storage.

5

Metal pipework may be stacked in the open, provided that such stacks are, in the Engineer‟s opinion, adequately protected from weathering. The pipework shall be located in steel pipe racks and clear of the floor, the floor being formed from either timber sleepers or paving slabs. A watertight lightweight roof shall be provided to extend 450 mm beyond the edges of the stack and tarpaulin or heavy gauge Polythene sheeting shall be provided to cover all sides.

6

The pipes and fittings beyond stock rust shall not be used.

5.2.2

Pipework Supports

1

All pipework shall be adequately supported. All support installations shall be in accordance with relevant standards, except where modified or extended by the Project Documentation.

2

Support shall allow free movement for expansion or contraction of pipework and shall be located to ensure that pipework branches or fittings are not fouled by the support during expansion or contraction of the pipework service.

3

Double banking of pipework from a single support position will be permitted, provided the normal operating temperature of the fluids in the two pipes do not differ by more than 30 ºC, but only where space restrictions prohibit individual support. Triple banking will not be permitted.

4

Where double banking is necessary, the larger of the two pipes shall be uppermost, and where pipes are the same size but manufactured from different materials, then the pipe having the material with the lowest coefficient of expansion shall be uppermost. Support intervals for double-banked pipework of different sizes shall relate to the smaller size.

5

Vertical rising pipes shall be supported at the base and the support shall withstand the total weight of the pipe and fluid contained.

6

Supports shall not be permitted which clamp the pipe so that it in contact with building fabric or structure.

7

All supports shall be specifically designed for the outside diameter of the pipe concerned (including specified packing). Oversized brackets will be rejected.

8

Where non-ferrous pipework is to be supported using ferrous pipe clamps or rings, an approved plastic coating applied to the clamp or ring shall be used to prevent contact between the ferrous and non-ferrous surfaces. Where cast iron rollers are to be used in contact with copper pipework, these shall be copper-plated.

9

Plastic pipework shall be supported using the pipework manufacturer‟s standard support clip.

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Page 4

Mild steel pipework shall be supported individually by hangers consisting of malleable split rings with malleable iron sockets or steel clevis type hangers or roller hangers where indicated.

11

All chilled water pipe supports shall be mild steel and painted with a protective coating to suit the environmental conditions.

12

Copper pipework where fixed against brick or dense concrete block walls shall be supported using polished cast brass built-in brackets. Build in brackets shall be long shank type, when pipework is to insulated or where the finish to the wall surface is greater than 15 mm, elsewhere build-in brackets shall be the short shank type.

13

Copper pipework in exposed positions where fixed against lightweight hollow block or other patent wall or partitions, shall be supported using polished cast brass screw on brackets.

14

All chilled water pipework services shall be supported around the insulation and not directly around the pipework. Care shall be taken to ensure the integrity of vapour sealing is not damaged in any way.

15

It shall be noted that in certain cases it will be necessary to adopt a combination of the support methods indicated, and when supports are required to be detailed to suit special site conditions or requirements, then these details shall be submitted to the Engineer for approval. Anti-vibration supports shall be fitted at all locations where pipework vibration is likely to be a problem.

16

Pipe support spacing shall be as detailed in Table 6.1.

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Pipe Size

Table 6.1 Pipe Support Spacing

Horizontal Spacing

Vertical Spacing

(m)

(m)

m

Steel Pipe Sch. 40

Copper

ABS/PVC-U

15

2.0

1.5

0.7

20

2.0

1.5

25-32

2.4

40

Steel

Copper

ABS/PVC-U

2.4

2.0

1.3

0.7

3.0

2.4

1.5

1.8

0.9

3.0

2.4

1.8

2.7

2.4

1.0

3.6

3.0

1.8

50

3.0

2.4

1.0

3.6

3.0

2.0

65

3.3

2.7

1.0

4.5

3.6

2.0

80

3.7

3.0

1.3

4.5

3.6

2.5

100/125

4.0

3.7

1.5

5.0

4.0

3.0

150

5.2

4.0

2.0

6.0

5.0

3.5

200

5.5

5.0

-

-

-

-

250

6.0

5.5

-

-

-

-

Sch. 40

QCS 2014


Pipe Size

Horizontal Spacing

Vertical Spacing

(mm)

(m)

(m)

Steel Pipe Copper

ABS/PVC-U

300

7.0

6.0

-

350

7.5

-

400

8.0

450 500

Steel

Copper

ABS/PVC-U

-

-

-

-

-

-

-

-

-

-

-

-

8.5

-

-

-

-

-

9.0

-

-

-

-

-

Sch. 40

.

Sch. 40

Page 5

spacing does not apply where span calculations are made or where concentrated loads are placed between supports, such as flanges, valves, specialities, etc. spacing lengths for pipework larger than listed in the table shall be the same as the largest size included.

(b)

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Condensation Drain Pipework

1

All exposed condensate piping at low level in plant rooms shall be galvanized medium weight seamless mild steel to BS 1387, with screwed joints. Fittings will be screw type, forged.

2

All concealed condensate drain piping shall be PVC-U Class E to BS 3505 with solvent welded joints.

3

All other exposed condensate piping shall be copper.

5.3

PIPE INSTALLATION

5.3.1

General

1

All pipework shall be arranged to set around piers and other obstructions and minor modifications shall be made as required by the Contractor to circumvent site difficulties.

2

Pipe shall be arranged to follow the contour of walls or beams or other building structure lines and all vertical pipework shall be plumb, without offsets and set as close as possible to any local projections consistent with maintaining adequate clearances for installation of wall plates or insulation.

3

Pipework shall be installed so as to give the following minimum clearances between adjacent services as follows:-

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5.2.3

(a)

walls

25 mm

(b)

ceilings 50 mm

(c)

finished floors either above top of skirting 50 or (if greater)

(d)

adjacent pipes, both insulated

(e)

adjacent pipes in trench, both insulated 100 mm

25 mm

150 mm

QCS 2014


(f)

adjacent pipe, both uninsulated 150 mm

(g)

adjacent pipes, one insulated

(h)

insulated pipes to adjacent conduit or trunking

(i)

adjacent electrical cables not in conduit or trunking

Page 6

75 mm 100 mm 150 mm

Not withstanding the above minimum clearances, sufficient space shall be allowed to facilitate easy application of insulating materials. Pipes shall not be enclosed in a common insulating covering. Pipework shall be graded to ensure adequate draining and venting. Draining and venting facilities shall be fitted at all low and high points respectively and wherever else necessary to ensure that all sections and subsidiary sections can be drained and that no air locks can form.

5

The Engineer may at his discretion ask for the removal of installed pipework for examination. No extra payment will be made when such removal is called for. If the pipework is found to have been installed in an unsatisfactory manner, then the complete installation shall be thoroughly inspected and all unsatisfactory sections shall be removed and re-fixed in a proper manner.

6

During construction work on all pipework services, care shall be taken to prevent any foreign matter entering the pipework. All open ends shall be capped with the appropriate pipework fittings. Wooden plugs and the like shall not be used. Valves fitted in the ends of pipework shall not be accepted as a means of preventing the ingress of foreign materials.

7

Failure to comply with these requirements shall mean that the Engineer shall have the right to instruct that pipework so left uncovered to be dismantled for such lengths as the Engineer requests, and the pipework blown through and/or cleaned at no cost to the contract.

8

All pipework fittings shall be installed in such a manner to ensure that air cannot be trapped and that pipework can be drained.

9

Unequal tees shall be used in preference to equal tees with separate reducing fittings. Bushes shall not be used. Unequal tees shall be eccentric pattern on horizontal pipework, and concentric on vertical pipework.

10

Segmented, cut-and-shut, or any other site manufactured bends or fittings shall not be installed in any section of the Works.

11

The use of fire or cold pulled bends will not be permitted.

12

Where weldable steel pipework fittings to BS 1965 are to be used then branch bends, although not covered by this standard, will be accepted, but only at the specific location designated by the Engineer and subject to total approval by the Engineer.

13

Where fittings are connected to light or medium weight pipework they shall be „medium‟ quality, and where connected to heavyweight pipework they shall be „heavy‟ quality.

14

All fittings, valves, cocks etc., shall be manufactured from materials guaranteed proof against de-zincification unless specifically stated otherwise elsewhere.

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Page 7

Only one manufacturer of pipework fitting shall be used for each differing range of fitting specified.

16

Reducers on all vertical pipework shall be concentric. In all other positions eccentric reducers shall be fitted in a manner to maintain a level bottom and ensure that fluids are not collected at that point in the system. Where it is not possible to fit eccentric reducers the Engineers approval shall be obtained before fitting concentric reducers. Reductions in all cases shall be made by use of factory made fittings.

17

Sufficient unions or flanges shall be provided to install and dismantle screwed or solvent jointed sections of pipework. Union on all steel pipework shall be of malleable iron construction with spherically ground bronze-to -bronze seats and shall have screwed ends to BS 21. Union on PVC-U systems shall be factory manufactured unions appropriate for the pipe.

18

All branches shall be made by easy sweep tees, twin elbows or sweep crosses. Bends shall be used wherever possible. All sweep fittings and all sweep bends shall be of the long radius pattern except where the use of these fittings would stand pipework too far from wall surfaces and make for unsightly appearance, in which case short sweep tees and elbows may be used provided that the Engineer‟s written approval is obtained beforehand.

19

Where copper pipework is specified, or allowed, as having bronze welded joints, the Engineer will allow the use of silver brazed joints (low temperature brazing) using brazing alloys conforming to BS 1845 Type CP1 or BS 1845 Type CP2. All details of inspection and testing procedures for bronze welding shall apply to silver brazing jointing methods, and all joints shall be made in accordance with the brazing alloy manufacturer‟s recommendations for the application concerned.

5.3.2

Installation of Steel Pipework

1

Black steel size up to 50 mm will be threaded and size 65 mm and above will be welded.

2

Threaded joints shall be: (a)

screw threads shall be clean and true in addition, all internal threads must be checked for quality and any with any indication of damage must be rejected and removed from site. All pipe shall be reamed or scraped to remove internal burrs after threading.

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3

Welding piping. Where so shown on drawings, specified or directed, welded joints, outlets and flanges shall be used. Welded joints may also be provided elsewhere, where approved by the Engineer, except on piping small than 80 mm, or at points where it may be explicitly specified or directed to leave flanged joints in order to facilitate future changes.

4

All welded joints (except pipe welded end-to-end) shall be made by use of forged one-piece welding flanges, caps, nozzles, elbows, branch outlets and tees as appropriate. Cut samples shall be submitted for approval if directed. All such fittings etc., shall be of type which maintains full wall thickness at all points, ample radius and fillets, and proper bevels or shoulders at ends.

QCS 2014

5


Page 8

Splayed type fittings may be used where standard fittings of required sizes are not available and elsewhere as approved. All job welding shall be done by the electric arc welding process in accordance with the following: (a)

all joints 45 º bevel type. Pipe shall be mill-bevelled or machine-bevelled

(b)

all scale and oxide removed with hammer, chisel or file a bevel left smooth and clean

(c)

pipe lengths lined up straight with abutting pipe ends concentric.

Both conductors from the welding machine shall be extended to locations at which welding work is being done. The leads from welding machine to locations of welding work is being done. The leads from welding machine to locations of welding works shall be held together with tape or other approved means so as to prevent induced current ins structural steel, in piping or other metals within the building. The ground lead shall be connected to length of pipe with suitable clamp in such manner that welding current will not flow through joints in pipe, structural steel of building or steel pipe supports.

7

Weld metal is to be thoroughly fused with base metal at all sections. Welds shall be sound metal, free from laps, slag inclusion or other defects.

8

All welders shall be certified by the Engineer for the service for which they are employed and on which they work.

9

Wherever welded piping connections to equipment, valves, or other units need maintenance, servicing, or required possible removal, the connection joint shall be flanged. Pressure rating of the pipe flanges shall match the pressure rating of the flanges on the equipment to which the piping connects.

5.3.3

Installation Copper Pipework

1

Hard drawn copper shall not be bent by any means. Care is to be taken during brazing that excess heat is not used. All copper pipe may only be cut by pipe cutting wheels. No flame cutting or hacksaw work will be permitted. No water quenching will be permitted.

2

All copper pipework and fittings shall be of copper to BS 2871 Part 1 Table X and fittings shall comply with BS 864 or their equivalent.

3

Pipe clamps shall be selected to ensure no reaction between dissimilar metals.

4

Pipes shall be supported as specified in Table 6.1

5

Dielectric joints shall be installed between copper and steel pipes. Direct joints will not be permitted.

6

All joints shall be properly cleaned before jointing.

7

All soldered joints shall be made with 95 % tin and 5 % antimony soldier, having a melting o point of not less than 238 C. All soldered joints for tubing larger than 50 mm in size shall be made with the simultaneous application of two or three blow torches.

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Page 9

Installation PVC-U Pipework

1

PVC-U piping system is to be installed in accordance with the manufacturer‟s recommendations, using appropriate pressure pipe and fittings.

2

Extreme care must be taken in the preparation of joints. All joints must be cut square. The burrs must be removed and a 2 mm chamfer filed onto the outside at 45 º.

3

The pipe is to be abraded using emery cloth to approximately the depth of the socket. In addition, the inside of the socket is to be roughened in a similar manner.

4

The roughened surfaces are to be cleaned using the proprietary cleaner from the system manufacturer.

5

The proprietary cement from the manufacturer of the system must be thoroughly stirred before each use. The cement is to be applied longitudinally to both the pipe and the fitting. Generally two coats will be necessary, but care is to be taken to ensure that no excess solvent is left on the inside of smaller fittings.

6

Immediately after application of the cement the pipe must be pushed fully home against the stop in the fitting. The pressure must be maintained for about 30 seconds.

7

Wipe off any excess cement. Clean brushes in cleaner solvent and close lids on all solutions.

8

The system is to harden at least 24 hours before pressurising.

5.3.5

Expansion Provisions and Anchor Points

1

All sections of pipework installation shall be installed in such a manner as to allow expansion and contraction for the pipework, without causing undue stress in any part of the installation.

2

The stress in the pipework shall be kept below the yield point. Care shall be taken to prevent branch connections becoming anchor points.

3

Wherever possible expansion and contraction shall be absorbed by natural offset and changes in direction of pipe runs. Anchors, pipe guides and expansion loops shall be provided where shown or required, to the Engineer‟s approval. Do not use screwed fittings on expansion loops.

4

Wherever it is not possible to accommodate expansion and contraction of the installations as described above, expansion devices shall be supplied, erected and connected into the pipework installation, and the position of these devices shall be to the approval of the Engineer. „Articulated‟ expansion devices shall be fitted on steel pipework systems.

5

The exact location and working details including anchor loads of all expansion devices, guides, anchors, and all associated equipment shall be submitted to the Engineer for approval prior to commencement of the installation, carrying the manufacturer‟s confirmation that these are in accordance with the requirements.

6

Connection to items of plant and equipment shall be made so that no stress in placed on the equipment or its‟ connections. All expansion devices shall be carefully erected in full accordance wit the manufacturer‟s recommendation and instructions, and be approved by the particular application concerned.

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5.3.4

QCS 2014


Page 10

No system of expansion control shall be accepted where the closure of movement exceeds the amount recommended by the manufacturer when operating from the cold to the upper limit working temperature. The minimum temperature difference for calculation purpose shall be 40 ºC for interior pipes, and 50 ºC for exposed or external runs.

8

All expansion devices shall be cold drawn by a distance equal to half the total expansion and all contraction devices shall be cold compressed by a distance equal to half the total contraction. Cold draw shall not be applied until the anchor installations have been completed and approved by the Engineer.

9

All anchor points shall be treated as main anchor points; the practice of utilising a less substantial anchor for intermediate positions shall not be permitted.

10

Where the installation is required to be tested in sections, extra anchor points shall be installed where necessary, for the protection of the expansion devices.

11

Pipework between anchors shall wherever possible be straight, but where this is not possible, the bracing of all guides shall be adequate to overcome this resultant turning moment produced by the offset forces, but the Engineer shall be informed before the work commences.

12

Each axial expansion device shall be guided as close as possible on both sides of the joint, but in no case more than 1.5 diameters away. A further set of guides shall be installed at a distance of not more than 15 diameters away from the axial expansion device unless the manufacturer imposes more stringent requirements.

13

The positioning of anchors and guides immediately adjacent to angular expansion devices shall be in accordance with the manufacturer‟s recommendation for the application concerned and shall be submitted to the Engineer for approval before installation commences. The remainder of the pipework shall be set in guides at a maximum of twice the maximum interval for support spacings specified elsewhere for the pipe size to which the expansion device is fitted.

5.3.6

Flanges

1

Flanges shall be provided on the pipework systems wherever necessary to connect to components, plant or equipment having flanged connection. In addition, flanges shall be provided where services are specified elsewhere as having flanged joints.

2

Flanges (including the associated nuts, bolts, and washers) shall be to the minimum requirements of BS 4504 to suit the conditions within the pipework or to suit equipment, valves and other pipework components having flanged connection. Where these connections have flanges shall be provided to suit the connection concerned. Where flanges to BS 4504 are not manufactured then flanges to BS 10 will be accepted.

3

Flanges shall be bolted up using hexagonal nuts and bolts manufactured from high tensile carbon steel in accordance with BS 916 using two flat steel washers, one each side of the jointed flanges.

4

Bolt threads shall not project more than 3.2 mm or less than 1.6 mm beyond the nuts when jointed up.

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Page 11

Blank flanges where required shall be manufactured from the same material and same thickness as the flanges to which they are mating.

6

Flanges shall be smooth machined across the full width of the flange and on the edge but may be rough turned on the back. Flanges shall be drilled off-centre.

7

Flanges shall be mounted square with the axis of the pipe after all surface scale, oxides, grease, oil and dirt have been removed.

8

Care shall be taken to avoid distortion of the flange during welding.

9

Steel flanges shall be provided on mild steel pipework.

10

Cast iron flanges shall be provided on cast iron pipework.

11

Steel and gunmetal flanges shall be of the welding neck pattern, welded to the pipework in accordance with the general requirements for welding detailed elsewhere in the Project Documentation.

12

Flanges shall be finished or coated exactly as specified for the pipework on which they are to be fitted.

13

Composite type flanges having gunmetal inner and steel outer flanges shall be provided on copper pipework.

14

Flanges for PVC-U pipe shall be to BS 10, Table E with 14 bar ratings. Backing rings will be provided for sizes of 150 mm and larger, nominal pipe size.

15

Stub flange assemblies will only be permitted if specifically requested for specific reason and if thought appropriate by the Engineer.

16

All items of plan including air heater batteries and fan coil units etc., shall be capable of being disconnected from connected pipework services by means of unions, union valves, flanges or flanged valves. Pipework shall be so arranged to allow the item to be removed.

5.4

VALVES

5.4.1

General

1

Valves shall be provided and installed where required for the purpose of circulation control and isolation. Valves shall be of full bore size to suit the mains into which they are installed.

2

All castings shall be clean close-grained metal, free from rough projections. Screwed valves shall have heavy hexagon reinforcement threads, ample length threads and heavy shoulder to prevent over entry of pipes. Flanged valves shall have the flanges flat faced and of thickness conforming to the appropriate standard and shall be drilled off-centre.

3

Valves shall have pressure rating as necessary for the service indicated on the drawing. Samples must be provided for inspection of the manufacturing methods.

4

Gate valves for sizes up to 50 mm, shall be bronze non rising stem, screwed bonnet, one piece wedge. The casting shall have large hexagon section at all threads to permit gripping to prevent in distortion during installation. Pressure rating shall be PN 16 bar.

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Page 12

Gate valves sizes 65 mm diameter and above shall be cast iron rising stem, inside screw, bronze trim and flanged to BS 4504. Pressure rating shall be PN 16 bar.

6

Globe valves sizes 50 mm diameter and below shall be bronze rising stem, screwed bonnet and renewable dynamic disk. The casing shall have a large hexagonal section at all threads to prevent distortion during installation. Pressure rating shall be PN 16 bar.

7

Globe valves sizes 65 mm and above shall be bronze trimmed cast iron body valves, with outside screw and yoke, bolted bonnet, guide feature for disc seating. Pressure rating shall be PN 16 bar.

8

Check valves size 50 mm and below shall be bronze body with bronze trim, rotating disc with flexible hinge assembly, threaded access to top. Pressure rating shall be PN 16 bar.

9

Check valves size 65 mm and over shall be iron body with bronze trim, 16 bar, rated rotating disc with flexible hinge assembly, bolted access to top with outside lever and weight to permit vertical installation if required.

10

Balancing valves up to size 50 mm shall be of bronze body. Valves to have differential pressure read out ports across valve seat area. Read out ports to be fitted with internal EPDM insert and check valve. Valve bodies are to have 6 mm tapped drain/purge port. Valves are to have memory stop feature to allow valve to be closed for service and then reopened to set point without disturbing balance position. All valves to have calibrated nameplate to assure specific valve setting. Valves to be leak tight at full rated working pressure. All valves to be provided with moulded insulation to permit access for balancing and read out.

11

Balancing valves size 65 mm diameter and above shall be of heavy duty cast iron flanged construction with flanged connections to BS 4504 PN 16 working pressure. Valves to have memory stop feature to allow valve to be closed for service and then reopened to set point without disturbing balance position. All valves to have calibrated nameplate to assure specific valve setting. Valves to be leak tight at full rated working pressure. All valves to be provided with moulded insulation to permit access for balance and read out.

12

Triple duty valves may be installed on chilled water pump discharge to perform the functions of a non slam check valve, throttling valve, shutoff valve, and calibrated balancing valve. The valve shall be of heavy duty cast iron construction with 9 bar ASNI flanged connections suitable for 12 bar working pressure for operating temperatures up to 120C. The valve shall be fitted with a bronze seat replaceable bronze disc with EPDM seat insert, stainless steel stem, and chatter preventing stainless steel spring. The valve design shall permit re-packing under full system pressure. Each valve shall be equipped with brass read out valves (with integral check valve) to facilitate taking differential pressure readings across the orifice for accurate system balance.

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Page 13

An angle pattern flow straightening suction diffuser may be installed at the chilled water pump suction connection. Each fitting shall be equipped with a combination diffuser strainer orifice cylinder, flow straightening vanes, start-up strainer, permanent magnet and adjustable support foot. The combination diffuser-strainer-orifice cylinder shall be designed to withstand pressure differential equal to the system pump shutoff head and shall have a free area equal to five times the cross section area of the pump suction opening. The length of the flow straightening vanes shall be no less than 2 times the diameter of the system pump suction connection. The flow straightening fitting shall be of cast iron construction with flanged system and flanged pump connections. The fitting shall have a carbon steel combination diffuser-strainer-orifice cylinder with 4 mm diameter perforations to protect the system pump. The full length carbon steel flow straightening vanes shall provide non-turbulent flow to the suction side for the system pump. The magnet shall be positioned in the flow stream to protect the pump seal(s). The start-up strainer shall be of 16 mesh bronze, and the adjustable support foot shall eliminate pipe strain at the flow fitting/pump connection. All internal components shall be replaceable.

14

All valves shall be rated for a working pressure of 16 bar, unless otherwise indicated.

15

All valves shall be pressure tested at the manufacturer‟s works to BS 6755.

16

All threaded valves shall be threaded to BS 21.

17

All flanged valves shall be flanged to BS 4504.

5.5

PUMPS

5.5.1

General

1

Pumps shall be provided from the factory complete with their electric motors mounted on a common cast iron or fabricated steel base and properly aligned.

2

Pumps and motor base shall be supported on an isolated reinforced concrete foundation as detailed on the drawings.

3

Pump and motor base shall be aligned and levelled throughout the length and width of the base and where necessary suitable shims shall be provided under the base to facilitate levelling.

4

Pump and motor base shall be secured to the foundation with proper size anchor bolts and completely grouted in to provide a rigid non-deflecting support.

5

Pump and motor shall be realigned in the field after grouting in of base and connecting piping.

6

Piping shall be supported independently of pump nozzles to prevent piping weight or stresses from bearing on or being transmitted to the pump nozzles.

7

Pumps shall be located in accessible locations for ease of repair and maintenance.

8

Drains for packing glands and base shall be piped to the nearest floor drain or sump.

9

Where required by pump design and recommended by the manufacturer, a clean water supply shall be provided for cooling and lubrication of shaft packing or mechanical seals.

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QCS 2014


Page 14

Pumps shall be provided with shaft packing or mechanical seals compatible with the pump design and nature of liquid pumped in accordance with manufacturer‟s recommendations or as specified for each particular pump.

11

Pumps shall be constructed of materials and shall have pressure ratings suitable for the service and operating conditions.

12

Where corrosion can occur, appropriate corrosion resistant materials and assembly methods shall be used including isolation of dissimilar metals against galvanic interaction.

13

Pumps shall be provided from the factory with plugged connections for casing vent, drain and suction and discharge pressure gauges.

14

Pump impellers and rotating assemblies shall be statically and dynamically balanced at the factory.

15

Packing rings shall be installed in alternative layers staggered at right angles to each other. The packing shall be tightened for seal while permitting the prescribed amount of leakage for lubrication.

16

Mechanical seals shall be installed and aligned in accordance with manufacturer‟s recommendations.

17

Before operating pumps, care shall be taken to ensure that the pump is properly lubricated, the rotating element rotates freely by hand, the casing is vented and full of water, the direction of rotation is correct, the strainer is clean and the suction and discharge valves are open.

18

Pumps shall operate in a stable manner without pulsation, noise, vibration or cavitation throughout their full capacity range.

19

Pumps shall be selected so that their operating point of specified flow and head falls at the point of maximum efficiency as obtained from manufacturers‟ published data. A pump will not be approved if it is selected to operate near the end of its curve.

20

The horsepower rating of the motor driving the pump shall be of sufficient magnitude to ensure non-overloading of the motor throughout the capacity range of the pump for the impeller diameter selected.

21

Electric motors shall always be specifically supplied for the available electric current voltage and frequency. Motor speed shall not exceed 1450 rpm unless specified otherwise.

5.6

STRAINERS

5.6.1

General

1

Strainer shall be full line size located ahead of all pumps and motorised control valves. Bodies shall be brass, screwed body, “Y” type, 16 bar rated up to 50 mm size with 37 % open mesh monel metal screen, and 1.4 mm diameter holes. For sizes 65 mm and above, iron body, flanged, “Y”.

2

All strainers 65 mm and above shall have a 20 mm bleed off/drain tapping and valve fitted.

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Page 15

AIR VENTS

5.7.1

General

1

Provide air vents at all high points in supply and return piping.

2

Vents will have a positive shut-off, and be connected to the nearest floor drain by means of a copper pipe.

3

Air vents shall not be installed directly on the pipework but shall be fitted to air bottles that are adequately sized for the pipe it is venting. air bottles shall be line size

(b)

65 mm - 100 mm

air bottles shall be 50 mm

(c)

125 mm -200 mm

air bottles shall be 80 mm

(d)

250 mm and above

air bottles shall be 100 mm.

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5.7

The body of automatic air vents shall be bronze with stainless steel float, lever trams and accessories

5

A separate gate valve shall be installed below the automatic air vent to facilitate future maintenance.

5.8

FLOW SWITCHES

5.8.1

General

1

Flow switches shall be provided at the outlet connection to each chiller.

2

Flow switches shall be paddle type with bronze construction for all parts in contact with water except the paddle which shall be in stainless steel.

3

Electrical termination box shall be weather protected to IP 65 and suitable for installation in ambient case temperature up to 85 C.

5.9

FLOW MEASUREMENT

5.9.1

General

1

Provide all equipment to enable flow measurement. If indirect measurements are used, provide all calibration equipment, charts etc.

2

Provide Binder Sockets suitable for the application of flow sensors at all locations shown or necessary for all balancing purposes. The binder test points shall be installed at the following locations.

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(a)

across all coils

(b)

across each chiller

(c)

across each 2 or 3 port control valves

(d)

across calibrated valves

(e)

across metering stations.

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Page 16

CLEANING OF WATER SYSTEM TREATMENT

5.10.1

General

1

The chilled water system shall be prepared by flushing with clean water to remove any debris. The system will then be further treated as described below.

2

Prior to testing and commissioning, the Engineer shall be provided with water conditioning programme, to control water quality. Cleaning shall be supervised and programme of conditioning administered by the conditioning company.

3

For pre-commission cleaning, the system shall be dosed with the prescribed amount of the non-acid cleaning agent and a surfactant as advised by the chemical company.

4

Cleaner shall be run into the system and retained for a period of 72 hours or more as advised by the chemical company. At the end of this period the system shall be drained and flushed with clean water.

5

All strainers and trapping points shall be inspected, and any debris removed.

6

System shall be refilled with clean water, re-circulated or run through for a further four hours, and again drained and flushed. The flushing shall continue till the effluent is clear, colourless, odourless, free from suspended solids and such that the iron level is not more than 10 ppm and the conductivity is no more than make up water.

7

Upon completion of flushing all strainers shall be inspected and any debris removed.

8

The system shall be refilled with clean water and a specified amount of inhibitor added.

9

The chemical company representative shall conduct an analysis of the system‟s water after the cleaning operation, and shall submit a report to the Engineer.

5.11

GAUGES AND ACCESSORIES

5.11.1

General

1

Wet service thermometers shall be straight shank mercury fill insertion type. They shall have a stem length of 80 mm and a scale length of 225 mm, and the capability of adjusting the angle of the scale to the stem. Provide copper or brass separable wells for each thermometer with 13 mm MPT connection. The range shall be – 6 C to 50 C unless otherwise advised.

2

Air service thermometers shall be straight shank mercury fill insertion type. They shall have a stem length of 150 mm and a scale length of 225 mm, and the capability of adjusting the angle of the scale to the stem.

3

Pressure gauges shall have 100 mm diameter stainless steel case, black figures, forged brass sockets with phosphor bronze bushed rotary type movement and Bourdon tube. Gauges shall be complete with impulse dampening insert and T-handle gauge cock.

4

Where the line size is 100 mm or less the gauge is to be installed into a T-branch with a reducer. For sizes above 125 mm, a splayed fitting with a threaded joint may be used, subject to the requirements of Clause 1.1.17 of Part 1 of this Section.

5

Range of gauges shall be selected such that the operating point is almost midway of the selected range.

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5.12

SUBMITTALS

5.12.1

General

1

Submittals shall comply with the relevant provisions of Section 1, General.

2

Technical submissions are to include the schematic for components actually to be installed showing flow rates, and accompanies by pressure drop calculation for the system.

3

The Contractor shall provide technical brochures and information on all components:pipework

(b)

pipe fittings

(c)

pipe supports

(d)

valves

(e)

strainer

(f)

gauges and accessories

(g)

air vents

(h)

flow measuring instruments

(i)

expansion joints

(j)

anchor points

(k)

test forms

(l)

water treatment.

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END OF PART

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DUCTWORK AND AIR-SIDE EQUIPMENT .................................................. 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 Submissions 2 DUCTWORK.................................................................................................. 3 Ductwork Material 3 Ductwork Specification 4 Ductwork General 4 Low Pressure Ductwork 6 Medium Pressure Ductwork 6 High Pressure Ductwork 7 Low Pressure Flexible Ductwork 7 Flexible Connections 7 Access Panels 8 BALANCING .................................................................................................. 8 Balancing Dampers 8 Flow Control Dampers 9 Motorised Dampers 9 Backdraft Dampers 9 Splitter Dampers 10 Fire Dampers 10 Smoke Dampers 10 SILENCERS ................................................................................................ 11 General 11 DIFFUSERS AND REGISTERS .................................................................. 11 General 11 LOUVRES .................................................................................................... 13 Outside Louvres 13 Sand Louvre 13

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6 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.4 6.4.1 6.5 6.5.1 6.6 6.6.1 6.6.2

Section 22: Air Conditioning, Refrigeration and Ventilation Part 06: Ductwork and Air-Side Equipment

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6

DUCTWORK AND AIR-SIDE EQUIPMENT

6.1

GENERAL

6.1.1

Scope

1

This Part details the requirements for the construction and installation of the ductwork and air side equipment.

2


References

1


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6.1.2

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Section 1

BS 1449 .....................Steel plate, sheet and strip

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BS 1470 ......................Wrought aluminium and aluminium alloys for general engineering purposes

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes; bars extruded round tubes and sections

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BS CP 352 ..................Mechanical ventilation and air conditioning in buildings NFPA 90A ..................Installation of Air Conditioning and Ventilating Facilities

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NFPA 96 .....................Ventilation Control and Fire Protection of Commercial Cooking Operation

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SMACNA ....................Ductwork design and installation

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UL 555 S ....................Smoke Dampers

6.1.3

Submissions

1

Technical Submissions. After award, the Contractor shall check design calculations and shall advise the Engineer of any discrepancies found.

2

The Contractor will also prepare an air balance for supply, return, exhaust, make-up, exfiltration etc.

3

The Contractor will prepare full shop drawings, including sections, of distribution systems and equipment.

4

Hardware Submissions. The Contractor will submit catalogue information for all distribution equipment including, but not limited to:(a)

ductwork, duct sealants, gaskets and tapes

QCS 2014

Section 22: Air Conditioning, Refrigeration and Ventilation Part 06: Ductwork and Air-Side Equipment flexible ductwork

(c)

flexible connections

(d)

access panels

(e)

balancing dampers

(f)

motorised dampers

(g)

backdraft dampers

(h)

splitter dampers

(i)

fire dampers

(j)

silencers

(k)

vibration isolators

(l)

diffusers, grilles and registers

(m)

louvres, sand louvres

(n)

filters.

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(b)

Page 3

The Contractor will submit samples for any or all of the above as requested by the Engineer after receipt of the catalogues.

6

Samples will definitely be required of these items which are exposed, such as diffusers, grilles, louvres. The samples must be of size, specification and finish as relevant to the project.

7

Where a country of origin is given, this refers to the head office in the case of international corporations. However, for each product not manufactured in that country separate approval must be obtained from the Engineer.

6.2

DUCTWORK

6.2.1

Ductwork Material

1

All ductwork except in laboratories, kitchens and laundry extract systems shall be manufactured from strip mill, cold reduced sheet, continuously hot dip galvanized in accordance with BS 2989 grade Z2. Unless specified elsewhere in the Project Documentation

2

All flanges and stiffeners used in the construction of galvanized mild steel ductwork shall be galvanized steel section.

3

Where flexible ductwork is used, it shall conform to ductwork of the type manufactured in accordance with BS 1470 aluminium strip corrugated and spirally wound with double lock seam.

4

The length of flexible ductwork shall not exceed 2 m per section and shall be supported as recommended by the manufacturer.

5

Kitchen extract ductwork shall be air and watertight welded construction manufactured from 16 g black steel sheets in accordance with BS 1449, Part 1 Grade CR4 GP. Ductwork shall be painted on the outside with two coats of heat resistant galvanic paint after manufacture.

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Page 4

Laundry extract ductwork shall be air and water tight construction manufactured from aluminium sheets in accordance with BS 1470.

7

Laboratory ductwork or systems carrying corrosive gases shall be manufactured of PVC or FRP. However before installation of such system the QGEWC shall be approached for written approval.

6.2.2

Ductwork Specification

1

Ductwork fabrication and hanging methods shall be as described in the “Equipment” Volume of the American Society of Heating, Refrigerating and Air Conditioning Engineers Guide and Data Book, latest edition, and/or current edition of applicable manuals published by the Sheet Metal and Air Conditioning Contractors National Association Inc., where methods described in these volumes are not at variance with the requirements of any authority having jurisdiction, or do not conflict with methods described hereafter. Ductwork shall not be ship fabricated until work has been job measured and interference situations co-ordinated.

2

Any Contractor who is very familiar with British Standards may refer to BS CP 352 and DW 144. Any discrepancy will be clarified by the Engineer on request.

3

In any event, the standard of work required is the best available, and the specifications are to be so interpreted.

6.2.3

Ductwork General

1

All dimensions shall be checked on site before ductwork manufacture is commenced.

2

The whole of the ductwork installation shall be carried out by an approved specialist in ductwork manufacture and installation. No ductwork shall touch the building structure or building finishes direct, but shall be isolated with insulating spacer.

3

The fabrication shall be carried out in a neat and workmanlike manner with all ductwork true in size and cross-section, braced and stiffened as specified and with all internal and external surfaces free from projections and sharp edges.

4

At each main branch in ductwork and at each fan discharge or suction, provide sufficient number of Pitot tube holes for balancing systems. Also, provide test holes for traverse fan discharge and at all equipment. Test holes shall be located within easy reach of catwalks or ladder. Each test hole shall have 20 mm clear opening, provided with a metal ring place with a threaded hole in the boss, and matching screwed head plug. Where these plugs are installed in insulated ductwork, provide an extension collar against which the insulation can be finished.

5

Reinforced holes shall be provided where thermometers, manometers, thermostats, gauges, damper rods etc., occur in ductwork. Extended collars shall be provided for the reinforced holes where these occur on insulated ductwork. Where copper tubing passes through ductwork, or casing, provide a rubber grommet to prevent damage to copper tubing.

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Page 5

Ductwork shall be rigidly suspended or supported from building structure. Expansion type concrete inserts shall be placed so that the fastener is in shear rather than tension. Powder actuated fasteners placed by an explosive charge will not be accepted. Angle type trapeze hangers with rod supports space at 2 m maximum shall be used. “C” type beam clamps will not be accepted. Provide necessary steel angle iron required for bracing of ductwork or equipment, and for supporting ductwork from building structure.

7

A layer of felts strip 12.5 mm compressed thickness shall be provided between any support member which is designed to clamp or grip the duct (e.g. circular duct band clip) or on which the duct is to rest. All supports shall be hot dip galvanized.

8

Increase in duct size shall be gradual. Where width or largest dimension of a duct is over 450 mm, duct shall be stiffened by bending in a break across corners in both directions. Ducts shall be self-supporting and complete in themselves. Single thickness partition between ducts will not be accepted. Visible internal portions of duct outlets to grilles and registers shall be painted in dull black.

9

All necessary allowances and provisions shall be made in the installation of the ducts for the structural framing of the building and when changes or offsets are necessary, the required cross-sectional areas shall be maintained. All of these changes however, shall be approved, and installed as directed at the time.

10

During installation, the open ends of ducts shall be protected with blank, flanged sheet metal baffles, securely attached to prevent debris and dirt from entering.

11

Where ducts are shown connecting to masonry openings and/or along the edges of all plenums at floors, walls, etc., provide a continuous 30 x 30 x 4 mm galvanized angle iron which shall be bolted to the structure and made airtight to same by applying caulking compound on the angles before they are drawn down tight. The sheet metal at these locations shall be bolted to the angle iron framing.

12

All air ducts, casings, plenums etc., shall be constructed of lock forming quality prime galvanized steel sheets, which are free from blisters, slivers, pits, imperfectly coated spots etc. No second quality sheet metal allowed.

13

Where damage (or rusting) has occurred on galvanized ductwork, the affected section shall be made good by painting with two coats of zinc-rich paint and approved finishing paint, or where the damage in the Engineer‟s opinion cannot be made good, then a new section of ductwork shall be provided at no cost to the contract.

14

Duct shall be constructed using double or Pittsburgh lock corner seams. All seams shall be hammered down and made airtight by applying sealant before hammering down. For transverse joints, refer to the current ASHRAE guide for low pressure ductwork.

15

Support the vertical ducts installed in the various shafts at each floor level with galvanized supporting irons of approved size.

16

Install these angles across the width of the shaft, with their ends attached to angle irons securely anchored into the masonry walls of the shaft, or attached to the framing of the floor openings. The ducts shall be bolted to these supporting angle irons.

17

Ensure that all openings required through floors, walls, partitions etc., for the duct system are provide in the exact location required.

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Page 6

Each piece of ductwork shall be wiped inside and out before installation and all open ends shall be capped and sealed to prevent entrance of dirt during construction. Ensure that ductwork systems are clean and free from dirt, dust, grime, debris etc., before initial operation of fans. Fans shall not be operated until the filters are installed and approved from the Engineer has been obtained.

19

The bottom joint and 150 mm of vertical joint on outside air intake ducts and mixing chamber ducts shall be soldered and made watertight. Provide drain connection and run copper drain pipe to nearest floor drain.

20

All fixing devices including nuts, bolts, washers etc., used in the construction or support of galvanized ductwork shall be sheradised, or cadmium-plated.

21

Final connections to diffusers shall be carried out using flexible ductwork or solid spigots as detailed in the Project Documentation.

22

Sealants, gaskets and tapes shall comply with DW 144 Part 7 section 27 or DW 151 section 12 as appropriate.

6.2.4

Low Pressure Ductwork

1

This applies to ductwork with mean velocities less than 10 m/s and static pressures of 500 Pa or less.

2

Rectangular low pressure ductwork shall be fabricated from prime quality, re-squared, tight coat galvanized steel sheets as specified in the relevant standard.

3

Reinforcing and joints shall be in accordance with ASHRAE Guide and Data Book, Equipment Volume, 1988 Chapter 1 or in accordance with DW 144.

4

Low pressure suction and discharge plenum chambers shall be fabricated from 1.3 mm galvanized steel with galvanized angle iron framework and bracing.

5

In square elbows and in elbows where the radius is less than 1.5 times the width of duct, sheet metal deflector vanes shall be installed the full height of the duct, being securely riveted in place. All vanes shall be double thickness vanes of two gauges heavier than the duct in which they are installed, and shall be factory made, not site fabricated. Vanes shall be tack welded to vane rail. For vane lengths over 1000 mm, tack weld vanes to 10 mm tie-rod at mid-span.

6.2.5

Medium Pressure Ductwork

1

This clause applies to ductwork subject to pressures up to 1000 Pa.

2

Rectangular medium pressure ductwork shall be fabricated from prime quality, re-squared tight coated galvanized steel sheet as specified in the DW 144.

3

Reinforcement and joints shall be as detailed in DW 144.

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Page 7

High Pressure Ductwork

1

This applies to ductwork subject to pressures up to 2000 and 25000 Pa.

2

Rectangular medium pressure ductwork shall be fabricated from prime quality, re-squared tight coated galvanized steel sheet as specified in the relevant standard.

3

Reinforcement and joints shall be as detailed in the DW 144.

4

All high pressure ductwork shall be pressure tested in accordance with the DW 144.

6.2.7

Low Pressure Flexible Ductwork

1

Flexible ductwork shall be manufactured with a two ply aluminium inner core, surrounded by 3 25 mm thickness of 24 kg/m density fibre glass, all wrapped in a reinforced aluminium outer jacket. Ductwork shall meet the standards of NFPA 90A, and be UL listed or to meet BS 476 and BS 413.

2

Flexible ducts installed in an externally insulated duct system shall be factory insulated with 3 glass fibre insulation not less than 25 mm thick and a density not less than 24 kg/m , recovered with an acceptable vapour seal.

3

Flexible ducts installed in internally (acoustic) insulated duct system, shall be factory insulated with glass fibre insulation not less than 20 mm thick and a density not less than 24 3 kg/m , faced on air side with PVC coated glass cloth having an open area not more than 25 %, and on room side with material specified above.

4

Flexible duct installation shall be in accordance with manufacture‟s instruction. Joints between factory insulated flexible ducts and field insulated ductwork shall be sealed and taped under this section.

5

Pre-insulated flexible ducts shall be subject to QGEWC approval.

6.2.8

Flexible Connections

1

Flexible connectors at inlet and discharge to air handling equipment shall be pre-assembled 0.7 mm galvanized steel with minimum of 100 mm width (exposed) fabric. For higher pressure applications 25 mm of width of fabric shall be used for each 25 mm of static pressure.

2

Flexible connectors attached to acoustically treated ductwork shall be insulated with 25 mm Fibre glass insulation packed between flexible connector and 16 gauge (1.5 mm) galvanized steel housing. Housing shall be fastened to duct with sheet metal screws. At equipment collar caulk between collar and flange on housing with 10 mm thick permanently flexible sealant. Care shall be taken to ensure that ducts on both sides of the connection are independently supported and that no “bridging” occurs.

3

All flexible connection will be an approved manufacturer, with ratings of fire spread, strength etc., listed by a recognised Testing Authority.

4

The fabric shall be rated for use up to 93 ºC working temperature with a tensile strength of not less than 690 kPa.

5

The material shall also be impervious to moisture, dimensionally stable, and shall not rot.

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6.2.6

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Page 8

Access Panels

1

Duct access doors shall be minimum 450 x 300 mm. All access panels shall be constructed from double thickness galvanized steel sheets, thickness to suit the duct insulation with necessary reinforcing inside for rigidity with space filled with glass fibre insulation. Panels shall be made airtight with a continuous neoprene rubber gasket.

2

Openings in ductwork shall be provided with continuous galvanized reinforcing bars, which on insulated ductwork, shall be extended to the face of the insulation. Small panels shall be provided with at least two brass window sash fasteners. All panels shall have brass drawer type handle.

3

Apparatus access doors shall be minimum 600 x 1500 mm with angle or channel frame. Provide two 75 mm strap hinges with brass pins; and two handles minimum, operate from inside and outside.

4

Provide access panels where shown, required and directed and in the following locations:

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6.2.9

bottom of all duct risers

(b)

next to outside intakes and outlets

(c)

at each fire damper

(d)

into apparatus casings to facilitate maintenance and cleaning of all components

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The duct access doors shall be fitted with CAM type to locks spaced to minimise leakage and drawer type handles.

6.3

BALANCING

6.3.1

Balancing Dampers

1

Install volume dampers in accessible locations at all branch connections and wherever necessary to adjust the flow of air to secure correct distribution. They shall be made of galvanized sheet metal, and be equipped with an approved device for fastening in any desired position. This device shall be such that the damper cannot move or rattle and pointer shall indicate the position of the damper from the outside of the finished duct insulation and shall be clearly marked with words „Open and Shut‟.

2

Dampers shall be multi-leaf opposed blade with blade height not more than 1.80 mm. PVC or similar blade seals shall be incorporated to the end of all blades. The blades shall be of an aerofoil design.

3

All blades shall be operated by a single operating quadrant with gears and links as necessary.

4

Spindles shall be non-corrodible, passing through non-ferrous bushings or ball bearing supports with seals.

5

The whole damper assembly shall be mounted in a galvanized frame with flanges.

6

Seal material shall be rated up to 93C with low water absorption and excellent chemical resistance to acids, alkalis and oils.

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Page 9

Flow Control Dampers

1

These dampers shall be installed in ductwork to maintain a constant air flow regardless of changes of pressure conditions. The damper shall be suitable for duct velocities ranging between 2 m/s to 8 m/s and shall operate from a minimum pressure of 20 Pa up to a maximum of 200 Pa. These dampers shall be installed in branch ducts fitted with high efficiency particle (HEPA) filters.

6.3.3

Motorised Dampers

1

The Contractor shall furnish and install, control dampers as required for the proper functioning of the system.

2

All control dampers shall he opposed blade.

3

Dampers frames shall be formed channels of not less than 1.8 mm galvanized steel with mounting holes for enclosed duct mounting.

4

Damper blades shall be of not less than 1.5 mm form galvanized steel. Blades on multiblade dampers shall not exceed 200 mm in width and 1200 mm in length. Blade shaft bearings shall be provided at the ends of each blade. Blade side edges shall seal off against spring stainless steel seals.

5

Dampers shall be supplied in standard sizes, in 50 mm even increments, with transition as necessary to mating duct sections.

6

Dampers shall be suitable for operation within the temperature limit of – 40 C to 93 C. Horizontal dampers shall have a rated face velocity of 2 m/s at 1500 Pa static pressure differential.

7

Dampers used for shut off function shall be of the low leakage type.

8

Damper blades shall have neoprene or PVC edging on all outside air dampers.

6.3.4

Backdraft Dampers

1

Backdraft dampers shall be low leakage with parallel blades and neoprene edge seals.

2

Damper frames shall be constructed from galvanized sheet steel with aluminium blades. Bearing shafts shall be stainless steel, in brass bearings.

3

All blades shall be coupled at the blade centres and shall be in width of not more than 1000 mm, with maximum blade size of 200 mm.

4

Leakage shall not exceed 10 m /h per m at 1000 Pa pressure differential.

5

Pressure relief dampers shall be multi-parallel blade with weighted arm closing assist. The frame shall be anodised aluminium channel sections with formed aluminium blades. Maximum blade length shall be 100 mm, and polyester foam seating strips shall be incorporated on blade edges. Bearing shall be in PVC with non-corrodible shafts.

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Splitter Dampers

1

In each low pressure system take off where opposed blade duct dampers are not specified, splitter dampers shall be provided. The only justification for not providing splitters is in a system which can be demonstrated to be sized by a static regain programme and which is run in high pressure fittings. Otherwise splitter dampens shall be installed at all take offs.

2

Splitters shall consist of hollow blades in a vane rail assembly, made from galvanized steel by a recognised manufacturer.

3

A lockable quadrant adjustment level shall be located outside the insulation, and marked clearly to show vane position.

6.3.6

Fire Dampers

1

Provide, where required by ordinances or codes, for dampers made to BS 476 or North American Standards or NFPA 90A, and complete with angle iron frame of 3 mm thickness, 70 C fusible link, pivot rods, and spring catches. Fire damper housings shall be galvanized steel duct sections around the fire dampers, and shall allow 100% unrestricted duct area while in the open position. Provide approved type access doors, with airtight gaskets, for inspection and servicing of fire dampers. Fire dampers shall be 2 hour rated and shall be labelled by manufacturer. The fire damper blades shall be out of the air stream.

2

Provide fire dampers in all duct over 125 cm in area, in the following locations, whether or not specifically required by ordinances and codes and as indicated the contract drawing:-

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duct entering and leaving fire shafts (duct shafts)

(b)

ducts passing through designated fire walls

(c)

ducts through floors, and not encased in fire shaft

(d)

ducts leaving and entering plant area

(e)

ducts entering and leaving storage areas.

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Where fire dampers are located remote from fire partition, duct between fire damper and partition shall be encased in double metal lathe and plaster or other fireproofing acceptable to Authorities having jurisdiction. This shall be arranged and paid for by this trade.

4

Dampers shall be operated by two stainless steel springs with the blades being held in the open position by a fusible link and stranded stainless steel strap. Blades shall be made from galvanized steel.

5

Fire dampers shall not be installed in kitchen exhaust ductwork. This shall comply in all respects with NFPA 96.

6.3.7

Smoke Dampers

1

Smoke dampers shall be the low leakage type, rated under UL 555 S as leakage Class I.

2

Frame shall be of formed channel of not less than 1.6 mm galvanized steel. Blades shall be 1.6 mm, airfoil shaped, double skin construction, opposed blade type.

3

Blade edge seals shall be silicon rubber and jamb seal shall be flexible metal compression type.

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Page 11

Bearings shall be stainless steel sleeve type pressed into frame.

5

Damper actuators shall be factory furnished suitable for either 240 volt or 24 volt application. Complete unit shall be factory tested in compliance with UL 555 S.

6

Damper and actuator shall be qualified under UL 555 S to an elevated temperature 120 ºC.

7

The damper unit shall be supplied with a two position indicator switch linked directly to the damper to provide the capability of remotely indicating damper blade position.

6.4

SILENCERS

6.4.1

General

1

Silencers shall be installed when required to achieve the specified noise levels.

2

At shop drawing stage, the contractor will undertake calculation for every unit and every area and determine the insertion loss required to meet the stated noise criterion.

3

Supply and return duct noise must be considered as well as duct breakout noise.

4

Materials of construction shall be galvanized sheet metal and mineral fibre acoustic fill which is inorganic, inert, moisture and vermin resistant. Silencers shall be so constructed as to prevent erosion and pregnability of the acoustic fill.

5

The silencers shall incorporate a removable panel which provides complete access to all internal surfaces for cleaning and also permits removal and replacement of acoustic fill.

6

Silencers shall be factory made, and shall have available certified test data concerning insertion loss. This must be available when required, in advance of ordering units. Where a silencers is made under licence, or part assembled locally, then tests must also be made after assembly and witnessed by and independent authority.

7

The static pressure loss of any required silencer must be considered in air handling equipment original selection.

8

Silencers shall be installed in locations as indicated on the contract drawings.

9

Silencers shall be flanged to exactly match the adjacent ductwork in which they are to be installed.

6.5

DIFFUSERS AND REGISTERS

6.5.1

General

1

Diffusers, registers and grilles shall be arranged for flush mounting in lay-in type ceilings and over lap mounting in plaster, mineral tile and similar ceilings, with concealed fixings unless otherwise directed

2

Grilles, register and diffuser locations shall be adjusted to suit reflected ceiling drawings, or Engineer's site instructions. All grilles, registers, diffusers, louvres shall be from one manufacturer.

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Provide plaster frame for grilles, and diffusers installed in plaster ceilings,

4

All diffusers, grilles and registers shall be supplied completely factory powder coated. Finish colour shall be to the approval of the Architect. The interior of all grilles and diffusers is to be factory painted matt black.

5

All supply grilles and diffusers will have opposed blade balancing dampers. All will have foam rubber sealing band around the edge to seal to the structure. All pivots will be round section, not of formed sheet, and not relying on a spring steel locking wire.

6

Basic grilles and diffuser materials shall be aluminium extruded sections. Sections in the air stream shall be carefully selected to minimise turbulence.

7

All grilles and diffusers supplied on this project shall be tested and rated in accordance with ASHRAE Standard 70-72, ADC Test Code 1062-GRD and ISO 3741 or have ARI certification.

8

Linear bar grilles shall be fabricated from aluminium, with 6.4 mm wide bars on 12.5 mm centres pressed into a notched steel retaining bar. The core can be either welded into the cuter frame, or where the grille is used in a sill application, held in the outer frame by spring clips fixed to the core retaining bar. The outer frame shall be 35 mm deep and shall have a visible flange 25.4 mm wide, milled end caps shall be welded to give a near invisible joint. The grill shall be complete with an opposed blade damper painted matt black, and shall be fixed with universal mounting brackets. Both the damper and the fixing brackets shall be accessible through the face of the grille. Continuous grilles shall be provided with positive alignment strips, which fit into special keyways extruded into the frame of the grille to ensure clean unbroken lines.

9

Ceiling Diffusers shall be multi-core giving 4 way horizontal discharge. The three centre cores of the diffuser shall be manufactured from pressed aluminium, with the remaining cores and the outer frame fabricated from extruded aluminium welded at the corners to give near invisible joints. One, two and three way pattern cores shall be used as indicated on schedules. All cores shall be interchangeable. The core shall be removable without the use of special tools, but for safety, shall be fixed to the outer frame by a small length of chain. The diffuser shall be complete with an opposed blade damper painted matt black." The damper shall be adjustable through the face of the diffuser".

10

Wall registers shall be double deflection fabricated from aluminium, the front vanes being horizontal, the rear vanes vertical. This grille shall be complete with an opposed blade damper painted matt black and adjustable from the face of the diffuser. Both sets of vanes shall be fully adjustable without the use of special tools.

11

Eggcrate return or extract grille shall be provided with 12.7 mm x 12.7 mm openings, giving a free area of 90 %. The core shall be fixed into an extruded aluminium frame, with welded corners and a 25 mm face flange. The grille is complete with an opposed blade damper painted matt black and adjustable through the face of the diffuser.

12

Circular ceiling diffuser shall be of aluminium construction with two concentric inner spinnings. The diffuser core shall be fully adjustable for vertical or horizontal air discharge, and shall be removable without the use of special tools. An iris damper shall be provided in the neck of the diffuser which is adjustable from the diffuser face.

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Vision proof door transfer grilles shall consist of an aluminium core with inverted-vee type blades, and an extruded aluminium frame with matching rear flange. The frame shall be adjustable from 28 mm to 60 mm to suit the door width. Transfer grilles for 'LIGHT TIGHT' applications such as dark rooms shall be with two vision proof cores back to back.

14

Linear slot diffusers shall provide an unobtrusive continuous air diffusion with a pleasing aesthetic appearance. Hairline butt joints shall ensure clean unbroken linear runs for active and dummy sections. The diffusers shall be complete with pattern control blades, fully adjustable from face of diffuser through 180 degrees and shall be fitted with end caps at each end. The diffuser members shall be constructed from high quality aluminium extrusions to BS 1474 while the pattern control blades shall be of black rigid PVC or aluminium extrusions.

6.6

LOUVRES

6.6.1

Outside Louvres

1

Outside louvres shall be supplied with sleeves for the appropriate openings, and with full installation instructions.

2

Louvres shall be extruded aluminium frame with aluminium blades of not less than 2 mm thickness, and shall be firmly fixed so as not to vibrate. Unsupported blade width shall not exceed 1800 mm.

3

Behind each louvre shall be an insect mesh screen 6 x 6 mm made from 2 mm diameter wire. The screen will be clamped by a 20 mm frame and will be firmly fixed to the outer edges of the louvre. The screen and frame shall be hot dip galvanized after fabrication.

4

The connection to the louvre shall be flexible and shall ensure no duct load is transmitted to the louvre.

5

Louvres shall be provided with powder coated finish to the approval of the Architect.

6.6.2

Sand Louvre

1

Sand louvres shall have a double deflection inlet passage to separate sand from incoming air by means of centrifugal forces.

2

Separation efficiency shall not be less than 80 % on 20 to 200 micron test dust, and 50 % on 1 to 70 micron test dust.

3

Sand louvre shall be mill finished aluminium sections with casing 2 mm thick and blades 1.5 mm thick. The base of the louvre shall have self-emptying sand holes.

4

Pressure drop at 2 m/s average face velocity shall not exceed 85 Pa.

5

Insect mesh shall be included.

6

Sand louvres shall be provided with powder coated finish to the approval of the Engineer.

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END OF PART

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THERMAL INSULATION ............................................................................... 2 GENERAL ...................................................................................................... 2 Scope of Work 2 References 2 Submissions 2 Contractor’s Responsibility 3 System Description 3 PIPE INSULATION ........................................................................................ 5 Fibreglass Insulation 5 Polyisocyanurate (Phenolic Foam) Insulation 6 Preinsulated Under Ground 6 CONCEALED COLD AIR DUCTS ................................................................. 7 Fibreglass Insulation 7 Polyisocyanurate (Phenolic Foam) Insulation 7 EXPOSED COLD AIR DUCTS ...................................................................... 7 Fibreglass Insulation 7 Polyisocyanurate (Phenolic Foam) Insulation 8 External Ductwork 8 Acoustic Lining 8 Circular Duct Insulation 9 EQUIPMENT INSULATION ........................................................................... 9 Refrigerant and Condensate Drain Pipe Insulation 9 Apparatus Casings 10

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7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.2 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.5 7.5.1 7.5.2

Section 22: Air Conditioning, Refrigeration and Ventilation Part 07: Thermal Insulation

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Page 2

7

THERMAL INSULATION

7.1

GENERAL

7.1.1

Scope of Work

1

This Part details the requirements for insulation for piping systems, ductwork systems, and equipment.

2

Related Sections and Parts are as follows: Chilled Water Pipework

Section 1

General

References

1

The following standards are referred to in this Part

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ANSI 331.1 .................Pipework Design

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This Section Part 5

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ASTM E-84 .................Test Method for Surface Burning Characteristics of Building Materials

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BS 4735 ......................Laboratory method of test for assessment of horizontal burning characteristics of specimens no larger than 150 mm x 50 mm x 13 mm (nominal) of cellular plastics and cellular rubber materials when subjected to a small frame

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DW 144 ......................Ductwork Installation Submissions

1

The Contractor shall submit manufacturer’s specifications and installation instructions for each type of mechanical insulation. The submittal shall include a schedule showing manufacturer’s product number, thickness and recommended furnished accessories for each system requiring insulation.

2

Samples for each type of insulation shall be provided. A 300 mm long sample of each piping insulation type and a 300 x 300 mm of each duct and equipment insulation type.

3

The Contractor shall submit certification and data necessary to show compliance with the specification and other governing regulations. These shall include proof of compliance for test of products for fire rating, corrosive resistance and compressive strength.

4

Where the specification calls for additional treatments such as wrapping and water proofing a complete sample shall be provided in addition to the above samples.

5

All samples shall be retained on site after approval to be a reference for future work.

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7.1.3

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Contractor’s Responsibility

1

The Contractor shall provide all necessary materials, labour, equipment, tools, appliances, services hoisting scaffolding supports and supervision to provide complete mechanical insulation in accordance with the Specifications.

7.1.5

System Description

1

The thermal insulation shall be in accordance with the QGEWC regulations unless specified differently in the Project Documentation. However QGEWC approval is required before any change will be permitted.

2

The whole of the insulation work shall be carried out by an approved specialist insulation Contractor. All allowances shall be included for arranging a specialist subcontractor accordingly and for informing the specialist subcontractor of all conditions relating to the contract and for co-ordinating his works with the remainder of the Works.

3

All allowances shall be included for informing the specialist subcontractor of all details of the building structure, programme arrangements, and other relevant details at the time of tender and for all necessary visits to site by the subcontractor or his workers.

4

In addition to complying with the relevant standards, all insulating material shall be free from asbestos.

5

Insulating materials shall be acceptable only if they are equal to or better than the grades or classes of fire resistance as follows: BS 4735, Class Q, for burning rate nil, and not producing melted droplets

(b)

BS 476 Part 4, for non-combustible grade

(c)

BS 476 Part 5, Class P, for not easily ignitable

(d)

BS 476 Part 7, for fire propagation index of a maximum of 12.6

(e)

BS 476 Part 7, Class 1, for surface spread of flame

(f)

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7.1.4

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BS 476 Part 9, for production of emitted smoke shall not give more than 35 % obstruction of the light beam.

6

All insulation finishes and coverings shall be classified as Class 1 surface spread when tested in accordance with BS 476, Part 7.

7

All adhesive, mastics, coatings, sealers and primers shall be classified as Class 1 surface spread when tested in accordance with BS 476, Part 7. They shall not in any way attack the insulation or the surface to which the insulation is being applied and shall be suitable for the working temperatures.

8

Insulating materials shall have thermal conductivity values not more than those listed as given in Table 8.1.

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Table 8.1 Thermal Conductivity Insulating Materials Type

Thermal Conductivity (W/m/C)

Mineral wool

Sectional

0.04

Mineral wool

Slabs

0.04

Fibre Glass

All

0.034

Closed Cell

All

0.038

Polyurethane

Sectional

0.025

Styrofoam

Rigid

0.026

.

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Note: all conductivity figures are rated at an average temperature of 24 C. All material delivered to site shall be new and fully dried out and so maintained throughout the progress of the works. All insulating materials shall be stored in storage sheds, and in accordance with the manufacturer’s recommendations.

10

In order to ensure that the insulation applied is in all respects in accordance with the Specification, sections shall, as required by the Engineer, be cut from the finished insulation. The Contractor is as allow in his price for the removal and replacement of two sections of each type of insulation. If however, defects are revealed, further sections shall be cut out for inspection, and all cut-out sections shall be replaced at no cost to the Contract. If further defects are revealed then the Engineer shall have the right, when in his opinion it is necessary, to issue instructions for any part or the whole of the insulation to be removed and replaced. The replacement with new insulation shall be to the satisfaction of the Engineer and the cutting out and replacement shall be at no cost to the Contract.

11

Particular attention shall be paid to the finished appearances of all thermal insulation which must present a neat and symmetrical appearance running true in the line with pipe layouts, etc.

12

Any rough, irregular and badly finished surfaces shall be stripped down and re-insulated to the Engineer’s satisfaction.

13

In certain cases the type of insulation specified will require a painted finish, in addition to identifying bands and any signs which are to be applied.

14

All systems are to have been tested and approved by the Engineer prior to installation of insulation.

15

All thermal insulation shall be non-corrosive to the metal, water repellent and fire retardant.

16

All metal surfaces shall be thoroughly cleaned and treated with approved corrosion inhibitor before applying the insulation. Insulation can be applied directly to galvanized surfaces.

17

Lead bearing inserts shall be provided at all supports to ensure that the insulation is not compressed or damaged. The inserts shall be treated hardwood or approved plastic.

18

The vapour barrier shall be continuous and not punctured at any point.

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Page 5

The cotton canvas/fibre glass cloth shall be soaked in a compound as approved by the Engineer and shall be overlapped at least 50 mm at transverse and longitudinal cloth joints.

20

Vapour seal materials shall be fire resistant, non-toxic, weather resistant, and anti-fungus quality. Bitumen based products shall not be used.

21

All access doors in ductwork shall be insulated to match the ductwork that they are installed in. The insulation shall be furnished to allow access without damage to the insulation.

22

Mechanical fasteners shall be used when installing slab or roll insulation. The fasteners shall be the self adhesive type and only fixed after cleaning to ensure proper adhesion.

7.2

PIPE INSULATION

7.2.1

Fibreglass Insulation

1

Pipe covering and insulation shall be manufactured by a recognised manufacturer, and shall be neatly installed to the following specifications. The general intent is to provide a sealed insulation which will not permit sweating of the pipes and which will not retain moisture to the detriment of it’s insulating capability.

2

Pipes shall be thermally insulated with rigid section of fibre glass insulation with density of 65 kg/m3, having a thermal conductivity factor of 0.03 W/m2/K at 10 oC with self applied aluminium craft paper. The minimum thickness shall be 500 mm unless otherwise specified in the Project Documentation.

3

The insulation, in sizes indicated shall be applied over clean, dry surfaces. Adjoining sections of insulation should be butted firmly together with the longitudinal seam of the jacket located on the bottom half of the pipe.

4

Pipes should be banded with at least three aluminium bands per section. One at the centre and one covering the edge of each circumferential strip.

5

Insulate and finish valves and fittings in the same manner and same thickness as piping in which such items are installed. Moulded, factory shaped sectional pipe covering, factory or job fabricated may be used subject to satisfactory visual checking by the Engineer.

6

Direct contact between pipe and hanger shall be avoided. Hangers shall pass outside of the sheet metal protection saddle, which shall cover a section of high density insulation, of sufficient length to support the pipe without crushing the insulation. The vapour barrier shall be lapped over the saddle and securely cemented to it. Minimum thickness of metal saddle is 1.5 mm. The method shall be in accordance with DW 144.

7

Internal chilled water pipe shall be covered by 50 mm of rigid insulation plus a 200 g/m2 woven glass cloth cover painted with two coats of approved sealant. External chilled water pipe shall be covered by 50 mm of rigid insulation plus a waterproof cover of 200 g/m2 woven glass cloth painted with two coats of approved sealant. Where any insulated piped service is run external to the building (including insulated pipework run on roofs), in trenches or in plant rooms, the piped services shall be clad using an outer covering of sheet aluminium with a minimum thickness of 0.7 mm.

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Where exposed, insulated pipework runs through occupied or public areas, chiller yards and plant rooms the exposed pipework shall be clad with sheet aluminium, of 0.7 mm or thicker. or may be painted as detailed in the Project Documentation.

9

Strainers and valves of diameter 80 mm and above and fittings which require opening for maintenance and repairs shall be provided with insulated boxes.

7.2.2

Polyisocyanurate (Phenolic Foam) Insulation

1

Chilled water pipe insulation shall be polyisocaynurate rigid closed cell pre-formed pipe insulation cut from blocks which have been factory produced from a chemical system complying with ASTM E-84, with a flame spread less than 25 and identified by a light green colour.

2

The density shall be 35 kg/m3 for all interior piping and 50 kg/m3 for external pipework.

3

All pipe insulation to be factory covered with reinforced aluminium foil/kraft paper laminate, the whole providing a Class I rating to BS 476 Part 7.

4

Bends are to be insulated with pre-moulded polyisocyanurate rigid closed cell foam meeting the same fire ratings as above but with aluminium foil applied separately on site.

5

Tees, valves, strainers etc. are to be produced by the Contractor forming suitable metal boxes and pouring in-situ polyisocyanurate chemical system supplied by the pipe insulation manufacturer and in accordance with his instructions.

6

High density pipe supports, 80 kg/m3, are to be produced from the same chemical system and by the same manufacturer of the insulation and covered with aluminium foil in the factory.

7

The manufacturer’s installation recommendations shall be strictly adhered to.

8

The use of fibrous insulation on chilled water pipes will not be permitted.

7.2.3

Preinsulated Under Ground

1

All underground chilled water pipework shall be pre-insulated.

2

The system shall be non corrosive, non metallic, structurally strong completely water proof and entirely resistance to attack by salts, water and all ground chemicals normally encountered.

3

The system manufacturer shall have fabricated systems of the composition defined here for at least two years.

4

All straight sections fittings, anchors end seals and other accessories shall be factory prefabricated to the project dimensions. The design shall be such to minimise the number of field welds.

5

The system design shall be in conformance with the latest edition of ANSI 331.1.

6

Pipe movement due to thermal expansion shall be accommodated with expansion loops or elbows.

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The system manufacturer shall provide an integrated leak detection/location system factory installed within the piping system. The leak detection system shall be connected to the leak detection panel.

8

The complete system shall be computer designed and analysed by the piping system manufacturer to determine stress and anticipated thermal movement of the pipework.

9

PVC warning tape shall be provided 300 mm above the buried throughout the length of the buried pipe.

7.3

CONCEALED COLD AIR DUCTS

7.3.1


1

Unless otherwise indicated, supply and return ductwork shall be insulated with 48 kg/m3 density aluminium foil faced fibreglass duct insulation. The insulation shall be fastened with adhesive of high quality and a thermal conductivity of not more than 0.037 W/m/C. The adhesive shall be applied to the entire surface of the ductwork and insulation. Butt all joints tightly and seal all breaks and joints by adhering a 75 mm aluminium foil vapour barrier tape or sheet with a fire retardant adhesive.

2

Insulate flexible connections and connections to diffusers with 25 mm thick, 24 kg/m3 density reinforced aluminium foil faced, flame resistant, flexible fibreglass insulation. Overlap onto adjacent insulation and seal with adhesive duct tape to give good closure.

3

Finish insulation on ductwork by applying a 200 g/m2 canvas cover adhered between two coats of approved fungicidal protective fire resistant lagging adhesive.

4

Bitumen based products shall not be used.

7.3.2


1

Unless otherwise indicated insulate supply and return ductwork with 25 mm of 35 kg/m3 nonhygnoscopic foil faced polyisocyanurate (phenolic foam) slabs.

2

Flexible connections shall be insulated with 25 mm of 24 kg/m3 reinforced flame resistant flexible fibreglass insulation.

3

The insulation shall be fixed by means of a non flamable adhesive recommended by the insulation manufacturer.

4

Finish insulation on duct work by applying a 200 g/m2 canvas cloth cover adhered between two coats of approved fungicidal protective fire resistant lagging adhesive.

7.4

EXPOSED COLD AIR DUCTS

7.4.1


1

For ducts exposed inside conditioned spaces, insulate as described above for concealed air ducts but using aluminium foil faced fibre glass boards with density 48 kg/m3. Then apply a 200 g/m2 canvas cover adhered between two coats of approved fungicidal protective fire resistant lagging adhesive.

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Where exposed cold air ductwork runs through occupied or public areas, it shall be clad with sheet aluminium, 0.9 mm or thicker as specified in the Project Documentation.

3

For ducts exposed in non air conditioned areas and plant rooms, insulate using the method described for concealed ducts, but using insulation with a minimum thickness of 50 mm, 48 kg/m3 density fibreglass insulation. If necessary due to market availability, this may be installed in two layers, but with each layers, but with each layer properly finished.

4

Finish insulation by applying a 200 g/m2 canvas cover adhered between two coats of approved fire resistant lagging adhesive.

5

Where ducts penetrate the building shell, the duct shall be flashed and waterproofed before any insulation is applied.

7.4.2


1

Exposed ductwork inside air conditioned spaces shall be insulated as described above for concealed duct work.

2

Exposed ductwork in non-air conditioned areas, insulate using the method described for concealed ducts but using insulation with 50 mm of 35 kg/m3 polyisocyanurate (phenolic foam) insulation. This may be installed in two layers, but with each layer staggered and properly finished.

3

Finish insulation on duct work by applying a 200 g/m2 canvas cloth cover adhered between two coats of approved funigicidal protective fire resistant lagging adhesive.

4

The finished insulation shall then be clad with aluminium sheet 0.9 mm thick.

5

Where ducts penetrate the building the duct shall be flashed and waterproofed before any insulation is applied.

7.4.3

External Ductwork

1

All external ductwork shall be insulated with 50 mm thick fibre glass slab.

2

The insulation shall be installed as detailed for exposed ductwork except that the insulation shall be covered with fibre glass cloth 200 g/m2.

7.4.4

Acoustic Lining

1

Acoustic lining shall be provided when specified in the Project Documentation.

2

The lining shall be glass fibre or mineral wool slab and faced to minimise fragmentation and fibre fly. The type and thickness of the lining shall be approved by the Engineer.

3

The ductwork shall be size to allow for the thickness of the lining.

4

The ductwork surfaces must be thoroughly cleaned and the lining fixed by an approved adhesive over the whole area to be lined.

5

Mechanical fasteners must be used at 400 mm maximum centres and not more than 75 mm from joints, corner breaks etc.

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Page 9

All edges shall be sealed or enclosed by a light metal section mechanical fastened to the duct.

7

If required by the Engineer, metal mesh may be required as a precaution against displacement or break up.

7.4.5

Circular Duct Insulation

1

Circular supply and return air ductwork shall be insulated with flexible fibre glass blanket of density 24 kg/m3 and covered with reinforced aluminium foil

2

Blanket thickness shall be 50 mm compressed to 25 mm during installation for internal ducts and 100 mm compressed to 50 mm for external ducts.

3

The method of installation shall be the same as for rectangular ducts.

4

Aluminium bands 25 mm wide shall be installed at 500 mm centres

5

Vapour sealing shall be carried out as specified for rectangular ducts

6

Additional protection shall be provided for exposed ducts if specified in the Project Documentation.

7.5

EQUIPMENT INSULATION

7.5.1

Refrigerant and Condensate Drain Pipe Insulation

1

The pipe covering and insulation shall be manufactured by a recognised manufacturer and shall be neatly installed to the following specification. The general intent is to provide a sealed insulation which will not permit sweating of the pipes and which will not retain moisture to the detriment of its insulating capability.

2

The refrigerant suction lines only shall be insulated with 19 mm thick foam rubber having a thermal conductivity factor of 0.036 W/m2/K and a maximum water permeability of 0.09 µgm/NH. Alternatively, the pipes shall be insulated with 50 mm thick rigid fibreglass insulation and vapour sealed in the same manner as chilled water pipes as detailed in Part 5 of this Section.

3

The material shall be supplied as pre-formed pipe sections in tubular or pre slit form.

4

The insulation shall be installed accordingly to the manufacturer’s recommendations using a non-flammable adhesive.

5

All exposed insulation shall be given two coats of chlorosulphonated polyethylene paint.

6

All condensate drains within plant rooms or other internal areas subject to damage or sweating shall be insulated using 25 mm thick rigid fibreglass or 10 mm thick foam rubber insulation. The insulation shall be vapour sealed as for chilled water pipes as detailed in Part 5 of this Section.

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Apparatus Casings

1

Insulate apparatus casings which are not provided with insulation as follows:

2

apply generally 50 mm of rigid polyurethane insulation, 24 kg/m3 density. On the underside of coil sections, apply 50 mm thick polyurethane insulation, 24 kg/m3 density. All joints are to be sealed in cold adhesive compound.

3

Ensure that any access panels are insulated to the same standard and are openable.

4

For small units, cover the entire outside assembly with waterproof self adhesive glass fibre tape. This must be at least 75 mm minimum width and must overlap at least 50 % on each application, to achieve watertight conditions.

5

For larger units, provide a weather resistant enclosure outside the insulation, subject to Engineer’s approval.

6

Ensure that all equipment meets these requirements, regardless of manufacturer’s standard practice, and add insulation as required to the above standard.

7

Where insulation, re-installation or additional insulation is required to the casing of externally mounted air conditioning units, the insulation shall be covered with sheet Aluminium, of 0.9 mm or thicker.

8

Insulation of drain pans is specified for AHU and FCU regardless of the manufacturer’s standard supply, the contractor shall re-insulate on site if necessary so that the specification is complied with in full.

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7.5.2

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EXHAUST FANS ........................................................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 EXHAUST FANS ........................................................................................... 2 General 2 Centrifugal Extract Fans 3 Axial Extract Fans 4 Roof Mounted Extract Fans 5 Twin Fan Toilet Extract Units 5 Wall and Window Mounted Extract Fans 5 Propeller Type Extract Fans 6 Kitchen and Smoke Extract Fans 6 Protectively Coated Extract Fans for Corrosive or Hazardous Use 6 Bifurcated Extract Fans 7 In-Line Extract Fans 7

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8 8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11

Section 22: Air Conditioning, Refrigeration and Ventilation Part 08: Exhaust Fans

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Page 2

8

EXHAUST FANS

8.1

GENERAL

8.1.1

Scope

1

This Part details the requirements for all types of extract fans as specified in the contract.

2

Related Sections and Parts are as follows: Section 1 Section 21

General Electrical

References

1


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BS 848 ........................Fans for general purpose

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8.1.2

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BS 5000 ......................Rotating electrical machines of particular types or for particular applications

EXHAUST FANS

8.2.1

General

1

The make and design of the exhaust fans shall be approved by the Engineer and evidence supporting the claimed noise efficiencies shall be submitted for approval prior to placing the order. Where fans are fitted with noise attentuators full details of the attenuators shall be given.

2

Belt driven fans shall be fitted with pulleys suitable for V-belts. The pulleys shall be fixed by taper lock type bushes and shall be secured to the fan and motor shaft by keys fitted into machined keyways.

3

All fans which are to large or heavy to be man handled safety shall be provided with eyebolts or other lifting facilities to enable mechanical lifting equipment to be used.

4

The whole fan assembly shall be fully finished against corrosion.

5

Access shall be provided to carry out all necessary maintenance required.

6

The electrical terminal box shall be located to allow for easy connection and disconnection the electrical supply.

7

Where required suitable guards shall be installed to protect against all moving parts including the motor.

8

All motors are to be positioned to permit effective ventilation of the motor and all components of the fan and motor are to be suitable to withstand the temperature conditions expected.

9

All fans shall be installed to avoid vibration and noise to the ductwork or building fabric.

10

Each fan motor shall be designed to drive its respective fan when the fan is operating at a speed or pitch angle 10 % in excess of that required to meet the fan performance.

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8.2

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Page 3

Where required flexible connections shall be installed at both the inlet and outlet of each fan.

12

All extract fans shall have the direction of rotation discharge direction and arrangement to suit the space conditions.

13

All extract fans shall be provided with an electrical isolator adjacent to the unit.

14

The fan motors shall be insulated to a minimum of a Class ‘B’ insulation

15

All fans shall be capable of operating at ambient temperatures of 50 C and the casing material shall be able to withstand sun radiation temperature upto 85 C.

16

The noise ratings for each fan shall not exceed the levels specified in the QGEWC regulations for the area being served.

17

All fans used for life safety operations or hazardous operations shall be subject to Civil Defence Department approval.

18

The extract fans shall be axial, centrifugal or mixed flow as detailed in the Project Documentation.

8.2.2

Centrifugal Extract Fans

1

The centrifugal extract fans shall be of the non-overloading type.

2

The fan housing shall be rigidly built and braced. Where the fan scroll is 450 mm or more in width an access door with frame and gasket shall be provided. All access doors shall be fabricated so that the inner surface is flush with the inside of the fan scroll.

3

The fans shall not produce excessive noise as compared to units of like size and power when used with the specified vibration isolation.

4

The fan manufacturer shall provide for approval for each fan, certified sound power ratings with a octave band analysis and also the volume, horsepower, pressure characteristic curves from shut-off to free delivery.

5

The fan impeller shall have ample strength and shall be statically and dynamically balanced to avoid vibration.

6

The blades shall be designed to ensure quiet and efficient operation.

7

The fans shall be V-belt driven unless otherwise indicated.

8

The motor pulley shall be an adjustable type for two (2) grooves or less. Drives requiring three (3) grooves or more shall be the variable pitch type.

9

Drives for fractional horsepower motors may have one belt rated at 200 % of motor horsepower. All other fans shall have not less than two belts and shall have sufficient capacity to drive the fan with one belt broken.

10

The fans shall be provided with belt and pulley guards manufactured of perforated metal or other approved material. Covers shall be provided in the guard for the fan and motor shafts for ease of taking tachometer readings without removal of the guard.

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The fan motor shall be sized to drive its respective fan when the fan is operating at a speed 10 % in excess of that required to meet the fan performance. No motor shall operate within the service factor.

12

All fans discharging directly up though the roof shall be equipped with a 40 mm casing drain which shall be connected to the nearest floor drain.

13

All fans shall be factory coated with one coat of primer and one coat of machine enamel. The interior of the fans shall be painted as per the manufacturer’s standard.

14

The fan shaft shall be supported by least two roller or ball bearings with easy access to the lubrication points where required.

15

All fans scheduled to be located outdoors shall be furnished with weather proof motor and drive housings.

8.2.3

Axial Extract Fans

1

Axial flow fans shall be capable of giving the design flow when tested to BS 848.

2

The fan casing shall be constructed of mild steel plates with angle stiffeners, with the easing hot dip galvanised after manufacture.

3

The inlet and outlet of the axial flow fans shall be flanged for connection to the system.

4

The casing shall cover both impeller and motor so that the fan can be removed without disturbing adjacent ductwork or other components of the system.

5

A flame proof external terminal box shall be fitted on the casing.

6

All lubrication points shall be extended to outside the casing and in a position that will permit easy access.

7

The impellers shall be die cast in aluminium and x-rayed after manufacture.

8

The impeller shall be capable of running continuously at 20 % in excess of the rated speed.

9

The impeller shall be keyed and locked to the shaft, which shall be statically and dynamically balanced and tested at over speed prior to dispatch from the manufacturer’s works.

10

The blade angle shall be adjustable over at least a 30  range with markings at the base to indicate the blade angle.

11

All motors are to be positioned to permit effective ventilation of the motor and all components parts of the fan and motor are to be suitable to withstand the temperature conditions expected.

12

A suitable support is to be provided for each fan. The frame is to be fabricated from rolled steel channel with adequate cross members for bolting the fan in position.

13

Anti-vibration mountings and flexible connection shall be provide to isolate the fans from the adjacent ductwork and building fabric.

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Roof Mounted Extract Fans

1

The roof mounted extract fans shall meet the appropriate requirements as detailed in the general section.

2

The cowls and bases shall be of a weather proof material such as galvanised after manufacture, aluminium, aluminium magnesium alloy or glass fibre.

3

Cases shall be formed so as to ensure a weather proof fitting.

4

Provision for access to the fan components shall be provided.

5

The fans shall be provided with back draught dampers and/or fire release dampers where indicated.

6

Bird guards of not greater than 25 mm mesh shall be provided as an integral part of the unit.

7

The fans shall be mounted on a weather proof curb at least 200 mm above the finished roof level.

8.2.5

Twin Fan Toilet Extract Units

1

The unit casing shall be manufactured in epoxy coated aluminium alloy and shall house the twin fan assemblies.

2

Each fan shall be a double inlet forward curved centrifugal impeller running in an individual scroll.

3

The impeller may be either direct driven or belt driven depending upon the fan duty.

4

Direct driven fans shall incorporate a volume control damper on the suction side to regulate the volume to the required duty.

5

The motors shall be manufactured to BS 5000 TEFV type with sealed for life bearings.

6

The fans shall be fitted with air flow sensors and shall discharge into a common plenum through a linked shutter system.

7

Motors and flow sensors shall be pre-wired to a fitted isolator accessible from outside the unit.

8

The toilet extract units shall be supplied for either roof mounting duct mounting or installation within a plant room as indicated on the drawings.

9

The toilet extract units shall be supplied with auto change over panels with duty/standby selector switch, run/fail indication lamps and cyclic relay for duty sharing.

8.2.6

Wall and Window Mounted Extract Fans

1

Extract fan shall be of the propeller type suitable for wall/window mounting.

2

The fan construction shall be of moulded plastic

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Motors shall be of the shaded pole induction type enclosed in an aluminium alloy case and protected by a thermal over load cut out.

4

The motor bearings shall be self alignment sealed for life type.

5

The fans shall be provided with a solenoid operated back draught shutters. The solenoid shall open and close the back draught damper silently as the fan is switched ON and OFF.

8.2.7

Propeller Type Extract Fans

1

The impeller shall be of steel or aluminium and the blades shall be fixed to the hub or the blades and hub shall be formed in one piece.

2

The bearings shall be ball, roller or sleeve type sealed for life or with accessible lubrication points.

3

The propeller fans may be ring mounted diaphragm mounted or diaphragm mounted in a casing. The casing shall be longer than the length of the motor and fan.

4

The casing shall be of steel construction with flanged ends and shall incorporate an inspection door.

5

The terminal box shall be mounted externally on the casing.

6

The tip speed of the fans shall not exceed 20 m/s.

7

Inlet and outlet grilles shall be installed on the fans incorporating gravity back draught damper.

8.2.8

Kitchen and Smoke Extract Fans

1

The fans shall be especially designed for smoke and kitchen extract

2

The fans can be either belt or direct driven with the motor fixed on resilent mountings outside the air stream.

3

Kitchen extract fans shall be fitted with a housing drain and grease trap easily removable for cleaning.

4

The fans shall be suitable for removal of smoke and grease laden vapours.

8.2.9

Protectively Coated Extract Fans for Corrosive or Hazardous Use

1

Where the fans are required to handle corrosive toxic flammable explosive or high temperature gases the materials and construction shall be required to suit the application and all relevant safety regulations shall apply.

2

Bearing and lubrication arrangements shall be suitable for the conditions expected.

3

Where protective coating is required to use with corrosive gases the coating shall cover al parts of the complete fan, motor and casing assembly which will be in contact with the corrosive gases.

4

No fan shall be installed if the protective coating has been damaged in any way.

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The impeller casing shall be as specified in the Project Documentation.

6

All fans shall be subject to Civil Defence Department approval.

7

The fan motors for hazardous use or required to handle flammable or explosive gases shall be flame proof.

8.2.10

Bifurcated Extract Fans

1

Bifurcated extract fans shall be axial type fans.

2

The motor shall be completely out of this air stream.

3

The motor may be placed between the two halves of the casing in the external air or may be placed within the casing provided that effective ventilation is given to the motor.

4

The fan motor and bearings shall be suitably rated for operation at the temperature they may experience.

5

The fan construction and installation shall be specified for axial extract fans in Clause 8.2.3 of this Part.

8.2.11

In-Line Extract Fans

1

In-line extract fans shall be centrifugal, axial or mixed flow type fans as detailed in Project Documentation.

2

The construction and installation shall be as specified

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centrifugal fans Clause 8.2.2

(b)

axial/mixed flow Clause 8.2.3.

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The casing shall be rigidly constructed of mild steel or aluminum alloy and shall be stiffened and braced to obviate drumming and vibration.

4

Mounting feet shall be provided for bottling to a base or supports.

5

The inlet and outlet shall terminate with flanges to facilitate installation and removal.

6

Access panels shall be provided and shall be sized to facilitate maintenance.

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END OF PART

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ACCESSORIES ............................................................................................. 2 GENERAL ...................................................................................................... 2 Scope 2 SOUND AND VIBRATION CONTROL EQUIPMENT .................................... 2 General 2 Silencers 2 Anti-Vibration Mountings 3 Resilient Hangers 3 Rubber or Neoprene Mounts 4 Concrete Inertia Base 4 Plate Bases 4 Acoustic Louvers 5 INSTRUMENTS AND GAUGES .................................................................... 5 Pressure Gauges 5 Thermometers 6 Dial Type Thermometer 6 Manometers 6 CONTROL SYSTEMS ................................................................................... 7 General 7 Temperature Humidity Sensor and Controller 8 Control Valves 10 Motorized Control Dampers 10 Step Controllers 11 Standard Control Interlocks 11 Control System Conduits and Wiring 12 Start up and Commissioning 12 Guarantee 12 CHILLED WATER TREATMENTS .............................................................. 13 Start up Chemicals 13

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9 9.1 9.1.1 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.5 9.5.2

Section 22: Air Conditioning, Refrigeration and Ventilation Part 09: Accessories

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ACCESSORIES

9.1

GENERAL

9.1.1

Scope

1

This Part details the requirements for accessories that are to be included as specified in the Project Documentation.

2



General Instrumentation control and Automation Electrical Works

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This Section Part 5

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9

SOUND AND VIBRATION CONTROL EQUIPMENT

9.2.1

General

1

The noise produced by the installation in the spaces served, in adjacent buildings and in the open air surrounding plant rooms shall be kept as low as possible. This shall be specially considered in the selection of fans (including those for condensers and cooling towers), motors fan coil units and terminal units, grilles and diffusers and the internal finish and arrangements distribution ducting.

2

All plant and equipment shall be isolated in such a manner that noise and vibration is not transmitted through the structure.

3

Anti vibration equipment will be manufactured by a specialist company acceptable to the Engineer with standard ratings information available.

4

All necessary provisions shall be included to reduce the noise level of all plan and equipment to the required level detailed in the QGEWC regulations.

9.2.2

Silencers

1

All silencers shall be fitted with drilled angle flanges to suit the adjacent plant.

2

The method of installing the acoustic elements in the casing shall not cause air leaks.

3

The acoustic elements shall incorporate full aerodynamic leading and trailing edges (not square ends).

4

The acoustic material installed in the element shall be inert, rot and vermin proof, nonhygnoscopic, non-combustible mineral wool or glass fibre acoustic medium.

5

The acoustic material shall be packed to a density of not less that 48 Kg/m and retained by a perforated steel sheet facing and fine membrane to stop the acoustic material contaminating the system air.

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Where required for water or grease laden duties an imperious but acoustically transparent membrane shall be fitted behind the perforated metal facing.

7

The silencer units shall be delivered to site with blocked ends to prevent the ingress of debris during installation and storage to reduce the risk of damage.

8

The silencers shall be constructed of heavy gauge steel and shall match the adjacent ductwork. Galvanized silencers shall not be used in stainless steel ductwork etc.

9

The silencers shall be factory manufactured and technical data submitted and approved in advance of ordering the units. The technical data shall include both the acoustic and aerodynamic performance.

10

Where a silencer is made under licence or part assembled locally, tests must be made after assembly and witnessed by an independent authority.

11

The static pressure loss of all silencers required shall be considered in all handling equipment original selection.

9.2.3

Anti-Vibration Mountings

1

All dynamic machinery shall be isolated from the building structure by vibration isolators and/or vibration isolation materials which shall be specifically designed and selected to suit the machinery for which it is to be used.

2

Spring anti-vibration mounts.

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each mounting shall consist of a telescopic top and bottom housing containing one or more helical steel springs of 50 mm minimum diameter as the principle isolation elements

(b)

the bottom plate shall be fitted with a 6 mm thick neoprene pad bonded to it to reduce high frequency flaming

(c)

when used with equipment having a fluid weight in excess of 25 % of the total empty equipment weight a suitable hold down or restrained shall be incorporated

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the mounting shall incorporate a built in levelling device and resilient inserts as guides for the upper and lower housings.

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(e)

all spring mounts shall be designed such that the lateral spring stiffness is equal to the vertical stiffness

(f)

the spring mounts shall be selected for all items of plant with stiffness to cater for any eccentric weight distribution over the unit base

(g)

an equal static deflection shall be provided on all mounts to avoid the possibility of flanking caused by the plant tilting and rendering one or more of the mounts solid.

9.2.4

Resilient Hangers

1

Resilient hangers shall be of the two element design with helical spring and neoprene in shear element.

2

The elements shall be mounted in a steel section pre-drilled and tapped at the top and bottom to receive threaded hanger rod.

3

The resilient hanger shall be located so that they are vertical.

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Rubber or Neoprene Mounts

1

The mounts shall consist of a steel top plate and base plate completely embedded in colour coded neoprene for easy identification of rated load capacity.

2

The mountings shall be moulded with non-skid ribbed construction on the top plate and base plate.

3

The mountings shall be equipped with bolt holes in the base plate and tapped holes in the top plate so that they can be bolted to the floor and equipment when required.

4

Plant and equipment as detailed in the QGEWC regulations shall be installed on antivibration units in the form of multi-layer rubber pads.

5

Multi-layer pads shall compose of rubber sheets with square grid pattern on both sides and steel insert sheets of 1.4 mm. The composite pad thickness shall be selected the suit the

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equipment but shall not be less than 32 mm. Concrete Inertia Base

1

The concrete inertia base shall be constructed of an all welded steel framework.

2

Height saving brackets shall be welded to the framework to install the anti-vibration mounts.

3

The frame depth shall be approximately 1½ the longest dimension of the equipment, with a minimum depth of 150 mm.

4

The bottom of the frame shall be blanked off and concrete (2,300 kg/m ) poured over steel reinforcing rods positioned 35 mm above the bottom.

5

The total weight of the base shall be at least 1.5 times the total equipment weight.

6

Concrete inertia bases for split case pumps shall be extended in width to allow for provision of supports for suction and discharge elbows.

7

When complete with the equipment installed checks shall be carried out to ensure that a positive air gap is present between the inertia base and floor.

9.2.7

Plate Bases

1

Where required equipment shall be mounted on anti-vibration rails or steel plant bases.

2

The anti-vibration rail shall comprise of steel beam with height saving brackets at each end.

3

The steel plant bases shall comprise of an all welded steel framework to support the equipment. This may form a composite A.V. rail.

4

The A.V. rails or steel plant bases shall be sufficiently rigid to provide adequate support for the equipment and prevent undue strain on the equipment.

3

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9.2.6

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Acoustic Louvers

1

All acoustic louvers shall be designed to reduce the airborne noise of plant down to minimum ambient levels with an air velocity not exceeding 3.0 m/s.

2

The louver aerofoils shall be constructed of perforated galvanized mild steel sheet and packed with a fibre acoustic medium as specified for silencers.

3

The complete unit shall be supplied complete or in sections with a galvanized mesh bird screen.

4

The unit shall be provided with all necessary fixing holes and lugs for location within a builders work frame.

5

The external finish of the unit shall be approved by the architect to match other finishes.

9.3

INSTRUMENTS AND GAUGES

9.3.1

Pressure Gauges

1

The pressure gauges shall be 100 mm diameter stainless steel case with black figures on a white background. The movement shall be stainless steel or phosphor bronze with rotary type movement and bourdon tube.

2

Where the line size is 100 mm or less the gauge is to be installed into a T-branch with

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subject to proper procedures and requirements of the Clause 1.1.17 of Part 1 of this Section. The gauges shall be mounted using a mild steel syphon and brass gauge cock.

4

The range of the gauges shall be selected such that the operating point is almost midway of the selected range.

5

Where gauges are to be mounted separate from the equipment to which they relate a gauge board shall be used. The gauges shall be fixed to resiliently mounted gauge boards with each gauge identified by a permanently fixed label

6

Where pressure gauges are mounted on the suction and discharge of pumps the gauges shall be connected to the tappings on the pumps when provided.

7

Pressure gauges shall be installed to monitor the pressure at the following locations.

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(a)

pump suction and discharge

(b)

chiller flow and return connections

(c)

AHU flow and return connection

(d)

heat exchange flow and return connections.

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9.3.2

Thermometers

1

Wet service thermometers shall be straight shank coloured mercury filled insertion type. They shall have a stem length of 80 mm and a scale length of 225 mm, and the capability of adjusting the angle of the scale to the stem. Copper or brass separable well shall be provided for each thermometer.

2

Air service thermometers shall be straight shank coloured mercury filled insertion type. They shall have a stem length of 150 mm and scale length of 225 mm, and the capability of adjusting the angle of the scale to the stem. The thermometers shall be graduated in °C with 2 °C divisions.

4

Where the temperature of equipment is to be monitored remotely, remote reading vapour actuated thermometers shall be used. The thermometer shall have a stainless steel case and phosphor bronze movement with 100 mm dial diameters with flush type back outlet. The

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connecting tube shall be double braided bronze armour over a copper capillary and copper bulb. Where thermometers are to be mounted separate from the equipment to which they relate a gauge board shall be used. The gauges shall be fixed to resilient mounted gauge boards with each gauge identified by a permanently fixed label.

6

Thermometers shall be installed to monitor the temperature at the following locations:

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chiller flow and return connections

(b)

AHU flow and return connections

(c)

heat exchangers flow and return connections.

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Dial Type Thermometer

1

The thermometers shall be 100 mm diameter vapour pressure type.

2

The casing and movement shall be non-ferrous material

3

The dial shall be white with black numbering

4

Dial type thermometers shall be installed as indicated in the Project Documentation.

9.3.4

Manometers

1

Incline or vertical manometers shall be plastic or metal construction. They shall be filled with coloured fluid to indicate the pressure being measured and have a zero adjustment for calibration.

2

The manometer shall be suitably sized for the pressures to be monitored.

3

The manometers shall be located in an accessible position so that the pressure can be recorded.

4

The tubing shall be neatly fixed and protected from damage when required.

5

Manometers shall be installed across all filters and the clean and dirty pressures shall be clearly identified.

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9.3.3

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CONTROL SYSTEMS

9.4.1

General

1

The Contractor shall include in his tender for an Automatic Control System to be supplied and engineered by a specialist controls supplier (SCS). In his choice of SCS, the Contractor must ensure that all systems to be supplied are fully and exactly compatible with the Project Documentation. The SCS shall be responsible for the entire control system. He shall allow for the supply, installation and commissioning of all items and materials necessary to achieve the control functions defined in this section and elsewhere in the Project Documentation. Subject to the Consultant's approval, control systems may also be supplied by the manufacturer of the equipment being controlled. Such manufacturer will be subject to the same terms and conditions as the SCS.

2

The SCS, as a specialist, will be aware of, and will include for any special services or conditions arising from any equipment to be supplied by the Contractor, whether the originally specified item or any proposed and approved alternate.

3

When the SCS staff are on site they shall work in close harmony with all other trades and shall assist other Subcontractors in works associated with the overall control system installation.

4

The SCS shall include in his costs for the preparation of all drawings, manuals, record drawings and labels as specified. He shall allow for the regular attendance on site of a qualified Engineer to provide technical liaison during the currency of the installation and ensure complete testing, commissioning, cleaning, making good and handing over of the works as detailed in this section.

5

The entire control system shall be complete with all necessary control devices, thermostats, valves, motors, relays, switches, dampers, panels, low voltage wiring, electronic components, etc., to provide the functions as described in this specification, or required, whether specifically mentioned or not. All controls shall be the product of one manufacturer, unless otherwise approved in advance.

6

The control system shall be installed or supervised complete in all respects by competent mechanics, regularly employed by the manufacturer of the control system.

7

All automatic control valves and dampers shall be manufactured by the control manufacturer or as otherwise specified and shall be installed in pipelines and ducts by the respective trade under the supervision of the control manufacturer. All electric wiring in connection with the control system shall be installed as hereinafter detailed.

8

Complete drawings shall be submitted to the Consultant for approval before any field installation is started. Such drawings shall give complete descriptions of all control elements and shall show complete schematic wiring diagrams including functional description. Drawing shall indicate specifically the type of finish of all room exposed controls, and such finish shall be subject to the Consultant's approval.

9

Any descriptive parts of this specification shall be considered complimentary to detail requirements for types of equipment. Any quantities noted are approximate and must be measured by the Contractor before bidding.

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10

Verification systems shall be interlocked with the fire alarm system as specified and as required by the Local Authority and all necessary control and interfacing devices shall be provided after fully co-ordination with fire alarm system controls.

11

Automatic control systems may be of the electromechanical or electronic type as described in the Project Documentation. Unless otherwise specified control systems shall be energised as follows: (a)

electric Control Systems 110 or 240 volts.

(b)

electronic Control Systems - Standard 24 volts

The installation may be a single system or a combination of systems. All control equipment including all control valves, dampers and actuators shall be selected sized and rated to suit the application and operating conditions of the systems in which they are installed to provide stable and repeatable performance of the systems being controlled.

13

All items of control equipment shall be compatible within any system, between systems and with controlled equipment.

14

All items of control equipment shall be sited such that access for adjustment and maintenance purposes is not impeded. However, where items of control equipment are mounted in accessible positions within normally occupied area, the control items shall be provided with secure tamper proof enclosures to prevent unauthorised interference.

15

Control system shall be arranged such that, in the event of electrical power failure or other abnormal operating conditions, inherent fail-safe features are provided to equipment and systems to prevent potentially hazardous conditions arising.

16

The sensitivity of sensors and the speed for response of actuators shall be selected for complete compatibility with the system application requirements.

17

All control components shall be of high quality, low risk rate and of long term reliability for both continuous and intermittent use and shall maintain accuracy and high repeatability of commissioned performance.

18

Where equipment requires less than 240 volts supply, all necessary voltage transformers shall be provided either separately or integrated with the various packaged equipment. Equipment requiring DC supply shall be provided with all current rectifiers and shall be suitable for the connected loads.

19

All controls shall be compatible with the existing building management systems when the system is an extension of an existing system.

9.4.2

Temperature Humidity Sensor and Controller

1

All temperature sensors shall be semiconductor type with NTC sensing element and shall have suitable range of operation i.e. 0 to 30C. 20 to 105C. etc. The housing shall be plug-in type with terminals on the base plate enabling the wiring without disturbing the sensor. The sensor shall be field wired using a unscreened cable to a base plate.

2

The temperature sensor shall have a tolerance of + 1C and a fast response time.

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QCS 2014

Elements sensing liquid temperature in pipework shall be: (a)

provided with means for withdrawal for calibration, servicing etc., without the need for draining the system

(b)

positioned so that the active part of the element is wholly within the liquid;

(c)

positioned so that the element is not less than 12 pipe diameters downstream from a point of mixing.

Elements sensing the temperature of air in a duct shall be positioned so that: the element is not subject to radiation

(b)

account is taken of temperature stratification, (i.e. positioning for high temperature limit sensing, positioning for average temperature sensing)

(c)

if of the capillary averaging type, it is installed on a suitable framework and is suitably arranged for servicing

(d)

if used for determining the dew point and the air adjacent to the element is known to be saturated within acceptable limits, the construction and material of the element shall be compatible for use in moist air.

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Elements sensing the temperature of a solid surface shall be positioned and fixed so as to give good thermal contact.

6

The precise location of site elements sensing the temperature of a room or other such space in a representative position shall be approved by the Engineer. where indicated it shall be at a height of approximately 1.7 m above floor level fitted in a room);

in the return air path where indicated.

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Room thermostats for FCU shall include a temperature set point with a remote sensor installed in return air duct work or as an integral part of the controller as specified a 3 speed switch for fan speed control and a fan-off-cool switch.

8

Humidity sensing element positions shall be:

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(a)

representative of the space in which the humidity is being measured

(b)

such that the air velocity is within the range required by the sensing element

(c)

arranged to ensure that the air reaching the elements is free from airborne contaminations.

9

Basically all sensing elements shall be correctly located strictly in accordance with the manufacturer as recommendations.

10

All controllers shall be fully proportional type with proportional band of upto 10 C. The dead zone between the stages shall be adjustable upto + 5 C. The controllers shall be of plug in type construction and shall be designed for removal from the pre-wired bases without disturbing the wiring. The electronic circuit shall amplify the deviation of the sensor signal from the setpoint on the controller to produce a fully proportional signal to modulate the controlled device such as three (3) way control valve etc.

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9.4.3

Control Valves

1

All control valves shall be selected and sized by the controls equipment manufacturer and shall be suitable for the systems application and operating conditions.

2

Unless otherwise stated valves shall be of the modulating type with adequate rangeability, having equal percentage or power linear characteristics.

3

Valves shall be provided with the following minimum valve lifts: valves up to 25 mm in size shall have a minimum lift of 8 mm

(b)

valves of 32 to 50 mm in size shall have a minimum lift of 12 mm

(c)

valves up to 65 mm in size shall have a minimum lift of 20 mm

.

(a)

Valve authorities shall generally be in the range of 0.3 to 0.5 but compatible with economic valve pressure drops sufficient to provide adequate control without promoting cavitation.

5

Actuators on all valve shall be capable of opening and closing the valves against the maximum system operating pressures,

6

All valves, other than on terminal units such as fan coil units shall be provided with external position indicators. They shall be complete with actuators, mounting brackets and all necessary auxiliary switches.

7

Seats and stems shall be removable and of stainless steel, except where alternative seating material is necessary to provide tight shut-off.

8

Valves upto 50 mm shall be of bronze bodies construction with stainless steel trim.

9

Valves of 65 mm size and above shall be of cast/nodular iron or steel bodies construction as suitable for the pressure and temperature conditions having stainless steel trim.

10

The copper content of alloy valves shall be as high as possible to avoid dezincification.

11

All valves shall be embossed with the manufacturer’s logo, valve size and direction of flow.

12

Valves, shall be provided with clutch or lifting mechanism to enable valves to be controlled manually in the event of power source failure.

13

Unless otherwise specified, control valve actuators for chilled water coils shall be fitted with spring returns to the safe position on failure of electrical supply, to provide necessary plant protection shut-off or relief conditions to systems or equipment.

9.4.4

Motorized Control Dampers

1

Control dampers and actuators shall be selected and sized to provide the desired power and performance characteristic in accordance with the control equipment manufacturer’s recommendations,

2

All damper shall be provided with a heavy duty and rigid mounting bracket and all necessary auxiliary switches.

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Mixing and volume control dampers shall be of the modulating type. (a)

actuators shall be provided with spring returns where they are specified to open or close on power failure

(b)

all fresh air dampers shall close on power failure of emergency and normal plant shut down

(c)

all actuators shall be provided with position and direction indicators.

Mixing and throttling dampers shall be sized to provide adequate control over the full movement of the dampers, giving near linear characteristics without incurring high pressure drops which should not exceed 10 % of the controlled circuit pressure drop when fully open.

5

Rotation angle of the damper motor spindle shall where possible correspond with the required operating angle of the damper to which it is connected.

9.4.5

Step Controllers

1

Step controllers shall have adjustable differential and time delay between operations of each step and speed of loading and unloading. Each stage shall operate in sequence. The controllers shall be capable of interlocking with each other for series operation from the same sensor output.

2

The controllers shall recycle to ensure that on normal shut-down, power failure or manual interruption of the power supply, the controllers recycle to the "off' position before reenergising the controlled circuits.

3

All contacts shall be suitably rated for the imposed load or loads

4

Where used to control electric air heaters, step controllers shall be heaters on in three phase balanced stages not exceeding 9.0 kW except that stages up to 3 kW may be single phase, providing the does not vary by more than 4 ºC. per stage. A time delay of not less precede each stage after the first on loading heaters.

5

Switching condition shall be indicated by lamps on the front face of the controller.

9.4.6

Standard Control Interlocks

1

Unless otherwise specified the following equipment interlocks shall be provided:

arranged to switch the per three-phase stage supply air temperature than five seconds shall

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(a)

provide timers in the control circuits of all pumps to enable the pumps to continue to run for a period after such-down of cooling plant

(b)

on plant start up and shut down operation, control circuits shall be arranged for staggered switching of motors to avoid simultaneous large electrical loads being imposed on the power cabling and power plants

(c)

under normal operating conditions, the extract fan starters shall be interlocked with their respective supply fan starters and stop locks

(d)

humidifiers and electric heater batteries shall be interlocked with their associated supply air fan to shut down the humidifier and electric heater battery when the supply fan stops, or on power failure

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fresh air inlet and discharge dampers shall close on normal plant shut down and power failure. Operation from smoke detectors shall be as specifically required by the local authority or as per the dictable of the fire alarm and control system

(f)

on full fresh air plants the air inlet dampers shall open before the fan can operate, by use of damper motor end switches

(g)

where duty and stand-by pumps are provided, the selected duty pump shall start and operate as required. Should the duty pump fail to start, a fault alarm shall be given and the stand-by pump, after a pre-set period, shall operate. The same automatic change-over sequence shall apply should a pump fail during normal running

(h)

when electric heating batteries and cooling coils are to be operated in sequence a dead zone shall be provided between each sequence

(i)

all chilled water valves shall close on all plant shut down conditions unless otherwise stated.

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(e)

Control System Conduits and Wiring

1

Wherever possible conduits are to run in poured concrete from control points to equipment locations. Terminations at both ends are to be standard electrical junction boxes. All conduit work will be done in accordance with the relevant provisions of Section 21, Electrical Works, and shall be undertaken by the Electrical subcontractor, In the event that conduit work is not undertaken at the time of concrete pouring, then the specified conduit shall be used and run on the surface, except in areas where surface conduit would be unacceptable to the Consultant.

2

Wiring shall be done in accordance with the relevant provisions of Section 21, Electrical 2 Works, with the minimum wire size of 0.8 mm with an outer metal screen for extra low 2 voltage systems and 1.5 mm for line voltage systems. In any event all wire sizes shall be calculated to ensure proper voltage conservation up to actuator points.

3

Wiring shall be the responsibility of the specialist control supplier (SCS) but may be done by the Electrical subcontractor under the supervision of the SCS.

9.4.8

Start up and Commissioning

1

After completion of the control system installation, the control supplier shall regulate and adjust all thermostats, control valves, damper motors, etc., and place them in complete working order subject to the approval of the Consultant.

2

Complete instructions shall be given to the operating personnel. Such instructions shall be exclusive of the time required for regulating and adjusting.

9.4.9

Guarantee

1

The control system herein specified shall be free from defects and workmanship and material under normal use and service. If within 400 days from the date of practical completion certificate any equipment herein described is proved to be defective in workmanship or material, it shall be adjusted, repaired or replaced free of charge.

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The SCS further guarantees that all components used on the project are State-of-the-Art components and that parts and service, etc., will be fully available for them for a period of at least 10 years after the date of acceptance. In the event of non-availability at any time in this period, the SCS is to replace the particular class of item with a similar functional item for which spares, service, etc., are available.

9.5

CHILLED WATER TREATMENTS

1

The chilled water system shall be prepared as detailed in Part 5, Chilled Water Pipework. The system will then be further treated.

2

Prior to testing and commissioning, the Engineer shall be provided with a water conditioning programme, to control water quality. Cleaning shall be supervised, and programme of conditioning administered by the conditioning company.

3

For pre-commission cleaning, the system shall be dosed with the prescribed amount of the non-acid cleaning agent and a surfactant as advised by the company supplying the chemicals

4

The cleaning agent shall be run into the system and retained for a period of 72 hours or more as advised by the company supplying the cleaning agent. At the end of this period the system shall be drained and flushed with clean water.

5

All strainers and trapping points shall be inspected, and any debris removed while the chemicals are being circulated.

6

System shall be refilled with clean water, re-circulated or run through for a further four hours, and again drained and flushed. The flushing shall continue till the effluent is clear, colourless, odourless, free from suspended solids and such that the iron level is not more than 10 ppm and the conductivity is no more than the make up water.

7

Upon completion of flushing all strainers shall be inspected and any debris removed.

8

The system shall be refilled with clean water and a specified amount of inhibitor added.

9

The Contractor shall arrange for an analysis of the system's water after the cleaning operation, and shall submit a report to the Engineer.

9.5.2

Start up Chemicals

1

The supply of all chemicals for system start up shall be the scope of this Contract. Chemicals sufficient for contractual maintenance period shall be arranged by the Contractor.

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END OF PART

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GENERAL ...................................................................................................... 2 INTRODUCTION ........................................................................................... 2 Scope 2 General 2 REGULATIONS ............................................................................................. 2 Electrical Installations 2 Civil Defence Department 2

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Section 23: Fire Fighting and Fire Alarm Systems Part 01: General

QCS 2014

Section 23: Fire Fighting and Fire Alarm Systems Part 01: General

Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for fire fighting systems, fire alarm systems and fire protection systems.

1.1.2

General

1

The Clauses in this Specification and all other information provided in the Project Documentation shall be considered to be a minimum requirement for performance and quality.

2

All electrical and electronic equipment shall be designed, manufactured, erected and tested to the International Electrotechnical Commission (IEC) standards.

1.2

REGULATIONS

1.2.1

Electrical Installations

1

All electrical installations shall comply with all the relevant provisions of the regulations of the following:

2

Qatar General Electricity & Water Corporation

3

Institution of Electrical Engineers.

1.2.2

Civil Defence Department

1

The entire fire alarm system, fire protection system and fire fighting system including all materials, components, equipment and accessories and their installation shall conform to the requirements of Civil Defence Department of the Ministry of Interior, State of Qatar. Particular attention should be made with respect to the time required by the Civil Defence Department for approval of schematic and wiring diagrams, layout diagrams etc.

2

The fire alarm system contractor shall be registered with, and on the approved list of, the Civil Defence Department.

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END OF PART

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FIRE ALARM AND DETECTION SYSTEMS ................................................. 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 Contractor‟s Responsibility 2 System Description 2 Quality Assurance 3 CABLING ....................................................................................................... 3 General 3 Cables 3 Insulation 3 CONTROL PANEL......................................................................................... 4 General 4 Fabrication 4 BATTERIES AND CHARGING EQUIPMENT ................................................ 6 General 6 Batteries 6 Battery Chargers 6 DETECTORS ................................................................................................. 6 General 6 Optical Smoke Detectors 7 Combined Smoke and Heat Detectors 7 Heat Detectors 7 Duct Mounted Smoke Detectors 7 Infra-Red Flame Detectors 8 Remote Indicating Lights 8 ALARMS ........................................................................................................ 9 Manual Fire Alarm Call Points 9 Alarm Bell 9 Electronic Sounders 9 Alarm Lights 10

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2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.6 2.6.1 2.6.2 2.6.3 2.6.4

Section 23: Fire Fighting and Fire Alarm Systems Part 02: Fire Alarm and Detection Systems

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FIRE ALARM AND DETECTION SYSTEMS

2.1

GENERAL

2.1.1

Scope

1

This part specifies the requirements for the material, installation, testing and commissioning of fire alarm and detection systems for use within buildings. It covers all the system components for efficient operation.

2.1.2

References

1

The following standards and references are referred to in this Part:

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BS 5445 ......................Components of automatic fire detection systems

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BS 5839 ......................Fire detection and alarm systems for building

BS 5306 ......................Fire extinguishing installations and equipment on premises

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BS 6360 ......................Conductors in insulated cables and cords Contractor’s Responsibility

1

The Contractor shall arrange for an approved sub-contractor, to supply, install, wire and commission the complete manual/automatic fire alarm system comprising manual fire alarm call points, alarm bells and sounders, smoke and heat detectors optical smoke detectors, combined smoke and heat detectors, duct mounted smoke detectors, flame detectors, alarm heights (xenon beacon), remote indicating lights‟ and control panels as indicated on the drawings. The system shall be designed, installed and maintained in accordance with the recommendations of BS 5839.

2.1.4

System Description

1

The Contractor shall provide and install the system in accordance with the Project Documentation, applicable codes and manufacturer‟s recommendations.

2

Fire alarm panels, repeater panels, detection components, alarm components, cables, other materials and their installation shall be approved by Civil Defence Department, Ministry of Interior, State of Qatar.

3

The fire alarm system sub-contractor shall be registered with, and on the approved contractors list of the Civil Defence Department.

4

The fire alarm and automatic detection systems shall meet the requirements and comply with the relevant British Standards and shall meet the requirements of National Fire Protection Association.

5

The system shall be suitable for 240 V, 1 phase, 50 Hz power supply and be complete with standby sealed lead acid gas-recombination type long life batteries and charger to provide a 24 V DC for detection and alarm system.

6

Where the installation extends beyond more than one building the system in each building shall be self-contained with visual and audible alarms. A common fire alarm and common fault signal from each system shall be displayed on the control room repeater panel.

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2.1.3

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2.1.5

Quality Assurance

1

Items and equipment specified in this part shall be provided by experienced and approved manufacturers and contractors as designated in the Project Documentation or to the written approval of the Engineer. All equipment shall be UL listed and shall be supplied from the same manufacturer who has a minimum of 10 years experience in the active manufacturing of fire alarm systems.

2.2

CABLING

2.2.1

General

1

The wiring size shall be not less than 1.5 mm for call/detector circuits and 2.5 mm for bell and battery circuits. The system shall be of the two wire type.

2

Cabling in fire alarm detection systems shall comply with the relevant provisions of BS 6883 and BS 5839.

3

In enclosed work areas and accommodation areas, zero halogen type cables shall be used.

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Cables shall be able to withstand the IEC 331 gas flame test, enhanced to 3 hours at 950 C.

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Conductors shall be circular tinned wires complying with the relevant provisions of BS 6360, Class 2.

5

The Contractor shall provide and install the system in accordance with Project Documentation, applicable standards and manufacturer‟s recommendations. All wiring shall be in a conduit system which is separate from other building wiring. Junction boxes shall be sprayed red and levelled “Fire Alarm”.

2.2.2

Cables

1

Fire alarm cables shall be rated for 600/1000 V grade unless otherwise stated in the Project Documentation.

2.2.3

Insulation

1

Fire alarm system cables shall have the following type of insulation as specified in the Project Documentation:

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(a)

pressure packed magnesium oxide insulation

(b)

a composite insulation of mica impregnated glass tape beneath an extruded layer of ethylene propylene rubber (EPR)

(c)

silicone rubber insulation.

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CONTROL PANEL

2.3.1

General

1

The main fire alarm control panel shall be located in the main control room and shall be wall mounted. The fire alarm system shall protect all risk areas within the premises by giving warning of a fire condition when detected by an automatic detector or by the manual operation of a break glass call point. The risk area shall be divided into zones and each zone shall have its own fire indicator on the control unit. The control and indicating equipment, power supply unit and repeater panels shall comply with the electro-magnetic compatibility (EMC) test requirements described in BS 5839 and the Electronic Engineers Commission (EEC) requirements for the EMC directive 89/336/EU and the subsequent amendment 92/31/EU.

2

A diagram shall be provided adjacent to the control panel showing the general layout of the building and the fire zones. The diagram shall be engraved with black paint filling on a white ebonite sheet of thickness not less than 2 mm. The letter height shall be 5 mm. The diagram shall be coloured to show the extent of the area covered by each fire zone. A different colour shall be used for each zone.

3

Upon receipt of an alarm, the control units shall perform the following actions:

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illuminate fire zone detector

(b)

activate alarm warning devices within the building

(c)

operate internal fire sounder

(d)

operate ancillary devices as appropriate

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Alarm warning devices shall be de-activated by operation of the „Silence Alarms‟ switch. The internal sounder will continue to operate and the fire indicators remain lit until the key switch controlled push switch is operated. This should only be achieved if the alarm initiating device is no longer in alarm.

5

Reset of the controller, after the fire incident has been investigated, will be achieved by operation of the „Reset‟ switch.

6

The fire alarm panel shall comply with BS 5839 Part 4 and requirements herein and be suitable for installation of fire detection and alarm systems to BS 5839 Part 1.

2.3.2

Fabrication

1

The panel shall be of the multi-zone, modular type and capable of extension. The number of zones shall be related to the requirements of the individual buildings and shall be agreed with the Engineer. As a minimum, the fire alarm panel is to be wall mounted and suitable for 6 zones with all modules installed.

2

A lockable smoked glass door shall protect the face of the panel from access by unauthorised personnel.

3

The enclosures of panels shall be fabricated from sheet steel, minimum thickness 1.5 mm and shall be provided with a hinged lockable door. Protection to at least IP54 shall be provided.

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Control panels shall as a minimum requirement be equipped with the following: mains supply on indicator

(b)

DC supply faulty indicator

(c)

alarm indicator for each zone

(d)

alarm accept push-button to acknowledge fire alarm signals, silence external audible alarms and energise an internal bleeper unit or sounder

(e)

reset push-button to restore monitoring systems to the inactive condition

(f)

integral sealed battery and trickle battery charger where appropriate

(g)

alarm transmission facilities via the telephone alarm system (this facility shall be provided for future use if not utilised under this Contract)

(h)

termination for incoming and outgoing wiring systems

(i)

voltage free normally closed circuits which shall open in the event of an alarm to shutdown ventilation and air conditioning equipment in the immediate vicinity of the alarm

(j)

suitable fault indication (both visual and audible)

(k)

interfacing facility to connect to Civil Defence Department system

(l)

interfacing facility to control elevator system

(m)

interfacing facility to control air handling units (AHU) of the HVAC systems

(n)

interfacing facility to control fire doors/dampers.

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Alarm indicators shall be of the light emitting diode type. Indicators shall be provided in pairs for each function.

6

Control panels shall continuously monitor all alarm circuits, including wiring and control devices. When a fault monitoring circuit has been energised it shall not rest until the fault condition is cleared.

7

The control panel shall include the following: (a)

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(b)

power supply fault light (amber LED)

(c)

battery charger fault light (amber LED)

(d)

general evacuate push button

(e)

silence alarm push button

(f)

reset push button

(g)

common fire light (twin red LED)

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power supply normal light (green LED)

8

Repeat facilities shall be available for common fire and fault conditions. In addition, two normally open/normally closed (NO/NC) volt free auxiliary contacts each rated at 2.5 amps (inductive) for 24 V DC and 240 V AC shall be available

9

Cable entries are to be made from knock-outs located on top and bottom of the fire alarm panel.

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The removal of any detector(s) shall not effect the performance of other detectors in the system.

11

The sensitivity of any of the sensors shall be adjustable from the control panel.

2.4

BATTERIES AND CHARGING EQUIPMENT

2.4.1

General

1

The system shall be of the 24 V DC, monitored, open circuit type utilising transformed and rectified mains voltage supply under all normal circumstances but with stand-by provision in the form of rechargeable sealed lead-acid batteries.

2.4.2

Batteries

1

Batteries shall have a capacity capable of maintaining the system in normal working condition for at least 24 hours and in the alarm state for at least 30 minutes without recharging unless otherwise stated in the Project Documentation.

2.4.3

Battery Chargers

1

Battery chargers are to be of sufficient capacity to power the system whilst recharging a fully discharged battery. The battery shall be fully charged within 8 hours.

2.5

DETECTORS

2.5.1

General

1

Detectors shall conform to the relevant provisions of BS 5445 and be fully compatible with the system offered and shall comprise a fixed base which can be used with other types of detector head.

2

The base shall have fixed non-corroding terminals and contain no electronic components.

3

The head shall comprise the sensing elements which shall be housed in a corrosion proof enclosure which can be fixed to the base by a bayonet or plug-in twist-lock mechanism.

4

The sensing elements shall be exposed to the atmosphere through a protective cover which will allow free movement of air but provide a high degree a resistance to dust and insects. A small drain hole shall be included to allow any condensation to drain.

5

Integral LED‟s shall be provided which will confirm operation and also permit detector testing.

6

The removal of a detector from its base shall cause a fault signal to be indicated.

7

It shall be clearly stated on the head of the detector the type of element it contains or the principle on which the detector operates.

8

All detectors shall operate at a nominal voltage of 24 V DC and shall exhibit long-term stability and reliability under the prevailing conditions at the installation location.

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Optical Smoke Detectors

1

The sensors shall utilise the light scattering principle. They shall employ a photoelectric cell and light source so arranged that only light scattered by smoke particles falls on the photoelectric cell.

2

The Optical smoke detector shall respond to the visible smoke produced by smouldering or burning materials.

3

The detector shall be fully operational after initiation of an alarm without any maintenance.

2.5.3

Combined Smoke and Heat Detectors

1

Combine smoke and heat detector shall comprise of two chambers. One chamber containing the photoelectric smoke detector and the other chamber shall contain the heat detector.

2

The smoke detector shall utilise a horizontal optical bench construction which houses the detector and the optical sensor. The detector shall be arranged for radial detection of forward scattered light.

3

The heat detector shall operate at fixed temperatures set at 57 C, 71 C or 99 C to trigger the alarm. The setting shall depend on the application and as specified in the Project Documentation.

4

The detector shall be fully operational after initiation of an alarm without any maintenance.

2.5.4

Heat Detectors

1

The detector shall be a combined unit including both fixed temperature element and rate of rise temperature element.

2

Each heat detector shall incorporate a dual thermal element which responds to either an excessively high temperature or a rate of rise of temperature which is unacceptable.

3

The heat detector shall operate on the principle that one element is exposed to the atmosphere whilst the other is contained in such a way that it is not so readily affected by increasing temperature. At a certain rate of rise of temperature or at a pre-set fixed temperature, the imbalance between the two elements shall cause the detector to trigger.

4

The fixed element of the heat detector shall be the type that can be reset for renewed detection. The detector shall be fully operational after initiation of an alarm without any maintenance

2.5.5

Duct Mounted Smoke Detectors

1

Duct smoke detectors shall be provided in the main return air duct adjacent to each air handling unit (AHU).

2

They shall be of the duct mounted type and initiate alarm in case of a developing fire. These shall be provided with two sampling tubes. The first, an inlet tube for intake of air from the duct to the sensor assembly. The second, an exhaust tube to allow air to leave the assembly.

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3

Duct smoke detectors shall be interlocked with the air handling unit motor and volt free contact shall also be provided to raise an alarm on the main fire alarm panel. Installation of duct mounted detectors shall be approved by the Air Conditioning Section of QGEWC.

2.5.6

Infra-Red Flame Detectors

1

The infra-red flame detectors shall be capable of detecting infra-red radiation produced by flaming fires involving carbonaceous materials.

2

The infra-red flame detectors shall be approved and listed by the Loss Prevention Council Board (LPCB) and manufactured under the appropriate category by the Underwriters Laboratories, Inc. (UL), and shall bear the “UL” mark.

3

The infra-red flame shall be able to detect a fuel fire of 0.1 m area from a distance of 30 m for the following fuels:

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N-heptane

(c)

kerosene

(d)

diesel oil

(e)

alcohol

(f)

ethylene glycol

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(a)

The infra-red flame detectors shall employ narrow band optical filters that block unwanted radiation such as that emanating from the sun or tungsten filament lamps.

5

The infra-red flame detectors shall be designed to be sensitive to modulation of the received radiation in a small range of frequencies corresponding to the flicker of flames.

6

The infra-red flame detectors shall be designed to have high resistance to contamination and corrosion.

7

The electronic assembly of the infra-red flame detectors shall be encapsulated in high resistivity epoxy resin.

8

The infra-red flame smoke detectors shall include radio frequency interference (RFI) screening and feed through connecting components to minimise the effect of radiated and conducted electrical interference.

9

The infra-red flame detector shall incorporate an LED, clearly visible from the outside, to provide indication of alarm actuation.

2.5.7

Remote Indicating Lights

1

All fire detectors shall be provided with remote indicator facility. The remote indicator output shall diode gated for protection against electrical interference generated along the remote indicator wiring and to enable one remote indicator to be connected to a number of detectors. The remote indicator shall be polarity independent and operate at constant brightness over the range of 8-28 V.

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ALARMS

2.6.1

Manual Fire Alarm Call Points

1

Manual fire alarm call points shall consist of a die cast plastic enclosure with a die cast plastic cover locked in position with screws. The enclosure shall house a micro switch. The micro switch plunger shall bear onto an inset break glass panel fixed into the cover. The call point shall be arranged for surface or flush mounting as appropriate. The cover and the enclosure shall be self coloured red. The words „BREAK GLASS FOR ALARM‟ shall be printed on the frangible glass. A testing facility using a special key shall be provided to enable the call point to be tested without breaking the glass and the frangible glass shall be covered with plastic film to prevent injury when the glass is broken. The mounting height shall be 1400 mm above finished floor level.

2

The switching unit contacts shall be gold or silver plated or on alloyed metal which will not corrode when left unattended in a highly polluted environment. Contact blades and other metal parts of the switching unit shall also be constructed form plated or alloyed metal which will not corrode when left unattended. Contacts shall be normally open or normally closed to suit the alarm monitoring system. The voltage and current rating of the contacts shall be marked within the enclosure. The items shall have approval and listing by the LPCB (Loss Prevention Council Board).

3

The call point shall be suitable for direct connection into the wiring system, and shall comply with the relevant provisions of BS 5839: Part 2.

4

The call point shall be resistant to the ingress of dust and water to IP55.

2.6.2

Alarm Bell

1

Red underdome indoor fire alarm bells shall be installed in locations complying with the relevant provisions of BS 5839 and in locations as indicated in the Project Documentation. Each bell shall be suitable for 24 V DC operation and shall be polarised. The output shall not be less than 90 dBA at 1 m distance. 150 mm diameter underdome bells shall be used indoors and 225 mm diameter underdome bells shall be used outdoors. Outdoor underdome bell shall be to IP44.

2

Alarm bells shall be of the gong type. They shall be continuously rated and mounted 2200 mm above finished floor level.

3

Bells shall be painted red and marked with the words “FIRE ALARM”.

4

Each bell or sounder circuit shall have a separate fuse at the fire alarm control unit.

2.6.3

Electronic Sounders

1

Electronic Sounders shall comply with the relevant provisions of BS 5389 and BS 5306 and shall be suitable for 24 V DC use. These sounders shall be coloured red and be polarised, suppressed and suitable for line monitoring. Electronic sounders are to have a low current consumption of approximately 30 mA but have a minimum output of 100 dBA at 1 m.

2

The electronic sounder shall be capable of providing at least two distinct and different sounds and be suitable for “on site” adjustments.

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2.6.4

Alarm Lights

1

Visual flashing alarm lights shall be located above doors and openings as indicated in the Project Documentation. They shall be of the xenon flashing type and suitable for 24 V DC. The wording “Fire” shall be prominently displayed when this alarm is activated.

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END OF PART

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Section 23: Fire Fighting and Fire Alarm Systems Part 03: Analogue Addressable Fire Alarm System

Page 1

3

ANALOGUE ADDRESSABLE FIRE ALARM SYSTEM ....................................... 2

3.1

INTRODUCTION ................................................................................................ 2

3.1.1 3.1.2 3.1.3 3.1.4

Scope References and Compliance General Quality Assurance

3.2

AUTOMATIC FIRE DETECTORS....................................................................... 4

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8

General Optical Smoke Detectors High Performance Optical Smoke Detectors Beam Smoke Detectors Aspirating Smoke Detectors Heat Detectors Linear heat detectors Infra-Red flame detectors

3.3

ENGINEERING ................................................................................................. 10

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

System Management Facilities Technical specification Cabling Addressable Manual Call Points Manual Pull Stations

3.4

MODULES ........................................................................................................ 13

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9

Remote Indicator Module Conventional Detector Interface Module Addressable Relay Output Module Addressable Contact Monitoring Module Addressable Sounder Driver Module Sounder Booster Module Addressable Power Supply Module Smoke Damper Module Plant Interface Module

3.5

MONITORING .................................................................................................. 16

3.5.1 3.5.2 3.5.3 3.5.4 3.5.5

Fire monitoring Fault and Warning Monitoring Supervision and Fault Reporting Alarm Output Functions Voice Evacuation Systems

3.6

INSTALLATION ................................................................................................ 20

3.6.1 3.6.2 3.6.3 3.6.4

General Installation of Detectors Installation of Control Devices Installation of Fire Controller Equipment

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ANALOGUE ADDRESSABLE FIRE ALARM SYSTEM

3.1

INTRODUCTION

3.1.1

Scope

1

This part specifies the requirements for the material, installation, testing and commissioning of services for analogue addressable fire alarm systems for use within buildings.

2

Fire alarm panels, repeater panels, detection components, alarm components, cables, other materials and their installation shall be approved by Civil Defence Department.

3

The fire alarm system contractor shall be registered with, and on the approved contractors list of, the Civil Defence Department.

3.1.2

References and Compliance

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BS 5839...................... Fire detection and alarm systems for buildings:

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BS 5445 ..................... Components of automatic fire detection systems: detectors

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BS 5501...................... Electrical apparatus for potentially explosive atmospheres BS 7671...................... IEE Wiring regulations

Where applicable, the fire detection and alarm system and its installation shall comply with the relevant standards, regulations, rules and recommendations of the following:

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British Standards National Fire Prevention Association Underwriters Laboratory, Inc. Loss Prevention Council Board

BS NFPA UL LPCB

Where applicable, the fire detection and alarm system and its installation shall comply with the relevant standards, regulations, rules and recommendations of the Civil Defence Department, Ministry of the Interior, State of Qatar.

3.1.3

General

1

The control and indicating equipment shall form the central processing unit of the system. It shall receive and analyse signals from fire sensors, providing audible and visual information to the user. It shall also initiate automatic alarm response sequences and providing the means by which the user interacts with the system. The housing enclosure shall be constructed to IP22 unless otherwise stated elsewhere in the Project Documentation.

2

The control and indicating equipment shall be modular in construction to allow for future extension of the system.

3

The control and indicating equipment shall be easily configurable so as to meet the exact detection zone and output mapping requirements of the building.

4

The control and indicating equipment shall be microprocessor based and operate under multitasking software program. Operating programs and configuration data must be contained in easily up-datable non-volatile memory (EPROM).

5

The control and indicating equipment shall incorporate a real-time clock to enable events to be referenced against item and date. This clock shall be accurate to within 1 minute per year under normal operating conditions.

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It shall be possible for an engineer to perform configuration updates on site by plugging a portable personal computer in to the control and indicating equipment. Configuration data shall be retained in an electronic (disk) format.

7

The company responsible for the installation shall operate an approved document control system for the retention of configuration data.

8

The control and indicating equipment shall meet the requirements of BS 5839 Part 4 and shall be approved, together with associated ancillary equipment, by the Loss Prevention Council Board (LPCB).

9

The control and indicating equipment shall comprise separate processors, cross-monitoring each other‟s correct operation, for the major functions of the system. In particular, different processors must be used for the main control function, the detection input and alarm output functions, and the display and control function.

10

No more than 200 addressable input or output points shall be controlled by a single processor.

11

To ensure continuous stability of the system, the setting of the address code in each addressable device shall be by either a DIL switch in the detector base or small card technology in addition to the adjustment provision in the central control panel.

12

In the case of plug-in analogue addressable detectors, the address code shall be set in the base to prevent unauthorised and potentially dangerous reconfiguration of the system.

13

The control and indicating equipment shall incorporate a key-switch with three positions “Normal”, “Trapped Normal” and “Enable” to prevent unauthorised use of the manual controls.

14

The control and indicating equipment shall be capable of operating with any of the following types of automatic detection equipment: conventional detectors

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(c)

analogue addressable detectors

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two-state addressable detectors

The control and indicating equipment shall be capable of operating with intrinsically safe conventional detectors and intrinsically safe analogue addressable detectors suitable for installation in hazardous areas.

16

Addressable input and output devices shall be connected to addressable loops capable of accepting up to 99 devices for cable lengths not exceeding 1 km.

17

The control and indicating equipment shall have a minimum capacity for operating 1 fully loaded addressable loop. This shall be extendible up to a maximum capacity of 10 addressable loops.

18

Provision shall be made for each addressable loop to be sub-divided into different geographical zones. The section of wiring corresponding to each zone circuit shall be protected from faults in other sections by line isolator modules. It shall be possible to allocate all 99 addressable devices on the loop to a single zone.

19

In order to facilitate re-configuration and system extension, the allocation of addresses to devices shall be independent of their physical arrangement on the loops.

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The control and indicating equipment shall have provision to drive and monitor up to 20 repeater panels providing a repeat of the indications on the control and indicating equipment display and up to a further three (3) repeater panels also incorporating the full set of system manual user controls.

21

The control and indicating equipment shall have provision to house the main power supply unit and the batteries required to power a systems of up to sixteen (16) zones.

22

The control and indicating equipment shall have provision for the connection of external power supplies, either local to the control and indicating equipment or distributed throughout the system, to supply power in excess of that stated as above.

23

The control and indicating equipment shall have provision for the connection of an 80 character line printer, either locally via a parallel port or remotely via a serial port. The fire alarm control panel shall be provided with a built-in printer, if specified in the Project Documentation.

24

The control and indicating equipment shall be capable of interfacing directly to an electronic radio paging system.

25

The control and indicating equipment shall be capable of being interfaced with the similar control and indicating equipment without locking up or being affected by feedback signals.

26

It shall be possible to connect a VDU monitor to the control and indicating equipment to display the information that would otherwise appear on the printer referred to in Clause 3.1.324.

27

The control and indicating equipment shall have the facility to enable an on board communications module to be added to allow local area networking to other controllers.

3.1.4

Quality Assurance

1

Items and equipment specified in this part shall be provided by experienced and approved manufacturers and contractors as designated in the Project Documentation or to the written approval of the Engineer.

3.2

AUTOMATIC FIRE DETECTORS

3.2.1

General

1

The system may include, but not be limited to, the following types of automatic detectors, manual call points and line modules for direct connection to the system addressable loops:

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(a)

ionisation smoke detectors

(b)

optical smoke detectors

(c)

high performance optical smoke detectors

(d)

infra-red flame detectors

(e)

heat detectors

(f)

manual call points for indoor use

(g)

(manual call points for outdoor use

(h)

ionisation smoke detectors for hazardous areas

(i)

optical smoke detector for hazardous areas

(j)

infra-red flame detectors for hazardous areas

(k)

conventional detector interface module

QCS 2014

(l)

addressable relay interface module

(m)

addressable contact monitoring module

(n)

addressable sounder driver module

(o)

addressable voice alarm module

(p)

addressable power supply module

(q)

line isolator module

(r)

special detector interface module

Page 5

The system may include, but not be limited to, both an analogue addressable and a two state addressable version of the following type of automatic fire detectors: ionisation smoke detectors

(b)

optical smoke detectors

(c)

high performance optical smoke detectors

(d)

infrared flame detectors

(e)

manual call points for indoor use

(f)

manual call point for outdoor use

(g)

sounder booster module

(h)

remote indicator module

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(a)

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The automatic fire detectors shall be fixed to the installation by means of plug-in detector bases.

4

The addressable base must incorporate all the circuitry required for communicating detector status to the control and indicating equipment, including the address setting switch.

5

Addressable detectors and modules must be able to transmit to the control and indicating equipment a pre-set and unique identifier to detect unauthorised changes in the system configuration.

6

It shall be possible to program and adjust the sensitivity of any of the detectors in the system from the central panel in addition to the local setting facilities. Removal of any detector shall not affect the performance of other detectors in the system

7

It shall be possible to program for automatic adjustment of sensitivity settings of the detectors on time-zone features, if required, for different hours of the day, for different days of the week, or for different months of the year.

8

The Contractor shall provide standard accessories for installing detectors in air ducts. This equipment shall be designed to accommodate the manufacturer‟s standard smoke detectors and bases, both conventional and addressable. All such detectors to be installed in the air duct system shall be approved by the Air Conditioning Section of QGEWC, Qatar.

9

It must be possible to connect and mix automatic detectors, manual call points and addressable modules within the same zone sub-division of an addressable loop.

10

All types of automatic detectors, the plug-in bases and the line isolator shall be intrinsically safe

11

The addressable contact monitoring module for connection of „simple apparatus‟ such as conventional manual call points shall be intrinsically safe.

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The intrinsically safe devices shall be designed to comply with the relevant provisions of BS 5501: Pt 7 and be certified by BASEEFA (British Approval Service for Electrical Equipment in Flammable Atmosphere) to EEx i IIC T5.

13

It shall be possible to connect several circuits of intrinsically safe addressable devices to a standard addressable loop via standard BASEEFA approved safety barriers from the loop as spurs.

14

All equipment connected to the system addressable loops, either directly or via interfaces, shall be proofed against electrical noise, high frequency pulses and electromagnetic influences from other equipment.

15

Both the conventional and addressable detector base shall be capable of driving a separate alarm LED indicator module.

3.2.2

Optical Smoke Detectors

1

The optical smoke detectors shall be capable of detecting visible combustion gases emanating from fires.

2

The optical smoke detectors shall comply with the relevant provisions of BS 5445: Pt.7 (EN 54: Pt.7).

3

The optical smoke detector shall have a sensitivity sufficient to be classified as „A‟ in BS 5445: Pt.9 (EN 54: Pt.9) test fires for TF2 and TF3.

4

The optical smoke detectors shall be approved and listed by the Loss Prevention Council Board (LPCB).

5

The optical smoke detectors shall employ the forward light scatter principle, using optical components operating at a wavelength of approximately 4.35 nm.

6

The design of the optical smoke detector sensing chamber shall be optimised to minimise the effect of dust deposits during a long period of operation.

7

The optical smoke detectors shall incorporate screens designed to prevent insects from entering the sensing chamber.

8

The optical smoke detectors shall incorporate a fin structure designed to totally eliminate the effect of very small insects such as thunder flies.

9

The optical smoke detectors shall be designed to have high resistance to contamination and corrosion.

10

The optical smoke detectors shall include RF1 screening and feed through connecting components to minimise the effect of radiated and conducted electrical interference.

11

The system may include, but not be limited to, the following versions of optical smoke detectors as required to meet different applications:

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(a)

analogue addressable

(b)

analogue addressable intrinsically safe

(c)

two state addressable normal sensitivity

(d)

conventional high sensitivity

(e)

conventional normal sensitivity

(f)

conventional normal sensitivity delayed response

QCS 2014

Section 23: Fire Fighting and Fire Alarm Systems Part 03: Analogue Addressable Fire Alarm System (g)

conventional low sensitivity

(h)

conventional normal sensitivity intrinsically safe

Page 7

The optical smoke detector shall incorporate an LED, clearly visible from the outside, to provide indication of alarm actuation.

3.2.3

High Performance Optical Smoke Detectors

1

In addition to the above :

2

The high performance optical smoke detectors shall have a sensitivity sufficient to be classified as „B‟ or better in accordance with BS 5445: Part 9 (EN 54: Part 9) test fires TF2 to TF5 inclusive and as „C‟ in test fire TF1.

3

The high performance optical detectors shall monitor and use rapid changes in temperature to increase the normal sensitivity of the light scatter optical sensor to obtain an improved response to fast burning fires.

4

The high performance optical detectors shall not generate an alarm condition from a rate of rise of temperature or absolute temperature alone.

3.2.4

Beam Smoke Detectors

1

The beam smoke detectors shall be capable of detecting the presence of smoke in large open type interiors.

2

The beam smoke detectors shall project a modulated infrared light beam from a transmitter unit to a receiver unit. The received signal shall be analysed and, in the event of smoke being present for a predetermined period an alarm condition be activated.

3

The detectors shall be capable of providing cover in open areas up to 100 m in length and up 2 to 14 m wide, giving an effective protection area of up to 1400 m .

4

The fire alarm output of the detectors shall be activated in the event of smoke reducing the signal strength between 40% and 90% for a period of approximately 5 seconds.

5

In the event of a power failure at the transmitter unit or if the transmitted signal is reduced by more than 90% for a period in excess of 1 second, then a fault alarm condition shall be indicated. This condition shall inhibit the fire alarm until the signal is restored.

6

The receiver unit of the detectors shall be capable of performing an automatic reset, approximately 5 seconds after a fault is indicated, if the fault is no longer present.

7

The detectors shall include Automatic Gain Control (AGC) circuitry capable of providing compensation for long-term degradation of signal strength caused by component ageing or build-up of dirt on the optical surfaces of the transmitter and receiver unit lenses.

8

The beam smoke detectors shall comply with the relevant provisions of either BS 5445: Part 5 (EN 54: Part 5) for detectors suitable for use in normal environments or BS 5445: Part 8 (EN 54: Part 8) for detectors designed for use in high ambient temperatures.

9

The beam smoke detectors shall be approved and listed by the Loss Presentation Council Board (LPCB).

10

The receiver unit of the detectors shall incorporate an alarm/fault lamp, clearly visible from the outside, to provide indication of both alarm and fault conditions.

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Aspirating Smoke Detectors

1

The aspirating smoke detectors shall be capable of detecting the presence of smoke particles in air samples drawn from several different locations.

2

The aspirating smoke detectors shall provide a continuous analogue profile of ambient air conditions.

3

The detectors shall be capable of responding to a developing fire situation with multiple staged alarms.

4

The fire alarm output of the detectors shall be programmable to allow sufficient time for action to be taken, from a detailed investigation of the cause of the alarm to a full scale evacuation.

5

The design of the detectors shall be such that they can be integrated with a fire alarm system and guard against specific pieces of equipment, such as computers, equipment racks, power boards and telecommunications switching racks, as well as entire rooms or floors.

6

The detectors shall include a facility to allow sensitivity threshold adjustments to suit the needs of particular environments.

7

Each detector system shall be capable of monitoring an area up to 2,000 m using easy to install PVC conduit.

8

The beam smoke detectors shall comply with the relevant provisions of either BS 5445: Part 5 (EN 54: Part 5) for detectors suitable for use in normal environments or BS 5445: Part 8 (EN 54: Part 8) for detectors designed for use in high ambient temperatures.

9

The aspirating smoke detectors shall be approved and listed by the Loss Prevention Council Board.

10

The detectors shall incorporate an LED indicator, clearly visible from the outside, to provide indication of alarm or fault condition.

3.2.6

Heat Detectors

1

The heat detectors shall be capable of detecting both rapid rise in temperature and fixed absolute temperatures.

2

The beam smoke detectors shall comply with the relevant provisions of either BS 5445: Part 5 (EN 54: Part 5) for detectors suitable for use in normal environments or BS 5445: Part 8 (EN54: Part 8) for detectors designed for use in high ambient temperatures.

3

The heat detectors shall be approved and listed by the Loss Prevention Council Board (LPCB).

4

The heat detector shall employ two heat sensing elements with different thermal characteristics to provide a rate of rise dependent response.

5

The temperature sensing elements and circuitry of the heat detectors shall be coated with epoxy resin to provide environmental protection.

6

The heat detectors shall include RF1 screening and feed through connecting components to minimise the effect of radiated and conducted electrical interference.

7

The system may include, but not be limited to, the following versions of the heat detector as required to meet different applications:

2,

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3.2.5

Section 23: Fire Fighting and Fire Alarm Systems Part 03: Analogue Addressable Fire Alarm System analogue addressable

(b)

analogue addressable intrinsically safe

(c)

two state addressable grade 1

(d)

conventional grade 1

(e)

conventional grade 1 intrinsically safe

(f)

conventional grade 3

(g)

conventional grade 3 intrinsically safe

(h)

conventional range 2 (98oC)

(i)

conventional range 2 intrinsically safe

(j)

conventional static 60oC (grade 2)

(k)

conventional static 90oC

.

(a)

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The heat detectors shall incorporate an LED, clearly visible from the outside, to provide indication of alarm actuation.

3.2.7

Linear heat detectors

1

The linear heat detectors shall be capable of detecting fire (or overheat) conditions in confined or polluted areas.

2

The sensor capable of the linear heat detectors shall be unaffected by dust, moisture or vibration and require little maintenance.

3

The detectors shall have a calibration switch mounted internally to set the alarm sensitivity threshold.

4

The detectors shall generate an alarm condition if the pre-determined alarm threshold is exceeded.

5

The detectors shall initiate a fault condition if the sensor cable has an open or short circuit condition present.

6

The detectors, upon detecting a cable open or short circuit or fault, shall be capable of signalling the condition to the main fire controller.

7

The linear heat detectors shall meet the requirements of either BS 5445: Part 5 (EN 54: Part 5) for detectors suitable for normal environment or BS 5445: Part 8 (EN 54: Part 8) for detectors designed for high ambient temperatures.

8

The linear heat detectors shall be approved and listed by the Loss Prevention Council Board (LPCB).

9

The detectors shall be suitable for use in hazardous areas and have mechanical protection for cables in areas where damage may occur.

10

The detectors shall incorporate red (fire) LED and yellow (fault) LED, clearly visible from the outside, to provide indication of alarm and fault condition.

3.2.8

Infra-Red flame detectors

1

The infra-red flame detectors shall be capable of detecting infra-red radiation produced by flaming fires involving carbonaceous materials.

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2

The infra-red flame detectors shall be approved and listed by the Loss Prevention Council Board (LPCB) and manufactured under the appropriate category by the Underwriters Laboratories, Inc. (UL), and shall bear the “UL.” label.

3

The infra-red flame shall be able to detect a fuel fire of 0.1 m area from a distance of 30 m for the following fuels:

2

petrol

(b)

N-heptane

(c)

kerosene

(d)

diesel Oil

(e)

alcohol

(f)

ethylene glycol

.

(a)

The infra-red flame detectors shall employ narrow band optical filters that block unwanted radiation such as that emanating from the sun or tungsten filament lamps.

5

The infra-red flame detectors shall be designed to be sensitive to modulation of the received radiation in a small range of frequencies corresponding to the flicker of flames.

6

The infra-red flame detectors shall be designed to have high resistance to contamination and corrosion.

7

The electronic assembly of the infra-red flame detectors shall be encapsulated in high resistivity epoxy resin.

8

The infra-red flame smoke detectors shall include RFI screening and feed through connecting components to minimise the effect of radiated and conducted electrical interference.

9

The system may include, but not be limited to, the following version of infra-red flame detectors to meet different applications: analogue addressable -intrinsically safe conventional -intrinsically safe

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The intrinsically safe versions of the infra-red flame detectors shall be suitable for use with safe area circuits.

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The infra-red flame detector shall incorporate an LED, clearly visible from the outside, to provide indication of alarm actuation.

3.3

ENGINEERING

3.3.1

System Management Facilities

1

The control and indicating equipment shall incorporate the following system management facilities:

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(a)

isolate/reconnect a particular addressable point

(b)

isolate/reconnect a particular detector zone

(c)

isolate/re-connect a particular sounder zone

(d)

walk test of a selected zone to verify detectors and sounders

(e)

view the number of alarms since power up

(f)

view the number of software initialisation since power up

Section 23: Fire Fighting and Fire Alarm Systems Part 03: Analogue Addressable Fire Alarm System (g)

view common alarm status

(h)

view common fault status

(i)

view common disabled status

(j)

view zonal alarm status

(k)

view zonal fault status

(l)

view zonal isolated status

(m)

view point address status

(n)

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print event log

(o)

print points isolated

(p)

print points in detector condition monitoring fault

(q)

print point statuses

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Access to the facilities described in clause above shall be restricted to authorised personnel using coded password.

3

The control and indicating equipment shall have an event log capable of storing up to the last 500 events that have occurred. It shall be possible to view the content of the log via an alphanumeric display. Events shall be displayed in chronological order in any of the following three options:

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newest event first

(b)

oldest event first

(c)

highest priority event first

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The control and indicating equipment shall be capable of isolating a group of selected detectors in areas of the building where maintenance work is carried out via a suitable timer unit. The detectors shall be automatically reinstated after a predetermined time.

5

The control and indicating equipment shall have a facility to enable the user to easily change the time and date settings of the system real-time clock.

3.3.2

Technical specification

1

The enclosure used to house the control and indicating equipment, standard system power supply and standard repeater panel shall not exceed the following overall dimensions unless otherwise stated in the Project Documentation:

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Height: Width: Depth:

400 mm 550 mm 200 mm

2

The control and indicating equipment shall be light in weight. The complete unit including standard power supply unit and standard repeater unit shall not exceed 7 kg excluding the weight of batteries unless otherwise stated in the Project Documentation.

3

The control and indicating equipment shall operate on a mains power supply rated for 240 V AC 10% @ 50Hz 4%

4

The control and indicating equipment, standard power supply unit and standard repeater unit shall comply with the following environmental conditions unless otherwise stated elsewhere in the Project Documentation: (a)

operating temperature range

0o C to 55oC

(b)

storage temperature

0o C to 65oC

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(c)

relative humidity

up to 95% (non-condensing)

(d)

IEC protection category

IP22 minimum

The control and indicating equipment, standard power supply unit and standard repeater unit shall comply with the EMC test requirements described in BS 5839 Pt.4 and the EEC requirements of the EMC Directive 89/336/EU and subsequent amendment 92/31/EU.

6

All equipment, including the fire alarm components and the control panel, shall be UL listed and shall be supplied from the same manufacturer. The manufacturer shall have a minimum of 10 (ten) years active experience in the manufacturing of fire alarm systems.

3.3.3

Cabling

1

Unless specified elsewhere in the Project Documentation, the cabling and wiring used in the fire alarm system shall comply with the provisions this Clause.

2

The cabling and wiring to be used in the system shall be fire resistant and approved to British Standard and LPCB specifications for use in fire detection and alarm systems.

3

Wiring used for driving devices requiring high currents (e.g. bells) shall limit the voltage drop to less than 10% of the nominal operating voltage.

4

Cables used for the transmission of system data and alarm signals shall be in accordance with the types recommended by the manufacturer of the fire alarm system.

5

The ends of all cables shall be sealed by means of proprietary seals and associated glands. No heat shall be applied to any seal or termination. Cable tails shall be insulated by means of gland PVC sleeving anchored and sealed into the seal.

6

Where protection of the cable glands is required or terminations are on display, the glands shall be enclosed in red coloured shrouds of the appropriate British Standard colour.

7

All cables to brick/concrete shall be securely fixed by means of copper saddles sheathed with red PVC. These saddles shall be provided near bends and on strength runs at intervals no greater than recommended in the British Standards or by the manufacturer.

8

Where multiple cables are to be attached to a wall or soffit, copper saddles shall enclose all cables and shall be secured by means of suitable masonry plugs and two round head plated wood screws.

9

Where multiple cables are to be attached to the top of horizontal trays they shall be neatly run and securely fixed at suitable intervals. Copper or plastic cable fixings shall be used.

3.3.4

Addressable Manual Call Points

1

The addressable manual call points shall monitor and signal to the control and indicating equipment the status of a switch operated by a „break glass‟ assembly.

2

The addressable call points shall comply with the relevant provisions of BS 5839: Part 2.

3

The addressable call points shall be capable of operating by means of thumb pressure and not require a hammer.

4

The addressable call points shall be capable of being mounted in weather-proof affording protection to IP65.

5

The addressable call points shall incorporate a mechanism to interrupt the normal addressable loop scan to provide an alarm response within less than 1 second.

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The addressable call points shall be field programmable to trigger either an alert or an evacuate response from the control and indicating equipment.

7

The addressable call points shall be capable of being tested using a special „key‟ without the need for shattering the glass.

8

The addressable call points shall provide an integral red LED to indicate activation.

3.3.5

Manual Pull Stations

1

The manual fire alarm pull stations shall monitor and signal to the control and indicating equipment the status of a switch operated by manual pulling down of a handle or lever.

2

The stations shall be capable of operating by hand pull and does not require special instrument.

3

The stations shall be capable of being mounted in weather-proof affording protection to IP65.

4

The pull station shall incorporate a mechanism to interrupt the normal addressable loop scan to provide an alarm response within less than 1 second.

5

The points shall be capable of being tested using a special „key‟ without actually initiating the alarm signal.

6

A glass cover shall be provided to deter the accidental or malicious activation of the manual call stations. After actuation, the cover can be replaced, and the system reset by use of a key only.

3.4

MODULES

3.4.1

Remote Indicator Module

1

The remote indicator module shall provide a remote indication for any conventional or analogue addressable detector that may be located in an enclosed or locked compartment.

2

The remote indicator module shall be driven directly from its associated local detector.

3

The connection to the remote indicator module shall be monitored for open and short-circuit.

3.4.2

Conventional Detector Interface Module

1

The conventional detector interface module shall monitor and signal to the control and indicating equipment the status of up to 20 conventional detectors and manual call points.

2

The conventional detector interface module shall be capable of monitoring automatic detector and manual call points from existing conventional systems.

3

The conventional detector interface module shall operate from a monitored 24 V AC power supply.

4

The conventional detector interface module shall operate integral red LED indication when in the alarm state.

3.4.3

Addressable Relay Output Module

1

The addressable relay output module shall provide a volt free changeover relay contact operated by command from the control and indicating equipment.

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The contacts of the addressable relay output module shall be rated for minimum of 1 Amp at 24 V DC.

3

The addressable relay output module shall monitor the relay coil open-circuit and transmit the fault signal to the control and indicating equipment.

4

The addressable relay output module shall derive its operating power from the addressable loop.

5

The addressable relay output module shall provide a red LED indication that the relay has operated.

3.4.4

Addressable Contact Monitoring Module

1

The addressable contact monitoring module shall provide monitoring of the status of switched input signals from either normally open or normally closed contacts.

2

The addressable contact monitoring module shall provide a red LED indication when the contact has operated.

3

The addressable contact monitor module shall derive its power directly from the addressable loop.

3.4.5

Addressable Sounder Driver Module

1

The addressable sounder driver module shall be capable of monitoring and driving a circuit of alarm sounders.

2

The output of the addressable sounder driver module shall be rated at 500 mA.

3

The addressable sounder driver module shall be capable of operating the sounders in a pulsing or continuous mode as determined by the control and indicating equipment.

4

The addressable sounder driver module shall provide the facility to monitor for failure of the power supply for the sounders and transmit the necessary fault signal to the control and indicating equipment.

5

The addressable sounder driver module shall provide a red LED indication that the sounder circuit has been actuated.

3.4.6

Sounder Booster Module

1

The sounder booster module shall be capable of monitoring and driving a heavy duty circuit of sounders up to 15 Amps.

2

The sounder booster module shall be capable of interfacing either to the common sounder outputs of the control and indicating equipment or to the output of the addressable sounder driver module.

3

The sounder booster module shall be designed to maintain the monitoring of the sounder circuit and transmit a fault signal either via the addressable sounder driver module or directly to the control and indicating equipment.

3.4.7

Addressable Power Supply Module

1

The addressable power supply module shall be capable of supplying up to 24 V DC. 3 Amps of power to local sounder circuits and ancillary equipment.

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Page 15

The addressable power supply module shall derive its power from the 240 V AC mains supply.

3

The addressable power supply module shall be able to contain and maintain in a charged state a 24 V battery set of up to 15 Ah capacity.

4

The addressable module shall monitor the mains power supply and the battery and transmit a fault signal as appropriate to the control and indicating equipment.

3.4.8

Smoke Damper Module

1

The smoke damper module shall provide the inputs and outputs required to monitor and control a smoke damper.

2

The smoke damper module shall be fully addressable and provide one volt-free changeover relay contact rated for 240 V AC @ 5 Amps.

3

A separate 24V DC supply shall be provided to operate the changeover relay.

4

The changeover relay contact of the smoke damper module shall be monitored and controlled by commands signalled from the fire alarm system control panel via the addressable loop.

5

The smoke damper module shall be capable of monitoring up to two external relay contacts.

6

The module shall derive its power directly from the addressable loop.

7

The outputs of the smoke damper module shall be capable of being controlled using a keypad via the addressable loop.

8

The keypad shall be capable of forcing the relay outputs LOW, HIGH or AUTO. It shall also be capable of reading the status of the relay outputs.

9

The smoke damper module shall have a red LED, clearly visible on the fascia panel of the unit, to provide an indication of relay operation.

3.4.9

Plant Interface Module

1

The plant interface module shall provide inputs and outputs required to monitor and control any plant and machinery.

2

The plant interface module shall be fully addressable and provide multiple volt-free DPDT changeover relay contacts rated for 240 V AC @ 5 Amps.

3

A separate 24 V dc supply shall be provided to operate the changeover relays.

4

The changeover relay contacts of the plant interface module shall be monitored and controlled by commands signalled from the fire alarm system control panel via the addressable loop.

5

The module shall be capable of monitoring multiple external relay contacts.

6

The plant interface module shall derive its power directly from the addressable loop

7

The plant interface module shall be capable of being link-configured to provide 2 inputs/2 outputs, 4 inputs/4 outputs or 6 inputs/6 outputs as required and specified in the Project Documentation.

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The plant interface module shall have six consecutive addresses provided for configuration.

3.5

MONITORING

3.5.1

Fire monitoring

1

The control and indicating equipment shall monitor the status of all devices on the addressable loops for fire, short-circuit fault, open-circuit fault, incorrect addressing, unauthorised device removal or exchange, pre-alarm condition and contaminated detector condition.

2

The control and indicating equipment shall monitor the status of all internal connection and interfaces, including charger, battery and remote signalling functions.

3

The control and indicating equipment shall provide the following discrete visual indications: green LED indicator

(b)

fire alarm

dual red LED indicator

(c)

fault

(d)

disabled/isolated

yellow LED indicator

(e)

fire zones

red LED indicator per zone

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In addition to the indications provided in Clause 3.5.1-3, the control and indicating equipment shall also have an integral LCD alphanumeric back-lit display unit. In order that an easy identification of different information is provided, the LCD display shall be arranged in the following categories: event type

(b)

zone message

(c)

addressable point message

(d)

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(a)

circuit identifier point number/zone number of events in the system

The control and indicating equipment shall provide a set of push button controls to enable an authorised operator to perform the following:

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(a)

evacuate - actuates ALL alarm sounders in the system

(b)

silence - stop all currently actuated alarm sounders

(c)

reset - return and control and indicating equipment to quiescent condition

6

The control and indicating equipment shall provide a facility to manually check all the discrete LED indicators. This shall be clearly marked LAMP TEST and be accessible at all time.

7

The control and indicating equipment shall provide a simple to operate keypad to enable the user to access the various built-in functions, and interact with the information displayed on the LCD. For security reasons, the control and indicating equipment shall provide a customer configurable password code facility in accordance with the relevant provisions of BS 5839 for the following levels of access: (a)

user operator

Access Level 3

(b)

user engineer

Access Level 1

(c)

user manager

Access Level 2

(d)

civil defence engineer

Access Level 3

(e)

alarm company engineer

Access Level 3

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8

Page 17

The control and indicating equipment shall provide facilities to drive visual indication LED mimic displays for each of the following zonal status: (a)

alarm

(b)

fault

(c)

isolated

The control and indicating equipment shall provide facilities for signalling the following system conditions to a remote (Central Station) and/or an on-site monitoring centre: (a)

alarm

(b)

pre-alarm

(c)

fault

(d)

zone isolated

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The control and indicating equipment shall be capable of monitoring and controlling remote site devices, such as door release unit and relays for the control of plants and dampers, directly from the addressable loops.

11

The control and indicating equipment shall be capable of monitoring fire doors such that, in the event of a fire alarm condition, an event is generated to warn of the failure of fire door to close.

3.5.2

Fault and Warning Monitoring

1

The control and indicating equipment shall interrogate each addressable device at least once every 5 seconds.

2

The control and indicating equipment shall incorporate fire decision algorithms specifically adapted to the response characteristics of the analogue addressable detectors employed.

3

The algorithms shall perform a trend analysis of the signal received from the analogue addressable detectors in order that non-fire events may be differentiated.

4

The control and indicating equipment shall be designed so that, each type of analogue addressable detector, the overall responses time, including that for the sensor, the signal transmission system and the fire decision algorithm, meets the requirement of the relevant provisions of BS 5445 (EN 54).

5

The response time of the control and indicating equipment to two-state addressable detectors and conventional detectors shall not exceed 10 seconds.

6

The control and indicating equipment shall have a special scanning sequence so that designated manual call points provide alarm indication and warning within 1 second of operation.

7

The control and indicating equipment shall have a facility to automatically adjust the sensitivity of analogue detectors to a higher level for periods of time when the building is unoccupied.

8

The control and indicating equipment shall have, as an optional software enhancement, the ability to automatically adjust the alarm and pre-alarm threshold levels to compensate for changes in detector sensitivity due to contamination over a period of time.

9

The control and indicating equipment shall have, as an optional software enhancement, the ability to provide automatic warning that a detector has reached a level of contamination which requires that it be replaced or serviced.

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3.5.3

Supervision and Fault Reporting

1

The control and indicating equipment shall monitor all critical system components and interconnections (internal and external). In the event of a failure occurring which prevents correct operation of the alarm functions, a FAULT indicator will light and message shall be given on the alphanumeric display within 100 seconds of occurrence.

2

The following faults shall be reported. loop short circuit

(b)

loop open circuit

(c)

un-configured device

(d)

addressable device failure

(e)

device not responding

(f)

incorrectly configured device

(g)

detector condition monitoring warning

(h)

conventional call point wiring open circuit

(i)

conventional call point wiring short circuit

(j)

conventional detector circuit wiring fault

(k)

repeater/repeater LCD, remote printer failure

(l)

power supply unit (PSU) fault

(m)

charger fault

(n)

battery fault

(o)

battery critical

(p)

mains failure

(q)

auxiliary power supply unit (PSU) failure

(r)

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(a)

(s)

signalling fault

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relay output stuck

sounder wiring open circuit

(u)

sounder wiring short circuit

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(t)

3

To help rapid fault finding and repair, the control and indicating equipment shall provide text messages to indicate the precise location of where a fault has occurred in the system.

4

The control and indicating equipment shall be capable of monitoring and indicating the status of auxiliary units, such as a remote signalling transmitter. This shall be achieved using a suitable addressable contact monitor module.

5

The control and indicating equipment shall have the facility to delay the generation of an event to confirm operation of the monitored device. This shall be either 6 seconds for normal non-fluctuating contacts, or 40 seconds for fluctuating contacts, e.g. sprinkler flow valve switches.

3.5.4

Alarm Output Functions

1

The control and indicating equipment shall provide the necessary outputs to separately operate two monitored circuits of common system sounders. Each output shall be capable of driving a sounder load of up to 1 Amp.

QCS 2014

(a)

The control and indicating equipment shall be capable of providing a two stage alarm sounder facility that can be programmed, either on a zonal basis or common system basis, to meet the requirements of the fire authority. Three possible sound output signals shall be available as follows:

(b)

alert pulsed tone (1 second ON, 1 second OFF)

(c)

evacuate continuous tone

(d)

user definable tone for specialised events (e.g. boom alert).

(b)

a manual call point

(c)

an evacuate command

(d)

a non-fire event (e.g. plant alarm)

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an automatic detector (e.g. smoke or heat)

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(a)

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The control and indicating equipment shall have the facility to change, on a per sounder zone basis, the sound output dependent upon whether the source of alarm is:

The control and indicating equipment shall be capable of generating customer definable time delay sequences to upgrade alarm sounder responses, without the need for external timers, as follows:

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4

The control and indicating equipment shall be able to monitor and control the integrity of zonal sounder circuits via a suitable addressable module.

(a)

silent to alert

(b)

alert to evacuate

(c)

silent to user defined tone

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2


The control and indicating equipment shall have the ability to delay the transmission to the Civil Defence Department of fire alarm signals from automatic detectors in pre-determined detection zones. The time delay shall be configurable up to a maximum time of 2 minutes.

6

The control and indicating equipment shall provide the facility to automatically inhibit the delay function described in clause above when the building is unoccupied.

3.5.5

Voice Evacuation Systems

1

The control and indicating equipment shall be capable of operating addressable voice alarm units and monitoring the integrity of the wiring connection to individual loudspeakers.

2

The system shall include power supply unit, amplifier, tone generator, synthesisers, message player, loudspeakers, cable and wiring system and other accessories required for independent operation.

3

The control and indicating equipment shall provide, additionally when specified in the Project Documentation, an interface to drive the public address system of the building in accordance with the relevant provisions of BS 5839: Pt.1. The system shall be arranged such that, in the event of a failure of the public address system, back-up sounders are available to alert or evacuate the relevant areas of the protected premises.

4

The fire alarm signal shall automatically activate the voice evacuation system and shall broadcast a suitable evacuation call (either pre-recorded or synthesised) over the loudspeaker system, independent of operator‟s action. At least one fire microphone should normally be sited near to the control panel for manual call for evacuation. To avoid confusion, the system should be so designed that both automatic call and operators call can not be broadcast simultaneously.

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INSTALLATION

3.6.1

General

1

Correct installation, combined with the use of high quality equipment, components and cabling ensures that the fire detection and alarm system shall operate as designed and provide many years of trouble free service.

2

The Contractor shall install the alarm system in accordance with the manufacturer‟s documented installation instructions.

3

The Contractor shall provide all relevant installation documentation required for each component of the system.

4

Installation of the system shall be in accordance with the relevant provisions of BS 5839: Part 1 and BS 7671.

5

The Contractor shall be responsible for the correct sitting of all equipment and components of the system in accordance with the Project Documentation.

6

All cabling and wiring shall be tested before they are connected to the fire controller and its associated devices. The Contractor shall note that if the tests are carried out after the cables and wires have been connected to the controller and its devices, components within the controller and devices will be damaged by high voltages used during testing.

7

At detector and sounder locations, cables shall be terminated in approved black enamelled/galvanized junction boxes. All other devices forming part of the system shall utilise dedicated/custom back boxes.

3.6.2

Installation of Detectors

1

All detectors (and bases) shall be installed in accordance with the relevant provisions of BS 5839: Part 1, BS 7671 and the installation instructions provided by the manufacturer.

2

The number and type of detectors required to be installed shall be as detailed on the Project Drawing. The location of each type of detector installed shall generally be as shown on the Project Drawings but their final position shall be determined on site.

3

All detector bases shall be securely fixed to boxes and allow for easy fitting and removal of detectors.

4

Cable and wire entries to detector bases shall be fitted with grommets to prevent possible damage to the insulation.

5

Cable and wire strain relief clamps shall be provided at all entries to detector bases.

6

Cable entries of detector bases used in environments with abnormal atmospheric or operating conditions shall be appropriately sealed to prevent ingress of dust, water moisture or other such contaminants.

3.6.3

Installation of Control Devices

1

All control devices (e.g. call points, sounders, interface modules, etc.) shall be installed in accordance with the relevant provisions of BS 5839: Part, BS 7671 and the installation instructions provided by the manufacturer.

2

The location of control devices and associated modules to be installed shall generally be as shown on the Project Drawings but their final position shall be determined on site.

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The type of control device installed in each particular location shall be the type specified in the Project Documents.

4

All control devices and associated modules shall be securely fixed, and if required, marked with appropriate notices, warnings, signs as applicable.

5

Cable and wire entries to all control devices and associated modules shall be fitted with grommets or glands so as to prevent possible damage to the insulation.

6

Cable entries of control devices and associated modules used in environments with abnormal atmospheric or operating conditions shall be appropriately sealed to prevent ingress of dust, water, moisture or other such contaminants.

3.6.4

Installation of Fire Controller Equipment

1

The fire controller equipment shall be installed in accordance with the relevant provisions of BS 5839: Part 1, BS 7671 and the installation instructions provided by the manufacturer.

2

The installation location of the fire controller and its associated component parts shall generally be as shown on the Project Drawings but their final position shall be determined on site.

3

The type of fire controller and its associated component parts installed shall be the type specified in the Project Documentation.

4

The fire controller equipment shall be securely fixed, and if required, marked with appropriate notices, warnings, signs as applicable.

5

Cable and wire entries to the fire controller and associated devices shall be fitted with grommets or glands to prevent possible damage to the insulation.

6

The fire alarm system mains power connections to the fire controller equipment shall be accordance with the guidelines set out in the relevant British Standards and the installation instructions provided by the manufacturer.

7

The fire alarm system mains power isolating switch shall be coloured red and clearly labelled “FIRE ALARM: DO NOT SWITCH OFF”.

8

Each circuit of the system shall be connected to the fire controller via associated fuse or circuit breaker devices located within the fire controller unit.

9

All cables from the fire controller equipment to the detection and alarm devices shall be clearly labelled as part of the fire detection and alarm system.

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END OF PART

QCS 2014

Section 23: Fire Fighting and Fire Alarm Systems Part 04: Fire Fighting System

Page 1

4

FIRE FIGHTING SYSTEM ........................................................................... 3

4.1

GENERAL.................................................................................................... 3

4.1.1 4.1.2

Scope Codes and Standards

4.2

SPRINKLER SYSTEMS .............................................................................. 4

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

System Description Sprinkler Heads Sprinkler System Alarm Devices Alarm Valve Basic Trip and Retarding Chamber Pressure Alarm Switches Water Motor Alarms Stop Valves Zoning Valve Water Flow Detectors Drain and Test Orifice

4.3

WATER SUPPLY......................................................................................... 6

4.3.1

General

4.4

HOSE REELS AND HOSES ........................................................................ 7

4.4.1 4.4.2 4.4.3 4.4.4

General Cabinets Hose Reels with Semi-Rigid Hose Hose Systems with Lay-flat Hose

4.5

FIRE HYDRANTS ........................................................................................ 9

4.5.1 4.5.2 4.5.3

General High Pressure Dry Barrel Hydrant Underground Fire Hydrants and Surface Box Frames and Covers

4.6

PIPES AND FITTINGS .............................................................................. 11

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4.6.1 4.6.2

3 3

General Hangers Supports Anchors and Guide

4 5 5 5 5 6 6 6 6 6 6 6 7 7 7 8 9 9 10 11 12

4.7

PUMPS ...................................................................................................... 12

4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10

General Horizontal Fire Pumps Construction Fittings Electric Motors Compression Ignition Engine Controller and Transfer Switch Alarm Panel Jockey Fire Pumps Field Quality Control

12 13 13 13 14 14 14 14 14 15

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Page 2

4.8

WET RISERS ............................................................................................ 15

4.8.1

General

4.9

PORTABLE FIRE EXTINGUISHERS ........................................................ 16

4.9.1

General

4.10

FIRE BLANKETS ....................................................................................... 17

4.10.1

General

4.11

FM 200 SYSTEM ....................................................................................... 17

4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 4.11.10 4.11.11 4.11.12 4.11.13 4.11.14 4.11.15 4.11.16 4.11.17 4.11.18 4.11.19 4.11.20 4.11.21

System description 17 Equipment Instruction -Plates 17 Basic Pipes and Pipe fittings 17 Control Panel 18 Storage Cylinders 19 Discharge Valve 19 Discharge Nozzles 19 Pressure Switch 19 Smoke Detectors 19 Graphic Annunciator 19 Battery Backup Power System 20 Alarm Horn/strobe Combination 20 Manual Pull Stations 20 Abort Switch 20 Automatic Fire Dampers 20 Basic Identification of Installation 20 Installation of Pipes and Pipe Fittings 21 Pressure Test 21 Flow and Compliance Test 21 Painting 22 CAPSULAR TYPE - FIRE EXTINGUISHING AND SUPPRESSION SYSTEM for the MCC/MV panels 22

15 16

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4

FIRE FIGHTING SYSTEM

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for fire fighting systems.

2

Related Sections are as follows: Section 21

Page 3

Electrical Works

4.1.2

Codes and Standards

1


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ANSI B16.1 ................Cast iron pipe flanges and flanged fittings

.

QCS 2014

rw

ANSI B16.5 ................Pipe flanges and flanged fittings

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ASTM A 47 .................Specification for Ferritic Malleable Iron Castings

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ASTM A 106 ...............Specification for Seamless Carbon Steel Pipe for High-Temperature Service ASTM A 135 ...............Specification for Electric-Resistant-Welded Steel pipe

as

ASTM A 183 ...............Specification for Carbon Steel track Bolts and Nuts ASTM A 197 ...............Specification for Cupola Malleable Iron

se

ASTM A 234 ...............Specification for Pipe Fittings of Wrought Carbon Steel and Alloy for Moderate and Elevated temperatures

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ASTM A 395 ...............Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures

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ASTM A 536 ...............Ductile Iron Castings

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BS 750........................Underground fire hydrants and surface box frames and covers BS EN 1561 ...............Specification for grey iron castings

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BS EN 1563 ...............Iron castings with spheroidal or nodular graphite BS 5163 .....................Double flanged cast iron wedge gate valves for waterworks purposes BS 5423 .....................Portable fire extinguishers BS 6575 .....................Fire blankets BS EN 671 .................Fixed fire fighting systems – Hose systems NFPA 13 .....................Installation of Sprinkler Systems 2

In addition to the above, all aspects of the fire fighting system shall comply with applicable national and international codes and standards including, but not limited to, those issued by the following organisations: (a)

Civil Defence Department

(b)

National Fire Prevention Association (NFPA)

(c)

British Standards (BS)

(d)

Loss prevention Council Board (LPCB)

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Page 4

SPRINKLER SYSTEMS

4.2.1

System Description

1

Wet pipe sprinkler systems shall employ automatic sprinklers attached to a piping system containing water and connected to a water supply. Each pipeline in the system shall be fully pressurised, so that water discharges immediately from sprinklers opened by a fire.

2

The system shall be designed that only those sprinklers that have been activated by heat will discharge water.

3

The design of the sprinkler system indicated on the Project Drawings is indicative only and is to be taken as general guide and not as final design unless specifically noted otherwise. The final detail design (including manufacturer components) shall be fully developed by the Contractor strictly in accordance with the requirements of the Civil Defence Department and the rules for automatic sprinkler installations in accordance with the relevant provisions of NFPA 13. The Contractor shall allow in his rates for components of sprinkler systems that are required to meet requirements but are not shown on the Project Drawings.

4

The fire fighting system shall be fed from a centralised fire water storage tank located inside the building or the basement of the building unless otherwise indicated in the Project Documentation.

5

The sprinkler system for each building shall be complete with an automatic packaged fire pumping station and valves, water motor alarm and gong, pressurised water main with distribution pipework, range pipes, hangers and supports, sprinkler heads and a piped drain system.

6

The sprinkler system shall be interconnected with the central fire alarm panel in order that the alarm bells and zone valves in various locations can be actuated.

7

The water motor alarm and gong should consist of a simple water turbine having the shaft connected to a rotary ball clapper mounted within a domed gong. The alarm system shall be self-winding, adjustable recycling non-thermal type and equipped with signal retarding device to prevent false alarms due to surges in the water system. Auxiliary pressure and flow sensing devices shall be incorporated in the feed to the alarm gong to actuate the central fire alarm panel.

8

A test valve shall be incorporated on a branch pipe from the alarm valve to allow operational conditions to be simulated for test purposes. Water from the test valve shall be properly drained.

9

The distance between sprinklers shall not exceed 3.5 m. The maximum floor area to be covered by a single sprinkler for different hazard class are as follows:

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4.2

(a)

ordinary hazard

=

12 m

2

(b)

extra light hazard =

21 m

2

(c)

extra high hazard =

9m

2

10

The distance from the walls to the end sprinklers on the branch lines shall not exceed half of the allowable distance between sprinklers on the branch lines. The distance from the walls to the end branch lines shall not exceed half the allowable distance between the branch lines.

11

The allowable distance between sprinklers on the branch lines is determined by the actual distance between the branch lines and the permissible protection area per sprinkler.

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Page 5

The Contractor shall install an adequate quantity of additional sprinkler heads of the correct temperature rating. The number will depend on the size of the installation and number of sprinkler heads likely to be opened. The following figures are the minimum number of additional sprinkler heads that should be installed: (a)

for systems not exceeding 300 sprinklers, 6 spare heads shall be installed

(b)

for systems exceeding 300 sprinklers but not exceeding 1000, 12 spare heads shall be installed

(c)

for systems exceeding 1000 sprinklers, 24 spare heads shall be installed.

All components for sprinkler system packages should be from one single manufacturer with an approved local agent. The Contractor shall maintain a technical representative from the manufacturer or the local agent on site for the duration of the Contract in order to supervise the installation. This representative shall issue a certificate upon completion of the Project stating that the complete system has been installed, tested and commissioned in accordance with the Project Documentation, the requirements of the NFPA and the Civil Defence Department.

4.2.2

Sprinkler Heads

1

The glass bulb sprinkler heads should be of the upright pendant type and rated for 68 C. They shall be arranged such that there is not interference with the discharge pattern and they shall be positioned between 75 and 150 mm below ceilings.

2

The sprinklers and pipelines shall not be spaced too close together in order to prevent an operating sprinkler from wetting, and thereby delaying the operation of, adjacent sprinklers.

3

In locations where sprinkler heads are liable to be operated or damaged by accidental blow, they should be protected by stout metal guards. Care shall be taken to ensure that the normal operation of the sprinkler head in the event of a fire is not impeded by such guards.

4

Sprinklers in false ceilings areas shall be the concealed or recessed type. They shall be the two-piece design with closure and mounting plate which allows for easy installation and removal.

5

Sprinklers in parking and hardware areas shall be the pendant or upright bulb type with a 12 o mm diameter orifice and temperature rated to 68 C with a natural brass finishes and sprinkler guard.

4.2.3

Sprinkler System Alarm Devices

1

The system shall be provided with alarm devices consisting of, but not limited to, the items described in the following clauses.

4.2.4

Alarm Valve

1

Alarm valves shall be UL listed and FM approved. They shall be check type, with a rubber faced clapper, designed for use in wet pipe systems for automatic actuation. The alarm valve may be installed vertically or horizontally with inlet and outlet connection in accordance with the relevant provisions of ANSI B 16.1.

4.2.5

Basic Trip and Retarding Chamber

1

Basic trip and retarding chamber shall be UL listed and FM approved. It shall be used in order to prevent any false alarm that may be caused by small variation in pressure. The chamber should consist of a by-pass check valve to permit slow as well as small transient increases in water supply pressure to be passed through to the system and held at their highest value, without opening of the water way clapper.

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Page 6

Pressure Alarm Switches

1

Pressure alarm switches shall be UL listed and FM approved. They shall be designed to indicate a water discharge from automatic sprinkler and the start-up or shut down of auxiliary fire protection system equipment. The one single pole double throw snap-action switch‟s components shall be enclosed in an oil resistant IP 22 rated enclosure.

4.2.7

Water Motor Alarms

1

Water motor alarms shall be UL listed and FM approved. They shall be hydraulically operated outdoor alarms, designed for use with fire protection system water flow detection devices. They shall be suitable for mounting to any type of rigid wall and to consist of an approved “Y” strainer for use in the alarm line utilising a high energy efficient, light weight, impeller design which can produce a very high sound pressure level. The gong, gong mount, and water motor casing shall be made with corrosion resistant aluminium alloy. The drive shall be of the type that does not require lubrication.

4.2.8

Stop Valves

1

Stop valves shall be UL listed and FM approved. They should be the gate valve type, designed specifically for fire line applications, where a positive indication of the open or closed position is necessary. The valve shall have flanged ends, an iron body and a working pressure of 12 bar.

4.2.9

Zoning Valve

1

Zoning valves shall be UL listed and FM approved. They shall be gear operated butterfly valves with internal or external monitor switch. They shall have a wafer or lug style body for mounting between ANSI 125/150 flanges. They shall be rated for a 12 bar operating pressure and have a cast iron body and an EPDM seat with bronze disc.

4.2.10

Water Flow Detectors

1

Water flow detectors shall be UL listed and FM approved and shall be designed for use with wet pipe, automatic sprinkler systems. They shall utilise a vane type sensor to actuate two (2) single pole double throw snap-action switches when water flows at a sustained rate of 17.5 litres or more. They shall be used where sectional water flow signals are required.

4.2.11

Drain and Test Orifice

1

The system shall incorporate a 30 mm drain and a 13 mm test orifice for flow control inspection testing and drainage of feed mains.

4.3

WATER SUPPLY

4.3.1

General

1

Unless otherwise stated elsewhere in the Project Documentation, the water supply shall consist of:

2

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4.2.6

(a)

electric motor driven fire pump with back-up

(b)

diesel motor driven fire pump with back-up

The capacity of the reservoirs from which fire fighting systems draw water shall be as stated in the Project Documentation.

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Page 7

HOSE REELS AND HOSES

4.4.1

General

1

Hose reels and hoses shall be installed in locations as stated in the Project Documentation unless otherwise directed by the Civil Defence Department.

2

Fire hose reel assemblies shall be provided with full operational instructions for display on or adjacent to the hose reel.

3

The supplier shall make available an installation and maintenance manual for the hose reel.

4

All hose systems shall be such that they can be operated efficiently by one person and that such system shall have a long service life and will not need excessive maintenance.

5

Hose reels shall be marked with the following information:

.l. l

.

4.4

suppliers name or trademark, or both

(b)

year of manufacture

(c)

maximum working pressure

(d)

length and bore of hose

(e)

nozzle diameter (marked on the nozzle)

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(a)

Cabinets

1

Cabinets shall be fitted with a door. The door shall open approximately 180 to allow the hose to run at freely in any direction.

2

Cabinets shall have suitable ventilation openings.

3

Cabinets shall be fitted with a lock if required by the Project Documentation. cabinets shall be fitted with an emergency opening device.

4

To provide access for inspection and maintenance, the cabinet shall be unlockable with a key or a special opening device. Lockable cabinets shall have provision for a security seal to be fitted.

4.4.3

Hose Reels with Semi-Rigid Hose

1

Hose reels with semi-rigid hose shall generally comply with BS EN 671-1.

2

The nominal bore of the hose shall be 19 mm or 25 mm or 33 mm.

3

The maximum length of the hose shall not exceed 30 m.

4

The reel shall rotate around a spindle. The reel shall consist of two wheel discs with a maximum diameter not more than 800 mm, and inside segments or drum with a minimum diameter not less than 200 mm for 19 mm and 25 mm hose and minimum diameter not less than 280 mm for 33 mm hose. The discs shall be red in colour.

5

The hose shall terminate in a shut-off nozzle which shall give the following control settings:

Lockable

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4.4.2

(a)

shut

(b)

spray (sheet or conical) and/or jet.

QCS 2014

6


Page 8

Rotary operated nozzles shall be marked to show the direction of closing and opening. Lever operated nozzles shall be marked to show the setting for: (a)

shut

(b)

spray and/or jet.

7

A manual or automatic inlet stop valve shall be fitted to each hose reel.

8

Working, test and minimum burst pressure for hose reels shall be as given in Table 4.1, unless otherwise stated in the Project Documentation or agreed with the Engineer. Table 4.1 Pressure for Hose Reels Working Pressure

Test Pressure

(mm)

(bar)

(bar)

12

33

7

.l. l

25

18

rw

12

(bar) 30

18

30

10.5

17.5

ta

19

Minimum Burst Pressure

.

Nominal Diameter

Testing, performance and materials of hose reels with semi-rigid hose shall comply with the relevant provisions of BS EN 671-1.

4.4.4

Hose Systems with Lay-flat Hose

1

Hose systems with lay-flat hose shall generally comply with BS EN 671-2.

2

The hose system shall be designed for mounting in one of the following forms:

as

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in a wall recess with cover

(b)

in a cabinet in a wall recess

(c)

in a cabinet for surface mounting

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(a)

The hose support shall be one of the following types: Type 1: rotating reel

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(b)

Type 2: cradle with the hose double coiled

(c)

Type 3: hose basket with the hose flaked

4

With Type 1 hose supports, the reel shall rotate around a spindle so that the hose can be withdrawn freely. The inside drum shall have a minimum diameter of not less than 70 mm and shall have a slit not less than 20 mm wide across the full diameter of the drum into which the folded house is located.

5

Type 1 and 3 supports, if fixed to the cabinet, shall allow a swing to a position at 90 to the plane of the back of the cabinet. The turning axis shall be vertical.

6

The hose shall be lay-flat, with a nominal bore of 52 mm, and shall not exceed 20 m in length.

7

A coupling shall be used to connect the hose to the valve and to the shut-off nozzle. The coupling shall be bound to the hose by means of an even pressure over the complete perimeter of the hose against the coupling shank.

QCS 2014

8

9


Page 9

The hose shall terminate in a shut-off nozzle which shall give the following control settings: (a)

shut

(b)

spray (sheet or conical) and/or jet.

Rotary operated nozzles shall be marked to show the direction of closing and opening. Lever operated nozzles shall be marked to show the setting for: (a)

shut

(b)

(spray and/or jet.

A manual inlet stop valve shall be fitted to the hose system. The valve shall be screw down or other slow-opening type. The inlet and outlet of the valve shall form an angle of not less than 90 and not more than 135

11

Hose assemblies shall be designed for the following pressures unless otherwise stated in the project documentation or agreed with the Engineer:

(b)

test pressure shall be 24 bar

(c)

minimum burst pressure shall be 42 bar

rw

maximum working pressure shall be 12 bar

ta

(a)

.l. l

.

10

Testing, performance and materials of hose systems with lay-flat hose shall comply with the relevant provisions of BS EN 671-2.

4.5

FIRE HYDRANTS

4.5.1

General

1

Fire hydrants shall be installed in locations as stated in the Project Documentation unless otherwise directed by the Civil Defence Department.

2

A certificate shall be obtained from the manufacturer stating that the fire hydrants to be supplied are suitable for use in Qatar.

3

Fire hydrants shall be installed in accordance with the manufacturer‟s instructions.

4.5.2

High Pressure Dry Barrel Hydrant

1

High pressure dry barrel hydrants shall come complete with removable/replaceable nozzles and hydrant seat, top stop nut, easily repaired traffic section, nozzle section with 360° rotation, main valve opening and bronze drain plug.

2

Working pressure of the hydrant shall be 14 bar and the testing pressure shall be 28 bar unless otherwise stated in the Project Documentation or agreed with the Engineer.

3

The hydrant shall comply with ASNI/AWWA C502 and shall be UL listed and FM approved.

4

Materials for the hydrants shall be as follows:

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(a)

nozzle section, barrels, stand pipe flanges, breakable flange, base, main valve flange, weather-shield operating nut and bonnet all shall be ductile iron

(b)

main valve disc shall be ductile iron core and fully encapsulated in EPDM rubber

(c)

caps shall be cast iron

(d)

coating above ground shall be fusion bonded epoxy inside and out

(e)

coating below ground shall be bitumen or fusion bonded epoxy

QCS 2014

Page 10

(f)

nozzles, valve seat ring, drain ring, drain bushings and plugs, stem nut, stem bushing and thrust nut shall be bronze

(g)

stop nut, cap chain, bolts and nuts shall be zinc plated steel

(h)

stem rod coupling, standpipe lock rings, nozzle lock screw, lock plate, lock plate screw and spider bolt shall be stainless steel

(i)

barrel gaskets and cap gaskets shall be nitrile rubber.

Each hydrant shall be clearly marked, either integrally with the stated components or on a plate of durable material securely fixed to that component, as follows: the number of the standard to which the hydrant conforms and the date of the standard

(b)

the manufacturer‟s name or trade mark

(c)

the identification number (the reference used by the manufacturer allowing identification for the supply of spares, etc).

.

(a)

.l. l

5


Underground Fire Hydrants and Surface Box Frames and Covers

1

Underground fire hydrants and surface box frames and covers shall generally comply with the requirements of BS 750.

2

Underground fire hydrants with wedge gate type or screw down type valves shall be suitable for a maximum working pressure of 16 bar.

3

Fire hydrants shall be of the wedge gate type or screw-down type.

4

The wedge gate valve shall comply with the requirements of BS 5163 for PN 16 valves. The associated duck foot bends shall be grey cast iron (CI) to BS EN 1561 Grade 250 or spheroidal graphite cast iron (SG) to BS EN 1563.

5

Materials and testing of underground fire hydraulic shall be to BS 750. Provision shall be made for a certificate to be made available which certifies that the hydrant has complied with all testing requirements of BS 750.

6

Each screw-down type hydrant and each duck foot bend on a wedge gate type hydrant shall be provided with a drain boss on the outlet side. It shall be located at the lowest practicable point.

7

The hydrants shall have screwed outlets. The screwed outlet shall be provided with a cap to cover the outlet thread. It shall be securely attached to the hydrant by a chain or other flexible device.

8

When fitted with a standard round thread outlet, the hydrant shall deliver not less than 2000 litres/minute at a constant pressure of 1.7 bar at the inlet to the hydrant.

9

The hydrant operating spindle shall be provided with a cast iron cap complying with the requirements of BS 5163. The cap shall be securely fixed to the spindle so that it remains fixed in position during normal use.

10

Each hydrant valve, duckfoot bend and outlet shall be clearly marked, either integrally with the stated components or on a plate of durable material securely fixed to that component, as follows:

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4.5.3

(a)

on wedge gate type hydrant valves: (i)

in addition to the marking requirements of BS 5163, the direction of valve opening on the gland or upper part of the hydrant.

(d)

on duckfoot bends: (i)

the number of the standard to which the hydrant conforms (i.e. BS 750) and the date of the standard

(ii)

the material designation of the body, for grey cast iron „CI‟, or for spheroidal graphite cast iron „SG‟

on screw–down type hydrants: the number of the standard to which the hydrant conforms (i.e. BS 750) and the date of the standard

(ii)

the material designation of the body, for grey cast iron „CI‟, or for spheroidal graphite cast iron „SG‟

(iii)

the direction of valve opening on the gland or upper part of the hydrant

(iv)

if loose valve mark „LV‟ or „‟Loose‟

(v)

the manufacturer‟s name or trade mark

(vi)

the identification number (the reference used by the manufacturer allowing identification for the supply of spares, etc)

on screwed outlets:

the number of the standard to which the hydrant conforms (i.e. BS 750) and the date of the standard.

qa

(i)

.

(i)

.l. l

(c)

Page 11

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(b)


ta

QCS 2014

Class, type, manufacture, workmanship, coating and design features of surface box covers and frames shall be in accordance with BS 750.

12

Surface box covers and frames shall be tested in accordance with the relevant provisions of BS 750. Provision shall be made for a certificate to be made available which certifies that samples from each production lot from which the delivery is made up comply with the requirements of BS 750.

13

Surface box covers shall be clearly marked by having the words “FIRE HYDRANT” in letters not less than 30 mm high, in English and Arabic, cast into the cover. The cover and frame shall have clearly cast thereon the following;

(b)

the date of the standard the grade of the cover and frame.

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(c)

the number of the standard to which the hydrant conforms (i.e. BS 750)

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(a)

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4.6

PIPES AND FITTINGS

4.6.1

General

1

Pipes shall be UL listed and FM approved. They shall be exterior galvanized steel to ASTM A 135 with a working pressure of 14.5 bar. Couplings may be of the rolled groove type or the mechanical locking type (push-on). Pipe end preparation for the mechanical locking type couplings will be in accordance with the manufacturer‟s recommendations.

2

Fittings shall be UL listed and FM approved. Mechanical grooved pipe couplings and fittings as manufactured by specialised manufacturers shall be used for all stand pipe systems. (a)

couplings shall be ductile iron to ASTM A 536, or malleable iron to ASTM A 47, with o chlorinated butyl gaskets suitable for an operating temperature of 95 C and heat treated carbon steel bolts and nuts to ASTM A 183

(b)

fittings shall be malleable iron to ASTM A 47 or ductile iron to ASTM A 536 with grooved or shouldered ends

QCS 2014


Page 12

(c)

flanges shall be malleable iron to ASTM A 47 or ductile iron to ASTM A 536, with a hinged, two-piece design, suitable for opening and engaging the groves, and shall be secured in position with a tight-fitting lock bolt. Cast iron flanges shall comply with ANSI B.16.1 and steel flanges steel shall comply with ANSI B 16.5

(d)

valves shall be grooved end design with encapsulated body and disc. Neck design shall readily accommodate insulation. Valves shall have pressure assisted double seal and be capable of 12 bar bubble tight shutoff. Butterfly valves shall be with gear actuator.

Hangers Supports Anchors and Guide

1

The pipework shall be supported, anchored and guided in order to preclude failure or deformation. The Contractor shall construct and install hangers, supports, anchors, guides and accessories as necessary to the approval of the Engineer. Supports shall be designed to support the weight of the pipe, the weight of fluid and the weight of pipe insulation.

2

Piping shall be securely fastened to the structure without over-stressing any portion of the structure itself. Pipe supports, anchors and guides shall be secured to concrete by means of inserts or if greater load carrying capacity is required by means of steel fishplates embedded in the concrete.

3

Hanger shall be arrange so as to prevent transmission of vibration from piping to building and supports.

4

Pipe hangers and supports shall be furnished complete with rods, bolts, lock, nuts, swivels couplings, brackets and all other components and accessories to allow installation to freely expand and contract.

5

Hangers spacing shall be such that the piping is installed without undue strains and stresses and provision shall be made for expansion, contraction, structural settlement and waterhammer.

6

Supports, clamps and hangers shall be made of galvanized steel, fixed with drilled plugs.

4.7

PUMPS

4.7.1

General

1

Furnish and install where shown on the drawings one LPCB listed fire pump package composed of both electrical and compression ignition engine driven single stage or multistage centrifugal fire pump complete with motor, control, fittings, jockey pump and speciality accessories necessary to complete the installation in every respect. The complete installation shall be in accordance with the requirements of, and meet with the approval of, the Civil Defence Department and any other authorities having jurisdiction. Centrifugal fire pumps shall have a horizontal shaft with electric motor drive. Jockey fire pumps shall have electric motor drives.

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4.6.2

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Page 13

Pumps serving water supply to fire fighting system are normally driven electrically with backup by a compression ignition engine and should always be arranged to start automatically in the event of system operation. In addition, arrangement for starting manually should also be installed. It is important that the electricity supply should always be maintained to the pumping set. It is therefore essential that the electrical connections be such that a power supply is always available for the motor when the switches for the distribution of electrical power throughout the building are cut. Any switches on the power feed to the motor should be clearly labelled, “FIRE PUMP MOTOR SUPPLY -NOT TO BE SWITCHED OFF IN THE EVENT OF FIRE”. Such switches should be of the locking type and should be kept locked on. An indicator lamp should be provided to show continuously that full power supply is available for the motor. Any fuses in the electricity sub-circuit should be of the high rupturing capacity (HRC) type.

4.7.2

Horizontal Fire Pumps

1

Pumps shall be horizontal fire pumps as indicated, factory assembled and tested. The capacity and electrical characteristics shall be as detailed elsewhere in the Project Documentation.

2

The pumps shall be capable of delivering not less than 150% of the rated flow at not less than 65% the rated head.

3

Pumps shall be hydrostatically tested at the factory and run tested pump prior to shipment. The hydrostatic test shall be at 150% of shut off head plus suction head but shall not less than 1725 kPa.

4

The pump shall meet or exceed 75% efficiency at design point.

4.7.3

Construction

1

They shall have cast-iron pump casing with suction and discharge flanges machined to ANSI B16.1 dimensions, of size and pressure rating detailed in the Project Documentation with a red paint finish.

2

Each pump shall be capable of continuous operation without producing noise in excess of hydraulic institute and OSHA guidelines.

3

Pump casing shall be close grain cast iron with a replaceable bronze case wear ring. The pumps shall be of the back pull out design so that the rotating element can be removed from the casing without disconnecting the suction or discharge piping. Full flange connections shall be integrally cast with the volute. Pump impeller shall be of cast bronze material and shall be statically and dynamically balanced. Impeller diameter shall be trimmed for the specified design conditions.

4

The pump shall be mounted on a heavy duty CI bearing frame.

5

The shaft shall be of stainless steel Grade 316 S31 to BS 970 Part 1.

6

The pump bearing shall be of the permanently sealed type designed for an L10 life of at least 50,000 hours in accordance with BS 5512 and requiring no external lubrication.

7

The pump shall be connected to drive motor by a flexible coupling capable of withstanding all torsional, radial and axial loads.

4.7.4

Fittings

1

The Contractor shall provide the following accessory fittings:

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2

(a)

eccentric tapered suction reducer

QCS 2014


(b)

concentric tapered discharge reducer

(c)

hose valve test head

(d)

hose valve with caps and chains.

(e)

pumps casing relief valve

(f)

ball drip valve

(g)

suction and discharge pressure gauges

(h)

mains relief valve

(i)

strainer (waste cone)

Page 14

Electric Motors

1

Electric motors for pumps shall be horizontal, foot mounted, ball bearing, induction motor with open drip-proof enclosure. The motor shall be mounted on the same steel base as the pump and connected to the pump with a flexible coupling. The coupling shall be protected by a coupling guard. The pump and motor shaft shall be aligned prior to shipment. The pump motor current will not exceed the full load ampere rating under any conditions of pump load. o Pump motor shall be suitable for 415/3/50 and 2900 RPM, class “F” insulation, 50 C ambient temperature indoor.

4.7.6

Compression Ignition Engine

1

1 Engine for fire pump shall be horizontal shaft, in-line, turbocharged, four stroke, liquid cooled, compression ignition type. The motor shall be mounted on the same steel base as the pump and connected to the pump with a flexible coupling. The coupling shall be protected with a coupling guard. The required pump horsepower shall not exceed the rated motor horsepower rating under any conditions of pump load. Accessories shall include 24V dc starting batteries, charging system, dual starting contactors, fuel filters, canister type air cleaner, fuel storage tank, cooling system heat exchangers, exhaust silencer and piping and engine control panel. Engine accessories shall be suitable for 240 V, single-phase, 50 Hz power supply.

4.7.7

Controller and Transfer Switch

1

The controller and transfer switch shall be LPCB listed and shall be the combined manual and automatic, across the line type. Control equipment shall be furnished in a steel mounted, drip proof enclosure with front operated circuit breaker and disconnect switch.

2

The circuit breaker shall be rated as approved for continued use.

3

The pressure regulator shall have a range of 0 to 2070 kPa with pressure settings, established at time of testing at the Site. An instantaneous recycling running period timer to prevent to frequent automatic starting of fire pump motor, set to keep the motor in operation for 6 minutes on automatic start, shall be interwired with the pressure regulator.

4

The controller shall be capable of interrupting a short circuit current at least equal to the short circuit current in the controller supply circuit.

4.7.8

Alarm Panel

1

An alarm panel with visible and audible signals for indication for FIRE PUMP CURRENT FAILURE and PUMP OPERATING shall be installed and connected to the fire pump controller.

4.7.9

Jockey Fire Pumps

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4.7.5

QCS 2014


Page 15

Jockey pumps shall be factory assembled and tested with capacities and electrical characteristics as detailed in the Project Documentation.

2

Jockey pumps shall be constructed from with cast iron diffusers and adapter with registered fits to maintain axial alignment. They shall have bronze enclosed impellers, bronze casing rings, bronze base bearing, steel clamp type shaft coupling and stainless steel shaft. The impellers shall be pinned to the shaft to prevent reverse rotation damage and to maintain proper inter-stage lateral setting. They shall incorporate threaded suction and discharge connections, mechanical seals and a cast-iron pump base with drain plug. They shall have a red paint finish.

3

The motor controller shall be LPCB listed and approved for fire pump service. Control shall include a combination type starter with fused disconnect switch, thermal over-current protection and a hand-off automatic selector switch in the enclosure. Control shall also include an adjustable pressure switch with gauge cock.

4

The installation shall come complete with a brass cased pressure gauge with a 100 mm dial on the discharge pipe near jockey pump.

5

The installation shall come complete with a 20 mm relief valve on the discharge line of the jockey pump to relieve excess pressure to floor drains.

6

The installation shall come complete with a controller sensing pipes, not less than 15 mm in diameter with a 15 mm globe valve for testing mechanism of controller.

7

The installation shall come complete with a 85 mm diameter bronze check valves with 85 mm orifice in the clapper or ground-face unions with non-corrosive diaphragm with a 85 mm orifice.

8

The jockey pumps and pump drives shall be installed on vibration isolators in accordance with the manufacturer‟s recommendations.

4.7.10


1

Upon completion of installation the Contractor shall perform field acceptance tests to demonstrate that the fire protection pumps comply with requirements of the Project Documentation.

4.8

WET RISERS

4.8.1

General

1

The wet riser installation shall incorporate an inlet box which shall be constructed from 1.5 mm thick galvanized sheet steel and shall be suitable for recessed mounting, with 3 mm thick x 40 mm wide architrave. The box shall be provided with a hinged, lockable door with a central panel glazed with wired glass and having the words “ WET RISER INLET” in 50mm high red letters on the inside face. The box shall be finished in baked enamel inside with prime coat outside to the required colour, and shall be supplied by an approved manufacture of fire equipment.

2

The wet riser installation shall incorporate inlet breaching which shall be horizontal or vertical pattern with integral spring loaded non-return valve, drain valve and blank cap. Each inlet shall incorporate a 65 mm diameter instantaneous male couplings. The body of the breaching piece shall be fitted in 25 mm gunmetal gate valve for drain purposes, with a plug and chain.

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1

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Page 16

The wet riser installation shall incorporate landing valves which shall be a spindle valve controlled breaching with a 50 mm diameter inlet and 65 mm diameter instantaneous female outlet with blank cap. The chain valves shall be straight or oblique pattern as required, and shall be fixed in the closed position. Each landing valve shall be provided with a 30 m long by 65 mm diameter fire hose lined with coated woven synthetic fire hose as well as a diffuser branch pipe nozzle. The valve, hose and nozzle shall be accommodated in a recessed box supported on purpose made hangers and ready for immediate use. The box shall be generally constructed as for the inlet breaching, but with the words “WET RISER OUTLET” in 50 mm high red letters on the inside face of the glazing.

4

The top of each dry riser shall be fitted with a 25 mm automatic air release valve, brass construction, with internal solid rubber ball.

4.9

PORTABLE FIRE EXTINGUISHERS

4.9.1

General

1

Fire extinguishers shall conform with the relevant provisions of BS 5423.

2

Fire extinguishers shall be colour coded according to their type. The colour shall be as follows:

rw

.l. l

.

3

red

-

water

(b)

cream -

foam

(c)

black

-

carbon dioxide

(d)

blue

-

dry powder

(e)

green

-

halon

as

qa

ta

(a)

The types of extinguishers that can be used on a fire is dependent upon the class of the fire. The fire classes and the types of extinguishers that can be used on them is given in Table 4.1. Final selection of extinguisher type shall be in accordance with and to the approval of the Civil Defence Department.

4

The capacity of fire extinguishers shall be as detailed in the Project Documentation.

A

Nature

Example

Extinguisher Type

Carbonaceous

Wood, paper, textiles

Water

Flammable liquids

Adhesives

Dry powder

Flammable liquid stores

Dry powder or foam

Bitumen boilers, petrol or diesel powdered equipment

Dry powder, foam, carbon dioxide or halon

Cooking range fires

Dry powder, carbon, dioxide or fire blanket

m

B

Table 4.2 Fire Class and Extinguisher Type

et it

Class

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3

C

Flammable gases

Lpg, acetylene

Carbon dioxide, powder or halon

dry

D

Reactive metals

Magnesium, sodium etc.

Dry powder specially developed for particular metals

E

Electrical

Any material where there is a danger of live electricity

Carbon dioxide, powder or halon

dry

QCS 2014


Page 17

FIRE BLANKETS

4.10.1

General

1

Fire blankets shall be manufactured from woven glass fabric coated on both sides with white silicon rubber, fully tested in accordance with BS 6575.

2

The blankets shall be supplied in white container suitable for wall mounting. Fire blankets shall be provided in the following standard sizes: 1000 x 1000 mm

(b)

1250 x 1250 mm

(c)

1500 x 1250 mm

(d)

1800 x 1250 mm

(e)

1800 x 1800 mm

.l. l

(a)

.

4.10

FM 200 SYSTEM

4.11.1

System description

1

The FM 200 system shall be sized to provide the required 5% concentration of agent in the space protected. A piping arrangement and nozzle shall convey the agent from the cylinders to the hazard and discharge the agent completely within 10 seconds. The piping and nozzles shall be engineered for the specific flow rates required and calculations shall be supplied with the system layout drawings for review and approval by the Engineer.

2

The system design shall incorporate the capability of fully testing all electrical detection, discharge control, abort, power shutdown, air conditioning shutoff, fire damper, and door closer circuits without discharge of the agent and without disconnecting the agent supply from the system.

3

Installed systems shall be complete with all control wiring for detectors, alarms, door releases, fire damper releases, abort stations, manual pull stations air conditioning and computer equipment shutdown devices, voltage trips and circuit breakers. All wiring, including control circuitry, shall consist of insulation copper conductors installed in metal conduit. The FM 200 alarm and detection system wiring and devices shall conform to QCS Section 23, Part 2, Fire Alarm and Detection Systems.

4.11.2

Equipment Instruction -Plates

1

The Contractor shall provide engraved instruction plates detailing emergency procedures at each system control panel and at each hazard area manual discharge station/abort switch location. Permanent name plates shall be used in the control panel to identify control logic unit contacts and major circuits.

2

Etched aluminium warning signs shall be provided at all entrances and exits of the protected area. Entrance sign shall read: "WARNING - DO NOT ENTER ROOM WHEN ALARM SOUNDS, FM 200 BEING RELEASED.” Exit sign shall read: “WHEN ALARM SOUNDS, VACATE AT ONCE, FM 200 BEING RELEASED.”

4.11.3

Basic Pipes and Pipe fittings

1

FM 200 manifold and piping shall conform to the relevant requirements of the latest codes and standards.

2

Pipes shall be black or galvanized steel, schedule 40 for 150mm diameter and smaller, complying with the relevant provisions of ASTM A 106.

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4.11

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Fittings shall be galvanized malleable iron 2070 kPa class complying with the relevant provisions of ASTM A 197; ductile iron 2070 class complying with the relevant provisions of ASTM A 395; or steel complying with the relevant provisions of ASTM A 234. For 20 mm diameter or smaller pipe sizes, 1035 kPa class fittings are acceptable.

4.11.4

Control Panel

1

The detection and extinguishing components shall be one integrated panel. The power source, for the system shall be two separately fused standard voltage circuits which will be connected to the control panel., The panel out-put shall be 24 Volts DC with a battery operated stand-by which will automatically take over and operate the system for 24 hours in the event normal power is interrupted. When trouble of this kind or within the system occurs, an audible signal as well as the indicating lights shall warn operating personnel. The fire detection and control system shall be comprised of a solid state, low power information processor and associated supervisory and interface circuitry. The system shall provide adequate isolation from external wiring to assure against transient signals causing false alarms. The system shall be optimised for use with graphic annunciation displays.

2

The unit shall include the following functions and logic sequence:

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operation of all smoke detection circuits

(b)

operation of all agent discharge circuit

(c)

operation of all audible (and visual) pre-alarm and alarm signals

(d)

provide primary power (and control backup power) for entire system.

(e)

provide interconnection to fire alarm and detection system and SCADA control station.

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The unit shall include supervision of the following circuitry: input power status

(b)

manual pull station circuits

(c)

alarm circuits

(d)

abort switch circuits

(e)

detection circuits

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A set of contacts for connection to pre-action valve shall be provided.

5

Activation of one detector shall activate the general alarm. The alarm shall be a combined horn and strobe (low pulse).

6

Remote annunciation to the buildings security system, and illuminate LED light on graphic annunciator

7

Activation of a cross-zoned detector in the same area shall: (a)

activation and annunciation of pre-discharge alarms. The alarm shall be combined horn and strobe (fast pulse).

(b)

energise a time delay mechanism which shall delay release for 30 seconds; the agent shall be released at the end of this time interval unless a deadman - “Agent Hold” (abort switch) is depressed; time delay to reset to 0 seconds when abort switch is depressed, restarting the time delay when released

(c)

Shut down the air-conditioning system and close its dampers.

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Discharge of the agent shall shut down power to equipment within the protected area.

9

If a manual pull station is energised, the actions detailed in Paragraphs 5, 6, 7 and 8 shall bypass the time delay and overriding abort switch.

4.11.5

Storage Cylinders

1

The FM 200 cylinders shall be constructed of high strength steel alloy conforming to applicable specifications of the Civil Defence Department. All containers shall be mounted securely in an upright position. Cylinders manifolded together shall be of the same size and weight/capacity. Each cylinder in a multiple cylinder group connected to a manifold shall be fitted with a flexible discharge hose and a manifold check valve. The check valve shall prevent agent loss during discharge should a cylinder be disconnected from the manifold. A mechanical method of actuation shall be provided at the cylinder location for local emergency operation.

4.11.6

Discharge Valve

1

Operation of the valve shall be by means of differential pressure using the container pressure at the source. The force differential and a metallic spring shall act to hold the valve closed prior to discharge and the force shall reverse upon actuation to open the valve. This reversal shall be accomplished by means of venting the agent through an opening on the container valve. The container valve shall be equipped with a pressure gauge for continuous monitoring of the container pressure safety outlet to automatically relieve pressure build-up.

4.11.7

Discharge Nozzles

1

Discharge nozzles shall be one piece cast aluminium, have either a 180° or 360° flat fanshaped discharge pattern and range in orifice sizes from 3 mm to 50 mm in 1 mm increments.

4.11.8

Pressure Switch

1

This pneumatically actuated switch shall be used to give positive identification of release of the agent in the piping system.

2

The switch shall have one set of normally open and one set of normally closed contacts.

4.11.9

Smoke Detectors

1

Devices shall be UL listed and FM approved. The minimum contacts rating shall be one ampere for both standard voltage, single phase, 50 hertz, ±10% fluctuation.

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4.11.10 Graphic Annunciator 1

An engraved multi-layer acrylic graphic display showing walls, doors, windows, location of control panel and location of all smoke detectors shall be provided. The number and location of the displays shall be as stated elsewhere in the Project Documentation. Silk screen graphics are not acceptable.

2

Panel colour shall be white with black lettering. Indicators shall be light emitting diodes (LED) in red, yellow or green. All points shall be wired to a labelled terminal strip which is plug compatible to the wiring harness for ease of installation. All graphics shall use a hideaway hinge system that eliminates the need for metal frames and visible screw heads. Back boxes shall be made of 1.5 mm thick steel.

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4.11.11 Battery Backup Power System 1

Battery backup of the entire FM 200 system, including detection, alarm, actuation and supervisory system is required. The backup system must be designed such that upon main power failure, backup power automatically services the system with no delay or interruption of any kind. The battery system must be capable of powering-the system for a period of-not less than 24 hours in a normal standby condition, at the end of which time it shall be capable of operating the entire system in a full alarm condition for period of not less than ten minutes. The trouble horn and light shall be activated to indicate that the system is operating on a battery power.

4.11.12 Alarm Horn/strobe Combination The alarm horn shall operate on 24 volt polarised DC power to allow supervision of the circuit wires.

2

The alarm horn shall have a minimum sound level of 98 decibels at 3 m.

3

A horn and strobe light shall operate simultaneously from one power supply with flash rate of 1-3 flashes per second with peak light intensity of 800 candlepower.

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4.11.13 Manual Pull Stations

The manual pull station shall be provided for the release of the FM 200 in case of an emergency.

2

The unit shall be contained within a metal body having a single pole switch. The unit shall require double action operation.

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4.11.14 Abort Switch

The abort switch shall be used where investigation delay is desired between detection and actuation of the system.

2

This switch shall be a momentary contact "dead-man" type switch requiring constant pressure to operate one set of normally open and one set of normally closed contacts on each contact block. Clear operating instructions shall be provided at the abort switch.

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4.11.15 Automatic Fire Dampers Provide press sure trips for automatic fire dampers in air conditioning ductwork servicing hazard areas separated by fire walls. Activation of fire dampers shall occur upon activation of FM 200 discharge. In case of motorised or electro thermal link dampers, pressure trips are not required.

4.11.16 Basic Identification of Installation 1

Piping System Identification : Bare and insulated piping shall be labelled in accordance with a piping colour code. Lines above ceilings shall have utility name and directional flow arrows stencilled in designated colour. Exposed piping in mechanical equipment room shall be painted with their designated colour, flow arrow to be painted in contrasting colour. Spacing of description and arrow to be 10 m.

2

Underground Piping Identification : Provide continuous underground type plastic marker, located directly over buried line at 150 to 200 mm below finished grade.

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3

Valve Identification : Provide valve tag on every valve in each piping system. Tag shall be brass, 50mm in diameter with utility service and valve number embossed or stamped on it. List each tagged valve in valve schedule for each piping system. Mount valve schedule frames and schedules in machine rooms.

4

Mechanical Equipment Identification : Provide engraved plastic laminate sign or plastic equipment marker on or near each major item of mechanical equipment and each operational device, including main control and operating valves and primary balancing dampers.

5

Install fire protection signs on piping in accordance with requirements of the Civil Defence Department.

4.11.17 Installation of Pipes and Pipe Fittings The Contractor shall comply with requirements of codes and standards for installation of fire protection piping materials. Install piping products where indicated, in accordance with manufacturer's written instructions, and in accordance with recognised industry practices to ensure that piping systems comply with requirements and serve intended purposes.

2

Co-ordinate with other work as necessary to interface components of fire protection piping properly with other work.

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4.11.18 Pressure Test

After portions of the FM 200 Systems work are completed, the work shall be hydrostatically tested in the presence be the Engineer. Five days advance notice of the tests shall be given to the Owner. Furnish all pumps, gauges, instruments, test equipment and personnel required for these tests and make all provisions for removal of test equipment.

2

Piping shall be tested individually by fire suppression zones, with plugs and/or caps in place of nozzles and agent storage containers as follows. A preliminary test of not more than 1500 kPa shall be applied to reveal possible major leaks. After this preliminary test, the pressure shall be raised to 2,000 kPa. If leaks are found, they shall be eliminated by tightening, repair or replacement. On completion of any remedial work, hydrostatic tests shall be repeated until no leakage occurs.

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4.11.19 Flow and Compliance Test The Contractor shall co-ordinate and schedule flow tests at a times agreed with the Engineer. The Contractor shall notify the Engineer as to the time of flow and compliance tests a minimum of two weeks In advance of any such tests.

2

The Contractor shall provide all test equipment necessary to test and demonstrate that the FM 200 Systems satisfactory complies with the Project Documentation requirements. The flow and compliance test report shall include recordings of the following data:

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(a)

verification of status; for each item of equipment, alarm signalling, and zone barrier closure device prior to the test and at each stage of FM 200 Alarm, including abort and reset to the manual mode

(b)

discharge time; time period to complete discharge by means of digital timing devices

(c)

concentration; use thermal conductivity recording gas analysers with a minimum of three simultaneous recording points. Concentrations shall be recorded through entire holding time

Complete data shall be recorded for each fire suppression zone per the following scenario description:

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Conditions Normal; simulate an occupied facility, and verify status of device and equipment, using test lights on valves in lieu of pressurised agent storage containers

(b)

Stage I FM 200 Alarm; activate a random smoke detector by canned smoke or similar agent and verify status of devices and equipment.

(c)

Stage II FM 200 Alarm; activate another random smoke detector by canned smoke, or similar agent; after alarm, activate abort mode and verify status of devices and equipment

(d)

Manual Mode; cancel the FM 200 timed release period logic by activated the key operated reset, and verify status of devices and equipment.

(e)

Stage III FM 200 Alarm; activate a manual discharge station and verify status of devices and equipment.

(f)

Conditions Normal; simulate an occupied facility and verify status of devices and equipment with pressurised agent storage containers replacing the test lights on valves.

(g)

Stage IV FM 200 Alarm; activate random smoke detectors by canned smoke, or similar agent, and allow the FM 200 timed release period logic to discharge the test gas; record times and concentrations.

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If flow and compliance test indicates a fire suppression zone including related accessory devices and equipment failed to function, or concentrations during holding period were not satisfactory; reschedule another flow and compliance test to demonstrate satisfactory performance after making corrections.

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4.11.20 Painting

Priming: All shop-fabricated and factory-built equipment,: devices and apparatus not galvanized, or protected by plating, or a baked enamel finish, shall be cleaned and given one shop coat of paint primer. Any portions of shop coat damaged in delivery, during construction, or prior to finish painting, shall be re-coated.

2

Finish Painting: Do not paint name plates, labels, placards, tags, stainless steel or plated items, valve stems, motor shafts, levers, handles, trim strips, etc. Exposed and visible piping, equipment devices and apparatus in FM 200 Systems shall be ANSI standard colour.

3

Identification: Stencil 40 mm high white enamel block type characters on all items of equipment for identification purposes. Also, stencil a complete system of pipe identification adjacent to each valve and branch-take-off, and at not over 15 m intervals along runs of pipe, with flow arrows at each marking. Pipe identification shall be contrasting colour, either white or red, to the finish coating of the piping

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4.11.21 CAPSULAR TYPE - FIRE EXTINGUISHING AND SUPPRESSION SYSTEM for the MCC/MV panels 1

Supply and install an automatic fixed type fire extinguishing and suppression system using clean agent (People safe gas - FM200 or NOVEC -123 or similar QCD approved) for all the MCC/MV panels.

2

The automatic capsular type fire extinguishing system shall have the required UL (USA)/FM /CE (Europe)/ or LPCB or CSIRO (Austr) and Qatar Civil Defence approvals.

3

The system shall consist in individual capsules installed in each column compartments.

4

The system shall be direct release–low pressure using suitable polymer tubing as fire detection and fire extinguishing delivery system. The tubing shall rupture when exposed to the flame at 100 Degree C.

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A local indication shall be provided by means of a pressure gauge for each system. A remote indication shall be provided for each system in the common alarm anunciator panel.

6

The system shall have a common anunciator panel installed in the same electrical room.

7

Common alarm from the capsular system common anunciator panel shall be transmitted to SCADA to indicate that the gas has been released.

8

A lock-off system shall be provided for use when maintenance is carried out and suitable warning notices shall be provided.

9

All control panels (such as but not limited to: MCC , MV panels, PFCC, synchronising DG panels, stand-alone VFD‟s and Electronic Soft Starters panels) shall be provided with the above mentioned automatically operated Capsular type fire extinguishing and suppression system.

10

The system shall have successful operation installations in Qatar for a minimum 5 years in substantial number of operational installations in similar applications.

11

The manufacturer of the capsular type fire extinguishing system shall provide the design installation and warranty of the complete capsular type fire extinguishing system.

12

Spares cylinders and components shall be provided in a quantity no less that 10% installed.

13

The system shall include permanent notices to warn the personnel of the presence of the system and to provide instructions on its use and detailing the actions to be taken in an emergency and after the fire has been extinguished.

14

The gas discharged shall disconnect the MCC main incomer, disconnect the AC and shall initiate an alarm in SCADA control Room.

15

The Contractor shall provide written confirmation from the MCC manufacturer of his approval of the Extinguishing design and installation and confirmation that the installation does not contravene any of his MCC design requirements or certifications.

16

A discharge test shall be carried out on site and the Contractor shall provide all test equipment and clean agent as necessary to carry out the site test.

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END OF PART

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TESTING AND COMMISSIONING ................................................................ 2 GENERAL ...................................................................................................... 2 Scope of Work 2 References 2 Definitions 2 System Description 2 TESTING, START-UP AND COMMISIONING .............................................. 3 General 3 MAINTENANCE ............................................................................................. 4 General 4 System Spare Parts 4 System Test Equipment 4 TRAINING ...................................................................................................... 5 General 5 System Supervision Training 5 Other Staff Training 5 SUBMITTALS ................................................................................................ 6 Record Drawings 6 Test Records 6

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5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2

Section 23: Fire Fighting and Fire Alarm Systems Part 05: Testing and Commissioning

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5

TESTING AND COMMISSIONING

5.1

GENERAL

5.1.1

Scope of Work

1

This Part specifies the requirement for the testing and commissioning of fire alarm systems, fire protection systems and fire fighting systems.

2

Related Sections are as follows: General

References

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Section 1

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BS 5839 ......................Fire detection and alarm systems in buildings

Definitions

1

Test: To determine quantitative performance of systems or components thereof.

2

Adjust: To regulate the specified rates, parameters at the terminal equipment.

3

Balance: To proportion flows within the distribution system.

4

Procedure: Standardised approach and execution of sequence of work operations to yield reproducible results.

5

Terminal: The point where the controlled fluid enters or leaves the distribution system.

6

Main: Pipe containing the system’s major fluid flow.

7

Sub-main: Pipe containing part of the system’s capacity and serving two or more branch mains.

8

Branch Main: Pipe serving two or more terminals.

9

Branch: Pipe serving a single terminal.

5.1.4

System Description

1

The Contractor shall provide all necessary personnel and equipment required to commission the various items of plant and equipment comprising the various systems included in the Works.

2

Any specific requirements relating to the commissioning of each system shall be carried out as detailed in the Project Documentation. All costs associated with providing the requirements shall be included within the Contractor’s rates.

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5.1.3

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Both the installation and the commissioning activities shall be undertaken as a single continuous operation. Upon completion of the installation activity, the Contractor shall test, start-up, commission and hand over the system.

5.2

TESTING, START-UP AND COMMISIONING

5.2.1

General

1

The Engineer shall be present at the tests and be at liberty to participate in them. Such participation shall not relive the Contractor of his responsibilities for carrying out the tests satisfactorily.

2

The Contractor shall be responsible for inspecting and testing all the components of the system. Such components shall include, but not limited to, the following:

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detectors

(b)

call points

(c)

alarms

(d)

ancillary devices

(e)

fire controller equipment and associated devices

(f)

auxiliary equipment

(g)

operating and control software.

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(a)

The fire controller and associated devices and modules shall be tested in accordance with the guidelines set out in BS 5839: Pt 1 and the testing instructions provided by the manufacturer.

4

The Contractor shall start up and operate the system for a trial period to ensure that it operates correctly. The duration of the trial period shall be as stated in the Project Documentation.

5

The Contractor shall test all performance of the completed system, including the software, to ensure that it operates in accordance with the requirements of the Specification, all relevant standards ad the manufacturer’s recommendations.

6

The Contractor shall undertake an audibility test of the alarms. The duration and performance assessment criteria shall be determined on-site by the Engineer unless otherwise stated in the Project Documentation.

7

The Contractor shall start-up the system, or parts thereof, and make the necessary adjustments to ensure correct functioning.

8

The Contractor shall at his own expense carry out alterations to the system if the testing fails to demonstrate the satisfactory nature of the system, or parts thereof.

9

The Engineer shall call for further tests when such alterations have been made and his decision as to what constitutes a satisfactory test shall be final. The cost of all such further testing shall be at the Contractors own expense.

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5.3

MAINTENANCE

5.3.1

General

1

The Contractor shall submit complete details of all materials and labour required to maintain the system in correct working order. The Contractor shall also include details of the testing procedures that need to be carried out and specify a maintenance schedule.

5.3.2

System Spare Parts

1

The Contractor shall provide a detailed list of the system spare parts that should be kept onsite for maintenance of the system. The system spare parts which should be considered for inclusion in the list include the following: heat detectors

(b)

smoke detectors

(c)

flame detectors

(d)

call points

(e)

alarms

(f)

beacons

(g)

door retention units

(h)

fuses

(i)

circuit breakers.

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(a)

The quantity of each of spare part kept on-site shall be sufficient to last for the duration of the maintenance period and in addition, for a further period of two (2) years unless otherwise stated elsewhere in the Project Documentation.

3

Details of the system spare parts that are to be kept on-site for maintenance of the system shall be stated in the Operations and Maintenance Manual.

4

The Contractor shall guarantee the availability of all system spares for a period of not less than ten (10) years.

5.3.3

System Test Equipment

1

The Contractor shall provide a detailed list of system test equipment and consumables that should be kept on-site for maintenance of the system. The system test equipment and consumables which should be considered for inclusion in the list include the following:

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(a)

detector head removal tool

(b)

detector base skirt removal tool

(c)

call point testing tool

(d)

detector test smoke canister

(e)

detector test adapter

(f)

aerosol dispensing tube

(g)

spare log book.

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Page 5

The quantity of each of spare part kept on-site

3

The quantity of each item of test equipment required and the quantity of each type of consumables required shall be sufficient to last for the duration of the maintenance period and in addition, for a further period of two (2) years unless otherwise stated elsewhere in the Project Documentation.

4

Details of the system test equipment and consumables that are to be kept on-site for maintenance of the system shall be stated in the Operations and Maintenance Manual

5

The Contractor shall guarantee the availability of all system test equipment and consumables for a period of not less than ten (10) years.

5.4

TRAINING

5.4.1

General

1

The Contractor shall provide details of the training required by personnel to operate and maintain the fire detection and alarm system.

2

The Contractor shall provide two levels of training:

(b)

other staff training.

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System Supervision Training

1

System supervision training shall include technical training sessions and on-site training given during installation and commissioning of the system.

2

An experienced and competent engineer familiar with the fire system being installed shall give system supervision training.

3

The scope of training provided shall depend on the type, size and complexity of the system.

4

The Contractor shall initially provided technical training in all aspects of the system. The trainee shall then be given full instructions in the use, operation and maintenance of the system. This shall include instruction in the procedures to be followed in the event of fire and false alarms, routine maintenance and testing procedures, and how to keep the Log Book.

5.4.3

Other Staff Training

1

Other staff training shall include training sessions provided on-site after hand over of the system.

2

An experienced and competent engineer familiar with the fire system installed shall give the training sessions.

3

The scope of training provided shall include full operating instructions in the use of the fire system. This shall include instruction in the procedures to be followed in the event of fire and false alarms.

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5.4.2

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5.5

SUBMITTALS

5.5.1

Record Drawings

1

The Contractor shall submit record drawings of installed fire alarm systems, fire protection systems, fire fighting systems including equipment data in accordance with the relevant provisions of Section 1, General.

2

Notwithstanding the foregoing, the drawings shall include but not be limited to the following: arrangement drawings of each complete installation to a scale of not less than 1:50

(b)

outline dimensioned drawings of each of the principal items of plant; each be accompanied by a schedule with full particulars of fittings, instruments and components

(c)

sectional drawings of each of the major items of plant with parts named and numbered to facilitate maintenance and overhauls; these drawings shall also show the type of fit and running clearance for fitted and running parts and with them shall be included such detailed workshop drawings as may be necessary for the manufacture of replacement components during the working lifetime of the plant

(d)

electrical, hydraulic and operational diagrams as may be necessary.

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Test Records

1

The format of recording tests shall be agreed with the Engineer. The Engineer shall be present at the tests and be at liberty to participate in them.

2

The Contractor shall make all records during the test and on completion thereof, shall provide the Engineer with a Test Report.

3

Test Reports shall be arranged and collated in a logical order. This data shall form a permanent record to be used as the basis for required future testing, adjusting and commissioning.

4

Test Records shall comply with the relevant provisions of Section 1, General.

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5.5.2

END OF PART

QCS 2014

Section 24: Finishes to Building Part 01: General

Page 1

GENERAL---------------------------------------------------------------------------------------------------------- 2

1.1

INTRODUCTION ------------------------------------------------------------------------------------------------- 2

1.1.1

Scope --------------------------------------------------------------------------------------------------------------- 2

1.1.2

References--------------------------------------------------------------------------------------------------------- 2

1.1.3

Workmanship------------------------------------------------------------------------------------------------------ 5

1.1.4

Scaffolding --------------------------------------------------------------------------------------------------------- 5

1.2

SAMPLE PANELS AND CONTROL SAMPLES ---------------------------------------------------------- 5

1.2.1

Samples ------------------------------------------------------------------------------------------------------------ 5

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Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the general requirements for various methods and types of interior finishes within buildings for walls, floors, and ceilings.

2


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General Concrete Insulation of Buildings Metalwork Carpentry, Joinery and Ironmongery Painting and Decorating

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References

1

The following standards are approved and/ or referred to in this Section:

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1.1.2

ASTM C514 ...............Standard Specification for Nails for the Application of Gypsum Board

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BS 476........................Fire tests on building materials and structures BS 812........................Testing aggregates

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BS 1202 .....................Nails

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BS 882........................Aggregates from natural sources for concrete

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BS 3416 .....................Bitumen based coating for cold application, suitable for use in contact with potable water

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BS 4223 .....................Determination of constructional details of textile floor coverings with yarn pile

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BS 4682 .....................Methods of test for dimensional stability of textile floor coverings BS 5212 .....................Cold applied joint sealant systems for concrete pavements

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BS 5325 .....................Installation of textile floor coverings, Code of practice BS 5390 .....................Code of practice for stone masonry BS 5808 .....................Underlays for textile floor coverings BS 5975 .....................Code of practice for temporary works procedures and the permissible stress design of falsework BS 6073-2 .................... Precast concrete masonry units: Guide for specifying precast concrete masonry units

BS 8000 .....................Workmanship on building sites BS 8203 .....................Code of practice for installation of resilient floor coverings BS 8203 .....................Code of practice for installation of sheet and tile flooring BS 8204 .....................In-situ flooring BS 8481 ....................Design, preparation and application of internal gypsum, cement, cement and lime plastering systems. Specification BS EN 459-1 .............Building lime: Definitions, specifications and conformity criteria

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Page 3

BS EN 520 ................Gypsum plasterboards. Definitions, requirements and test methods BS EN 649 ................Resilient floor coverings. Homogenous and heterogenous polyvinyl chloride floor coverings. Specification BS EN 772-2.................. Methods of test for masonry units: Determination of percentage area of voids in masonry units (by paper indentation)

BS EN 10142 .............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions. BS EN 10143 .............Continuously hot-dip metal coated steel sheet and strip – Tolerances and dimensions and shape BS EN 12163 .............Copper and copper alloys. Rod for general purposes BS EN 12164 .............Copper and copper alloys. Rod for free machining purposes BS EN 12167 ............Copper and copper alloys. Profiles and bars for general purposes

..........Aggregates for mortar

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BS EN 13139

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BS EN 12878 ............Pigments for the colouring of building materials based on cement and/or lime. Specifications and methods of test

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BS EN 13914-2 ..........Design, preparation and application of external rendering and internal plastering: Design considerations and essential principles for internal plastering

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BS EN 13914-1 .........Design, preparation and application of external rendering and internal plastering: External rendering

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BS EN 14353. ............... Metal beads and feature profiles for use with gypsum plasterboards. Definitions, requirements and test methods

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BS EN 14411 ............Ceramic tiles. Definitions, classification, characteristics, evaluation of conformity and marking

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BS EN 14496 ................. Gypsum based adhesives for thermal/acoustic insulation composite panels and plasterboards. Definitions, requirements and test methods

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BS EN 14566 ................. Mechanical fasteners for gypsum requirements and test methods

plasterboard

systems.

Definitions,

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BS EN ISO 2081 .......Metallic and other inorganic coatings. Electroplated coatings of zinc with supplementary treatments on iron or steel of

cadmium

with

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BS EN ISO 2082 .......Metallic coatings. Electroplated coatings supplementary treatments on iron or steel

BS EN ISO 10595 ......Resilient floor coverings. Semi-flexible/vinylcomposition (VCT) poly (vinyl chloride) floor tiles. Specification EN 197-1 ....................Portland cement EN 998-1:2010 ..........Specification for mortar for masonry. Rendering and plastering mortar EN 1745:2002 ...........Methods for determining thermal properties GSO EN 413-1 ...........Masonry cement: Composition, specifications and conformity criteria GSO EN 771-3 ............. Specification for masonry units: Aggregate concrete masonry units (dense and lightweight aggregates)

GSO EN 13950 .........Gypsum plasterboard thermal/acoustic insulation composite panels Definitions, requirements and test methods GSO EN 13963 .........Jointing materials for gypsum requirements and test methods

plasterboards

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Definitions,

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Page 4

GSO EN 14195 .........Metal framing components for gypsum plasterboard systems Definitions, requirements and test methods GSO EN 13748-2:2008 Terrazzo tiles. Terrazzo tiles for external use GSO EN 13748-1:2008 Terrazzo tiles. Terrazzo tiles for internal use GSO ISO 105 ............... Textiles. Tests for colour fastness

GSO ISO 6308 ..........Gypsum plaster board specification GSO ISO 13006 ........Ceramic tiles. Definitions, classification, characteristics and marking GSO ISO 10545-16 (BS EN ISO 10545-16) Ceramic tiles: Determination of small colour differences

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GSO ISO 10545-15 (BS EN ISO 10545-15). Ceramic tiles: Determination of lead and cadmium given off by glazed tiles

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GSO ISO 10545-14 (BS EN ISO 10545-14). Ceramic tiles: Determination of resistance to stains

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GSO ISO 10545-13 (BS EN ISO 10545-13). Ceramic tiles: Determination of chemical resistance

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GSO ISO 10545-12 (BS EN ISO 10545-12). Ceramic tiles: Determination of frost resistance

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GSO ISO 10545-11 (BS EN ISO 10545-11). Ceramic tiles: Determination of crazing resistance for glazed tiles

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GSO ISO 10545-10 (BS EN ISO 10545-10). Ceramic tiles: Determination of moisture expansion

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GSO ISO 10545-9 (BS EN ISO 10545-9) Ceramic tiles: Determination of resistance to thermal shock

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GSO ISO 10545-8 (BS EN ISO 10545-8). Ceramic tiles: Determination of linear thermal expansion

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GSO ISO 10545-7 (BS EN ISO 10545-7). Ceramic tiles: Determination of resistance to surface abrasion for glazed tiles

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GSO ISO 10545-6 (BS EN ISO 10545-6). Ceramic tiles: Determination of resistance to deep abrasion for unglazed tiles

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GSO ISO 10545-5 (BS EN ISO 10545-5). Ceramic tiles: Determination of impact resistance by measurement of coefficient of restitution GSO ISO 10545-4 (BS EN ISO 10545-4). Ceramic tiles: Determination of modulus of rupture and breaking strength GSO ISO 10545-3 (BS EN ISO 10545-3). Ceramic tiles: Determination of water absorption, apparent porosity, apparent relative density and bulk density GSO ISO 10545-2 (BS EN ISO 10545-2). Ceramic tiles: Determination of dimensions and surface quality GSO ISO 10545-1 (BS EN ISO 10545-1) Ceramic tiles: Sampling and basis for acceptance GSO ISO 13007-4 (BS ISO 13007-4) Ceramic tiles. Grouts and adhesives: Test methods for grouts GSO ISO 13007-3 (BS ISO 13007-3)_ Ceramic tiles. Grouts and adhesives: Terms, definitions and specifications for grouts GSO ISO 13007-2 (BS ISO 13007-2) Ceramic tiles. Grouts and adhesives: Test methods for adhesives

GSO ISO 13007-1 (BS ISO 13007-1) Ceramic tiles. Grouts and adhesives: Terms, definitions and specifications for adhesives

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ISO 14544 .................Fine ceramics (advanced ceramics, advanced technical ceramics) -Mechanical properties of ceramic composites at high temperature -Determination of compression properties ISO 14574 .................Fine ceramics (advanced ceramics, advanced technical ceramics). Mechanical properties ISO 15165 .................Fine ceramics (advanced ceramics, advanced technical ceramics) -Classification system PD CEN/TR 15123 .....Design, preparation and application of internal polymer plastering systems QS 12/2012 ................Specifications of Recycled Aggregates of Construction Waste for using in Construction Works Workmanship

1

All work is to be performed by experienced and trained specialists or under supervision by specialists or trained personnel.

1.1.4

Scaffolding

1

Scaffolding is to be erected to external facades and any other areas where it is required before any work is commenced, so that good access is obtained to the whole of the working area

2

Scaffolding is to be supported independently of the working area and is to provide platforms at about 2 metre intervals. A gap of at least 250mm should be left between the work face and the scaffolding to allow sufficient clearance for working.

3

Scaffolding to be designed and erected in accordance with BS 5975.

1.2

SAMPLE PANELS AND CONTROL SAMPLES

1.2.1

Samples

1

Sample panels minimum size 600 x 600mm are to be prepared for all textured coatings to be used in the Works.

2

If the Engineer so requires, a control samples of a finishing materials shall be prepared in an agreed location within the Works (e.g. the floor tiling to a complete room). The area to be used as a control is to be completed and approved to the standard of workmanship and appearance obtained before the application of the material is proceeded with elsewhere in the Works.

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END OF PART

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JOINTS, CAULKING AND SEALANTS ......................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 System Description 2 Samples 2 Test Panels 3 Certification 3 MOVEMENT JOINTS IN TILED FLOORS ..................................................... 3 Installation and Workmanship 3 Movement Joint Filler and Sealant 4 BRASS DIVIDING STRIP .............................................................................. 4 General Requirements 4 MATERIALS .................................................................................................. 4 General Requirements 4 Products 4 WORKMANSHIP ........................................................................................... 5 Execution 5

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10 10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.2 10.2.1 10.2.2 10.3 10.3.1 10.4 10.4.1 10.4.2 10.5 10.5.1

Section 24: Finishes to Buildings Part 10: Joints, Caulking and Sealants

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JOINTS, CAULKING AND SEALANTS

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the requirements for joints, caulking and sealants.

2

Related Parts and Sections are as follows


General Concrete Metalwork

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Tiles Terrazzo Stone Flooring Unit Masonry Flooring Floor Screeds and Treatments

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10

References

1


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BS 5212 ......................Cold applied sealant systems for concrete pavements

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BS 5390 ......................Code of practice for stone masonry BS 8203 ......................Code of practice for installation of sheet and tile flooring

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BS 8204 ......................In-situ flooring

System Description

1

The Contractor is to include for all pointing, sealing, jointing caulking etc., in all locations indicated on the drawings and where elsewhere required for waterproofing, movement, sealing, etc. All materials shall be of a proprietary manufacture whose instructions shall be followed at all times and shall be to the approval of the Engineer.

2

All materials shall be compatible with the other materials they shall come into contact with and shall be specifically manufactured for the location in which they have to be used.

10.1.4

Samples

1

The Contractor shall submit two cartridges or representative samples of all sealants and backup materials.

2

The samples shall include the following information:

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10.1.3

(a)

supplier

(b)

name of material

(c)

specification

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(d)

colour

(e)

date of manufacture

(f)

life expectance and shelf life.

Page 3

The Contractor shall submit two (2) copies of manufacturer’s specifications, recommendations and installation instructions for each type of sealant and associated miscellaneous backup material required.

4

These shall include manufacturer’s published data or letter of certification, or certified test laboratory reports, indicating that each material is intended generally for the applications shown.

10.1.5

Test Panels

1

Before sealant installation work commences, test panels of each type and application of sealant shall be installed in strict conformity with the manufacturer’s requirements in finished work. If necessary, this work shall be supervised by a representative of the sealant supplier.

2

The Engineer shall be informed of the location of such test panels, and may change their location if he deems necessary.

3

Test panels designated to be incorporated in the Works shall not be considered acceptable until the Engineer provides written approval. As-built drawing with the locations of each test panel shall be submitted to the Engineer.

4

Each test panel of a type and application of sealant shall be no less than 7.5 linear metres. The test panels shall be used for determining faults should any joint failure occur at a later stage.

10.1.6

Certification

1

The manufacturer of the sealant shall certify: that the sealants and accessory materials to be used are compatible with each other, chemically and in adhesion

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(b)

that the materials are fit for the purpose and conditions of use

(c)

that the sealant, primer where required, and backer rod are compatible and will cause no staining of material in which they are installed.

10.2

MOVEMENT JOINTS IN TILED FLOORS

10.2.1

Installation and Workmanship

1

Unless otherwise indicated in the Project Documentation, a 10 mm movement joint is to be formed at the perimeter of all tiled floors and where the tiling meets structural features such as columns, machine bases etc.

2

In clay floor tiling additional intermediate movement joints are to be provided where the flooring exceeds 6 m in any direction. In other tiled floor finishes additional intermediate movement joints are to be provided where the flooring exceeds 12 m in any direction.

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Page 4

Where a structural movement joint is provided in the base, a movement joint of the same width in the bedded finish is to be positioned immediately above.

4

The movement joint cavities are to extend through the combined thickness of the finish and the bedding mortar or compound and be completely filled and sealed after grouting of the normal joints takes place.

5

The requirements of this Part shall be implemented with additional compliance to BS 5212: Part 2, BS 5390, BS 8203, and BS 8204 as applicable for the flooring system used.

6

Changes in colour or type of finish in doorways where movement joints occur are to be situated under the centreline of the door leaf.

10.2.2

Movement Joint Filler and Sealant

1

Movement joint filler is to be approved impregnated fibreboard or cellular polyethylene which is compatible with the sealant being used and which does not excrete bituminous or oily products.

2

Sealants are to comply with the requirements recommended by the manufacturer for the situation in which they will be used.

3

Butyl mastics and other forms of soft sticky mastics are not to be used.

10.3

BRASS DIVIDING STRIP

10.3.1


1

Where used for tile edging, brass dividing strips shall be flush with tile surface and shall comply with the relevant provisions of Section 17.

10.4

MATERIALS

10.4.1


1

Materials shall be installed in strict accordance with manufacturer’s instructions. Where necessary, the manufacturer shall provide training and/or site supervision.

10.4.2

Products

1

Before purchase of each sealant the Contractor shall investigate its compatibility with the joint surfaces, joint fillers and other materials.

2

Three part sealants shall be an epoxidised polyurethane mixed in strict accordance with manufacturer’s instructions. Activated (mixed) sealant not used on the job shall be discarded after a period of hours as instructed by the manufacturer, but in no case shall activated sealant be held overnight.

3

Two part sealants shall be a 100 % urethane abrasion-resistant products. They must be installed with a primmer under the optimum surface conditions as indicated in the manufacturer’s printed data.

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Interior sealants shall be one-part, non-sag in areas of constant water or moisture contact, where no painting will take place. In places where painting or other dry wall finishing conditions prevail, the interior sealant shall be a one-part latex acrylic with a fungicide to reduce mildew, solvent-based acrylic 100% terpolymer, or silicon.

5

Joint cleaner shall be a cleaning compound recommended by the sealant manufacturer, for the joint surfaces to be cleaned.

6

Joint primer/sealer shall be as recommended by the sealant manufacturer, for the joint surfaces to be primed or sealed.

7

Bond breaker self-adhesive tape shall be polyethylene tape or other plastic tape as recommended by the sealant manufacturer. It shall be applied to sealant-contact surfaces where bond to the substrata or joint filler must be avoided for the proper performance of the sealant.

8

Sealant backer rod shall be compressible rod stock, non-grassing, closed cell urethane foam, polyethylene foam or neoprene foam or other flexible, permanent, durable, non-absorptive material as recommended for compatibility with sealant by the sealant manufacturer.

10.5

WORKMANSHIP

10.5.1

Execution

1

Sealants shall be installed by a firm with a minimum of 5 years successful experience in the application of the types of materials required.

2

Joint surfaces shall be cleaned immediately before installation of sealant. Dirt, insecure coatings, moisture and other substances, which would interfere with the bond of sealant or caulking compound, shall be removed.

3

Sealants shall not be placed on joint surfaces that have been painted, lacquered, waterproofed or treated with water repellent or other treatment or coating unless a laboratory test for durability (adhesion) has successfully demonstrated that the sealant bond is not impaired by the coating or treatment. If a laboratory test has not been performed or shows bond interference, the coating or treatment shall be removed from joint surface before installing the sealant.

4

Joint surfaces on vitreous coated and similar non-porous materials shall be roughened wherever sealant manufacturer’s data indicates lower bond strength or porous surfaces.

5

Joint surfaces shall be primed and sealed wherever shown or recommended by the sealant manufacturer.

6

Sealant backer rod shall be installed behind sealants unless otherwise indicated in the Project Documentation or recommended by the sealant manufacturer.

7

Bond breaker tape shall be installed wherever recommended by the manufacturer to ensure that sealants will perform properly.

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The sealant shall be installed to the depths as detailed in the Contract Documentation or as recommended by the sealant manufacturer but within the following general limitations. Measured at the centre (thin) section of the joint. (a)

for sidewalks, pavements and similar joints subject to traffic and other abrasion and indentation, joints shall be filled to a depth equal to 75% of joint width, but not more than 16 mm deep and not less than 10 mm deep.

(b)

for normal movement joints not subject to traffic, joints shall be filled to a depth equal to 50% of joint width, but not more than 12 mm deep and not less than 9 mm deep

(c)

where joints are wider than 25 mm, the recommendations of the sealant manufacturer shall be followed

Sealants, primers and sealers shall not be allowed to overflow or spill onto adjoining surfaces or to penetrate into the voids of adjoining surfaces. Masking tape or other precautionary devices shall be used to prevent staining of adjoining surfaces.

10

Excess and spilled sealants/primers/sealers shall be removed promptly as the work progresses. All adjoining surfaces shall be cleaned by whatever means may be necessary to eliminate evidence of spillage, without damage to the adjoining surfaces of finishes.

11

Sealants shall be cured in compliance with the manufacturer’s instructions and recommendations, to obtain high early bond strength, internal cohesive strength and surface durability.

12

Procedures required for the curing and protecting of sealants during the construction period, as recommended by the manufacturer, shall be strictly followed.

13

No surface treatments will be allowed that will affect either appearance or physical characteristics of the sealing being installed.

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END OF PART

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Section 24: Finishes to Buildings Part 11: Recessed Duct Covers

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11 RECESSED DUCT COVERS ........................................................................ 2 11.1 GENERAL ...................................................................................................... 2 11.1.2 Recessed Duct Covers and the Like 2

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Section 24: Finishes to Buildings Part 11: Recessed Duct Covers

Page 2

11

RECESSED DUCT COVERS

11.1

GENERAL

1

This Part specifies the requirements for the use of recessed duct covers or removable covers for other type floor openings.

2

Related Parts and Sections are as follows: This Section

All Parts

Recessed Duct Covers and the Like

1

Floor finishes are to be fitted into recessed duct covers shall finish flush with the surrounding floor. Tiled finishes are to be orientated so as to continue the joint pattern of the surrounding floor unless otherwise stated in the Project Documentation or required by the Engineer.

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11.1.2

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END OF PART

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CARPETING .................................................................................................. 2 GENERAL REQUIREMENTS ........................................................................ 2 Scope 2 References 2 Submittals 2 CARPET CUSHION (UNDERLAY) ................................................................ 3 General 3 Materials and Workmanship 3 SHEET CARPETING (STANDARD ROLL CARPET) .................................... 3 General 3 Products 3 Installation of Carpet 4 Installation of Carpet Using Tackless Fixings 4 CARPET TILES ............................................................................................. 5 General Description 5 Submittals 5 Installers Qualifications 6 Carpet Tiles 6 Accessories 6 Surface Preparation 6 Installation 6 Edge Strip Installation 7 Protection and Cleaning 7 WALL CARPET ............................................................................................. 7 General Requirements 7 Installation 8 OUTDOOR CARPET ..................................................................................... 8 General Requirements 8 Installation 8 CARPET ADHESIVES ................................................................................... 8 Installation of Carpet Using Adhesive 8 Tapes and Trims for Carpet 9

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12 12.1 12.1.1 12.1.2 12.1.3 12.2 12.2.1 12.2.2 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.4 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5 12.4.6 12.4.7 12.4.8 12.4.9 12.5 12.5.1 12.5.2 12.6 12.6.1 12.6.2 12.7 12.7.1 12.7.2

Section 24: Finishes to Buildings Part 12: Carpeting

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Page 2

12

CARPETING

12.1


12.1.1

Scope

1

This Part specifies requirements for carpet and other textile floor coverings and installation requirements for the same.

2

Carpet and other textile floor coverings are collectively referred to as “carpet” in this Section.

3

Related Parts and Section are as follows: General Floor Screeds and Treatments Recessed Duct covers


General Carpentry, Joinery and Ironmongery Painting and Decorating

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References

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12.1.2

BS 1006 ......................Methods of test for colour fastness of textiles

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BS 4223 ......................Determination of constructional details of textile floor coverings with yarn pile

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BS 4682 ......................Method of test for the dimensional stability of textile floor coverings BS 5229 ......................Code of Practice for the installation of textile floor coverings

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BS 8203 ......................Code of Practice for the installation of sheet and tile flooring

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BS 5808 ......................Underlays for textile floor coverings

12.1.3

Submittals

1

The Contractor shall submit the following samples with an attached label stating brand name and ordering reference to the Engineer for approval:

2

(a)

carpet, 300 mm square, of each colour and texture, with cut edges sealed if necessary

(b)

metal edge strip, 150 mm long

(c)

plastic edge strip, 150 mm long, each colour

(d)

carpet edge strip, 150 mm long, each colour.

Manufacturer’s certificates for the following shall be submitted: (a)

stating critical radiant flux rating of carpet

(b)

stating approval of adhesive, crack filler and seaming tape

(c)

installer’s qualifications as specified.

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Page 3

Manufacturer’s literature and data, including maintenance and cleaning manuals, shall be submitted to the Engineer.

4

Manufacturer’s guarantee is to be provided for all carpeting is to be submitted. The guarantee shall be valid from the date of handover of the Works to a period of three (3) years unless otherwise stated in the Project Documentation. The guarantee shall cover excessive wear, edge ravel, backing separation, shrinking, stretching and static electricity. Excess surface wear means loss of more than 15 % by weight of face fibre.

5

Shop drawings, including installation layout plan showing seams and cuts, shall be submitted to the Engineer for approval.

6

All carpet and textile products used for flooring shall comply with the relevant provisions of BS 1006, BS 4223, BS 4682 and BS 8203.

12.2

CARPET CUSHION (UNDERLAY)

12.2.1

General

1

This Clause provides the specification for use of carpet underlay.

12.2.2

Materials and Workmanship

1

Underlays used for textile floor coverings shall comply with the relevant provisions of BS 5808 unless specified otherwise elsewhere in the Project Documentation.

2

All underlays containing natural fibre are to be mothproofed by the manufacturer.

3

Underlays of felt or cellular rubber, suitable for medium traffic shall be not less than 6 mm 2 thick and shall weigh not less than 1.40 kg/m . For heavy traffic areas, underlays shall be to the manufacturer’s recommendations.

12.3

SHEET CARPETING (STANDARD ROLL CARPET)

12.3.1

General

1

This Clause specifies installation of standard roll carpet.

12.3.2

Products

1

Carpet to be included in the Works will include manufacturer’s written verification of following characteristics:

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(a)

construction type

(b)

gauge

(c)

finished pile height

(d)

pile weight

(e)

face yarn

(f)

yarn weight

(g)

dye method

(h)

total weight

(i)

static control

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(j)

primary backing

(k)

secondary backing

Page 4

12.3.3

Installation of Carpet

1

Carpet is to be installed in accordance with the requirements of BS 5229 by skilled operatives so that it is flat and sufficiently taut to ensure that movement of furniture over the surface does not cause racking to take place.

2

Carpet is not to be laid until: the building is weathertight

(b)

the wet trades have finished their work

(c)

all painted work is finished and dry

(d)

the air-conditioning system is fully operational if the carpet is to be laid in the hot months between April and November

(e)

socket outlets, duct covers and the like around which the carpet needs to be cut have been fixed

(f)

the substrate is dry and clean.

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(a)

Carpet is to be cut and fitted to all socket outlets and other fixtures and be cut in at all doorways and recesses. It is not to be pieced in.

4

Where practicable, room coverings are to start with a full width of carpet on the same side as the door.

5

On completion of the installation, all loose nap ends are to be trimmed and the carpet cleaned with a beater type vacuum cleaner. Upon completion of the cleaning, the carpet shall be covered with clean dustsheets, hardboard or similar, as necessary to prevent damage from dust and traffic until handover.

6

Spare carpet suitable for patching is to be handed to the Engineer.

12.3.4

Installation of Carpet Using Tackless Fixings

1

Unless the manufacturer specifically recommends otherwise, all carpet other than foam backed and fibre bonded carpet, shall be fixed by means of tackless strip (gripper).

2

The underlay is to be installed so that its seems do not shadow through the carpet and do not coincide with those of the carpet when laid in the same direction. Uneven edges are to be overlapped and cut through.

3

The seams of rubber and rubber-based underlays are to be joined with approved tape not less than 50 mm wide.

4

The underlay is to be fixed along its perimeter in accordance with the manufacturer’s recommendations and be butted up to the edge of the gripper.

5

The underlay is to cover the treads and risers of stairs and be fixed to prevent movement and wrinkling.

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Seams in carpet are to be joined by approved heat-bonded tape unless alternative forms of jointing are indicated elsewhere in the Project Documentation. Care is to be taken to ensure that: (a)

the joints are strong enough to permit the carpet to be stretched and not break down under use

(b)

the pile is laying in the same direction

(c)

the pattern matches where a repeating motif occurs

(d)

the pile is not caught down into the seam

(e)

the seams are straight.

The carpet is to be laid with the seams parallel to one main axis of the room.

8

The gripper is to be fixed around the perimeter of the area to be covered, leaving a gap approximately two thirds of the thickness of the carpet. The carpet should be stretched into position over the gripper using a knee kicker or power stretcher as appropriate to form a neat edge.

9

Binder bar are to be used at all free edges of carpet and double binder bar are to be used where carpets of a different type, colour or pattern meet.

10

Single or double binder bars as appropriate are to be used at all doorways situated under the centre line of the door leaf. Grippers are not to be fixed across doorways.

11

At stairs, the pile of the carpet is to be inclined towards the bottom of the stair unless otherwise recommended by the manufacturer and approved by the Engineer. Grippers are to be fixed to the bottom of all the risers and to the adjacent horizontal surface of the tread.

12

All carpet is to be re-stretched at least once during the Maintenance Period.

12.4

CARPET TILES

12.4.1

General Description

1

This Clause specifies carpet tiles or modules, edge strips, adhesive, and other items required for the installation specified.

12.4.2

Submittals

1

In accordance with the relevant provisions of Section 1 the Contractor is to provide:

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(a)

(b)

(c)

samples (i)

one carpet module of each type, colour and texture.

(ii)

plastic edge strip, 150 mm long, for each type, colour and texture

manufacturer’s certificates: (i)

stating critical radiant flux rating of the carpet modules.

(ii)

approving the proposed method of installation, type of adhesive, crack filler

manufacturer’s literature and data, including maintenance and cleaning manual

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(d)

shop drawings showing:

(i)

Page 6

dimensions of carpeted areas (ii)

pattern direction and layout

(iii)

location of edge strips.

Installers Qualifications

1

The carpet modules are to be installed by operatives regularly engaged in installing carpet modules and accessories of the type specified.

12.4.4

Carpet Tiles

1

Carpet tiles to be included in the Works will include manufacturer’s written verification of following characteristics:

(b)

gauge

(c)


(d)

face yarn

(e)

yarn weight

(f)

dye method

(g)

total weight

(h)

backing

(i)

static control

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12.4.3

Accessories

1

Adhesive and crack fillers shall be types recommended by the carpet module manufacturer.

2

Plastic edge strips shall be the custom type, with an integral 40 mm wide base and 6 mm lip.

12.4.6

Surface Preparation

1

Cracks and holes in subfloors shall be filled with crack filler to give a smooth and level surface.

2

Grease, loose particles, dirt and all other foreign substances shall be removed

3

When placing carpeting over existing waxed floors, the wax is to be removed prior to laying the carpet.

4

Concrete floors are to have dust thoroughly removed by sweeping and wet mopping. The concrete is to be sealed as per carpet manufacturer’s recommendations.

12.4.7

Installation

1

The manufacturer’s installation instructions shall be followed.

2

Release type adhesives, applied as recommended by the carpet tile manufacturer, shall be used.

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12.4.5

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The carpet tile manufacturer’s recommendations for matching pattern and texture shall be followed.

4

Lay carpet tiles uniformly to provide a tight, smooth finish. The carpet is to be free from movement when subjected to traffic.

5

Install carpet with the pile inclination in one direction.

12.4.8

Edge Strip Installation

1

Edge strips shall be installed over exposed tile edges adjacent to uncarpeted finish flooring.

2

Edge strips shall be anchored to floors with suitable fasteners or adhesive. If adhesive is used, the following installation sequence shall be followed:

(b)

insert tile into the lip of the edge strip

(c)

press down lip over carpet.

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apply adhesive to the edge strips

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Protection and Cleaning

1

On completion of the installation, the carpet shall be cleaned with a beater type vacuum cleaner.

2

Remove spots and smears of adhesive from the carpet surface with approved cleaning agents.

3

Upon completion of the cleaning, the carpet shall be covered with clean dustsheets, hardboard or similar, as necessary to prevent damage from dust and traffic until handover.

12.5

WALL CARPET

12.5.1


1

This Part specifies the requirements for wall carpeting.

2

Carpet to be included in the Works will include manufacturer’s written verification of following characteristics:

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12.4.9

(a)

construction type

(b)

gauge

(c)


(d)

face yarn

(e)

yarn weight

(f)

dye method

(g)

total weight

(h)

backing

(i)

static control

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Page 8

Installation

1

Carpet is to be installed by skilled operations so that it is flush to the wall and sufficiently taut to ensure no bubbles or loose areas are to occur.

2

Carpet installation will be in accordance with the relevant provisions of Clause 12.3.3 or 12.3.4.

3

The Contractor is to use methods of fixing as necessary in order to ensure achieving the requirements above. This may include the use of adhesive, tackless strips or tacks. The Contractor is to obtain the Engineers approval of the method to be used prior to installation.

12.6

OUTDOOR CARPET

12.6.1


1

Textile floor coverings for outdoor use specifically manufactured for outdoor use. The manufacturer shall submit a certificate stating that the carpet to be used is suitable for outdoor use when subjected the climatic conditions normally encountered in Qatar.

2

Synthetic product for outdoor carpeting shall comply with the relevant provisions of BS 1006 and BS 4682.

12.6.2

Installation

1

Installation of outdoor carpeting shall be in accordance with the relevant provisions of BS 5229 and the manufacturer’s requirements.

12.7

CARPET ADHESIVES

12.7.1

Installation of Carpet Using Adhesive

1

Adhesives used for fixing carpet are to be waterproof, peel-up type recommended for the purpose by the carpet manufacturer.

2

Fibre bonded, high density foam backed carpet and carpet where the manufacturer specifically so recommends shall be fully bonded to the floor using a peel-up adhesive applied in accordance with the manufacturer’s instructions. Low density foam backed carpet 2 (less than 1.2 kg/m backing weight) should not be fixed with adhesive.

3

Joints in the carpet are to be bonded with adhesive recommended by the manufacturer of the carpet are to be parallel to one main axis of the room. Where applicable care is to be taken to ensure that:

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12.5.2

(a)

the pile is laying in the same direction.

(b)

the pattern matches where a repeating motif occurs.

(c)

the pile is not caught down into the joint.

(d)

the joints are straight.

4

Adhesive marks are to be removed from the carpet and other exposed surfaces as the work proceeds.

5

Edge trim or dividing strip is to be used at free edges and where carpets of different type, colour or pattern meet. The trim or strip is to be situated under the centreline of the door leaf at all doorways.

QCS 2014


Page 9

6

At stairs the pile of the carpet is to be towards the bottom. The carpet is to be folded under any exposed edges and fixed to each tread and riser as one continuous piece unless a nosing is provided.

12.7.2

Tapes and Trims for Carpet

1

Adhesive tapes for seams are to be approved heat bonded type, minimum 75 mm wide, and as recommended by the manufacturer of the carpet.

2

Fixing bars and carpet grippers used with self adhesive surface strip or for application of adhesive, are to be of the type recommended by the manufacturer of the carpet and are to have an anodised aluminium finish to exposed surfaces where applicable.

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END OF PART

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Page 1

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OTHER FLOOR COVERINGS ...................................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 FLEXIBLE FLOORING .................................................................................. 2 Flexible Sheet and Tile Flooring 2 Laying Flexible Sheet and Tile Flooring 2 BITUMEN COATING SOLUTION .................................................................. 3 General 3

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Section 24: Finishes to Buildings Part 13: Other Floor Coverings

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Page 2

13

OTHER FLOOR COVERINGS

13.1

GENERAL

13.1.1

Scope

1

This Part specifies the requirements for floor coverings not dealt with elsewhere.

2


.

Concrete Carpentry, Joinery and Ironmongery

References

1

The following Standards are referred to in this Section:

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General Floor Screeds and Treatments Carpeting

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BS 2592 ......................Thermoplastic flooring tiles

BS 3260 ......................Semi-flexible PVC floor tiles

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BS 3261 ......................Unbacked flexible PVC flooring

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BS 3416 ...................... Bitumen-based coatings for cold application, suitable for use in contact with potable water

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BS 8000 ......................Workmanship on building sites

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BS 8203 ......................Code of Practice for installation of sheet and tile flooring

FLEXIBLE FLOORING

13.2.1

Flexible Sheet and Tile Flooring

1

Unbacked PVC sheet flooring and homogeneous flooring to comply with BS 3261, Part 1, Type “A”.

2

Thermoplastic floor tiles shall comply with the relevant provisions of BS 2592.

3

PVC (Vinyl) asbestos floor tiles to comply with the relevant provisions of BS 3260.

4

Adhesives used for fixing PVC, thermoplastic or similar material in sheet or tile form are to be as recommended for the purpose by the manufacturer.

5

Cork tiles shall comply with the relevant provisions of BS 8203.

13.2.2

Laying Flexible Sheet and Tile Flooring

1

Laying of flexible sheet or tile flooring shall be carried out in accordance with the relevant provisions of BS 8203 and BS 8000, Part 11.

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QCS 2014


Page 3

Floor screed is to be laid in accordance with Part 9 except that the requirement for laying in bays will not apply.

3

The subfloor is to be smooth, hard, clean and dry before laying commences. All minor irregularities, cracks and hollows are to receive a skim coat of proprietary levelling compound as necessary to give a fine, true surface suitable to receive the flooring.

4

The Engineer may require all of the subfloor to be treated with levelling compound if, in his opinion, the quality of the surface is unsuitable.

5

The flooring is to be laid with an adhesive that will be spread evenly over the subfloor with a trowel recommended by the adhesive manufacturer. Trowel ridges and high spots on the subfloor will not be accepted.

6

Flexible PVC flooring, and other materials where the manufacturer so recommends, is to be 2 thoroughly rolled in two directions with a 70 kg/m weight applied floor roller.

7

Tiles are to be laid with tight joints and with sides parallel to the room axis.

8

Joints in sheet flooring are to be seam welded.

13.3

BITUMEN COATING SOLUTION

13.3.1

General

1

Bitumen coating solution shall comply with BS 3416, Type 1.

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END OF PART

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2

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CEILINGS ...................................................................................................... 2 GENERAL DESCRIPTION ............................................................................ 2 Scope 2 References 2 General Requirements 2 Submittals 3 LAY-IN TYPE SUSPENDED CEILINGS ........................................................ 3 General 3 Installation 3 FIXED TYPE SUSPENDED CEILINGS ......................................................... 4 General Requirements 4 Materials 4 Installation 5

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Section 24: Finishes to Buildings Part 14: Ceilings

QCS 2014


Page 2

CEILINGS

14.1

GENERAL DESCRIPTION

14.1.1

Scope

1

This Part specifies the requirements for suspended ceiling systems of lay-in type and fixed type construction.

2



Metal Work Carpentry Painting and Decorating

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General Dry lining (Wallboard) Joints, Caulking and Sealants

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References

1


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BS 476 ........................Fire tests and building materials and structures BS 1191 ......................Gypsum building plasters

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BS 1230 ......................Gypsum plasterboard BS 5492 ......................Code of practice for internal plastering

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BS 8212 ......................Code of practice for dry lining and partitioning using gypsum plasterboard

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BS 8290 ......................Suspended ceilings

14.1.3


1

The suspended ceilings shall not be installed until:

2

(a)

the building is weathertight

(b)

the wet trades have finished their work

(c)

all work above the ceilings such as ductwork, pipework and electrical work has been installed, tested, inspected and approved

(d)

the positions of light fittings, diffusers and the like have been checked

(e)

the position of access panels have been confirmed with the Engineer.

The ceiling shall be installed to within 3 mm of required level. When measured against a straight edge over a distance of 3 m, the gap between the straight edge and the ceiling shall not exceed 3 mm.

QCS 2014


Page 3

3

The manufacturer’s recommendations for the use and installation of products covered in this Part shall be strictly adhered to unless otherwise agreed with the Engineer.

4

Existing conditions shall be inspected before commencing installation of suspended ceilings to ensure the following: (a)

that services all have been installed

(b)

that fastenings and supports installed by others are in place

(c)

that installation of others will not touch the back of ceiling system.

The Contractor shall verify to the Engineer in writing that such inspections has been performed and that work is ready to commence. Submittals

1

The Contractor is to submit shop drawings showing general layout, support framing, and installation details including lay-in, hanger and support details.

2

Samples of support framing, lay-in, lay-in hangers and hanger insert are to be submitted for approval.

3

Suspended ceilings shall comply with the relevant provisions of BS 8212 and BS 8290.

14.2

LAY-IN TYPE SUSPENDED CEILINGS

14.2.1

General

1

The lay-in material shall be tile, plank or strip membrane, as detailed in the Project Documentation.

2

The lay-in material shall have a fire performance when tested in accordance with BS 476 which satisfies the requirements of:

class 1 - BS 476, Part 7.

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class 0 - BS 476, Part 6.

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14.1.4

3

The Contractor shall produce certificates that certify that the requirements of Clause 14.2.1-2 are met.

4

The suspension system and shall be constructed from hot dipped galvanized steel sections and galvanized wire or similar non-corrodable materials and fixings.

14.2.2

Installation

1

The tiles shall be set out so that: (a)

the soffits are level, free from undulations and lipping, with all lines and joints straight and parallel to walls unless shown otherwise in the Project Documentation

(b)

they are symmetrical about the centre lines of the roof, or space, beginning with a tile or joint line as required to avoid narrow tiles at the perimeter edges.

QCS 2014


Page 4

At junctions between the ceiling and walls, and between the ceiling and columns, the ceiling shall be finished with perimeter edge trim. The trim shall be fixed at maximum 450 mm centres.

3

Additional hanging supports shall be provided between the floor or roof structure above and the suspended ceiling at all access panels, light fittings, diffusers, etc. The lay-in material shall be accurately cut to accommodate all such fittings. Under no circumstance shall any fitting be supported by the lay-in material.

4

Care shall be taken to ensure that the tiles, planks and strip membrane are kept clean if subsequently removed for access to services, for inspection or for remedial work.

14.3

FIXED TYPE SUSPENDED CEILINGS

14.3.1


1

Gypsum board will be used for fixed type suspended ceilings unless otherwise indicated in the Project Documentation.

2

Installation of gypsum board for suspended ceilings and associated plaster or rending work shall comply with the relevant provisions of BS 1191 and BS 5492.

14.3.2

Materials

1

Gypsum wall board shall be either 9.5 or 12.7 mm thick gypsum plasterboard complying with BS 1230, having one face finished for direct decoration.

2

Thermal wall board shall comply with Table 3.1 of Part 3 of this Section and shall consist of an insulation core having a thermal conductivity of not less than 0.037 W/m ºC bonded on one side to gypsum wall board and on the reverse side with a water-vapour resistant membrane.

3

The edge profiles of wall board shall be: (a)

“tapered” for smooth seamless jointing. “bevelled” for V-jointing.

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(c) 4

“square” for stippled textured coatings, cornerstrip jointing or plaster.

Accessories for installing wallboard shall be approved proprietary materials recommended by the manufacturer of the wallboard or ceiling system, inclusive of the following: (a)

soffit assemblies, where indicated on drawings shall consist of galvanized steel channel runners and studs faced with gypsum panels, screw attached unless specified otherwise and approved by the Engineer

(b)

hangers, hanger attachments, support carrier members with connectors, and trim members related to ceiling as is required for complete

(c)

fabricated miscellaneous clips, splices, connectors, screws, and other standard metal accessories of strength and design compatible with the suspension methods and system.

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Page 5

14.3.3

Installation

1

The Contractor shall ensure that adequate preparation is made for attachment of hangers and fasteners and provide for support and incorporation of flush-mounted and recessed fittings and service components.

2

The ceiling system shall be installed in accordance with manufacturer’s recommendations and to BS 8290 Part 3.

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END OF PART

QCS 2014

Section 24: Finishes to Building Part 02: Lath and Plaster

Page 1

LATH AND PLASTER ------------------------------------------------------------------------------------------- 1

2.1

GENERAL---------------------------------------------------------------------------------------------------------- 1

2.1.1 2.1.2

Scope --------------------------------------------------------------------------------------------------------------- 1 References--------------------------------------------------------------------------------------------------------- 1

2.2

NON-LOAD BEARING WALL FRAMING SYSTEMS --------------------------------------------------- 3

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8

General Description --------------------------------------------------------------------------------------------- 3 Terminology ------------------------------------------------------------------------------------------------------- 3 Submittals ---------------------------------------------------------------------------------------------------------- 3 Protection ---------------------------------------------------------------------------------------------------------- 3 Steel Studs and Runners --------------------------------------------------------------------------------------- 4 Fasteners, Clips, and Other Metal Accessories ---------------------------------------------------------- 4 Execution of Work------------------------------------------------------------------------------------------------ 4 Installing Supports Required by Other Trades ------------------------------------------------------------ 5

2.3

NAILS, SCREWS AND WASHERS ------------------------------------------------------------------------- 5

2.3.1

General Requirements ------------------------------------------------------------------------------------------ 5

2.4

GYPSUM LATH AND PLASTER ----------------------------------------------------------------------------- 5

2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9

General Requirements ------------------------------------------------------------------------------------------ 5 Terminology ------------------------------------------------------------------------------------------------------- 6 Submittals ---------------------------------------------------------------------------------------------------------- 6 Project Conditions ------------------------------------------------------------------------------------------------ 6 Plastering Bases (Lath) ----------------------------------------------------------------------------------------- 7 Gypsum Plasters ------------------------------------------------------------------------------------------------- 7 Fasteners ---------------------------------------------------------------------------------------------------------- 7 Fixing Lath Bases ------------------------------------------------------------------------------------------------ 7 Gypsum Plaster Application ----------------------------------------------------------------------------------- 8

2.5

METAL LATH ----------------------------------------------------------------------------------------------------- 9

2.5.1 2.5.2 2.5.3 2.5.4

General ------------------------------------------------------------------------------------------------------------- 9 Fixing Plain Expanded Metal Lath Backgrounds ------------------------------------------------------- 10 Fixing Ribbed Lathing Backgrounds ----------------------------------------------------------------------- 10 Expanded Metal Lath at Junctions of Differing Backgrounds --------------------------------------- 11

2.6

SKIM COAT PLASTER BASE AND PLASTER --------------------------------------------------------- 11

2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 2.6.9 2.6.10 2.6.11

General ----------------------------------------------------------------------------------------------------------- 11 Terminology ----------------------------------------------------------------------------------------------------- 11 Submittals -------------------------------------------------------------------------------------------------------- 11 Skim Coat Base ------------------------------------------------------------------------------------------------ 12 Gypsum Skim Coat Plaster ---------------------------------------------------------------------------------- 12 Accessories ------------------------------------------------------------------------------------------------------ 12 Installation Criteria --------------------------------------------------------------------------------------------- 12 Application of Skim Coat Base ------------------------------------------------------------------------------ 12 Sealant Application -------------------------------------------------------------------------------------------- 14 Skim Coat Plaster Application Over Gypsum Board Base ------------------------------------------- 14 Repairs ----------------------------------------------------------------------------------------------------------- 14

2.7

BEADS AND STOPS ------------------------------------------------------------------------------------------ 15

2.7.1 2.7.2

Materials ---------------------------------------------------------------------------------------------------------- 15 Fixing Beads and Stops -------------------------------------------------------------------------------------- 15

2.8

WELDED-FABRIC MESH FOR REINFORCED RENDERING ------------------------------------- 15

2.8.1

Materials ---------------------------------------------------------------------------------------------------------- 15

2.9

PREPARATION OF SUBSTRATA ------------------------------------------------------------------------- 15

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2

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Page 2

Preparation of Background to be Rendered ------------------------------------------------------------- 15

2.10

PREPARATION OF MIXES FOR RENDERING -------------------------------------------------------- 16

2.10.1 2.10.2

Preparation Procedures and Selection of Materials --------------------------------------------------- 16 Application of the Various Render Coats ----------------------------------------------------------------- 17

2.11

PORTLAND CEMENT PLASTER -------------------------------------------------------------------------- 18

2.11.1 2.11.2

Materials ---------------------------------------------------------------------------------------------------------- 18 Application of Portland Cement Plaster. ------------------------------------------------------------------ 18

2.12

POLYMER PLASTERING ----------------------------------------------------------------------------------- 19

2.12.1

Materials and Application of Plaster ----------------------------------------------------------------------- 19

2.13

TABLE PIGMENTS FOR CEMENT ----------------------------------------------------------------------- 19

2.13.1

Materials ---------------------------------------------------------------------------------------------------------- 19

2.14

TEST FOR DRYNESS ---------------------------------------------------------------------------------------- 19

2.14.1

Procedures------------------------------------------------------------------------------------------------------- 19

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2.9.1

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Page 1

2

LATH AND PLASTER

2.1

GENERAL

2.1.1

Scope

1

This Part specifies requirements for lath and plaster finishes for buildings and related structures.

2

Related Parts and Sections are as follows: This Section Part 1 ..........................General

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Part 3 ..........................Dry Lining (Wallboard)

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Part 5 ..........................Tiles

Section 15 ..................Insulation of Buildings

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Section 17 ..................Metalwork

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Section 1 ....................General

Section 18 ..................Carpentry, Joinery and Ironmongery References

1

The following standards are approved and/ or referred to in this Part:

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ASTM C150 ................Standard Specification for Portland Cement

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ASTM C472 ................Test Methods for Physical testing of Gypsum, Gypsum Plasters and Gypsum Concrete ASTM C514 ...............Standard Specification for Nails for the Application of Gypsum Board

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ASTM C842 ................Standard Specification of Interior Gypsum Plaster Application

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ASTM C897 ................Standard Specification for Aggregate for Job-Mixed Portland CementBased Plasters

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ASTM C926 ................Standard Specification for Application of Portland Cement-Based Plaster ASTM C1063 .............Standard Specification for Installation of Lathing and Furring to Receive Interior and Exterior Portland Cement-Based Plaster BS 405........................Uncoated expanded metal carbon steel sheets for general purposes BS 476........................Fire tests on building materials and structures BS 882........................Aggregates from natural sources for concrete BS 1202 .....................Nails BS 1449 .....................Steel plate, sheet and strip BS 1494 .....................Fixing accessories for building purposes BS 4551 ..................... Mortar. Methods of test for mortar and screed. Chemical analysis and physical testing

QCS 2014


Page 2

BS 5270-1 .................Bonding agents for use with gypsum plasters and cement Specification for polyvinyl acetate (PVAC) emulsion bonding agents for indoor use with gypsum building plasters BS 8000 .....................Workmanship on building sites BS 8481 ....................Design, preparation and application of internal gypsum, cement, cement and lime plastering systems. Specification BS EN 197-1 ..............Portland cement BS EN 459-1 .............Building lime: Definitions, specifications and conformity criteria BS EN 1008:2002. ....Mixing water for concrete. Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete

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BS EN 10142 .............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions

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BS EN 10143 .............Continuously hot-dip metal coated steel sheet and strip – tolerances on dimensions and shape

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BS EN 13139 ............Aggregates for mortar

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BS EN 12878 ............Pigments for the colouring of building materials based on cement and/or lime. Specifications and methods of test BS EN 13279-2 .........Gypsum binders and gypsum plasters Test methods

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BS EN 13279-1 .........Gypsum binders and gypsum plasters Definitions and requirements

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BS EN 13658-2 .........Metal lath and beads. Definitions, requirements and test methods: External rendering

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BS EN 13658-2 .........Metal lath and beads. Definitions, requirements and test methods External rendering

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BS EN 13658-1 .........Metal lath and beads. Definitions, requirements and test methods: Internal plastering

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BS EN 13658-1 .........Metal lath and beads. Definitions, requirements and test methods internal plastering

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BS EN 13914-2 .........Design, preparation and application of external rendering and internal plastering: Design considerations and essential principles for internal plastering BS EN 13914-1 .........Design, preparation and application of external rendering and internal plastering External rendering BS EN ISO 2081 .......Metallic and other inorganic coatings. Electroplated coatings of zinc with supplementary treatments on iron or steel BS EN ISO 2082 .......Metallic coatings. Electroplated coatings supplementary treatments on iron or steel

of

cadmium

with

EN 998-1:2010 ..........Specification for mortar for masonry. Rendering and plastering mortar EN 1745:2002 ...........Methods for determining thermal properties PD CEN/TR 15123 .....Design, preparation and application of internal polymer plastering systems

QCS 2014


Page 3

NON-LOAD BEARING WALL FRAMING SYSTEMS

2.2.1

General Description

1

Steel stud wall systems, shaft wall systems, ceiling or soffit suspended or furred framing, wall furring, fasteners, and accessories for the screw attachment of gypsum board, plaster bases or other building boards are to be as described herein.

2

The following requirements are applicable for wall framing members of 1 mm thick material or lighter with the exception of rolled steel channels of 1.5 mm thick material.

2.2.2

Terminology

1

Underside of Structure Overhead: In spaces where steel trusses or bar joists are shown, the underside of structure overhead is to be the underside of the floor or roof construction supported by beams, trusses, or bar joists. In mezzanine spaces, the underside of the walk-on floor is the underside of structure overhead.

2

Thickness of steel is specified in millimeters and is the minimum bare (uncoated) steel thickness.

2.2.3

Submittals

1

In accordance with the relevant provisions of Section 1, General, the Contractor is to provide the manufacturer's literature and data on the following:

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(b)

hanger inserts

(c)

channels (rolled steel)

(d)

furring channels

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studs, runners and accessories

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(a)

screws, clips and other fasteners.

In accordance with the relevant provisions of Section 1, General, the Contractor is to provide the shop drawings showing the following:

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2.2

(a)

typical ceiling suspension system

(b)

typical metal stud and furring construction system including details around openings and corner details

(c)

typical shaft wall assembly

(d)

typical fire rated assembly and column fireproofing showing details of construction as used in fire rating test.

3

In accordance with the relevant provisions of Section 1, General, the Contractor is to provide the literature test results indicating the fire rating test designation, for each framing system.

2.2.4

Protection

1

Steel studs, runners, rigid furring channels, “Z” shaped furring channels and resilient furring channels shall be galvanized in accordance with the relevant provisions of BS 1369.

QCS 2014


Page 4

Steel Studs and Runners

1

Not less than two cutouts shall be provided in the web of each stud, approximately 300 mm from each end, and intermediate cutouts on approximately 600 mm centres.

2

Doubled studs for openings and studs for supporting concrete backer-board shall be not less than 850 mm thick.

3

Studs 3.5 m or less in length shall be in one piece.

2.2.6

Fasteners, Clips, and Other Metal Accessories

1

Fasteners, clips, and other metal accessories for fire rated construction shall be of the type and size used in fire rating test.

2

Fasteners for steel studs thicker than 8 mm are to be steel drill screws of size and type recommended by the manufacturer of the material being fastened.

3

Clips used in lieu of tie wire are to have a holding power equivalent to that provided by the tie wire for the specific application.

4

Concrete ceiling hanger inserts (anchorage for hanger wire and hanger straps) shall be galvanized steel, designed to support twice the hanger loads imposed.

2.2.7

Execution of Work

1

Where fire rated construction is required for walls, partitions, columns, beams and floor-ceiling assemblies, the construction shall be the same as that used in any fire rating tests undertaken. Construction requirements for fire rated assemblies and materials shall to conform to BS 476.

2

Installing studs shall be carried out as follows:

when studs are to extended to underside of structure overhead, they shall be cut 6 mm to 9 mm less than floor to underside of structure overhead

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2.2.5

(c)

where studs are shown to terminate above suspended ceilings, bracing shall be provided as indicated in the Project Documentation. Alternatively, the studs shall be extended to the underside of the structure overhead.

(d)

studs shall be extended to the underside of the structure overhead for fire partitions, smoke partitions, shafts, and sound rated partitions or insulated exterior wall furring.

(e)

at existing plaster ceilings, studs may terminate at the ceiling

(f)

at openings: (i)

frame the jambs of openings in stud partitions with two steel studs placed back to back.

(ii)

fasten back to back studs together with 9 mm long “S” type panhead screws at not less than 600 mm centres, staggered along webs

QCS 2014

Section 24: Finishes to Building Part 02: Lath and Plaster (iii)

studs fastened flange to flange are to have splice plates on both sides. The splice plates shall be approximately 600 mm x 75 mm in size. They shall be screwed to each stud with two screws. The splice plates shall be located at 600 mm centres, between the runner tracks.

Fastening studs shall be carried out as follows: studs located adjacent to partition intersections, corners and studs at jambs of openings to shall be fastened to the flange of runner tracks with either two screws through each end of each stud and the flange of runner; alternatively, by use of a metal lock fastener tool

(b)

studs shall not be fastened to the top runner track when studs extend to underside of structure overhead

(c)

at chase wall partitions, locate cross braces for the chase wall partitions to permit the installation of pipes, conduits, carriers and similar items; studs or runners used as cross bracing are to be not less than 60 mm wide.

(d)

building seismic or expansion joints shall be formed with double studs, back to back, spaced 75 mm apart plus the width of the joint

(e)

control joint shall be formed with double studs spaced 12.5 mm apart.

.

(a)

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Page 5

Installing Supports Required by Other Trades

1

Provide for the attachment and support of electrical outlets, plumbing, laboratory or heating fixtures, recessed type plumbing fixture accessories, access panel frames, wall bumpers, wood seats, toilet stall partitions, dressing booth partitions, urinal screens, chalkboards, tackboards, wall-hung casework, handrail brackets, recessed fire extinguisher cabinets and other items supported by stud construction.

2.3

NAILS, SCREWS AND WASHERS

2.3.1


1

Nails, screws and washers are to be galvanized or of stainless steel as indicated in the Project Documentation or directed by the Engineer. Pins for shot-firing to be of steel with a tight coating of cadmium or zinc complying with ISO 2081 or ISO 2082 or equivalent.

2

Clout nails shall be galvanized steel and shall comply with BS 1202, Part 1 or equivalent.

3

Staples shall be galvanized steel and shall comply with BS 1494, Part 1 or equivalent.

2.4

GYPSUM LATH AND PLASTER

2.4.1


1

Proprietary spray-on plaster systems may be substituted for plaster system specified herein if approved by Engineer upon submission of complete details of materials and methods of the spray-on system.

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2.2.8

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Page 6

Terminology

1

Underside of Structure Overhead: In spaces where steel trusses or bar joists are shown, the underside of structure overhead is to be the underside of the floor or roof construction supported by beams, trusses, and bar joists.

2

Self-furring Lath: Metal plastering bases having dimples or crimps designed to hold the plane of the back of the lath 6 mm to 9 mm away from the plane of the solid backing.

3

Solid Backing or Solid Bases: Concrete, masonry, sheathing, rigid insulation, and similar materials to which plaster is directly applied.

4

Wet Areas: Areas of a building where cyclic or continuous exposure to very humid or wet conditions occurs, or in which a dew point condition may occur in the plaster.

2.4.3

Submittals

1

In accordance with procedures of Section 1, General, the Contractor is to submit Shop drawings showing:

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Details of floating interior angle, unrestrained construction.

(b)

Details of assembly and anchorage of lath and accessories.

(c)

Locations and installation of expansion joints, including plans, details and attachments to other works.

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(a)

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In accordance with procedures of Section 1, General, the Contractor is to submit manufacturers' literature and data of the following: accessories for plaster, each type

(b)

metal plaster bases, each type

(c)

fasteners

(d)

bonding compounds, including application instructions & method of statement

(e)

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2.4.2

Mixture components including mixing instructions.

In accordance with procedures of Section 1, General, the Contractor is to submit manufacturers certificates for details of gypsum plaster cement to be used in the Works.

4

In accordance with procedures of Section 1, General, the Contractor is to submit samples of each type of plaster accessory. The samples shall be of a size approved by the Engineer.

2.4.4

Project Conditions

1

Comply with ASTM C 842 requirements or gypsum plaster manufacturer's written recommendations, whichever are more stringent.

2

Avoid conditions that result in gypsum plaster drying out too quickly.

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(a)

Distribute heat evenly; prevent concentrated or uneven heat on plaster.

(b)

Maintain relative humidity levels for prevailing ambient temperature that produces normal drying conditions.

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(c)


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Ventilate building spaces in a manner that prevents drafts of air from contacting surfaces during plaster application and until plaster is dry.

2.4.5

Plastering Bases (Lath)

1

Expanded Metal used for plastering shall be to BS 405.

2

Gypsum Lath used for plastering shall be to BS 1369.

2.4.6

Gypsum Plasters

1

Base Coat premix Gypsum Plaster Material

(b)

Setting time: around 2hours 30 minutes.

(c)

Density of hardened product: 1.3

(d)

Compressive strength: > 3 MPa at 28 days

(e)

Composition: Gypsum, selected sand and fillers, additives.

(f)

Coat Thickness: up to 15 mm in one coat.

(g)

Consumption: 1.3kg/m2/1 mm thickness.

(h)

Mixing ratio: 40 kg bag with 12 to14 liters of water.

(i)

VOC and Formaldehyde: None (<10μg/l) according to ISO/FDIS 11890-2 GC-MS.

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Grain size: 0 to 1mm

Finish Coat Premix Gypsum Plaster Material. Grain size: 0 to 0.5mm.

(b)

Setting time: around 2 hours 30 minutes.

(c)

Dried density: 1.2

(d)

Composition: Gypsum, selected fillers, additives.

(e)

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Mixing ratio: 40 kg bag with 20 liters water.

3

Thermal conductivity according to EN 1745 or as required by the engineer.

2.4.7

Fasteners

1

Tie, wire, screws, clips, and other fasteners shall conform to BS 1706, BS 1202 and BS 1494 or equivalent..

2

Fasteners for securing metal plastering bases are to have heads, or be through washers large enough to engage two strands of the metal plastering base.

3

For fire rated construction, the type and size of fastener shall be as used in the fire rated tests.

2.4.8

Fixing Lath Bases

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Page 8

Fixing lath bases shall be carried out in accordance with BS 1369 unless otherwise indicated in the Project Documentation.

2

Metal plastering bases shall be used where the plaster is required on partitions, ceilings and furring. Where required, metal plastering bases shall also be used for setting ceramic tiles in adhesive on gypsum plaster and for lighting troughs, beams and other curved or irregular surfaces.

3

Gypsum plaster or gypsum board may be used for adhesive applied ceramic tile in areas not considered wet. Portland cement plaster is required for walls and ceilings above ceramic wall tile in showers and similar wet areas.

4

Where plaster is required on solid bases, metal plastering bases are not required, unless otherwise indicated in the Project Documentation.

5

Form true surfaces in plaster board, straight or in fair curves where shown, without sags or buckles and with long dimension of lath at right angles to direction of supports.

6

Shape lathing to within 19 mm of the finished profiles of irregular surfaces.

7

Lath for ceiling construction should terminate at a casing bead where butting into or penetrated by walls, columns, beams, and similar elements.

8

Gypsum lath may be used in lieu of metal lath for gypsum plaster only on straight flat surface of partitions and walls, and on furring, except for lathing in wet areas and as a base for marble finishes.

9

Installation of metal plastering bases shall be undertaken in accordance with the following:

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1

where metal plastering bases are required over solid backing, self-furring, galvanized metal plastering base with vapour permeable backing shall be used

(b)

self-furring metal lath shall be attached directly to masonry and concrete with hardened nails, power actuated drive pins or other approved fasteners; fasteners shall be located at the dimples or crimps only where metal plastering bases are required over steel columns, self-furring, diamond mesh, expanded metal lath shall be used

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(d)

with the exception of 9 mm rib lath used above ceramic title wainscots where the finish above the wainscot is required to finish flush with the tile face, rib lath should not be used

(e)

metal plastering bases should not be continuous through expansion and control joints, but shall terminate at each side of the joint.

2.4.9

Gypsum Plaster Application

1

Gypsum plaster application shall be undertaken in accordance with BS 8000, Part 10 or ASTM C842.

2

The thickness of plaster to shall be in accordance with BS 5492, BS 1199 and BS 8000 except as follows: (a)

where greater thickness is indicated in the Project Documentation

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Page 9

(b)

where thickness is required to match existing

(c)

where greater thickness is required for fire rated construction

(d)

finish coats shall be applied at a uniform thickness of approximately 1.5 mm with not more than 3 mm thickness at any point.

A 1.5 mm deep V-joint shall be cut in the finish coat of plaster adjacent to metal doorframes and wherever plaster finishes flush with other materials, except where casing beads are required. The 1.5 mm deep V- joint shall be omitted on walls and partitions where the plaster is recessed back from face of doorframes and other such similar conditions.

4

Plaster is to have a smooth-trowel finish unless indicated otherwise in the Project Documentation.

5

Cleaning and patching upon application of gypsum plastering shall be as follows:

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remove plaster droppings from property, materials and all other surfaces of others before it sets

(b)

cut off beads, screeds and metal trim, and leave plaster and accessory surfaces ready for specified finishing

(c)

cut-out and patch defective plaster and cracks, prior to decorating to match adjacent surfaces in texture and finish and with no visible joint lines.

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Concealed plaster application behind built-in cabinets, similar furnishings, and equipment, apply finish coat, where concealed above suspended ceilings and in similar locations, finish coat may be omitted.

7

Plaster application will be used as a base for adhesive application of tile and similar finishes, finish coat may be omitted.

2.5

METAL LATH

2.5.1

General

1

Expanded mesh lath is to be manufactured from galvanized steel as per BS EN 10346:2009, minimum zinc coating of 225 g/m². It shall have a minimum aperture of 5 mm measured the short way of the mesh, minimum thickness of base metal is to be 0.3 mm as per BS EN 13658-1 for internal plastering.

2

Welded wire lath or mesh can be used with a minimum weight of 1.22 kg/m² where used as reinforcement over different backgrounds, and with a minimum weight of 1.90 kg/m² where used as a background for plastering or rendering as per BS EN 13658-2:2005

3

Where shown on the drawings for external rendering or as directed by Engineer, stainless steel expanded metal lath can be used in the works. Minimum thickness shall be 0.3 mm as per BS EN 13658-2 for external rendering.

4

Wire ties are to be galvanized with a minimum diameter of 1.20 mm.

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Fixing Plain Expanded Metal Lath Backgrounds

1

Hangers, runners and bearers are to be spaced at intervals recommended by the manufacturer of the lath.

2

The lath is to be fixed with the long way of the mesh at right angles to the supports and with all strands sloping in the same direction. In vertical work the strands are to slope inwards and downwards from the face of the coating.

3

The side edges of the lath are to be lapped not less than 25 mm and secured with wire ties at not more than 150 mm centres.

4

The ends of the lath are to be lapped not less than 50 mm at supports and 75 mm between supports and secured with wire ties at not less than 150 mm centres.

5

The lath is to be fixed to timber supports with 40 mm clout nails or staples at not more than 100 mm centres along each support, driven at and angle to tighten the mesh. Hardwood or galvanised metal distance pieces are to be placed between the timber supports and the lath to permit the render to be forced through the openings completely encasing the lath.

6

The lath is to be fixed to metal supports with wire ties at not more than 100 mm centres along each support.

7

The ends of wire ties are to be twisted tightly together, the surplus cut off and bent away from the face of the coating.

8

The lath is to be fixed tightly from the centre outwards in such a manner that the lath and support system create a rigid background to receive the render or other coating.

9

After fixing, staples, nail heads, all cut edges and breaks in the coating to the lathing is to be treated with one coat of black bitumen.

2.5.3

Fixing Ribbed Lathing Backgrounds

1

Hangers, runners and bearers are to be spaced at intervals recommended by the manufacturer of the lath.

2

The lath is to be fixed with all strands sloping in the same direction and with the ribs towards and at right angles to the supports. In vertical work the strands should slope inwards and downwards from the face of the coating.

3

The side ribs of adjacent sheets are to be lapped, pressed well together and secured with wire ties at not more than 150 mm centres.

4

The ends of the lath are to be lapped at supports wherever possible. The lap should not be less than 50 mm and are to be secured with a wire tie at each rib. Between supports the lap must not be less than 100mm and are to be secured with two wire ties at each rib.

5

The lath is to be fixed to timber supports with one 40 mm clout nail driven through each rib at a slight angle.

6

The lath is to be fixed to metal supports with two wire ties at each intersection of rib and support.

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2.5.2

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The ends of wire ties are to be twisted tightly together, the surplus cut off and bent away from the face of the coating.

8

The lath is to be fixed tightly from the centre outwards in such a manner that the lath and support system create a rigid background to receive the render or other coating.

9

After fixing, staples, nail heads, all cut edges and breaks in the coating to the lathing are to be treated with one coat of black bitumen solution.

2.5.4

Expanded Metal Lath at Junctions of Differing Backgrounds

1

Where a rendering or plaster is to be continuous across backgrounds of different types, a strip of metal lath with a minimum width of 300 mm and an isolating membrane of polythene sheet or building paper behind, is to be fixed across the junction. Where small widths of one material less than 300 mm wide are, the width is to be bridged completely and for a distance of 150 mm on both sides.

2

The metal lath should be stretched taut and fixed along each edge at 100 mm centres using washers and shot fired pins, nails or screws. The screws shall be fixed into plugs in predrilled holes.

3

All cut edges of the metal lath and the fastenings are to receive a coating of bitumen solution.

4

Zinc coatings only partially surrounded by cement plaster or rendering are particularly liable to corrosion and care should be taken to ensure that the metal lath is completely embedded.

5

Metal lath should not be provided where the drawings show a groove in the rendering or plaster.

2.6

SKIM COAT PLASTER BASE AND PLASTER

2.6.1

General

1

The location and type of skim coats and plaster bases shall be defined in a finishing schedule included in the Project Documentation.

2.6.2

Terminology

1

Underside of Structure Overhead: In spaces where steel trusses or bar joists are shown, the underside of structure overhead is the underside of the floor or roof construction supported by the trusses or bar joists.

2.6.3

Submittals

1

In accordance with procedures in Section 1, General, the Contractor is to furnish manufacturer’s literature and data on the following:

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(a)

gypsum skim coat plaster

(b)

gypsum base for skim coat plaster

(c)

accessories

(d)

joint reinforcing materials

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(e)


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laminating adhesive.

In accordance with procedures in Section 1, General, the Contractor is to furnish shop drawings for typical skim coat plaster installation, showing corner details, casing details, control joint details and other similar details.

2.6.4

Skim Coat Base

1

Skim coat base when used shall be 15 mm thick unless otherwise approved by the Engineer.

2.6.5

Gypsum Skim Coat Plaster

1

The minimum compressive strength of finish coat plaster is to be 17.25 MPa.

2.6.6

Accessories

1

Corner bead, edge trim and control joints shall comply with the relevant provisions of BS EN 13658-1 unless otherwise indicated in the Project Documentation.

2

Corner bead and edge trim shall be a minimum of 4 mm thick, galvanized or stainless steel sheet or rigid PVC plastic as indicated in the project Documentation or directed by the Engineer.

3

Flanges of the bead or trim not less than 22 mm wide with punch-outs are to provide a plaster bond.

4

Joint reinforcing tape shall be as required or recommended by the skim coat plaster manufacturer.

5

Laminating adhesive shall be as recommended by skim coat base manufacturer.

6

Screws shall comply with the relevant provisions of BS 1706 and BS 1202 or equivalent.

7

Staples shall be flattened zinc-coated steel wire, with a minimum 15 mm leg for securing corner beads or casing and a minimum 10 mm leg for securing joint reinforcement to BS 1494.

8

Bonding compounds shall comply with the relevant provisions of BS 5270.

2.6.7

Installation Criteria

1

Where fire rated construction is required for walls, partitions, columns, beams and floor-ceiling assemblies, the construction is to be the same as that used in fire rating test.

2.6.8

Application of Skim Coat Base

1

Unless otherwise indicated in the Project Documentation, gypsum board shall be extended from the floor to the underside of structure overhead on partitions and furring as follows:

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(a)

two sides of the wall for (i)

fire rated partitions

(ii)

smoke partitions including cross corridor smoke partitions

QCS 2014

(b)

Section 24: Finishes to Building Part 02: Lath and Plaster (iii)

sound rated partitions

(iv)

full height partitions

(v)

corridor partitions

Page 13

one side of the wall for (i)

the inside of exterior walls and furring

(ii)

the room side of rooms without suspended ceilings

(iii)

furring for pipe and duct shafts except where fire rated construction is shown.

All layers of gypsum board construction used for fireproofing of columns shall be extended from the floor to underside of structure overhead, unless otherwise indicated in the Project Documentation.

3

In locations other than those specified above, extend gypsum board as follows:

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not less than 100 mm above suspended acoustical ceilings

(b)

to ceiling of suspended gypsum board ceilings.

(c)

to existing ceilings.

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(a)

A skim coat base of maximum practical length shall be used.

5

Skim coat base shall be installed with the long dimension direction as follows:

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on ceilings, at 90 to the framing to which it is applied.

(b)

on partitions, horizontally or vertically, except when the partition is fire rated apply base as designed in the fire rating test.

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In the vertical application of a skim coat base, panels of length required to reach the full height of vertical surfaces in one continuous piece shall be used.

7

The skim coat base shall be erected so that the leading edge of the base is first attached to the open end of the metal stud flange.

8

A space approximately 6 mm shall be left at the bottom of the skim coat base for caulking or sealant.

9

At edge and end joints:

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(a)

locate edge joints over framing in fire rated partitions

(b)

locate end joints over furring or framing in all cases

(c)

stagger end joints of adjoining boards or multiple layer boards

At control joints: (a)

are not required for wall length less than 10 m

(b)

do not extend the skim coat base across control joints

(c)

extend control joints the full width and height of the wall or length of soffit/ceiling skim coat plaster membrane.

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Page 14

For two-ply construction: (a)

joints between layers to be staggered or off-set and falling over framing member

(b)

use screws to hold skim coat base in place

Accessories and casings beads to be installed where required or shown.

2.6.9

Sealant Application

1

Sealants should be applied to the skim coat plaster base and to all cut outs, penetrations, and intersections with adjoining materials prior to application of skim coat plaster for acoustic partitions.

2

Refer to part 10 of this Section for application of sealants.

2.6.10

Skim Coat Plaster Application Over Gypsum Board Base

1

Skim coat plaster for one-component plasters shall be mixed and applied in accordance with BS 1191 unless otherwise indicated in the Project Documentation.

2

Joint reinforcement shall be as recommended by the skim coat plaster manufacturer for plaster systems applied over steel framing.

3

A smooth-trowel finish shall be applied to skim coat plaster over gypsum board base.

4

On fire rated, smoke barrier, sound barrier and other partitions, which are shown to extend to the underside of structure overhead or full height (floor to floor), the skim coat plaster finish may terminate 100 mm above the suspended ceiling.

5

All joints and fastener heads shall be sealed and reinforced above ceilings.

2.6.11

Repairs

1

After accessories and joint reinforcement have been installed and before application of skim coat plaster, all damaged and defective skim coat base work including non-plastered areas shall be repaired as follows to the satisfaction of the Engineer. holes or openings 12.5 mm or less in diameter (or equivalent size) shall be patched with a setting type joint adhesive or patching plaster

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(b)

holes or openings over 12.5 mm diameter (or equivalent size) shall be repaired with a 16 mm thick skim coat base secured in such a manner as to provide solid tight construction of skim coat base

(c)

any water damaged skim coat base shall be removed and replaced

(d)

paper face that is loose or stripped shall be removed and replaced.

Damaged skim coat plaster: (a)

at crumbly areas, remove loose material, brush, clean, apply bonding agent and refinish

(b)

for blistering, cut and remove unbonded paper face, apply bonding compound if gypsum core is exposed and refinish

(c)

repair, as recommended by manufacturer of skim coat plaster, other defects such as:

QCS 2014

Section 24: Finishes to Building Part 02: Lath and Plaster (i)

joint ridging and beading

(ii)

craze and map cracking

(iii)

field cracking

(iv)

spalling

(v)

stain

(vi)

soft, weak surfacing

(vii)

dryouts.

Page 15

BEADS AND STOPS

2.7.1

Materials

1

Beads and stops for internal plastering are to be manufactured from galvanized steel with minimum zinc coating of 225 g/m² and 0.40 mm minimum thickness in accordance with BS EN 13658-1, or from stainless steel with 0.30 mm minimum thickness in accordance with BS EN 13658-1, beads and stops to be profiled to suit the depth of plaster to be applied.

2

Stainless steel beads and stops shall be used for external rendering, minimum thickness is to be 0.30mm in accordance with BS EN 13658-2, beads and stops to be profiled to suit the depth of plaster or render to be applied.

2.7.2

Fixing Beads and Stops

1

Beads, stops and the like are to be fixed plumb, square and true-to-line with 40 mm galvanized clout nails or plaster dabs at not more than 600 mm centres to each mesh wing.

2

Cut edges are to be treated with one coat bituminous solution.

2.8

WELDED-FABRIC MESH FOR REINFORCED RENDERING

2.8.1

Materials

1

Reinforcement for rendering is to consist of galvanised welded-fabric mesh in accordance with BS EN 13658-2 having wires not less than 3.0 mm diameter spaced at distances 50 mm. Wires spacing can be greater than 50 mm but shall not be greater than 150 mm if approved by the Engineer or project drawings and in accordance with BS EN 13658-2.

2.9

PREPARATION OF SUBSTRATA

2.9.1

Preparation of Background to be Rendered

1

Surfaces to be rendered are to be thoroughly cleaned of all mould oil, dust and loose particles.

2

If dubbing out is required it should be done well in advance of the undercoat, using a mix at least as strong as the undercoat but not stronger than the background. If the thickness needed is greater than 16 mm, it is be built-up in two coats; no coat is to exceed 13 mm thick.

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Concrete surfaces are to receive one of the following treatments before the application of the undercoat: (a)

hacking by hand or mechanical means to remove all laitence and to roughen the whole of the surface to a depth of at least 3 mm to expose the aggregate.

(b)

a spatterdash treatment of one part of cement and two parts of coarse sand, mixed with sufficient water to give a consistency of a thick slurry is to be dashed on to the dampened background with either a trowel or a scoop to give a thin coating with a roughcast uneven appearance. To prevent rapid loss of moisture the spatterdash is to be dampened periodically and then be permitted to dry out slowly and harden before the application of the rendering.

Blockwork surfaces are to have the joints raked out during construction. Where the joints have not been raked out or where in the opinion of the Engineer high strength concrete blocks with smooth surfaces will provide insufficient key, a spatterdash treatment is to be applied in accordance with Clause 2.9.1-3.

5

Junctions of differing backgrounds are to be treated in accordance with Clause 2.5.4. A strip of metal lath minimum 200 mm wide should also be provided over all electrical conduits and service pipework running within chases, fixed in accordance with Clause 2.5.4.

2.10

PREPARATION OF MIXES FOR RENDERING

2.10.1

Preparation Procedures and Selection of Materials

1

Unless specified elsewhere in the Project Documentation the mixes for rendering are to be selected from Table 2.1 and will vary in accordance with the types of background to which the render is to be applied. Backgrounds are subdivided as follows:

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dense, strong and smooth materials - which include high density concrete and concrete blocks providing low porosity, little suction and having smooth surfaces

(b)

moderately strong and porous materials - which include medium density concrete and concrete blocks providing some suction and mechanical key moderately weak and porous materials - which include medium density concrete and concrete blocks providing some suction and mechanical key

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metal lathing Table 2.1 Rendering Mixes Undercoats Cement : Lime : Sand

Final Coat Cement : Lime : Sand

1 : ½ : 4½

1 : 1 : 6

Moderately strong, porous

1 : 1 : 6

1 : 2 : 9

Moderately weak, porous

1 : 2 : 9

1 : 2 : 9

Metal lathing (first coat)

1 : ¼ : 3

1 : 1 : 6

1 : ½ : 4½

1 : 1 : 6

Background Material Dense, strong, smooth

Metal lathing 2

The selection of the mixes is to take account of the following: (a)

strong mixes rich in cement have a relatively high drying shrinkage and are liable to cracking and crazing

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Page 17

(b)

the high drying shrinkage of strong mixes applied to weak backgrounds may cause shearing at the surface of the background

(c)

the mix for each successive coat must never be richer in cement than the mix used for the coat to which it is applied

(d)

two coats having the same mix proportions can only be applied successively if the second coat is appreciated thinner than the first. A 10 to 12 mm first coat should only receive a 5 to 6 mm final coat of the same mix.

The mixes for rendering below ground level are to be made with sulphate resisting cement.

4

Cement, lime and sand for each batch are to be accurately measured by volume using properly constructed gauge boxes or, wherever possible, whole bags of cement or hydrated lime. Lime shall comply with the relevant provisions of BS 890.

5

Mixing should preferably be by machine. Where, however, small quantities are required, mixing may be carried out on a board or platform which should be cleaned after each batch has been removed.

6

The hydrated lime is first to be thoroughly mixed with the sand. Cement shall then added and mixing continued until the material is uniform in appearance. Water should then be added while continuing mixing until the materials are workable and of a uniform colour and consistency.

7

To improve workability of the mix, the hydrated lime, sand and water may first be mixed in the required proportions and then allowed to stand undisturbed for at least 16 hours before mixing with the cement. If allowed to stand for a longer period it must be protected from drying out.

8

Propriety plasticisers may not be used as a substitute for lime without the approval of the Engineer. Amongst other considerations, the Engineer will not give approval unless:

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the manufacturer, brand and chemical composition of the admixture is disclosed

(b)

the Engineer is satisfied that correctly calibrated equipment is available to control the amounts used.

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The whole of each batch is to be used within an hour of being mixed.

2.10.2

Application of the Various Render Coats

1

The work is not to be started until the background has been properly prepared in accordance with Clause 2.9 of this Part.

2

The render shall generally be applied in two coats except where the background is metal lathing where three coats shall be applied.

3

Before applying any coat the background or preceding coat is to be brushed down to remove any loose particles and is to be dampened sufficiently to ensure uniform absorption.

4

The undercoat is to be applied either by laying on with, or throwing from, a trowel or float. It should be as uniformly thick as possible, and not less than 8 mm or more than 13 mm thick in any part.

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The undercoat is to be left rough and open from the edge of the trowel, and after it has been left long enough to set firm, it should be combed with evenly spaced wavy horizontally lines. the lines are to be approximately 20 mm apart and 5 mm deep (less in the case of a first coat on metal lathing). The surface should not be scratched, however, when it is to receive a Tyrolean finish.

6

The first undercoat applied to metal lathing is to be well worked into the lath to ensure that the material is completely embedded.

7

The finishing coat should not to be less than 5 mm or more than 10 mm thick and is to be laid on with a trowel and finished with a wood float, care being taken not to over-work the surface.

8

All coats are to be applied with firm pressure to exclude air and to ensure a good bond.

9

All coats are to be prevented from drying out too quickly. Between the hot months of April and November the work should only be carried out in the shade. All external rendering is to be protected by properly constructed hessian or similar screens during this period.

10

Each coat is to be kept damp by means of a fog spray of water for a minimum of three days to allow the render to cure and then be allowed to dry out for at least a further three days before a subsequent coat is applied or, in the case of the finish coat, before the protective screens are removed.

11

The surface of the finish coat is to be smooth, true and free from waviness, irregularities or blemishes with straight, level or plumb angles. External angles are to be pencil rounded.

12

Care is to be taken when rendering up to plaster beads or stops to avoid excessive polishing at the arris and damage to the galvanizing, or stainless steel.

2.11

PORTLAND CEMENT PLASTER

2.11.1

Materials

1

Cement shall comply with the requirements of EN 197-1.

2

If premix Portland cement plasters are used they shall be polymer modified premixed cementitious base, complying with ASTM C150, ASTM C897 or equivalent, and application standard ASTM C926 or BS EN 13914 or equivalent.

3

Aggregate shall comply with the requirements of BS EN 13139 and the relevant provisions of section 5, concrete,

4

Mixing ratio: 50 kg bag with 10 to 12 liters of clean cool water (water part 4 sec. 5).

5

VOC and formaldehyde: None (<10μg/l) when tested according to ISO/FDIS 11890- 2/GCMS

6

Thermal conductivity according to EN 1745 or as required by the engineer.

2.11.2

Application of Portland Cement Plaster.

1

Application shall comply with ASTM C926 or BS EN 13914

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Do not deviate more than plus or minus (3.1 mm in 3 m) from a true plane in finished plaster surfaces, as measured by a (3-m)straightedge placed on surface.

3

Grout hollow-metal frames, bases, and similar work occurring in plastered areas, with basecoat plaster material, before lathing where necessary. Except where full grouting is indicated or required for fire-resistance rating, grout at least (152 mm)at each jamb anchor.

4

Finish plaster flush with metal frames and other built-in metal items or accessories that act as a plaster ground, unless otherwise indicated. Where casing bead does not terminate plaster at metal frame cut base coat free from metal frame before plaster sets and groove finish coat at junctures with metal.

5

Provide plaster surfaces that are ready to receive field-applied finishes indicated.

6

Concealed plaster application behind built-in cabinets, similar furnishings, and equipment, apply finish coat, where concealed above suspended ceilings and in similar locations, finish coat may be omitted. Plaster application will be used as a base for adhesive application of tile and similar finishes, finish coat may be omitted.

7

Water shall comply with the requirements of part 4 of section 5

2.12

POLYMER PLASTERING

2.12.1

Materials and Application of Plaster

1

Materials and Application shall comply with the requirements of PD CEN/TR 15123

2.13

TABLE PIGMENTS FOR CEMENT

2.13.1

Materials

1

Any pigments used to colour cement or cement products shall meet the requirements of BS EN 12878 or relevant ASTM standards.

2.14

TEST FOR DRYNESS

2.14.1

Procedures

1

Moisture content is to be ascertained by use of a hygrometer or similar approved instrument. A substrate will be considered “dry” when all readings taken in the corners, along edges and at various points over the area being tested show 75 % relative humidity or less.

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2

END OF PART

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DRY LINING (WALLBOARD) ........................................................................ 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 DRY LININGS ................................................................................................ 2 Materials 2 Storage of Materials 3 FIXING OF WALLBOARD ............................................................................. 3 Fixing Wallboard to Framed Backgrounds 3 Fixing Wallboard to Solid Background 4 Jointing of Dry Lining for Direct Decoration 5

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3 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3

Section 24: Finishes to Buildings Part 03: Dry Lining (Wallboard)

QCS 2014


Page 2

3

DRY LINING (WALLBOARD)

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for use of dry wallboard or plaster board.

2

Related Parts and Sections are as follows: General Lath and Plaster

Section 1

General

References

1


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BS 1230 ......................Gypsum Plasterboard

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3.1.2

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DRY LININGS

3.2.1

Materials

1

Gypsum wallboard is to consist of either 9.5 or 12.7 mm thick gypsum plasterboard complying with BS 1230, having one face finished for direct decoration.

2

Thermal wallboard is to comply with Table 3.1 and consist of an insulation core having a thermal conductivity of not less than 0.037 W/mºC bonded on one side to the gypsum wallboard and on the reverse side with a water-vapour resistant membrane.

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Table 3.1 Thermal Wallboard

Nominal Overall Thickness

Wallboard Thickness

Insulation Thickness

Minimum Thermal Resistance

(mm)

(mm)

(mm)

(W/m ºC)

22

9.5

12.7

0.40

25

12.7

12.7

0.42

28

9.5

19.0

0.57

32

12.7

19.0

0.59

QCS 2014

3


Page 3

The edge profiles of wallboard to be: (a)

tapered - for smooth seamless jointing

(b)

bevelled - for V-jointing

(c)

square - for stippled textured coatings, corner strip jointing or plaster.

Accessories for installing wallboard are to be approved proprietary materials recommended by the manufacturer of the board and are to comply with the requirements of BS 8000, Part 8.

3.2.2


1

Wallboards are to be stored flat in dry conditions and should always be carried on edge.

2

Rolls of sheet materials are to be stored standing on end.

3.3

FIXING OF WALLBOARD

3.3.1

Fixing Wallboard to Framed Backgrounds

1

The background is to provide supports at the maximum centres shown in Table 3.2. Additional framing members are to be provided as necessary to ensure that all board edges are supported.

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Table 3.2 Maximum Support Centres for Gypsum Wallboard and Thermal Wallboard on Framed Background Thickness

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Type Of Board

Maximum Centres

(mm)

(mm)

(mm)

9.5

900

450

450

9.5

1200

400

400

12.7

600

600

450

12.7

900

450

450

12.7

1200

600

600

Thermal

22

1200

400

400

Wallboard

25

1200

600

600

28

1200

400

400

32

1200

600

600

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(mm)

Wallboard

2

Width

The boards are to be fixed to backgrounds with the paper covered edges vertical and to ceilings with the paper covered edges at right angles to the main supporting members/joists.

QCS 2014


Page 4

3

The boards are to be fixed to the backgrounds not nearer than 15 mm from the edges using 40 x 2 mm galvanized clout nails for wallboard and 60 x 2.5 mm galvanized clout nails for thermal wallboard.

4

The nails should be driven home straight and firmly so that the heads are slightly below the surface of the board. Care shall taken not to fracture the board. Care shall also be taken to ensure hat the insulation is not compressed unduly.

5

Boards to receive direct decoration are to be fixed so that: Paper covered edges are lightly butted together

(b)

Cut edges occur at internal angles

(c)

Cut edges occurring at external angles are masked by paper covered edges

(d)

Cut edges meeting in the same plane have a 3 mm gap between them.

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(a)

The insulation to thermal wallboard is to be rebated at external angles to give a continuous plasterboard face.

3.3.2

Fixing Wallboard to Solid Background

1

The walls are to be thoroughly brushed down with a hard broom to remove dust, crystallised efflorescent salts and loose mortar.

2

Bitumen impregnated fibreboard levelling pads size approximately 75 x 50 mm are to be bedded into minimum 3 mm thick plaster dabs set plumb by use of a straightedge and builder’s level at not more than 1 metre centres vertically and to bridge each board joint plus one intermediate row horizontally.

3

When the pads have set an adhesive recommended by the manufacturer of the boards should be applied to the wall in dabs to stand proud of the pads. Unless recommended otherwise the dabs shall be 50 to 75 mm wide by the length of the trowel with 50 to 75 mm gaps, in lines: (a)

Set in 25 mm around the perimeter of each board. On the line of the intermediate fixing pads.

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4

The boards shall then to be pressed back firmly to the line of the pads and temporarily fixed with double headed nails until the adhesive has set. A true and flat surface should be achieved.

5

Boards to receive direct decoration are to be fixed so that:

6

(a)

paper covered edges are lightly butted together.

(b)

Cut edges occur at internal angles.

(c)

Cut edges occurring at external angles are masked by paper covered edges.

(d)

Cut edges meeting in the same plane have a 3 mm gap between.

The insulation to thermal wallboard is to be rebated at external angles to give a continuous plasterboard face.

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Page 5

Jointing of Dry Lining for Direct Decoration

1

The joints of square edge boards which are to receive a stippled textured coating are to be finished with a paper faced cotton joint tape fixed with a suitable adhesive.

2

The joints of bevelled edge boards are to have the “V” joint completely filled with joint filler and the surplus removed.

3

The joints of tapered edge boards should either be finished by the manual methods described in the following paragraphs, or except for joints at external angles, by approved mechanical methods recommended by the manufacturer of the board.

4

Before jointing commences the boards are to be checked to ensure that all are securely fixed and protruding screws or nails are driven home. Cut edges are to be lightly sanded to remove burrs and treated with a brush coat of PVC sealer.

5

Joints in straight runs of tapered edge boards are to be finished as follows:

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3.3.3

A continuous, thin band of joint filler is to be applied to the trough of the tapered edge joints using an applicator and making sure areas are not left uncovered. A 45 mm wide joint tape is to then be pressed into the band of filler using a taping knife. The tape is to be firmly bedded and free from air bubbles, with sufficient filler under the tape to ensure good adhesion

(b)

Immediately after the tape has been fixed a new layer of filler is to be applied over it. This should be brought flush with the surface of the board. Before the filler begins to stiffen, a jointing sponge should be moistened and surplus material wiped from the edges of the joint, taking care not to disturb the main joint filling

(c)

Once the filler has set, any slight depressions in the surface are to be filled with another coat of the filler an any projections cut back with the taping knife.

(d)

When the filler has set a thick layer of joint finish is to be applied to a broad band 200 to 250 mm wide over the joint using the applicator. The edges of this band shall be immediately feathered out with a slightly damp jointing sponge. When this band of jointing finish has dried, another application is to be made and feathered out as before. The first coat of finish must dry before the final finish coat is applied.

7

Joints at internal angles of tapered edge boards are to be finished as follows:

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(a)

(a)

The jointing tape is to be folded and pressed firmly into the angle using a brush or applicator to make sure any air bubbles are removed and the tape is firmly bedded. A thin layer of joint finish 150 mm wide centred on the joint is to be applied immediately and the edges feathered out with the jointing sponge.

(b)

surplus material is to be removed from the extreme edges as described in subparagraph 5(b) above.

(c)

when this coat has dried, another coat of joint finish 200-250 mm wide is to be applied and the edges feathered out with the jointing sponge.

Joints at external angles of tapered edge boards are to be finished as follows: (a)

the edges of the board to be treated as recommended by the dry lining manufacturer with the insulation cut back and using a bound and tapered edge so as to mask the cut edge of the dry lining.

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Page 6

the angles should be reinforced with a 54 mm wide corner tape consisting of strong paper tape with bonded parallel steel reinforcement strips. The tape is to be cut to the required length and creased firmly at the angles to allow the steel strips to lie close to the board surfaces. A 50 mm wide band of joint filler is to be applied to each side of the angle and the tape be pressed firmly into the corner with a taping knife, making sure that the arris of the folded tape is straight.

(c)

immediately after bedding the tape, a 125 mm band of joint filler shall be applied to both sides of the angle with an applicator and the edges feathered out with the jointing sponge.

(d)

after the filler coat has set, a thin layer of joint finish is to be applied and the edges again feathered out with the jointing sponge.

(e)

when the first filler coat is dry, the process is to be repeated with a further application of joint finish.

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(b)

Nail and screw indentations are to be filled with joint filler and finished flush. When the filler has set a thin layer of joint finish is to be applied and the edges feathered out with the jointing sponge.

9

When all jointing and filling has been completed and the last application of joint finish has dried, a slurry coat of joint finish shall be applied over the entire surface of the boards to give an even sponged texture.

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END OF PART

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SPECIAL WALL SURFACES ........................................................................ 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 AGGREGATE COATINGS ............................................................................ 2 Tyrolean Rendering 2

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4 4.1 4.1.1 4.1.2 4.2 4.2.1

Section 24: Finishes to Buildings Part 04: Special Wall Surfaces

QCS 2014

Section 24: Finishes to Buildings Part 04: Special Wall Surfaces

Page 2

SPECIAL WALL SURFACES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for manufactured special or non-standard wall surface, both interior and exterior use, and special protective wall coatings. As these items may be non-standard and tailored individually for specific projects, it will be the Contractors responsibility to ensure that specifications or requirements are provided by manufacturers and approved by the Engineer. Where applicable, the relevant provisions of BS 8000 shall be complied with.

2


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Section 1

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General Lath and Plaster Dry Lining (Wallboard)

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This Section: Part 1 Part 2 Part 3

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4

References

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BS 8000......................Workmanship on Building Sites

AGGREGATE COATINGS

4.2.1

Tyrolean Rendering

1

Tyrolean rendering is to consist of white cement and coarse washed sand complying with Tables 2.2 and 2.3 of Part 2 of this Section in the proportions of 1:1.5 or 1:2 applied to a rendered undercoat.

2

Sufficient supplies of sand from a single source are to be stockpiled on site to ensure that the Tyrolean finish is of even texture and colour throughout the Works.

3

The rendered undercoat is to be applied in accordance with Tables 2.2 and 2.3 of Part 2 of this Section except that the surface of the undercoat is to be finished smooth with a wood float and not scratched.

4

The Tyrolean finish coat is to be applied by an approved hand-operated machine in layers to build up an average thickness of 6 mm and be allowed to cure and dry in the same way as a final rendering coat.

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END OF PART

QCS 2014

Section 24: Finishes to Building Part 05: Tiles

Page 1

TILES ...................................................................................................................... 2

5.1 5.1.1 5.1.2


5.2 5.2.1 5.2.2 5.2.3

TILE ADHESIVES AND GROUTS ........................................................................... 3 Adhesive Types 3 PREPARATION 3 INSTALLATION, GENERAL 4

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7

CERAMIC TILES ..................................................................................................... 5 General 5 Glazed Ceramic Wall Tiles 5 Fixing Internal Ceramic Wall Tiles 5 Fixing External Ceramic Tiles 6 Floor Tiles 7 Laying Ceramic Floor Tiles by the Semi-Dry Mix Method 7 Laying Ceramic Floor Tiles by the Direct Mortar Bedding Method 8

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Page 2

TILES

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for use of ceramic tile products and the installation of such for wall and floor surfaces.

2


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This Section Part 1 ............... General Part 2 ............... Lath and Plaster Part 3 ............... Dry Lining (Wallboard) Part 4 ............... Special Wall Surfaces Part 6 ............... Terrazzo Part 7 ............... Stone Flooring Part 8 ............... Unit Masonry Flooring Part 9 ............... Floor Screeds and Treatments Part 10 ............. Joints, Caulking and Sealants

.

5

Section 13 ....... Masonry References

1

The following standards are approved and/ or referred to in this Part:

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5.1.2

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BS 8000 .....................Workmanship on building sites

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BS 8000-11 ...............Workmanship on building sites. Internal and external wall and floor tiling. Ceramic and agglomerated stone tiles, natural stone and terrazzo tiles and slabs, and mosaics. Code of practice

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BS 8298-1 ..................Code of practice for the design and installation of natural stone cladding and lining. General

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BS 7956 .....................Specification for primers for woodwork BS EN 12057 .............Natural stone products. Modular tiles. Requirements

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BS EN 12058 .............Natural stone products. Slabs for floors and stairs. Requirements BS EN 15285 .............Agglomerated stone. Modular tiles for flooring and stairs (internal and external) BS EN 12440 .............Natural stone. Denomination criteria BS EN 14411 ............Ceramic tiles. Definitions, classification, characteristics, evaluation of conformity and marking BS EN 12004 .............Adhesives for tiles. Requirements, classification and designation

evaluation

of

conformity,

GSO ISO 13006 ........Ceramic tiles. Definitions, classification, characteristics and marking GSO ISO 10545-16 (BS EN ISO 10545-16) Ceramic tiles: Determination of small colour differences GSO ISO 10545-15 (BS EN ISO 10545-15). Ceramic tiles: Determination of lead and cadmium given off by glazed tiles GSO ISO 10545-14 (BS EN ISO 10545-14). Ceramic tiles: Determination of resistance to stains GSO ISO 10545-13 (BS EN ISO 10545-13). Ceramic tiles: Determination of chemical resistance

QCS 2014


Page 3

GSO ISO 10545-12 (BS EN ISO 10545-12). Ceramic tiles: Determination of frost resistance GSO ISO 10545-11 (BS EN ISO 10545-11). Ceramic tiles: Determination of crazing resistance for glazed tiles GSO ISO 10545-10 (BS EN ISO 10545-10). Ceramic tiles: Determination of moisture expansion GSO ISO 10545-9 (BS EN ISO 10545-9) Ceramic tiles: Determination of resistance to thermal shock GSO ISO 10545-8 (BS EN ISO 10545-8). Ceramic tiles: Determination of linear thermal expansion GSO ISO 10545-7 (BS EN ISO 10545-7). Ceramic tiles: Determination of resistance to surface abrasion for glazed tiles GSO ISO 10545-6 (BS EN ISO 10545-6). Ceramic tiles: Determination of resistance to deep abrasion for unglazed tiles GSO ISO 10545-5 (BS EN ISO 10545-5). Ceramic tiles: Determination of impact resistance by measurement of coefficient of restitution

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GSO ISO 10545-4 (BS EN ISO 10545-4). Ceramic tiles: Determination of modulus of rupture and breaking strength

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GSO ISO 10545-3 (BS EN ISO 10545-3). Ceramic tiles: Determination of water absorption, apparent porosity, apparent relative density and bulk density GSO ISO 10545-2 (BS EN ISO 10545-2). Ceramic tiles: Determination of dimensions and surface quality

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GSO ISO 10545-1 (BS EN ISO 10545-1) Ceramic tiles: Sampling and basis for acceptance

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GSO ISO 13007-4 (BS ISO 13007-4) Ceramic tiles. Grouts and adhesives: Test methods for grouts GSO ISO 13007-3 (BS ISO 13007-3)_ Ceramic tiles. Grouts and adhesives: Terms, definitions and specifications for grouts

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GSO ISO 13007-2 (BS ISO 13007-2) Ceramic tiles. Grouts and adhesives: Test methods for adhesives

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GSO ISO 13007-1 (BS ISO 13007-1) Ceramic tiles. Grouts and adhesives: Terms, definitions and specifications for adhesives

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ISO 15165 .................Fine ceramics (advanced ceramics, advanced technical ceramics) -Classification system

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ISO 14574 .................Fine ceramics (advanced ceramics, advanced technical ceramics). Mechanical properties

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ISO 14544 .................Fine ceramics (advanced ceramics, advanced technical ceramics) -Mechanical properties of ceramic composites at high temperature -Determination of compression properties ANSI A108 / A118 / A136.1 American National Specifications for the Installation of Ceramic Tile The Tile Council of America TCA Handbook for Ceramic Tile Installation (The Tile Council of North America TCNA Handbook for Ceramic, Glass, and Stone Tile Installation)

5.2

TILE ADHESIVES AND GROUTS

5.2.1

Adhesive Types

1

Adhesives used for fixing ceramic tiles to comply with. GSO ISO 13007-1 or BS EN 12004

5.2.2

PREPARATION

1

Remove coatings that are incompatible with tile-setting materials from substrates, including curing compounds and other substances that contain soap, wax, oil, or silicone.

QCS 2014

2


Page 4

For concrete substrates for tile floors installed with adhesives or thin-set mortar, correct conditions that do not comply with flatness tolerances specified in referenced ANSI A108 Series of tile installation standards. (a)

Fill cracks, holes, and depressions with trowel able leveling and patching compound according to tile-setting material manufacturer's written instructions. Use product specifically recommended by tile-setting material manufacturer.

(b)

Remove protrusions, bumps, and ridges by sanding or grinding.

3

Apply primer-sealer to wood and plywood subfloors when recommended by tile-setting material manufacturer.

4

Lay out tile patterns by marking joint lines on substrates to verify joint placement at edges, corners, doors, and other critical elements. Notify Architect seven days in advance of dates and times when layout will be done.

(b)

Obtain Architect's approval of layout before starting tile installation.

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(a)

INSTALLATION, GENERAL

1

Installation standards shall comply with requirements of ANSI A108 or TCNA or BS 8000-11.

2

ANSI Tile Installation Standards: Comply with requirements of ANSI A108 that apply to types of setting and grouting materials and to methods indicated.

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5.2.3

For stone tile floors, follow procedures in ANSI A108 for providing 95 percent mortar coverage.

(b)

For stone tile walls, follow procedures in ANSI A108 series for the materials being used.

(c)

For stone threshold, follow procedures in ANSI A108 series for the materials being used

(d)

For stone countertops, follow procedures in ANSI A108 series for the materials being used

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(a)

TCA Installation Guidelines or TCNA Handbook : Comply with TCA's "Handbook for Ceramic Tile Installation" and TCA installation methods indicated.

4

Wipe backs of tiles with a damp cloth to remove dirt and dust before units are installed.

5

Extend tile work into recesses and under or behind equipment and fixtures to form complete covering without interruptions, unless otherwise indicated. Terminate work neatly at obstructions, edges, and corners without disrupting pattern or joint alignments.

6

Accurately form intersections and returns. Perform cutting and drilling of tile without marring visible surfaces. Fit tile closely to electrical outlets, piping, fixtures, and other penetrations so plates, collars, or covers overlap tile.

7

Finish cut tile edges that will not be concealed by other construction by grinding and honing cut surfaces and easing edges to match factory-fabricated edges, unless otherwise indicated.

8

Jointing Pattern: Lay tile in grid pattern, unless otherwise indicated. Align joints when adjoining tiles on floor, base, walls, and trim are same size. Lay out tile work and center tile fields in both directions in each space or on each wall area. Adjust to minimize tile cutting.

9

Match tiles within each space by selecting tiles to achieve uniformity of color and pattern. Reject or relocate tiles that do not match color and pattern of adjacent tiles.

10

Mix tiles to achieve a uniformly random distribution of color shadings and patterns.

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QCS 2014


Page 5

11

Pattern Orientation: For stone varieties with directional pattern, orient pattern as directed by Architect.

12

Expansion Joints: Locate expansion joints and other sealant-filled joints, including control, contraction, and isolation joints, where indicated during installation of setting materials, mortar beds, and tile. Do not saw-cut joints after installing tiles. (a)

Locate joints in tile surfaces directly above joints in concrete substrates.

(b)

Use single-component, non sag polyurethane for joints in walls.

(c)

Use single-component, non sag polyurethane for joints in floors.

CERAMIC TILES

5.3.1

General

1

This specification includes ceramic wall tiles used in standard applications for floor and wall surfaces.

2

Tile products for walls and floors shall comply with BS EN 14411 or GSO ISO 10545 or ISO 15165 or ANSI A118 / A136.1 Material Specifications.

3

Application shall comply with BS 8000, Part 11 or ANSI A108 or TCNA Handbook for Ceramic.

5.3.2

Glazed Ceramic Wall Tiles

1

Glazed ceramic wall tiles for internal use shall comply with the approved references and for external use must be recommended for the purpose by the manufacturer.

2

Grout for wall tiling to be an approved proprietary grout.

5.3.3

Fixing Internal Ceramic Wall Tiles

1

Ceramic wall tiles shall be fixed by bedding in an approved adhesive on cement rendering. The rendering shall be applied in accordance with Part 2 of this Section except where modified by the requirements of this Part.

2

All backgrounds are to receive the spatterdash treatment described in Clause 2.9.1 – 3(b) of Part 2 of this Section before the surfaces are rendered.

3

The rendering is to be in one coat, except where applied to metal lathing when two coats are to be used, and be left with a wood float finish. It is to be as uniformly thick as possible and not less than 8 mm or more than 13 mm thick in any part.

4

Mesh reinforcement is to be incorporated in the rendering in accordance with Clause 2.8 of Part 2 of this Section where:

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5.3

(a)

the structure is out of line and the thickness of render required exceeds 13 mm

(b)

the rendering is to be applied over differing structural materials (See Clause 2.9 of Part 2 of this Section)

(c)

the surface of the structural wall will be subject to excessive movement.

Where the tiling is to be bedded in a thin-bed adhesive, the trueness of the rendering is to be such that when tested with a 3 m straightedge, no gap exceeds 3 mm. Where the gap exceeds 3 mm but is less than 6 mm, or if the walls are out of plumb by not more than 6 mm, the Engineer may permit a thick-bed adhesive to be used or may direct that the defective areas are cut back and made good. Deviations from true or plumb in the surface of the rendering exceeding 6 mm are to be made good.

QCS 2014


Page 6

6

Thin-bed adhesive should not be used for fixing tiles with backs incorporating deep keys or frogs; for these thick-bed adhesives must be used.

7

The tiles are to be set out before the work commences so that: (a)

cut tiles are kept to a minimum and where they do occur, are as large as possible

(b)

joints are horizontal and vertical, with horizontal joints aligning in walls that are adjacent.

The tiles shall be neatly and accurately cut to a close fit where necessary at abutments and around outlets, pipes and the like.

9

Movement joints not less than 6 mm wide are to be provided:

(b)

at all angles with structural walls and ceilings

(c)

to give bays not greater than 3000 x 4500 mm

(d)

over all structural movement joints.

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(a)

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8

The joints are to be carried through the rendering to the structural wall and shall be partially filled with an approved joint filler and finished flush with an approved sealant recommended by the manufacturer for the situation in which it will be used.

11

Glazed edge tiles to be used where edges are exposed.

12

The adhesive is to be prepared and applied with a trowel to dry rendering in the manner recommended by the manufacturer. The tiles are to be pressed firmly into the adhesive with a twisting/sliding action, tapped firmly into position and cleaned as soon as the bedding is complete.

13

It is essential that the tiles are fixed in position before the surface of the adhesive dries and 2 the work is to be carried out in small areas of not more than 1m at a time.

14

The finished surface of the tiles should be plumb and true such that when checked with a 3 m straightedge no gap exceeds 3 mm.

15

The joints are to be even, approximately 2 mm wide and where tiles without spacer lugs are used, spacer pegs of suitable and even thickness to be inserted between the tiles as the work proceeds.

16

The joints are to be grouted after the adhesive has set and not less than 48 hours after fixing. The grout should be well worked into the joints so that they are completely filled, and finished flush. Surplus grout is to be cleaned off as the work proceeds using a damp cloth and the joints tooled smooth.

5.3.4

Fixing External Ceramic Tiles

1

The ceramic wall tiles are to be fixed by bedding in an approved adhesive or cement rendering. The adhesive must be suitable for external application and the Contractor is to obtain confirmation from the manufacturer that it is suitable for the type of tile to be fixed and in the climatic conditions prevalent in Qatar and provide the Engineer with copies of the correspondence.

2

The tiling is to be carried out generally in accordance with Clause 5.3.3 of this Part describing internal work except that the rendered backing is to be reinforced with galvanized welded fabric reinforcing mesh and except where modified by this Clause.

3

Stainless steel reinforcing mesh to be used where shown on the drawings or as directed by the Engineer.

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Page 7

The mesh is to be fixed, with the horizontal wires outwards by means of 25 mm stainless steel anchors or by drilling holes in which plastic anchors are inserted to receive 38 mm stainless steel, slotted head, countersunk wood screws. It is essential that the fixings extend into the structural wall by a minimum of 25 mm after passing through any dubbing etc.

5

The fixings are to be set at maximum 450 mm centers in both directions and staggered, located so that the horizontal wires of the mesh rest on the screws. The vertical wires of the mesh shall be spaced 3 mm from the structure by stainless steel washers placed as the screws are inserted.

6

The mesh should be secured to the screws by stainless steel binding wire of softened quality and 1.22 mm in diameter, twisted tightly and with its ends turned inwards.

7

The mesh is to be cut off at all movement joints leaving 40 mm free space on either side.

8

All cut edges of the mesh are to receive a coating of bitumen solution.

9

A slurry coat of neat cement is to be brushed on the background and the mesh. Whilst the slurry coat is still wet, the rendering is to be applied, working around and through the wires and ensuring that it is fully bonded to the background and that the wire is covered by a thickness of 7 mm.

10

Joints in tiled areas are not to be less than the width of the joints in the tiling and be provided in positions to be agreed with the Engineer, generally:

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4

over all structural movement joints.

(b)

to give bays not greater than 3000 by 4500 mm.

(c)

at all internal and external vertical corners.

(d)

at each storey height level coinciding with the bottom of the floor slab.

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(a)

Floor Tiles

1

Ceramic floor tiles and clay floor quarry tiles shall comply with the approved references.

2

Tiles designated as fully vitrified clay on the drawings shall have a water absorption below 0.5%.

5.3.6

Laying Ceramic Floor Tiles by the Semi-Dry Mix Method

1

The areas of concrete substrata to be tiled are to be brushed clean and dampened until absorption ceases and the finished floor level is to be established by means of dots and rules.

2

The mortar for bedding the tiles is to be to the thickness shown elsewhere in the Project Documentation. It shall consist of 1 part of cement to 4 parts of sand by volume, mixed semidry in a mechanical mixer with only sufficient water added to give a crumbly consistency that retains its shape when squeezed in the hand.

3

The minimum thickness of bedding with this system of laying is to be 40 mm. Where a bedding thickness in excess of 70 mm is required a maximum 10 mm aggregate is to be incorporated in the proportion of 1 part cement, 1.5 parts dry sand and 3 parts dry coarse aggregate, by weight, laid in two applications of approximately equal thickness. The lower layer is to be roughly compacted, but not allowed to stiffen, before the final layer is placed on top.

4

The mix is to be spread to a thickness approximately 10 mm greater than that actually required for the bed and be thoroughly compacted by tamping and drawing off to the required level with a screed board. Only sufficient mortar is to be mixed and spread as can be covered with tiles before it has attained its initial set.

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5.3.5

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Page 8

A slurry of 1 part cement and 1 part sand, by volume, is to be poured over the surface of the semi-dry mix bedding and spread with a trowel until it is approximately 2 mm thick. Dry tiles are then to be laid on the slurry and beaten firmly into position with a wooden beater to ensure a true surface and contact between the tiles and bedding is complete.

6

The tiles must be correctly positioned at the time they are placed and laid with joints of about 3 mm.

7

Grouting of the joints to be carried out within a period of 4 hours of the completion of the laying of the tiles so that the grout will attach itself firmly to the bedding. Care is to be taken to avoid disturbing the tiles and walking boards are to be used during the grouting operation.

8

The grouting mix is to either consist of 1 part cement to 1 part fine, dry sand by volume, or an approved proprietary grout may be used.

9

The tiles are to be neatly and accurately cut to a close fit where necessary at abutments and around outlets, pipes and the like.

10

Tiles are to be laid level or to 1% falls in “wet” areas, as may be required. Localised variations in level for a nominally flat floor are to be a maximum of ±3 mm under a 3 m straightedge. Particular care is to be taken in “wet” areas to prevent low spots and the pooling of water.

11

Skirtings of the same tile size as the floor are to be fixed in such a manner that their vertical joints coincide with the horizontal joints of the floor tiles.

5.3.7

Laying Ceramic Floor Tiles by the Direct Mortar Bedding Method

1

The areas of concrete substrata to be tiled should be brushed clean and dampened until absorption ceases and the finished floor level is to be established by means of dots and rules.

2

The mortar for bedding the tiles is to consider of 1 part of cement to 4 parts of sand by volume, mixed in a mechanical mixer to a stiff plastic consistency so that when tamped and fully compacted into place free water does not bleed to the surface.

3

The bedding mortar is to be laid on the concrete substrata 15 to 25 mm thick, except where tiles 10 mm thickness or less are used in which case the bedding is not to exceed 15 mm, and shall be levelled and tamped with a straightedge board.

4

The tiles are to be soaked in clean water for 15 to 30 minutes before fixing and allowed to drain for 10 minutes to remove all surplus water. Fully vitrified tiles do not require soaking.

5

The bedding mortar is to be lightly dusted with dry cement sprinkled from a flour sieve and lightly trowelled level until the surface becomes damp. The tiles are then to be laid on the bedding and beaten firmly into position with a wooden beater to ensure a true surface and that contact between the tiles and bedding is complete.

6

Grouting and the other requirements of the semi-dry mix method described in Clause 5.3.6 of this Part of this Section also apply to the direct mortar bedding method.

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END OF PART

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TERRAZZO ................................................................................................... 2 GENERAL REQUIREMENTS ........................................................................ 2 Scope 2 References 2 PORTLAND CEMENT TERRAZZO ............................................................... 2 General 2 Terrazzo Floor Tiles and Skirtings 2 Laying Terrazzo Tiles 3 PRECAST TERRAZZO UNITS ...................................................................... 4 General 4

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6 6.1 6.1.1 6.1.2 6.2 6.2.1 6.2.2 6.2.3 6.3 6.3.1

Section 24: Finishes to Buildings Part 06: Terrazzo

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Page 2

6

TERRAZZO

6.1


6.1.1

Scope

1

This Part provides specification for terrazzo products and the installation of same.

2


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1


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6.1.2

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BS 8204 ......................In-situ flooring

Terrazzo tiles. Terrazzo tiles for external use

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GSO EN 13748-2:2008

Terrazzo tiles. Terrazzo tiles for internal use

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GSO EN 13748-1:2008

PORTLAND CEMENT TERRAZZO

6.2.1

General

1

Terrazzo floor tiles and skirtings as described below are to comply with GSO EN 13748-1 and GSO EN 13748-2, BS 8204, and BS 8000, Part 11 as applicable.

6.2.2

Terrazzo Floor Tiles and Skirtings

1

Portland cement and aggregates for the base layer and pigments used in the manufacture of the tiles are to comply with Part 5 where applicable and the manufacturer’s recommended standards. Aggregates for the facing layer are to consist of good quality, hard marble or other approved natural stone with similar characteristics. The marble aggregates are to be graded, but not to include a high fines or dust content and shall be sharp and angular.

2

The base layer is to consist of 3 to 3.5 parts of aggregate to 1 part of cement, proportioned by weight. The facing layer should be such as to provide a minimum wearing surface of 6 mm after grinding and generally consist of 2.5 parts of aggregate to one part of coloured cement by volume.

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Page 3

During manufacture, the tiles are to be vibrated to an extent which allows the entrapped air to escape to the surface and compacts the aggregate at the wearing surface and hydraulically pressed sufficient to mould the facing to the base layer.

4

The surface of the facing layer is to be ground and slight imperfections to be filled by grouting with a neat cement paste coloured to match the original mix and well worked into the surface before it is re-ground to a fine grit finish.

5

Skirting tiles are to have square or bevelled, ground top edges. Cut floor tiles are not to be used for skirtings.

6

The tile facings are to be free from projections, depressions, flakes and crazes and the aggregate be evenly distributed. The tiles should be square and of rectangular cross section with sharp and true arises, and comply with the performance requirements of GSO EN 13748-1 and GSO EN 13748-2 and be of the minimum thickness given in Table 6.1.

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Table 6.1 Thickness of Terrazzo Tiles

Minimum Thickness

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Length Of Each Side

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(mm) 150

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200

(mm) 20 20 20 30

400

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500

Laying Terrazzo Tiles

1

The areas of concrete substrata to be tiled are to be brushed clean and dampened until absorption ceases and the finished floor level is to be established by means of dots and rules.

2

The mortar for bedding the tiles is to be to the thickness as detailed elsewhere in the Project Documentation. It shall consist of 1 part of cement to 4 parts of sand by volume, mixed semidry in a mechanical mixer with only sufficient water added to give a crumbly consistency that retains its shape when squeezed in the hand.

3

The mix is to be spread to a thickness approximately 10 mm greater than that actually required for the bed and thoroughly compacted by tamping and drawing off to the required level with a screed board. Only sufficient mortar is to be mixed and spread as can be covered with tiles before it has attained its initial set.

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6.2.3

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Page 4

A stiff slurry consisting of cement and water is to be prepared and spread on the back of the tiles about 2 mm thick before they are laid on the bed and tapped firmly into position with a rubber or wooden hammer. The tiles are then to be vigorously beaten with a wooden beater to ensure a true surface and that contact between the titles and bedding is complete.

5

The tiles should be laid with joints of about 3 mm wide. Proper alignment shall be maintained with continuous joints in both directions. The joints are to line-up through doorways where possible.

6

At least 24 hours after laying the tiles, the joints are to be filled with neat cement grout to a colour approved by the Engineer. Excess grout is to be removed with a squeegee and be cleaned off the face of the tiling and surrounding surfaces as the work proceeds.

7

The tiles are to be laid with a minimum of cut tiles, but where it is necessary, they are to be cut with a power driven saw and any rough edges be rubbed smooth. Rough cutting by means of a chisel is not permitted.

8

Tiles are to be laid level or to 1 % falls in “wet” areas, as may be required. Localised variation in level for a nominally flat floor is to be a maximum of ±3 mm under a 3 m straightedge. Particular care is to be taken in “wet” areas to prevent low spots and the pooling of water.

9

Skirting is to be fixed in such manner that their vertical joints coincide with the horizontal joints of the floor tiles.

6.3

PRECAST TERRAZZO UNITS

6.3.1

General

1

Precast terrazzo units to comply with the requirements of GSO EN 13748-1 and GSO EN 13748-2.

2

Precast terrazzo treads and risers are also to comply with Clause 5.3.3-16 of Part 5 of this Section except that the facing layer of the treads are to be such as to provide a minimum wearing surface of 12 mm after grinding.

3

All exposed edges of the units are to be terrazzo faced.

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END OF PART

QCS 2014

Section 24: Finishes to Building Part 07: Stone Flooring

Page 1

STONE FLOORING --------------------------------------------------------------------------------------------- 2

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5

GENERAL REQUIREMENTS --------------------------------------------------------------------------------- 2 Scope --------------------------------------------------------------------------------------------------------------- 2 References--------------------------------------------------------------------------------------------------------- 2 Allowable Tolerances ------------------------------------------------------------------------------------------- 3 Submittals ---------------------------------------------------------------------------------------------------------- 3 Product Delivery, Storage and Handling ------------------------------------------------------------------- 3

7.2 7.2.1 7.2.2 7.2.3 7.2.4

MATERIALS ------------------------------------------------------------------------------------------------------- 4 General ------------------------------------------------------------------------------------------------------------- 4 Other Materials --------------------------------------------------------------------------------------------------- 4 Mortar --------------------------------------------------------------------------------------------------------------- 4 Grout ---------------------------------------------------------------------------------------------------------------- 4

7.3 7.3.1 7.3.2

EXECUTION OF WORK --------------------------------------------------------------------------------------- 4 Inspection ---------------------------------------------------------------------------------------------------------- 4 Application --------------------------------------------------------------------------------------------------------- 4

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7

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Page 2

7

STONE FLOORING

7.1


7.1.1

Scope

1

This Part specifies requirements for interior stone flooring, set in mortar on a rigid base.

2


Section 1 Section 5

General Concrete

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General Tiles Unit Masonry Flooring Flooring Screeds and Treatments Joint Caulking and Sealants

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Part 1 Part 5 Part 8 Part 9 Part 10

.

This Section

References

1


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7.1.2

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ASTM C1063 .............Standard Specification for Installation of Lathing and Furring to Receive Interior and Exterior Portland Cement-Based Plaster

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ASTM C150 ................Standard Specification for Portland Cement

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ASTM C472 ................Test Methods for Physical testing of Gypsum, Gypsum Plasters and Gypsum Concrete

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ASTM C897 ................Standard Specification for Aggregate for Job-Mixed Portland CementBased Plasters

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ASTM C926 ................Standard Specification for Application of Portland Cement-Based Plaster

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BS 1202 .....................Nails BS 1449 .....................Steel plate, sheet and strip BS 1494 .....................Fixing accessories for building purposes BS 405........................Uncoated expanded metal carbon steel sheets for general purposes BS 4551 ..................... Mortar. Methods of test for mortar and screed. Chemical analysis and physical testing BS 476........................Fire tests on building materials and structures BS 5270-1 .................Bonding agents for use with gypsum plasters and cement Specification for polyvinyl acetate (PVAC) emulsion bonding agents for indoor use with gypsum building plasters BS 5390 .....................Code of practice for stone masonry BS 8000 .....................Workmanship on building sites BS 8000-11 ...............Workmanship on building sites. Internal and external wall and floor tiling. Ceramic and agglomerated stone tiles, natural stone and terrazzo tiles and slabs, and mosaics. Code of practice

QCS 2014


Page 3

BS 8204 .....................Screeds, bases and in situ floorings BS 8298-1 ..................Code of practice for the design and installation of natural stone cladding and lining. General BS 882........................Aggregates from natural sources for concrete BS EN 1008:2002. ....Mixing water for concrete. Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete BS EN 10142 .............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions BS EN 10143 .............Continuously hot-dip metal coated steel sheet and strip – tolerances on dimensions and shape BS EN 12057 .............Natural stone products. Modular tiles. Requirements BS EN 12440 .............Natural stone. Denomination criteria

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BS EN 12058 .............Natural stone products. Slabs for floors and stairs. Requirements

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BS EN 13139 ............Aggregates for mortar

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BS EN 12878 ............Pigments for the colouring of building materials based on cement and/or lime. Specifications and methods of test

BS EN 197-1 ..............Portland cement

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BS EN 15285 .............Agglomerated stone. Modular tiles for flooring and stairs (internal and external)

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BS EN 413-1:2011 .....Masonry cement. Composition, specifications and conformity criteria

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BS EN 459-1 .............Building lime: Definitions, specifications and conformity criteria EN 1745:2002 ...........Methods for determining thermal properties

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EN 998-1:2010 ..........Specification for mortar for masonry. Rendering and plastering mortar

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The Tile Council of America TCA Handbook for Ceramic Tile Installation (The Tile Council of North America TCNA Handbook for Ceramic, Glass, and Stone Tile Installation) Allowable Tolerances

1

Floor surface shall be true to plane within 3 mm in 3 m not cumulative.

2

Joint width deviation shall not be greater than 10 % of dimension shown on drawings.

7.1.4

Submittals

1

In accordance the with procedures in Section 1 the Contractor is to furnish the following:

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7.1.3

(a)

samples : minimum of five individual samples of stone showing range of extreme variations in colour and texture.

(b)

shop drawings : showing special stone shapes or patterns to be constructed.

7.1.5


1

Deliver materials in original sealed containers marked with name of manufacturer and identification of contents.

QCS 2014


Page 4

Store materials under waterproof on covering planking clear of ground, and protect from handling damage, dirt stain, water and wind.

7.2

MATERIALS

7.2.1

General

1

Stone slabs to be uniform in quality and texture, free from shale, excess mica, seams, sealing and disintegration to BS 5390.

2

Stone tiles shall be to BS 8000, Part 11 unless otherwise specified and detailed in the drawings.

3

Rigid base of concrete in-situ floor to BS 8204 or as otherwise detailed in the drawings shall be provided.

4

Provision and application of materials shall comply with the relevant provisions of BS 5390.

7.2.2

Other Materials

1

Sand to be used for setting beds and mortart or grout mixtures shall be to BS 1199, BS 1200, and BS 882 as applicable.

2

Portland cement shall be to EN 197-1.

3

Colouring pigments shall be pure mineral pigments. They shall be lime proof and non-fading and shall be added to grout or mortar by the manufacturer. In-situ coloured grout or mortar is not acceptable unless otherwise agreed by the Engineer.

7.2.3

Mortar

1

Mortar shall comply with the relevant provisions of BS 5224.

7.2.4

Grout

1

Grout shall consist of one part cement to three parts sand by volume, mixed with enough water for flowability.

7.3

EXECUTION OF WORK

7.3.1

Inspection

1

Ensure that substrate is without voids or projections that would interfere with installation of stone paving.

7.3.2

Application

1

General: Do not use stone slabs with chips, cracks, discoloration or other visible defects.

2

Installation with Portland cement grout.

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(a)

spread and screed the mortar setting bed mixture 12mm to 25mm in thickness true to plane to BS 8000 Part 9

QCS 2014

Page 5

(b)

limit the setting bed to minimum amount which can be covered with stone before initial setting

(c)

apply 0.75 mm layer of neat cement paste over the setting bed. Set and level each unit immediately. Tamp the stone brick to completely contact the setting bed

(d)

grout the joints as soon as initial set is achieved. Place the grout in joints, strike flush and tool slightly concave

(e)

cure the grout by maintaining in a damp condition for seven days.

Installation with Portland cement mortar: install the stone in a full mortor bed. Remove excess mortar. Strike the joints flush with the top surface of stone and tool slightly concave

(b)

cure the mortar by maintaining in a damp condition for seven days.

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END OF PART

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UNIT MASONRY FLOORING ........................................................................ 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 Allowable Tolerances 2 Submittals 2 Product Delivery, Storage and handling 3 MATERIALS .................................................................................................. 3 Unit Masonry 3 Other Materials 3 Mortar 3 Grout 3 EXECUTION OF WORK ................................................................................ 3 Inspection 3 Application 3

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8 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.3 8.3.1 8.3.2

Section 24: Finishes to Buildings Part 08: Unit Masonry Flooring

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Page 2

UNIT MASONRY FLOORING

8.1

GENERAL

8.1.1

Scope

1

This Part specifies requirements for interior and unit masonry flooring, set in mortar on a rigid base.

2


General Concrete Masonry

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General Tiles Terrazzo Stone Flooring Floor Screeds and Treatments Joint, Caulking and Sealants

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8

References

1


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8.1.2

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EN 197-1 ....................Portland cement

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BS 1199 .....................Building sands from natural sources BS 1200 .....................Building sands from natural sources

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BS 5224 .....................Masonry cement

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BS 6073 .....................Precast concrete masonry units

Allowable Tolerances

1

Floor surfaces are to be level and true to plane. The tolerance for deviation shall not be more than a 3 mm over a distance 3 m.

2

Joint width deviation shall not be greater than 10 % of dimension indicated in the project Documentation.

8.1.4

Submittals

1

In accordance with the relevant provisions of Section 1, General, the Contractor is to furnish the following:

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8.1.3

(a)

samples: five individual samples of unit masonry flooring showing extent of variations in colour and texture

(b)

shop drawings: showing special brick shapes and construction patterns.

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Page 3

Product Delivery, Storage and handling

1

Materials shall be delivered and stored on Site in their original sealed containers marked with name of manufacturer and identification of contents.

2

The Contractor is to store materials under waterproof covers on planking clear of ground.

8.2

MATERIALS

8.2.1

Unit Masonry

1

Unit masonry or paving bricks shall comply with BS 6073.

8.2.2

Other Materials

1

Sand shall comply with the relevant provisions of BS 1199 and BS 1200.

2

Portland Cement shall comply with the relevant provisions of EN 197-1.

3

Colouring pigments shall be pure mineral pigments. They shall be lime proof and non-fading and shall be added to grout or mortar by the manufacturer. In-situ coloured grout or mortar is not acceptable unless otherwise agreed by the Engineer.

8.2.3

Mortar

1

Mortar shall comply with the relevant provisions of BS 5224.

8.2.4

Grout

1

Grout shall consist of one part cement to three parts sand by volume, mixed with enough water for flowability.

8.3

EXECUTION OF WORK

8.3.1

Inspection

1

The Contractor is to inspect the substrate and make sure that it is without voids or projections that would interfere with installation of brick or other unit masonry paving.

8.3.2

Application

1

The use of unit masonry with chips, cracks, discoloration or other visible defects is not permitted.

2

Installation with Portland cement grout.

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8.1.5

(a)

spread the mortar setting bed mixture 12 mm to 25 mm in thickness to a true plane

(b)

limit the setting bed to minimum amount which can be covered with brick before the initial setting

(c)

apply 0.75 mm layer of neat cement paste over the setting bed, set and level each unit immediately and tamp bricks to completely contact the setting bed

QCS 2014

Page 4

(d)

grout the joints as soon as the initial set is achieved; place the grout in joints, strike flush and tool to form slightly concave finish

(e)

cure the grout by maintaining in a damp condition for seven days.

Installation with Portland cement mortar: (a)

install bricks in a full mortar bed, remove excess mortar and strike the joints flush with top surface or stone and tool to form a slightly concave finish

(b)

cure the mortar by maintaining in a damp condition for seven days.

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END OF PART

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FLOOR SCREEDS AND TREATMENTS ...................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 References 2 PREPARATION AND PROCEDURES .......................................................... 2 Cement and Sand Floor Screeds 2 INSTALLATION ............................................................................................. 2 Workmanship 2

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9 9.1 9.1.1 9.1.2 9.2 9.2.1 9.3 9.3.1

Section 24: Finishes to Buildings Part 09: Floor Screeds and Treatments

QCS 2014


Page 2

FLOOR SCREEDS AND TREATMENTS

9.1

GENERAL

9.1.1

Scope

1

This Part specifies the requirements for the installation of floor screeds and treatment.

2


Section 1 Section 5

General Concrete

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Tiles Terrazzo Stone Flooring Unit Masonry Flooring

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.

9

References

1


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9.1.2

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PREPARATION AND PROCEDURES

9.2.1

Cement and Sand Floor Screeds

1

The surface of the concrete base must be clean, firm and rough to ensure a good bond. This is to be achieved by hacking thoroughly to remove all laitence and to expose the aggregate over the whole area, followed by sweeping clean and hosing down to remove all dust.

2

The base is to be soaked with water for at least 12 hours and any surplus water removed before laying commences.

3

Screeds to receive thin flexible finishes (i.e. of vinyl and rubber sheet or tile) are to consist of 1 part of cement of 3 parts of sand by weight to BS 8000, Part 9.

4

Screeds to receive strong rigid coverings (e.g. quarry and ceramic tile) are to consist of 1 part of cement to 4 parts of sand by weight to BS 8000, Part 9.

9.3

INSTALLATION

9.3.1

Workmanship

1

To obtain the required thickness of screed, leveling battens are to be used, carefully fixed to line and level and fully bedded. There is to be a minimum thickness of screed of 20mm over the top of any conduit or duct.

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Page 3

The screed is to be laid in alternate bays with plain butt joints. The length of a bay is not to 2 exceed 1.5 times the width. The maximum plan area of a bay shall not exceed 15 m . Movement and construction joints in the base are to be carried through the screed.

3

Immediately prior to laying the screed a thick brush coat of wet cement grout is to be applied to the damp surface of the base concrete and be well scrubbed in. The brush coat must not be applied more than 10 minutes before it is covered with screed.

4

The mix is only to contain sufficient water that will allow full compaction and shall be evenly spread to a thickness approximately 10mm greater than that required. The screed should then be thoroughly compacted by tamping and drawing off to the required level with a screed board.

5

If a smooth surface is required, the final working up is to be done with a wood float, steel trowel, power float or other finish as specified elsewhere in the Project Documentation. Care is to be taken to avoid excessive trowelling which may cause crazing.

6

Screeds to receive thin flexible finishes or screeds which are finished as paving are to be laid to a tolerance such that localized variations do not exceed ± 2 mm under a 3 metre straightedge and ±10 mm over large areas, measured from datum.

7

As soon as each bay is completed and has hardened sufficiently to prevent damage to its surface, it is to be covered with polythene or similar sheets which are to be adequately lapped and held down. The screed should not be allowed to dry out for a minimum period of 7 days and no traffic shall be permitted on the surface during this time.

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END OF PART

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GENERAL ...................................................................................................... 2 INTRODUCTION ........................................................................................... 2 Scope 2 References 2 Labels 2 Submittals 3

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Section 25: Glass and Glazing Part 01: General

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Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for glass, plastic, glazing related materials and glazing accessories. Glazing products specified apply to factory or field glazed items.

2


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Thermal Insulation Metalwork Carpentry, Joinery and Ironmongery Finishes to Buildings External Works to Buildings

References

1

The following standards referred to in this Section:

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1.1.2

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BS 544 ........................Linseed oil putty for use in wooden frames

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BS 952 ........................Glass for glazing

BS 1494 ......................Fixing accessories for building purposes

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BS 2571 ......................General purpose flexible PVC compounds for moulding and extrusion BS 5051 ......................Security glazing

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BS 5357 ......................Code of Practice for installation of security glazing

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BS 5516 ...................... Code of Practice for design and installation of sloping and vertical patent glazing

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BS 5544 ......................Anti-bandit glazing (glazing resistant to manual attack)

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BS 5588 ......................Fire precautions in the design and construction of buildings BS 5713 ......................Hermetically sealed flat double glazing units

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BS 6206 ......................Impact performance requirements for flat safety glass and safety plastics for use in buildings BS 6262 ......................Code of Practice for glazing for buildings BS 8000 ......................Workmanship on building sites BS EN 572 ..................Glass in Buildings - Basic soda lime silica glass products

1.1.3

Labels

1

Temporary labels are to be provided on each pane of glass or plastic material identifying manufacturer or brand and glass type, quality and nominal thickness. Temporary labels shall remain intact until the Engineer approves the pane.

QCS 2014

2


Page 3

Permanent labels in accordance with BS 952 and the manufacturer’s standard label are to be provided on the following: (a)

tempered glass panes

(b)

laminated glass panes

(c)

organic coated glass panes

(d)

bullet resistive glass or plastic panes in accordance with BS 5051, BS 5357, and BS 5544

The label shall be located in the corner for each pane.

1.1.4

Submittals

1

Samples not less than 150 mm square shall be submitted for approval by the Engineer for all types of panes to be used in the Works.

2

Manufacturer's certificates for glazing to be used in the Works are to be provided as follows:

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3

certificates stating that tempered glass, laminated glass, organic coated glass, and wire glass meet the requirements for safety glazing material as specified in BS 5357

(b)

certified test report stating that bullet resistive material meets the test requirements of BS 5051

(c)

certificates stating the following characteristics of the glass:

as

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(a)

visible light transmittance

(ii)

visible light reflectance

(iii)

shading coefficient

(iv)

winter U-value

(v)

summer U-value

(vi)

k-value

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(i)

relative heat gain

(viii)

any other characteristic as required by the Project Documentation or as requested by the Engineer.

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(vii)

3

Manufacturer’s guarantees are to be provided by the Contractor for the following: (a)

guarantee bullet resistive plastic material to remain visibly clear without discoloration for 10 years

(b)

guarantee insulating glass units to remain sealed for 10 years

(c)

guarantee laminated glass units to remain laminated for 5 years

(d)

guarantee polycarbonate to remain clear and ultraviolet light stabilised for 5 years

(e)

guarantee insulating plastic to not have more than 6 % decrease in light transmission and be ultraviolet light stabilised for 10 years.

QCS 2014

Manufacturer's literature and data is to be submitted to the Engineer for the following:

(a)

glass, for each type required plastic glazing materials, for each type required

(c)

distance setting and location blocks

(d)

elastic compound for metal sash glazing

(e)

putty, for wood sash glazing

(f)

glazing cushions

(g)

sealing compounds

(h)

transparent (one-way vision glass) mirrors

(i)

gaskets

(j)

any other component or material if asked for in the Project Documentation.

.

(b)

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Storage for all glass to be used in the Works is to be in a shaded and ventilated area and to be protected from dirt and accidental damage. Care is to be taken to prevent the accumulation of water between the sheets and any stacked glass that show signs of dampness are to be separated and dried.

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END OF PART

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QCS 2014

Section 25: Glass and Glazing Part 02: Glass

Page 1

GLASS ..................................................................................................................................... 2

2.1

GENERAL GLASS TYPES AND GLAZING ............................................................................. 2

2.1.1

Scope

2

2.1.2

References

2

2.2

GLASS TYPES AND REQUIREMENTS .................................................................................. 2

2.2.1


2

2.2.2

Transparent Glass

3

2.2.3

High Performance Glass

3

2.2.4

Mirror Glass

4

2.2.5

Fire Resistant Glass

4

2.2.6

Patterned and Rough Cast (obscured) Glass

4

2.2.7

Bullet Resisting Glass

4

2.2.8

Anti-bandit Glass

2.2.9

Toughened Glass

2.3

GLAZING MATERIALS ............................................................................................................ 5

2.3.1

Glazing Compounds

2.3.2

Distance Setting and Location Blocks

2.3.3

Glazing Gasket

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4 5 5 5 5

Page 2

GLASS

2.1

GENERAL GLASS TYPES AND GLAZING

2.1.1

Scope

1

This Part specifies various types of glass available.

2

Related Sections are as follows: General Workmanship


Thermal Insulation Metalwork Carpentry, Joinery and Ironmongery Finishes to Buildings External Works to Buildings

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QCS 2014

References

1


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2.1.2

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BS 952 ........................Glass for glazing

BS 2571 ......................General purpose flexible PVC compounds for moulding and extrusion

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BS 5051 ......................Security Glazing

BS 5713 ......................Hermetically sealed flat double glazing units

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BS 5544 ......................Anti-bandit glazing (glazing resistant to manual attack) BS 5588 ......................Fire precautions in the design and construction of buildings

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BS 6206 ......................Impact performance requirements for flat safety glass and safety plastics for use in buildings

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BS 6262 ......................Code of Practice for glazing for buildings BS EN 572 ..................Glass in Buildings - Basic soda lime silica glass products

2.2

GLASS TYPES AND REQUIREMENTS

2.2.1


1

Glass shall comply with the relevant provisions of BS 952.

2

Glazing for buildings shall comply with the relevant provisions of BS 6262.

3

Vacuum sealing requirements for double glazing units shall comply with the relevant provisions of BS 5713.

QCS 2014


Page 3

2.2.2

Transparent Glass

1

Transparent glass shall be clear float or polished plate glass not less than 4 mm nominal thickness. Sheet glass shall not be used in the Works.

2.2.3

High Performance Glass

1

High performance glass (which includes reflective and insulating glass) is at minimum to comply with the following: high performance glass for vision areas shall be 6 mm toughened (heat strengthened) glass. The glass may be clear, coloured or colour coated. The characteristics of the glass shall be as detailed in the Project Documentation. Typically, the characteristics of the glass will be as shown in Table 2.1.

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(a)

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Table 2.1 Characteristics of Glass for Vision Areas

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Coloured or Colour Coated Glass

Clear Glass

5 to 45

> 85

Light Reflectance (%)

5 to 45

< 10

0.20 to 0.60

> 0.95

4.0 to 5.5

5.5 to 6.0

0.70 to 0.95

0.95 to 1.05

0.17 to 0.50

> 0.80

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Light Transmittance (%)

2

U-Value in W/(m .K) o

2

insulating high performance glass units for vision areas are to consist of an outer pane of 6 mm toughened (heat strengthened) glass and an inner pane of 6 mm clear toughened glass separated by a 12 mm airspace. The outer pane of glass may be clear, coloured or colour coated. The characteristics of the glass used in the units shall be as detailed in the Project Documentation. Typically, the characteristics of the units will be as shown in Table 2.2.

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(b)

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Heat Gain Coefficient

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U-Value in Btu/( F.ft .h)

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Shading Coefficient

Table 2.2 Characteristics of Insulating Glass Units Coloured or Colour Coated Glass Units

Clear Glass Units

Light Transmittance (%)

2 to 75

80 to 85


5 to 45

10 to 15

0.25 to 0.70

0.80 to 0.85

1.5 to 3.0

3.15 to 3.20


0.25 to 0.55

0.55 to 0.56


0.10 to 0.60

0.7 to 0.75

Shading Coefficient 2


2

QCS 2014

(c)


Page 4

high performance reflective glass for spandrel areas shall be 6 mm toughened (heat strengthened) glass with colour coating or coloured glass. The characteristics of the glass used in the spandrel areas shall be as detailed in the Project Documentation. Typically, the characteristics of spandrel areas will be as shown in Table 2.2.. Table 2.3 Characteristics of Spandrel Glass Light Transmittance (%)

2 to 75


5 to 45

Shading Coefficient

> 0.70

2


2.5 to 4.5

2

0.55 to 0.80

.


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applicable standards:

all substrates for coatings shall be of float quality and shall conform to BS 952

(ii)

all fully tempered glass to be tested to BS 6206

(iii)

all insulating glass units to be tested to BS 5713.

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(i)

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(d)

> 0.60

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Mirror Glass

1

Mirror glass is to be 6 mm float glass or polished plate glass, silvered on one side. The silvering shall be protected by a copper backing and protective paint coating. Mirror edges shall be ground and polished. Mirror edges shall be bevelled.

2.2.5

Fire Resistant Glass

1

Fire rated clear glass to meet minimum 1 hour rating to Engineers approval. Resistance for integrity, stability and insulation shall comply with the relevant provisions of BS 5588 Part 3.

2

Wired glass to be square pattern (13 mm square), 6 mm nominal thickness and shall conform to BS EN 572 Part 3.

2.2.6

Patterned and Rough Cast (obscured) Glass

1

To be 6 mm nominal thickness unless otherwise to the approval of the Engineer.

2.2.7

Bullet Resisting Glass

1

Bullet resisting glass shall comply with the relevant provisions of BS 5051.

2.2.8

Anti-bandit Glass

1

Anti-bandit glass to shall comply with the relevant provisions of BS 5544.

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2.2.4

QCS 2014


Page 5

Toughened Glass

1

Toughened glass shall be processed float or polished plate glass satisfying the impact requirements of BS 6206 Class B.

2.3

GLAZING MATERIALS

2.3.1

Glazing Compounds

1

Glazing compounds shall be non-setting oil based materials containing butyl rubber and shall be approved by the Engineer.

2.3.2

Distance Setting and Location Blocks

1

Distance pieces (for setting between glass panes), setting and location blocks shall be plasticised PVC complying with BS 2571 (softness numbers 35 to 45), rigid nylon or sealed hardwood. Plasticised PVC shall not be used for heavy glass panes, or solar control (reflective and insulating) glasses or sealed double glazing units.

2.3.3

Glazing Gasket

1

Glazing gaskets shall be of neoprene or EPDM material as approved by the Engineer.

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2.2.9

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END OF PART

QCS 2014

Page 1

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WORKMANSHIP ........................................................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 STANDARD GLAZING .................................................................................. 2 General Requirements 2 GLAZING ALUMINIUM WINDOWS EXTERNALLY ...................................... 3 General Requirements 3 FIXING MIRRORS ......................................................................................... 5 General Requirements 5

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3 3.1 3.1.1 3.2 3.2.1 3.3 3.3.1 3.4 3.4.1

Section 25: Glass and Glazing Part 03: Workmanship

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Page 2

3

WORKMANSHIP

3.1

GENERAL

3.1.1

Scope

1

This Section specifies workmanship requirements for glazing.

2


.

General Glass Glazed Curtain Wall

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STANDARD GLAZING

3.2.1


1

External glazing is to be wind and watertight on completion.

2

All rebates and grooves are to be clean, dry, free from burrs and other projections, smooth and undistorted.

3

The minimum thickness of glass other than fully toughened glass is to be 6 mm when situated in the following locations:

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3.2

any hinged fully, or partly, glazed door and any adjacent side panel

(b)

any sliding fully, or partly, glazed door and any adjacent side panel

(c)

any glass wholly or partially within a zone between floor level and 800 mm above floor level.

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(a)

Glazing to internal wood doors and screens is to be bedded in self-adhesive black velvet or approved proprietary tape and secured with hardwood glazing beads fixed with brass cups and screws.

5

Glazing to external wood doors and screens to be bedded in approved polymer mastic preformed tape and secured with hardwood glazing beads fixed with brass cups and screws.

6

All rebates to wood doors and screens to be primed and sealed.

7

Fire resistant glazing channel shall be butt jointed at corners and fixed with 38 mm countersunk brass screws at not more than 200 mm centres and not more than 50 mm from each end. The butt joints of glazing channels for one-hour fire resisting doors are to be sealed with intumescent mastic.

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QCS 2014


Page 3

GLAZING ALUMINIUM WINDOWS EXTERNALLY

3.3.1


1

Generally, the glazing system will utilise snap-in beads and glazing gaskets of neoprene or EPDM as approved by the Engineer. Other glazing techniques involving the use of glazing compounds, sealants, etc. are to be submitted to the Engineer for approval together with details of similar installations successfully employed elsewhere in the Gulf region.

2

Unless otherwise indicated elsewhere in the Project Documentation the maximum permitted size of an external glass pane, with all four edges fully supported, in a low rise building (maximum 10 m high) should not exceed the areas given in Table 3.1.

3

For maximum areas of glass panes situated externally, the recommendations of the glass manufacturer are to apply in situations that are not covered by Table 3.1, provided that information is not provided elsewhere in the Project Documentation. The recommendations are to be based on a 3 second gust exceeding 180 kph (50 m/s) at 10 m above ground level and a ground roughness category of 1.

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3.3

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Table 3.1 Maximum Areas for Glass Panes Situated Externally Nominal Thickness (mm)

4

5

6

7

10

12

1.30

2.00

3.00

4.00

5.50

8.00

-

-

1.25

-

-

-

-

-

1.80

-

-

-

0.70

1.20

1.75

-

-

-

1.80

2.90

4.20

-

1.00

-

-

-

2.80

4.00

5.50

-

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Transparent float or polished plate

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Type of Glass

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Wired polished

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Wired cast

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Rough cast and patterned

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Fully toughened

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Transparent laminated

Notes:(i) Areas given are in square metres (ii) The Table does not apply where the building exceeds 10 m high or where the length to breadth ratio of the pane is greater than 3:1, in such cases the recommendations of the manufacturer shall be followed. 4

The depth of rebates for bead glazing are not to be less than that shown in Table 3.2 and the minimum edge clearance (distance between the edge of the glass and the surround) should not be less than 3mm for any glass up to and including 12 mm nominal thickness. The recommendations of the glass manufacturer are to apply for all glass over 12 mm nominal thickness.

QCS 2014


Page 4

Table 3.2 Minimum Rebate Depths for Bead Glazing

4

10

5

12

6

12

10

15

12

15

.

Minimum Rebate Depth (mm)

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The minimum edge cover to single glazing shall be as Table 3.3 and equal all round each pane. The edge cover and clearance to double glazing units shall be as recommended by the manufacturer of the units.

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5

Nominal Glass Thickness (mm)

ta

Table 3.3 Minimum Edge Cover for Single Glazing

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Glass Area (m²)

0.5 to 1.5

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1.5 to 4.0

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Up to 0.5

5 9 12

As recommended by glass manufacturer

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Over 4.0

Edge Cover (mm)

Setting blocks are to be used between the edges of the glass and the frame or surround in order to support and centralise the glass in the opening. The minimum length of each block 2 shall be equal to 30 mm per m of glass area and the width to be equal to the thickness of the glass (or glass insulating unit) plus the back clearance.

7

Location blocks shall be used in opening windows and doors between the edges of the glass, other than the bottom edge, to prevent movement when they are opened. Each block shall be at least 25 mm long and the width shall be equal to the thickness of the glass (or glass insulating unit) plus the back clearance.

8

Setting and location blocks shall be positioned as near to the quarter points of each side as possible.

9

Glazing gaskets are to be positioned on both sides of the glass and be correctly sized so that when forced into the space between the glass and surround, sufficient pressure is provided to support the glass structurally and to form an effective seal against the weather. Care is to be taken to ensure that the gasket is correctly located in the grooves and that the glass is completely bedded.

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Page 5

3.4

FIXING MIRRORS

3.4.1


1

Mirrors are to be fixed with spacer washers to compensate for irregularities in the wall surface and with sleeves and washers to prevent contact between the mirror and the fixings.

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END OF PART

QCS 2014

Section 25: Glass and Glazing Part 04: Glazed Curtain Walling Systems

Page 1

4

GLAZED CURTAIN WALLING SYSTEMS .............................................................................. 2

4.1

GENERAL ................................................................................................................................ 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References System Description Qualifications

4.2

CURTAIN WALLS .................................................................................................................... 3

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9

General Requirements Performance Requirements Submittals Alternative Design, Materials and Methods of Construction Quality Control Delivery, Storage and Handling General Warranty Special Finish Warranty Testing and Mock-Ups

4.3

STRUCTURAL GLAZING ........................................................................................................ 8

4.3.1 4.3.2 4.3.3

General Structural Sealant Use of Sealants

4.4

INSTALLATION ........................................................................................................................ 9

4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.4.9

Anchors and Connections Corrosion Protection Lightning Protection Insulation and Safing Flashing Field Quality Control Cleaning Maintenance Manual Inspection

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2 2 2 3

3 3 4 5 6 6 6 7 7

8 8 8

9 9 9 9 9 9 9 9 10

QCS 2014


Page 2

GLAZED CURTAIN WALLING SYSTEMS

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements, components and workmanship for glazed curtain walling systems.

2



Metal Work Painting

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General Glass Workmanship

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.

4

References

1

The standards referred to in this Section are as follows:

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4.1.2

BS 4315......................Methods of test for resistance to air and water penetration

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BS 5368......................Methods for testing windows

BS 6262......................Code of Practice for glazing for buildings

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BS 6375......................Performance of Windows

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BS 6469 .....................Powder organic coatings for application and stoving to aluminium alloy extrusions, sheet and pre-formed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and pre-formed sections coated with powder organic coatings

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BS 6497......................Powder organic coatings for application and stoving to hot-dipped galvanized hot-rolled steel sections and steel sheet for windows and associated with external architectural purposes, and for the finish on galvanized steel sections and sheet coated with powder organic coatings 4.1.3

System Description

1

Glazed curtain walling systems shall include the following components: (a)

curtain wall, infill, and skylight glazing

(b)

access doors and panels, including all hardware required for a complete and operable assembly

(c)

all hardware and operating mechanisms for access door and all other operable assemblies

(d)

all main and secondary runners and runner support systems, anchors, fixings, attachments, reinforcements and steel reinforcing for mullions and transoms required for a complete installation, except those indicated as being provided under other sections

(e)

finishes, protective coatings, and treatments

(f)

internal gutter and other water drainage systems

QCS 2014

(g)


Page 3

all thermal insulation and safing associated with the work included in this Part, including supports, backing, and reinforcements

(h)

all gaskets, sealants, elastomeric and metal flashing, including sealing at junctions with roofing waterproofing

(i)

electrical bonding and earthing of all metal curtain wall components.

Qualifications

1

The Contractor's engineer or curtain wall subcontractor shall be experienced in providing engineering services of the kind indicated and as covered in this Part and are subject to approval by the Engineer.

2

Manufacturers and suppliers of all materials and components of the Work of this Part are subject to approval by the Engineer.

3

The installers of the Work of this Part are to have proven achievement and experience in similar work as applicable for at least 5 years and are subject to approval by the Engineer.

4.2

CURTAIN WALLS

4.2.1


1

Curtain wall systems are at a minimum to meet the requirements of this Section. Where special conditions or proprietary systems are to be used, the specifications herein are to be considered a performance specification guideline with specific additional specifications included elsewhere in the Project Documentation.

2

Where alternative curtain wall systems are to be developed and specified by implementation of the performance specification or as design of a proprietary system, the curtain wall works are to be carried out by an approved sub-contractor who fulfils the following requirements:

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4.1.4

regularly engaged in engineering, manufacturing, finishing, installing, glazing and sealing of the type of work specified in this section for minimum of five years

(b)

able to demonstrate satisfactorily completed works of minimum size equal to that to be

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(a)

able to demonstrate an understanding of the principles of rain screen, stack effect, air seals, dynamic forces, behaviour of cast-in-place concrete structures, water and weather controls as affecting building cladding systems

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(c)

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included in the Works

(d)

able to provide documentation of calculations to verify design of the curtain walls

(e)

provide documents to include details of all products, fixings and interfaces necessary to complete the fabrication and installation.

4.2.2

Performance Requirements

1

Glazing for curtain walls is to be double glazing and is to comply with the relevant provisions of BS 6262.

2

The Contractor shall submit documentation and drawings for approval by the Engineer for internal framing members and external components as follows: material: finish: colour:

type of metal alloy, size and details powder coated, anodised, or other finish in accordance with the relevant provisions of BS 6496 and BS 6497 designated colour referred by British Standard Colour Chart Number

QCS 2014


Page 4

1

The minimum film thickness on curtain walls shall be 60-80 microns (refer to coating specification in Section 17).

3

Framing members, glass and glass fixings, frame fixings and ironmongery are to be designed to satisfy the following: (a)

Sustain wind loadings and sufficient to avoid damage or excessive deflection when subjected to these loads

(b)

meet the weather tightness and other performance requirements in BS 4315, BS 6375 and BS 5368 resistance to water and air penetration to the standards for the above exposure when tested in accordance with BS 4315 Part 1

(d)

resistance to damage from thermal movement of the assembly or adjacent structure and assembles over the air temperature range 0 ºC to 50 ºC

(e)

resistance to damage from the designed deflection of any adjacent structure shown on

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(c)

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the arrangement drawings or as can be ascertained from the associated shop drawings 2

thermal conductance of work, U-value shall be less than 2.8 W/m²K (0.009 Btu/ft /h)

(g)

opening vents (windows) will include the following:

ta

(f)

extruded aluminium framed opening vents, side hung outward opening with integral drainage.

(ii)

weathertightness to BS 6375 Part 1

(iii)

(hermetically sealed double glazed units in accordance with BS 6262

(iv)

opening panes shall be provided with friction stays capable of holding the pane open in any position against a pressure of 50 Pa.

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(i)

Submittals

1

Shop drawings are to be prepared and approved by the Engineer before off-site fabrication of any item. The shop drawings shall clearly illustrate all aspects of the walling system and are to include, but not be limited to, the following information: (a)

the relationship of the Works to the structure, mechanical systems, roofs, and other related work the arrangement of components

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(b)

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4.2.3

(c)

the sequence and details of fabrication assembly and erection

(d)

dimensions of all components

(e)

details of materials and finishes

(f)

type, size, location and spacing of screws, bolts, welds anchoring devices and other accessories

2

(g)

isometric drawings of sealing, flashing and jointing

(h)

details of all connections to contiguous work

The Contractor shall submit samples of all components, materials and finishes as listed below. The size of the samples shall be as approved by the Engineer. (a)

samples matching the colour, texture, and other characteristics of each finish of each major component to be included in the glazed curtain wall

(b)

finished samples of panels and major extrusions

QCS 2014


Page 5

(c)

samples showing finishes over welds and over welded materials.

(d)

fastening devices

(e)

flashing

(f)

gaskets

(g)

sealants

(h)

stud or plug welds to sheet and plate

(i)

finish hardware

The Contractor shall submit manufacturer's performance data as well as application and removal procedures for all protection materials used during shipping, storage and installation.

4

Full scale mock-ups of the curtain wall system shall be provided for testing as detailed in the Clause 4.2.9 of this Part unless otherwise stated by the Engineer. The size, materials and construction of the mock-ups shall be to the standard and quality as required for the Works. The Contractor shall provide visual mock-ups and field mock-ups as indicated in the Project Documentation

5

The Contractor shall submit calculations, showing the following:

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3

design load assumptions

(b)

pressure equalisation

(c)

detailed engineering of mullions

(d)

moment of inertia of mullions

(e)

detailed engineering of anchorage hardware, clip angles, washers, anchor bolts, welds, torque pressures.

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(a)

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The calculations shall be prepared and signed by the Contractor’s engineer or curtain wall subcontractor (refer to Clause 4.1.4-1 of this Part). The calculations shall bear the Contractor’s stamp. Alternative Design, Materials and Methods of Construction

1

Design, materials and methods of construction other than those indicated in the Project Documentation may be employed when such designs, materials and methods conform to all of the following: (a)

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4.2.4

(b)

the specified performance requirements

(c)

all applicable codes and standards

(d)

approval by the Engineer.

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the design intent and specified design requirements

2

If option for alternative design or design by performance specification is required, the Contractor’s engineer is to comply as follows: (a)

prepare and endorse complete engineering design and calculations and check and monitor the preparation of all shop drawings for conformance with the engineering design and calculations, and for compliance with the Project Documentation

(b)

structural calculations are to be submitted for all components of the walling system (including for mock-ups) and are to indicate ultimate factors of safety

(c)

the Contractor's engineer will be present at the Site during erection and installation of the walling system

QCS 2014

(d) 3


Page 6

upon completion of the walling system, the Contractor's engineer is to prepare and endorse the necessary as-built drawings for submission to the Engineer.

Manufacturers and fabricators of curtain wall systems are to provide calculations as follows: (a)

submit glass fabricator/manufacturer's calculations for wind pressure analysis and thermal stress analysis

(b)

submit written confirmation that the glass fabricator/manufacturer has reviewed the pertinent shop drawings and has confirmed the acceptability of the proposed use of the specified glass products

(c)

submit written confirmation that the sealant manufacturer has reviewed the pertinent shop drawings and has confirmed the acceptability of the proposed use of the specified sealant products.

Quality Control

1

Prior to the start of fabrication, the Contractor is to submit a comprehensive Quality Control Program covering all phases of the walling system including, but not necessarily limited to, the following:

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4.2.5

procurement of materials including quality assurance programmes of major suppliers

(b)

fabrication of components

(c)

final assembly of components

(d)

installation and Site quality control.

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(a)

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The above are in addition to the requirements of Section 1, General. Delivery, Storage and Handling

1

The requirements of this Clause are in addition to the requirements for delivery, storage and handling of materials as detailed elsewhere in the Project Documentation.

2

The Contractor is to verify with the Engineer the location and adequacy of temporary storage and lay-down areas of curtain wall materials prior to delivery.

3

Curtain wall components are to be delivered to the Site in labelled protective packages individually identified for each intended location.

4.2.7

General Warranty

1

The Contractor is to provide agreement to indemnify the Owner against any defects in the design, workmanship, quality of materials, water tightness or performance of the Works included in this Part and to repair or replace defective design, workmanship or materials of the walling system during the warranty period. Defective materials and workmanship include:

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4.2.6

(a)

abnormal deterioration, ageing and weathering of the walling system

(b)

leakage of water or air exceeding specified limits

(c)

structural failure of components resulting from exposure to pressures and forces within specified limits

(d)

failure of operating parts to function normally

(e)

glass breakage due to defective design, manufacture or installation or exposure to pressures and forces within specified limits

(f)

deterioration or discoloration of finishes in excess of normal weathering and ageing

(g)

failure of the walling system to meet any other specified performance requirements

QCS 2014


Page 7

The warranty shall not include damage caused by vandalism, or natural conditions exceeding the performance requirements.

3

The warranty period shall be as stated elsewhere in the Project Documentation.

4.2.8

Special Finish Warranty

1

Where special finishes (a finish required by the design, but not a manufacturer’s standard finish) are specified, the Contractor shall obtain a warranty from the manufacturer covering failure of the applied finish, and agreeing to repair or replace items that show evidence of finish deterioration. Deterioration of finish includes but is not limited to, colour fade, chalking, cracking, peeling, and loss of film integrity.

2

The special finish warranty period shall be as stated elsewhere in the Project Documentation.

4.2.9

Testing and Mock-Ups

1

Propriety curtain walling and roof light systems are to have been subject to testing of specimens under laboratory conditions for resistance to:

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water leakage

(c)

wind leakage

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air leakage

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(a)

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The Contractor is to ensure that the proper testing authority requirements are complied with; such requirements include the following: testing shall be conducted by an independent testing laboratory, identified by the

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Contractor and approved by the Engineer. all measurement devices used in the tests are to have been calibrated and documented to meet applicable British Standards.

(c)

the independent testing laboratory undertaking the tests shall be accredited for the required tests to an appropriate national body.

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(b)

The specimens shall be subject to a performance test. The specimens used for performance testing will have been designed and constructed using the same methods, materials and sequences as for the system to be installed on the building. The techniques, skills and quality control used for the installation in the test will be those that are to be used for installation on the building.

4

Laboratory tests required to be undertaken are as follows:

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(a)

air permeability tests method in accordance with the provisions of BS 5368 Part 1

(b)

watertightness static test method in accordance with the provisions of BS 5368 Part 2

(c)

watertightness dynamic test method in accordance with the provisions of Architectural Aluminium Manufacturers Association Standard AAMA 501.183.

(d)

wind resistance serviceability test in accordance with the provisions of BS 5683 Part 3, as modified by BS 6375 Part 1.

(e)

wind resistance safety test in accordance with the provisions of BS 5368 Part 3

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STRUCTURAL GLAZING

4.3.1

General

1

All structural glazing work must be done under factory controlled conditions, the exception being for field replacement of broken glass and for two sided structural work.

2

All structural glazing work must be quality controlled and monitored on a full-time basis by experienced quality control supervisory personnel, suitably qualified, and approved by the Engineer.

3

No glazing is to proceed until all aspects of testing, certification, compatibility, etc. as outlined herein have been performed and satisfactorily met all requirements.

4.3.2

Structural Sealant

1

All structural glazing must be installed with an approved structural silicone sealant meeting the requirements of BS 2571.

2

Surface preparation, priming and application will include the following:

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a primer shall be used only if required by sealant manufacturer to obtain specified adhesion and performance

(b)

sealant shall not be applied when substrates are wet or when the temperature is below

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4.4 ºC units shall not be moved until the silicone sealant is fully cured and in no cases before the times given below unless otherwise confirmed in writing by the manufacturer: from the plane in which the unit is sealed (minimum 24 hours).

(ii)

shipment to site (minimum 3 days from sealing).

(iii)

erection to site (minimum 7 days from sealing).

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The Contractor is to provide certification from the sealant manufacturer that he has reviewed the Contractor’s shop drawings and sealant details and has tested all components of the glazing work to be included in the Works that will come into contact with sealant, and finds the same compatible and suitable for the purpose intended for.

4

The sealant manufacturer is to make periodic inspections of the glazed curtain walling work during the course of the Project. An initial inspection shall be undertaken at the start of glazing to verify that sealant work is proceeding in accordance with their recommendations, including de-glazing of randomly selected units to inspect and verify quality of sealant and workmanship. The sealant manufacturer is to submit inspection reports covering his observations and any recommendations.

4.3.3

Use of Sealants

1

Sealants specified in this Section are to be used in strict in accordance with the manufacturer’s printed instructions and should be applied only by craftsmen specially trained or experienced for their use. Before applying sealing materials, all mortar, dirt, dust, moisture and other foreign matter is to be completely removed from surfaces it will contact.

2

When adjoining surfaces are required to be masked (to maintain a clean and neat appearance), sealant shall be to be tooled to fill the joint and provide a smooth finished surface.

3

Sealant shall be black in colour unless otherwise approved by the Engineer.

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INSTALLATION

4.4.1

Anchors and Connections

1

Anchors and connections for the curtain walling system are to be provided as designated and as applicable Section 17, Part 6, or if part of a proprietary system or manufacturer’s design, as submitted and approved by the Engineer.

4.4.2

Corrosion Protection

1

Corrosion protection for components of the curtain walling system shall comply with Section 17, Part 6.

4.4.3

Lightning Protection

1

Lightning protection measures are to comply with Section 17, Part 6.

4.4.4

Insulation and Safing

1

Installation of insulation and safing (fire protection) are to comply with Section 17, Part 6.

4.4.5

Flashing

1

Flashing requirements are to comply with Section 17, Part 6.

4.4.6


1

Field quality control of site tests, air filtration and water penetration tests are to comply with Section 17, Part 6.

4.4.7

Cleaning

1

Cleaning of the entire walling system is required in compliance with Section 17, Part 6 and as specified herein.

2

The Contractor shall provide instruction and training for the proper cleaning and routine maintenance of the façade. The instruction and training shall be such that personnel working to an agreed procedure, based upon the supplier’s recommendations can undertake the cleaning of the installation.

4.4.8

Maintenance Manual

1

For projects of major size which include within the Project Documentation a requirement for the preparation of a maintenance manual, the manual shall be developed in parallel with the design and shall include, but not be limited to the following information:

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4.4

(a)

the name, address and telephone number of each company, manufacturer, supplier and subcontractor involved in the supply of materials, components, assemblies and finishes

(b)

clear and concise description of the construction used to form the various areas of the installation

(c)

recommendations for routine maintenance, cleaning, suitable cleaning agents and details of any lubrication and adjustments required for working parts

(d)

a full set of as-built drawing time of completion

(e)

copies of all guarantees, including details of their term and conditions

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Page 10

4.4.9

Inspection

1

The completed curtain wall system is to be inspected at regular intervals. The purpose of this inspection includes, but is not necessarily limited to the following: to review the effectiveness of the cleaning methods employed

(b)

to monitor the performance of the material and components of the curtain walling system against their anticipated life

(c)

inspecting for damage or failure of any part of the system

(d)

checking on the effectiveness of maintenance or remedial work.

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A detailed inspection plan shall be developed for use by the Owner. The inspection plan shall be to the approval of the Engineer. The inspection plan shall developed in consultation between the manufacturer and Contractor. It shall include procedures and recording methods to enable a systematic monitoring of the condition of the installation and assist in the prediction of the need for preventive maintenance or replacement of component parts.

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END OF PART

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QCS 2014

Section 26: Painting and Decorating Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

GENERAL INTRODUCTION ......................................................................... 2

1.1.1 1.1.2

Scope References

1.2

SUBMITTALS AND SAMPLES ...................................................................... 2

1.2.1 1.2.2

Samples List of Materials

1.3

DELIVERY, STORAGE, HANDLING AND PRODUCT MARKING ................ 3

1.3.1 1.3.2

Marking of Containers Marking of Papers/Fabrics

2 2

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Page 2

1

GENERAL

1.1

GENERAL INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for the following: preparation, painting or finishing of exterior and interior surfaces exposed to view

(b)

wall covering requirements and installation of fabrics, vinyl, decorative papers and other such decorative wall coverings

(c)

it does not include factory applied finishes and the painting of metal surfaces of mechanical and electrical installations unless otherwise required by Project Documentation.

Metalwork Carpentry, Joinery, and Ironmongery Finishes to Buildings External Works to Buildings

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(a)

References

1


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BS 245 ........................Mineral solvent (white spirit and related hydrocarbon solvents) for paints and other purposes

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BS 1336 ......................Knotting

BS 4652 ......................Metallic zinc-rich priming paint (organic media)

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BS 4756 ......................Ready-mixed aluminium priming paints for woodwork

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BS 5082 ......................Water-borne priming paints for woodwork

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BS 5358 ......................Solvent-borne priming paints for woodwork

1.2

SUBMITTALS AND SAMPLES

1.2.1

Samples

1

Sample panels are to be prepared for each type and colour of coating material to be used in the Works and shall be submitted to the Engineer for approval. As a minimum, the following sample panels shall be submitted:

2

Paint Colours: 300 x 300 mm samples labelled to indicate finish, formula, colour name and/or, number, sheen and gloss units of approved colours for:

3

(a)

each specified colour in each specified finish coat material.

(b)

each standard wood finish on specified wood species.

Other Materials: 500 x 500 mm (minimum) samples of each paper/fabric material minimum size showing at least the pattern repeat where applicable.

QCS 2014


Page 3

1.2.2

List of Materials

1

Before ordering materials, the Contractor is to submit a list of those materials proposed for use on the Project for the Engineer’s approval.

1.3

DELIVERY, STORAGE, HANDLING AND PRODUCT MARKING

1.3.1

Marking of Containers

1

Materials to be delivered in sealed containers shall be clearly labelled with the following information: manufacturer’s name, initials or recognised trade mark

(b)

title and specification number

(c)

whether the material is primer, undercoat or finishing coat

(d)

whether the material is for internal or external use, where appropriate

(e)

colour reference from BS 4800

(f)

method of application

(g)

batch number and date of manufacture or re-test.

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(a)

No paint is to be used more than 18 months after manufacture or re-test.

3

Coating materials other than spray paints, bituminous paints and textured masonry paints are to be in containers not exceeding 5 litres capacity.

1.3.2

Marking of Papers/Fabrics

1

Papers/fabrics are to be clearly marked with batch and shade numbers as appropriate.

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END OF PART

QCS 2014

Section 26: Painting and Decorating Part 02: Surface Preparation for Painting

Page 1

2

SURFACE PREPARATION FOR PAINTING................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2

Scope References

2.2

GENERAL PREPARATIONS ......................................................................... 2

2.2.1 2.2.2

Preparation Preparatory Materials

2.3

PREPARATION OF PLASTERED AND RENDERED SURFACES ............... 3

2.3.1


2.4

PREPARATION OF WOOD SURFACES ...................................................... 3

2.4.1


2.5

PREPARATION OF METAL SURFACES ...................................................... 4

2.5.1


2.6

PAINT REMOVERS ....................................................................................... 4

2.6.1

Materials

2 2 2 2

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Page 2

2

SURFACE PREPARATION FOR PAINTING

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the process and workmanship to be used in preparing surfaces to be painted.

2

Related Parts and Sections are as follows: Primers, Paints and Coatings

Section 24

Finishes to Buildings

References

1


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This Section Part 3

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BS 245 ........................Mineral solvent (white spirit and related hydrocarbon solvents) for paints and other purposes

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BS 1336 ......................Knotting

GENERAL PREPARATIONS

2.2.1

Preparation

1

Before painting commences all surfaces in the work area are to be washed and scrubbed clean of debris and every possible precaution taken to keep down dust. No paint is to be applied to surfaces structurally or superficially damp and all surfaces must be ascertained to be free from condensation, efflorescence, etc., before the application of each coat.

2

All items not required to be painted (e.g., ironmongery) are first to be fitted and then removed before any painting preparation commences. The fittings shall be refixed in position when all painting is completed.

3

Brushes, pails, kettles, etc., used in carrying out the work are to be clean and free from foreign matter. They are to be thoroughly cleaned before being used for different types or classes of material.

4

All materials to be used for surface preparations are to be used strictly in accordance with the manufacturer’s instructions.

2.2.2

Preparatory Materials

1

Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping, knotting, fillers and other commodities are to be of the types recommended by the manufacturer of the coating to be applied.

2

White spirit shall comply with BS 245.

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QCS 2014


Page 3

Knotting shall comply with BS 1336.

4

Stopping and filler for woodwork shall be an approved proprietary lead free, oil-based type recommended for internal or external work as appropriate. Stopping for woodwork to receive a clear finish shall be tinted to match with the surrounding woodwork.

5

Filler for plaster and rendering to be an approved proprietary type.

2.3

PREPARATION OF PLASTERED AND RENDERED SURFACES

2.3.1


1

The surface is first to be scraped to remove mortar splashes, etc., and then made good, cutting out all defective work and repairing with plaster or render of the same type as previously used.

2

The surface is then to be rubbed down with fine glass paper to remove loose particles and to smooth irregularities before the application of the filler coat which is to be spread evenly with a scraper over all surfaces and allowed to dry.

3

The first application of filler coat will be rubbed down and a second application of filler coat made as before.

4

The surface is then to be sanded using progressively finer grades of paper until perfectly smooth and approved by the Engineer.

5

All rendered surfaces are to receive one full coat of alkali resistant primer before the application of oil based paints.

2.4

PREPARATION OF WOOD SURFACES

2.4.1


1

All large, loose or resinous knots are to be cut out and the holes plugged with sound wood. Nails are to be punched well below surfaces.

2

All surfaces are to be rubbed down with fine glass paper in the direction of the grain to give a smooth, even finish with arises rounded or eased.

3

After dusting off all oily woods such as teak and afrormosia they are to be washed with white spirit.

4

Two thin coats of knotting should be applied to all knots and any other resinous parts of softwood.

5

A full coat of primer is to be vigorously brushed in, particular care being taken to fill end grain. Backs of members are to receive two coats of primer.

6

After priming all nails, screw holes and similar depressions are to be filled with stopping, pressed well in and finished off flush with the surface. Screw heads are to be countersunk sufficiently to hold the stopping.

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Page 4

After priming and stopping is completed, pore and grain irregularities are to be treated with a coat of brush or knife applied filler, and the surface rubbed down smooth and even.

2.5

PREPARATION OF METAL SURFACES

2.5.1


1

Iron and steel surfaces are to be wire brushed to remove rust, loose scale, welding slag and spatter, and cleaned with white spirit to remove oil, grease and dirt.

2

Iron and steel surfaces are to receive two coats of primer.

3

On pre-primed surfaces care is to be taken to ensure that defective primer, rust and loose scale are removed back to bare metal and patch primed.

4

Blast cleaned surfaces shall be primed within 1 hour of blasting. All other surfaces shall be primed no later than 3 hours after preparation.

2.6

PAINT REMOVERS

2.6.1

Materials

1

The use of paint remover products are to be used only under conditions of acceptable air ventilation/circulation for those performing the work and for the surrounding environs if occupied or used by the public.

2

Paint remover products are to be of the type recommended by the manufacturer of the coating to be applied.

3

Mineral solvent (white spirit and related hydrocarbon solvents) used in relation to paint removal process is to conform to BS 245.

4

Manufacturer’s recommended procedures and application of paint remover products are to be followed.

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END OF PART

QCS 2014

Section 26: Painting and Decorating Part 03: Primers, Paints and Coatings

Page 1

3

PRIMERS, PAINTS AND COATINGS ....................................................................... 2

3.1

GENERAL REQUIREMENTS ................................................................................... 2

3.1.1

Scope

2

3.1.2

References

2

3.2

APPLICATION ........................................................................................................... 2

3.2.1

General

3.3

PRIMERS AND UNDERCOATINGS ......................................................................... 3

3.3.1

Materials

3

3.3.2

Workmanship

4

3.4

PAINTS AND FINISH COATINGS ............................................................................ 4

3.4.1

Materials

3.4.2

Workmanship

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QCS 2014


Page 2

PRIMERS, PAINTS AND COATINGS

3.1


3.1.1

Scope

1

This Part specifies requirements for products of primers, paints and coatings for building surfaces and elements.

2

Related Sections are as follows: General Surface Preparation for Painting

Section 24

Finishes to Buildings

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3

References

1

The following Standards are referred to in this Section:

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3.1.2

BS 4652......................Metallic zinc-rich priming paint (organic media)

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BS 4756......................Ready-mixed aluminium priming paints for woodwork BS 5082......................Water-borne priming paints for woodwork

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BS 5358......................Solvent-borne priming paints for woodwork

APPLICATION

3.2.1

General

1

Coatings are to be applied in accordance with the manufacturer’s instruction to clean, dry surfaces, in dust free and dry atmospheric conditions and after any previous coats have hardened.

2

All brands of primers, paints and coatings are to be approved and shall comply with the relevant British Standards.

3

Paints of different brands are not to be mixed or used in the same coating system.

4

No dilution of painting materials is to be allowed except strictly as detailed by the manufacturers and as approved by the Engineer

5

No primed or undercoated woodwork and metalwork is to be left in an exposed or unsuitable location for any undue period before completion of the painting process. No exterior or exposed painting is to be carried out under adverse weather conditions, such as rain, extreme humidity, dust storms, etc.

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QCS 2014


Page 3

3.3

PRIMERS AND UNDERCOATINGS

3.3.1

Materials

1

Primers for plaster and rendering are to be alkali resistant. Primers for other surfaces shall comply with Table 3.1. Table 3.1 Suitable Primers for Background SURFACE

PRIMER

Non resinous wood

Low lead oil based primer to BS 5358 or

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Aluminium wood primer to BS 4756 or Solvent borne acrylic primer Aluminium wood primer to BS 4756 or long oil alkyd based oxidative drying primer

Iron and steel

Red lead primer to BS 2523, Type “B” or zinc phosphate pigmented urethane alkyd modified primer

Galvanised steel

Calcium plumbate primer to BS 3698, Type “A” or

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Resinous woods

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Zinc chromate primer

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Blast cleaned iron and steel or touching-up damaged zinc coatings

Two component polyamide cured epoxy or modified vinyl based physically drying primer. Zinc-rich primer to BS 4652, Types 1, 2, and 3

Etch primer plus zinc chromate primer

Copper

Two component polyamide adduct cured epoxy or

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Lead

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Aluminium and aluminium alloys

Plastics

Modified vinyl based physically drying primer Long oil alkyd based oxidative drying primer Two component polyamide adduct cured epoxy primer or Solvent borne acrylic based physically drying primer.

2

Undercoats on wood and metal surfaces are to be of the drying-oil/resin binder type pigmented with titanium dioxide and/or coloured pigments providing a matt or low-sheen finish suitable for subsequent application of a drying-oil type finish.

3

Water thinned priming paints and undercoats shall only be used with the approval of the Engineer. In order to obtain such approval, the Contractor shall demonstrate that proposed water thinned priming paints and undercoats comply with BS 5082.

QCS 2014


Page 4

Workmanship

1

Priming coats are to be applied by brush unless other methods are approved taking care to work the primer into the surface, joints, angles and end grain.

2

Any primed surfaces which have deteriorated on site or in transit are to be touched up to the approval of the Engineer.

3

All surfaces of joinery which have not been primed in the workshop are to be primed immediately on arrival at site and before fixing.

4

Undercoats are to be applied as an even film over all exposed surfaces avoiding an uneven thickness at edges and angles.

5

All priming and undercoats are to be rubbed down to a smooth surface with fine abrasive paper and cleaned of all dust before the application of the next coat.

3.4

PAINTS AND FINISH COATINGS

3.4.1

Materials

1

The number of coats shall be as specified by the paint manufacturer, or at minimum, as specified on Table 3.2.

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PAINT SYSTEM 1 coat primer 1 coat undercoat 1 coat alkyd gloss finish or 1 coat primer 2 coats alkyd mid-sheen finish

External

1 coat primer 2 coats undercoat 1 coat alkyd gloss finish (lead free)

Wood-natural finish

Internal

3 coats varnish or polyurethane

External

4 coats exterior grade varnish

Iron and steel including

Internal

1 coat primer 1 coat undercoat 1 coat alkyd gloss finish (lead free)

Galvanised steel

External

2 coats primer 2 coats undercoat 1 coat alkyd gloss finish (lead free)

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Internal

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Wood-oil paint

LOCATION

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Table 3.2 Minimum Number of Coats for Drying-Oil/Resin Based Paint Systems on New Work

QCS 2014

Section 26: Painting and Decorating Part 03: Primers, Paints and Coatings SURFACE

Page 5

LOCATION

PAINT SYSTEM

Internal and External

1 coat etch primer 1 coat primer 1 coat undercoat 1 coat alkyd gloss finish (lead free)

Cement rendering

Internal

1 coat alkali resistant primer 1 coat undercoat 1 coat alkyd gloss finish (lead free)

.

Aluminium

Workmanship

1

Care shall be taken to ensure that finish coats applied over calcium plumbate primer are compatible with the primer.

2

Finish coats will be applied as an even film over all exposed surfaces, avoiding brush marks, sags, runs and other defects. Where two gloss finish coats are specified the second coat shall be applied within 48 hours of the first.

3

The application of paint systems for iron and steel should result in a minimum total film thickness of 125 microns internally or externally notwithstanding the number of coats specified.

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END OF PART

QCS 2014

Section 26: Painting and Decorating Part 04: Decorative Papers and Fabrics

Page 1

4

DECORATIVE PAPERS AND FABRICS .................................................................. 2

4.1

GENERAL ................................................................................................................. 2

4.1.1

Scope

4.2

MATERIALS .............................................................................................................. 2

4.2.1 4.2.2

Products Requirements Adhesives

4.3

PREPARATION OF NEW SURFACES FOR PAPERS AND FABRICS .................... 2

4.3.1


4.4

PREPARATION OF PREVIOUSLY PAPERED/PAINTED SURFACES .................... 3

4.4.1


4.5

HANGING OF DECORATIVE PAPERS AND FABRICS ........................................... 3

4.5.1


2 2 2

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Page 2

4

DECORATIVE PAPERS AND FABRICS

4.1

GENERAL

4.1.1

Scope

1

The Part provides specification for use of decorative papers or fabrics for application as wall or other surface covering.

2

Related Sections are as follows: This Section Part 1 Part 2 Part 3

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General Surface Preparation for Painting Primers, Paints, and Coatings

MATERIALS

4.2.1

Products Requirements

1

Samples of all materials to be submitted in accordance with Part 1 of this Section to the Engineer for approval.

4.2.2

Adhesives

1

Adhesives for wallpaper/fabrics shall be of a type recommended by the manufacturer of the material to be fixed, and in the absence of such recommendation, to be of to the approval of the Engineer.

4.3

PREPARATION OF NEW SURFACES FOR PAPERS AND FABRICS

4.3.1


1

Rendered surfaces are to be scraped to remove mortar splashes and all irregularities, cracks and blow holes to be filled and rubbed down when dry to a smooth surface removing all nibs and loose material.

2

Rendering and other alkaline surfaces are to receive one coat of alkali resistant primer.

3

All nail and screw heads to rigid sheet surfaces are to be below the surface, touched in with metal primer and allowed to dry before filling.

4

Paperfaced plasterboard, hardboard, chipboard and the like are to receive one coat of general purpose primer.

5

Surfaces which have not been primed and other surfaces recommended by the adhesive manufacturer are to receive one coat of size which shall be allowed to dry.

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4.2

QCS 2014


Page 3

PREPARATION OF PREVIOUSLY PAPERED/PAINTED SURFACES

4.4.1


1

All existing paper or fabric should be removed and the surface washed down with warm water to remove old adhesive and size. All existing painted surfaces are to be scraped to remove any loose material and washed with a detergent solution to remove any dirt and grease.

2

All irregularities and cracks are to be filled and rubbed down when dry to a smooth surface.

3

Bare and filled areas are to be touched in with general purpose primer.

4.5

HANGING OF DECORATIVE PAPERS AND FABRICS

4.5.1


1

Hanging should not commence until:

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all work affecting the surfaces to be covered is complete

(b)

the surfaces to be covered are dry and free from dust

(c)

the painting of adjacent surfaces is finished and dry

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(a)

Switch plates, grilles, etc., are to be removed before hanging commences and replaced when the surfaces are dry.

3

The Engineer’s instruction is to be obtained where the specified covering will allow minor blemishes in the surfaces to show.

4

Only rolls with the same shade number are to be used in any one area. Before hanging, the rolls are to be carefully matched for colour.

5

The manufacturer’s recommendations for hanging the covering and to which surface the adhesive is best applied is to be followed. Great care shall be taken to avoid staining the face of the paper or fabric.

6

All lengths are to be in one piece unless greater than the roll length.

7

Patterned paper or fabric is to be correctly aligned and accurately matched. Where mismatching is unavoidable the Engineer’s approval is to be obtained to the position allocated.

8

Wallpaper is to be accurately butt jointed. Where incomplete widths are required or where materials do not have straight edges the joints are to be overlapped and cut through using a straight edge to form a butt joint. Edges are to be neatly trimmed to a true line at junctions with other finishes.

9

When finished, papers and fabrics are to be free from air bubbles, wrinkles, gaps, tears, adhesive marks and stains and should be secure and smooth.

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END OF PART

QCS 2014

Section 27: External Works Part 01: General

Page 1

1

GENERAL ................................................................................................................................ 2

1.1

INTRODUCTION...................................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4

Scope References Quality Standards System Description

1.2

MATERIALS ............................................................................................................................. 2

1.2.1 1.2.2

Supply, Handling and Storage Approval of Supply Source

2 2 2 2

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Section 27: External Works Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section provides specifications for miscellaneous external works.

2


1.1.2

References

1


.

Section 1

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BS 729........................Hot dipped galvanized coating BS 3470......................Field Gates and Posts

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BS 6717......................Precast concrete paving blocks

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BS 1722......................Fences

BS 7293......................Precast concrete flags, kerbs, channels, edging and quadrants

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BS 7671......................Requirements for electrical installations

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BS EN 60598 .............Luminaries Quality Standards

1

All items within this Section are to be designed, manufactured, and installed with safety of the public as a priority.

1.1.4

System Description

1

Some of the Parts in this Section specify the work in general terms only. If external work items related to this Section are not fully specified or otherwise detailed within the Project Documentation, the Contractor shall submit appropriate specifications for approval by the Engineer.

2

Any standards or other documentation to support the suitability of Contractor supplied specifications for the work shall be submitted to the Engineer for review.

1.2

MATERIALS

1.2.1

Supply, Handling and Storage

1

All materials, components and accessories shall be stored in accordance with the relevant provisions of Section 1, General.

1.2.2

Approval of Supply Source

1

All products supplied under this Section must be obtained from an approved source.

2

The Contractor will not be permitted to change his source of supply without the permission of the Engineer.

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1.1.3

END OF PART

QCS 2014

Section 27: External Works Part 02: Block Paved Areas

Page 1

BLOCK PAVED AREAS .......................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 General Requirements 2 Compliance 3 Materials 3

2.2 2.2.1 2.2.2 2.2.3

PRECAST CONCRETE PAVING FLAGS ................................................................ 3 General Requirements 3 Precast Concrete Flags 3 Laying Concrete Paving Flags 3

2.3 2.3.1

INTERLOCKING CONCRETE PAVING BLOCKS ................................................... 3 Materials 3

2.4 2.4.1

CLAY PAVING BLOCKS ......................................................................................... 4 Materials 4

2.5 2.5.1 2.5.2 2.5.3

GRANITE PAVING BLOCKS ................................................................................... 5 Materials 5 Surface Finish 5 Top Surface Finish 5

2.6 2.6.1

INSTALLATION OF PAVING BLOCKS ................................................................... 6 General Requirements 6

2.7 2.7.1

PLAYGROUNDS, PARKS AND OTHER AREAS .................................................... 6 General Requirements 6

2.8 2.8.1

SPORTS ACTIVITY PLAYING SURFACES ............................................................ 6 General Requirements 6

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Page 2

2

BLOCK PAVED AREAS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements block paved areas surfaces not otherwise covered in Section 6, Roadworks.

2


2.1.2

References

1


.

Roadworks

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Section 6

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ASTM C 97 .................Test Methods for Absorption and Bulk Specific Gravity of Dimension Stone. ASTM C 99 .................Test Method for Modulus of Rupture of Dimension Stone.

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ASTM C 241 ...............Test Method for Abrasion Resistance of Stone Subjected to Foot Traffic. ASTM C 880 ...............Test Method for Flexural Strength of Dimensional Stone.

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ASTM C 936 ...............Specification for Solid Concrete Interlocking Paving Units BS 1014 ......................Pigments for Portland cement and Portland cement products

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BS 7293 ......................Precast concrete flags, kerbs, channels, edging and quadrants

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BS EN 1338 ................Precast concrete paving blocks

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BS EN 10545 ..............Ceramic Tiles General Requirements

1

All items in this Part require approval by the Engineer.

2

The Contractor shall submit manufacturer’s literature, drawings, samples or mock-up units for items covered in this Part for approval by the Engineer.

3

If external work items related to this Part are not specified or otherwise detailed within the Project Documentation, the Contractor shall submit appropriate specifications for approval by the Engineer.

4

Bedding requirements for paved surfaces shall be in accordance with Section 6, Roadworks.

5

Blocks supplied in accordance with this part shall be marked with the following particulars:

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2.1.3

(a)

identification of the manufacturer by name or logo

(b)

date of production

(c)

product name

(d)

standards to which the block is manufactured

The surface of paving blocks shall not exhibit any defects such as cracking, delamination or flaking.

QCS 2014


Page 3

Compliance

1

All paving works which are subject to public use or use by any governmental department or agency shall comply with all health and safety requirements of all applicable government departments and agencies.

2

The Contractor is responsible to obtain written approvals or documentation from all applicable government departments and agencies in connection with Clause 2.1.4-1.

2.1.5

Materials

1

The paving material shall be such that it does not develop a polished surface of low skid resistance when trafficked.

2

The colour of the paving units shall be as described in the Project Documentation.

2.2

PRECAST CONCRETE PAVING FLAGS

2.2.1


1

Precast concrete paving flags shall comply with the relevant provisions of Section 6, Roadworks, and as specified herein.

2.2.2

Precast Concrete Flags

1

Precast concrete flags shall be hydraulically pressed and shall comply with the relevant provisions of BS 7293: Part 1 and Section 5, Concrete. Unless otherwise described in the Project Documentation, flags shall be 50 mm thick.

2

Precast concrete paving blocks shall comply with the relevant provisions of BS EN 1338.

3

Pigments shall be inorganic, stable and shall comply with BS 1014. Pigments can be used in powder, liquid or granular form.

2.2.3

Laying Concrete Paving Flags

1

Precast concrete flags shall be laid to the required falls on sub-base material as described in the Project Documentation, bonded with joints at right angles to the kerb, and spot bedded with Class M4 mortar with no lipping of top surfaces.

2

Flags shall be cut to fit around surface boxes and other furniture and, on circular work where the radius is 12 m or less, shall be radially cut on both edges to the required lines.

2.3

INTERLOCKING CONCRETE PAVING BLOCKS

2.3.1

Materials

1

Materials for interlocking concrete paving blocks shall conform to BS EN 1338 and Section 5, Concrete.

2

Pigments shall be inorganic, stable and shall comply with BS 1014. Pigments can be used in powder, liquid or granular form.

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2.1.4

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Page 4

3

The facing layer of composite blocks consisting of a facing layer and a backing layer shall not be less than 4 mm.

4

The thickness of interlocking concrete paving blocks shall be:

(b)

80 mm on roads and parking areas unless otherwise detailed in the Project Documentation or instructed by the Engineer.

The strength of interlocking concrete paving blocks shall be as follows: the average tensile splitting strength of 16 blocks shall be tested in accordance with BS EN 1338 and shall be not less than 3.6MPa and the failing load not lower than 250N/mm.

(b)

the tensile splitting strength of any individual block shall be not less than 2.9MPa.

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(a)

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Water absorption of interlocking concrete paving blocks shall be as follows: (a)

an average of 3 specimens tested in accordance with BS EN 1338 shall not be greater than 5%

(b)

no individual result shall be greater than 6%.

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60mm on footpaths

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(a)

CLAY PAVING BLOCKS

2.4.1

Materials

1

Clay paving blocks shall have chamfers, be colour resistant and without nibs.

2

The clay paving blocks shall be classified as follows:

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A

(b)

Type

B

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Type

:

to be used in pedestrian/footpath areas.

:

to be used in trafficked areas.

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(a)

The clay paving blocks shall comply with the requirements given in the following Table:

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Item No.

Table 2.1 Requirements for clay paving blocks Specified Limits Requirement

Test Method Type A

Type B 65 mm (± 3 mm)

1.

Work size thickness (tolerance)

BS 6677 : Part 1 : 1986

50 mm (± 3 mm)

2.

Average Compressive Strength

BS 3921 : 1985

50 N/mm min

3.

Individual Compressive Strength

BS 3921 : 1985

4.

Average Transverse Breaking Load

BS 6677 : Part 1 : 1986

2

75 N/mm min

2

47 N/mm min

2

70 N/mm min

5.0 kN min

7.0 kN min

2

QCS 2014


Page 5

Specified Limits

Item No.

Requirement

Test Method Type A

Type B

Individual Transverse Breaking Load

BS 6677 : Part 1 : 1986

3.0 kN min

4.0 kN min

6.

Water Absorption

BS 3921 : 1985

12 % max

7 % max

7.

Mean Wet Skid Resistance Value

BS 6677 : Part 1 : 1986

60 min

60 min

8.

Efflorescence

BS 3921 : 1985

Nil to moderate

Nil to slight

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5.

GRANITE PAVING BLOCKS

2.5.1

Materials

1

Materials for granite paving blocks shall be of first quality natural granite.

2

Granite paving block thickness shall be 70 mm on roads and parking areas unless otherwise detailed in the Project Documentation.

3

The density of granite paving blocks shall be 2,560 kg/m or more when measured in accordance with ASTM C 97.

4

The water absorption of granite paving blocks shall be 0.40% (maximum) when measured in accordance with ASTM C 97.

5

The minimum compressive strength of granite paving blocks shall be 131 MPa when measured in accordance with ASTM C 170.

6

The modulus of rupture of granite paving blocks shall be 10.34 MPa or more when measured in accordance with ASTM C 99.

7

The abrasion resistance of granite paving blocks shall be HA25 (minimum) when measured in accordance with to ASTM C 241 / C 1353.

8

The flexural strength of granite paving blocks shall be 8.27 MPa or more when measured in accordance with ASTM C 880.

2.5.2

Surface Finish

1

Edges shall be split in a straight line with a hydraulic guillotine. The resulting edge shall be straight, but broken along the natural grain structure of the stone with concave and convex areas along the edge.

2.5.3

Top Surface Finish

1

Granite paving blocks shall be finished with a thermal, highly slip resistant, rough textured surface.

3

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2.5

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Page 6

INSTALLATION OF PAVING BLOCKS

2.6.1


1

These clauses are for the installation of interlocking concrete, clay and granite paving blocks.

2

Paving blocks shall be laid on the sand laying course in such a manner as not to disturb the blocks already laid.

3

Each block shall be placed firmly against its neighbour so that they fit closely together.

4

Joints between blocks shall not exceed 3 mm.

5

Laying of the paving blocks shall commence at right angles to the main pavement axis starting at one end of the area.

6

The blocks shall be laid in patterns as shown in the Project Documentation or instructed by the Engineer.

7

Where blocks do not fit the edge restraints or other obstructions such as manholes or upstands, the gaps shall be filled using cut blocks.

8

Blocks shall be cut using only a mechanical or hydraulic block splitter.

2.7

PLAYGROUNDS, PARKS AND OTHER AREAS

2.7.1


1

The Contractor shall provide test certificates for surfaces made specifically for outdoor playing areas, such as soft impact type paving, showing compliance with all pertinent health and safety requirements of the applicable government departments and agencies.

2

Surfaces made specifically for outdoor playing areas shall be installed by specialised subcontractors experienced in such work unless otherwise approved by the Engineer.

2.8

SPORTS ACTIVITY PLAYING SURFACES

2.8.1


1

Outdoor sporting surfaces such as tennis courts, running tracks and the like shall be installed by specialised sub-contractors experienced in such work unless otherwise approved by the Engineer.

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2.6

END OF PART

QCS 2014

Section 27: External Works Part 03: Fences and Gates

Page 1

3

FENCES AND GATES ............................................................................................................. 2

3.1

GENERAL ................................................................................................................................ 2

3.1.1 3.1.2 3.1.3


3.2

FENCES ................................................................................................................................... 2

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8

General Requirements Chain Link Fences and Gates Ornamental Metal Fences Wire Fences Wood Fences Open Mesh Steel Panel Fences Security Fences Tennis Court Fencing

3.3

FIELD GATES .......................................................................................................................... 4

3.3.1


3.4

WIND BREAKS ........................................................................................................................ 4

3.4.1


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2 2 2 2 3 3 3 3 4 4 4 4 4

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Page 2

3

FENCES AND GATES

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for fences and gates and for wind breaks.

2

Related Sections and Parts are as follows: Section 5 Section 6 Section 18

Concrete Roadwork Carpentry, Joinery and Ironmongery

References

1


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3.1.2

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BS 729........................Hot dipped galvanized coatings on iron and steel articles BS 3470 .....................Field Gates and Posts

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BS 1722 .....................Fences

Submittals

1

Shop drawings are to be provided with layout of fences and gates with dimensions, details of all components, accessories, material finishes and post foundations.

2

The Contractor shall provide manufacturer’s catalogues indicating proposed materials and components for approval by the Engineer.

3

The Contractor shall provide a colour selection for finishes designated and samples of materials (e.g., finials, caps, and accessories) if instructed by the Engineer.

4

The Contractor shall provide mock-ups if instructed by the Engineer.

3.2

FENCES

3.2.1


1

Fittings and dimensions of fences shall be as detailed in the Project Documentation.

2

Permanent gates shall generally be built in accordance with the relevant provisions of BS 1722 and as specified herein. Table 3.1 provides Part numbers of BS 1722 for all fencing types.

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3.1.3

QCS 2014


Page 3

Table 3.1 Fencing Types in BS 1722 Part of BS 1722

Type of fencing Chain link fences

2

Woven wire fences

3

Strained wire fences

4

Cleft chestnut pale fences

5

Close boarded fences

6

Wooden palisade fences

7

Wooden post and rail fences

8

Mild steel (low carbon steel) continuous bar fences

9

Mild steel (low carbon steel) fences with round or square verticals and flat posts and horizontals

10

Anti-intruder chain link fences

11

Woven wood and lap boarded panel fences

12

Steel palisade fences

13

Chain link fences for tennis court surrounds

14

Open mesh steel panel fences

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1

Concrete for the surrounding the bases of fencing posts shall be in accordance with BS 1722 and shall comply with the relevant provisions of Section 5, Concrete.

4

All timber work for permanent fencing shall be given preservative treatment in accordance with the relevant provisions of BS 1722 and Section 18, Carpentry, Joinery and Ironmongery.

5

The Contractor shall provide calculations showing that the fence and it components can satisfactorily sustain a 3 second gust of 180 kph (50 m/s).

3.2.2

Chain Link Fences and Gates

1

Chain link fencing shall comply with the requirements of BS 1722 Part 1 and of Section 6, Roadworks.

3.2.3

Ornamental Metal Fences

1

Ornamental metal fences and gates shall comply with the relevant provisions of BS 1722 Parts 8, 9 and 12 and of Section 18, Carpentry, Joinery and Ironmongery.

3.2.4

Wire Fences

1

Wire fences shall comply with the relevant provisions of BS 1722 Parts 2 and 3 and of Section 18, Carpentry, Joinery and Ironmongery.

3.2.5

Wood Fences

1

Wood fences shall comply with the relevant provisions of BS 1722 Parts 4, 5, 6, 7 and 11 and of Section 18, Carpentry, Joinery and Ironmongery.

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QCS 2014


Page 4

Open Mesh Steel Panel Fences

1

Open mesh steel panel fences shall comply with the relevant provisions of BS 1722 Part 14 and of Section 18, Carpentry, Joinery and Ironmongery.

3.2.7

Security Fences

1

Security fences shall comply with the relevant provisions of BS 1722 Part 10 and of Section 18, Carpentry, Joinery and Ironmongery.

2

Any additional requirement by the end user of security fencing shall also be complied with.

3.2.8

Tennis Court Fencing

1

Tennis court fences shall comply with the relevant provisions of BS 1722 Part 13 and of Section 18, Carpentry, Joinery and Ironmongery.

3.3

FIELD GATES

3.3.1


1

Fittings and dimensions for gates shall be as detailed in the Project Documentation.

2

Field gates, posts and fittings shall comply with the relevant provisions of BS 3470.

3

All timber for field gates and posts shall be given preservative treatment in accordance with the provisions of BS 3470 and Section 18, Carpentry, Joinery and Ironmongery.

4

All fittings and steel field gates and posts shall be hot dip galvanized in accordance with BS 729.

3.4

WIND BREAKS

3.4.1


1

Components, fittings and dimensions for wind breaks shall be as detailed in the Project Documentation.

2

The Contractor shall provide calculations showing that the wind break and its components can satisfactorily sustain the wind loads.

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3.2.6

END OF PART

QCS 2014

Section 27: External Works Part 04: Fountains and Aquatic Features

Page 1

4

FOUNTAINS AND AQUATIC FEATURES ................................................................ 2

4.1

GENERAL ................................................................................................................. 2

4.1.1 4.1.2 4.1.3


4.2

FOUNTAINS .............................................................................................................. 2

4.2.1


4.3

DESIGN CONSIDERATIONS ................................................................................... 3

4.3.1 4.3.2 4.3.3

Provision of Overflow Drain Provision of Drain Down Testing of Features Designed to Retain an Aqueous Liquid

2 2 2

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2

3 3 3

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Page 2

4

FOUNTAINS AND AQUATIC FEATURES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for specifications for water fountains, waterfalls and other aquatic features.

2


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Mechanical and Electrical Work Plumbing Work Drainage Works for Buildings

References

1


ta

4.1.2

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qa

BS 7671......................Requirements for electrical installations

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BS EN 60598 .............Luminaries


1


2


3


4.2

FOUNTAINS

4.2.1


1

Pumps for fountains shall comply with the relevant provisions of Section 9, Mechanical and Electrical Equipment, and Section 19, Plumbing Work.

2

Pipework associated with fountains shall comply with the relevant provisions of Section 19, Plumbing Work.

3

Electrical works related to fountains shall comply with the relevant provisions of BS 7671 and the requirements of QGEWC.

4

Luminaries for fountains shall comply with the relevant provisions of BS EN 60598-2-18.

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4.1.3

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Page 3


4.3.1

Provision of Overflow Drain

1

All tanks, water holding structures and the like associated with fountains and aquatic features shall include provision for an overflow drain.

2

Overflow pipework shall be sized to accommodate flows in excess of the maximum incoming flow where appropriate.

3

Pipework associated with overflow drains shall comply with the relevant provisions of Section 20, Drainage for Buildings.

4.3.2

Provision of Drain Down

1

All tanks, water holding structures and the like associated with fountains and aquatic features shall include provision for a drain down.

2

Pipework associated with drain downs shall comply with the relevant provisions of Section 20, Drainage for Buildings.

4.3.3

Testing of Features Designed to Retain an Aqueous Liquid

1

Unless otherwise stated by the Engineer, all structures designed to retain an aqueous liquid shall be tested for watertightness.

2

After cleaning, structures designed to retain an aqueous liquid shall be filled with water at a uniform rate. A period of 21 days shall be allowed by the Contractor for stabilisation, after which the water level shall be recorded by approved means at 24 hour intervals for a test period of 7 days. During the test period, the total permissible drop, after allowing for evaporation and rainfall, shall not exceed 10 mm.

3

Notwithstanding the satisfactory completion of the above test, any leakage visible on the outside faces of the structure shall be stopped.

4

The Contractor is responsible for provision and disposal of water for testing purposes.

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4.3

END OF PART

QCS 2014

Section 27: External Works Part 05: Site Furniture

Page 1

5

SITE FURNITURE ..................................................................................................... 2

5.1

GENERAL ................................................................................................................. 2

5.1.1 5.1.2


5.2

PRODUCTS .............................................................................................................. 2

5.2.1

Manufactured Units

5.3

EXECUTION.............................................................................................................. 2

5.3.1

Installation

2 2 2

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2

QCS 2014

Section 27: External Works Part 05: Site Furniture

Page 2

SITE FURNITURE

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for site furniture.

5.1.2


1


2


3


5.2

PRODUCTS

5.2.1

Manufactured Units

1

Items covered in this Part include, but are not limited to the following:

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planters

(b)

benches

(c)

tables

(d)

rubbish bins

(e)

ash type rubbish bins

(f)

combination rubbish bins (ash type/non ash type)

(g)

bicycle storage racks

(h)

street furniture

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(a)

Information on items covered in this Part that are to be submitted to the Engineer for approval to include:

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5

(a)

dimensions

(b)

weight

(c)

construction

(d)

material

(e)

colour

(f)

finish

5.3

EXECUTION

5.3.1

Installation

1

Site furnishings and associated components and accessories shall be installed in accordance with the manufacturer's installation instructions. END OF PART

QCS 2014

Section 27: External Works Part 06: Flag Poles

Page 1

6

FLAG POLES ........................................................................................................................... 2

6.1

GENERAL ................................................................................................................................ 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5

Scope References Submittals Delivery, Storage and Handling System Description

6.2

CONSTRUCTION .................................................................................................................... 2

6.2.1 6.2.2 6.2.3

Materials Finishes Installation

2 2 2 2 2

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6

FLAG POLES

6.1

GENERAL

6.1.1

Scope

1

This Section specifies the requirements for manufacture, materials and installation of flag poles.

6.1.2

References

1


Submittals

1

The Contractor shall submit the following:

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6.1.3

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BS 729........................Hot dipped galvanized coating

manufacturer’s descriptive literature for flagpoles, including all components, accessories and configuration

(b)

shop drawings indicating detailed dimensions, base attachment details and anchor requirements

(c)

structural calculations showing stability under imposed loads

(d)

two samples illustrating pole material, colour, and finish.

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(a)


1

The delivery, storage and handling of components included in this Part shall comply with the requirements of Section 1, General, and the following clauses.

2

The flagpole shall be spiral wrapped with protective covering and packed in protective shipping tubes or containers.

3

Flagpoles shall be delivered complete with all accessories.

6.1.5

System Description

1

Each flag pole including fittings, accessories, bases and anchorage devices shall be provided complete by a single manufacturer.

2

Flag poles and associated accessories should be designed to withstand wind loads.

3

Flag poles shall be constructed and delivered to the site in one piece, where possible and practicable. If more than one piece is necessary, provide close-fitting joints with self-aligning, internal sleeve arrangement. Joints shall be inconspicuous and weather tight.

4

The method of hoisting the flag shall be by an internal or external halyard as detailed in the Project Documentation.

6.2

CONSTRUCTION

6.2.1

Materials

1

Materials for flag poles shall be as follows unless otherwise detailed in the Project Documentation:

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6.1.4

QCS 2014


(a)

aluminium

(b)

steel

(c)

stainless steel

(d)

bronze

(e)

fibre glass

Page 3

6.2.2

Finishes

1

Finishes for flag poles shall be as follows unless otherwise detailed in the Project Documentation: satin brush finish (aluminium, stainless steel and bronze)

(b)

anodised finish (aluminium)

(c)

organic coatings such as paint, air drying epoxies, urethanes, and thermally cured fluorocarbons (aluminium and steel).

(d)

chemically oxidised (antique) finish (bronze)

(e)

galvanized finish (steel) in accordance with BS 729.

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(a)

Installation

1

The flag pole and associated components and accessories shall be installed in accordance with the manufacturer's installation instructions.

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6.2.3

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PROTECTIVE OR SHADE COVER SYSTEMS ............................................. 2 GENERAL ...................................................................................................... 2 Scope 2 General Requirements 2

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Section 27: External Works Part 07: Protective or Shade Cover Systems

QCS 2014

Section 27: External Works Part 07: Protective or Shade Cover Systems

Page 2

PROTECTIVE OR SHADE COVER SYSTEMS

7.1

GENERAL

7.1.1

Scope

1

This Part provides provision for inclusion of special specifications for specialised structures of protective or shade covering systems. It includes items such as awnings, tents, canopies of fabric or membrane materials supported by or stretched over metal, plastic or concrete frames.

7.1.2


1


2


3


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PLAY FIELD AND PARK EQUIPMENT ......................................................... 2 GENERAL ...................................................................................................... 2 Scope 2 General Requirements 2

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Section 27: External Works Part 08: Play Field and Park Equipment

QCS 2014

Section 27: External Works Part 08: Play Field and Park Equipment

Page 2

PLAY FIELD AND PARK EQUIPMENT

8.1

GENERAL

8.1.1

Scope

1

This Part provides provision for inclusion of special specifications for equipment for use in playing fields and parks for sport and recreational use. It shall include for both “active use” for individuals using the facility, and for “passive use” for individuals observing the “active use”.

8.1.2


1


2


3


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8

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END OF PART

QCS 2014

Section 27: External Works Part 09: Miscellaneous Other External Works

Page 1

9

MISCELLANEOUS OTHER EXTERNAL WORKS .................................................... 2

9.1

GENERAL ................................................................................................................. 2

9.1.1 9.1.2


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2 2

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Section 27: External Works Part 09: Miscellaneous Other External Works

Page 2

MISCELLANEOUS OTHER EXTERNAL WORKS

9.1

GENERAL

9.1.1

Scope

1

This Part provides for inclusion of special specifications for any external building works or elements designated in the Project Documentation.

9.1.2


1


2


3


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QCS 2014

Section 28: Landscaping Part 01: Landscape Planting

Page 1

LANDSCAPE PLANTING ....................................................................................................... 3

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

GENERAL REQUIREMENTS .................................................................................................. 3 Scope ....................................................................................................................................................... 3 References............................................................................................................................................... 3 Quality Assurance ................................................................................................................................... 5 Submittals ............................................................................................................................................... 5 Job Conditions ......................................................................................................................................... 7

1.2 1.2.1 1.2.2 1.2.3

SHIPPING, DELIVERY, STORAGE AND HANDLING ............................................................ 7 Shipping and Delivery .............................................................................................................................. 7 Storage .................................................................................................................................................... 8 Handling .................................................................................................................................................. 8

1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.3.11 1.3.12 1.3.13 1.3.14 1.3.15 1.3.16 1.3.17 1.3.18 1.3.19 1.3.20 1.3.21 1.3.22 1.3.23 1.3.24

PRODUCTS ............................................................................................................................. 9 General .................................................................................................................................................... 9 Plants ....................................................................................................................................................... 9 Labels .................................................................................................................................................... 10 Workmanship / Qualifications .............................................................................................................. 10 Soil Preparation ..................................................................................................................................... 11 Subsoil Preparation ............................................................................................................................... 11 Spreading and Preparation of Topsoil ................................................................................................... 12 Soil Specification ................................................................................................................................... 12 Alternative Soil Specification ................................................................................................................ 13 Soil Additives – Procedure A ................................................................................................................. 14 Soil Additive - Procedure B .................................................................................................................... 16 Alternative Soil Additive Specifications ................................................................................................. 17 Compost Specifications ......................................................................................................................... 18 Contractor’s Responsibilities ................................................................................................................. 21 The Supervising Officer’s Responsibilities ............................................................................................. 22 Chemical Testing for Fertiliser Equivalence of the Compost ................................................................ 22 Planting Soil Mixture ............................................................................................................................. 23 Planting Soil Mixture (Sweet Soil) ......................................................................................................... 23 Dry Plant Fertiliser ................................................................................................................................. 23 Turf Fertiliser ......................................................................................................................................... 23 Mulch .................................................................................................................................................... 23 Guys and Stakes .................................................................................................................................... 24 Edging Material ..................................................................................................................................... 24 Irrigation Water..................................................................................................................................... 24

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5

SITE PREPARATION FOR PLANTING AREAS ................................................................... 24 General Requirements .......................................................................................................................... 24 Sub-Surface Grading.............................................................................................................................. 25 Finished Grading ................................................................................................................................... 25 Planting Operations and Layout ............................................................................................................ 25 Protection of Existing Vegetation.......................................................................................................... 26

1.5 1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7 1.5.8 1.5.9

PLANTING ............................................................................................................................. 26 Plant Pits ............................................................................................................................................... 26 Backfill Mixture ..................................................................................................................................... 26 Installation for Trees and Shrubs .......................................................................................................... 27 Installation of Palms .............................................................................................................................. 28 Cultivation of Turf Areas ....................................................................................................................... 28 Seeding .................................................................................................................................................. 28 Sprigging ................................................................................................................................................ 29 Turfing ................................................................................................................................................... 29 Plant List, Spacing and Sizes .................................................................................................................. 30

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Edging Plant Beds .................................................................................................................................. 64 Mulch .................................................................................................................................................... 64 Watering of Plants................................................................................................................................. 64 Pruning .................................................................................................................................................. 65 Anti-Desiccant Application .................................................................................................................... 65 Clean up and Site Restoration ............................................................................................................... 65 Maintenance during Planting Operations ............................................................................................. 65

1.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6

EXISTING LANDSCAPING ................................................................................................... 66 Care of Existing Landscaping ................................................................................................................. 66 Identification of Existing Plants ............................................................................................................. 66 Watering and Fertilizing Existing Non Native Trees .............................................................................. 66 Fertilizing Existing Non Native Shrubs and Groundcover Beds ............................................................. 66 Watering Native Trees, Shrubs and Groundcovers ............................................................................... 66 Pruning and Cavity Work....................................................................................................................... 66

1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6 1.7.7 1.7.8 1.7.9 1.7.10

PLANTING MATERIALS ........................................................................................................ 67 General .................................................................................................................................................. 67 Nomenclature ....................................................................................................................................... 67 Guaranties – Planting Material ............................................................................................................. 68 Accessories ............................................................................................................................................ 68 Transplanting Plants .............................................................................................................................. 69 Planting Time ........................................................................................................................................ 70 Water Consumption .............................................................................................................................. 70 Percolation Test .................................................................................................................................... 71 Installation for Trees and Shrubs .......................................................................................................... 71 Installation of Palms .............................................................................................................................. 72

1.8 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5 1.8.6 1.8.7

GRASS ................................................................................................................................... 73 Materials and Products ......................................................................................................................... 73 Workmanship ........................................................................................................................................ 73 Soil Preparation ..................................................................................................................................... 73 Delivery ................................................................................................................................................. 74 Seeding .................................................................................................................................................. 74 Preparation and Installation of Carpet Grass ........................................................................................ 74 Watering, Cutting, and Completion ...................................................................................................... 75

1.9 1.9.1

APPLICATION OF PESTICIDE ............................................................................................. 75 General Requirements .......................................................................................................................... 75

1.10 1.10.1 1.10.2 1.10.3 1.10.4 1.10.5

WARRANTy, MAINTENANCE AND HANDOVER ................................................................. 75 Plant Establishment and Warranty Period ............................................................................................ 75 Plant Maintenance during the Establishment Period ........................................................................... 76 Replacement Plants during the Establishment Period .......................................................................... 76 Lawn Maintenance during Plant Establishment Period ........................................................................ 76 Final Acceptance ................................................................................................................................... 77

1.11 1.11.1 1.11.2 1.11.3

MAINTENANCE ..................................................................................................................... 77 General .................................................................................................................................................. 77 Appearance of the Ground ................................................................................................................... 79 Grass Maintenance ............................................................................................................................... 81

1.12

APPENDIX A – Landscaping Details 1 .................................................................................. 86

1.13

APPENDIX B – Ashghal irrigation rates ................................................................................. 89

1.14

APPENDIX C – Landscaping Details 2 .................................................................................. 89

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1.5.10 1.5.11 1.5.12 1.5.13 1.5.14 1.5.15 1.5.16

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Page 3

LANDSCAPE PLANTING

1.1


1.1.1

Scope

1

Work covered under this section consists of furnishing all labour, equipment and material necessary to perform all operations required for landscaping herein specified.

2

Landscape planting is inclusive but not limited to finished grading, supplying and spreading of soil, layout of plants and areas, turfing, seeding and sprigging of new lawns, ground cover plantings, shrub planting, tree planting, landscape edges, maintenance period, landscape warranty, appliances and services necessary for and incidental to completing all the planting operations in a workmanship like manner, according to the provisions of the Project Documentation.

3

The details pertaining to this scope of work are herein Appendix A and Appendix B. The Contractor shall execute his work as per the details in Appendix A and Appendix B.

4


as

Road works Earthworks Related to Buildings

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References

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ASTM C516 ................Specification for Vermiculite Loose Fill Thermal Insulation ASTM C549 ................Specification for Perlite Loose Fill Insulation ASTM C136 ................Standard Methods of Sieve and Screen Analysis of Fine and Coarse Aggregates ASTM D422 ................Standard Methods of Particle Size Analysis of soil ASTM D2607 .............. Standard Classification of Peat, Mosses, Humus, and Related Products ASTM D2974 ..............Standard Method of Test for Moisture, Ash, and Organic Matter of Peat Materials ASTM D2976 .............. Standard Method of Test for pH of Peat Materials ASTM D2977 .............. Standard Method of Test for Particle Size Range of Peat Materials AS 3743 .....................Potting mixes. Standards Australia, Sydney Australia AS 4419 .....................Soils for landscaping and garden use. Standards Australia, Sydney Australia BS 1377 .....................Method of test of soils for civil engineering purposes BS 3998 .....................Tree Work BS 4043 .....................Transplanting Trees BS 3882 .....................Topsoil BS 3936 .....................Nursery Stock and Shrubs

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Page 4

BS 4428 .....................General Landscape Operation BS 5236 ....................Cultivation and Planting of Trees in the Extra Large Nursery Stock Category ANSI Z60-1 ................American Standard for Nursery Stock NATSPEC – Specifying Trees Official Method of Analysis, Association of Analytical Communities (AOAC International) The Australian Dangerous Goods Code (ADG), Department of Infrastructure and Transport, Government of Australia

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Standard Plant Names, American Joint Committee on Horticultural Nomenclature (AJCHN)

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Grade and Standards for Nursery Trees – Part II: Palms and Trees, Department of Agriculture, Florida, USA

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Environmental Regulations and Technology, Control of Pathogens and Vector Attraction in Sewage Sludge, United States Environment Protection Agency, Cincinnati, OH, USA

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Environmental Guidelines, Use and Disposal of Bio solids Products, Environmental Protection Agency, NSW, Australia

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Kirchhoff C, Malina J and Barrett (2003) Characteristics of Compost: Moisture Holding and Water Quality Improvements. CRWR On-line Report, Centre for Water Resources, University of Texas, Austin

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Rayment GE and Higginson FR (1992) Australian Laboratory Handbook of Soil and Water Chemical Methods. Inkata Press, North Ryde Sydney Australia RHS Complete Gardener’s Manual, Royal Horticultural Society, UK

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RHS Encyclopaedia of Plants and Flower, Royal Horticultural Society, UK The Royal Horticultural Society A-Z Encyclopaedia of Garden Plants, Royal Horticultural Society, UK

Post, George E., Flora of Syria, Palestine and Sinai, American University of Beirut. Sunset Western Garden Book, Latest Edition. Wyman, Donald, Wyman’s Gardening Encyclopedia, Macmillan Publishing Company, New York, U.S.A., Colliers Macmillan Publishers, London, Second Edition, 1986.

Tropica Color Encyclopedia of Exotic Plants and Trees, Alfred Byrd Graf

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Page 5

1.1.3

Quality Assurance

1

Landscape works including soil preparation and planting shall conform to the relevant requirements of the respective standards, unless otherwise directed by the Engineer.

2

Landscape work must be undertaken by an experienced subcontractor specialising in landscape work. Work shall be performed and supervised at all times by qualified personnel.

3

All landscape materials shall be shipped with certificates of inspection as required by the Engineer. Manufacturer’s certified analysis for standard packaged products shall be provided.

4

Defective plant material shall be considered to be any tree, shrub or other plant that is: Dead, dying, damaged or otherwise defective upon completion of the works after six weeks or at the first leafing out, whichever is later

(b)

Not in accordance with the Project Documentation.

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(a)

Submittals

1

The Contractor shall submit catalogue data and literature of manufacturers and suppliers.

2

The Contractor shall submit manufacturer’s certified analysis of all standard products. The certificate of origin for all chemicals and pesticides should clearly state that the product is used in the manufacturers country.

3

The Contractor shall submit certificates confirming the origin, size, age of all plant materials and that the same are free from insects and disease.

4

The contractor shall ensure that all landscape materials including soil additives, fertilizers, compost, organic materials and plants have the required authority approvals affixed.

5

The Contractor is to submit his method statement for his fertilizer application for the approval of the Engineer.

6

The Contractor shall submit a Plant Procurement Schedule within fourteen (14) days of the start of the Contract. All plants for Ashghal projects are to conform with 1.5.9 Table 9b.This schedule shall identify the source of every plant species to be included in the Works and highlights plants that must be imported due to non-availability in Qatar. The schedule shall be documented with the listing of names and locations of all nurseries, growers and plant material sources. The schedules are a guide and any departure from the guide needs to be justified on technical grounds that the species will thrive in Qatar.

7

The Contractor shall submit a weekly work schedule for approval before work is started. The schedule shall identify tasks to be completed on a weekly basis and the anticipated schedule for completing the tasks. The Contractor will then modify and submit the schedule on a weekly basis identifying tasks completed, tasks to be completed, problems encountered and recommendations additional to a monthly report contains all the above in details.

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1.1.4

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Page 6

A soils report is to be submitted by the Contractor for all soils to be used for landscaping purposes in the Works. The Contractor shall arrange for an approved independent analyst to prepare a physical and chemical analysis of the soil and irrigation water to be used. The analyst shall also provide recommendations on soil amendment, fertiliser application and the like. The report shall be submitted to the Engineer for approval before soil is placed. In the case of imported soil, the report shall be submitted at least 10 days prior to delivery. The report shall identify the source(s) from which imported soils are to be furnished. At a minimum, the soil shall be analysed for: Total salts (Electro-Conductivity of soil solution)

(b)

Soil pH

(c)

Exchangeable Sodium, Calcium, Magnesium and Potassium

(d)

Available Phosphates

(e)

Organic matter as a percentage

(f)

Available Zinc, Manganese, Iron and Boron

(g)

Total Sulphates

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The soil analysis shall also include fertilisers and other amendment requirements and quantities which when incorporated with the soil will provide the required nutrient levels for vigorous plant growth.

10

Additional soil samples shall be taken at the rate of one in every 20 loads or as directed by the Engineer and analysed. The results will be compared with the original sample to ensure consistency and compatibility of supply.

11

An operations and maintenance manual is to be provided by the Contractor. Instructions shall be furnished for year round care of installed plants to be followed by the Owner. As a minimum, the manual will include the following:

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irrigation details: including water application rates and maintenance procedures

(b)

fertilisation: including fertiliser descriptions, application rates and application schedule salinity control: including leaching methods and leaching program monitoring pesticide/fungicide/herbicide procedures, and schedules

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(a)

applications:

including

safety

application

rates,

(e)

turf grass management: including mowing procedures, aerification, topdressing, vertical mowing for thatch removal, rolling, overseeding and sprigging

(f)

propagation and seasonal replacement of all flowers and flowerbeds

(g)

general maintenance: including pruning, stakes and ties, replacement and clean-up, protective fencing and grading

(h)

equipment inventory: maintenance manual

(i)

landscape maintenance personnel requirements and job descriptions.

including

maintenance

procedures

and

manufacturer’s

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Page 7

Job Conditions

1

The Contractor shall proceed with and complete planting operations as rapidly as possible as portions of the Site become available, working within seasonal limitations for each type of landscape work required.

2

No planting shall be carried out during periods of heavy rain, sandstorms, heavy winds, or during intense daytime heat. Plants and trees shall only be moved or planted between midSeptember and mid-May.

3

When special conditions warrant a variance to the planting time and conditions, a proposed planting schedule shall be submitted to the Engineer for review and approval. In such cases, the planting will be installed at no additional cost and all conditions and obligations such as maintenance and warranty remain the same as specified herein.

4

Planting of trees and shrubs will occur prior to lawn plantings.

1.2

SHIPPING, DELIVERY, STORAGE AND HANDLING

1.2.1

Shipping and Delivery

1

Prior to shipping all plants shall be inspected, dug, and made ready for transport in accordance with standard practices and procedures. The Engineer shall inspect all plants at the source prior to delivery to the Site. The Engineer shall be notified of the delivery schedule in advance so the plant material can be inspected upon arrival at the Site. All unacceptable plant material shall be removed from the Site immediately. The Engineer reserves the right to reject any plant material that does not meet the quality requirements of the Project Documentation.

2

The Contractor shall protect plants to prevent damage to the root balls, containers or desiccation of leaves. All plant material shall be delivered in a closed vehicle or in open vehicles with the load properly covered in transit for protection from drying winds.

3

Fertiliser, pesticides, fungicides, chemicals and seed shall be delivered to the Site in the original unopened containers bearing the manufacturer’s guaranteed chemical analysis, name, trade name, or trademark. In lieu of containers, fertiliser’s and seed may be furnished in bulk and a certificate indicating the above information shall accompany each delivery. The fertiliser shall be kept dry and protected from contamination.

4

Palms shall be transported by covered truck. Such transportation shall not exceed 24 hours from time of loading until arrival at the site. The palms shall be transported and handled in the following manner:

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1.1.5

(a)

When the palms are to be shipped, gently place the palm horizontal on a level surface and tighten the wrapping and tying of frond. At least two layers of burlap must be used.

(b)

Wrap the root ball with a minimum of two layers burlap. Saturate with water and cover. Periodically, the burlap must be watered. Do not allow the burlap to dry out at any time.

(c)

Do not damage the growth bud in any manner.

(d)

Do not water the trunk of the palm.

QCS 2014


Page 8

(e)

Do not permit the root ball to become dry.

(f)

Use only sharp tools in cutting and trimming.

(g)

A bed of 150mm of moist organic soil shall be placed on the floor of the truck. The palms shall be hoisted by means of nylon or canvas slings and placed horizontally on the bed of the truck. They shall be laid carefully in an alternating fashion. Moist burlap shall be placed over the roots to keep them moist.

(h)

The entire load shall be covered snugly with two layers of tarpaulin.

(i)

The palms shall be secured in such a manner so as to prevent wind from lifting the tarpaulin and drying the palms.

(j)

The palms shall be unloaded using nylon or canvas slings.

Storage

1

Plants shall be installed as soon as possible after delivery to the Site. Plant material shall be protected from exposure to wind and direct sunlight prior to installation. Plants not installed on the day of arrival shall be stored in shaded areas, protected from the wind and maintained and watered to good horticultural standards until planted. Care shall be taken to ensure that the plants do not dry out. No plant shall be stored on site for more than 3 days prior to planting.

2

Root balled and container grown trees and plants shall be placed close together with root balls covered with approved soil, peat or straw and kept medium moist until planted.

3

Bare rooted trees and shrubs shall be heeled into prepared trenches and covered with agricultural soil or peat and kept medium moist until planted.

4

Seed and fertilizers shall be kept in dry storage away from contaminants in areas as designated or approved by the Engineer. All seed containers shall show clearly the germination and the purity percentages.

5

Soil, compost and other organic materials, fertilisers and other mineral amendments shall be delivered to the Site and stored separately in approved locations and in a manner to avoid contamination and wetting until soil mixing operations commence.

6

Fertilisers, antidessicants, pesticides and other chemicals shall be delivered to the Site in the manufacturer’s unopened containers, each fully labelled, conforming to applicable regulations and bearing the trade name and warranty of the producer. All products if stored by the Contractor on-site shall remain his responsibility.

1.2.3

Handling

1

Care shall be taken to avoid injury to the plants. Plant material shall not be dropped from vehicles. Balled and burlapped plants shall be handled carefully to avoid cracking or breaking the earth ball or damaging any other part of the plant. Container grown plants shall be handled by the container. Plants shall not be handled by the trunk or stem with the exception of large trees and Date Palms to be lifted by crane using purpose made sling and harness..

2

Chemicals shall be stored in a manner to avoid cross contamination. No measuring, mixing or work of any kind shall be permitted within storage area.

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1.2.2

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PRODUCTS

1.3.1

General

1

All plants and turf material will conform to the varieties specified or shown in the Project Documentation and be true to the botanical name as listed in publications.

2

Substitutions shall only be made when a plant (or alternative as specified) is not obtainable and the Engineer authorises a change order providing for use of the nearest equivalent obtainable.

3

Plants shall be supplied from localities similar to the climatic conditions of the Project and be grown in those conditions for 9 months, a minimum of one complete growing season.

1.3.2

Plants

1

Only nursery grown plants shall be provided except for palm species.

2

Plants to be used in the Works shall be well branched and formed planting stock. They shall be sound, vigorous and free from disease, sunscald, windburn, abrasions, harmful insects or eggs, and have a normal healthy, well developed and non-broken root system, evenly distributed through the root ball, free of circulation. Plant structure shall be well balanced, self supporting with unrestricted superstructure and root form.

3

Deciduous and evergreen trees shall be a single trunk with a single leader, unless otherwise indicated, and display no weak crotches.

4

Symmetrically developed trees and shrubs shall be provided with uniform habit and shall be free from objectionable disfigurement.

5

Groundcover and vines shall be provided with the number and length of runners for the size specified.

6

Trees shall be earth balled and burlapped covered or pot grown.

7

Shrubs, vines and ground cover plants shall be provided well established in removable containers or formed homogenous soil sections.

8

Palms shall have straight parallel sides and healthy stems that are not rotted, infected or eaten by pests or with root systems extending above the level which the palm was originally planted. Palms should have vigorous root system, a crown of new leaves, leaves the colour of an adult palm and proper hardiness. Palms shall be balled and burlapped unless container grown palms are available. Off shoots are not acceptable.

9

The digging and lifting of palms shall take place in accordance with the following procedure:

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1.3

(a)

Remove all suckers, all flowering and fruiting parts and approximately 30 % of the fronds

(b)

Trim remaining fronds to 65 % of original length, lift fronds to enclose and protect the growing tip. Wrap in burlap cloth and securely tie in place

(c)

Saturate the entire root ball with water prior to excavation

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Page 10

(d)

Dig with hand tools a vertical sided trench to a minimum depth of 750 mm, cleanly cutting roots no closer than 250 mm from the stem

(e)

Under cut roots and carefully lift tree, avoiding any shock which may damage leaf heart

(f)

Wrap root ball with burlap and secure with wire mesh to contain soil and retain maximum soil moisture.

The minimum acceptable sizes of all plants measured before pruning in normal position shall conform to the measurements specified in the Project Documentation. Plants larger in size than specified may be used with the approval of the Engineer, at no extra cost.

11

Container grown trees, shrubs, groundcover and vines shall have sufficient root growth to hold the earth intact when removed from the containers, but shall not be rootbound. Containers shall be sufficiently rigid to hold ball shape and protect root mass during shipping.

12

A plant schedule is to be provided listing the designated plants and following information:

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Botanical Name

(b)

Common Name

(c)

Quantity

(d)

Size, including height, caliper and root ball

(e)

Condition

(f)

Additional Pertinent Data

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(a)

Plants which are provided in pots or other containers and which have been acclimatised to outside conditions are acceptable provided they are equal in quality to field grown stock and are not root bound. Ground cover plants shall be of the species, sizes, and spacing shown on plant materials schedule, sufficient to cover fully the designated area as shown on drawings.

14

It is the Contractor’s responsibility for potting on plants as required to prevent root binding. The Engineer can reject any plant that is root bound. All costs of potting on will be the Contractors responsibility.

1.3.3

Labels

1

Each plant, or group of plants or container of the same species, variety, and size of plant, shall be legibly tagged with a durable, waterproof and weather resistant label indicating the nursery source, correct plant name and reference number if applicable. Labels shall be securely attached and not removed.

1.3.4

Workmanship / Qualifications

1

The Contractor shall submit samples of materials for approval as per the list below. For standard products, the manufacturer’s analysis will be acceptable. For all other materials, analysis is to be provided by recognized laboratories.

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(a)

Soil Mix

(b)

coco peat or equivalent organic materials such as recycled peat moss.

QCS 2014


(c)

Fertilizer

(d)

Organic Manure

(e)

Soil Conditioner

(f)

Pesticides

(g)

Gravel Mulch

(h)

Wood Mulch

(i)

Pruning Paint

(j)

Gypsum Paint

(k)

Wood Stakes

Page 11

Soil samples will be taken by the Engineer upon his request and at random time and location, samples will be tested at a certified soil lab at the Contractor’s expense.

3

Sampling and testing shall be the responsibility of the Contractor and shall be performed at no additional cost to the Client, by an approved commercial testing laboratory.

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2

Tests shall be performed in sufficient number to ensure that the materials meet the specified requirements.

(b)

Copies of the test results shall be furnished to the Engineer for approval.

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(a)

Soil Preparation

1

Soil preparation materials and products shall conform to the description herein after.

2

Soil: soil is composed of a mixture of sand and clay. Sand is dune sand from Government approved site. Clay is from Government approved site.

3

Drainage Stone: Crushed hard durable stone washed free of loam, sand, clay, and other foreign substances and evenly graded from 20 mm minimum to 30 mm maximum size.

4

Stone Mulch: washed white stone pebbles, washed free of loam, sand, clay, and other foreign substance, evenly graded 25 to 50 mm.

5

Wood Bark Mulch: coniferous wood bark, free of disease and pests, not shredded, min. 10 mm x 50 mm pieces with a pH of 4.5 as minimum.

6

Permeable Membrane: non-woven, 70% polypropylene, 0.3 mm thick, weighing 70 g/m , 2 with permeability to water of 80 litres/m /sec at 100 mm head of water. Membrane is to be resistant to all naturally occurring soil acidities and to tearing and stress and is to remain unaffected by direct sunlight for up to one month.

7

Nursery: shall be Qatari based company of proven experience, specializing in growing and cultivating plants as listed in this specification.

1.3.6

Subsoil Preparation

1

The Contractor shall excavate and Provide Earth filling as necessary to achieve the subsoil levels and profiles required.

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1.3.5

2

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Break up soil for a depth of 300 mm and grade to levels and profiles shown on drawings in order to achieve tolerances specified for the finished level of topsoil.

3

Where the topsoil is to be laid on rock sub-strata, break up and loosen the rock surface for a minimum depth of 300 mm.

4

Root Barrier (Root control system), as per the details drawings,.

5

is to line the tree pits or trenches, over or beside service pipes and hard landscape structures such as sidewalks, pavements, and concrete building foundations to prevent structural damage due to root penetration or heaving

1.3.7

Spreading and Preparation of Topsoil

1

Topsoil Filling: spread over prepared subsoil in layers not exceeding 200 mm and firm gently each layer by watering lightly before spreading the next.

2

Final Grading: Drawings.

3

Finished Levels: unless otherwise stated, finished levels of topsoil after settlement to be 70 mm below adjacent paving or curbs not less than 150 mm below finished ground floor slab level of adjoining buildings married-in with adjoining soil areas

4

Fallow Period: where possible carry out cultivation of topsoil sufficiently early for it to lie fallow for several months. During this period, prevent growth and seeding of weeds by further cultivation or by application of herbicides if permitted.

1.3.8

Soil Specification

1

The contractor shall be responsible for the procurement, transportation, mixing, placing, mounding and finished grading. The specified mix shall be strictly controlled over all the grading work.

2

Soil mix shall consist of a mix of dune sand, clay and approved organic materials with the following proportion:

3

75% sand, 20% clay, 5% organic materials for all plants in parks, roads and open areas.

4

100% sand for grass in sports fields.

5

Dune Sand: shall be suitable for inclusion into the soil mix and free from excessive salts, weeds, stones or other foreign matter taken from a maximum depth of 500 mm having removed surface crust and gypsoferrous accumulations.

6

Dune sand shall be obtained from an approved source. Irrigate at maximum rate for two days before planting to wash salt from the sand.

7

Dune sand shall possess the following physical and chemical characteristics.

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when topsoil is reasonably dry and workable, grade to levels shown on

(a)

Physical Characteristics (Table 1):

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Table 1: Dune Sand Grading Criteria Sieve Size

% of Material Passing

No 10 sieve

100%

No 35 sieve

85 to 100%

No 140 sieve

5 to 25%

No 200 sieve

0 to 10%

Loamy sand, clay to be less than 0.002 mm

(c)

Chemical Characteristics: Salinity (ECE x 1000):

less than 4

(ii)

SAR (Sodium Absorption Ratio):

less than 2

(iii)

Boron (saturation extract):

less than 1.0 ppm

(iv)

pH:

between 6.0 – 7.5

(v)

Free carbonates:

less than 0.5% air dried soil

(vi)

Chlorides:

less than 200 ppm in saturation extract

(vii)

Sulphates:

less than 15% in neutral saturation extract

(viii)

Nitrates:

(ix)

Phosphorous:

(x)

Exchangeable sodium:

less than 15% in neutral normal ammonium acetate

(xi)

Potassium:

100 – 400 ppm in 1.5 ammonium nitrate extract (½ hour shake)

(xii)

Magnesium:

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less than 75 ppm in saturation extract

Clay shall be obtained from an approved source.

9

Clay shall have uniform composition and structure, a lean clay character, and be free from roots, stones, clods larger than 50 mm in greatest dimension, pockets of coarse, sand, noxious weeds, sticks and other litter. It shall not be infected with nematodes or other undesirable insects and plant disease organisms. Prior to mixing all lumps shall be thoroughly broken up.

1.3.9

Alternative Soil Specification

1

Alternatively (to Clause 1.3.8) soil shall be sweet sand free of admixtures of subsoil, foreign matter, toxic substances, weeds and any material or substance that may be harmful to plant growth upon the Engineer’s approval.

2

The Contractor shall furnish agricultural soil from approved sites.

3

Material shall be stored in piles less than 1 metre high. Piles shall be protected from undue compaction and maintained free of contamination and construction debris.

4

The soil shall comply with the following chemical criteria:

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(a)

pH value:

not less than 6.5 nor more than 8.5

(b)

electro-conductivity:

(c)

free carbonates: less than 0.5 % air dried.

(d)

chlorides:

less than 200 ppm in saturated extract.

(e)

sulphates:

less than 200 ppm in saturated extract.

(f)

exchangeable sodium: less than 15 % in neutral normal ammonium acetate.

(g)

boron: less than 1.5 ppm, hot water soluble.

less than 4 mm mhos/cm saturated extract at 25oC

The soil shall comply with the grading criteria in Table 2.

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Table 2 Grading Criteria % by Mass Passing

5.000

100

2.380

65 to 100

1.180

45 to 100

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0.150

35 to 80

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0.600 0.300

5 to 48 0 to 15 0 to 3

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0.075

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Sieve Size (mm)

Soil Additives – Procedure A

1

There are two applicable procedure, contractors shall follow EITHER procedure (A) OR procedure (B).

2

Procedure A Consists of the following components:

3

Composted organic waste shall be a recycled waste product such as cocopeat, or a fully natural authority approved composted product shredded and granulated to pass through a 12 mm mesh screen and conditioned in storage piles for at least 6 months. The compost shall be free from sticks, stones, roots, and other objectionable matter. It shall have a pH value of not less than 7 and nor more than 7.5. The minimum organic content shall be 85% on a dry weight basis. Compost shall be delivered in undamaged recyclable bags in air dry condition.

4

Manure shall be pasteurized dried pelletized sewage sludge or decomposed animal manure of fully fermented pre-dried, sheep, horses, goat, cow or chicken manure with nitrogen, phosphoric acid and potassium and a pH value of 6.0 to 7.5. Manure shall be free of stones, sticks and non-biodegradable material. Manure shall be heat treated, free from pathogen, weeds and other pollutant. A health certificate shall be submitted for the proposed sample. Animal manure shall not be used for top dressing of grass area.

5

Vermiculite shall be horticultural grade and free of any toxic material and conform to ASTM C516.

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1.3.10

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Perlite shall conform to ASTM C549.

7

Natural zeolite products

8

Fertilizer shall be commercial grade and uniform in composition. Fertilizer shall be of slow release 2 month minimum and shall bear the manufacturer’s guaranteed statement of analysis.

9

Granular fertilizer for trees, shrubs, ground covers and seasonal shall consist of, percentage by weight, 5 % nitrogen (N), 10 % available phosphoric acid (P) and 5 % potassium (K). For grass use minimum 11 % nitrogen (N), 11 % available phosphoric acid (P) and11 % potassium and micro nutrients.

10

Plant derived fertilizers: shall be used in all soil mix as alternative option to animal manure. It shall be heat treated, free from seeds and nematodes and possess the following characteristics. Organic content: more than 70%

(b)

C:N ratio more than 20%

(c)

Particle size not bigger than 2 mm for 80% of the mix

(d)

Humic Acid more than 10%

(e)

pH 5-6.

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Dry Plant Fertilizers shall have following properties: Fertiliser shall be commercial grade and uniform in composition.

(b)

Packets of slow release fertiliser shall bear the manufacturer’s guaranteed statement of analysis.

(c)

Granular fertiliser for trees and shrubs shall consist of, by percentage by weight, 5 % nitrogen (N), 10 % available phosphoric acid (P) and 5 % potassium (K).

(d)

Controlled release fertiliser shall consist of, by percentage by weight, 5 % nitrogen (N), 10 % available phosphoric acid (P) and 5 % potassium (K). Control released fertiliser may be in packet or tablet form.

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Turf Fertilizer shall be commercial grade, free flowing and uniform in composition and bear the manufacturer’s guaranteed statement of analysis.

13

Edging Material shall be galvanized steel, polyethylene, electrostatically painted aluminium or other as approved by the Engineer. The material shall be to the sizes designated in the drawings. Edging anchors shall be as recommend by the manufacturer.

14

Irrigation Water shall be provided by the Contractor from an off-site source approved by the Engineer as being suitable for irrigation. Water shall be free from substances harmful to plant life. Water sources shall not exceed the following parameters: (a)

pH: 6 to 7

(b)

total dissolved solids: less than 1000 ppm

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Soil Additive - Procedure B

1

There are two applicable procedure, contractors shall follow EITHER procedure (A) OR procedure (B).

2

Procedure B Consists of the following components:

3

Manure: shall be the decomposed animal manure, pasteurized dried pelletized sewage sludge or fully fermented pre-dried heat treated sheep, horses, goat, cow or chicken manure with nitrogen, phosphoric acid and potassium and a pH value of 6.0 to 7.5. Manure shall be free of stones, sticks and non-biodegradable material. Manure shall be heat treated, free from pathogen, weeds and other pollutant. A health certificate shall be submitted for the proposed sample. Animal manure shall not be used on the top dressing of grass area.

4

Soil conditioner: shall be as detailed in the following paragraphs.

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Soil conditioner shall be added with the organic manure only, it must meet the requirements below (Table 3).

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1.3.11

Organic or other composted waste

Palms

As per manufacturer recommendations

5% soil volume

Trees


Shrubs Large


Organic Fertilizer

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Table 3: Soil Additives Proportion for Plants

or Plant

Inorganic Fertilizer

Mixing Depth

25 kg/Tree

5 Kg/Tree

100 g/Tree

40 cm

5% soil volume

12.5 kg/Tree

5 Kg/Tree

50 g/Tree

40 cm

5% soil volume

7 kg/Shrub

1 Kg/Shrub

25 g/Shrub

30 cm


5% soil volume

5 kg/Shrub 0.5 Kg/Shrub

Hedges


5% soil volume

5 kg/linear m

Ground Cover & Seasonal


5% soil volume

5 kg/m

2

0.5 kg/m

Lawn


5% soil volume

5 kg/m

2

1 kg/m

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(b)

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25 g/m

2

30 cm

0.5 kg/linear 25 g/ linear m 20 cm m

2

2

25 g/m

2

20 cm

50 g/m

2

20 cm

Materials supplied shall NOT be any of the following: (i)

classified as hazardous according to National Occupational Health & Safety Commission, Australia (NOHSC) criteria or equivalent

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(ii)

classified as a dangerous good by the criteria of the Australian Dangerous Goods (ADG code) or equivalent

(iii)

classified as a dangerous good for transport by Australian Code for the Transport of Dangerous goods by Road and Rail or equivalent

(iv)

flammable or explosive

(v)

poisonous or allocated a poison schedule number by Standard for the Uniform Scheduling of Drugs and Poisons (SUSDP) or equivalent

Composition / Information on ingredients: The materials used in the production process must be derived from naturally occurring and sustainable sources and are consistent with organic principals. It shall NOT contain synthetic chemicals, animal components, animal by-products, manure or manure by-products. It must be environmentally safe and is not harmful to animals, plants or humans and shall not contain chemicals or genetically modified materials.

(d)

Accidental Release Measures and Spillage: The soil conditioner must have moisture content above 32%. Ventilate spillage area. Collect and place in sealable containers for disposal. Avoid generating dust.

(e)

Handling and storage

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(c)

Handling: Before use contractors shall carefully read the product label. Use of safe work practices are recommended to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating. Prohibit eating, drinking and smoking in contaminated areas.

(ii)

Storage: Store in well-ventilated area, removed from oxidising agents and heat sources. Ensure containers are adequately labelled, protected from physical damage and sealed when not in use. Check regularly for leaks or spills.

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The Contractor shall ensure the safety of the workers and the environment at all times

(g)

Fertilizers/plant nutrients must be beneficial to plants at low levels, not in high levels which might cause reducing growth or burns in sensitive species. Excess shall be washed through soil to waterways. Contractors shall minimize Fertilizers released to waterways which might cause algal blooms, with potential for toxic effects on aquatic organisms.

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(f)

(h)

(i)

Disposal Considerations (i)

Waste Disposal: Reuse or recycle where possible. Alternatively, ensure material is covered with moist soil to prevent dust generation and dispose of to an approved landfill site.

(ii)

Legislation: Dispose of in accordance with Qatari local legislation.

Material shall contain only chemicals listed on the Australian Inventory of Chemical Substances (AICS) or equivalent.

1.3.12

Alternative Soil Additive Specifications

1

Should the Engineer decide on an alternative soil Additive (to Clause 1.3.11), the Contractor may use the specification listed below hereinafter.

2

Preamble

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The following is a specification for composted products suitable for use as a soil amelioration agent. Hereinafter described as “the composted product.”

4

Definition

5

“HACCP” – Hazard Analysis and Critical Control Points is a method that addresses physical, chemical and biological controls as a means of prevention rather than inspection of finished product inspection.

6

Supply Conditions All products supplied shall conform fully, to the standards indicated herein or to an equivalent standard subject to the agreement of the Supervising Officer (SO).

(b)

It is noted that the composted products may vary, (within acceptable limits) to the physical and chemical parameters stated within this specification. Such variations must not compromise the agronomic characteristics of the product and where variations in analysis occur the supervising officer must be informed prior to placement of the product.

(c)

The contractor shall demonstrate to the supervising officer that the manufacturers (“The Suppliers”) of the composted product have HACCP accreditation or equivalent with the agreement of the supervising officer. Where HACCP accreditation is not in place documentation of a site based product management plan that demonstrates the principles of HACCP is necessary.

(d)

The contractor shall supply appropriate production and sampling documentation from the supplier that shall clearly indicate that the product conforms to the composted specification.

(e)

The supervising officer may reject any product or batch that (on the basis of analysis and documentation) is deemed not to conform to standards specified herein. On this basis the Contractor must submit all documentation 10 (ten) working days prior to placement to allow for interpretation of the analyses and for approval of placement to be granted or with-held as appropriate.

(f)

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The whole quantity required to complete the project must be of the same type, manufacture and/or source. No change of source will be permitted without approval. As such written evidence of the source of the compost must be supplied when requested by the supervising officer.

1.3.13

Compost Specifications

1

All composted products must conform to the minimum requirements specified in Tables 4 and 5. The particle size distribution grades of the composted product must meet the criteria for a top-dressing product (Table 5, as specified in AS 4419 soils for landscaping and garden use).

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Table 4: Contaminant acceptance concentration limits, Sludge Quality for Land Application / composted soil conditioners (Exceptional Quality USEPA Part 503 / EC Directive 86/278/EEC / NSW EPA/ GCC Fertilizer Law 2006). maximum concentration mg/kg

Organic chemical contaminant

maximum concentration mg/kg

Arsenic Cadmium Chromium (total) Copper Lead Mercury Nickel Selenium Zinc

10 20 300 1000 300 10 200 50 2500

DDT/DDD/DDE Aldrin Dieldrin Chlordane Heptachlor HCB Lindane BHC PCBs

0.5 0.02 0.02 0.02 0.02 0.02 0.02 0.02 not detectable

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Heavy Metal contaminant

As a minimum requirement, all composted products to be used as a soil conditioner must meet the temperature, time and turning frequency as specified by the USEPA standard for pathogen disinfection and vector reduction.

3

Pathogen disinfections and weed seed reduction shall be achieved by the aerobic, thermophilic decomposition of organic matter which produces a humus-like material. Using o the windrow composting method, the temperature of the windrow is maintained at 55 C o (131 F) or higher for 15 consecutive days or longer. During the period when the compost is o o maintained at 55 C (131 F) or higher, there shall be a minimum of 5 turnings of the windrow (USEPA).

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Table 5: Chemical testing results required for the < 2mm fines of a composted soil conditioner to verify the suitability of the soil conditioning properties of the composted product for Qatar. Test Method

Parameter Requirements

Top Dressing AS 4419

<2% by wt > 5mm, <15% by wt pass a 5 mm sieve but not a 2 mm sieve

Heavy metal and organic chemical contaminants

NSW EPA - threshold levels for grade A Biosolids

Refer Table 4

pH

1:5 soil water extract#

5.5 to 8.5

Electrical Conductivity

1:5 soil water extract#

< 2.5 dS/m

Wettability

Appendix C AS 3743

< 2 minutes

Total water holding capacity

Appendix B AS 3743

> 40%

Chloride

*1:5 soil water extract

< 600 mg/kg

% organic carbon

*Dichromate wet oxidation

>15% by mass

Effective Cation Exchange

*1 M ammonium chloride pH7, no

> 40 meq/100g

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Compost Parameter

Test Method

Parameter Requirements

Capacity (ECEC)

pretreatment for salts

Exchangeable sodium % (from exchangeable cations)

*1 M ammonium chloride pH7, no pretreatment for salts

As received moisture content

*Oven-dry 105 C basis

º

< 15% < 40% by mass

Methods indicated by a hatch (#) and the parameter requirements are based on the Australian Standard AS 4419 - soils for landscaping and garden use.

.

Reference to AS 3743 - potting mixes indicates that the method and the parameter requirements are based on this australian standard (AS 3743).

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Methods preceded by an asterisk (*) are internationally recognised for testing the chemical properties of soil, and are described in the text Rayment and Higginson (1992), Australian Laboratory Handbook of soil and water chemical methods.

Contamination of the compost may occur due to poor source separation as with municipal green-waste and/or through poor control in turning and loading during production. These indicate poor composting practice and procedure. As such, any batches found to contain deleterious material (for example soil, sharps such as glass or metal, contaminants such as plastic or stones) will be rejected by the supervising officer.

5

In addition, the fines of the compost (<10 mm particle size) shall be analyzed for chemical and organic contaminants, to verify compliance with appropriate threshold levels (Table 4 and Table 5) for minimizing the contamination of soils with potentially hazardous substances (e.g. NSW EPA - threshold levels for grade A biosolids). Where a case can be made that higher concentrations of trace elements such as copper and zinc may be beneficial, limits of 1,500 mg/kg and 2,800 mg/kg may be accepted (Kirchhoff et al 2003). No detectable PCB compounds are permitted, at a 0.2 mg per kg detection limit.

6

Attributes of the Compost shall be appropriate for use as a soil conditioner in the sandy soils of Qatar, the composted product must be verified as possessing the following attributes: a high total water holding capacity to function in part as a replacement for sphagnum peat

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(b)

a high cation exchange capacity (nutrient holding capacity of the soil), to function in part as a replacement for sphagnum peat

(c)

a low chloride ion concentration and a low exchangeable sodium percentage to minimize the salt concentration in the rooting zone, and

(d)

a high proportion of the nitrogen and phosphorus fertilizer value of the product to be in the slow-release organic form, to reduce the risk of leaching nutrients into the groundwater

Application rates shall be as follows: (a)

The composted product will be incorporated into a soil to improve its physical and chemical properties at rates determined by the site, planting and soil parameters.

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Composted products verifying compliance with Tables 4 and 5 are considered suitable for application to soils in Qatar as a soil conditioner. The preferred mode of application is incorporation into the soil, to a depth of 20 cm. However, after a routine cultivation maintenance operation such as plugging in turf, a composted soil conditioner may be applied to the surface of the soil as a top-dressing.

(c)

The rate of application to soil of a composted soil conditioner shall be based on the fertilizer equivalence of the product. For chemical testing (refer to Table 5), the composite sample shall be screened through a sieve with an aperture size of 2 mm with the particles retained on the sieve excluded from the analysis. A bulk density test shall be undertaken on the compost (refer to the method in Appendix B of AS 4419), to enable the calculation of fertilizer equivalence on a mass basis, to a volumetric basis for ease of application.

(d)

The maximum application rate permitted for incorporation into a soil shall be based on the results of chemical testing of the receiving soil.

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(b)

The contractor shall ensure that the supplier takes from each separate batch, at least x10 random samples each having a volume of not less than 200ml that are blended to produce a composite sample of not less than 2 ltr (Appendix A AS 4419). Where necessary, the compost sample shall be air dried overnight (room temperature less than 35°C) to facilitate sieving. The size of a batch will be determined in accordance with the HACCP procedures

9

Internationally accepted testing methods must be applied to the compost samples and a certificate of analysis supplied with each compost consignment or as requested by the supervising officer.

1.3.14

Contractor’s Responsibilities

1

The contractor shall verify that the compost has been produced according to a HACCPbased site and product management plan, and that production temperature and turning records comply with the USEPA pathogen disinfection and vector reduction requirements of the relevant sections of the specification.

2

The contractor shall use the results of the chemical tests listed in Table 4 and Table 5, to calculate the plant-available (immediate fertilizer) and slow-release fertilizer equivalence of each specific batch of compost intended for use as a soil conditioner. The results shall be expressed on the oven-dry mass basis of the <2mm particle size grade.

3

The contractor shall also calculate the maximum (field weight basis) application of the composted soil conditioner on the fertilizer (plant-available) equivalence of the least limiting major nutrient (most commonly phosphorus or potassium) in the compost, and the annual fertilizer application recommendations for the receiving soil.

4

The contractor shall ensure that the supplier has provides all documentation to the Contractor as required by same – this shall include: HACCP (or equivalent) certification; temperature and turning records of the material; physical and chemical testing results for each batch of compost supplied.

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The Supervising Officer’s Responsibilities

1

The supervising officer (Engineer) shall ensure that the appropriate documentation is in place in accordance with the specification. Adjust all other inorganic fertilizer application rates to account for the fertilizer equivalence of the applied compost (eg sewage sludge pellets). Accounting for the fertilizer contribution of the compost in the fertilizer management regime is necessary, to avoid causing nutrient imbalance or nutrient excess in the rooting zone. Nutrient imbalance and/or excess are known to increase the severity of root disease.

1.3.16

Chemical Testing for Fertiliser Equivalence of the Compost

1

Chemical testing for results required to determine the fertiliser equivalence of the compost shall be as described herein.

2

The following methods have been selected as the most suitable for testing of minerals contained within an organic matrix. Subtracting the fertilizer value of the nutrient from the total value indicates the slow-release (organic) nutrient pool. In the case of nitrogen, subtracting the ammonium concentration (Table 6) from the total kjeldahl nitrogen value will indicate the slow-release (organic) nutrient pool. Potassium is a component of the cell sap in organic materials, with very little locked up in the organic (slow-release) form. The as received moisture content is required to enable calculations of the oven-dry application rates to be adjusted for the field moisture content of the product.

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1.3.15

Test Method

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Compost Parameter

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Table 6: Chemical testing results required to determine the fertiliser equivalence of the compost.

Bicarbonate extractable P

9B

Total phosphorus

X-ray fluorescence or sodium carbonate fusion

9A

Fertilizer potassium

Bicarbonate extractable P

18A1

Nitrate nitrogen

In the presence of nitrite

7C1b

Total nitrogen

Kjeldahl

Exchangeable Cations

From ECEC in Table 4 & 5

15A1

As received moisture content

From Table 4 & 5

2B1

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Fertilizer phosphorus

Reference in Rayment & Higgins on

7A

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Planting Soil Mixture

1

The planting soil mixture for shall consist of approved soil, cocopeat or recycled organic compost,, manure, pasteurized pelletized sludge and other soil conditioners as specified in the Project Documentation.

2

The mixture shall be placed in accordance with the requirements of the trees, shrubs or grass to be planted.

1.3.18

Planting Soil Mixture (Sweet Soil)

1

The planting soil mixture shall consist of approved soil (sand and clay), cocopeat,; approved organic compost; pasteurized pelletized sludge; organic and inorganic fertilizer. Peat is not to be used without manufacturer’s certification confirming that it is a recycled product.

2

The mixture shall be placed in accordance with the requirements of the trees, shrubs or grass to be planted as per Table 3 (Soil Additives Proportion for Plants).

3

Soil additives: Shall be added as per Table 3 (Soil Additives Proportion for Plants).

4

Peat and compost or soil conditioner shall be added for palms earlier than 4 months after planting, subject to the Engineer approval.

5

Provide analysis of soil mixture from samples approved by the Engineer.

1.3.19

Dry Plant Fertiliser

1

Fertiliser shall be commercial grade and uniform in composition.

2

Packets of slow release fertiliser shall bear the manufacturer’s guaranteed statement of analysis.

3

Granular fertiliser for trees and shrubs shall consist of, by percentage by weight, 5 % nitrogen (N), 10 % available phosphoric acid (P) and 5 % potassium (K).

4

Controlled release fertiliser shall consist of, by percentage by weight, 5 % nitrogen (N), 10 % available phosphoric acid (P) and 5 % potassium (K). Control released fertiliser may be in packet or tablet form.

1.3.20

Turf Fertiliser

1

Fertiliser shall be commercial grade, free flowing and uniform in composition and bear the manufacturer’s guaranteed statement of analysis.

1.3.21

Mulch

1

Mulch shall be free of weeds, sticks and other deleterious material.

2

Inert mulch material shall be crusher run rock, granite chips, marble chips or other suitable material approved by the Engineer.

3

Organic mulch material shall be coco bean shell, shredded bark or other suitable recycled organic material approved by the Engineer.

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1.3.17

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Guys and Stakes

1

Stakes for tree support shall be rough sawn wood, free from knots, rot, cross grain, or other defects that impair the strength. Stakes shall be treated with pentachlorophenol or other approved non-injurious green preservative.

2

Bracing stakes shall be a minimum of 50 mm by 50 mm by 2,400 mm long and pointed at one end.

3

Ground stakes shall be a minimum of 50 mm by 50 mm by 900 mm long and pointed at one end.

4

Guying wire shall be 2.7 mm annealed galvanized steel wire.

5

Guying cable shall be a minimum of five strand, 2.76 mm diameter cadmium plated steel cable.

6

Hose chafing guards shall be new 2-ply reinforced rubber or plastic hose and shall be of the same colour for the entire Project. The length of hose chafing guards shall be 1½ times the circumference of the plant at its base.

7

Flags shall be fastened to the guys and be white surveyor’s tape.

1.3.23

Edging Material

1

Edging material shall be galvanized steel, polyethylene, electrostatically painted aluminium or other as approved by the Engineer. The material shall be to the sizes designated in the drawings. Edging anchors shall be as recommend by the manufacturer.

1.3.24

Irrigation Water

1

Irrigation water shall be provided by the Contractor from an off-site source approved by the Engineer as being suitable for irrigation. Water shall be free from substances harmful to plant life. Water sources shall not exceed the following parameters: pH : 6 to 7

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(a)

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1.3.22

(b)

total dissolved solids : less than 1000 ppm

1.4

SITE PREPARATION FOR PLANTING AREAS

1.4.1


1

The contractor shall examine areas to receive landscaping for compliance with requirements and conditions affecting performance of work in this section. The contractor shall not proceed with plant operations until unsatisfactory conditions are discussed with the engineer and corrected.

2

The contractor shall determine the location of above grade and underground utilities and perform work in a manner which will avoid damage to them. Damage to underground utilities shall be repaired at the contractor’s expense.

3

When conditions detrimental to plant growth are encountered, such as rubble, adverse drainage or obstructions, The Contractor shall notify the Engineer prior to planting.

QCS 2014


Page 25

The Engineer shall verify that sub-grades are as indicated in the project documentation.

5

Grade stakes shall be maintained until removal of them is mutually agreed upon by all parties concerned.

6

When grades are encountered that are detrimental to finished grading and planting operations, the contractor shall notify the Engineer prior to planting.

1.4.2

Sub-Surface Grading

1

All perennial weeds shall be treated with an approved herbicide and the period of time recommended by the manufacturer shall be allowed to elapse prior to commencing grading operations

2

Grading operations shall occur when the sub-soil is reasonably dry and workable.

3

Areas to be graded shall be shaped to smooth flowing contours with all minor hollows and ridges removed. Rock projections and boulders shall be removed and disposed of at a location as agreed with the Engineer.

4

Non-cohesive, light subsoil shall be loosened with a 3-tine ripper to a depth of 300 mm at 600 mm centres. Limestone and other cohesive substrate shall be loosened with a single tine ripper to a depth of 450 mm at 1 m centres.

5

A minimum of 150 mm of approved soil shall be spread uniformly over the loosened area and incorporated into the sub-grade soil to obtain a uniform and well pulverised soil mix.

6

The area shall be compacted to a minimum of 90% of maximum dry density as determined in accordance with test 13 of BS 1377.

1.4.3

Finished Grading

1

Grades shall be brought to the finished ground levels as indicated on the project drawings or as agreed with the Engineer to a tolerance of ± 25 mm. finished ground levels shall be 30 mm below adjoining paving or kerbs after compaction and settlement. Grading shall be carried out in such a manner that even gradients are formed between the spot levels indicated on the project drawings. No depressions shall remain which could collect standing water.

2

Soil shall be placed in lifts not greater than 150 mm in thickness.

3

The filled area shall be compacted to a minimum of 90% of maximum density as determined in accordance with test 13 of BS 1377.

1.4.4

Planting Operations and Layout

1

Plant material locations and planting bed outlines shall be staked two (2) days before any excavations are made.

2

The Contractor shall notify the Engineer two (2) days before the start of planting operations.

3

Plant locations may be adjusted by the Engineer to meet site conditions.

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QCS 2014


Page 26

Protection of Existing Vegetation

1

Grassed areas that have been established prior to planting operations shall be covered before any excavations are made in a manner that will afford adequate projection.

2

Existing shrubs, trees and groundcover shall be barricaded in a manner to protect them during planting operations and they shall be maintained with adequate irrigation to ensure their survival.

1.5

PLANTING

1.5.1

Plant Pits

1

Plant pits shall be dug to produce vertical sides and flat uncompacted bottoms. Excavated material shall be disposed of in a proper manner. If approved by the Engineer, excavated material may be used as fill in areas where fill material is required.

2

Upon completion of excavation, the pit shall be filled with water and then left to thoroughly drain prior to setting plants.

3

Excavate and provide earth filling as necessary to achieve the subsoil levels and profiles required. Depths of excavation shown below are from finished top soil level.

4

Minimum acceptable pit sizes shall be as shown in Table 7.

as

qa

ta

rw

.l. l

.

1.4.5

se

Table 7: Plant Pit Size Schedule

er

Item

ov

Palm Trees for Ashghal projects Palm Trees for other projects

et it

Large Shrub

o

Ornamental Trees

Small Shrub

m

Hedges

Ground cover, seasonal flowers and turfed areas Grass

Pit Size 2000 x 2000 x 2000 mm 2000 x 2000 x 2000 1500 x 1500 x 1500 mm 1000 x 1000 x 1000 mm 600 mm 600 mm width and 600 mm depth 500 mm depth 400 mm depth with proper drainage if ground below is impermeable

5

Break up bottom of pits to a depth of 300mm for trees and palms and 400mm for shrubs and ground cover.

6

Ensure planting areas and tree pits are well drained.

1.5.2

Backfill Mixture

1

The backfill mixture shall be apportioned by volume and shall be made from a mixture of agricultural soil and selected soil amendments as detailed in Table 8

QCS 2014


Page 27

Table 8: Mix Proportions Item

Backfill Component

Mix Proportion

Trees

Soil Cocopeat or compost clay or other approved mineral general Fertiliser

80 % of mixture 5 % of mixture

Soil Cocopeat or compost Manure General Fertiliser


Soil Cocopeat or compost Manure General Fertiliser


. .l. l

rw

10 % of mixture 50 g per pit

qa

Shrubs

35 g per pit

ta

Palms

15 % of mixture

as

Soil Cocopeat or Compost Manure General Fertiliser

85 % of mixture. 10 % of mixture. 5 % of mixture. 25 g per pit

ov

er

se

Groundcover and Vines

5 % of mixture 30g per pit

Installation for Trees and Shrubs

1

Plants shall be handled carefully and arranged so they take full advantage of the individual character of each plant in relationship to other plants.

2

Plants shall place in the centre of each pit, set plumb and held in place until sufficient backfill mixture has been firmly placed around the root ball. Plants shall be placed so that the level at which they were set with respect to surrounding ground level before installation is the same as after installation.

3

Ball and burlap plants shall have twine, metal, plastic and wire ties removed from the tops of the earth ball after backfill soil has been placed to approximately two thirds of the ball depth, tamped lightly and watered. Backfilling around plant shall be completed in 150 mm layers after water has drained away. Burlap wrapping shall not be pulled out from under the earth ball.

4

Plants supplied in non-biodegradable containers shall be removed in such a way as to prevent damage to plant or root system. Before planting, any damaged or broken roots shall be carefully trimmed and removed. Plants in biodegradable of organic containers may be installed with the container in place.

5

A 150 mm high earth saucer shall be formed around individual plants. The diameter of the saucer should be larger than and outside the backfilled area.

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QCS 2014


Page 28

After planting, plants shall be guyed or staked as required or directed by the Engineer. Trees and shrubs shall be protected against wind and sun with burlap wrapping where necessary or directed to ensure satisfactory establishment of plant.

7

Trees 1.2 to 1.8 m tall shall be held in place with one (1) bracing stake. The stake shall be positioned close to the tree on the windward side. The stake shall be driven vertically into firm ground taking care not to injure the roots. The tree shall be held firmly to the stake with a double strand of wire placed 1m above ground level. A chafing guard shall be used were the wire is in contact with the tree.

8

Trees 1.8 to 2.5 m tall shall be held in place with two (2) bracing stakes placed on opposite sides. The stake shall be driven vertically into firm ground taking care not to injure the roots. The tree shall be shall be held firmly in place with a double stand of wire placed 1m above ground level and chafing guards shall be used where the wire is in contact with the tree.

9

Trees taller than 2.5 m shall be held firmly in place with three (3) guying lines of double strand wire placed equidistantly around the tree. The wire shall be anchored with ground stakes driven into firm ground outside the earth saucer. The wire shall be anchored to the tree at a point 1m above ground level. a flag shall be securely fastened to each guying wire.

1.5.4

Installation of Palms

1

Palms shall be lifted and moved with a crane and purpose made sling with harness or other approved method to avoid any damage to any part of the palm.

2

Palms shall be placed in the centre of each pit, set plumb and held in place until sufficient backfill mixture has been firmly placed around the root ball. The top of the root ball should be 100 mm below the top of the planting pit. The pit shall be backfilled with specified mixture to approximately two thirds of depth of the root ball, tamped lightly and watered. Backfilling around plant shall be completed in 150 mm layers after water has drained away. A 100 to 150 mm high earth saucer shall be formed around the palm. The diameter of the saucer should be larger than and outside the backfilled area.

1.5.5

Cultivation of Turf Areas

1

After the areas required to be turfed have been brought to the specified levels, fertiliser shall be applied at the rate recommended by the manufacturers. Soil conditioners shall be spread uniformly over the soil. The soil shall be raked to a true and even surface. All stones of greater than 25 mm diameter are to be removed.

1.5.6

Seeding

1

Seed shall be spread over a fine levelled, cultivated soil bed by hand or mechanical seeder. Half of the specified rate applied twice in perpendicular directions so as to achieve an even seed distribution rate.

2

Following seeding, the bed shall be raked, harrowed or gilled to cover the seed with soil to a maximum depth of 25 mm.

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QCS 2014


Page 29

Cut straw or other fibrous mulch shall be applied over seeded areas to protect from direct sun exposure and blowing winds. Whenever necessary, mulch shall be covered with jute netting to hold the mulch in place. The netting shall not be removed until directed by the Engineer.

4

The perimeter of seeded area shall be flagged off to restrain foot traffic until after the second mowing following complete grass coverage or as directed by the Engineer.

5

Water shall be applied lightly and frequently until one week after 50 % germination and then gradually increase duration and period between watering until normal irrigation programme is met.

1.5.7

Sprigging

1

Sprigs shall be broadcast uniformly by hand, with mechanical equipment or other approved method. The maximum planting spacing between viable sprigs shall be 300 mm. sprigs shall be forced into the prepared soil to a minimum of 25 mm by hand, disk-rolling or other approved method.

2

Immediately after completion of the sprigging operation the entire area shall be firmed with a roller not exceeding 135 kg for each metre of roller width. The planted area shall have a smooth uniformed finish without depressions or ridges.

3

The perimeter of the sprigged area shall be flagged off to restrain foot traffic until after the second mowing following complete grass coverage or as directed by the Engineer.

4

Watering shall be started immediately after completing each day of sprigging. Water shall be applied at a rate sufficient to ensure moist soil conditions to a minimum depth of 70 mm. Watering shall continue until majority of sprigs can sustain themselves on the normal irrigation programme. Run-off and puddling shall be prevented.

1.5.8

Turfing

1

Turfing shall be laid on cultivated soil within 24 hours of stripping. The turf shall be laid to form a solid mass with tightly fitted joints. The ends of the turf shall be butted. Strips shall be staggered to offset joints in adjacent courses.

2

The turf shall be tamped or rolled to ensure contact with the sub-grade. Soil shall be worked into minor spaces between pieces of turf and excess soil removed.

3

The perimeter of the turfed area shall be flagged off to restrain foot traffic until after the third mowing or as directed by the Engineer.

4

The turfed area shall be watered with a fine spray immediately after completing each day of turfing operations. Water shall be applied to ensure a moist sub-grade soil to a minimum depth of 70 mm is achieved. Watering shall continue until turf can maintain itself on the normal irrigation programme.

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QCS 2014


Page 30

1.5.9

Plant List, Spacing and Sizes

1

The Contractor shall follow the requirements of Table 9a & 9b for plant list, plant spacing, sizes required and other relevant information which is provided in the Table 9a for other projects and Table 9b for all Ashghal Projects. Table 9a: Plant List, Spacing and Sizes Required for the Projects

Spreading

CM

Stem Girth

M

CM

CM

CM

rw

.l. l

.

Pot Size

L/PLANT

Root Ball DIA

Spacing

Common Name

Clear Trunk

1.5 -2.0 M

Bismarckia palm

120.0

Brahea Armata

Blue hesper Palm

120.0

1.5 -2.0 M

Butia capitata

Pindo palm

120.0

1.5 M

Chamaerops humilis

European fan palm

Cocos nucifera

Coconut palm

120.0

Cocos plumosa

Coconut palm

120.0

Copernicia alba

Wax Palm

Dioon edule Elaeis oleifera

qa

as

1.0 -1.5 M

30

se

er

o

m

Cycas revoluta

80.0

As

75

1.5 -2.0 M

75

1.5 -2.0 M

120.0

1.80 3.0 M

60.0

1.0 -1.5 M

Queen Sago

et it

Cycas circinalis

ta

Bismarckia nobilis

ov

BOTANICAL NAME

Water Requirements

Palms & Cycads

Sago palm

60.0

2530

0.75 1.5 M

60.0

2530

0.75 1.5M

Mexican Cycad American oil palm

Hyophorbe Lagenicaulis

Bottle Palm

Hyophorbe verschaffeltii

Spindle Palm

Livistona chinensis

Chinese fan palm

Phoenix canariensis

Island Date palm

Phoenix dactylifera

Date palm

80.0

75

2.0 3.0 M

80.0

75

1.25 2.0 M 1.25 2.0 M

80.0 80.0

Per

120.0 120.0

Design

2.0 3.0 M

30 125

1.5 2.0 M

125

2.0 3.0 M

QCS 2014


Phoenix roebelenii

Pygmy date palm

Phoenix sylvestris

Silver date palm tree Cuban Royal Palm

Roystonea regia

Sabal domingensis

the Hispaniola palmetto

Trachycarpus fortunei

Page 31 1.0 1.5M 2.0 3.0M

60.0

60

120.0

125

120.0

60

1,5 M

60

2.0 3.0 M

120.0

35

Chusan Palm 60.0

Washingtonia robusta

Washingtonia palm

120.0

Wodyetia bifurcata

Foxtail Palm

Zamia furfuracea

Cardboard Palm

rw

80.0

75

2.0 3.0 M

60

1,5 M

0.25 0.40M

qa

40.0

2.0 3.0 M

75

.

120.0

.l. l

California fan palm

ta

Washingtonia filifera

1.5 M

et it

m

Brachychiton Populneus Casuarina equisetifolia

Chorisia speciosa

Spacing

Pot Size

Root Ball DIA

Stem Girth

Spreading

L/PLANT

M

CM

CM

CM

CM

Clear Trunk

Water Requirements

ov

Common Name

o

Botanical Name

er

se

as

Large Evergreen Trees

Bottle tree Horsetail tree, Australian pine

80.0

25.0

8.0

50.0

2.0 M

80.0

25.0

8.0

50.0

2.0 M

80.0

35.0

50.0

100.0

2.0 M

Bottle tree

Ficus Alii

Amstel king

Ficus Alii

Amstel queen

Ficus altissima

Council tree

Ficus bengalensis

Banyan tree

Ficus infectoria

White-Fruited Wavy Leaf Fig

80.0

2.0 M

80.0

2.0 M

80.0 80.0 80.0

As

25.0

8.0

50.0

2.0 M

25.0

8.0

50.0

2.0 M

25.0

2.0 M


Willow leaved fig

Ficus sycomorus

sycamore fig

Harpullia Pendula

tulip lancewood

Khaya senegalensis

African mahogany

Kigelia Pinnata

Sausage tree

Moringa oleifera pterygosperma

Horse radish tree

Parkinsonia aculeata

Jerusalem thorn

Pithecelobium dulce

Manila tamarird

Prosopis alba

White carob tree

Prosopis juliflora

Honey mesquite

Schinus molle

Pink pepper, peruvian pepper Tamarind

Taxodium Distichum

bald cypress

er

Chinese date

et it

Zizyphus jujuba

jujuba tree

o

Zizyphus chinensis

2.0 M 2.0 M

80.0

2.0 M

80.0

2.0 M

80.0

2.0 M

80.0

2.0 M

60.0

Per

25.0

8.0

50.0

2.0 M

60.0

25.0

8.0

50.0

2.0 M

80.0

Design

25.0

8.0

50.0

2.0 M

60.0

25.0

8.0

50.0

2.0 M

60.0

25.0

8.0

50.0

2.0 M

80.0

25.0

8.0

50.0

2.0 M

80.0

25.0

8.0

50.0

2.0 M

80.0

2.0 M

80.0

25.0

8.0

50.0

2.0 M

60.0

25.0

8.0

50.0

2.0 M

60.0

25.0

8.0

50.0

2.0 M

80.0

25.0

8.0

50.0

2.0 M

Christ Thorn

m

Zizyphus spina - christi

50.0

Indian almond

ov

Terminalia cattapa

8.0

80.0

se

Tamarindus indica

25.0

.

Ficus Salicifolia

80.0

2.0 M

.l. l

Scacred ficus

25.0

rw

Ficus religiosa

80.0

ta

indian ficus panda

qa

Ficus panda

Page 32

as

QCS 2014

Albizia julibrissin

Silk tree

Albizia lebbeck

Women's tongue

Root Ball DIA

Stem Girth

Spreading

L/PLANT

M

CM

CM

CM

CM

Clear Trunk

Pot Size

Common Name

Spacing

Botanical Name

Water Requireme nts

Decidious Trees

80.0

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M


Azadirachta indica

Page 33

Neem tree 80.0

Bauhinia variegata

As

20.0

8.0

50.0

2.0 M

60.0

20.0

8.0

50.0

2.0 M

60.0

20.0

8.0

50.0

2.0 M

60.0

20.0

8.0

50.0

2.0 M

Orchid tree

Seagrape tree

Royal poinsiana, flame tree

80.0

Per

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M

20.0

8.0

50.0

2.0 M

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M

80.0

20.0

8.0

50.0

2.0 M

60.0

20.0

8.0

50.0

2.0 M

Flame of forest

Millingtonia hortensis

qa

Delonix regia

.

Delonix elata

Silk-Cotton Tree

Indian Cork Tree

se

China berry

as

80.0

Melia azedarach

.l. l

cochlospermum religiosum

ta

Coccoloba uvifera

rw

QCS 2014

Design

er

80.0

Fruitless mulberry

o

ov

Morus alba

Black mulberry

m

et it

Morus nigra

peltophorum inerme

Paulownia tomentosa

Thespesia populnea

Medium Evergreen Trees

yellow ponciana

Princess Tree

Portia tree

SPREADING

CM

CM

6.0

50.0

2.0 M

6.0

50.0

2.0 M

20.0

6.0

50.0

2.0 M

20.0

6.0

50.0

2.0 M

60.0

20.0

6.0

50.0

2.0 M

60.0

20.0

6.0

50.0

2.0 M

20.0

6.0

50.0

2.0 M

20.0

12.0

35.0

1m

L/PLANT

M

CM

60.0

As

20.0

.

Arabian acacia

yellow mimosa

.l. l

Acacia farnesiana

Indian rosewood

as

Pink Lapacho

o

ov

Tabebuia impetiginosa

Silver Trumpet Tree

60.0

se

Tabebuia argentea

Brazilian pepper tree

er

Schinus terebintifolius

Per

qa

60.0

ta

Dalbergia sisso

20.0

rw

60.0

White trumpet tree

m

et it

Tabebuia rosea

Xanthorrhea sp.

Clear Trunk

STEM GIRTH

CM

POT SIZE

Acacia arabica

COMMON NAME

SPACING

BOTANICAL NAME

Page 34

ROOT BALL DIA

Section 28: Landscaping Part 01: Landscape Planting WATER REQUIREMENT

QCS 2014

60.0

Design

Grass Tree 40.0

ROOT BALL DIA

STEM GIRTH

SPREADING

L/PLANT

M

CM

CM

CM

CM

TOTAL HEIGHT

POT SIZE

COMMON NAME

SPACING

BOTANICAL NAME

WATER REQUIREMENT

Small Trees Or Large Shrubs

QCS 2014


Aillanthus altissima

Tree Of heaven

20.0

Alstonia Scholaris

Devil tree

20.0

bauhinia purpurea

orchid tree

bauhinia variegata

orchid tree

Bucidia Buceras

Black Olive tree

Bambusa ventricosa -Thick stem

Buddha's Belly Bamboo

Caesalpinia gilliesii

Bird of paradise bush yellow flowers

Page 35 1520 1520 1520 1520 1520

20.0 20.0 20.0

4.0

40.0

2.0 M

4.0

40.0

2.0 M

4.0

40.0

2.0 M

4.0

40.0

2.0 M

4.0

40.0

2.0 M

1520

4.0

40.0

2.0 M

20.0

1520

4.0

40.0

2.0 M

20.0

1520

4.0

40.0

2.0 M

1520

3.0

60.0

2.0 M

50.0

2.0 M

3.0

60.0

2.0 M

Calotropis procera

Dead sea apple

Carica papaya

Papaya

Cassia fistula

Golden shower tree

20.0

Cassia glauca apple blossom tree

ov

er

Cassia javanica

Pink & white shower

m

et it

o

Cassia nodosa

Cordia sebestena

20.0

Scarlet cordia, aloe wood

Dodonaea viscosa

Hopseed bush

Hibiscus rosa-sinensis

China rose

1520

4.0

60.0

2.0 M

60.0

1520

4.0

60.0

2.0 M

20.0

1520

60.0

2.0 M

20.0

1520

3.0

60.0

2.0 M

1520

3.0

60.0

2m

1520

3.0

10.0

0.5 m

1520

3.0

30.0

0.5 m

1520

3.0

30.0

0.5 m

1520

3.0

40.0

2.0 M

3.0

40.0

2.0 M

3.0

40.0

2.0 M

60.0

Peregrina

Lagerstroemia indica

Crape myrtle Thai Bungor

Lagerstroemia speciosa

Pride of India

Leucophylum frutescens

Texas ranger

Malvaviscus arboreus pendiluflorus

Sleepy hibiscus

Per

20.0 20.0

Lagerstroemia loudonii

As

12.0 20.0

Jatropha integerrima

1520 1520

60.0

se

Cassia glauca

20.0

ta

Weeping bottle brush

qa

Callistemon viminalis

rw

Red Powder Puff

as

calliandra haematocephala

.l. l

.

20.0

20.0 20.0

Design

1520 1520

20.0

1520

3.0

30.0

0.5 m

20.0

1520

3.0

30.0

1m


Musa paradisiaca

Banana

Nerium oleander

Oleander

parmentiera edulis

Candle Tree

Plumeria obtusa

Temple tree

Plumeria rubra acutifolia

Temple tree Red flower

1520

3.0

50.0

.75 m

20.0

1520

3.0

30.0

1m

20.0

20.0

3.0

60.0

2.0 M

60.0

20.0

3.0

60.0

2.0 M

60.0

20.0

3.0

60.0

2.0 M

60.0

20.0

3.0

60.0

2.0 M

60.0

1520

3.0

40.0

2.0 M

1520

3.0

40.0

2.0 M

25.0

6.0

50.0

1.5 m

1520

3.0

20.0

1.0 m

1520

3.0

20.0

1m

1520

3.0

20.0

0.5 m

Ashoka tree Pomegranate

Sesban Athel tree

Tecoma stans

Yellow bells

20.0

qa

Tamarix sp.

ta

60.0

Thevetia peruviana nereifolia

Yellow oleander

Vitex agnus castus

Hemp tree

Acalypha wilkesiana

Bougainvillea glabra

SPACING

POT SIZE

ROOT BALL DIA

STEM GIRTH

SPREADING

COMMON NAME

WATER REQUIREME NT

et it m

BOTANICAL NAME

20.0

ov

er

se

20.0

o

Shrubs

as

20.0

L/PLANT

M

CM

CM

CM

CM

TOTAL HEIGHT

Sesbania sesban

.l. l

Punica granatum

20.0

.

Polyalthia longifolia

Page 36

rw

QCS 2014

Irish Petticoat 12.0

20.0

3.0

20.0

0.5 m

12.0

20.0

3.0

30.0

1m

Paper flowers

Bougainvillea torch glow

Torch Glow

Bougainvillea spectabilis

Bougainvillea

Caesalpinia pulcherrima

Barbados pride orange-red flowers

3.0 12.0 20.0

As

30.0

3.0

50.0

1m

20.0

3.0

40.0

0.75 m

Section 28: Landscaping Part 01: Landscape Planting Natal plum

Cassia alata

the Candle Bush

20.0

3.0

20.0

3.0

20.0

3.0

30.0

0.5 m

12.0

20.0

3.0

20.0

0.5 m

12.0

20.0

3.0

20.0

0.5 m

20.0

1015

3.0

15.0

0.5 m

Flame of the woods

12.0

20.0

3.0

10.0

0.3 m

Flame of the woods

12.0

rw

Carissia grandiflora

12.0

Page 37

Per

20.0

3.0

10.0

0.3 m

20.0

3.0

10.0

0.3 m

12.0

20.0

3.0

25.0

0.3 M

12.0

20.0

3.0

25.0

0.3 M

12.0

20.0

3.0

10.0

0.4

12.0 Cassia bicapsularis

Senna

Cestrum diurnum

Day jasmine

jungle geranium

Lantana camara

Lantana

Lantana montevidensis

Lantana Sacred bambo Great Rosebay

Tabernaemontana divaricata

crepe jasmine

Cupressus sempervirens

.

12.0

3.0

12.0

3.0

M As Per Design

25.0

CM

CM

CM

3.0

30.0

COMMON NAME

Italian cypress

80.0

CM

TOTAL HEIGHT

L/PLANT

SPREA DING

et it

m BOTANICAL NAME

0.5 m

o

ov

er

Tabernaemontana corymbosa

Conifers

.l. l

se

Nandina domestica

12.0

qa

Ixora javanica

ta

Ixora coccinea

Arabian jasmine

SPACIN G

Ixora chinensis

0.5 m

Night jasmine

as

Jasminum sambac

Design

WATER REQUIR EMENT

Cestrum nocturnum

12.0

30.0

POT SIZE ROOT BALL DIA STEM GIRTH

QCS 2014

2.0 M

TOTAL HEIGHT

SPREA DING


COMMON NAME

SPACIN G

BOTANICAL NAME

WATER REQUIR EMENT

Hedge

QCS 2014


Page 38

L/PLANT

M

CM

CM

CM

CM

Salt bush-high salt tolerant

12.0

0.4

15.0

15.0

0.5 M

Atriplex lentiformis

Salt bush

12.0

0.4

15.0

15.0

0.5 M

Clerodendron inerme

Wild jasmine

12.0

0.4

15.0

15.0

0.5 M

Dodonaea viscosa

Hopseed bush

12.0

0.4

15.0

15.0

0.5 M


Texas ranger

12.0

0.4

15.0

15.0

0.5 M

Myrtus Communis

Myrtle

12.0

0.4

15.0

15.0

0.5 M

Nerium oleander

oleander

Ruellia tuberosa

Ruellia

12.0

0.4

1015

15.0

0.5 M

Vitex agnus castus

Hemp tree

12.0

0.4

15.0

15.0

0.5 M

rw

ta

CM

CM

ov

Desert rose

o

Adenium obesum

CM

CM

TOTAL HEIGHT

SPREA DING

SPACIN G M

COMMON NAME

er

BOTANICAL NAME


qa L/PLANT

se

WATER REQUIR EMENT

as

Succulents & Cactus

o.40 M

Century Plant

10.0

30.0

0.3 M

Caribbean Agave

10.0

30.0

o.40 M

Agave attenuata

lion's tail

10.0

30.0

o.40 M

Agave elegans

Salm-Dyck

10.0

30.0

o.40 M

Agave filifera

thread agave

10.0

30.0

o.40 M

Agave geminiflora

Twin-flowered Agave

10.0

30.0

o.40 M

Agave lechugilla

lechuguilla

10.0

30.0

o.40 M

Agave macroacantha

Black-spined Agave

10.0

30.0

o.40 M

et it

Agave americana

.l. l

.

Atriplex halimus

m

Agave angustifolia variegata

QCS 2014


Page 39

sharkskin agave

10.0

30.0

o.40 M

Agave potatorum verscafeltii

Dwarf Butterfly Agave

10.0

30.0

o.40 M

Agave pygmaea

Dragon Toes

10.0

30.0

o.40 M

Agave stricta

A young specimen

10.0

30.0

o.40 M

Agave titanotta

Rancho Tambor

10.0

30.0

o.40 M

Agave verschaffeltii

Blue Agave

10.0

30.0

o.40 M

Agave Victoria regina

Queen Victoria agave

10.0

30.0

Aloe vera Berbadensis

Medical plant

10.0

Agave america mediopicta

Agave mediopicta

10.0

Agave Victoria regina

Queen Victoria Agave Zebra Agave

rw

o.40 M

20.0

0.3 M

20.0

0.3 M

10.0

20.0

0.3 M

10.0

30.0

as

qa

ta

As Per Design

Madagascan Ocotillo

10.0

30.0

1.5 M

Aloe arborescens

candelabra Aloe

10.0

30.0

1.5 M

Aloe clavifolia

Aanteelaalwyn

10.0

30.0

1.5 M

quiver tree

10.0

30.0

1.5 M

on the coast

10.0

30.0

1.5 M

10.0

30.0

1.5 M

o et it

m

Aloe dichothoma

er

Alluaudia procera

ov

se

Agave zebra

.l. l

.

Agave nigra

Aloe littoralis

Aloe eru vicornuta Aloe excelsa

Zimbabwe Aloe

10.0

30.0

1.5 M

Aloe humilis

Spider Aloe

10.0

30.0

1.5 M

Aloe maculata

Zebra Aloe

10.0

30.0

1.5 M

Aloe marlothii

Mountain Aloe

10.0

30.0

1.5 M

Aloe melanacantha

Black-spined Aloe

10.0

30.0

1.5 M


Page 40

Pauline

10.0

30.0

1.5 M

Aloe ramosissima

Maiden's Quiver Tree

10.0

30.0

1.5 M

Aloe mitriformis

Gold Tooth

10.0

30.0

1.5 M

Aloe squarrosa

Yemen Aloe

10.0

30.0

1.5 M

Aloe striata

coral aloe

10.0

30.0

1.5 M

Aloe tharskii

the Dune Aloe

10.0

30.0

1.5 M

Aloe tomentosa

Hairy Green Aloe

10.0

30.0

1.5 M

Aloe vaombe

Malagasy Tree Aloe

10.0

30.0

1.5 M

Aloe vera Berbadensis

Aloe indica royle

10.0

30.0

1.5 M

Aloe zebrina

Zebra Leaf Aloe

10.0

30.0

1.5 M

Austrocephalocereus dybowskii

Cereus dybowskii

10.0

30.0

1.5 M

Austrocephalocereus estevesii

Thumbnail

10.0

30.0

1.5 M

10.0

30.0

1.5 M

10.0

30.0

1.5 M

Old Man Cactus

10.0

30.0

1.5 M

Cleistocactus braunii

climbing cactus

10.0

30.0

1.5 M

Cleistocactus jujuyensis

argentina cactus

10.0

30.0

1.5 M

Cleistocactus strausii

silver torch

10.0

30.0

1.5 M

Copiapoa cinerea

chalky/white stems

10.0

30.0

1.5 M

Copiapoa haseltoniana

chille cactus

10.0

30.0

1.5 M

Crassula

baby jade

10.0

30.0

1.5 M

m

ta qa

as se

er

o

saguaro cactus

et it

cephalocereus senilis

ov

Aylostera archibuininguiana Carnegiea gigantea

.l. l

.

Aloe pelegrae

rw

QCS 2014

QCS 2014


Cylindropuntia bigelowi

Page 41

10.0

30.0

1.5 M

10.0

30.0

1.5 M

10.0

30.0

1.5 M

10.0

30.0

1.5 M

10.0

30.0

1.5 M

10.0

30.0

1.5 M

Euphobia enopla

10.0

30.0

Euphorbia erythraea

10.0

Didierea madagascariensis

Didierea

Discocactus

Dyckia

brazilian cactus

Euphorbia alba Canary Island spurge

rw

.l. l

.

Euphorbia canariensis

1.5 M 1.5 M

30.0

1.5 M

30.0

1.5 M

30.0

1.5 M

10.0

30.0

1.5 M

ta

30.0

Euphorbia candelabrum

10.0

Euphorbia lactea

brain plant

10.0

Euphorbia milli

Christ plant

Euphorbia tirucallii

pencil tree

Euphorbia stenoclada

Euphorbia insulae-europae

10.0

30.0

1.5 M

Cereus sp.

Lady of the night cactus

10.0

35.0

1M

Golden barrel

10.0

20.0

0.25 M

Euophorbia lactea

Mottled Spurge

10.0

20.0

0.35 M

Echinopsis hauscha

Red torch cactus

10.0

20.0

0.20 M

Ferocactus sp.

Desert Barrel

10.0

20.0

0.25 M

Furcraea gigantea

boojum tree

Cephalocerus seniies

Old Man Cactus

10.0

20.0

0.35 M

Carnegia giganta Cactus

saguaro cactus

10.0

30.0

1M

as

o

ov

er

se

10.0

et it

m

Echinocactus grussonii

qa

Euphorbia ingens

QCS 2014


Page 42

Monstrous Lady Fingers

10.0

20.0

0.25 M

Melocactus

Melon cactus

10.0

20.0

0.25 M

Pachypodium Lamerei

Madagascar Palm

10.0

20.0

1M

Portulacaria afra

elephant bush

Sansevieria trifasciata

bird's nest snake plant

Sansevieria Hahnii

baseball bat

Yucca elephantips

soft-tip yucca

10.0

30.0

1.5 M

Yucca filamentosa

Adam's needle

10.0

30.0

.l. l

.

Mamelaria elongata

1.5 M

rw

30.0

Coral vine

12.0

Bougainvillea sp

Bougainvillea

20.0

Clerodendron inerme

Wild Jasmine

20.0

CM

TOTAL HEIGHT

CM

CM

15.0

1.0 m

15.0

15.0

1m

15.0

15.0

0.75 m

10.0

15.0

0.3 m

10.0

15.0

0.3M

15.0

15.0

1.0 M

Railway creeper

12.0

Jasminum officinalis grandiflorum

Poet's Jasmine

20.0

Lonicera sempervirens

trumpet vine

20.0

15.0

15.0

1.0 m

Quisqualis indica

Rangoon creeper

20.0

15.0

15.0

1.0 m

SPREA DING

15.0

12.0

m

Ipomoea palmata

Per

CM


As

SPREA DING

M

Beach Morning Glory

et it

Ipomoea pes-caprae

o

Antigonom leptopus

ov

er

L/PLANT


as

COMMON NAME

se

BOTANICAL NAME

SPACIN G

WATER REQUIR EMENT

qa

ta

Vines

Design

REQUIR ED SIZE

COMMON NAME

SPACIN G MIN.

BOTANICAL NAME

WATER REQUIR EMENT

Ground Covers


Page 43

LTR/M2

PLANT/M2

CM

CM

CM

CM

red border weed

10.0

9.0

10.0

30.0

0.2 M

Aptenia cordifolia

Baby sun rose

10.0

9.0

10.0

30.0

0.2 M

Asparagus densiflorus

Asparagus fern

10.0

9.0

10.0

30.0

0.3 M

Asparagus myers

Monrovia's Foxtail Fern

Canna indica

Lana

10.0

9.0

10.0

10.0

0.3 M

Carissa prostrata

Natal plum dwarf

10.0

9.0

10.0

30.0

0.3 M

Cortaderia selloana

Pampas grass

10.0

10.0

10.0

0.3 M

Cyperus alternifolius

Umbrella sedge

10.0

10.0

10.0

0.3 M

9.0

10.0

10.0

0.1 M

10.0

9.0

10.0

10.0

0.1 M

.l. l

rw

Dianella tasmanica

Tasman Flax Lily

Drosantemum hispidum

Rose ice plant

Euphorbia milii

Crown of thorns

10.0

9.0

10.0

20.0

0.3 M

Gazania rigens

ov

qa

White ice plant

Treasure flower

10.0

9.0

10.0

10.0

0.1 M

railroad vine

12.0

9.0

10.0

1015

0.3 M

Railway creeper

10.0

9.0

10.0

1015

0.3 M

Blood leaf

10.0

9.0

10.0

1015

0.2 M

et it

o

er

se

as

Delaspermum alba

Ipomea pes-caprae

10.0

As Per Design

.

Alternanthera versicolor

ta

QCS 2014

m

Ipomoea palmata or cairica Iresine herbstii

Lampranthus aureus/ Malephora crocea

Orange ice plant

10.0

9.0

10.0

1015

0.7 M

Lampranthus spectabilis

Training ice plant

10.0

9.0

10.0

1015

0.1 M


Geeper lantana

10.0

9.0

10.0

1015

0.3 M

Limonium sinuatum

Sea-lavender

10.0

9.0

10.0

1015

0.2 M

Ocimum basilicum

Sweet basil

10.0

As Per Design

10.0

1015

0.3 M

Osteospermum fruiticosum

African daisy

10.0

9.0

10.0

1015

0.2 M

QCS 2014

Section 28: Landscaping Part 01: Landscape Planting Purple fountain grass

10.0

1015

10.0

0.3 M

Beach grass Fountain grass

10.0

As Per Design

10.0

1015

0.3 M

Portulacaria afra

Elephant bush

10.0

9.0

10.0

1015

0.15 M

Pseuderanthemum atropurpureum

Chocolate plant dark purple

8.0

15.0

20.0

0.3 m

Pseuderanthemum atropurpureum tricolor

Chocolate plant 3 colors

8.0

As Per Design

15.0

20.0

0.3 m

Rhoeo discolor

Moses in the cradle, Boat lily

10.0

9.0

10.0

1015

0.2 M

Rosmarinus officinalis

Rosemary

10.0

9.0

10.0

1015

0.2 M

Russelia equisetiformis

Coral plant, firecracker plant

10.0

As Per Design

10.0

1015

0.3 M

Sesuvium portulacastrum

Sea pureslane

9.0

10.0

1015

0.2 M

Setcreasea pallida

Purple heart

10.0

9.0

10.0

1015

0.15 M

Verbena peruviana

Blood leaf "Springtime"

10.0

9.0

10.0

1015

0.1 M

10.0

9.0

10.0

1015

0.15 M

er

.l. l ta

qa

as

se

10.0

Creeping daisy

m

Wedelia trilobata

et it

o

ov

.

Pennisetum setaceum

rw

Pennisetum setaceum rubrum

Page 44

SPREA DING

LTR/M2

PLANT/M2

CM

CM

9.0

10.0

COMMON NAME

Floss flower

10.0

CM

CM

REQUIRED SIZE


Ageratum mexicanum

SPACIN G MIN.

BOTANICAL NAME

WATER REQUIR EMENT

SEASONALS

One flower


Page 45

Amaranthus tricolor

Joseph's coat

10.0

9.0

10.0

One flower

Antirrhinum majus

Floral snapdragon

10.0

9.0

10.0

One flower

Asclepias curassvica

Blood flower

10.0

9.0

10.0

Calendula officinalis

Port marigold

10.0

9.0

10.0

One flower One flower

Callistephus chinesis

China aster

10.0

9.0

10.0

Catharanthus roseus

Madagasar periwinkle

10.0

9.0

10.0

Celosia cristata

Fair fountains

10.0

9.0

10.0

Celosia cristata var.nana

Cockscomb

10.0

9.0

10.0

Celosia plumosa

Burut plume

10.0

9.0

rw

QCS 2014

Chrysanthemum carinatum

Monarch court

10.0

Chryanthemum morifolium

Florist's mum

10.0

Cosmos bipinnatus

Mexican aster

Dianthus barbatus

Sweet william

Dianthus chinensis Gaillardia pulchela Gazania splendens

One flower One flower One flower

9.0

10.0

One flower

9.0

10.0

One flower

9.0

10.0

10.0

9.0

10.0

Chinese pink

10.0

9.0

10.0

Blanket flower

10.0

9.0

10.0

One flower One flower One flower One flower

Gazania

10.0

9.0

10.0

Globe amaranth red

10.0

9.0

10.0

Kochia scoparia

Summer cypresus

10.0

9.0

10.0

One flower

Lobularia maritima

Sweet alysum

10.0

9.0

10.0

One flower

Mathilola incana

stock

10.0

9.0

10.0

Pelargonium x hybrida

Garden Geranium

10.0

9.0

10.0


Pellionia pulchra

Training begoria

10.0

9.0

10.0

Petunia x hybrida

Petunia hybrid

10.0

9.0

10.0

Polianthes tuberosa

The pearl

10.0

9.0

10.0

One flower

Portulaca graniflora Var.Corniche

Moss rose, sun plant

10.0

9.0

10.0

One flower

qa

as 10.0

se

er

o

et it

m

Gomphrena globosa

ta

10.0

ov

.l. l

.




QCS 2014


Page 46

Salvia splendens

Scarlet sage

10.0

9.0

10.0

One flower

Senecio cineraria

Dusty miller

10.0

9.0

10.0

Tagetes

Marigold

10.0

9.0

10.0

Verbena peruviana

Aztec queen

10.0

9.0

10.0

One flower One flower One flower

Viola tricolour

Kiss-me-love

10.0

9.0

10.0

Zinnia sp.

Zinnia

10.0

9.0

10.0


Paspalum vaginatum notatum

Bahia grassseashore paspalum

Zoysia japonica

Japanese grass

SPREADI NG

CM

CM

12 T0 18

12 TO 18

er

ov

et it

o

12 TO 18

Clear Trunk/ Total Height/ Required Size

Root Ball dia cm

22

Pot Size cm

80

l/plant/ day/year

Mean Daily Demand

Common Name

Peak Daily Demand l/plant/ day

Botanical Name

Irrigation Group

Palms

m

Table 9b: Plant List, Spacing and Sizes Required for Ashghal Projects

PALMS Bismarkia nobilis

Bismark Palm

3

2.0 m

REQUIRED SIZE

STEM GIRTH

.l. l ROOT BALL DIA CM

as

Bermuda grassHigh salt tolerant

CM

se

Cynodon dactylon

POT SIZE

PLANT/M2

rw

SPACING MIN.

LTR/M2

ta

COMMON NAME

qa

BOTANICAL NAME

WATER REQUIRE MENT

.

Grass

QCS 2014


Page 47

Brahea armata

Mexican Blue Palm

3

80

22

40

1.50 m

Chamaerops humilis

European Fan Palm

2

70

15

30

1.50 m

Chamaerops humilis

Mediterranean Fan Palm

2

70

15

40

Cocos nucifera

Coconut palm

4

120

29

Cycas revoluta

Sago palm

3

80

22

25-30

0.50 m

Dioon edule

Mexican Cycad

3

80

22

25-30

1.0 m

Elaeis oleifera

American oil palm

3

80

22

Hyophorbe lagenicaulis

Bottle Palm

3

80

22

Hyophorbe verschaffeltii

Spindle Palm

3

80

22

Livistona chinensis

Cabbage Palm

3

80

Livistona marie "Oombulgurri"

Australian Cabbage Palm

3

Livistonia chinensis

Chinese Fan Palm

Nanorrhops ritcheana

Mazari Palm

Phoenix canariensis Phoenix dactylifera Phoenix roebelenii

Miniature Date Palm

75

2.0 m

1.50 m

75

1.25 m

40

2.0 m

80

22

40

2.0 m

3

80

22

30

1.50 m

3

80

22

24

Island Date palm

4

120

29

125

2.0 m

Date palm

4

120

29

125

2.0 m

3

80

22

60

1.0 m

3

80

22

40

2.0 m

Wild Date Palm

4

120

29

40

2.0 m

Roystonea regia

Cuban Royal Palm

4

120

29

60

1.50 m

Sabal domingensis

Hispaniola Palmetto

4

120

29

60

2.0 m

Washingtonia filifera

California Fan Palm

3

80

22

75

2.0 m

Washingtonia robusta

Washingtonia Palm

3

80

22

75

2.0 m

Wodyetia bifurcata

Foxtail Palm

4

120

29

60

1.50 m

m

Phoenix sylvestris

Large Evergreen Trees

qa

as

se

o

Miniature Date Palm

et it

Phoenix roebelenii

ta

22

er

1.25 m

ov

rw

.l. l

.

75


Page 48

2

70

15

24

10

60

Acacia auriculaformis "Gaypari"

Ear Pod Wattle

2

70

15

24

10

60

Acacia pendula "Amata"

Weeping Myall

2

70

15

30

10

60

1.0 m

Acacia salicina "Marntala

Willow Acacia

2

70

15

30

10

70

1.0 m

Adansonia gregorii "Jamulang"

Baobab Tree

4

100

40

15

80

1.50 m

Alstonia actinophylla “Jabiru”

Australian Milkwood Tree

3

22

30

10

80

1.50 m

Alstonia scholaris

Milkwood

Brachychiton "Bella Donna"

Belladonna Flame Tree

Brachychiton acerifolius “Allowrie”

.

Stem girth cm

Irrigation_Group

Botanical Name

80

22

30

10

80

1.50 m

3

80

22

24

10

80

1.20 m

Illawarra Flame Tree

3

80

22

24

10

80

1.20 m

Pink Kurrajong

3

80

22

24

10

80

1.20 m

Bottle tree

3

80

22

25

8

50

1.50 m

Bucida bucares

Antigua Whitewood

3

80

22

40

10

80

1.50 m

Caesalpinia ferrea

Leopard Tree

3

80

22

40

10

80

1.50 m

Casuarina equisetifolia

Horsetail tree, Australian Pine

3

80

22

25

8

50

1.50 m

Chorisia speciosa

Bottle tree

3

80

22

35

50

100

2.0 m

Corymbia apperinja "Alice Para"

White Gum

2

70

15

24

10

70

1.20 m

Erythrina orientalis variegata "Ngukurr"

Variegated Coral Tree

4

100

25

24

10

80

1.50 m

m

Brachychiton Populneus

er

ov

et it

Brachychiton diversifolius

se

3

o

as

80

.l. l

rw

ta

qa

25

Spreading cm

Nyanga Flat Top

Pot Size cm

Acacia abyssinica

Common_Name

Mean Daily Demand l/plant/day/year

Section 28: Landscaping Part 01: Landscape Planting Peak Daily Demand l/plant/day

QCS 2014

Northern Salmon Gum

3

80

22

24

10

75

1.50 m

Ficus altissima

Council tree

3

80

22

25

8

50

1.50 m

Ficus benghalensis

Banyan Tree

3

80

22

24

10

80

1.0 m

Ficus religiosa

Peepul Tree

3

80

22

24

10

80

1.0 m

Ficus religiosa

Sacred ficus

4

100

25

25

8

50

1.50 m

Ficus salicifolia

Willow Leaf Fig

2

70

15

24

10

80

1.0 m

Ficus sycomorus

Mulberry Fig

3

80

22

24

10

80

1.0 m

Mangifera indica

Mango Tree

3

80

22

40

10

80

1.0 m

Millingtonia hortensis

Tree Jasmine

3

80

22

24

10

80

1.0 m

Moringa oleifera

Horse radish tree

3

80

22

25

8

50

1.50 m

Parkinsonia aculeata

Jerusalem thorn

2

70

15

25

8

50

1.50 m

Pithecelobium dulce

Manila Tamarird

3

22

25

8

50

1.50 m

Prosopis alba

White Carob Tree

70

15

25

8

50

1.50 m

Prosopis cinerarea

Ghaf Tree

2

70

15

20

8

80

1.0 m

Prosopis juliflora

Honey Mesquite

2

70

15

25

8

50

1.50 m

Schinus molle

Pink pepper, Peruvian Pepper

3

80

22

25

8

50

1.50 m

Tamarindus indica

3

80

22

Arjun Tree

3

80

22

33

10

75

1.0 m

Terminalia cattapa

Indian almond

3

80

22

25

8

50

1.50 m

Zizyphus jujuba

Chinese date

3

80

22

25

8

50

Zizyphus spinachristi

Sidr

2

70

15

25

8

50

rw

ta

qa 80

as

se

er

ov

Tamarind

et it

m

Terminalia arjuna

2

.l. l

.

Eucalyptus bigalareta "Mijilypa"

Mean Daily Demand l/plant/day/ year

Page 49



o

QCS 2014

1.50 m


Spreading cm

Stem girth cm

Pot Size cm

Irrigation Group

Common Name

Botanical Name

Medium Evergreen Trees

QCS 2014


Page 50

Arabian acacia

2

70

15

24

10

50

1.50 m

Acacia arnesiana

Yellow Mimosa

2

70

15

20

6

50

1.50 m

Acacia nilotica

Scented Acacia

2

70

15

24

10

50

1.50 m

Calliandra haematocephala

Powder Puff

2

70

15

40

10

80

1.50 m

Cassia brewsterii

Velvet Cassia

3

80

22

20

8

75

0.75 m

Cassia grandis

Coral Shower

3

80

22

24

10

80

1.0 m

Cassia roxburghii

Red Cassia

3

80

22

24

10

80

1.0 m

Casuarina cristata

Belah

2

70

15

24

Dalbergia sissoo

Indian Rosewood

3

80

22

Pongamia pinnata

Pongam

3

80

Saraca indica

Ashok

3

Schinus terebinthifolius

Brazilian Pepper Tree

2

Tabebuia rosea

White Trumpet Tree

Tipuana tipu Xanthorrhoea australis

Grass Tree

.l. l

.

Acacia Arabica see A.nilotica

60

20

6

50

1.50 m

10

80

1.0 m

ta

33

80

22

33

10

50

1.0 m

70

15

20

6

50

1.50 m

3

80

22

20

6

50

1.50 m

Rosewood Tree

3

80

22

24

8

50

1.0 m

ov

rw

8

2

70

15

20

12

35

1.0 m

qa

as

se

o

er

22


22

20

8

50

1.50 m

Albizia lebbeck

Woman's Tongue

3

80

22

20

8

50

1.50 m

Azadirachta indica

Neem tree

3

80

22

20

8

50

1.50 m

Bauhinia variegata

Orchid tree

3

80

22

20

8

50

1.50 m

Delonix elata

Royal Poinciana, Flame Tree

3

80

22

20

8

50

1.50 m

Common Name

Botanical Name

Spread cm

80

Stem girth cm

3

Pot Size cm

Mean Daily Demand l/plant/day/ year

Silk tree, Mimosa

Irrigation Group

Albizia julibrissin

m


et it

Semi Deciduous Trees

QCS 2014


Page 51

Flame of forest

4

100

25

20

8

50

1.50 m

Melia azedarach

China Berry

3

80

22

20

8

50

1.50 m

Morus alba

White Mulberry

3

80

22

20

8

50

1.50 m

Morus nigra

Black mulberry

3

80

22

20

8

50

1.50 m

Peltophoroum inerme

Yellow Poinciana

3

80

22

20

8

50

1.50 m

Thespesia populnea

Portia Tree

3

80

22

20

8

50

1.50 m

Acacia colei


Spreading cm

Stem girth cm

Pot Size cm

ta

rw



qa 20

4

20

6

Australian Soap Wattle

2

20

4

20

8

60

Acacia cowleana

Halls Creek Wattle

2

20

4

20

8

50

Acacia ehrenbergiana

ov

Kimberley's Wattle

Salam

1

25

2

20

8

50

Acacia etbaica

Arad

2

20

4

20

8

50

Grey Haired Acacia

2

20

4

20

8

50

Acacia jennerae

Coonavittra wattle

2

20

4

20

8

50

Acacia kempeana

Wanderry Wattle

2

20

4

15

6

30

Acacia mountfordiae

Mountford's Wattle

2

20

4

20

8

50

Acacia saligna "Cujong"

Golden Wreath Wattle

2

20

4

20

8

50

1.0 m

Acacia tortillis

Samr

1

25

2

20

10

60

1.0 m

Boswellia sacra

Frankincense Tree

2

20

4

20

8

60

1.0 m

Caesalpinia gilliesii

Bird of Paradise Bush

3

20

5

1520

40

0.50 m

Calliandra haematocephala

Red Powder Puff

3

20

5

1520

40

1.0 m

er

et it

m

Acacia gerardii

se

2

o

Acacia anthochaera

as

Irrigation Group

Common Name

Botanical Name

Small Trees or Large Shrubs

.l. l

.

Delonix regia


Page 52

Australian Weeping bottle brush

3

20

5

1520

3

60

1.0 m

Callophyllum inophyllum

Beauty Leaf

3

20

5

24

10

80

1.0 m

Calotropis procera

Dead Sea Apple

1

25

2

1520

50

0.50 m

Carica papaya

Papaya

4

25

7

1520

3

60

1.50 m

Cassia biflora

Desert Cassia

2

20

4

20

8

50

0.75 m

Cassia fistula

Golden Shower Tree

3

20

5

1520

4

60

1.50 m

Cassia glauca

Kalamona

3

20

5

20

8

50

0.75 m

Cassia javanica

Apple Blossom Tree

3

20

5

1520

60

1.0 m

5

1520

60

1.0 m

Cordia lutea

Yellow Geiger Tree

Cordia sebestena

Scarlet Cordia, Aloe Wood

Dodonaea viscosa Dracaena draeco

rw

ta

2

20

4

20

10

50

3

20

5

20

10

50

3

20

5

1520

60

2.0 m

Hopseed Bush

2

20

4

1520

10

0.50 m

Dragon Tree

3

20

5

20

75

Eremophila longifolia "Tulypurpa"

Weeping Emu Bush

1

25

2

15

20

Eucalyptus lucens "Manyuwan"

Shiny Leaved Mallee

2

20

4

20

8

50

Eucalyptus miniata

Darwin Woolly Butt

3

20

5

15

8

50

Eucalyptus thozetiana

Thozets Gum

2

20

4

15

8

50

Geijera parviflora

Wilga

2

20

4

20

10

75

Gossypium australe "Nurom"

Australian Desert Rose

1

25

2

15

80

Gossypium bickii

Desert Rose

1

25

2

15

80

Gossypium darwinii

Darwin's Cotton

2

20

4

15

80

m

et it

ov

er

se

Myhrr

20

o

Commyphora myrrha

qa

3

as

Cassia nodosa

.l. l

Callistemon viminalis “Tubada”

.

QCS 2014

QCS 2014


Page 53

Gossypium sturtianum "Kintore'

Sturt's Desert Rose

2

20

4

15

80

Hibiscus rosasinensis

China Rose

3

20

5

1520

30

Hibiscus tiliaecius

Sea Hibiscus

3

20

5

20

Jatropha integerrima

Peregrina

3

20

5

1520

Lagerstroemia indica

Crepe Myrtle

3

20

5

1520

Lagerstroemia speciosa

Pride of India

3

20

5

24

Leptadenia pyrotechnica

Firecracker Plant

1

25

2


Texas Ranger

2

20 20

50 30

0.50 m

40

1.50 m

40

1.0 m

.l. l

.

3

rw

ta

qa

2

15

80

1520

30

0.50 m

80

1.0 m

30

1.0 m

4

24

20

5

1520

3

20

5

24

8

50

Malvaviscus arboreus pendiluflorus

Sleepy Hibiscus

Melaleuca bracteata

Black Ti Tree

Melaleuca quinquenervia

ov

8

Paperbark

3

20

5

24

10

50

Moringa perigrina

o

as

Mauera crassifolia

4

10

0.50 m

Drumstick Tree

2

20

4

20

8

80

Banana

4

25

7

1520

Myoporum floribundum

Weeping Boobialla

2

20

4

20

Nerium oleander

Oleander

2

20

4

1520

Olea europea

Olive

2

20

4

20

Pandanus utilis "Arkaroola"

Screw Palm

3

20

5

20

50

Pandanus viethchii

Variegated Screw palm

3

20

5

20

50

Plumeria obtusa

Temple Tree

3

20

5

20

3

60

1.50 m

Plumeria rubra acutifolia

Temple Tree

3

20

5

20

3

60

1.50 m

se

er

et it

m

Musa paradisiaca

3

50

8

6

0.75 m

80

30

1.0 m

60

1.50 m

QCS 2014


Page 54

Polyalthea longifolia

Mast Tree

3

20

5

33

75

Punica granatum

Pomegranate

3

20

5

1520

Scaevola frutescens

Beach Naupaka

3

20

5

20

Tabebuia argentea

Silver Trumpet Tree

3

20

5

33

10

50

1.0 m

Tabebuia spectabilis

Yellow Tabebuia

3

20

5

33

10

50

1.0 m

Tamarix aphylla

Tamarix or Athol Tree

2

20

4

15

Tamarix sp.

Athel Tree

2

20

4

25

Tecoma stans

Yellow Bells

2

20

4

1520

Tecomella undulata

Roheda

2

20

4

Thevetia peruviana nereifolia

Yellow Oleander

3

20

Vitex agnus castus

Chaste Tree

2

Vitex purpurea

Arabian Lilac

Zizyphus numalaria

Jahrber

3

40

1.50 m

40

30 50

1.50 m 1.0 m

50

1.0 m

1520

20

1.0 m

4

1520

20

0.50 m

20

4

20

50

20

4

20

ta

qa

5

20

20

10

8

30

6

40

Acacia victoriae "Alita"

Elegant Wattle

1

25

2

20

6

50

3

20

5

20

et it

m

Acalypha wilkesiana

Spreading cm

20

Stem girth cm

4

Pot Size cm


20

Irrigation Group 2

Common Name

Sims wattle

o

Acacia simsii

Botanical Name


ov

Shrubs

20

Aerva javanica

Desert Cotton or Snow Bush

1

25

2

15

Atriplex numalaria

Old Man Saltbush

1

25

2

15

30

Bougainvillea glabra

Bougainvillea

2

20

4

20

30

5


er

2

rw

20

as se

2

.l. l

.

6

0.50 m

30

1.0 m

QCS 2014


Page 55

Caesalpinia pulcherrima

Barbados Pride

3

20

5

20

40

Calligonum comosum

Arta

1

25

2

15

60

Carissa edulis

Akamba Bush

2

20

4

20

50

Carissia grandiflora

Natal plum

2

20

4

20

30

3

20

5

20

Cassia alata

0.75 m

0.50 m 0.50 m

Senna

3

20

5

20

30

0.50 m

Cestrum diurnum

Day Jasmine

2

20

4

20

20

0.50 m

Cestrum nocturnum

Night Jasmine

3

20

5

20

20

0.50 m

Crotalaria cunninghamiana

Bird Flower

2

20

4

Duranta repens

Blue Butterfly Bush

3

20

Eremophila alternifolia "Irmangka"

Narrow Leaved Emu Bush

1

Eremophila bignoniflora x polyclada "Kurubimi"

White Emu Bush

Eremophila christopheri "Areyonga"

Blue Emu Bush

.l. l

rw

30

20

50

2

15

20

ta

15

qa

5

se

as

25

.

Cassia bicapsularis

25

2

15

20

1

25

2

15

20

Red Emu Bush

1

25

2

15

20

Red Emu Bush

1

25

2

15

20

1

25

2

15

20

et it

o

ov

er

1

m

Eremophila maculata " Brevifolia Eridunda" Eremophila maculata "Atitjere" Eremophila obovata Eremophila polyclada "Imampa"

Fine Leaf Emu Bush

1

25

2

15

20

Eremophila racemosa

Pink Emu Bush

1

25

2

15

0

Eremophila Summertime Blue

Deep Blue Emu Bush

1

25

2

15

20

Euphorbia larica

1

25

2

15

60

Galphimia glauca

3

20

5

15

80

QCS 2014


Page 56

Rimth

1

25

2

15

50

Ixora chinensis

Flame of the Woods

3

20

5

20

10

0.30 m

Jasminum sambac

Arabian Jasmine

3

20

5

10-15

15

0.50 m

Lantana camara

Lantana

3

20

5

20

25

0.30 m

Lawsonia inermis

Henna

2

20

4

20

10

0.50 m

Malvaviscus arboreus

Turks Cap

3

20

5

15

80

2

20

4

15

Pandanus singaporensis pygmaeus

Dwarf Variegated Screw Palm

3

Radyera farragei

Desert Rose Mallow

2

Senna artemisioides

Narrow Leaf Desert Cassia

Senna desolata sturtii

Sturts Senna

Tabernaemontana divaricata

Pin Wheel Flower

12-15

1015

5

20

30

4

15

30

2

20

4

15

30

1

25

2

15

30

3

20

5

20

30

as

20

se

er

20

30

8

80

Callitris preissii

Cypress pine

2

70

15

24

8

60

Cupressus sempervirens

Italian Cypress

2

70

15

25

3

30

Botanical Name


24

Spread cm

22

Stem girth cm

80

Pot Size cm


3

Irrigation Group

Blue Cypress Pine

Common Name

Callitris intratropica "Oenpelli"

m


et it

Conifers

Hedge

0.50 m

o

ov

.l. l

3

rw

Madagascar Palm

ta

Pachypodium lamerei

qa

Ochradenus baccatus

.

Haloxylon salicornicum

1.50 m


Page 57

1

12

1.2

15

15

0.50 m

Atriplex lentiformis

Salt Bush

2

10

1.9

15

15

0.50 m

Clerodendron inerme

Wild Jasmine

3

10

2.5

15

15

0.50 m

Dodonaea viscosa

Hopseed Bush

2

10

1.9

15


Texas Ranger

2

10

1.9

Vitex agnus castus

Chaste Tree

2

10

.l. l

Spread cm

.

Irrigation Group

Common Name

Stem girth cm

Salt Bush

Pot Size cm

Atriplex halimus

Botanical Name

Mean Daily Demand l/m2/day/year

Section 28: Landscaping Part 01: Landscape Planting Peak Daily Demand l/m2/day

QCS 2014

0.50 m

15

15

0.50 m

15

15

0.50 m

ta

rw

15

qa

1.9

Agave

2

10

1.9

20

0.30 m

Century Plant

2

10

1.9

30

0.30 m

Agave attenuata

2

10

1.9

20

0.30 m

Agave parryi

2

10

1.9

20

0.30 m

Aloe africana

2

10

1.9

20

0.30 m

Aloe claviflora

2

10

1.9

20

0.10 m

Aloe debrana

2

10

1.9

20

0.10m

Aloe rupestris

2

10

1.9

20

0.20 m

Irrigation Group

se

er

Common Name

ov

o et it

m

Agave america mediopicta

Clear Trunk/ Total Height/ Required Size 0.30 m

Spreading cm

20

Queen Victoria Agave

Stem girth cm

1.9

Agave "Victoria Regina"

Pot Size cm


10

as 2

Botanical Name

Peak Daily Demand l/m2/day

Succulents

Agave americana

Aloe sessiflora

Lebombo Aloe

2

10

1.9

20

0.20 m

Aloe striata

Coral Aloe

2

10

1.9

20

0.20 m

QCS 2014


Page 58

Aloe vera

medical plant

2

10

1.9

20

0.30 m

Euophorbia lactea

Mottled Spurge

1

12

1.2

20

0.35 m

Kalanchoe diagremontiana

2

10

1.9

15

0.15 m

Kalanchoe rotundifolia

2

10

1.9

1215

0.15 m

Monstrous Lady Fingers

1

12

1.2

20

0.25 m

Yucca elephantipes

Soft-Tip Yucca

3

10

2.5

30

1.50 m

Yucca filamentosa

Adam's needle

3

10

2.5

30

1.50 m


15

15

1.0 m

2

20

4

20

15

1.0 m

Bougainvillea

2

20

4

20

15

1.0 m

Butterfly Pea

3

20

5

15

1.0 m

Lavender Trumpet Vine

3

20

5

20

1.0 m

Cryptostegia madagascarensis

Rubber Vine

3

20

5

15

1.0 m

Dipladenia sanderi

Brazilian Jasmine

3

20

5

20

1.0 m

Gelsemium sempervirens

Carolina Jasmine

3

20

5

20

1.50 m

3

20

5

10

15

0.30 m 0.30 m

Bougainvillea

Bougainvillea spectabilis Clitoria ternata

Ipomea pes-caprae

Spreading cm

Stem girth cm

Pot Size cm

qa

as

ov

et it

m

Clytostoma callistegioides

er

Bougainvillea sp

se

Common Name Coral vine

ta

Peak Daily Demand l/plant/day

5

Antigonom leptopus

Irrigation Group

20

Botanical Name

3

o


.l. l

30

rw

Vines

.

Mamelaria elongata

Ipomoea palmata

Railway creeper

3

20

5

10

15

Jacquemontia violaceae

Sapphire Vine

3

20

5

15

80

QCS 2014


Page 59

Jasminum officinalis "Grandiflorum"

3

20

5

15

15

1.0 m

Lonicera sempervirens

3

20

5

15

15

1.0 m

Petrea volubilis

Purple Wreath

3

20

5

20

30

Pyrostegia venusta

Flame Vine

3

20

5

15

50

Quisqualis indica

Rangoon Creeper

3

20

5

15

15

Tecoma capensis

Cape Honeysuckle

2

20

4

20

30


Spread cm

.l. l Stem girth cm

Pot Size cm

qa

ta

rw



as

Irrigation Group

Common Name

Botanical Name

.

Ground covers

1.0 m

3

10

2.5

10

30

0.20 m

2

10

1.9

10

30

0.20 m

2

10

1.9

15

15

3

10

2.5

10

30

Australian Saltbush

1

12

1.2

15

10

Canavalia rosea

Beach Pea

2

10

1.9

15

50

Canna indica

Lana

4

12

3.2

10

10

0.30 m

Carissa prostrata

Natal plum dwarf

3

10

2.5

10

30

0.30 m

Clianthus formosus

Sturts Desert Pea

1

12

1.2

15

35

Cortaderia selloana

Pampas grass

3

10

2.5

10

10

2

10

1.9

15

15

Baby sun rose

er

Aptenia cordifolia

se

Alternanthera versicolor

ov

Arctotis hybrids Asparagus densiflorus

et it

m

Atriplex semibaccata

0.30 m

o

Asparagus fern

Crassula multicava Cuphea mexicana compacta

Mexican Heather

3

10

2.5

15

15

Cyperus alternifolius

Umbrella sedge

4

12

3.2

10

10

0.30 m

0.30 m

QCS 2014


Page 60

Delaspermum alba

White ice plant

2

10

1.9

10

10

0.10 m

Drosantemum hispidum

Rose ice plant

2

10

1.9

10

10

0.10 m

Echeveria elegans

2

10

1.9

15

10

Encelia farinosa

2

10

1.9

15

10

Arakoora Emu Bush

1

12

1.2

15

20

Euphorbia milii

Crown of Thorns

2

10

1.9

10

20

Frankenia hirsuta

Hairy Sea Heath

1

12

1.2

15

Gazania rigens

Treasure flower

2

10

1.9

10

10

Heliotropium curassavicum

Wild Heliotrope

1

12

1.2

1215

25

Ipomea pes-caprae

Railroad Vine

3

2.5

10

1015

Ipomoea batata

Ornamental Sweet Potato

Ipomoea palmata

Railway creeper

Iresine herbstii Lampranthus aurantiacus

.l. l

rw

ta

qa

0.10 m

10

2.5

15

20

3

10

2.5

10

1015

0.30 m

Blood leaf

3

10

2.5

10

1015

0.20 m

2

10

1.9

1215

30

Orange Ice Plant

2

10

1.9

10

1015

2

10

1.9

1215

30

ov

er

se

as

0.30 m

3

et it

m

Lampranthus aureus

10

o

10

0.30 m

.

Eremophila arookara "Amoonguna"

Lampranthus saturatus

0.70 m

Lampranthus spectabilis

Trailing Ice Plant

2

10

1.9

10

1015

0.10 m


Geeper lantana

3

10

2.5

10

1015

0.30 m

1

12

1.2

1215

20

1

12

1.2

10

1015

Limmonium axillare

Limonium sinuatum

Sea- Lavender

0.20 m

QCS 2014


Page 61

Lippia nodiflora

Lippia

3

10

2.5

1215

10

Ocimum basilicum

Sweet basil

3

10

2.5

10

1015

0.30 m

Osteospermum fruiticosum

African daisy

2

10

1.9

10

1015

0.20 m

3

10

2.5

1215

15 1015

Pedilanthus thymaloides Beach grass Fountain grass

2

10

1.9

10

Pennisetum setaceum rubrum

Purple fountain grass

2

10

1.9

10

Portulacaria afra

Jade Plant

2

10

1.9

Pseuderanthemum atropurpureum tricolor

Chocolate Plant

3

Rhoeo discolor

Moses in the Cradle, Boat lily

Rhoeo spathacea

Moses In The Cradle

Rosmarinus officinalis Ruellia tuberosa

0.30 m

rw

.l. l

.

Pennisetum setaceum

1015

0.30 m

1015

2.5

15

20

0.30 m

0.20 m

qa

ta

10

10

as

2.5

10

1015

3

10

2.5

1215

10

Rosemary

2

10

1.9

10

1015

0.20 m

Ruellia

o

3

10

2.5

1015

15

0.50 m

Coral plant, Firecracker Plant

3

10

2.5

10

1015

0.30 m

Sesuvium portulacastrum

Sea Pureslane

2

10

1.9

10

1015

0.20 m

Setcreasea pallida

Purple Heart

3

10

2.5

10

1015

0.15 m

Tradescantia pallida

Purple Heart

3

10

2.5

1215

10

Verbena tenuisecta

Moss Verbena

3

10

2.5

1215

10

Vitex rotundifolia

Beach Vitex

2

10

1.9

1215

20

er ov

m

Russelia equisetiformis

se

3

et it

10

Wedelia trilobata

Creeping Daisy

Page 62

3

10



Irrigation Group

QCS 2014

2.5

1015

10

0.15 m


Spread cm

Stem girth cm

Pot Size cm

10

10

Amaranthus tricolor

Joseph's Coat

10

10

10

One flower

Antirrhinum majus

Floral Snapdragon

10

10

10

One flower

Asclepias curassvica

Blood Flower

10

10

One flower

Calendula officinalis

Port Marigold

10

10

10

One flower

Callistephus chinesis

China Aster

10

10

10

One flower

Catharanthus roseus

Madagasar Periwinkle

10

10

10

One flower

Celosia cristata

Fair Fountains

10

10

10

One flower

Cockscomb

10

10

10

One flower

Celosia plumosa

Burut Plume

10

10

10

One flower

Chryanthemum morifolium

Florist's Mum

10

10

10

One flower

Chrysanthemum carinatum

Monarch Court

10

10

10

One flower

Cosmos bipinnatus

Mexican Aster

10

10

10

One flower

Dianthus barbatus

Sweet William

10

10

10

One flower

o

et it

m

Celosia cristata var.nana

se

as

10

ta

rw

.l. l

.

10

qa


Floss Flower

ov

Ageratum mexicanum

er

Common Name

Botanical Name

Seasonals

One flower

QCS 2014


Page 63

Chinese Pink

10

10

10

One flower

Gaillardia pulchela

Blanket Flower

10

10

10

One flower

Gazania splendens

Gazania

10

10

10

One flower

Gomphrena globosa

Globe Amaranth

10

10

10

One flower

Kochia scoparia

Summer Cypresus

10

10

10

One flower

Lobularia maritima

Sweet Alysum

10

10

10

10

10

rw

.l. l

.

Dianthus chinensis


10

10

One flower

10

10

10

One flower

10

10

10

One flower

10

10

One flower

10

10

One flower

Scarlet Sage

10

10

10

One flower

Senecio cineraria

Dusty Miller

10

10

10

One flower

Tagetes

Marigold

10

10

10

One flower

Verbena peruviana

Aztec Queen

10

10

10

One flower

Viola tricolour

Kiss-Me-Love

10

10

10

One flower

Zinnia sp.

Zinnia

10

10

10

One flower

Garden Geranium

Pellionia pulchra

Training Begoria

Petunia x hybrida

Petunia Hybrid

Polianthes tuberosa

The Pearl

er

10

Portulaca graniflora var. Corniche

Moss Rose, Sun Plant

10

et it

m

Salvia splendens

Grass

se

as

qa

10

o

ov

Pelargonium x hybrida

ta

10

Mathilola incana

10

1.9

15

20

Cymbopogon citratus

Lemon Grass

3

10

2.5

15

15

Cynodon dactylon

Bermuda grass

3

10

2.5

Imperata cylindrica

Blood Grass

3

10

2.5

Paspalum vaginatum notatum

Bahia grass, Seashore Paspalum

3

10

2.5

Pennesetum villosum

African Fountain Grass

2

Pennisetum divisum

Dwarf Fountain Grass

Pennisetum macrourum

African Feathergrass

Stipagrostis plumosa

Desert Grass

Zoysia japonica

Japanese Grass

qa

Spread cm

. .l. l

rw

ta

0

1.9

15

30

1

12

1.2

15

30

2

10

1.9

15

30

2

10

1.9

1215

20

3

10

2.5

se

10

as

Common Name

er

15

o

ov

Stem girth cm

2

Pot Size cm


Australian Lemon Grass

Botanical Name Cybopogon ambiguus


Page 64



Irrigation Group

QCS 2014

Edging Plant Beds

1

Planting beds shall be uniformly edged, using a sharp tool to provide a clear cut division line between the planted area and adjacent area and to provide the required shape. The entire planted area shall be raked smooth while retaining the earth saucers.

2

Edging materials shall be installed in accordance with the manufacturer’s instructions.

1.5.11

Mulch

1

Mulch shall be spread to a uniform depth of 100 mm no later than 48 hours after planting. Mulch should be kept out of lawn areas, crowns of shrubs and off paved areas and buildings.

1.5.12

Watering of Plants

1

The contractor shall water the plants as necessary to maintain an adequate supply of moisture within the root zone and maintain healthy growth. The water shall be allowed to flow gently around the plant and shall not be delivered to cause disturbance to the roots or soil. Run-off, puddling and wilting shall be prevented. Earth saucers shall be rebuilt as needed to retain water.

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QCS 2014


Page 65

Pruning

1

Immediately after planting, all plants are to be pruned as directed by the Engineer and in accordance with accepted horticultural practices. The total amount of foliage shall be pruned by one fourth to one third on the installed trees and shrubs to compensate for loss of roots and transporting shock. Pruning shall be done to carefully. Any damaged, dead or diseased branches shall be cut back and any weak or malformed growth shall be removed. The typical growth habit of the individual plant shall be retained.

2

Cuts shall be clean and shall be made flush with the parent trunk or branch. Improper cuts, stubs, dead and broken branches shall be removed. Right angle cuts to the line of growth shall not be permitted. Trees shall not be poled or the leader removed, nor shall the leader be pruned or topped off. Cuts or wounds shall be painted with an appropriate wound dressing.

1.5.14

Anti-Desiccant Application

1

Plants requiring additional protection against wilt and shock shall be sprayed with antidesiccant in accordance with the manufacturer’s instructions.

1.5.15

Clean up and Site Restoration

1

Excess and waste material shall be removed daily. Pavements and work areas shall be kept in a clean and orderly fashion. Pedestrian access points and vehicular access points shall be maintained and kept clear at all times. All rubbish and litter shall be cleared as it accumulates within the landscape work area.

2

When planting and turf work has been completed, all debris including subsoil, excess agricultural soil, litter, and debris shall be removed and disposed of at a location as agreed with the Engineer

3

Existing turf areas, pavements and facilities that have been damaged from planting operations shall be restored to the original condition at the Contractor’s expense.

1.5.16

Maintenance during Planting Operations

1

Newly installed plants shall be maintained in a healthy growing condition.

2

Maintenance operations shall begin immediately after each plant is installed and shall continue until the plant establishment period commences.

3

Maintenance includes watering, pruning, wound dressing, straightening and other necessary operations.

4

Plant beds and saucers shall be kept free of weeds and other undesired vegetation.

5

Plants shall be checked for settlement and shall be reset to the proper level as necessary.

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1.5.13

QCS 2014


Page 66

EXISTING LANDSCAPING

1.6.1

Care of Existing Landscaping

1

Where construction procedures or site conditions may cause damage or impact to existing landscaping, it shall be the Contractor’s responsibility to take measures as described below to protect and maintain such plant materials throughout the duration of the project, or to replace such materials at his own expense if accepted by the Engineer.

1.6.2

Identification of Existing Plants

1

Existing plants shall be tagged with a durable, waterproof and weather resistant label indicating the correct plant name. Labels shall be securely attached and not removed until directed by the Engineer.

1.6.3

Watering and Fertilizing Existing Non Native Trees

1

Holes at 600 mm centres shall be dug by hand or with a mechanical device, a minimum 40 mm in diameter and 500 mm deep, over the outer half of the branch spread zone of each tree.

2

Slow release fertiliser shall be placed in each hole to within 100 mm of the surrounding ground level.

3

The holes shall be backfilled with approved soil.

4

Plants shall be irrigated regularly to maintain them in good condition and where necessary a 150mm earth berm shall be formed to contain the water within the plants root zone

1.6.4

Fertilizing Existing Non Native Shrubs and Groundcover Beds

1

Existing shrubs and groundcover beds shall be topdressed with slow release fertiliser. Fertiliser adhering to plants shall be flushed with water.

1.6.5

Watering Native Trees, Shrubs and Groundcovers

1

Existing plants shall be irrigated regularly to maintain them in good condition and where necessary a 150mm earth berm shall be formed to contain the water within the plants root zone.

1.6.6

Pruning and Cavity Work

1

A suitably qualified tree surgeon shall perform the required pruning and cavity work on existing plants. Sucker growth, deadwood larger than 15 mm in diameter, branches interfering with or hindering growth of plants and diseased branches shall be removed.

2

The contractor shall cut back or remove branches as necessary to give plants proper shape and balance.

3

Stubs, improper cuts and broken limbs shall be removed.

4

Cuts shall be clean and shall be made flush with the parent limb or trunk. Cuts, wounds and cavity work shall be painted with an appropriate tree wound dressing.

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1.6

QCS 2014


Page 67

PLANTING MATERIALS

1.7.1

General

1

Planting materials are to comply with BS 3936: 1980 and Part 10: 1981, free from pest and diseases, representative of their species or variety, or size not less than specified in plants Table Table 9a and 9b, with well-branched head and vigorous root system, free from injury and obtained from a nursery or other approved sources.

2

All plants and turf material will conform to the varieties specified or shown in the Project Documentation and be true to the botanical name as listed in publications.

3

Substitutions shall only be made when a plant or alternative as specified is not obtainable and the Engineer authorises a change order providing for use of the nearest equivalent obtainable.

4

Plants shall be supplied from localities similar to the climatic conditions of the Project.

1.7.2

Nomenclature

1

The Contractor shall ensure that nomenclature of trees and plants shown on the drawings conform to the approved standards and literatures of this section.

2

Trees are to have straight trunks or trunks characteristics of species, well-shaped tops, and intact leaders and are to be undercut at least once in the nursery. All trees are to be supplied earth balled and hessian covered or container grown. Trees shall be of the quantities, species, and sizes as shown in plants table Table 9a and 9b defining the perimeter or the circumference of the trunk measured at 1.50 m from the base.

3

Fruit trees shall be grafted on true rootstock, graft to be at least 20 about planting soil level, one meter minimum height or as specified by the Engineer.

4

Palms are to have crown of new leaves, proper colour of leaves of adult palms, and sufficient hardiness. Palms are to be supplied earth balled and hessian covered, with the exception of imported palms, handling of which may be subject to government current regulations. Palms shall be of the quantities, species, and sizes as shown in the plant materials schedule in the drawings.

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1.7

(a)

Date palms to be minimum 2 m and maximum 3 m straight clear trunk female type local variety of “KHALAS, KHNAIZI, SHISHI, OR BERHI” from approved nursery. Height of palms shall be as per plants Table Table 9a & 9b.

(b)

Palm trees could be imported if not available locally but the root system shall be at least 30 cm around the base of the tree in all direction. Local palm trees shall have a root zone at least 50 cm around the base of the tree in all direction.

5

Shrubs are to be well grown and filled out. Deciduous shrubs may be supplied bare rooted, earth balled, or container grown. Evergreen shrubs and vines are to be either earth balled or container grown. Shrubs shall be of the quantities, species and sizes as shown in the plants table Table 9a & 9b.

6

Hedges shall have a spacing of 30 to 50 cm and height as specified in plants table Table 9a & 9b and planted as single row in one straight continuous trench.

QCS 2014


Page 68

Ground covers and succulents plants which are provided in pots and other containers and which have been acclimatized to outside conditions are acceptable provided they are equal in quantity to field grown stock and are not root bound. Ground cover plants shall be of the species, sizes, and spacing shown on the plant materials schedule plants table Table 9a & 9b.

1.7.3

Guaranties – Planting Material

1

The Contractor shall certify in writing that all plant material of each consignment delivered to site to be utilized will be according to these specifications are true to their species. If contractor supply through import, he shall submit a guaranty of availability of plants with specified characteristics sizes, height, calipers etc. Issued by the supplier for engineer’s approval.

2

The Contractor shall also submit certificate of origin, phyto sanitary certificate and certificate of guarantee from supplier stating that the imported plants are true to the specified speciesvarieties for engineer’s approval.

3

If the plants are to be grown in Qatar, samples of all specified varieties shall be submitted in the form of a reserved plot at the mother nursery ready for inspection and approval by the Engineer.

4

Due to some project need the Engineer could ask for site nursery to be used for storing and caretaking of plants prior to planting. This site nursery shall have its own water tanks, power, shade and irrigation system.

5

Trees, shrubs, ground cover and grass shall be guaranteed for the duration of the 400 days maintenance period. Palm trees shall be guaranteed for a period of 400 calendar days after installation approval.

1.7.4

Accessories

1

Stakes for Trees:

De-barked timber, straight, free of knots, splits or other projections, pointed at the end, lower end to min. 15 cm above grade level shall be treated with non-injurious wood preservative carried out at least two weeks before stakes are used, minimum section 50 mm and length 2 m depending on height of a tree. The stakes shall be laid 50 cm deep in the soil.

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7

2

(b)

Position two stakes close to tree but outside the perimeter of the root-ball, and drive vertically a minimum 50 cm into pit and until top of stake is required height.

(c)

Consolidate material around stake during backfilling, secure trees with wire and tree tie as shown on drawings.

Stakes for Small Shrubs and Hedges: (a)

De|-barked timber, straight, free of knots, splits or other projections, pointed at the end, lower end to min. 15 cm above grade level shall be treated with non-injurious wood preservative carried out at least two weeks before stakes are used, minimum section 25 mm and length depending on height of a shrub or hedge. The stakes shall be laid 30 cm deep in the soil.

QCS 2014 (b)


Page 69

Position one stake close to shrub or hedge but outside the perimeter of the root-ball, and drive vertically a minimum 30 cm into pit and until top of stake is required height.

Protection shelter for fruit and specimen trees shall be made of 4 wood stakes 2 meter long, 5x5 cm section and 30 cm deep in the ground at 10 cm away from tree branches. The wooden stakes are wrapped with shade net 70% shade factor and braced one to the other on top.

4

Guys for Palms: Only for palms with root balls less than 40 cm. Palms shall be tied to the ground from 50 cm below crown with three gI wire placed inside a 15 mm Polyethylene Tube around the palm trunk, and tied to steel anchors dug 60 cm deep into the soil and flush with ground level.

5

Tree Stakes Wires: 3 mm diameter, solid galvanized wire in suitable lengths fixed to a position approximately two thirds of a tree height, looped around the stem and protected by an approved tree-tie.

6

Twine for Tying: lightly tarred medium or coarse sisal yarn.

7

Burlap: jute of 0.20 kg/m2 or cloth having same strength and resistance to tearing and capable of rotting in the ground.

8

Plastic Mowing Strip: Super-Edge made of durable, flexible polypropylene.

as

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3

The edge shall have 3.5 to 4% carbon black concentrate added for UV stabilization and medium density with a melt factor under 2. Minimum average thickness shall be 95/1000 to 95/1000 of an inch.

(b)

Overall height shall be 5 inches minimum. Top edge shall have a 1 inch horizontal circle and galvanized steel anchoring stakes at least every 2 meters.

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(a)

Rubber Ties: Shall be manufactured from UV stabilize rubber or equal approved by engineer. It shall be ideally suitable for outdoor application.

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A 15 years guarantee shall be given against cracking, rot, disintegration and manufacturer defects.

(b)

The type of rubber ties shall be chain look or strap or twist look or equivalent.

10

Labels: Each plant, or group of plants or container of the same species, variety, and size of plant, shall be legibly tagged with a durable, waterproof and weather resistant label indicating the correct plant name and reference number if applicable. Labels shall be securely attached and not removed.

1.7.5

Transplanting Plants

1

Certificates: provide manufacturer’s or supplier’s certified analysis for fertilizer materials and other substantiating that materials comply with specified requirements.

2

Samples: submit samples of materials for approval. For standard products, the manufacturer’s analysis will be acceptable. For all other materials, analysis is to be provided by recognized laboratories.

QCS 2014


Page 70

Inspection: the Engineer reserves the right to inspect trees and shrubs either at place of growth or on site before planting, to verify compliance with requirements for names, variety, size and quality, condition of root systems, presence of insects, injuries, and latent defects. Remove rejected trees and shrubs immediately from site at Contractor expenses.

4

Planting Schedule: the Contractor shall submit planting schedules, showing proposed planting dates for each type of planting to be approved by the Engineer taking into consideration season limitation on planting seasonal plants, grass, and palms.

5

Packaged Materials: deliver packaged material in unopened containers showing weight, analysis, and name of manufacturer. Protect materials from deterioration during delivery and while stored in site. Damaged materials are to be replaced as required.

6

Manufacturers’ Recommendations: apply fertilizer, herbicides and the like strictly in accordance with manufacturers’ recommendations, observe all precautions. Remove containers from site when no longer required.

1.7.6

Planting Time

1

Plant during normal planting seasons for each type of plant as approved by the Engineer.

2

Do not plant when soil is waterlogged or excessively dry or when persistent cold or drying winds are likely to occur, obtain approval from the Company to vary planting dates if special conditions so warrant.

3

Give the Engineer 48 hours notice before commencing planting, maintenance, or replacement work using checklists supplied by the Engineer.

4

No planting shall be carried out during periods of heavy rain, sandstorms, heavy winds, or during intense daytime heat. Plants and trees shall only be moved or planted between midSeptember and mid-May.

5

When special conditions warrant a variance to the planting time and conditions, a proposed planting schedule shall be submitted to the Engineer for review and approval. In such cases, the planting will be installed at no additional cost and all conditions and obligations such as maintenance and warranty remain the same as specified herein

1.7.7

Water Consumption

1

Daily water requirement for different plant type is as shown below in Table 10

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3

(a)

Daily water requirement will differ depending on season and particular type of ground cover and shrub species.

(b)

During Rain: Irrigation system feeding drip emitters shall be switched off, when precipitation rate exceeds 12mm, otherwise allow for more salt leaching effects to happen.

QCS 2014


Page 71

Table 10: Peak Daily Water Requirements See Irrigation 2.6.1 for details Daily Water Requirement

Palms

120 ltr/day/palm

Large trees

80 ltr/day/per tree

Small trees

60 ltr/day/tree

Ground cover

10 ltr/day/m

2

Seasonals

10 ltr/day/m

2

Hedges

12 ltr/day/m length

Large shrub

20 ltr/day/plant

Small shrub

8 ltr/day/plant

qa

ta

rw

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.

Plant Type

Grass

12-18 ltr/day/m

2

se

as

Note the above rates are peak rates for maximum demand volume calculations. Seasonal gradation needs to be calculated for annual irrigation water budget as per Section 28 Part02 Irrigation system Appendix 2.6.1. Actual irrigation water scheduling shall be based on weather station to ensure only the required water is delivered to the plant Percolation Test

1

Fill each planting pit with irrigation water and ensure that the water can drain away. In case of poor drainage, a percolation test shall be carried out and drainage holes augured if required.

2

Percolation Test Procedure: One day prior to the test the pit/bed shall be filled with water.

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1.7.8

(b)

A marker bar is placed in the pit/ bed before the test is performed.

(c)

The pit / bed are half filled with water and the level is indicated with tape on the marker bar.

(d)

The test is monitored over a period of one hour. If the water level drops by 20 mm. or more within that time the pit/ bed passes.

(e)

If a pit/ bed fail the percolation test, boreholes shall be augured 2 No/tree pit or 10 m spacing in planting beds. Tests shall repeat at each 0.5 m depth of borehole until the test is passed.

1.7.9

Installation for Trees and Shrubs

1

Plants shall be handled carefully and arranged so they take full advantage of the individual character of each plant in relationship to other plants.

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Plants shall be placed in the centre of each pit, set plumb and held in place until sufficient backfill mixture has been firmly placed around the root ball. Plants shall be placed so that the level at which they were set with respect to surrounding ground level before installation is the same as after installation.

3

Ball and burlap plants shall have twine, metal, plastic and wire ties removed from the tops of the earth ball after backfill soil has been placed to approximately two thirds of the ball depth, tamped lightly and watered. Backfilling around plant shall be completed in 150 mm layers after water has drained away. Burlap wrapping shall not be pulled out from under the earth ball.

4

Plants supplied in non-biodegradable containers shall be removed in such a way as to prevent damage to plant or root system. Before planting, any damaged or broken roots shall be carefully trimmed and removed.

5

A 100 to 150 mm high earth saucer shall be formed around individual plants. The diameter of the saucer should be larger than and outside the backfilled area.

6

After planting, plants shall be guyed or staked as required or directed by the Engineer. Trees and shrubs shall be protected against wind and sun with burlap wrapping where necessary or directed to ensure satisfactory establishment of plant.

7

Trees 1.2 to 1.8 m tall shall be held in place with one 1 bracing stake. The stake shall be positioned close to the tree on the windward side. The stake shall be driven vertically into firm ground taking care not to injure the roots. The tree shall be held firmly to the stake with a double strand of wire placed 1m above ground level. A chafing guard shall be used were the wire is in contact with the tree.

8

Trees 1.8 to 2.5 m tall shall be held in place with two 2 bracing stakes placed on opposite sides. The stake shall be driven vertically into firm ground taking care not to injure the roots. The tree shall be shall be held firmly in place placed 1m above ground level with a double stand of wire Chafing guards shall be used where the wire is in contact with the tree.

9

Trees taller than 2.5 m shall be held firmly in place with three 3 guying lines of double strand wire placed equidistantly around the tree. The wire shall be anchored with ground stakes driven into firm ground outside the earth saucer. The wire shall be anchored to the tree at a point equal or greater than one third of its height. A flag shall be securely fastened to each guying wire.

1.7.10

Installation of Palms

1

Palms shall be lifted and moved with a crane or other approved method to avoid any damage to any part of the palm.

2

Palms shall be placed in the centre of each pit, set plumb and held in place until sufficient backfill mixture has been firmly placed around the root ball. The top of the root ball should be 100 mm below the top of the planting pit. The pit shall be backfilled with specified mixture to approximately two thirds of depth of the root ball, tamped lightly and watered. Backfilling around plant shall be completed in 150 mm layers after water has drained away. A 100 to 150 mm high earth saucer shall be formed around the palm. The diameter of the saucer should be larger than and outside the backfilled area.

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GRASS

1.8.1

Materials and Products

1

Grass Stolons: Paspalum vaginatum, Bermuda or other type as specified by the Engineer minimum age of 12 months, with root of sufficient development that will support growth. Submit certification for grass species.

2

Grass sprigs shall be provided as healthy living stems stolons or rhizomes with attached roots including two to three nodes. They shall be 5 to 15 mm long without adhering soil. The limitation of time between harvesting and planting of sprigs shall be 24 hours. Sprigs shall be obtained from heavy and dense turf, free from weeds. Sprigs that have been exposed to heat and excessive drying will be rejected. Sprigs shall be planted at 150 mm apart in both directions.

3

Turf shall be strongly rooted, not less than 2 years old, free of weeds and undesirable native grass. Only turf that is capable of vigorous growth and development when laid shall be used. Turf shall be of a uniform size in width and length. Broken pads or pads with uneven ends will not be acceptable.

1.8.2

Workmanship

1

Provide manufacturer's or supplier's certified analysis for grass and fertilizer materials and other data substantiating that materials comply with specified requirements.

2

Provide certificate of compliance from authority having jurisdiction indicating approval of fertilizer and herbicide composition and mixtures.

3

Submit samples of materials for approval. For standard products, the manufacturer's analysis will be acceptable. For all other materials, analysis is to be provided by recognized laboratories.

4

Supplier/Grower shall be a Qatar based company or equivalent specializing in the production/propagation of the work of this section.

5

Installer shall have a minimum of 5 years experience and approved by the Engineer.

6

Deliver packaged materials in unopened containers showing weight, analysis, and name of manufacturer. Protect materials from deterioration during delivery while stored on site. Damaged materials are to be replaced as required.

7

Apply fertilizer, herbicides, and the like strictly in accordance with manufacturers' instructions, observe all precautions. Remove containers from site when no longer required.

8

Co-ordinate with installation of underground sprinkler system piping and watering heads. Coordinate with installation of trees, palms, shrubs and groundcover.

1.8.3

Soil Preparation

1

Final cultivation of planted areas: remove stones and fill eroded areas with fresh topsoil in case found.

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Final cultivation of seeded grass areas: after final grading, lightly and uniformly firm soil and reduce top 100 mm to fine tilts. Rake to true, even surface, removing stones more than 25 mm in any dimension. Add organic fertilizer or inorganic fertilizer at recommended and approved rates.

3

Obtain approval of prepared soil areas before seeding.

1.8.4

Delivery

1

Deliver grass in stolons, or sprigs form bundled and packaged in accordance with standard trade practices.

2

Do not deliver sprigs quantities which is more than can be spread and planted within 24 hours.

1.8.5

Seeding

1

Grass seed shall be the latest season’s crop and shall be delivered in original sealed packages bearing the producer’s guaranteed analysis for percentage of mixtures, purity, weed seed content, and inert material. Seed that has become wet, mouldy, or otherwise damaged will not be acceptable. On-site seeding shall be done in the presence of the Engineer. The seed mixture shall be sown at the rate of 35 g/m2. Grass seed mixtures shall be listed by schedule with information as follows:

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botanical name

(b)

common name

(c)

proportion by weight

(d)

minimum percentage of pure seed

(e)

minimum percentage of germination

(f)

maximum percentage of weed seed

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Do not sow if soil is waterlogged or excessively dry or when persistent drying winds are likely to occur.

3

One day before sowing apply inorganic fertilizer at the rate of 50 gm/m over grass areas and water in.

4

Spread seed evenly at rate of 1 kg/30 m or as stated on supplier’s catalogue and approved by the Engineer applied in two equal sowings in transverse directions. Lightly harrow or rake and water.

1.8.6

Preparation and Installation of Carpet Grass

1

Verify that prepared soil mixture base is ready to receive the work of this section.

2

Prepare sub-soil and eliminate uneven areas and low spots.

3

Maintain lines, levels, profiles and contours. Make changes in grade gradually to blend slopes into level areas.

4

Scarify topsoil to a depth of 100 mm where soil mixture is placed.

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Repeat cultivation in areas where equipment used for hauling and spreading soil mixture has compacted subsoil.

6

Co-ordinate works with irrigation installer and utility inspections prior to this work.

7

Placing soil mixture: refer to section 1.3.17 & 1.3.18 above.

8

Roll carpet grass with a use of water drum roller to compact lightly.

9

Fill low patches and low areas with dune sand as final levelling.

10

Irrigate adequately to saturate the top 100mm of soil.

1.8.7

Watering, Cutting, and Completion

1

During establishment of grass areas ensure that sufficient water is applied to maintain healthy growth. Carry out watering using sprinkler until full depth of topsoil is saturated.

2

Separate grassed planting bays planting separator from adjacent ground covers, shrubs, or aggregate finish areas by approved plastic mowing strips fixed to manufacturer's recommendations.

3

When 90% of area is covered by grass, cut first cut to a height of approximately 40 mm using mowing machines in preference to cutting knives. After cutting, fertilize area covered 2 by grass with sulphate of ammonia at the rate of 30 gm/m then water thoroughly.

4

Mow subsequent cuts to keep grass at approximately 50 mm height.

5

Remove soil from hard surfaces and leave the site in a clean and tidy condition.

1.9

APPLICATION OF PESTICIDE

1.9.1


1

When pesticide becomes necessary to remove a disease or pest, a trained and certified operative shall apply the required pesticide in accordance with the recommendations of the manufacturer.

2

Hydraulic equipment shall be provided for liquid application of pesticides with a leak proof tank, positive agitation methods, controlled application pressure and metering gauges.

3

Prior to application the Contractor shall submit a pesticide treatment plan to the Engineer.

1.10

WARRANTY, MAINTENANCE AND HANDOVER

1.10.1

Plant Establishment and Warranty Period

1

Upon substantial completion of landscaping works as approved by the Engineer, the plant establishment period for maintaining installed plants in a healthy growing condition shall commence. The plant establishment period shall be in effect until the end of the warranty period. At the end of the warrantee period, all plants and turf shall be in a healthy and living condition.

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When planting operations extend over more than one season or there is a variance to the planting times, the plant establishment periods shall be furnished for work completed, as directed. Written calendar dates shall be furnished to the Engineer for the beginning of the plant establishment period. When there is more than one plant establishment period, the boundaries of the planted areas covered for each period shall be detailed.

1.10.2

Plant Maintenance during the Establishment Period

1

Maintenance of plants shall include straightening plants, tightening stakes and guying material, repairing wrapping, protecting plant areas from erosion, supplementing mulch, application of tree wound dressing, removing dead or broken tip growth by pruning, maintaining edges of plant beds and earth saucers, maintaining plant labels, salinity control, watering, weeding, removing and replacing unhealthy plants, pesticide treatment and other horticultural operations necessary for proper plant growth and keeping the Site neat in appearance. The Contractor shall provide all necessary labour, equipment and materials to comply with this operation.

2

Watering shall be conducted regularly to maintain an adequate supply of moisture within the root zone.

3

Weed control and debris removal shall be routinely performed by the Contractor. Grass and weeds shall not be allowed to reach a height of 50 mm in any tree basin or around any plant before being completely removed, including the root growth.

4

Throughout the maintenance the Contractor shall continue a fertiliser programme to maintain soil nutrients, and fertility suitable to proper plant growth.

5

Amended agriculture soil shall be added to maintain finished ground levels and to maintain earth saucers. Serious settlement affecting the setting /level of the plant in relation to the depth at which it was grown will require replanting in accordance with Clause 1.5.

6

Treatment for disease or pest shall be in accordance with Clause 1.10.

1.10.3

Replacement Plants during the Establishment Period

1

A survey of the landscaping works shall be carried out fifty 50 days after acceptance of substantial completion. Following the survey, the Engineer will direct the Contractor to remove and replace all plants determined as dead. Plants reviewed that exhibit questionable abilities to survive will be tagged by the Contractor in the presence of the Engineer and be reviewed after an additional twenty five 25 days to determine acceptance or rejection. The Contractor shall make reasonable efforts to stabilise the quality of the tagged plants.

2

All replacement planting shall be at the Contractor’s expense.

1.10.4

Lawn Maintenance during Plant Establishment Period

1

Maintenance shall consist of watering, fertilising, weeding, mowing, trimming and other operations as required to establish a smooth acceptable lawn free of eroded or bare areas. If required, the Contractor shall apply maintenance fertiliser after the second mowing. Any additional fertiliser shall be added when grass is dry. After application of the fertiliser, the area shall be watered well

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The Contractor shall maintain lawns for not less than the period stated below and longer as required to establish an acceptable lawn.

3

Seeded lawn areas shall be maintained through three 3 maintenance cuttings but not less than sixty 60 days after substantial completion.

4

Sprigged and turfed lawn areas shall be maintained through two 2 maintenance cuttings but not less than thirty 30 days after substantial completion.

1.10.5

Final Acceptance

1

Prior to the completion of the plant establishment period, a preliminary inspection shall be undertaken by the Engineer. The time for this inspection shall be established in writing. The quantity and types of plants installed and the acceptability of the plants shall be determined. The plant establishment and warranty period will end with this inspection provided that the Contractor has complied with the work required under Clause 1.11.1. The Contractor shall also comply with the following requirements.

2

Dead, missing or defective plant material or turf shall be replaced. Replaced plants will be of the same size and species as originally specified.

3

Weed plant beds and saucers. Prior to inspection treat these areas with an application of approved pre-emergent herbicide.

4

Remove stakes, guy wires and wrappings from plants as directed by the Engineer.

5

Complete remedial measures as directed by the Engineer.

6

Repair damages caused while making plant or turf repairs.

7

A final inspection, if required, shall be undertaken by the Engineer to determine that the deficiencies noted in the preliminary inspection have been corrected. The time for this inspection shall be established in writing.

1.11

MAINTENANCE

1.11.1

General

1

Maintenance Personnel: to have experience in Qatar based landscape contracting company specializing in installing and planting.

2

Maintenance Manual: upon completion of defects and liability period, and prior to final acceptance, provide the company with four 4 copies of a bound, waterproof maintenance manual.

3

The manual shall contain seasonal irrigation water and fertilizer application rates, pesticide, insecticide, fungicide and herbicide applications by plant type.

4

Maintenance Manual shall also include in detail all general landscape maintenance procedures for soil and all types of planting groups being part of this project, including but necessarily limited to:

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(a)

pruning, trimming, thinning, edging, mowing, fertilization, top-dressing, weeding, irrigation, disease control, insect control, pest control, weed control, re-sprigging, replanting, pruning, repairs, thinning,

(b)

The minimum requirements for fertilizer application program are as per Table 11 & 12.

(c)

The manuals shall be both in Arabic and English

Penalty for Non-Performance/ Delay: Due to the nature of the soft landscaping and the effect it has on the public appearance, the Contractor must carry out the maintenance work as scheduled and direct by the Engineer. Failure to do so will have severe consequences on the Contractor and the Engineer may take action the maintenance work. The Main Contractor shall bear all the cost implications arising from this action and no payment shall be processed until the Main Contractor processes the payment due to the new contractor that carried out the work.

6

The Contractor shall execute the require maintenance work in accordance with the approved maintenance program / schedule without any delay and to the satisfaction of the Engineer. In the event the Contractor fails to carry out the work specified, Public Work Authority shall employ persons other than the Contractor’s staff to carry out the work and shall recover from the Contractor such costs incurred thereby from any monies due, or which become due, to the Contractor. In addition the Contractor shall be liable to Penalties as follows:

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Delay in cutting and maintaining grass.

(b)

Delay in cutting and maintaining ground cover plants

(c)

Delay in pruning and maintaining hedges.

(d)

Delay in pruning and maintaining trees, shrubs.

(e)

Delay in applying fertilizer and soil amendment.

(f)

If delay in replacing dead plant is more than 6 days the Engineer will reserve the right to hire another Contractor to replant the missing plant and shall recover from the Main Contractor such costs incurred thereby from any monies due, or which become due, to the Contractor.

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Plant replacement: all dead and unhealthy plants shall be removed immediately; palms that do not show a healthy growth within 90 days shall be replaced.

8

Duration of maintenance period: maintenance works upon planting material and irrigation installations shall be carried-out by the Contractor for the time period of 400 days from the date of issue of primary handover certificate.

9

Cleanliness: the Contractor shall maintain all materials installed and keep the site clean during maintenance.

10

During the works: the premises shall be kept neat and orderly at all times including storage areas for plants and other materials.

11

Rubbish: including debris resulting from horticultural works shall be removed from the site daily as the work progresses.

12

Paved Areas: shall be kept clean by sweeping and / or hosing.

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13

Tags, Labels: nursery stakes and ties shall be removed from all plants.

14

Personnel: the Contractor shall separately list of the personnel, workforce and adequate equipment to perform the maintenance works herein specified to be carried out from the date of acceptance of the project by the Engineer until completion of the 400 days plant establishment period.

1.11.2

Appearance of the Ground

1

The grass, trees, shrubs and other plants shall thrive and the Contractor shall carry out all normal horticultural operations to ensure coming about. The contractor shall plant the seasonal flowers during normal planting season.

(b)

All the supplied plants shall be healthy and not weak or dead, it must be meeting the project's requirements as per the specifications.

(c)

During the maintenance period, the Contractor is responsible for maintaining and replacing the seasonal flowers till the end of the contract.

(d)

All the agricultural processes to be under the supervision and approval of the Engineer.

(e)

The contractor shall submit for approval by the Engineer the seasonal flowers replacement during maintenance period contains information about plants genus, 2 species, number of plants per m , planting date, replacement date, replacements type and observation in an approved form.

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The ground shall appear neat, tidy and well cared for and the collection and disposal of rubbish and litter of all sorts from paths, lawns and beds shall be part of the Contractor responsibilities and he shall allow for it in his rates.

3

Fallen leaves and small bark and twigs debris shall be cultivated in to the soil if approved by the Engineer.

4

Surfaces for palms and trees shall not be dug deep, on the contrary the saucers shall be maintained as shallow as possible and surrounding ground cover or grass shall not be allowed to reach the tree.

5

Defects: remove and immediately replace trees, shrubs, or plants found to be dead, unhealthy or vandalized during the maintenance period with approved, true to species equivalent trees, shrubs, or plants.

6

Provide maintenance of the planted areas from date of provisional acceptance until the end of the maintenance period and final acceptance.

7

Cultivation: keep beds clear of weed by cultivating and use of approved herbicides. Fork over beds as necessary to keep soil loose.

8

Fertilizer: to be applied for all plants as specified in the Table 11 below:

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Table 11: Fertilizer application schedule during maintenance period

Item

Type of Plant

Type of fertilizer

Ground cover

Grass

Seasonal Hedges

Date palms

Trees

Urea/ Ammonium Sulfate

2

20 g/m Monthly

2

25 g/m Monthly

2

1

25 g/m Monthly

30 g/m 1Kg/Tree every Monthly 6 Month

2

25 g/m Monthly

2

NPK

20 g/m Monthly

2

2

25 g/m Monthly

30 g/m 1 Kg/Tree every Monthly 6 month

3

Slow Release Fertilizer

20 g/m every 2 Month

NA

NA

NA

4

Organic Fertilizer

After plug aeration

Every 6 month

Before planting

Every 6 Month

25 g/m Monthly

2

25 g/m Monthly

2

25 g/m Monthly

2

25 g/m Monthly

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200 g/3 times

Jan & May

40 g/3 times

Jan & May Jan & May

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The Contractor shall prune the plants as follows: At appropriate time to remove dead or dying and diseased wood and suckers, to promote healthy growth and natural shape.

(b)

Dress cut ends exceeding 25 mm diameter with approved tree wound dressing.

(c)

Preserve the natural character. Do not remove leader or small branches along trunks.

(d)

Use clean sharp tools and make cuts clean and flush without leaving stubs.

(e)

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Shrubs

10

Pruning paint to be approved asphalt based commercial paint Tree seal or equal approved prepared for tree surgery containing fungicide and shall be applied to any tree/shrub wound large then 20 mm. Paint shall cover all exposed cambium as well as other exposed living tissue.

11

Pruning of Hedges and Topiary: all shall be trimmed every four weeks during high vegetation period, every two weeks in case of excessive growth of certain species. The wood shall never appear after trimming. Topiary shall be trimmed with specific steel wire frame to match designed topiary. The geometrical patterns shall be trimmed using stretched ropes and high guides to maintain shape personnel. (a)

Trimming of topiary shall be done in accordance with designed shapes. Where hedges are designed continuity of hedge shall be maintained.

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(b)

Cut back dead stems to just above healthy buds monthly. Limit amount of pruning to minimum necessary to encourage proper growth and not to change natural habit of shape.

(c)

Apply tree wound dressing or fungicide on all pruned stems to avoid infection.

Remove Burlap Wrapping from palm when new leaves show vigorous growth.

13

Tree Stakes: check condition of stakes, ties, and guards. Replace broken or missing items. Adjust ties if necessary to prevent rubbing of bark. Cut back damaged bark and treat wound with tree wound dressing.

14

Raking: rake gravel to even surface and remove any litter.

15

Weeding:

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Removal of weed is to be done on a weekly basis for both Dicotyledonous and Monocotyledonous weeds.

(b)

Weeds have to be removed with roots and shall not be left on grass areas for any reason, and instead shall be put in a fresh directly to avoid spreading and falling of seeds.

(c)

Herbicides can be used for controlling Dicotyledonous weeds.

(d)

Before every mowing, the grass areas are to be checked for presence of any weeds.

(e)

The weeding dates shall be mentioned by the Contractor and the work to be done under the supervision and approval of the Engineer's according to the site requirements as per the relevant weeding activity record form.

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Pest and disease control: the Contractor shall check plants material and take remedial action as appropriate and in accordance with manufacturer's recommendations. Application of pest control schedule is required and approval from site engineer is needed. Fungicides or Insecticides shall not be performed during the day to avoid leaf burns; application shall be done in the evening or early morning.

17

Cultivating / Hoeing: cultivating shall consist of scarifying the top 80-100mm of planting bed so lumps of soil are all less than 50mm and all weeds are removed.

18

Iron Deficiency: plants prone to iron and/or trace elements deficiency shall be checked monthly and diluted iron applied as required.

1.11.3

Grass Maintenance

1

Maintain grassed areas immediately after placement until grass is well established and exhibits a vigorous growing condition. Continue maintenance until final acceptance. Turf areas will be accepted upon 100% coverage being as approved by the Engineer.

2

Defects: re-cultivate and re-seed bare areas and areas of dead grass. At the end of the maintenance period gassed areas in a healthy condition, with full coverage of grass, without thin or bald areas.

3

Provide maintenance of the grassed areas as specified below from date of handing over until the end of the maintenance period.

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Mowing: cut grass regularly during the growing season to maintain a height of approximately 50 mm, using approved mechanical cylindrical mowers. Mowing of the grass areas must be done to keep the height of the grass at 3cm minimum and 5 cm maximum.

(b)

For mowing operations only cylindrical lawns mowers are to be used,, the blades of mowers shall be always sharp to have proper cutting,, use of blunt blades will not produce even shape,, the lawn mowers shall be in proper condition and there shall not be leakage of oil or petrol on the grass areas,, only trained personnel are allowed to mow the grass areas.

(c)

The mowing must be done in one direction, the Contractor shall change the mowing direction each two mowing operations.

(d)

The contractor must ensure the removing of the grass cutting's products and all garbage properly and in the same day after the grass mowing and dumped to an approved dumping yard.

(e)

Grass cuttings to be collected prior to disposal on top of a shade net not directly on top grass

(f)

Where mowing strip is not provided, edges shall be trimmed with an appropriate weed-eater machine. Vertical trim shall be done using manual lawn trimmer

(g)

Clippings shall be raked off and taken away from site unless directed otherwise by the Engineer.

(h)

Grass shall be mowed in parallel strips at regular speed. Edges shall be trimmed manually and maintained neat and tidy, curves to be smooth to centres.

(i)

The Contractor shall submit a schedule about mowing operation containing the mowing operation record each week for all the season in an approved form by the Engineer.

.

(a)

(a)

Along with the mowing operations the edges of the grass areas are to be trimmed with approved trimming machines. Under no circumstances the grass shall be allowed to grow down the road kerbstone or along the walkways.

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Edging and Trimming:

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(c)

The Contractor must be accurate during edging's operation and shall maintain a constant distance of 5 cm between the grass and the garden kerbstone.

(d)

The grass growing along the tree barns is to be trimmed and properly maintained.

(e)

The edging must be done under the supervision and approval of the Engineer.

(f)

The edging dates shall be mentioned by the Contractor for each month of the year in an approved form by the Engineer.

Plug Aeration: (a)

Plug aeration must be done by using specific machines Aerators.

(b)

To have an effective growth aeration of the grass shall be done once in every four months

(c)

Immediately after aeration & scarification, fertilization with NPK + urea has to be done followed by rolling after 2 days.

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Aeration shall be done immediately after hard mowing to a depth of 12 cm minimum.

Verticutting shall be done every 6 months and immediately followed by watering and rolling. Speed of scarifying shall be to the manufacturer’s specifications. Rake to remove matted and dead grass and roots (a)

First the Contractor has to mow the lawns as normal and then use scarification machine to loosen and thin the root zone

(b)

Direction of scarifying shall be alternated at each scarifying session.

Water grass to prevent grass and soil from drying out.

9

Percolation: in a case of visibly poor soil drainage, perform soil percolation test and prepare remedy report for the Engineer approval.

10

Rolling: roll grass, after watering using a light roller as required.

11

Inorganic fertilizer:

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The grass areas are to be fertilized once a month, this has to be done under the Engineer's approval and supervision.

(b)

Fertilization is to be done immediately after the mowing operations.

(c)

A part from those mentioned, macro – nutrients application or micro – nutrients is to be applied when required.

(d)

Immediately after fertilization, proper wetting is to be done to dissolve the fertilizer.

(e)

The used mixture must be done according to the following proportions shown in the Table 12 below. The Contractor shall inform the Engineer regarding the used NPK contents and any observations in a periodical manner approved by the Engineer.

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Table 12: Monthly Inorganic Fertilization application for grass

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Months

Mixture Proportions/m

January

32 g NPK + 8 g Urea

February

20g NPK + 20 g Urea

March

20g NPK + 20 g Urea

April

20g NPK + 20 g Urea

May

24 g NPK + 16 g Urea

June

36 g NPK + 4 g Urea

July

36 g NPK + 4 g Urea

August

36 g NPK + 4 g Urea

September

36 g NPK + 4 g Urea

October

32 g NPK + 8 g Urea

November

32 g NPK + 8 g Urea

December

32 g NPK + 8 g Urea

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12

Sprinklers level: all pop-up grass sprinklers / heads shall be adjusted to be flush with final grade and 25 cm below edge of grass.

13

Grass shall be replaced immediately after showing signs of deterioration or bare spots. Protect sowed areas with warning signs during maintenance period.

14

Hard mowing: to be done three times per year to 5 mm prior to aeration.

15

Pesticide application: Application of Pesticides must be undertaken by an experienced staff, The work shall be performed and supervised at all times by qualified personnel , The Contractor has to ensure all the safety conditions for his staff, They must be wearing a proper working clothes , gloves and put mask's during treatment.

(b)

The contractor shall arrange for an inspection request prior to application.

(c)

The contractor shall submit catalogue's data and literature's of manufacturers and suppliers, it must contains information's about :

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(a)

The chemical name, structure and concentration of the active ingredients with the spreading and emulsion materials of each product.

(ii)

The date of product and expiry, all products must be produced no more than one year before treatment and not expired.

(iii)

The commercial name of each product , formula's description , The manufacturer's recommended dosage for each plant, The safety period after treatment , The chemical residues of each product on plants or soil , The mixing ability with other pesticides or fertilizer's, and the LD 50 .

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(i)

All the pesticides shall be delivered to the site in the original, unopened containers bearing the manufacturer's guarantee and all the necessary information's of usage.

(e)

The treatment must be done at early morning or before sun set, water shall not be applied only at least 24 hours after treatment.

(f)

The contractor must not spray pesticides during windy and rainy weather. Ideal pressure setting shall be used to avoid air drifting of pesticides.

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Prior to application the Contractor shall submit a pesticide's treatment plan to the Engineer, applying program to be approved and supervised by the Engineer.

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(h)

The contractor shall use the same active ingredients mentioned in the plan, approved by the Engineer who will preserve the rights to increase or decrease the dosage and choose the best formulations of each pesticide.

(i)

Hydraulic equipment spraying machine shall be provided for liquid application of pesticide with a leak proof tank, two operational nozzle's to ensure a good and sufficient coverage, positive agitation methods, controlled application pressure and metering gauges , the Contractor may use the pesticide's holder with multi nozzle's for application.

(j)

The contractor must not apply all pesticides mentioned in the specification at the same application to prevent the bad effects of the chemical on plants or soil, he shall also use a vary types of pesticides alternatively to avoid the pest's resistance, this to be approved and supervised by the Engineer.

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(k)

The contractor must keep newly treated area's with pesticides off limit as per the manufacturer's recommendations, he shall protect treated area's with warning tape and signage approved by the Engineer showing the date of re-entry in Arabic and English.

(l)

According to the activity peak of the pests in Qatar , the Contractor shall do four preventive applications to ensure the inhibition of the pests during season as following In November, the Contractor shall apply fungicide of Metalaxyl in a slow release formulation such as granules to control the soil born fungi's addition to another general fungicide and a systemic insecticide to control the other types of fungi's and the insects which are capable of being active during cold weather.

(ii)

In February, The contractor shall apply the same formulation of Metalaxyl with a mixture of another general fungicide and a systemic insecticide taking into consideration that the Contractor shall use a different types of the general fungicide and insecticide than the previous application to avoid pest's resistance.

(iii)

In May, the Contractor shall apply a mixture of insecticides consisting of systemic and contact insecticides addition to a general fungicide.

(iv)

In September, the Contractor shall apply the same mixture of insecticides and fungicides but he shall use different active ingredients to ensure the best results from application.

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(i)

Any occurrence of infection with different types of pests, insects, fungi's and nematodes during the whole project's period, the Contractor shall be responsible of identifying and controlling all type of infections by using the proper pesticides. Selection of pesticides with a proper formulation and dosage will be done by the Engineer.

(n)

The contractor shall fill the pesticides treatment in a schedule contains all the necessary information in an approved form by the Engineer.

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(m)

Top dressing: immediately after pesticide application and plug aeration spread and brush in organic fertilizer as per quantities shown above in Table 11 & 12.

17

Lawn mowers: maintenance shall be in accordance with manufacturer's recommendation especially in regard to greasing and blades sharpening.

18

Blunt blades shall not be used; they alter the general appearance of lawns.

19

Spiking and raking: once a year, during the dormant period, spike the grassed area, using a spiked or hollow tined roller and rake to remove matted and dead grass and roots.

20

Weeding: remove weeds as they develop either by hand or use of approved selective weed killer. Apply herbicides in accordance with manufacturer's recommendation. Remedy damage resulting from improper use of herbicides.

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APPENDIX A – LANDSCAPING DETAILS 1

Appendix A contains the details listed below: 30mm / 20mm Cell to Capture Surface Water

2

Palm Planting Details

3

Palm Tie Details

4

Typical Tree and Excavation Details

5

Typical Tree Wooden Stakes Details

6

Small Shrub Planting Details

7

Hedge Planting Details

8

Large Shrub Planting Details

9

Grass Planting Details

10

Ground Cover Planting Details

11

Plan for Ground Covers

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1.13

APPENDIX B – ASHGHAL IRRIGATION RATES

1.14

APPENDIX C – LANDSCAPING DETAILS 2

2

Drainage Pipes

3

Nursery Pot

4

Side Walk / Kerbs and Cart Paths

5

Greens / Trees

6

New Applications

7

Underground Tank

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Appendix C contains the details listed below:


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EN D O F P A RT

QCS 2014

Section 28: Landscaping Part 02: Irrigation System

Page 1

IRRIGATION SYSTEM ............................................................................................ 2 GENERAL ---------------------------------------------------------------------------------------------- 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.2

Description 2 Scope Of Work 2 Quality Assurance 3 References 3 Submittals 3 PRODUCTS ------------------------------------------------------------------------------------------- 6

2.2.1 2.2.2 2.3

Pipe And Fittings 6 Application Devices 6 EXECUTIONS --------------------------------------------------------------------------------------- 13

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.4

Protection 13 Inspection 14 Installation 14 System Testing 18 Flushing 19 Testing and commissioning 19 OPERATION AND MAINTENANCE ----------------------------------------------------------- 19

2.4.1 2.4.2 2.4.3 2.5

Maintenance Program 19 Operational Personnel and Manual 20 Operation Program 21 SPARE PARTS ------------------------------------------------------------------------------------- 21

2.5.1

General

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APPENDIX A – IRRIGATION DETAILS ------------------------------------------------------------ 25

2.6.1 2.6.2 2.7

Irrigation Rates 25 Details 29 APPENDIX B – IRRIGATION DETAILS WITH PUMPS-------------------------------------------- 39

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IRRIGATION SYSTEM

2.1

GENERAL

2.1.1

Description

1

The purpose of this project is to supply, install and commission an automated irrigation system with all related components for the “Project” consisting of field remote control valves, control wires, filter, integrated dripper lines, drippers, flush valves, sprinklers, bubblers and control system.

2.1.2

Scope Of Work

1

The scope of work shall be read in conjunction with the contract material specifications, contract drawings, bill of quantities, contract documents and installation details and it includes but not limited to the following:

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The contractor shall prepare the shop drawings showing but not limited to The Main line, Laterals, solenoid valves, control wires route and numbers, Irrigation Controllers, integrated dripper lines, on line drippers, Bubblers and flush valves.

(b)

All equipment and materials shall be supplied, installed, tested and commissioned by an irrigation specialist employed by the contractor and approved by the engineer.

(c)

The contractor shall submit for Engineer’s approval the technical information and samples of the material he intends to use which should be in accordance with the material specifications of this project.

(d)

It shall be the responsibility of the contractor specialist to ensure that the plant and equipment supplied by them produces the desired results. The Specialist shall include all equipment, materials, accessories, finishing materials etc., required so as to have a complete functional system. This shall include all items of a minor nature necessary to complete the installation and usually included in similar work whether or not specifically mentioned in the contract documents.

(e)

All materials and workmanship not fully specified herein or covered by QCS, BS or BSCP or approved alternative shall be of such a kind as is used in first class work and is suitable for the climatic conditions of the state of Qatar. The complete irrigation system for each site shall be fine tuned to efficiently and evenly irrigate all areas in accordance with the engineered design and shall be complete in every respect. The system shall be set in operation and adjusted to the satisfaction of the Engineer.

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(g)

All irrigation equipment and components shall be the product of a manufacturer having a local representative Engineer capable of advising and assisting in making the required adjustments to the system.

(h)

The contractor shall commission the irrigation system upon completing the work and then shall be handed over.

(i)

The contractor and upon completing the work shall provide the Engineer with four original sets of As-Built drawings accurately reflecting the executed works and installation details.

(j)

The contractor shall upon completing the works provide the Engineer with detailed Operation and Maintenance Manuals (With applicable Arabic translations) in four originals. The manuals shall include but not limited to; complete and marked literature of all products used on the project and its reordering part numbers. It shall also include a list of the recommended spare parts for a period of 5 years. It shall include original color print and softcopy of the As Built drawings.

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(k)

The Engineer prior to issuing the Project Handing over Certificate shall approve the As-Built Drawings and the Operation & maintenance Manual.

(l)

The details pertaining to this scope of work are herein Appendix A and Appendix B. The Contractor shall execute his work as per the details in Appendix A and Appendix B.

Quality Assurance

1

Manufacturers: Firms regularly engaged in the manufacture of irrigation equipment, control systems, pumps, pipes and fittings whose products have been in satisfactory use in similar service for not less than 5 years and backed by a recognized local agent or to the approval of the engineer.

2

Installers: Firms regularly engaged in the installation of irrigation works of a similar quality and scope as this project and to be approved by the Engineer.

2.1.4

References

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2.1.3

ASTM D2241 ..............Specifications for Polyvinyl Chloride (PVC) pressure rated pipes.

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ASTM B3 ....................Bare soft and annealed copper un-insulated uncoated 14-4 AWG solid wire. ASTM B8 ....................Class B concentric-lay-stranded copper conductors

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ASTM D2466 ..............Specification for uPVC pipe Fitting Schedule 40. ASTM D2467 ..............Specification for uPVC pipe Fitting Schedule 80

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ASTM D1248 ..............Standard specification for polyethylene plastic ASTM D1785 ..............American standard for testing of material for PVC pipes.

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ASTM D2219 ..............Specification for PVC insulation for wire and cable BS 1780 .....................Specification for bourdon tube pressure and vacuum gauges.

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BS 3505 .....................Specification for uPVC pressure pipes for cold potable water. BS 4346 ....................Joints and fittings for use with uPVC pressure pipes.

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BS 5150 .....................Specification for cast iron wedge and double disk gate valves for general purposes.

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BS 5154 ....................Specification for copper alloy globe, globe stop and check, check and gate valves for general purposes. BS 8010 ....................Code of practice for pipelines. Din 8061 .....................Confirming to German Standards Din 8061. Din 8062 .....................uPVC pipes Dimensions According to German Standard. Din 8063 ..................... Pipe joint Assembly and fitting for uPVC pressure pipe. SASO 14&15 ..............Conforming to Saudi Pipes Standards 2.1.5

Submittals

1

Prior to start of any work at site the contractor has to approach all Service Authorities in Qatar to get their no objection for the work included in this contract and record drawings for their existing services. Copy of these drawings and no objection certificate shall be submitted to the Engineer before starting the actual work at site.

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Page 4

Shop Drawings - The contractor shall submit shop drawings in 3 sets of black hardcopies, one set colored hardcopy and a soft copy, which to be approved by the Engineer representative prior to commencing installation work. The shop drawings shall show but not limited to valves, control wires route and numbers, controllers’ location and flow balancing.

3

Please note that the contractor shall prepare detail survey of existing levels in the contract area.

4

Trial pits should be taken at every 50 meter interval. All the existing services shall be marked in reference to the road edge & building line along with these depths from existing ground level & the proposed Landscape finish level. Contractor to check availability of all the existing ducts that are marked on the tender drawings. Contractor to propose the route of Irrigation piping based on this information. All this information regarding trial pits, existing and proposed levels, availability of existing ducts shall be made available to the Engineer within mobilization period of the contract. All information shall be made available on hardcopy & in Digital format to the Engineer as it is required for adjusting landscape and pipes/services alignment.

5

Any delay to provide the above-mentioned information regarding trial trenches, existing services & levels which affect the progress of works shall be the responsibility of the Contractor

6

The successful contractor shall submit shop drawings, for approval by the Engineer, for the following:

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2

In case of any conflict between contract drawings and any existing or future services which may necessitate re-routing the proposed irrigation Main or laterals, the contractor has to prepare the shop drawings accordingly and submit it to the Engineer for approval. This shall be considered as integral part of the contract.

(b)

The Pump /Filtration Chamber mechanical, electrical and civil works shop drawings. Necessary modifications to the existing feeding chambers (civil and mechanical). Valve chambers including valves, pipe works and civil works. Electrical control equipment with circuit diagrams

(c)

Details of mainline, Profile drawings for Mainline, lateral pipes and other typical connections Wiring diagrams including conduits, pull boxes, sizing and calculations to verify that cable sizing is in accordance with Kahrama regulations and equipment manufacturers recommendations

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(e)

Electrical power and control wiring diagrams for irrigation controllers, field wiring and grounding.

(f)

Layout plans for drip line layout.

(g)

Layout plans for Sprayer and Sprinkler layouts

(h)

Detail of valve chambers and any modification to the existing feeding chambers

(i)

The approval shall not relieve the Contractor of any of his responsibility under the contract for successful completion of the work

Products

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(a)


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The contractor shall submit for Engineer’s approval prior to commencing installation works; the products he intends to use with all technical details and literature in accordance with the specifications below. Material submittal shall include all irrigation system component, fitting and accessories including but not limited to warning tape, PVC cement and cleaner, wires, Teflon tape. A sample board shall be submitted for approval. A material submittal list must be arranged by the contractor as below (Table 1): Table 1: Material Submittal List

Description

Abbreviations

1

Air Release Valve

AP

Approved

2

Screen Filter

AN

Approved As Noted

3

Polyethylene In Line Drip

AI

Additional Information

4

On Line Drippers

5

Pressure Compensating Bubbler

6

Rotor Sprinkler

7

Pop Up Spray

8

Central Irrigation System

9

Irrigation Controller

10

Weather Station

11

Irrigation Control Wire

12

Flow Meter

13

Solenoid Valves

14

Quick Coupling Valve

15

Gate Valve

16

Check Valve

17

Valve Boxes

18

PVC Pipes

19

PVC Fittings

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PVC Cement

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PVC Cleaner

22

DC Aluminum Cover

23

Shop Drawing Submittal

24

Flow Balance Submittal

25

Irrigation Pumps & Panels

26

Submersible Pump

27

Water Tanks

28

Water Cooler

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Item

NA

Not Approved

SR

Sample Required

GR

Guarantee Required

NS

Not Submitted

TR

Test Required

OT

Others

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Operation and Maintenance Manuals-The contractor shall submit 4 sets of black hardcopies, one set colored hardcopy and a soft copy of detailed Operation & Maintenance Manual and one softcopy with equipment reordering codes and literature.

(c)

As-Built Drawings- The contractor shall submit 3 sets of black hardcopies, one set colored hardcopy and a soft copy of the complete project as-built drawings reflecting the actual site installation.

(d)

Calculation: The contractor shall submit a friction loss calculation for the irrigation system installed including a full system flow balance calculation.

(e)

Guarantees: The contractor shall submit manufacturer and supplier material guarantees for materials submittal as specified in the material specification below.

(f)

Origen catalogue cuts, diagrams, samples, drawings and such other data may be required to demonstrate compliance with the specification.

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(b)

PRODUCTS

2.2.1

Pipe And Fittings

1

All primary distribution pipe work shall be non plasticized Polyvinyl Chloride (uPVC) class E or equivalent for all lateral and mainlines.

2

PVC pipes shall be manufactured according to ASTM D1785 or equivalent.

3

All primary distribution pipe fittings shall be solvent welded uPVC 15 bars or equivalent.

4

All non plasticized Polyvinyl Chloride Pipe fittings shall be manufactured to ASTM D1785 or Equivalent and class E or equivalent.

5

Polyethylene pipes and fittings:

6

Flexible Pipes for irrigation on line drippers shall be in the required sizes as shown on the drawings and extruded from linear low density polyethylene version raw material. Pipes shall be resistant to algae and ultraviolet deterioration with Carbon Black content not less than 2.25%.

7

Pipes and fittings manufacturer should be ISO certified with 5 years manufacturing experience, test certificate from reputable labs should be available prior to material ordering.

2.2.2

Application Devices

1

Spray Pop-Up Sprinkler

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(a)

The spray pop-up sprinkler shall be equipped with an adjustable arc (25-360) nozzle discharging at half circle as shown in design drawings

(b)

The spray pop-up sprinkler nozzle shall automatically adjust the flow depending on the arc setting in order to have a matched precipitation rate.

(c)

The sprinkler shall have arc and radius reduction capability. It shall also be possible to adjust arc and radius from the top of the riser assembly, using an adjustment key.

(d)

The sprinkler shall have an inlet screen. The body and riser of the sprinkler shall be constructed of non-corrodible, heavy duty A.B.S or UV R.P.

(e)

The sprayers shall be located 25 cm from grass edge or as noted on design drawings

(f)

Refer to design drawing for exact radius of coverage and flow needed for each sprayer.

(g)

Sprinkler flow and radius coverage should be as per design drawings.

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(h)

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The sprinkler shall carry a one-year manufacturer and supplier exchange warranty (not prorated).

Rotor Pop-Up Sprinkler (a)

The rotor pop-up sprinkler shall be of the gear-driven, closed case rotary type or as specified in the design drawings.

(b)

The rotor pop-up sprinkler shall have a gear drive reversing or non reversing mechanism.

(c)

The rotor pop-up sprinkler shall be available with standard nozzles.

(d)

The sprinkler shall have minimum 25% radius adjustment capabilities by means of a stainless-steel nozzle retainer/radius adjustment screw.

(e)

The sprinkler shall be available in both full-circle and adjustable part-circle configurations. The adjustable part circle unit shall be minutely adjustable from 40° to 360°. The adjustable unit shall be adjustable in all phases of installation (i.e., before installation, after installation while static, and after installation while in operation).

(f)

The sprinkler shall have a constant rotation speed irrespective of the nozzle installed.

(g)

The sprinkler shall have a minimum of 4-inch (10 cm) pop-up stroke to bring the rotating nozzle turret into a clean environment.

(h)

The sprinkler shall have a thick rubber cover firmly attached to the top of the sprinkler riser.

(i)

The sprinkler shall be equipped with a drain check valve to prevent low head drainage, and be capable of checking a minimum of 7 feet (2.1 m) in elevation change.

(j)

The sprinkler shall be serviceable after installation in the field by unscrewing the body cap, removing the riser assembly, and extracting the inlet filter screen.

(k)

The body and riser of the sprinkler shall be constructed of non-corrodible, heavy-duty A.B.S or durable plastic. It shall have a stainless steel spring for positive retraction of the riser when irrigation is complete.

(l)

Sprinkler flow, radius coverage, and operating pressure should be as per design drawings.

(m)

The sprinkler shall carry a one-year manufacturer and supplier exchange warranty.

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(b)

The tube shall have a 15 to 17 mm outside diameter.

(c)

The dripper shall be constructed of plastic with a hard plastic diaphragm retainer and a self cleaning diaphragm extending the full length of the dripper. It shall have an inlet filter raised from the wall of the tubing. It shall have the ability to independently regulate discharge rates with a constant flow at an inlet pressure of 7-60 psi.

(d)

The dripper discharge shall be as specified on the design drawings utilizing a combination turbulent flow/reduced pressure compensation cell mechanism and a diaphragm to maintain uniform discharge rates. It shall also be continuously selfcleaning during operation and under pressure.

(e)

The dripper flow versus pressure shall be tested by an independent reputable organization, and shall have available reports to be presented upon request by the Engineer.

Integrated Dripper Line The dripper line shall consist of on ultra violet resistant low density Linear polyethylene tube with internal pressure compensating continuously self cleaning integral flat or cylindrical drippers welded to the inside of wall of the tube at the specified spacing as an integral part of the tubing assembly.

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(f)

The dripper flow shall not be affected by temperature up to 60 degrees Celsius and shall not have a spike at start up.

(g)

The filtration requirement of the dripper shall be a maximum of 120 mesh.

(h)

The dripper line shall have a 2 years guarantee against solar radiation and 1 year manufacturer and supplier warranty against manufacturing defects.

On- Line Dripper For Irregularly Layed-Out Shrubs Single outlet, pressure compensating drippers are acceptable.

(b)

Pressure compensating design deliver uniform flow at a pressure variable from 15 to 50 psi.

(c)

Made of durable plastic construction and UV resistant.

(d)

Diaphragm resistant to chemicals.

(e)

Built in self flushing action

(f)

Available in self piercing inlet barb.

(g)

The flow is as per design drawing.

(h)

On-line dripper shall be extended with a distribution component made of a UV resistant polyethylene resin materials, 4 mm inside diameter.

(i)

Polyethylene and UV resistant pipe 16 mm is used to insert in the on line drippers, this pipe is laid underground at 5 cm depth including the online dripper, only the distribution component is extended out the ground to a maximum of 25 cm length.

(j)

The dripper line shall have a 2 years guarantee against solar radiation and 1 year manufacturer and supplier warranty against manufacturing defects.

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Bubblers (a)

The bubbler shall be of the pressure compensating type having a fixed flow under a pressure range of 20 to 70 PSI. It shall be constructed of corrosion and UV resistant plastic material.

(b)

The bubbler shall have an integral flow bushing to maintain a constant flow at different pressure range.

(c)

The bubbler shall have a plastic screen filter to protect it from debris that could be available in the water.

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(e)

Bubblers flow and numbers are as per design drawing details and two bubblers are needed for palm trees and one bubbler for trees.

(f)

The bubbler shall carry a two years manufacturer and supplier replacement warranty.

Electrical Control Solenoid Valves (a)

The electrical control solenoid valves shall be of the electronically actuated, diaphragm operated.

(b)

The valve’s body and bonnet shall be molded of non-corrodible, glass filled nylon, rated at an operating pressure of 200 PSI. The body of the valve shall have brass inserts, with through holes, which will accept the bonnet Stainless steel bolts.

(c)

The valve shall be equipped with an internal filter as well with a self-cleaning metering rod, so that only clean water can enter the solenoid chamber. A filter cleaning system, that continuously cleans the filter when the valve is operating, shall be available.

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(d)

The valve shall be equipped with a flow control mechanism with handle, which regulates the flow from full on to completely off. It shall have an accurate set pressure regulator, to keep the downstream pressure constant after setting it. The regulator shall be of the top dial model with clearly shown pressure values in bars and PSI. It shall regulate the flow at a pressure range of 20 to 100 PSI.

(e)

The valve shall be available in 1, 1.5, 2 and 3” inch sizes and it shall have a BSP female thread inlet and outlet.

(f)

The valve shall be equipped with automatic self-cleaning system for filter.

(g)

The valve sizes, number and flow rate are shown on the design drawings.

(h)

The valve shall carry a 3 years manufacturer and supplier exchange warranty.

Quick Coupling Valves The Valve shall be operated by insertion of a compatible hollow coupler key.

(b)

The valve shall be operated by a 90º turn in clockwise direction with reverse turn for closure and be capable of 360-swivel action.

(c)

The valves shall be of the low-pressure loss type.

(d)

The Valve Body shall be made from brass material and have the one or two-section type with removable upper body. It shall be supplied with spring loaded locking cover made from thermoplastic rubber. The cover spring shall be of stainless steel material.

(e)

The valve size is 1”.

(f)

The valve shall carry a 3 years manufacturer and supplier exchange warranty.

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Gate Valves

Gate valves shall be designed for a working pressure of not less than 10 bars and water operating temperature of 45° C.

(b)

Valves shall be the same size as the incoming line size with a clear waterway equal to the full nominal diameter of the valves and shall be opened by turning counterclockwise.

(c)

The operating nut or wheel shall have an arrow cast in valve indicating the direction of opening.

(d)

Valves smaller than 4” shall be all bronze or brass conforming to BS or ASTM with screwed end connections. Valves 4” and larger shall be cast iron body, and shall conform to BS or ASTM with flange end connections.

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(e)

The valve shall carry a five years manufacturer and supplier exchange warranty.

(f)

PVC valves up to 4" diameter, with working pressure of not less than 10 bars and watering temperature of 50° C are acceptable with 3 years manufacturer and supplier exchange warranty.

Air/Vacuum Release Valves Specifications (a)

Air relief valves shall be (1”-3”) size as shown on the Drawings and shall be of the kinetic/automatic type that will automatically release air when the lines are being filled with water and when air entrapment occurs while the system is working.

(b)

The Valves shall be of plastic or brass male base.

(c)

The body of the valve shall be constructed of heavy duty plastic or 100% corrosion resistant materials.

(d)

The valve working components shall be constructed of 100% corrosion resistant materials to ensure maximum life and minimum water loss due to leaks.

(e)

The Valve shall remain open even when pipeline air pressure reaches (3-10) psi.

QCS 2014

(f)

The air release valve shall employ rolling seal mechanism made of EPDM.

(g)

The valve shall carry a 3 years exchange warranty.

Check Valves The valve shall be having constructed of Brass, Cast Iron, Ductile Iron and stainless steel materials, 100% non-corrosive.

(b)

The valve shall allow flow in one direction by the action of a spring loaded flap which closes against a rubber seal.

(c)

The spring and the flap shall be connected via a moment arm in order to ensure that the spring pressure is maximum when the valve is closed.

(d)

The valve shall have a pressure rating of 16 bars

(e)

The valve shall have an external position indicator.

(f)

The valve shall be available in 3”, 4”, and 6”size.

(g)

The valve shall carry a 3 years exchange warranty.

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(a)

Valve Boxes (a)

The valve boxes shall have enclosures, which are injected molded plastic or HDPE with ultra violet additives. It shall be light in weight with reduced side angles and increased break resistance.

(b)

The valve box shall be non-conductive or sparking.

(c)

The valve boxes shall be available in sizes to fit the solenoid valve assembly including the union fittings and allow for easy removal of valves for maintenance.

(d)

The valve box should have a two years replacement warranty against buckling and five years against cracking. All valve boxes should be name tagged with aluminum or brass name tags, placed inside the valve box and riveted to the outside box cover. The name tag size should be 2" by 3" and 2mm thick.

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Filters

Use a 3” disc filter on all distribution chambers with a disc filters of 120 mesh size of 0.10 mm.

(b)

Disc filters shall be corrosion resistant, with minimum pressure and high particle retention filter area.

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(d)

The filter shall carry a 1 year manufacturer and 2 years supplier warranty.

Filters shall handle a pressure of 8 bars minimum.

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Controllers (a)

The controllers should be capable of running the irrigation system as scheduled; it should have a seasonal adjustment option, 4 programs, running 2 solenoid valves at the same time using one station.

(b)

The controllers should have a stainless-steel or plastic pedestal and should be weatherproof and resists the elements.

(c)

The number of stations for each controller should be equal to the total of existing stations for all used solenoid valves, the extra spare wires for future use and wires for future flow meter and master gate valves at each chamber.

(d)

Additional 2 numbers of 10 gauge wires should be laid as provisional for future installation of flow sensor and master gate valves at each distribution chamber.

QCS 2014

(e)

18

(a)

The contractor shall be responsible for providing the electrical power source to the controller from any nearby distribution panel board.

(b)

The location of the controllers should not be changed and the power sourcing should be done to suit that condition. All coordination and permits should be arranged by the contract and at his own expense.

Trench Marker Tape Furnish and install trench marker above all buried irrigation pressure Pipelines and electric power cable.

(b)

Provide tape manufactured from low density polyethylene material or equivalent approved material.

(c)

Provide tape 150mm wide and a minimum thickness of 100 micron.

(d)

Print tape in both Arabic and English. CAUTION: IRRIGATION LINE BURIED BELOW / ELECTRIC CABLE BURIED BELOW (or) equivalent text that is applicable for usage.

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Water Wire Connector & Sealant

Wire connector shall be waterproof underground wire connections.

(b)

Splices of wire shall be accomplished using 3M or equivalent epoxy type compound.

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Power Cable For Irrigation Controller And Control Panel (a)

Selection of power cable for irrigation controller and panel as per the manufacturer recommendation.

(b)

The detail of Voltage, Ampere and size of cable as per the manufacturer recommendation and technical data.

(c)

The cable shall carry a 1 year manufacturer and 2 years supplier warranty.

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Power Source

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The controller should have 2 years minimum warranty against malfunctioning and 10 years available software upgrade. Irrigation schedule should laminated and placed in each controller cabinet.

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Irrigation Control Cables Electrical materials for irrigation purposes shall comply with the relevant provisions of Section 21, Electrical Works.

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(b)

Irrigation control cables shall be used between the solenoid valves and the irrigation controllers. The cables shall be of the single conductor type UF and they shall be engineered for direct burial use. The common wire shall be gauge 12 and the control wire shall be gauge 14.

(c)

For master control valves and flow meter wires use 10 gauge wires.

(d)

The wires shall be of the solid or stranded construction with soft bare copper conductor. They shall have extra heavy thickness of special polyvinyl chloride insulation highly resistant to the saline, acid or alkaline contaminants.

(e)

The copper conductors of the wires shall meet the requirements of ASTM B-3, B-8.

(f)

The thermoplastic insulation shall meet U L standard 493 and 83. All irrigation wires shall have surface printing on insulation.

Irrigation Pump (a)

The irrigation pumping system shall consist of a main irrigation pump, a booster pump. The size of the pump is as specified in each project specification.

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22

(b)

The irrigation pump should have a variable frequency drive that controls and keep pressure constant with a variable drive system.

(c)

The pump should be made of the best materials and made by a reputable manufacturer.

(d)

The operation and maintenance schedule should be submitted.

(e)

The minimum replacement warranty for the pump should be 2 years if defect occurs more than twice per year.

(f)

The supplier should submit a guarantee of 2 days maximum repair time for the pump including availability of spare parts.

(g)

The pump warranty should cover all parts of the pumping system including the control board piping and check valve to a minimum of five years against manufacturer defects.

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Flow Sensor

The flow meter shall be of an Electromagnetic insertion type, operated with 24 V direct current.

(b)

It shall be compatible with the irrigation control system. And Capable of reading flow from 0 to 25% higher than the maximum flow in the largest mainline pipe.

(c)

Frequency of sampling and reading flow shall be selectable from 10 times per second to one time in 10 minutes or (As per manufacture requirements).

(d)

The wire of flow sensor should be minimum 20 AWG.

(e)

The warranty shall include the flow meter and the signal converter and should be for 5 years suppliers’ warranty.

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Master Control Valve

The master control valve should be cast iron compatible with the existing controller and operated with 24 V direct Electrical current.

(b)

The warranty should be for 3 years suppliers warranty and 1 years minimum manufacturer warranty.

(c)

The local supplier should be an existing Qatari firm with minimum 5 years of operational history.

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Miscellaneous

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(a)

Irrigation Drip Line Stakes: Stakes for securing flexible pipes shall be heat resistant plastic.

(b)

Keys: the Contractor shall provide Keys for all valves, controller cabinets, boxes, quick couplers, etc. The number of keys to be provided to the Engineer for each type of fitting shall be six (6).

(c)

Hoses: Hoses, quick couplers and appropriate connectors shall be provided by the Contractor for quick coupling valves, drain down points, etc. The number of hoses/connectors shall be: 1 (one as sample) the hose should be fifty (50) meters of industrial weight double nylon cord reinforcement or double tire cord reinforced of an untangling and high pressure type.

(d)

Quick couplers Swivel end unit: One (1) quick coupler with swivel end unit shall be provided for each installed eight (8) quick coupling valves.

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(e)

Distribution chamber: Should be made of reinforced concrete as specified and approved by the drainage department, it should allow for easy installation and removal of component inside and should be water proofed with waterproofing paints and membrane. The membrane should be protected with a protection board.

(f)

Chamber Aluminum cover: The aluminum cover should be made to fit the new chambers shown on the project details drawing and it should have the following: Hinged aluminum access cover shall be obtained from an approved experienced manufacturer and shall be fabricated from checker-plate. The cover shall be capable of withstanding a load of 750 kg/m2 without deflecting more than 1% of the span, and without damage or permanent deflection.

(ii)

Hinges shall not stand proud of the cover, and sealed lifting eyes shall be provided completed with two lifting keys for each cover.

(iii)

Covers should open to approximately 10 degree past the vertical, and stays should be provided to hold the cover in this position.

(iv)

All joints shall be welded/soldered in an inert atmosphere.

(v)

The faces of the frame which will come into contact with the cement mortar or concrete shall be painted with two coats of bituminous paint before installation of the frame.

(b)

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The Contractor shall co-ordinate and provide water and electrical connection points as follows: (i)

connections to water sources

(ii)

make all connections to electrical panels or transformers

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Connection to Existing Services

The Contractor shall be responsible for making connections to existing piping, valves, conduit, and appurtenances utilising proper adaptation tools and procedures.

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(i)

EXECUTIONS

2.3.1

Protection

1

All materials shall be handled and shipped in accordance with the relevant provisions of Part 9 of Section 1, General.

2

All materials shall be shipped or otherwise conveyed in such a manner as to assure no damage. All boxes shall be securely sealed and clearly marked with the name of the manufacturer. All pipes shall be protected from crimping, crushing and splitting. All nonmetallic system components shall be protected from sunlight exposure as per the manufacturer's recommendations.

3

Work and materials shall be protected from damage during storage, handling and construction. Particularly, non-metallic pipes and fittings shall be protected from direct sunlight during storage. Facilities of the necessary dimensions shall be provided and maintained for storage of all non-metallic irrigation materials in their entirety. All non-metallic materials shall be handled carefully and stored under cover to avoid damage. Pipes that have been damaged or dented will not be used in this work.

4

In addition to the provisions for the protection of non-metallic components, special attention shall be given to the protection of the control system components; protection shall be provided as per the manufacturer's written recommendations.

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5

Openings into the system, apparatus and equipment shall be securely covered, both before and after being set in place, to prevent obstruction in the pipes and the breakage, misuse or disfigurement of the apparatus or equipment.

6

Barricades, guards, warning signs and lights as necessary or required, for the protection of the public and the work force shall be provided.

7

Utilities: The location of existing underground utilities shall be determined and the works performed in a manner which will avoid possible damage. Hand excavation, as required shall be carried out to minimize the possibility of damage to existing underground utilities.

Performance The Contractor shall stake-out the locations of all pipe and valves and the layout of work as accurately as possible.

9

The Contractor shall verify all horizontal and vertical site dimensions prior to staking.

10

The Contractor will be responsible for relocating any existing services after first obtaining the Engineer's approval. The Contractor shall remove and relocate such services, at his own expense, if so directed by the Engineer.

11

Before starting work on irrigation systems, the Contractor shall carefully check all grades to determine that work may safely proceed, keeping within the specified material depths.

12

Fittings installed on pipes beneath pavements or walls shall be shown on drawings.

13

All changes shall be recorded daily on the “As-Built" worksheets.

2.3.2

Inspection

1

The Contractor shall inspect all products for damage immediately before installation. Any products that are found to be damaged or not in accordance with the specifications shall immediately be repaired or removed from the site and replaced. Repairs shall not be undertaken without the Engineer's approval of Contractor's proposed action.

2.3.3

Installation

1

Excavation and backfilling shall be in accordance with detail drawings.

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Mainline shall be placed at 70 cm deep and warning tape 20 cm above pipe as shown in design drawings.

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(c)

Width of trench to be 40 cm minimum width.

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Lateral lines should be placed at 40 cm deep without warning tape above.

2

Sand bedding layer of 15 cm minimum is required under the irrigation pipe.

3

Sand surround to a minimum 15 around the irrigation pipe is required.

4

In bedding and backfilling granular material shall be used below and above the pipes. The backfill material shall be free of stones bigger than

5

Cast-in-place concrete shall be in accordance with the common civil works standards covering the concrete class, shattering work, curing procedures etc.

6

All products shall be installed in accordance with the manufacturer's instructions and the Drawings.

7

Location of Irrigation Lines (a)

Where the location of an irrigation line is not clearly dimensioned on the Drawings, the irrigation line shall not be laid horizontally closer than 3.0 meters from a sewer.

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Page 15

However, where the bottom of the irrigation line will be at least 0.3 meters above the top of the sewer pipe, the irrigation line shall not be laid closer horizontally than 1.5 meters from the sewer.

(c)

Where irrigation lines cross under gravity-flow sewer lines, the sewer pipe shall be fully encased in concrete, for a distance of at least 3.0 meters each side of the crossing or shall be made of pressure pipe with no joint located within 1.0 meters horizontally of the crossing.

(d)

Irrigation lines shall, in all cases, cross 0.6 meter above sewage pressure mains.

(e)

Lateral lines shall be 2 meters away from center of trees, palms and large shrubs.

(f)

Generally, where the irrigation distribution or secondary main with accompanying cable bundle is running under hard surfaces or landscaped areas the pipe and the cables will be directly buried in a clean sand bed with a marker tape above. At road junctions or other locations where pipes cross the road they shall be contained in a direct buried PVC sleeve. The sleeve shall extend beyond the road crossing by at least one meter on both sides. The sleeve shall be a minimum of 100 mm diameter and for larger pipes will be at least 25mm greater in diameter than the pipe running through it.

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Placing and Laying

Pipes shall not be laid in water or when trench conditions are otherwise unsuitable for the work. Water shall be kept out of the trench until the material in the joints has hardened or until caulking or jointing is completed. When work is not in progress, open ends of the pipe, fittings, and valves shall be securely closed so that no substance will enter the pipes or fittings.

(b)

Pipe ends left for future connections shall be valved, plugged or capped, and anchored, as shown or as directed. Pipes that have the grade or joint disturbed after laying shall be taken up and re-laid.

(c)

All piping with the exception of the flexible irrigation drip line shall be surrounded by a sand bed to the dimensions as shown on the Drawings.

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Plastic pipes: Pipes with threaded joints shall be snaked from side to side of the trench to allow for expansion and contraction.

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Jointing

Pipe joints of UPVC shall be installed in accordance with recommendations of the manufacturer. Excess jointing material shall be removed. Heavy duty jointing material will be used only.

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(b)

UPVC male adaptors with specified threaded joint compounds to make connections between plastic pipe and valves shall be used as detailed, and tightened with light wrench pressure.

11

Concrete thrust blocks shall be constructed on main pipelines at all changes in direction or size. The thrust blocks shall be non reinforced concrete and shall have a minimum dimension of 300 mm. The pipelines shall be located centrally in the thrust blocks.

12

Irrigation piping from the remote control valve boxes to the end of the irrigation drip lines shall be buried to the depths as shown on the Drawings.

13

Closing of Pipe and Flushing Lines (a)

Closing: Openings in piping systems shall be capped or plugged, leaving caps and plugs in place until removal is necessary for completion of the installation. Dirt and debris shall be prevented from entering pipe or equipment.

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(b)


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Flushing: All pipes and tubing shall be thoroughly flushed out before installation of the emitter control valves. Butt joints, fittings and connections shall remain visible.

14

Tagging and Identification: All remote control valves, motor-operated valves, pressure reducing valves, manually-operated gate valves and controllers shall be tagged and identified. All identifying numbers shall be consistent with like designations indicated on the irrigation controller schedule.

15

Site Equipment Installation Isolation Valve/Gate Valve: Shall be installed as detailed and where indicated on Drawings.

(b)

Remote Control Valve Assembly: Shall be installed in the positions as indicated in the details, remote control valve assembly comprising gate valve, remote control valve with pressure regulator, and all appurtenances. Valve boxes containing the assembly shall not be placed closer than 300mm to paved areas. When the pressure gauge will be properly attached, the outlet pressure shall be set as required during coverage tests.

(c)

Valve Boxes: Shall be installed as detailed and where indicated on Drawings. All valves and valve assemblies shall be mounted in boxes as detailed.

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(a)

The top of all boxes shall be set parallel with the grade and as detailed in a neat and orderly fashion.

(ii)

Shall be placed parallel to paving, kerbstone, walls or similar structures and where more than one box, parallel to each other.

(iii)

All box locations shall be reviewed with the Engineer prior to installation of valves.

(iv)

Valve boxes shall not rest on or come in contact with the valve, piping, hose or conduit.

(v)

Solenoid valve boxes shall have a weather proof tag attached on the inside showing the valve number, controller number and station number.

(vi)

A filter fabric shall cover the valve box and the soak away and taped to the valve box side just 10 cm below cover.

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Control System

Irrigation Controller

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An irrigation controller shall be installed in locations approved by the Engineer, with the control cables, clearly marked with identification markers, attached to the appropriate terminals in the approved manner.

(ii)

Shall be secure to a concrete pad with approved anchor bolts. Chipping, cracking, or otherwise marring the finish of enclosure when securing to the concrete pad shall be avoided.

(iii)

Programming of Irrigation Controller: Using the controller schedule provided on the drawings, as a guide, the irrigation controller shall be programmed to correspond with the initial irrigation sequencing and duration of the cycles for each zone. The Contractor may find that during establishment and maintenance the schedule has to be modified to achieve a correct irrigation regime in accordance with good horticultural practice, such modification shall be approved by the engineer.

Irrigation - Electrical

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Page 17

All electrical work shall be in conformance with Qatar General Electricity & Water Corporation (QGEWC) Regulations and as further specified in Section 21, Electrical Work, inclusive of the following: (i)

The contractor shall provide, install, test and commission all items of electrical equipment associated with the irrigation systems.

(ii)

All electrical works shall be in accordance with the BS and IEC.

(iii)

The irrigation system shall commence at the controllers, which shall be fitted into a dwarf type distribution cabinet with solar shade and shall have a bolting down foot for mounting on a pre-formed concrete base. All incoming and outgoing cables shall be from below ground level. The cabinet shall have a hinged lockable opening door to provide full front access to the controller and equipment and shall be sized according to the equipment being installed.

(iv)

All equipment, conductors, termination, etc., within the pillar and throughout the irrigation system generally shall be fully insulated such that there are no live parts or connections exposed and shall be to the complete satisfaction of the Engineer.

(v)

The irrigation pillar shall have sufficient free space for fitting a kWh meter together with any additional equipment or accessories required to complete the equipment.

(vi)

Each irrigation pillar shall have permanently fixed on the inside of the door, a distribution diagram showing all circuits connections, ratings, cable sizes, etc., together with a current controller schedule.

(vii)

All terminals shall be of the crimped spade type with insulated grip. At all connection locations 150 mm of "slack" shall be provided.

(viii)

Conductor markers shall be used throughout which shall clearly indicate the circuit reference or number. These shall be white plastic with black letters or numbers and of the type which acts as a sleeve over the conductor insulation.

(ix)

Connections onto valves shall be made in a below ground PVC resin filled molded waterproof connector with integral wire clamp.

(x)

Solenoid valve cables shall be laid along the mainline at a horizontal distance of 20 cm from the irrigation pipe.

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Wiring under streets, driveways and other vehicular areas, and under walks, plazas and other hardscaped areas shall be installed as specified in Section 6, Roadworks:

Drip Line/Soft line Testing (a)

Drip lines shall be carefully uncoiled and laid in position without kinking. Any kinked section shall be cut from the line and subsequently rejoined with a line joiner section.

(b)

Drip lines shall be snaked as required for maximum coverage without the use of compression fittings. Sharp bends shall be avoided where there is a likelihood of causing kinks in the line.

(c)

Drip lines shall be laid on the ground surface for a minimum of 48 hours prior to the installation of irrigation emitters or stakes.

Concrete Pads (a)

Installation as detailed and where shown on the Drawings of controllers manufacturer.

(b)

The exact location shall be confirmed to the Engineer prior to pouring.

QCS 2014


(c)

Specified non-metallic conduit shall be provided as required to penetrate boxes and enclosures as approved by the Engineer.

(d)

The anchor bolts shall be set in coordination with enclosure hole locations.

2.3.4

System Testing

1

Purging Immediately prior to hydrostatic testing, all irrigation lines shall be thoroughly purged of all entrapped air.

(b)

Mainline piping system may be tested in sections. Lateral Systems shall be tested valve by valve.

(c)

Water shall be discharged from a single outlet by manipulation of isolation control valves and installation of temporary caps.

(d)

Water shall be introduced into lines to be tested at full operating head and the water flow at end discharge point, and observed until all air and residual debris has been expelled from the line.

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(a)

Initial System Test

Individual parts of the main network between isolation valve points having a length not greater than 500 meters shall be tested together with dead legs before backfilling operation.

(b)

Test shall be made only after completion of the above operations and not until at least seven days after the last concrete thrust anchor block has been cast.

(c)

Contractor shall supply all testing material and equipment, including all caps, valves, pumps, tanks, water and gauges as required.

(d)

Pressure gauges shall be dual reading in bar and psi units. Calibration shall be such that accurate determination of potential pressure loss can be ascertained.

(e)

The section of the main pipeline to be tested shall be filled with potable water and all air expelled. After the main pipeline has been completely filled, the pressure shall be steadily and gradually increased until the specified test pressure has been reached. Simultaneous pressure and leakage tests and separate pressure test shall be made at 150 % of working pressure at the point of test, but not less than 125% of normal working pressure at highest elevation. Separate elevation test shall be made at 150 % of normal working pressure of the segment tested. The minimum pressure test for mainlines is 9 bars and leakage test for lateral lines. Duration of pressure and leakage tests shall be 4 hours. All testing shall comply with AWWA M23-80, Polyvinyl Chloride Pipe Design and Installation. Testing shall comply with AWWA specifications and requirements.

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(f)

Separate tests shall be applied to the lateral distribution pipe work and the irrigation pipe work from the remote control valves outwards. Test pressures for these shall be as described above.

(g)

When testing the irrigation lines from the valves, discharge devices shall be replaced with temporary plugs or caps.

(h)

All trenches with pipe installed shall be immediately backfilled with preliminary sand backfill sufficient to prevent arching or slipping under pressure. All joints, fittings and connections are to remain exposed until successful completion of hydrostatic testing.

(i)

Other than for preliminary sand backfill over pipes, no work shall be covered before it has been inspected, tested and approved by the Engineer.

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(j)

During the tests, all exposed couplings, fittings and valves shall be carefully examined for defects and leakage. Leaking pipes, couplings, joints, fittings and equipment shall be repaired or replaced and the section retested as previously specified.

(k)

Upon receipt of approval of the Engineer to proceed, the remaining backfill shall be placed and compacted to ninety percent (90%) of maximum dry density.

Final System Test: The tests as specified above shall be repeated for the entire network after pipelines have been backfilled, cleaned and inspected. Each test shall be restricted to pipes of one class and particular care shall be taken to isolate air valves, etc. and not to apply higher pressures than specified at any point on the pipeline and to ensure that the pipelines are adequately anchored before any test is carried out.

4

Test Results: Written records of every test clearly identifying the tested section of the pipe together with time of test and name of testing engineer in tabulated format shall be submitted for review and approval by the Engineer upon completion of the tests.

2.3.5

Flushing

1

General: On completion of the system test, the system is to be thoroughly flushed, the velocity of water being at least 1 m/s. Should the main water supply be unavailable or inadequate for this purpose at the time of flushing, then a swab of adequate size shall be used to remove all foreign matter from the pipeline. This process shall continue until the pipeline is completely clean. Each control valve shall be opened separately and the terminal systems also thoroughly flushed. After completion of flushing, the emitters and other discharge devices shall be fitted.

2

Operation Test: After the hydrostatic test, emitters shall be installed and the system completed and tested to demonstrate functional efficiency. This shall be prior to covering the laterals with mulch if used.

3

The lines shall be operated for a period of 24 hours, not necessarily in one continuous period, and all emitters checked for satisfactory operation. Any faulty/blocked emitters shall be replaced.

2.3.6

Testing and commissioning

1

On completion of the entire irrigation system installation, the system shall be commissioned to demonstrate the proper functioning of the system. The process of commissioning shall be carried out in the presence of the Engineer’s Representative.

2

Adjustment and re-testing of emitters, control valves etc., shall be carried out until satisfactory result is obtained and the whole system is functioning to the design requirement.

2.4

OPERATION AND MAINTENANCE

2.4.1

Maintenance Program

1

Maintenance Personnel: to have experience in Qatar based landscape contracting company specializing in installing irrigation system for landscape.

2

Maintenance Manual: Upon completion of work and prior to initial acceptance, provide the Engineer with Four (4) copies of a bound maintenance manual and one (1) softcopy.

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(a)

The manual shall contain a list of all irrigation system components including: (i)

Component description.

(ii)

Supplier name, address, telephone, email and contact person.

(iii)

Warranty start and end date.

(iv)

Spare parts available for each component.

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Section 28: Landscaping Part 02: Irrigation System (v)

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Maintenance program by date for each component and the description of the maintenance procedure, cleaning, flushing, lubricating, changing parts, updating etc.

The general manual headings and descriptions shall be both Arabic and English.

4

PENALTY FOR NON-PERFORMANCE/ DELAY: Due to the nature of the soft landscaping and the effect it has on the public appearance, the contractor must carry out the irrigation maintenance work as scheduled and direct by the Engineer. Failure to do so will have severe consequences on the contractor and the Engineer may take action the maintenance work. The Main Contractor shall bear all the cost implications arising from this action and no payment shall be processed until the Main Contractor processes the payment due to the new contractor that carried out the work.

5

The Contractor shall execute the required maintenance work in accordance with the approved maintenance program / schedule without any delay and to the satisfaction of the Engineer. In the event the Contractor fails to carry out the work specified, The authorized person shall employ persons other than the Contractor’s staff to carry out the work and shall recover from the Contractor such costs incurred thereby from any monies due, or which become due, to the Contractor. In addition the Contractor shall be liable to Penalties as follows:

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Delay in replacing damaged sprinklers.

(b)

Delay in replacing damaged manual valves.

(c)

Delay in replacing damaged remote valves.

(d)

Delay in replacing damaged valve boxes .

(e)

Delay in replacing damaged pipes .

(f)

Delay in cleaning 2” Y strainer .

(g)

Delay in cleaning 3” disc filters.

(h)

Delay in repair of pumps beyond 2 days- Replacement of the pump in addition to cost of irrigating by hand.

(i)

Delay or manual operation of controllers.

(j)

Delay in replacement of controllers.

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Delay in watering plants. Not following the approved irrigation schedule.

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Opening irrigation valves outside the irrigation schedule.

(n)

Water leaks to the street.

(o)

Due to non availability of TSE water the contractor shall deliver and properly irrigate the area.

2.4.2

Operational Personnel and Manual

1

Operational Personnel: to have experience in Qatar based landscape contracting company specializing in installing irrigation system for landscape.

2

Operational Manual: Upon completion of work and prior to initial acceptance, provide the Engineer with Four (4) Hard copies of a bound operational manual and one (1) softcopy. (a)

The manual should contain a list of all irrigation system components including: (i)

Original operational manual.

(ii)

Operational schedules.

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Section 28: Landscaping Part 02: Irrigation System (iii)

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The general manual headings and descriptions shall be both in Arabic and English.

2.4.3

Operation Program

1

The contractor shall operate and maintain the irrigation system throughout the maintenance period, and shall provide staff in full time attendance throughout the period.

2

The maintenance of the irrigation system shall cover all work necessary to adequately operate and keep all irrigation equipment, valves, pipelines and appurtenances in proper operating condition, all to the satisfactory of the engineer.

3

Maintenance shall include but not limited to the following: Supply of irrigation water of suitable quality and adequate quantities to meet the irrigation requirements. The contractor shall arrange to obtain water from an approved source. A full analysis of the irrigation water shall be submitted to the engineer for approval and then at one month intervals thereafter during the maintenance period.

(b)

Irrigation of areas forming part of the works at a frequency and depth as required for every season in the maintenance period.

(c)

Maintenance and repair of all irrigation equipments, pipes , valves and all appurtenances; records shall be kept of all maintenance ,repairs and operation activities carried out during the maintenance period.

(d)

The contractor shall provide to the engineer at the end of the maintenance period a report which shall include details of the date, location and type of work performed , all repairs and replacements , the amount f water applied and the duration of each irrigation cycle , results of water analysis and all other relevant information of work and activities carried out during the maintenance period.

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Layout work

The contractor shall be responsible for the accuracy of all layout work.

(b)

Drawings are diagrammatic to the extent that swing joints offsets and all fittings are not shown and shall be the responsibility of the contractor to incorporate as needed and as compatible or acceptable with other included items.

(c)

Lines are to be in common trenches wherever possible.

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Remote controls valves shall be grouped wherever possible and aligned at a set distance from road edges, footpaths and buildings.

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2.5

SPARE PARTS

2.5.1

General

1

The Contractor shall submit to the Engineer a list of all spare parts to be required for a further two years operation from the date of issue of the Maintenance Certificate or otherwise specified herein after.

2

Spare parts required include but not necessarily limited to those listed below, provided specified in the Project Documentation or where quantities for each item or equipment is recommended by the manufacturer

3

Spare parts are to be delivered to central stores.

4

The tenderer shall submit with his offer detail prices of the spare parts he is required to provide under the Contract indicating the quantity and the unit rate of each item.

5

The Contractor shall provide sufficient spare parts as follows.

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Air Release Valve: 10 % spare, but in any case not less than 1 nos as specified and used in the project or in this section & shall carry a 3 years exchange warranty.

(b)

Screen Filter: 10 % spare, but in any case not less than 2 nos of cartridges as specified & used in the project or in this section.

(c)

Polyethylene In Line Drip: 10 % spare, but in any case not less than 1 roll as specified & used in the project or in this section with 2 years guarantee against solar radiation and 1 year manufacturer and supplier warranty against manufacturing defects.

(d)

On Line Drippers: 20 % spare from the different flow size, as specified & used in the project or in this section with 2 years guarantee against solar radiation and 1 year manufacturer and supplier warranty against manufacturing defects.

(e)

Pressure Compensating Bubbler: 20 % spare from the different flow size used in the project, with all fittings and accessories specified by the manufacturer for a proper usage with two years manufacturer and supplier replacement warranty.

(f)

Rotor Sprinkler: 10 % spare from the different flow sizes and ranges & 25 % of the required nozzles, spare parts must be from the same brand used in the project or equivalent up to engineer's approval with all fittings and accessories specified by the manufacturer for a proper usage with two years manufacturer and supplier replacement warranty.

(g)

Pop Up Spray: 10 % spare from the different flow sizes and ranges & 25 % of the required nozzles, spare parts must be from the same brand used in the project or equivalent up to engineer's approval with all fittings and accessories specified by the manufacturer for a proper usage with two years manufacturer and supplier replacement warranty.

(h)

Irrigation Control Wire: 10 % from the total length used in the project, the detail of Voltage, Ampere and size of cable as per the manufacturer recommendation and technical data and shall carry a 1 year manufacturer and 2 years supplier warranty.

(i)

Solenoid Valves: 10 % from the total no. used in the project plus 20 % from the required coils, The valve sizes, number and flow rate must be as used & shown on the design drawings and shall carry a 3 years manufacturer and supplier exchange warranty.

(j)

Quick Coupling Valve: 10 % spare, but in any case not less than 1 valve. The valve must be of the low-pressure loss type of 1 inch, brass body with all fittings and accessories used in the project or specified by the manufacturer and shall carry a 3 years manufacturer and supplier exchange warranty.

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(a)

(k)

Gate Valve: 10 % spare, but in any case not less than 1 valve. As specified and used in the project or in this section and shall carry a five years manufacturer and supplier exchange warranty for the bronze or brass type and 3 years manufacturer and supplier exchange warranty for the PVC types with all fittings required by the manufacturer manual.

(l)

Check valve: 10 % spare, but in any case not less than 1 valve. As specified and used in the project or in this section and shall be available in 3”, 4”, and 6”size & carry a 3 years exchange warranty.

(m)

Valve Boxes: 10 % spare, but in any case not less than 1 box. As specified and used in the project or in this section with two years replacement warranty against buckling and five years against cracking.

(n)

PVC Pipes & Fittings: 10 % from the total length used in the project from different sizes with same ratio of the required fittings and accessories or equivalent all up to engineers approval.


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APPENDIX A

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Irrigation Details 2.6 APPENDIX A – IRRIGATION DETAILS ------------------------------------------------------------ 25 25

Irrigation Rates are in two parts

25

Details

29

1

Bubbler Typical Connection and Section for Trees

29

2

Bubbler Typical Connection and section for Palms

29

3

Sprinkler Installation

30

4


30

5

Air Release Valve Assembly

31

6

Quick Coupling Valve Typical Connection and Section

31

7

Drip Line Poly Pipe Connection: For Elbow Connection Typical Section

32

8

Drip Line Poly Pipe Plan Layout

32

9

Drip Line Poly Pipe Connection: For T Connection Typical Section

2.6.2

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Irrigation Rates

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33 33

11 Thrust Block Arrangements: Typical Plans and Section

34

12 Pipe Sleeve Detail for Under Asphalt and Pavement

34

13 uPVC Pipe Main and sub Main Line Installation: Typical Section

35

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10 Irrigation Duct: Typical Section for under Walkways

14 Pipe Sleeve Detail

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2.6

APPENDIX A – IRRIGATION DETAILS

2.6.1

Irrigation Rates

1

Irrigation Rates are in two parts (A)

Part 1: Peak Rate for determination of maximum volume and pipe sizing

(B)

Part 2: A graduated mean based on seasonal demand variations enabling calculation of a annual water demand budget. Table 10 : Irrigation Requirements Ashghal Projects

Group 4: High Water Demand Total Annual Demand

Mean Annual Daily Demand

Cycle (days)


Total Annual Demand (m³/plant/ year)

Mean Annual Daily Demand (l/plant/ /day/year)

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100

8

100

4

100

8.97

24.58

50

5

50

8

50

3

50

4.74

12.98

3

100

5

100

8

100

4

100

8.97

24.58

100

3

70

5

70

8

70

4

100

7.81

21.39

1 to 2 Years

100

3

40

5

40

6

40

4

100

6.80

18.62

Mature

25

3

25

5

25

7

25

3

25

2.41

6.60

1 to 2 Years

20

3

20

4

20

7

20

3

20

1.99

5.45

50

3

4

Mature

100

3 to 8 YEARS

Trees

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Days

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Palms

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3 to 8 Years

Irrigation Group

120

.

Peak Daily Demand

Quantity (l) per plant

5

3

90

Cycle (days)

29.49

120

Days


10.76

Mature

61

Cycle (days)

120


4

Age

Cycle (days)

120

Days


8

153

4

April to May

120

Days

Type

January to March

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November to December

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June to October

4

Quantity l/m²

Cycle (days)

Quantity l/m²

Cycle (days)

Quantity l/m²

Cycle (days)

Quantity l/m²

Cycle (days)

Peak Daily Demand l/m²

Total Annual Demand (m³/m²/ year)

Mean Annual Daily Demand (l/m²/ day/year)

4

Shrubs & Small Trees

4

Ground Covers

12

3

12

5

12

7

12

3

12

1.16

3.17

4

Turf Grass

15

3

15

4

15

5

15

3

15

1.57

4.30

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Table 10 Continue… Group 3: Medium Water Demand

Peak Daily Demand

Total Annual Demand


Cycle (days)

Peak Daily Demand l/plant

Total Annual Demand (m³/plant/ year)

Mean Annual Daily Demand (l/plant/ day/ year

3

60

6.10

16.70

80

3

80

4

80

6

3 to 8 Years

60

3

60

4

60

3

1 to 2 Years

40

3

40

4

3

Mature

80

3

80

3 to 7 Years

60

3

60

1 to 2 Years

40

3

Mature

20

1 to 2 Years

15

3

3

3

40

4.18

11.46

as 80

6

80

3

80

8.13

22.26

4

60

6

60

3

60

6.10

16.70

40

4

40

5

40

3

40

4.18

11.46

3

20

5

20

7

20

4

20

1.83

5.00

2

15

5

15

7

15

4

15

1.75

4.80

Quantity l/m²

Cycle (days)

Quantity l/m²

Cycle (days)

Quantity l/m²

Cycle (days)

Peak Daily Demand l/m²

Total Annual Demand (m³/m²)


Ground Cover /Grasses

40

Cycle (days)

3

5

Quantity l/m²

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Mature

Irrigation Group:

Age

Days

.

Quantity (l) per plant 60

90

Cycle (days)

22.26

Days

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61


80

Days

Cycle (days)

3

153


80

Days

Type

April to May

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January to March

Cycle (days)



June to October

10

3

10

5

10

7

10

4

10

0.91

2.50

Table 10 Continue…

2 Ground Cover /Grasses Age Quantity (l) per plant Cycle (days) Quantity (l) per plant Cycle (days)

.

90

Mature 70 4 70 5 70 7

3 to 7 Years 60 4 60 5 60 8

1 to 2 Years 30 4 30 5 30 8

Mature 20 4 20 7 20

1 to 2 Years 12 4 12 7

10

4 Cycle (days)

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Quantity l/m² Cycle (days) Quantity l/m² Cycle (days) Peak Daily Demand l/m² Total Annual Demand (m³/m²) Mean Annual Daily Demand (l/m²/ day/year)

10 7 10 10 10 5 10 0.68 1.87

4

70

60

4

60

4.62 12.65

30

4

30

2.31 6.32

7

20 4 20 1.50 4.11

12

8 12 4 12 0.88 2.42

January to March Total Annual Demand



61

Total Annual Demand (m³/plant)

Days

Peak Daily Demand

April to May


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70

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Quantity l/m²


Cycle (days)

Days

Cycle (days)

June to October


61

er

Days

Cycle (days)

Shrubs & Small Trees 153


2

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2 Trees Days

Quantity l/m²

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2 Type

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Irrigation Group:

QCS 2014 Section 28: Landscaping Part 02: Irrigation System Page 27


Group 2: Low-Medium Water Demand

5.50 15.07


1 Ground Cover /Grasses 12

7

Quantity (l) per plant Cycle (days)

Mature 100 7 100 12 100 20

1 to 2 Years 50 7 50 12 50 14

Mature 25 10 25 12

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1 to 2 Years 12 7 12 10

25

20

25 12 25 0.75 2.05

20 12 12 12 0.44 1.20

Peak Daily Demand l/m² Total Annual Demand (m³/m²)

12 0.45

12 12 20 12

50

50

1.97 5.41

10


100


10

Total Annual Demand

100

Total Annual Demand (m³/plant)

61 Peak Daily Demand

April to May




12

Days

Cycle (days)

January to March

Cycle (days)

12

90

Quantity l/m²

Days

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12

61

Cycle (days)

Days

Quantity l/m²

.

Cycle (days)

153

Cycle (days)




Days

as

Quantity l/m²

Cycle (days)

June to October

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Cycle (days)


Trees

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Age

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Type

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Irrigation Group:

QCS 2014 Page 28


Group 1: Low Water Demand

3.75 10.29

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Details

1

Bubbler Typical Connection and Section for Trees

2

Bubbler Typical Connection and section for Palms

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2.6.2

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4


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Drip Line Poly Pipe Connection: For Elbow Connection Typical Section

8


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10

Irrigation Duct: Typical Section for under Walkways

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Thrust Block Arrangements: Typical Plans and Section

12

Pipe Sleeve Detail for Under Asphalt and Pavement

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uPVC Pipe Main and sub Main Line Installation: Typical Section

14

Pipe Sleeve Detail

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uPVC Pipe Lateral Line Installation: Typical Section

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APPENDIX B

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APPENDIX B – Irrigation Details with Pumps 2.7 APPENDIX B – IRRIGATION DETAILS WITH PUMPS-------------------------------------------- 39 Solenoid Valve Assembly Typical Connection and Section

39

2

Bubbler Typical Connection and Section

39

3


40

4


40

5

Disc Filter Assembly Chamber, Master Control Valve and Provision for Future Flow Meter 41

6


41

7

Disc Filter Plan View

42

8

Drip Line Ply Pipe Connection: for Elbow Connection Typical Section

42

9


43

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1

43

11 Front Elevation

44

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10 Drip Line Poly Pipe Connection: For T Connection Typical Section

qa

12 Side Elevation 13 Typical Pump Details

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14 Irrigation Duct: Typical Section for Under Walkways

44 45 45 46

16 Pipe Sleeve detail: For Under Asphalt and Pavement

46

17 uPVC Pipe Main and Sub Main Line Installation: Typical Section

47

18 Pipe Sleeve Detail

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15 Thrust Block Arrangements: Typical Plans and Section

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19 uPVC Pipe Lateral Line Installation: Typical Section

47 48

QCS 2014

2.7


Page 39

APPENDIX B – IRRIGATION DETAILS WITH PUMPS

Appendix B contains the details listed below:

Solenoid Valve Assembly Typical Connection and Section

2

Bubbler Typical Connection and Section

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1

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4


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3

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Disc Filter Assembly Chamber, Master Control Valve and Provision for Future Flow Meter

6


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Disc Filter Plan View

8

Drip Line Ply Pipe Connection: for Elbow Connection Typical Section

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7

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10


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Front Elevation

12

Side Elevation

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Typical Pump Details

14

Irrigation Duct: Typical Section for Under Walkways

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Thrust Block Arrangements: Typical Plans and Section

16

Pipe Sleeve detail: For Under Asphalt and Pavement

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uPVC Pipe Main and Sub Main Line Installation: Typical Section

18

Pipe Sleeve Detail

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uPVC Pipe Lateral Line Installation: Typical Section

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END OF PART

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PLAY EQUIPMENT ................................................................................................................. 2 GENERAL REQUIREMENTS ...................................................................................................2 Scope ........................................................................................................................................2 References ................................................................................................................................2 Material......................................................................................................................................2 Capacities .................................................................................................................................3 Maintenance Schedule..............................................................................................................3 Testing.......................................................................................................................................3 Warranty ....................................................................................................................................3 Approval ....................................................................................................................................4

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3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

Section 28: Landscaping Part 03: Play Equipment

QCS 2014


Page 2

PLAY EQUIPMENT

3.1


3.1.1

Scope

1

Public play areas for children are considered the most critical places for safety issue. It should be very well planned, designed and constructed to fulfill the maximum safety requirements.

2

The play equipment products are to be in conformance with the following international standards for safety and materials:

3.1.2

References

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ASTM F1487-93 .........Standard consumer safety performance specifications for playground equipment for public use, 2001 revision CAN/CSA Z614-98 .....Guideline on children’s play spaces and equipment or both, May 1998 CPSC ......................... Handbook for public playground safety, 1998 BS EN 1176 ............... Playground equipment and surfacing Material

1

The Contractor shall supply materials as per the specification herein after.

2

Steel: Steel to be cold rolled, electric resistance welded tubing. Black steel is not acceptable only galvanized steel is acceptable.

3

Aluminum

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Aluminum should be an all welded assembly fabricated of 6061-T6 extruded seamless aluminum alloy tubing for support post and sleeve

(b)

Aluminum should be an all welded assembly fabricated of 6063-T4 extruded seamless aluminum alloy tubing for architectural parts.

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Plastic

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3.1.3

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6

(a)

All metal bridges, decks, platforms and stairs should have an oven cured PVC coating with a matte finish and a nominal coating thickness of 0.125” guaranteed for 10 years minimum against peeling and cracking.

(b)

All plastic materials should be molded UV resistant, impact resistant low density polyethylene material including UV stabilized color pigments and anti-static additives with minimum 10 years guarantee.

Wood (a)

All wood material should be pressure treated with material preventing splitting, rain damage and attack by insects or termites. A minimum 5 years guarantee is needed against splitting and warping, attack by insect and rain damage.

(b)

No wood to be used for foundation or placed underground.

Concrete : No exposed concrete foundation is allowed and foundation should be at least 20 cm below sand or soil cover

QCS 2014


Page 3

7

Paints: Paint should be electrostatically lead free powder coating treated in six stage iron phosphate bath.

8

Fibers and fabrics: All shades and tent made of shade-net or fabric components should be made of durable materials color resistant and sunlight resistant.

9

Moving parts: All moving parts should have a self lubricating closed system.

10

Fasteners All fasteners to be 18-8 grade stainless steel, capped with lock nuts which cover bolts ends. The bolts and fasteners should have a mechanism to secure them against getting loose.

(b)

All protruding bolts, screws and hard parts should be covered with shock absorbing materials.

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(a)

Capacities

1

Play equipment should be designed for children 5 to 12 years of age but for safety reasons all equipment should be able to handle occasional adult use; this is to reflect the maximum weight allowed.

2

Play equipment capacity should be stated including safety factor for uncontrolled use. Capacity of each play equipment to be calculated based on number of activities in use and persons on board.

3.1.5

Maintenance Schedule

1

All play equipment should have a maintenance schedule, spare parts list and catalogue, Qatari local supplier, layout and foundation design drawings.

3.1.6

Testing

1

The Engineer reserves the right to test any material at the contractor’s expenses.

3.1.7

Warranty

1

LIMITED LIFETIME WARRANTY on all aluminum deck posts, steel deck posts, fastening system, clamps and fasteners for structural failure due to corrosion or deterioration from exposure to weather, or by defects in materials or workmanship.

2

LIMITED FIFTEEN (15) YEAR WARRANTY on main support materials and decks. This limited warranty applies to structural failure caused by corrosion, defective materials, or defective workmanship.

3

LIMITED TEN (10) YEAR WARRANTY on steel playsystem components including railings, loops, and rungs against structural failure caused by defective materials or defective workmanship.

4

LIMITED TEN (10) YEAR WARRANTY against peeling of PVC Coating.

5

LIMITED TEN (10) YEAR WARRANTY against loss of color and anti-static additives.

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Page 4

LIMITED FIVE (5) YEAR WARRANTY against splitting and warping, attack by insect and rain damage.

7

LIMITED FIVE (5) YEAR WARRANTY against peeling of powder coating materials caused by normal weathering effects.

8

LIMITED FIVE (5) YEAR WARRANTY against concrete foundation cracking and exposure of steel reinforcement.

9

LIMITED FIVE (5) YEAR WARRANTY against tear, color fading and wind damages of shade-nets and fabric materials not exposed to direct sunlight.

10

LIMITED FIVE (2) YEAR WARRANTY against tear of shade-nets, color fading and wind damages of shade nets and fabric materials exposed to direct sunlight.

3.1.8

Approval

1

The engineer has the right for approval and non-approval of any play equipment that does not esthetically and functionally conform with the play equipment specified in the design specifications.

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END OF PART

QCS 2014

Section 29: Railways Part 01: Design Aspects

Page 1

1

DESIGN ASPECTS ....................................................................................... 2

1.1

BASIC DESIGN PARAMETERS .................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8

General Design Philosophies Deflection Criteria Durability Requirements Fire Resistance Period Crack Width Flexural Cracking Early Age Thermal and Shrinkage Cracking

1.2

LOADS AND LOAD REQUIREMENTS.......................................................... 5

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.12 1.2.13 1.2.14 1.2.15

General Nominal Loads Design Loads Dead Loads Superimposed Dead Loads and Imposed (Live) Load Railway Loads Fatigue Dynamic Effects Derailment Temperature Wind Seismic Loads Groundwater and Uplift Loads Highway Loading Loading Combinations

1.3

ALIGNMENT SPECIFICATION.................................................................... 10

1.3.1

General

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2 2 2 3 4 4 4 4 5 5 6 6 6 7 8 8 8 8 9 9 9 10 10 10

QCS 2014


Page 2

DESIGN ASPECTS

1.1

BASIC DESIGN PARAMETERS

1.1.1

General

1

The works shall be designed in accordance with the standards specified by the Employer’s Requirements.

2

If no local standard exists or the applicable standard is not specified otherwise, the appropriate and compatible internationally recognised standard or code of practice shall be adopted.

3

A consistent set of standards that specifically apply to the design of civil and structural elements shall be adopted.

4

The hierarchy of standards is as follows:

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1

Qatar Construction Specifications;

(b)

Euro Norms (EN);

(c)

National European Standards; and

(d)

International Standards and Codes of Practice.

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(a)

Design Philosophies

1

The design shall ensure and demonstrate throughout the Works that the requirements of future operation and maintenance (O&M) activities have been considered and incorporated to produce a design that is based on a whole-life approach that optimises both capital and operating cost. Evidence of this approach shall be incorporated into the Contractor’s project plans and, particularly, in the design documentation.

2

The design shall ensure and demonstrate throughout the Works that he has considered and incorporated construction and O&M safety requirements into the design. Evidence of these considerations shall be incorporated into the Contractor’s project plans.

3

The design shall ensure that both the serviceability and ultimate limit states have been checked in accordance with the standards and codes as specified herein.

4

The design shall take full account of the prevailing soil and groundwater conditions and those predicted to occur at the site within the design life of the Works.

1.1.3

Deflection Criteria

1

Vertical Deflection Limits

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1.1.2

(a)

The deflection of a structure or part thereof shall not adversely affect the appearance, functionality, durability or efficiency of the structure, or associated finishes or partitions.

(b)

The deflection of the retaining walls shall comply with the applicable design codes and standards as specified herein.

QCS 2014

(c)


Page 3

The final deflection due to all loads including the effects of temperature, creep and shrinkage shall be measured from the as-cast level of the supports of floors, roofs and all other horizontal members and should not exceed the ratio of (span)/500.

Durability Requirements

1

Durability requirements shall be addressed throughout the design, construction, operation and maintenance of all assets and shall be reflected in the Contractor’s project plans and O&M manuals.

2

The design shall consider the highly aggressive nature of the geological units in Qatar with regards to soluble sulphate, chloride and salt concentrations. This shall be taken into account for durability purposes when designing the underground structures.

3

In designing structures and selecting materials for durability, reliance shall not be placed solely on the recommendations of codes and standards, but due account shall be taken of the environment in which the structures are situated and to the monitoring and maintenance works required to maximise the life of the structures.

4

The primary approach to designing concrete elements for durability shall be based on the need to achieve a high quality and relatively impermeable concrete, paying particular attention to structural detailing. Construction joints in underground conditions are vulnerable to deterioration by aggressive agents and shall be designed to incorporate details that provide two lines of defence against leakages.

5

The presence of highly aggressive groundwater requires careful design of resistant concrete mixes, increased cover to reinforcing steel, close control of flexural cracking and very careful detailing of gaskets, water bars and hydrophilic water stops to ensure water tight, durable structures.

6

Particular attention shall be given to the detailing and appropriate selection of durable tunnel lining materials. Lining materials (concrete and reinforcement) and lining components (gasket seals and fixings) are to be designed and specified to satisfy this durability requirement.

7

Particular attention shall be given to the deterioration of those elements which cannot be easily accessed for maintenance or repair during the design life, such as reinforcement within the inaccessible faces of structures. In such a case the design shall ensure that the durability of the element can be achieved without maintenance.

8

Where the structure interfaces with, or is in close proximity to other light rail or metro facilities, provisions to reduce and control stray current shall be adopted to mitigate associated corrosion problems.

9

Where particularly aggressive conditions are found, a detailed assessment should be carried out to determine the need to install a full cathodic protection system or if a corrosion monitoring system is needed in order to achieve the design life of the structure.

10

Cathodic protection shall be considered for all underground reinforced concrete structures. Connection points and other necessary devices shall be provided to enable the future installation of a cathodic protection system or electro chemical chloride extraction using electrical techniques in retaining walls and concrete reinforcement cage continuity. For diaphragm wall construction, special attention shall be paid to detailing in order to provide continuity between adjacent wall panels.

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1.1.4

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The Design shall include analysis of thermal strains and stresses to mitigate early-age cracking.

12

The Design shall address all physical or chemical factors such as corrosion, chloride penetration, carbonation, sulphate cracking and corrosion of the steel reinforcement, steel spacer, steel accessories, embedded items and similar components that adversely affect the durability of the Works shall be identified and taken into account in the design to ensure the specified design life is achieved.

1.1.5


1

All structures shall be designed for fire protection as specified by the Qatar Ministry of the Interior General Directorate of Civil Defence and as otherwise specified by the Contract. Materials specified for the Works shall be non-combustible and shall not emit toxic fumes when subject to heat or fire, except where permitted under the Contract. In all cases where there are significant fire risks materials shall be self-extinguishing, low flammability, low smoke and low toxicity.

1.1.6

Crack Width

1

All structural concrete elements shall be designed to prevent excessive cracking due to flexure, early age thermal phenomena and shrinkage. The maximum crack widths shall be as specified in Table 1.1.

1.1.7

Flexural Cracking

1

Flexural crack width shall be checked in accordance with the applicable design codes and standards as specified herein. The limits specified in the table below shall apply irrespective of whether any additional protection, such as a waterproofing membrane, is applied to the elements of the structure.

1.1.8

Early Age Thermal and Shrinkage Cracking

1

Suitable reinforcement shall be designed to prevent early-age thermal and shrinkage cracking for walls and slabs of more than 250 millimetres in thickness if they are subjected to internal and external restraint during construction. Thermal and shrinkage strains due to early-age temperature differences and shrinkage shall be accounted for in the design of reinforcement for cracking.

2

The preferred method for control of early age thermal and shrinkage cracks is to use small diameter reinforcing bars placed at close intervals. The limits specified in table below shall be imposed. Guidance can be sought from CIRIA Report C660 on Early Age Thermal Control of Concrete.

3

For massive structural elements additional considerations shall be taken into account, including the duration of hydration and the related concrete strength.

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Table 1.1 Cover and Crack Width Criteria Element Concrete surface direct in contact with the ground/blinding Underground, external concrete surfaces protected by a waterproofing membrane

Exposure Condition Very severe

Max. Crack Width [mm] 0.15

Very severe

0.15

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Exposure Condition Severe

Max. Crack Width [mm] 0.2

Very severe

0.2

Moderate

0.3

Element Above ground, external concrete surfaces Tension piles direct in contact with ground All other concrete surfaces

LOADS AND LOAD REQUIREMENTS

1.2.1

General

1

Unless specified otherwise the design of concrete and steel elements shall conform to the following:

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1.2

EN 1997-1: Eurocode 7: Geotechnical Design, Part 1: General Rules;

(b)

EN 1537: Execution of special geotechnical work – Ground anchors;

(c)

EN 1990 Eurocode 0: Basis of Structural Design;

(d)

EN 1991 Eurocode 1: Actions on structures;

(e)

EN 1992 Eurocode 2: Design of concrete structures. Part 1-1 General rules of buildings;

(f)

EN 1993 Eurocode 3: Design of steel structures;

(g)

Qatar Construction Specifications, QCS;

(h)

‘Designers’ Guide to EN 1997-1 Eurocode 7: Geotechnical design – General rules’ by R. Frank, C. Bauduin, R. Driscoll, M. Kavvadas, N. Krebs Ovesen, T.Orr and B. Scuppener (by Thomas Telford, 2004); and

(i)

‘Hoek – Brown Failure Criterion – 2002 Edition’, by Evert Hoek, Carlos Carranza – Torres and Brent Corium; and.

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EN 1998 Eurocode 8: Design of structures for earthquake resistance.

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(a)

1.2.2

Nominal Loads

1

As a minimum, for the purpose of computing stresses and deformations, the following load types and consequential effects shall be taken into account as applicable. Table 1.2 Loading Types

Loading Type Dead loads (including notional loads) Superimposed Dead loads

Acronym DL SIDL

Imposed (Live) loads

LL

Railway loads

RL


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Loading Type

Acronym

Fatigue

GG

Dynamic

DY

Derailment

DR

Wind Loads

WL

Temperature loads

TE

Seismic Loads

EQ

Construction/Erection

ER

Shrinkage

SH

Creep

CP

Movement/ Distortion

MD EP

Surcharge

SR

Hydrostatic

WP

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Earth Pressure

.

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Accidental

AC R

1.2.3

Design Loads

1

Design loads shall include:

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Redundancy

The weight of the load carrying structures themselves (‘self-weight’) and the loads imposed on to them, both dead and live;

(b)

The deformations imposed on to the structures by temperature variations, concrete shrinkage and creep and other similar factors; and

(c)

Inertial loading, caused by seismic actions, oscillations due to impact, explosion loadings and machine vibrations and other similar factors.

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(a)

Dead Loads

1

Self-weight of the materials shall be calculated in accordance with the relevant codes as specified herein.

1.2.5

Superimposed Dead Loads and Imposed (Live) Load

1

Superimposed dead loads include the weights of all the permanent elements of the structures (except the load bearing elements), such as floor and roof finishes, cables, trackwork and other similar installations, to the dimensions in the Contractor’s design.

2

The self-weights of the elements in (a) above shall be assessed according to the relevant codes and standards, by other valid sources, or by substantiated and controllable manufacturer’s information, or by experimental measurements.

3

For live loads on all underground structures beneath green areas (such as squares, parks, open-air recreation areas) a minimum distributed load of 10 kN/m2 on the entire surface of the roof of the structure, at ground level, shall be assumed. For these areas a single concentrated load of 100 kN minimum shall be assumed.

4

For all stations the minimum distributed and concentrated loads shall be in accordance with the table below.

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Table 1.3 Superimposed Dead Loads (SIDL) & Imposed (Live) Load #1 #1 Superimposed Dead Load Imposed Load Uniform Area Ceiling & Concentrated Finishes Distributed #2 Description Services Load [kN/m²] Load [kN/m²] [kN] [kN/m²] Public Area

5

1.0

5.0

5.0

5

1.0

3.5

5.0

Under platform

2.5

1.0

10.0

10.0

Stairs and Landings

2.5

1.0

5.0

5.0

Equipment Rooms

2.5

1.0

10.0

#3

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Non-public Area

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Surcharge Load on Roof Slabs

10.0

10.0 100.0

1.2.6

Railway Loads

1

Vertical Train Live Loads

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Each component of the structure shall be designed / checked for all possible combinations of these loads and forces. They shall resist the effect of all combinations: Figure 1.1 Vertical Train Live Loads

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#1 this is a minimum requirement. If higher loads apply due to architectural, MEP or any other circumstances, these shall be used. #2 concentrated load distributed on an area 300 x 300 mm. #3 Areas like offices, staff rooms, toilets etc. (not equipment rooms).

Axle loads = 16 tons Maximum number of successive cars = 6 car or 2 units L = max 20 m (Length of a car) a = 2.65m for the external cars of a 3 car set and 2.35m for the internal car of a 3 car set (Overhang) b = 2.10m (Wheel base in a bogie) c = 10.50m (Distance between Axle-2 and Axle-3 in the car)

QCS 2014

(b)

Page 8

The maximum number of axles will be applied to the structure to arrive at the maximum vertical force, maximum shear and maximum bending. The structure shall be suitable for both single-track and (double) 2-tracks load conditions.

Horizontal Train Live Loads (a)

The braking loads shall be assumed to be 30% of the vertical loads. The traction loads shall also be assumed to be 30% of the vertical loads. Where the structure carries two tracks, both tracks shall be considered to be occupied simultaneously. Traction forces shall be considered as acting on one track and braking forces acting on the other, with both forces acting in the same direction simultaneously to produce the worst loading condition in the rails and supporting elements. Provision shall be made in supporting elements for the effects of horizontal and vertical forces transferred to rails.

(b)

Centrifugal Force shall be considered, taking into account a design speed for various radii of curvature as stipulated in the alignment design specification.

(c)

Hunting/noising forces shall be considered in accordance with EN 1991.

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Fatigue

1

The nominal loadings on the structures for the purposes of the Contractor’s fatigue assessment shall comprise trains as advised by the Engineer.

2

Fatigue load histories shall be evaluated to provide valid and representative design spectra, with stress histories analysed by the rain-flow counting algorithm or equivalent method, both in conjunction with the projected annual tonnages of rail traffic per track. The provisions of BS 5400 Part 10 Clause 9.3.3 or other relevant methods may be used as a rigorous method of evaluation of compliance with fatigue criteria.

1.2.8

Dynamic Effects

1

Dynamic effects resulting from the operation of the metro system shall be considered in accordance with EN 1991 and EN 1998.

1.2.9

Derailment

1

The impact loads on adjacent structures due to derailment shall be considered at all locations.

2

The adjacent structures are to be protected by direct means (e.g., strengthening) or indirect means (e.g., repositioning of rail alignments or providing barriers) to ensure these structures are still functional after an impact occurs.

3

Where indirect measures are employed in the design these can be considered when calculating the impact loads.

1.2.10

Temperature

1

The effects of temperature shall be considered in the design of the Works using the external temperatures as stated in the Qatar Rail Development Program Definition Document.

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1.2.7

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Wind

1

Wind loading may affect the surface elements such as vent-shafts, cooling towers, pedestrian bridges and entrances/exits. It is also a factor on temporary structures during construction. As per EN 1991, wind speed of 160 km/h shall be applied to determine the appropriate design wind loads.

2

Applied wind loads on bridges and other above ground structures shall be in accordance with EN 1991.

1.2.12

Seismic Loads

1

The Works shall be designed to withstand a seismic acceleration (horizontal) of 0.07g.

2

Seismic effects shall be considered on all permanent structures.

3

The effects of load changes and deformation as a result of soil behaviour (eg, liquefaction) shall be allowed for in the design.

4

The design of the tunnels final linings shall be made for static loadings and shall be checked against the seismic loadings, by any simplified method similar or comparable to the method developed for the San Francisco Metro (‘Earthquake Design Criteria for Subways’, ASCE, Volume 95, No ST6, June 1969, pp 1213-1231).

5

The seismic design of bridges and other elevated structures shall comply with the requirements of EN 1998 and the clauses of EN 1992 and EN 1993 as relevant.

1.2.13

Groundwater and Uplift Loads

1

Loads due to water pressure shall be calculated using a unit weight of 10 kN/m³ for fresh water and a unit weight of 10.3 kN/m³ for brackish-water. Should liquefaction of soils be a potential risk, then the design water table level for permanent structures shall include layers affected by liquefaction if this is above the design groundwater levels. The effects of temporary drawdown, seepage and base heave effects shall be considered in the design of the temporary works, and catered for in the permanent works if there is a ‘locked-in’ effect from transferred forces. The extent of the temporary walls shall be sufficient to mitigate the effects of such loads during construction.

2

Groundwater level for design of the permanent structure shall be assumed at ground level. In the event that long-term groundwater data is available and sufficient to accurately predict the groundwater level over the design life of the structure, the Contractor may propose a revised design ground water level based on the maximum groundwater level plus an additional 2m. The revised design ground water level will be subject to independent verification prior to submission to the Engineer for a approval. For Temporary Works, the design groundwater level shall not be lower than 500 mm above the maximum present groundwater level.

3

The effects of floatation loads shall be considered in the design of both the Temporary and Permanent Works. The Contractor shall check the structure’s stability for resistance to buoyancy and shall design the structure such that adequate factors of safety against buoyancy are provided. For this check overburden height less 2m for the possible excavation for utilities in the future shall be considered. A study showing different possible scenarios for future excavation above the stations shall be considered in the buoyancy check and submitted to the Engineer for approval.

4

Protection against buoyancy shall comply with EN 1997.

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1.2.11

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Suitable measures from those listed below to counteract buoyancy forces for the Permanent Works shall be incorporated in the Contractor’s design. The measure(s) chosen shall suit the particular conditions and the method of construction: (a)

Toe-in of the base slab into the surrounding ground; and

(b)

Increasing the dead weight of the structure.

Where the base slab has toe-in to the surrounding ground, a partial safety factor of 2.0 shall be applied to the shear resistance of the ground above the toe and the adhesion factor shall not apply. The value of the weight of ground above the toe shall be calculated as for the backfill material.

7

If tension piles are used to counteract buoyancy forces, special precautions shall be made to preserve the integrity of the waterproofing system and the durability of the tension pile. These precautions shall be submitted to the Engineer for a SONO.

8

The proposed structures (primarily the stations) may act as obstructions to groundwater movement. The Contractor shall design and subsequently allow for unobstructed movement of the groundwater through and around these structures so that there are no changes to the groundwater level that exceeds normal expected diurnal fluctuations.

1.2.14

Highway Loading

1

Highway loading shall not be less than that specified in EN 1991-2, LM 1.

2

Loads shall be applied for the worst-case combinations and shall be multiplied by the specified impact coefficients. No dynamic allowance shall be added for underground structures with an overburden greater than 1 m.

3

For underground structures, beneath existing or planned public roads, with a minimum cover thickness equal to, or greater than 2.0 m, a minimum uniform live load of 20 kN/m2 shall be applied at any position and configuration to give the worst-case loading. Whenever the minimum cover thickness is less than 2.0 m, the live load shall be determined precisely.

1.2.15

Loading Combinations

1

The load factors and load combinations for ultimate and serviceability limit states shall comply with EN 1991 and EN 1997.

1.3

ALIGNMENT SPECIFICATION

1.3.1

General

1

This section refers to the alignment specification defined in Qatar Rail’s document:

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(a)

Alignment Design Specifications P000-QRC-ALI-SPE-00001

2

The Alignment Design Build Specifications apply to the subsystems of the Qatar Rail Development Program (QRDP) namely the High-Speed, Conventional Long Distance Rail (LD), Freight Lines, LRT and Metro. All units of measure shall be in accordance with the International System of Units (SI) and in metric units.

3

The operational speed is the speed with which the line will be operated.

4

The permissible speed includes the additional margins for safety, commissioning and future upgrading of the line. END OF PART

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Section 29: Railways Part 10: Railway Track

Page 1

10

RAILWAY TRACK.......................................................................................... 3

10.1

TRACK WORK SPECIFICATION .................................................................. 3

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

General Rail Inclination Track Stiffness Rail Fastener Spacing Clear Distance between Slab Surface and Rail Bottom

10.2

REINFORCED CONCRETE DESIGN ........................................................... 4

3 3 3 3 4

10.2.1 General 10.3

4

RAIL STRESS AND TRACKWORK – STRUCTURE INTERACTION............ 4

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10.3.1 General

TRACKFORMS FOR VIBRATION MITIGATION (MASS-SPRING SYSTEMS) .................................................................................................... 5

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RAILS ............................................................................................................ 5

10.5.1 General

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10.6.1 General 10.7

12

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EMC, STRAY CURRENT PROTECTION AND EARTHING ........................ 12

10.12.1 General 10.13

12

INFILL CONCRETE ..................................................................................... 12

10.11.1 General 10.12

9 10 11

TRACK SLAB CONCRETE ......................................................................... 12

10.10.1 General 10.11

9

TRACKFORMS FOR VIBRATION ATTENUATION ....................................... 9

10.9.1 General 10.9.2 Noise and Vibration Prediction Report 10.9.3 High Resilient Base plates (HRB) 10.10

7 8 8

INTERFACE LAYER FOR AT-GRADE SLAB TRACKS ................................ 9

10.8.1 General 10.9

6

RAIL FASTENERS ........................................................................................ 7

10.7.1 General 10.7.2 Direct Fixation Systems 10.7.3 Indirect Fixation Systems 10.8

5

GUARD RAILS............................................................................................... 6

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10.6

5

ta

10.4.1 General 10.5

4

12

TRANSITIONS ............................................................................................. 13

10.13.1 General

13

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10.14


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CLOSURE OF SPACE BETWEEN AT-GRADE TRACK SLABS ................. 13

10.14.1 General 10.15

13

DERAILMENT CONTAINMENT................................................................... 13

10.15.1 General 10.16

13

BUFFER STOPS ......................................................................................... 14

10.16.1 General 10.17

14

INSULATED RAIL JOINTS .......................................................................... 14

10.17.1 General 10.18

14

RAIL EXPANSION JOINTS ......................................................................... 14

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10.19

.

10.18.1 General

CABLE CROSSINGS AND RECESSES...................................................... 15

10.19.1 General

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10.20.1 General 10.21

15

PERMANENT MARKERS ............................................................................ 16

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10.21.1 General

16

GRATINGS .................................................................................................. 16

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10.22

15

TRACKSIDE LUBRICATION ....................................................................... 15

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10.20

14

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10.22.1 General

16

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RAILWAY TRACK

10.1

TRACK WORK SPECIFICATION

10.1.1

General

1

All tracks for the Network are slab track systems according to the requirements as described herein. The Contractor shall propose an integrated system, which allows the use for tunnel, elevated and at-grade sections, on railway track and in turnouts/rail expansion joints.

2

Where necessary, the slab track shall be modified for noise and vibration mitigation, for High Resilient Fasteners (HRF), Light Mass-Spring-Systems (LMSS) and Heavy Mass-SpringSystems (HMSS).

3

Exceptions shall be for vibration mitigation systems with special rail fasteners and of the type LMSS and HMSS, which shall be similar to the standard (turnout) trackform, but additionally equipped with bearings for vertical and horizontal support.

4

Trackwork shall be designed in accordance with the following standards:

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EN 1990 Basis of structural design;

(b)

EN 1991 Actions on structures;

(c)

EN 1992 Design of concrete structures; and

(d)

EN 1993 Design of Steel Structures.

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(a)

Rail Inclination

1

The rails shall be inclined towards the centre line of the track at 1:40.

10.1.3

Track Stiffness

1

The Track Stiffness Ctr is defined as the vertical force that creates a unit deflection of the continuous rail. Throughout standard tracks, turnouts and crossings the Track Stiffness shall be

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10.1.2

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10.1.4

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Rail Fastener Spacing Table 10.1 Rail fastener spacing Distance d Track Geometry

Standard [mm]

Exceptional* [mm]

Straight and curved with radius R≥500m

700

800

Curved with radius 500>R≥300m:

650

750

Curved with radius R<300m

600

700

(*) Exceptional with mean spacing = d over 5 distances (e.g. at structural expansion joints).

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Clear Distance between Slab Surface and Rail Bottom

1

In at-grade sections the clear distance between slab surface and rail bottom shall be 100 mm.

2

On elevated sections the clear distance between slab surface and rail bottom shall be not less than 50 mm and not more than 100 mm.

3

In all other sections the clear distance between track slab surface and rail bottom shall be 50 mm.

10.2

REINFORCED CONCRETE DESIGN

10.2.1

General

1

The reinforced concrete design shall be based on EN 1992.

2

The track slab shall be designed for crack prevention. In areas with embedded anchor devices the calculated crack width shall not exceed 0.1 mm.

3

Notwithstanding the Contractor’s calculated minimum reinforcement, the Contractor shall provide the following minimum longitudinal reinforcement content (as percentage of the cross sectional area):

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10.1.5

Elevated and at-grade sections: 0.80%;

(b)

Tunnel and other underground sections: 0.50%.

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RAIL STRESS AND TRACKWORK – STRUCTURE INTERACTION

10.3.1

General

1

The Contractor shall check Additional Rail Stress according to EN 1991-2.

2

In calculating Additional Rail Stress the following load cases (including their combinations) shall be considered: elevated structure temperature variation;

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10.3

3

4

(b)

braking and/or traction; and

(c)

elevated structure end rotation from vertical axle loads including impact.

Unless the Contractor verifies other temperature variations, the following maximum temperature changes shall be considered for prestressed concrete superstructures: (a)

maximum temperature drop = 35K; and

(b)

maximum temperature rise = 20K.

For calculating Additional Rail Stress the Creep Resistance – Displacement diagram shown herein shall be used.

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10.4

TRACKFORMS FOR VIBRATION MITIGATION (MASS-SPRING SYSTEMS)

10.4.1

General

1

The overall layout of vibration mitigation measures shall be based on the Contractor’s vibration mitigation prediction report and vibration mitigation design.

2

The natural frequency f0 of mass-spring systems shall be calculated taking into account the permanent mass “m” consisting of rails, fasteners, sleeper/bearer and slab concrete: √ is the dynamic stiffness of the bearing material.

.

where

The discontinuity at expansion joints of mass-spring system slabs shall be minimized.

4

Transition zones shall be inserted between track slab systems of different stiffness. A gradual change shall be provided.

5

Displacement limitations of mass-spring system slabs shall be as follows:

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Table 10.2

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Allowable displacement differences

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Total transverse displacement

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Type

Limit 5 mm 2 mm

Vertical displacement difference at expansion joint under turnout and/or crossing

1 mm

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Vertical displacement difference at expansion joint under normal track

m

Angular change in vertical plane from slab end rotation

Remarks Caused by centrifugal force and impact

0.003 rad

Transverse displacement difference at expansion joint

2 mm

Angular change in horizontal plane from slab end rotation

0.003 rad

10.5

RAILS

10.5.1

General

1

All running rails shall be 60E1 profile manufactured and supplied according to EN 13674-1. The minimum length of rail supplied shall be 25 m. The minimum closure rail length to be installed in the system shall be 6.0 m.

2

The Contractor shall verify an optimal rail – wheel profile compatibility.

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All running rails for straight tracks and for curved tracks with radius equal or greater 500m shall be supplied as standard Grade R260. For curved tracks with radius less than 500m running rails shall be of Grade 350HT heat treated or head hardened.

4

Rails to be used for turnouts, crossovers and crossings shall be of Grade 350HT according to EN13674-1.

5

The whole surface area of all rails shall be corrosion protected to cover shipping, delivery and storage. The corrosion protection shall be maintained until completion as far as possible.

6

Rails shall be supplied undrilled unless specified otherwise and be marked in accordance with EN13674-1 and EN13674-2.

7

Rails shall be prepared by flash-butt welding to form Long Welded Rails (LWR).

8

The Contractor shall submit the LWR schedule to the Engineer for review.

9

The Contractor shall prepare the LWR schedule with the objective to minimise the number of joints of Grade 350HT rails, for which aluminothermic welding must be carried out.

10

The minimum length of one LWR shall be 125 m. In exceptional cases the minimum length may be revised to fit local conditions.

11

The LWR shall be connected by mobile flash-butt or aluminothermic welding.

12

Rail straightness, surface flatness and twist shall be in accordance with EN13674-1.

10.6

GUARD RAILS

10.6.1

General

1

Guard rails shall be installed to avoid collision of derailed vehicles with major structural elements:

single columns in a clear distance from track axis of less than 3.20m.

m

(b)

steel truss bridges with distance track axis to truss diagonals smaller 3.50m; and

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(a)

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3

2

Guard rails shall be of 60E1 profile in Grade R260 according to EN 13674-1.

3

The guard rail fastening system shall be independent of the running rail fasteners.

4

Removal of the running rail shall be possible without removal of the guard rail.

5

The clear spacing between running rail and guard rail shall be 180 to 300 mm.

6

At the end of guard rail sections the guard rails shall be installed such that they are able to catch an already derailed vehicle and guide the wheels into the 180 to 300 mm flange way.

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RAIL FASTENERS

10.7.1

General

1

The Contractor’s attention is drawn on the local conditions under which rail fasteners have to o perform. Surface temperatures up to 84 C have been recorded and it is likely that rails in atgrade and viaduct tracks may reach such temperatures. Therefore, the Contactor shall demonstrate that non-metallic materials of rail fasteners are suitable to retain their specified properties in the local climate.

2

Rail fasteners shall be supplied by original manufacturer, who shall have a supply record of similar rail fastenings installed for more than five (5) years with a minimum length of 10 km.

3

In order to facilitate maintenance procedures fastening assemblies and their components shall be single type and delivered by one supplier to the highest possible standard.

4

Rail fasteners shall ensure support and guidance, secure track gauge and rail inclination, provide resilience as required to maintain the specified track stiffness, electrical insulation and adequate creep resistance.

5

The rail fasteners shall be categorized as a “Category B Fastener” according to EN13481-1.

6

Rail fasteners shall comply with EN 13481-1, EN 13481-2, EN 13481-5, EN13146-1 to 13146-9 as appropriate.

7

Rail fasteners shall be designed to provide a high degree of electrical insulation. As a minimum the Contractor shall demonstrate that the proposed fastening system is suitable to meet the requirements of EN 50122-2.

8

The fatigue resistance of the rail clips shall be tested with 2mm amplitude and 3 million cycles in accordance with EN 13 146-4 dynamic fatigue test and to international recognized quality control tests. After testing the clip force shall not be reduced more than 10% of the initial force.

9

If the Contractor proposes fastening systems with components for which records of five (5) years satisfactory performance cannot be submitted, acceptance may be granted based on satisfactory type test results. Test programme and laboratory shall be submitted to the Engineer for review.

10

To achieve the specified track stiffness the vertical static secant stiffness of one fastening assembly shall be 22.5 ± 2.5 kN/mm. The static secant stiffness shall be determined from the vertical deflection of the assembly measured under 18 and 68 kN test loads.

11

The toe load exerted by the fixed rail clips shall be 18±2 kN (per fastener).

12

The rail fasteners shall have a minimum creep resistance of 9.0 kN. The creep resistance (longitudinal restraint) shall be measured in accordance with EN 13146-1.

13

The maximum creep resistance of one rail fastener shall not exceed 13.0 kN. The creep resistance shall be measured in accordance with EN 13146-1.

14

The resistance against effect of severe environmental conditions shall be determined in accordance with EN 13146-6.

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10.7

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Rail fastening systems shall have provisions to raise and lower the rail with a total vertical adjustment of at least +30 mm, and a lateral adjustment of each rail of at least ±5 mm. The Contractor shall not use this adjustability for his installation method, and the full adjustability shall be available after completion of the track.

16

Rail fastening systems shall be designed to prevent corrosion. Clips and all other steel components shall be coated. The Contractor shall propose coating material to the Engineer for review.

10.7.2

Direct Fixation Systems

1

Direct fixation systems are fastening systems for prefabricated concrete components (sleepers, prefabricated slabs), which are formed to allow direct transfer of lateral forces (without anchored base plates).

2

If the Contractor proposes a trackform with direct fixation fasteners, all standard trackforms shall be equipped with direct fixation fasteners.

3

The main components of direct fixation fasteners are

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HDPE rail pad;

(b)

steel spreader plate;

(c)

elastic rail pad;

(d)

insulating elements;

(e)

tension clamps (rail clips);

(f)

sleeper screws or similar; and

(g)

embedded inserts/shoulders.

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Indirect Fixation Systems

1

Indirect fixation systems are fastening systems with base plates that are separately anchored with embedded bolts or with bolts and embedded inserts.

2

If the Contractor proposes indirect fixation fasteners, all standard trackforms shall be equipped with indirect fixation fasteners.

3

The main components of indirect fixation fasteners are:

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10.7.3

(a)

HDPE rail pad;

(b)

steel spreader plate;

(c)

elastic rail pad;

(d)

insulating elements;

(e)

tension clamps (rail clips) with fixing bolts or similar;

(f)

steel base plate (SG casting);

(g)

insulation and adjustment pads;

(h)

helical springs; and

(i)

anchor bolts separated by insulation bushings.

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Page 9

The base plates shall have two to four anchor bolts depending on track geometry and the Contractor’s design.

5

Anchor bolts, which are designed for bending from horizontal rail forces, shall be checked to have satisfactory fatigue resistance. For this purpose the possible play between bolts and insulation bushings and between insulation bushings and base plates shall be taken into account. Unless the Contractor can verify that his design does not allow for any play, it shall be assumed that in case of a 2-bolt base plate one bolt takes at least 75% of the horizontal force to be transmitted. In case of a 4-bolt plate one bolt shall take 40% of the total horizontal force.

6

High Resilient Fasteners (HRF) shall be fasteners of the indirect fixation type.

10.8

INTERFACE LAYER FOR AT-GRADE SLAB TRACKS

10.8.1

General

1

The Contactor shall place an interface layer between track slab and the top surface of the protection layer to prevent any over-stressing of the protection layer due to dynamic forces from train operation.

2

The Contractor shall propose thickness and type of interface layer.

3

The Contractor shall design the type and distance of joints (crack inducers) in order to avoid detrimental cracks.

10.9

TRACKFORMS FOR VIBRATION ATTENUATION

10.9.1

General

1

For areas with vibration sensitive receptors, the Contractor shall propose vibration mitigation trackforms suitable to reduce the vibration impact as required.

2

So far areas of vibration sensitive receptors were identified in the Employer’s Environmental Impact Assessment (EIA) Report. After award the Contractor shall review and update this information on vibration sensitive receptors.

3

The Contractor shall undertake further investigations to identify the sensitivity categories of all areas along the alignment, such as hospitals, schools, residential buildings etc. which require the measurement for noise and vibration protection.

4

Depending on the required level of vibration attenuation for a classified area, the Contactor shall propose one of the following vibration mitigation systems:

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(a)

standard track with high resilient fasteners;

(b)

light mass-spring system (LMSS); or

(c)

heavy mass-spring system (HMSS); or

(d)

other suitable .

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Noise and Vibration Prediction Report

1

In coordination with and under guidance of the Employer’s Environment Consultant, the Contractor shall submit for the Engineer’s review a Noise and Vibration Prediction Report to identify type, location and dynamic properties of required vibration mitigation trackforms.

2

Measurements for verification of assessed transmission functions shall be performed. The Contractor shall propose possible procedures (e.g. simulations). A test plan shall be prepared that defines method, including specification of test equipment, test sites, and number and distances of measurement points. The test plan shall be in accordance with the EIA targets as agreed by the MOE.

3

The Contractor’s Noise & Vibration Prediction Report that shall be based on the procedures outlined in “United States of America Department of Transport – Transit Noise and vibration Impact Assessment Handbook” (May 2006).

4

Acceptance criteria in terms of vibration velocities and ground borne noise levels, as specified in the “United States of America Department of Transport – Transit Noise and vibration Impact Assessment Handbook”, are given in Table 10.3. Table 10.3

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10.9.2

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Acceptance criteria for vibration and ground borne noise Infrequent events (<30 events per day)

as

Frequent events (>70 events per day)

Vibration velocity limit

Lmax(fast)

se


Lmax(fast)

[mm/s]

[dB(A)]

[mm/s]

[dB(A)]

0.1

35

0.254

43

0.1

35

0.254

43

0.143

40

0.359

48

Industrial

N/A

N/A

N/A

N/A

Rural

N/A

N/A

N/A

N/A

Schools and mosques

0.143

50

0.359

58

Category 1 buildings where vibration would interfere with internal operations; research and manufacturing facilities, hospitals with vibration sensitive equipment; university 1 research departments

0.045

N/A

0.045

N/A

Concert halls, TV studios and recording studios

0.045

25

o

Residential (Urban)

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Frequent events (>70 events per day) Receptor type

Auditoriums and theatres

Infrequent events (<30 events per day)


Lmax(fast)

[mm/s]

[dB(A)]

0.1

35

2


Lmax(fast)

[mm/s]

[dB(A)]

2

43

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Note 1: The criteria will depend on the use; a detailed assessment shall be carried out at such facilities. Note 2: Ground borne noise levels (Source: Qatar Integrated Rail Project – Environmental Impact Assessment Scoping Addenda – Noise and vibration (13. September 2012)

High Resilient Base plates (HRB)

1

To avoid potential derailments, the two ends at a fracture gap should remain in similar level under approaching wheels. HRF fasteners are softer than standard fasteners and need special features to restrict vertical deflection under accidental conditions. HRB fasteners shall have suitable features to restrict possible vertical steps of rail fracture gaps to 30mm.

2

HRBs shall have a static secant stiffness as specified in the Contractor’s noise and vibration design, but not less than 6 kN/mm.

3

HRBs shall have a minimum creep resistance of 9.0 kN. The creep resistance (longitudinal restraint) shall be measured in accordance with EN 13146-1.

4

The maximum creep resistance of one HRB shall not exceed 13.0 kN. The creep resistance shall be measured in accordance with EN 13146-1.

5

HRBs shall be designed for high damping (impact reduction > 30%), which shall be measured in accordance with EN 13146-3.

6

The effect of repeated loading shall be tested in accordance with EN 13146-4. Test loads and positions are:

7

As alternative to high resilient fasteners the Contractor may propose a bi-block booted sleeper track system with direct fixation fasteners and soft elastomeric pads below the sleepers blocks.

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10.10


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TRACK SLAB CONCRETE

10.10.1 General 1

Minimum concrete quality of slab/plinth concrete is C30/37 in accordance with EN 206, with maximum aggregate size 20 mm.

2

Track slabs/plinths shall be reinforced as proposed and verified by the Contractor.

3

Surface finish of track slab/plinth shall be: upper surfaces: levelling the compacted concrete and steel towelling under firm pressure; gradual irregularities < 5 mm in 2 m; and

(b)

formed surfaces: sealed plywood; abrupt irregularities < 1 mm.

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In tunnels track slabs with sleepers shall be cast in lengths not exceeding 30m.

5

For water runoff track slabs shall be separated by a 150mm wide gap at drainage inlets.

6

Cast in-situ plinth tracks or slabs without sleepers/bearers shall be cast in lengths not longer than 5600 mm with 100 mm gaps between consecutive slabs/plinths. This requirement applies to all track areas.

7

On elevated sections track slabs with sleepers shall be cast in lengths not exceeding 8000 mm with 100 mm gaps between consecutive slabs.

8

For at-grade sections the Contractor shall propose the maximum length of slabs with sleepers.

9

For at-grade sections the Contractor shall design and implement anchorage provisions for free slab ends.

10.11

INFILL CONCRETE

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10.11.1 General

Infill concrete for tunnel track base shall be of grade C25/30.

10.12

EMC, STRAY CURRENT PROTECTION AND EARTHING

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10.12.1 General 1

All trackforms shall include a stray current protection system in accordance with EN 50122-2 and EN 50162.

2

The Contractor shall demonstrate that the leakage between rails and track slab cross section is  0.1 S/km per track under new built condition.

3

The Contractor shall design electrical insulation provisions suitable to limit leakage of the system in operation and during design life to 0.5 S/km per track.

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For calculation of stray currents and failure currents and for the design of conductors inside structures (e.g. stray current earthing conductors, reinforcement or other structural elements) the following shall be considered: (a)

maximum operational current;

(b)

maximum short circuit current;

(c)

leakage rails to ground: 0.7 S/km per track (2 rails); and

(d)

the Contractor shall calculate with full current along the slab track body.

Stray current transfer between Trackwork to and from other systems (including gas and water pipelines) is prohibited.

6

All earthing and bonding measures shall be based on standards EN 50122 group and EN 50162.

7

The return current path shall be strictly separated from other conductors.

8

In the upper layer of the concrete slab structure a minimum of six (6) continuous reinforcing bars with a minimum diameter of 16 mm shall be placed in the vicinity of the running rails (3 pieces per rail).

9

At slab/plinths ends the continuous reinforcing bars shall be connected by flat steel plates 2 with a minimum of 120 mm cross sectional area. The steel plates shall be connected by 2 welds of a minimum of 20 mm cross sectional area per connected reinforcing bar. The steel plates shall be bolt-connected to earthing terminals according to EN 20122-2, which shall be preferably located at the lateral edges of slabs/plinths.

10

The Contractor shall connect the earthing terminals of the slabs/plinths by insulated copper 2 wires with a minimum cross sectional area of 80 mm .

10.13

TRANSITIONS

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Transitions are required to assure a gradual change of the track stiffness in all cases where there are changes in the type of track carrying structures (for example change of bridge deck and earthwork).

10.14

CLOSURE OF SPACE BETWEEN AT-GRADE TRACK SLABS

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10.14.1 General 1

The Contractor shall provide and install a water-permeable gravel-sand mix in order to fill the space between parallel tracks in at-grade sections.

10.15

DERAILMENT CONTAINMENT

10.15.1 General 1

Derailed trains shall be prevented from tilting, running into the structure gauge of the opposite track and from colliding with bridge/tunnel equipment. For that reason derailment containment is required for all tracks.

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Page 14

2

Derailment containment may be provided by reinforced concrete upstands that are integral part of the track slab or by guard rails.

10.16

BUFFER STOPS

10.16.1 General The Contactor shall install buffer stops at the ends of all main lines, siding and depot access tracks.

2

Buffer stops shall be designed to be capable stopping trains of 384 t mass and with 15 km/h residual speed at impact without major damage to the train or to the stopping device.

3

All buffer stops shall be positioned such that the required braking length can be safely achieved.

4

The Contractor shall prepare a painting specification and submit to the Engineer for a SONO. The painting specification shall ensure a design life of 10 years before repainting.

10.17

INSULATED RAIL JOINTS

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10.17.1 General

Insulated rail joints are required for all depot access tracks.

2

For the insulated rail joints the Contractor shall propose a design suitable for main line track conditions and in accordance with the following requirements:

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All insulated rail joints shall be factory-made and welded into the track;

(b)

The prefabricated rail joint shall be manufactured from rail, which has been cut in its centre for the insulated rail joint, matching profile and rail type of a length >5 m;

(c)

Insulated rail joints shall be of a glued design with fishplates of approximately 1000 mm length and six high strength bolts; and

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The rail head shall be suitably treated to reduce wear.

The Contractor shall submit a proven insulated rail joint design to the Engineer for review.

10.18

RAIL EXPANSION JOINTS

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10.18.1 General 1

2

Rail Expansion Joints are required for the following cases but are not limited to: (a)

elevated superstructure temperature variation;

(b)

braking and/or traction; or

(c)

elevated superstructure end rotation from vertical axle loads including impact.

The Contractor shall perform Trackwork structure interaction analyses according to EN19912 to determine structural expansion joints of elevated structures where rail expansion joints need to be installed.

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Page 15

The required movement capacity of rail expansion joints shall be based on the following load cases: (a)

movement of superstructure from temperature;

(b)

movement of superstructure from creep and shrinkage;

(c)

movement from braking and/or traction; and

(d)

movement of the rail ends from temperature.

If rail expansion joints are required, expansion joint types shall be used that are suitable to bridge the variable expansion joint gap of the bridge superstructure. The function shall follow the work principle of movable stock rails/fixed switch rails according EN 13232-8.

5

Continuous welded rail (CWR)

6

Closure welds shall be made while the rail temperature is within the Neutral Temperature Range.

7

The Neutral Rail Temperature Range shall be defined such, that rail temperature variations after closure will not exceed ±45 K.

8

Unless the Contractor verifies other maximum and minimum rail temperatures, the following rail temperature limits shall be considered:

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maximum rail temperature in open air is +83 C;

(b)

maximum rail temperature in tunnel is +50 C; and

(c)

minimum rail temperature is +7 C.

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10.19

CABLE CROSSINGS AND RECESSES

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10.19.1 General

The Contractor shall provide cable crossings in track slabs with pipes supplied by Interfacing Parties and reviewed by the Engineer.

2

The Contractor shall implement in his design and provide recesses in slab concrete for other system components, as instructed by Interfacing Parties and reviewed by the Engineer.

10.20

TRACKSIDE LUBRICATION

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10.20.1 General 1

For curves with radius smaller 300 m the Contractor shall propose suitable means to reduce wear and noise. The Contractor shall consider the permanent presence of fine sand in the local environment that might obstruct certain types of lubrication.

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10.21


Page 16

PERMANENT MARKERS

10.21.1 General Permanent markers shall be manufactured from aluminium plates with a thickness of 3mm. The background colour shall be washable reflective yellow with the characters in matt black.

2

The permanent markers shall be connected to the relevant surfaces as described below, using suitable provisions.

3

Permanent markers are required for: chainage markers at distances of 100 m;

(b)

turnout markers at every switch toe; and

(c)

fouling point markers at all locations where tracks converge.

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The Contractor shall propose positions for fixing permanent markers to the Engineer for review.

5

The Contractor shall provide holes in rails as required for cable connections.

10.22

GRATINGS

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10.22.1 General

The Contractor shall design, deliver and install gratings including appropriate support structures for inspection chamber covers and for covers of space beside mass-spring system trackforms in tunnels.

2

Gratings and support structures shall be made of steel and galvanised.

3

As a minimum, gratings shall resist 5 kN/m uniform load or 1.0 kN point load at any position, whichever produces worse effects.

4

Gratings shall be fixed to avoid unintended dislocation

5

Fixing devices shall be suitable for easy removal of gratings for maintenance purposes.

2

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END OF PART

QCS 2014

Section 29: Railways Part 11: Monitoring and Instrumentation

Page 1

MONITORING AND INSTRUMENTATION .................................................... 2

11.1

INTRODUCTION ........................................................................................... 2

11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6 11.1.7

General Instrumentation Personnel and Resources Monitoring database Zone of Influence Warning and Alarm levels Automated monitoring system of real time total displacements (3D) Instrument specifications

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2 2 2 3 3 4 4

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MONITORING AND INSTRUMENTATION

11.1

INTRODUCTION

11.1.1

General

1

The objectives of the instrumentation and monitoring of the Works are to determine ground movements and the effects on existing structures, services and utilities in a form that will allow direct comparison with the Contractor’s performance criteria and design expectations.

2

Instrumentation and monitoring system that covers all aspects of the Works (surface, tunnel structure, bridge structure, embankment and surrounding ground) shall be designed and implemented.

3

A computer database for the integration, storage, analysis, recording and processing of all monitored data shall be established. The computer database shall be stored on a web based server

4

Real-time remote access to all monitoring data shall be provided.

5

The instrumentation and monitoring system shall include the real-time information on buildings/structures within the zone of influence of the Works.

6

An automatic data acquisition system shall be designed that captures the measured results of all suitable instruments (above and below ground), irrespective of the type of sensor and the physical measurement parameters, and can be automatically viewed in real time and transmitted to a central station outside the settlement zone.

11.1.2

Instrumentation Personnel and Resources

1

A monitoring team shall be established that is responsible for the geotechnical investigations, monitoring and to obtain the permission of third parties and/or owners for the installation of the monitoring systems for the management of hazards and level of the risk to buildings and other structures. This organization shall be staffed with experienced personnel. A representative of the Contractor’s design engineer shall be part of the monitoring team and be involved actively in the analysis of data and comparison between predictions and performance.

11.1.3

Monitoring database

1

The database shall include the following but not be limited to:

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(a)

levelling of the surface;

(b)

levelling of buildings;

(c)

vertical and horizontal deformation of existing buildings and other structures;

(d)

3D reflectors automatic optical deformation monitoring systems;

(e)

load/stress cell measurements for concrete lining;

(f)

inclinometers, extensometers, and other in-ground instruments;

(g)

groundwater monitoring;

QCS 2014


(h)

construction progression and data acquisition;

(i)

geometrical data;

(j)

vibration measurements;

(k)

Geotechnics and geology support systems.

Page 3

11.1.4

Zone of Influence

1

Instruments shall predominantly be placed within the influence zone of the Works. Consideration shall be given to the layout and spacing of instrumentation arrays, and shall be selected with due consideration to specific site conditions with a degree of redundancy incorporated. The minimum geometrical requirements concerning the influence zone are given in the following figures:

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Figure 11.1

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Influence Zone

11.1.5

Warning and Alarm levels

1

Trigger (warning and alarm) levels shall be established based on design and allowable values in accordance with the Contractor’s Design Documents governing failure mechanisms assessed by the designers, enabling preventative measures to be introduced in an acceptable time.

2

When exceeding the aforesaid values the reporting chain or alarm is activated.

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Page 4

The warning and alarm levels shall account for the serviceability requirements of all monitored structures. These values shall be checked according to the observations and investigations during construction but shall not be limited to key indicator parameters of displacement, strain or pressure which determine appropriate actions in response to these values being exceeded.

11.1.6

Automated monitoring system of real time total displacements (3D)

1

An automated measuring system for the total displacements (3D) in real time shall be established, to demonstrate that the Works do not impact on sensitive buildings and other structures. Monitoring records shall be examined by the Contractors expert to detect any unexpected trends and to take necessary measures to compare predictions with observed values. All monitored observations shall be provided to the Engineer.

11.1.7

Instrument specifications

1

All instruments and measuring devices shall be manufactured by companies with proven experience in the field of construction or geotechnical instrumentation, as appropriate. The accuracy and dependability of the equipment shall not be affected by changes in temperature, humidity, stray currents or contaminants that may be encountered. Calibration certificates shall be provided by an accredited testing company. Instrumentation shall be selected to site specific conditions, but not limited to: extrusion of ground ahead of face;

(b)

relative vertical movement;

(c)

lateral displacement;

(d)

change in inclination;

(e)

change in earth pressure;

(f)

change in water pressure;

(g)

crack or joint movement;

(h)

strain in structural member or lining;

(i)

tunnel lining diametrical distortion;

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lining stress;

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(k)

lining leakage;

(l)

noise and vibration. END OF PART

QCS 2014

Section 29: Railways Part 12: Survey and Setting Out

Page 1

12

SURVEY AND SETTING OUT....................................................................... 2

12.1


12.1.1 General

2

12.2

SURVEY CONTROL...................................................................................... 2

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

Survey Markers Control Observation, Adjustment and Presentation. General Setting Out Pre-Start Survey Survey during Construction

12.3

FINAL AS-BUILT SURVEY ............................................................................ 3

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12.3.1 Underground Works 12.3.2 Elevated and At Grade Works 12.3.3 General

2 2 2 2 3 3 3 3

MONITORING SURVEYS ............................................................................. 3

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12.4.1 General

3

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12

SURVEY AND SETTING OUT

12.1


12.1.1

General

1

A method statement for the survey and the setting out shall be submitted to the Engineer for a SONO. This method statement shall include, but not be limited to: Surveying Equipment;

(b)

Inspection and testing regime and acceptance criteria;

(c)

Details of the pre start surveys, surveys during construction and the as built surveys for underground, elevated and at grade works;

(d)

Specific strategy for Site conditions including but not limited to:

(e)

Climatic conditions;

(f)

Dusty environment.

(g)

Calibration of instruments and certification;

(h)

Details of protection and security of all survey markers.

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(a)

Records of all raw and processed survey data shall be kept for inspection by the Engineer.

3

All survey data shall be recorded and submitted in accordance with the Employer’s Requirements.

12.2

SURVEY CONTROL

12.2.1

Survey Markers

1

Survey Markers shall be durable, appropriate to location and intended use and shall have an unambiguous centre point. For installation of a Survey Marker into reinforced concrete no steel reinforcement bars are permitted.

2

Benchmarks shall have a domed surface.

12.2.2

Control Observation, Adjustment and Presentation.

1

The method statement shall contain proposals for conducting regular surveys of all existing survey control including the benchmarks.

12.2.3

General Setting Out

1

A comprehensive level survey of the Contract area shall be conducted before any work commences on the Site.

12.2.4

Pre-Start Survey

1

For tunnel alignment a list of coordinates (easting, northing & elevation) shall be generated at one-meter chainage intervals along the length of the design tunnel alignment.

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Survey during Construction

1

Survey control (horizontal and vertical) shall be installed progressively along the alignment.

2

During tunnel construction the entire tunnel survey control scheme shall be re-observed from the shaft bottom at intervals to be proposed by the Contractor in his method statement.

12.3

FINAL AS-BUILT SURVEY

12.3.1

Underground Works

1

Upon completion of tunnelling, when the breakthrough has been made, the survey connection shall be made and the survey misclosure determined. A survey report shall be prepared detailing the final adjusted values for all the survey control to remain in the tunnel for the purpose of track laying.

2

A final as-built survey to determine the 3D coordinates of the tunnel lining at least 8 points, at even intervals around the circumference of the leading edge, of each alternate ring shall be carried out. The best-fit centre of the ring and its minimum radius shall be determined. The computed horizontal, vertical and radial offset of the centre of each surveyed ring relative to the design centre shall be plotted for the entire tunnel, giving an indication of potential out of tolerance zones.

3

A detailed report for each completed tunnel drive shall be submitted to the Engineer, for SONO. Each report shall be prepared and submitted within four (4) weeks of tunnel breakthrough.

12.3.2

Elevated and At Grade Works

1

A detailed report for each completed section of works shall be submitted to the Engineer, for SONO. Each report shall be prepared and submitted within four (4) weeks of completion of the section of works.

12.3.3

General

1

As-built surveys of all platform edges, columns and any other adjacent structures shall be conducted to ensure that there is no infringement of the structure gauge. All out of tolerance areas shall be highlighted.

12.4

MONITORING SURVEYS

12.4.1

General

1

As a minimum requirement, the design of a monitoring scheme shall take into consideration the likely range of movements to be incurred, accuracy required, accessibility to the area of interest, instrumentation to be used, the use of any special accessories, frequency of monitoring, particular Site conditions, safety, data collection/processing techniques, real time or post process, maintenance of the system, stability of the points of reference and the presentation format.

2

All 2D and 3D monitoring schemes shall be coordinated on the Project grid and datum. All elevation monitoring shall be conducted on the Project datum. All monitoring points shall be clearly identified.

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12.2.5

END OF PART

QCS 2014

Section 29: Railways Part 02: Site Clearance

Page 1

2

SITE CLEARANCE ........................................................................................ 1

2.1

GENERAL SITE INSTALLATION AND SITE MANAGEMENT ...................... 1

2.1.1 2.1.2

General Site Restrictions

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Section 29: Railways Part 02: Site Clearance

Page 1

SITE CLEARANCE

2.1

GENERAL SITE INSTALLATION AND SITE MANAGEMENT

2.1.1

General

1

All project related works for site installation and site equipment shall be done according to QCS Section 1.

2.1.2

Site Restrictions

1

The Contractor shall confine the work activities, including storage of construction materials, movement and packing of equipment, machinery and Contractor’s Equipment within the allocated Works areas.

2

The Contractor shall execute his work in such a manner as to cause minimal inconvenience to the public and other contractors.

3

The Contractor shall fully control his workforce and those of his Subcontractors, to ensure that workers do not loiter in public areas or facilities and do not intimidate local residents.

4

Concrete batching and mixing plant, supplied as Contractor’s Equipment and erected on the Site shall only be used for the Works.

5

Bituminous materials, batching and mixing plant, supplied as Contractor’s Equipment and erected on the Site shall only be used for the Works.

6

Unless otherwise stated, the Contractor shall pay all rates and charges of any nature whatsoever arising out of his use of the Site and all Works areas provided therein under the Contract.

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END OF PART

QCS 2014

Section 29: Railways Part 03: Geotechnical Specifications

Page 1

GEOTECHNICAL SPECIFICATIONS ............................................................ 3

3.1

ADDITIONAL GEOTECHNICAL INVESTIGATIONS ..................................... 3

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7

Field of application General Regulatory Reference Documents and Terminology Terminology Worksite Organisation Principles for Depth Definition of Boreholes Principles on the definition of minimum number of coring boreholes

3.2

BOREHOLE, SAMPLING AND GROUNDWATER MEASUREMENTS SPECIFICATIONS .......................................................... 5

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10

General Requirements Selection of Sampling Method Pre-excavation Pits Trial Pits Soil Sampling Methods Rock Sampling Methods Groundwater Sampling Methods Handling, Transport and Storage of Samples Backfilling and Site Abandonment Topographical ‘As Built’ Survey

3.3

IN SITU TESTS SPECIFICATIONS ............................................................... 8

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

Test Standards Standard Penetration Test (SPT) Pressure meter Test Water Permeability Tests Measurements of Volatile Organics

3.4

LABORATORY TEST SPECIFICATIONS ..................................................... 9

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

Laboratory Test Program Soil samples Rock samples Aggressiveness of soil and groundwater Geochemical Detection of Hydrocarbons Pollution

3.5

GEOTECHNICAL REPORTS ...................................................................... 10

3.5.1 3.5.2

General Photographic Archive

3.6

PILING AND DIAPHRAGM WALLING ......................................................... 12

3.6.1 3.6.2

Piling Diaphragm Walling

3.7

PILING – EXECUTION ................................................................................ 12

3.7.1 3.7.2 3.7.3

General Boring Tolerances

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3 3 3 4 4 4 5

5 5 5 5 5 6 6 7 7 8 8 8 8 8 9 9 9 9 9 10 10 12 12 12 12 12 13

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Page 2

3.7.4 3.7.5 3.7.6 3.7.7

As-built Details Placing Concrete Pile Tests Protection of Piling from Chemical Attack

13 13 13 13

3.8

DIAPHRAGM WALLING – EXECUTION ..................................................... 13

3.8.1 3.8.2

General Cleaning

3.9

ANCHORING, BRACINGS, NAILS AND BOLTS ......................................... 13

3.9.1 3.9.2 3.9.3 3.9.4

General Anchoring Bracing Nails and bolts

3.10

ANCHORING EXECUTION ......................................................................... 14

3.10.1 3.10.2 3.10.3 3.10.4

General Testing Corrosion protection of anchors Tolerances

3.11

BRACING EXECUTION ............................................................................... 14

13 13

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3.11.1 General

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GEOTECHNICAL SPECIFICATIONS

3.1

ADDITIONAL GEOTECHNICAL INVESTIGATIONS

3.1.1

Field of application

1

This section refers to all works related to the execution of the additional geotechnical investigation (AGI) and the instrumentation monitoring, to be executed by the Contractor.

3.1.2

General

1

The Contractor shall carry out Additional Geotechnical Investigations (AGI) in order to examine the geological, hydrogeological and geotechnical conditions (including but not limited to the existence of karstic voids and earth gas) and determine the design geotechnical parameters, as required.

2

The Contractor shall submit his AGI programme in advance of undertaking any investigations for a SONO from the Engineer.

3

All AGI works and investigations shall be in accordance with latest version of, in order of priority:

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Qatar Construction Specifications: ‘Ground Investigation’ Section 3;

(b)

EN 1997 – 2: ‘Eurocode 7, Geotechnical Design, Part 2: Ground investigation and testing’;

(c)

BS 5930: ‘Code of Practice for Site Investigations’.

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(a)

Regulatory Reference Documents and Terminology

1

All Works shall be executed according to the relevant specifications included in the QCS, Section 3 (which shall have priority) and as indicated, but not limited to the following:

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3.1.3

ΕΝ 1997, Eurocode 7, Geotechnical Design

(b)

EN ISO 14688, Geotechnical investigation and testing - Identification and classification of soil

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EN ISO 14689-1, Geotechnical investigation and testing - Identification and classification of rock

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(a)

(d)

ΕΝ ISO 17025, General requirements for the competence of testing and calibration laboratories

(e)

EN ISO 22475-1, Geotechnical investigation and testing - Sampling methods and groundwater measurements

(f)

EN ISO 22476-3, Geotechnical investigation and testing - Field testing

(g)

ISO 710, Graphical symbols for use on detailed maps, plans and geological crosssections

(h)

BS 5930:1999 + A2:2010 Code of practice for site investigations

(i)

BS 1377:1990 Methods of test for soils for civil engineering purposes. BS 10175:2001 Investigation of potentially contaminated sites. Code of practice

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Page 4

3.1.4

Terminology

1

The terminology used in this specification comes from ΕΝ 1997-1 and 2, EN ISO 14688-1 and 2, EN ISO 14689-1 and EN ISO 22475-1.

3.1.5

Worksite Organisation

1

Mechanical Equipment (a)

Safety Existence of Utilities, Pre-excavation pits

Communication with Land Owners

Having obtained the required permit and prior to the commencement of the Works, the Contractor shall contact and co-operate with land owners, neighbours, shop owners or any other parties, whose activities may be adversely affected by the execution of the drilling, by informing them of the purpose of the Works, the time period required for its execution and assuring them that he shall ensure that disturbance due to the Works shall be limited to the minimum possible extent.

(b)

The area shall be fully reinstated following the completion of works.

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Permits from relevant Authorities shall be obtained prior to the commencement of any Work.

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2

An adequate number and type of drilling rigs in order to carry out the Works and in accordance with the AGI programme shall be provided.

Principles for Depth Definition of Boreholes

1

The borehole depths shall be defined as the greatest of the following criteria: The boreholes shall be constructed to a depth at least 10 m from the deepest level of the relevant structures general excavation works.

(b)

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3.1.6

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In the case of boreholes intended for the investigation of the conditions related to foundations or piles, and for diaphragm walls, the borehole depth shall be 5 m deeper than the estimated depth that the piles or the diaphragm walls are planned to be constructed.

(c)

For boreholes intended for the investigation related to surface foundations, the borehole depth shall be 15 m (and at least 2B, where B is the foundation width), in case of soil foundation conditions, or 5.0 m, in case of rock foundation conditions. Where rock foundation conditions are covered by weathered mantle, the minimum borehole depth shall be equal to the thickness of the weathered mantle in addition to 5m inside the rock substratum.

(d)

In case of underground structures (tunnels etc.), the depth of the boreholes shall be 2D (D=Diameter or equivalent diameter of the tunnel/underground structure) deeper than the invert level of the structure.

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Page 5

3.1.7

Principles on the definition of minimum number of coring boreholes

1

Notwithstanding that the entire geotechnical risk lies with the contactor the main principles of the AGI to be followed by the Contractor are: A minimum of one (1) borehole for every 100m of alignment.

(b)

A minimum of six (6) boreholes at each Metro Station and switchbox.

(c)

A minimum of one (1) borehole at each Shaft shall be drilled.

(d)

A minimum of one (1) borehole, for bridges having span dimension 6.0m≤S≤8.0 m.

(e)

A minimum of one (1) borehole at every pier’s location, for bridges having span dimension S>8.0 m.

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(a)

BOREHOLE, SAMPLING AND GROUNDWATER MEASUREMENTS SPECIFICATIONS

3.2.1


1

The works shall be performed in accordance with EN ISO 22475-1 and in accordance with the following paragraphs.

2

All AGI boreholes shall be of continuous sampling except for the pressure meter boreholes.

3

The sampling category of soils and rocks and quality class of soil samples shall be the minimum required, depending on the laboratory test which is planned for each sample contained in table 6.1 (for soil samples) and Para. 3.4 and Para 3.5 (for soil and rock samples, respectively) of EN ISO 1997-2.

3.2.2

Selection of Sampling Method

1

The selection of sampling method shall be made as per Para. 5 of EN ISO 22475-1.

3.2.3

Pre-excavation Pits

1

Pit Excavation and Restoration All pre-excavation pits shall be excavated by hand or by very light mechanical means.

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(b)

All pits shall be immediately restored to their previous condition upon completion of work according with the requirements of Para. 5.5 of EN ISO 22475-1 and if pits are to remain open after the day of excavation, the Contractor shall provide adequate fencing or covering, signalling and/or lighting to ensure the safety of the public and workers.

3.2.4

Trial Pits

1

The excavation of any trial pits to investigate soil conditions, sample recovery or execution of field tests shall follow the same procedures as for pre-excavation pits.

3.2.5

Soil Sampling Methods

1

General (a)

Soil sampling shall be based on the provisions of Para. 6 of EN ISO 22475-1.

QCS 2014

2

Page 6

Sampling Categories (a)

The acceptable sampling categories according to EN1997-2 standard and EN ISO 22475-1 standard for the Works are A and B and shall be applied.

(b)

The appropriate method for sampling to ensure minimal disturbance of samples shall be selected. The quality of the samples shall be adequate to execute the required laboratory tests and to make the appropriate engineering geological description.

Continuous Sampling during Drilling (a)

Samples shall be recovered by rotary core drilling with a double or triple tube core barrel as per Para. 6.3.2.2 of EN ISO 22475-1. Additionally, the inner sleeve shall be divisible in two (2), along the axis (split inner tube). In the event that the Contractor wishes to use another method of continuous sampling, he shall submit the relevant justification to the Engineer for a SONO, within the AGI program.

(b)

The use of single tube core barrel shall only be allowed in cases of cleaning of the borehole, or in cases of loose gravel that can be sampled by no other method.

(c)

Clean water shall be used for flushing.

(d)

Water supply during the drilling-sampling shall be continuous in order to achieve the optimum sampling.

(a)

General

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Rock sampling shall be executed on the basis of Para. 7 of EN ISO 22475-1.

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Sampling Categories

The appropriate method for sampling to ensure minimal disturbance of samples shall be selected. The quality of the samples shall be adequate to execute the required laboratory tests and to make the appropriate engineering geological description.

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Rock Sampling Methods

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Block sampling is executed based on the provisions of Para. 6.5 of EN ISO 22475-1.

3.2.6

(a)

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Block Sampling from Trial Pits

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Sampling by Drilling (a)

Samples shall be recovered by rotary core drilling, with a double or triple tube core barrel as per Para. 7.3.3 of EN ISO 22475-1. Additionally, the inner sleeve shall be divisible in two (2) along the axis (split inner tube).

(b)

The use of single tube core barrel shall be only allowed in cases of cleaning of the borehole.

(c)

Clean water shall be used for flushing.

(d)

Water supply during the drilling-sampling shall be continuous in order to achieve the optimum sampling.

3.2.7

Groundwater Sampling Methods

1

Groundwater sampling shall follow the provisions of Para. 8 of EN ISO 22475-1.

QCS 2014


Page 7

2

Samples of groundwater shall be taken from each open standpipe piezometer following its cleaning and its air-lift development.

3

At boreholes where more than one aquifer has been detected, separate samples shall be taken for each aquifer.

3.2.8

Handling, Transport and Storage of Samples

1

General (a)

2

Handling, transportation and storage of samples shall be carried out in compliance with the guidelines of chapter 11 of EN ISO 22475-1 and the requirements below.

Core Boxes Core boxes shall be made in compliance with Para. 11.6 of EN ISO 22475-1.

(b)

The packed samples shall then be transported to the laboratory of the Contractor, in accordance with the requirements of Para. 11.5 of EN ISO 22475-1.

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Preservation and Disposal of Laboratory Samples All samples delivered to the Contractor's laboratory shall be kept for a period of one (1) month after the Engineer has given its SONO to the Geotechnical Factual Report.

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The selection of samples shall be made in accordance with the Proposed Laboratory Test Program. After sample selection, the samples shall be packed according to the terms in Para. 11.3 of EN ISO 22475-1.

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Description of Borehole Cores, Core Boxes Photographing and Selection of Samples

Transport and Storage of Core Boxes The Contractor shall provide an adequate storage facility for the core boxes at all times. The Employer shall have custody of the core boxes, at the storage facility. The Contractor shall fully cooperate with the Employer to allow the Employer to maintain the security of the core boxes. Following the engineering geological description and the selection of the samples for the execution of laboratory tests, the core boxes shall be carefully transported and delivered to the storage facility provided by the Contractor and shall be available for inspection by the Engineer at all times.

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(c)

All core boxes shall be protected at all times during handling, transportation and storage against precipitation, sunlight, vibrations and drying.

3.2.9

Backfilling and Site Abandonment

1

Upon completion of each borehole, following the measurement of a final water level, boreholes shall be backfilled immediately in accordance with one of the following methods: (a)

Installation of piezometers; or

(b)

In the event no piezometer is installed, the borehole shall be sealed with grout from the bottom to the surface, with specified cement grout (with a water/cement ratio 0.6 by weight) or any other method in compliance with Para. 5.5 of EN ISO 22475-1.

QCS 2014


Page 8

When artesian conditions are encountered such that water flows from the borehole to the surface, the Contractor shall immediately notify the Engineer and shall grout the borehole in order to prevent water flow, after the completion of the borehole to the required depth and the installation of the required instrumentation.

3.2.10

Topographical ‘As Built’ Survey

1

A topographically survey of all boreholes, trial pits and other investigations at their final locations shall be conducted. Drawings showing the location of the ‘as-built’ borehole or trial pit with the location marked by the measured distance from fixed objects shown on the drawings shall be prepared.

3.3

IN SITU TESTS SPECIFICATIONS

3.3.1

Test Standards

1

In situ tests shall be carried out in accordance with the provisions of Chapter 4 of ΕΝ 1997-2.

3.3.2

Standard Penetration Test (SPT)

1

This test shall be carried out in accordance with EN ISO 22476-3.

3.3.3

Pressure meter Test

1

Pressure meter tests shall be carried out in accordance with Para. 4.4 of EN1997-2.

3.3.4

Water Permeability Tests

1

General

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The Contractor shall execute variable head tests, constant head tests and packer tests in accordance with Earth Manual E-18 and the requirements below.

Water Permeability Test Program The execution of water permeability tests shall cover the total geological formations encountered at each borehole.

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(a)

Water permeability tests shall be conducted, for each borehole, as follows:

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(i)

In situ water permeability tests shall generally be carried out every six (6) drilling meters. Where there is high water permeability, the test shall be executed upon each cycle of sampling sequence.

(ii)

The maximum length of the tested section is 3 m, except where there is low permeability.

(iii)

Permeability tests shall commence at the ground water table or at a depth of 3 m from ground surface (whichever is shallower).

(iv)

In tunnel areas, at least two (2) water permeability tests shall be carried out at the tunnel face depth.

(v)

In tunnel areas, water permeability tests shall be conducted at the 6-metre zone above the crown (at least two (2) tests) and at the 3-metre zone below the invert (at least one (1) test).

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Page 9

Measurements of Volatile Organics

1

All AGI boreholes shall be checked for potentially contaminated soil which shall include taking field measurements indicative of volatile organic compounds (VOC).

3.4

LABORATORY TEST SPECIFICATIONS

3.4.1

Laboratory Test Program

1

The minimum requirements with regard to the program and the number of the laboratory tests are presented below.

3.4.2

Soil samples

1

Physical properties tests

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3.3.5

Determination of specific gravity and unit weight, water content, Atterberg limits and particle size analysis: One (1) test per formation, one additional test if the formation is thicker than 2 metres and, subsequently, one (1) additional test every 3 metres. Hydrometer tests shall be executed, when following particle size analysis with sieves the fine fraction is higher than 5%.

(b)

Organic substances tests shall be executed on organic soil materials.

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Engineering properties tests

Unconfined compression test: One (1) test per formation, one additional test if the formation is thicker than 2 metres and, subsequently, one additional test every 3 metres.

(b)

One dimensional consolidation tests, triaxial tests, shear tests, residual shear strength and swelling test: These tests shall be executed, taking into account the homogeneity of the soil and the type of the structure.

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Rock samples

1

The tests shall be performed, taking into account the homogeneity of the soil and the type of the structure.

2

Physical properties tests

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(a)

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Water content, porosity and density: one test per formation, one additional test if the formation is thicker than four metres and subsequently an additional test every 5 metres.

Engineering properties tests (a)

A uniaxial compression test with elasticity modulus and Poisson ratio determination and two point load tests, axial and diameter, every 3 m.

(b)

CHERCHAR abrasiveness test every 5 m.

3.4.4

Aggressiveness of soil and groundwater

1

For the determination of basic design parameters, regarding the permanent underground works from reinforced concrete, sampling and testing according to ASTM D4373, ASTM C114, ASTM D1411, APHA 4500-H and the relevant articles of QSC, Section 5, shall be conducted.

QCS 2014

The following sampling and tests shall be conducted, at a minimum: (a)

For stations: at four (4) locations (e.g. two (2) each along the long sides - towards the corners) at two (2) depths per location (e.g. -10 and -20 m).

(b)

For tunnels: at two (2) locations per tunnel, at two (2) depths per location (e.g. at the middle of the tunnel overburden and at the middle of the tunnel face).

(c)

If defective values and/or unusual deviations of the values are identified, per area, additional sampling and checking is required (including doubling the locations and the samples).

Aggressivity parameters that shall be checked at minimum are:

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(ii)

Sulphurous, as sulphur ions SO2-4 (mg/kg).

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Acidity degree as per Baumann – Gully.

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(i)

Sulphurs SO2-4 (mg/l).

(ii)

pH.

(iii)

CO2 (mg/l).

(iv)

Cations NH4 +(mg/l).

(v)

Cations Mg2+(mg/l).

(vi)

Chlorides Cl-(mg/l).

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Groundwater:

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(b)

Soil:

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Geochemical Detection of Hydrocarbons Pollution

1

At boreholes in the vicinity of petrol stations or where there is suspicion or evidence of pollution relative to the measurements with PID, soil and water samples shall be taken for TPH tests, according to method EPA8015b or APHA 5520-C or other equivalent method approved by EPA.

2

Especially for boreholes in the vicinity of petrol stations, regardless of evidence of pollution, at least four (4) soil samples, appropriately distributed, shall be obtained for the abovementioned tests.

3.5

GEOTECHNICAL REPORTS

3.5.1

General

1

The Contractor shall submit, for obtaining Engineer’s SONO reports, in the following order:

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(a)

Geotechnical Appraisal Report (GAR) including the Additional Geotechnical Investigations programme.

(b)

Geotechnical Factual Report (GFR) including the results of the Additional Geotechnical Investigations (AGI).

(c)

Geotechnical Interpretive Report (GIR) for each station, shaft and tunnel between stations.

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Page 11

Design geotechnical parameters The design values of the geotechnical parameters shall be estimated on the basis of the procedure described in paragraphs 2.4.5.2 and 2.4.6.2 of Eurocode 7, using the characteristic values of geotechnical parameters.

(b)

The types and the selected values of the design and geotechnical parameters shall include proposals about the design soil parameters, for the various depths under the surface of the ground, according to the geological formations and the proposed stratigraphy of the soil in the area where the works are to be performed. They shall take into consideration the type, extent and geometry of the underground and other structures, the construction methods and the requirements of the proposed analysis method, and any other relevant factors.

(c)

In the GIR, the design assumptions of the geotechnical conditions shall correspond to the actual:

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Types of soil and their natural properties (specific weight, density, particle size, Atterberg limits, natural water content, and any other relevant properties).

(ii)

Variation of soil properties.

(iii)

Succession and layers of thickness, presence of discontinuities.

(iv)

Ground water level and hydrogeological conditions, piezometric pressures that shall be used in the temporary retaining systems and long term conditions, permeability.

(v)

Loading rate and analysis method (total or active pressures).

(vi)

Shear strength parameters in terms of total and active stresses.

(vii)

Soil pressure coefficients (active, at-rest, passive) and any proposed modifications of the theoretical values.

(viii)

Strength and compressibility parameters, including consolidation properties, compression module when loading and unloading, Poisson ratio, non-linear stress and deformation parameters (if applicable), dynamic shear module and any other relevant properties.

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(ix)

If anchoring is to be used, values of ultimate bond strength and working bond strength between anchor or anchoring and environmental medium (soil or rock).

(d)

To calculate the regime of the initial geostatic stress field (coefficient of earth pressure K), a typical range of its values shall be proposed to be used in a sensitivity analysis during the design, as well as design values for each section or sub-section or structure.

(e)

These values shall be based on: (i)

Appropriate laboratory strength tests (e.g. triaxial tests and other relevant types of testing) as well as on in-situ tests (e.g. pressure meters and other relevant types of testing); and

(ii)

Well documented empirical correlations taken from relevant available sources according to the local conditions, including the soil type and loading history (e.g. pre-consolidation stress, over consolidation ratio, and other relevant factors).

QCS 2014

(f)


A sensitivity analysis of the geotechnical parameter values shall be included as a part of the GIR.

3.5.2

Photographic Archive

1

General (a)

2

Page 12

The Contractor shall perform detailed photographing of the works. Digital pictures shall be taken from the borehole worksites, the pre-excavation pits and trial pits (four sides and floor), the core boxes and the samples for testing.

Borehole Cores’ Photographs The Contractor shall take photographs to provide a fully detailed record of all borehole cores. Colour and length scales shall be included in each photo. The cores shall be photographed twice.

Samples’ Photographs

The Contractor shall take sets of photographs of all samples (before and after the tests), to create a fully detailed archive. Rock samples are cleaned and lightly sprayed with water prior to photographing to reveal structure and bedding.

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(a)

PILING AND DIAPHRAGM WALLING

3.6.1

Piling

1

This section specifies the materials and workmanship required for bored piles and bored pile walls. The design and installation shall be in accordance with EN 1997-1 and EN 1536.

2

Particular attention shall be paid to all safety aspects of the work, employing barriers and covers as necessary.

3

Compliance with all applicable environmental laws has to be achieved. Relevant permits and licenses shall be acquired by the Contractor.

3.6.2

Diaphragm Walling

1

This Section specifies the materials and workmanship required for diaphragm wall construction.

2

EN 1997-1 and EN 1538 shall be strictly followed in relation to diaphragm wall construction, except where higher standards are required in this specification.

3.7

PILING – EXECUTION

3.7.1

General

1

All related works shall be according to QCS - Section 4 Piling, EN 1536 and EN 1997-1.

3.7.2

Boring

1

In the event of rapid loss of drilling fluid from a pile excavation, the bore shall be backfilled immediately.

2

All reasonable steps shall be taken to prevent the spillage of drilling fluid on the Site, or in areas outside the immediate vicinity of boring.

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For a pile constructed in a stable cohesive soil, without the use of temporary casing or drilling fluid, the pile shall be bored and concrete shall be placed as soon as practical.

3.7.3

Tolerances

1

Tolerances shall be as per EN 1997-1 and EN 1536.

2

Records of the installation of each pile shall be kept. Any unusual or difficult driving or boring operation shall be noted in these records.

3.7.4

As-built Details

1

Records of as-built details of the piling works, including soil conditions encountered during boring shall be kept and delivered to the Employer as part of the O&M documentation.

3.7.5

Placing Concrete

1

The method of placing and the workability of the concrete shall be such that a continuous monolithic concrete shaft of full cross section is formed.

3.7.6

Pile Tests

1

Pile tests shall be performed according to EN 1997-1 and EN 1536.

3.7.7

Protection of Piling from Chemical Attack

1

Piles shall be protected against aggressive soil and ground water conditions, both during and after installation. The Contractor shall demonstrate that he has considered the protection required to the steel reinforcement cage and the concrete.

3.8

DIAPHRAGM WALLING – EXECUTION

3.8.1

General

1

Execution shall be carried out in accordance with EN 1997-1 and EN 1538.

3.8.2

Cleaning

1

The exposed surface of the diaphragm wall shall be thoroughly cleaned to ensure bonding of any subsequent material placed on the wall.

3.9

ANCHORING, BRACINGS, NAILS AND BOLTS

3.9.1

General

1

This section specifies materials and workmanship requirements for pre-stressed anchoring, bracings, nails and bolts. The design and installation shall be in accordance with EN 1997- 1 and EN 1537.

3.9.2

Anchoring

1

Temporary anchors shall have a design life of a minimum of 10 years.

3.9.3

Bracing

1

All steel components for bracings shall be in accordance with EN 10025.

2

All concrete components for bracings shall be in accordance with EN 1992.

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Nails and bolts

1

All metal components of the bolts/nails shall conform to the standard specification EN 10025.

3.10

ANCHORING EXECUTION

3.10.1

General

1

Anchoring shall avoid damage to all existing buildings, structures and utilities.

2

In the event temporary anchors are required to be placed in adjacent properties, the approval of owners of adjacent properties shall be obtained.

3.10.2

Testing

1

The Contractor shall test all anchors according to EN 1537.

3.10.3

Corrosion protection of anchors

1

Anchors shall be protected against corrosion during service life according to EN 1537.

3.10.4

Tolerances

1

The tolerances for anchoring shall be in accordance with EN 1537.

3.11

BRACING EXECUTION

3.11.1

General

1

Bracings shall be installed so that the waterproofing will not be damaged.

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3.9.4

END OF PART

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Section 29: Railways Part 04: Tunnel

Page 1

4

TUNNEL ........................................................................................................ 2

4.1

PRIMARY SUPPORT OF SPRAYED CONCRETE LINING TUNNELS ...................................................................................................... 2

4.1.1 4.1.2

Description Sprayed Concrete Tunnel Design and Analysis Methodology

4.2

TUNNEL FINAL LINING ................................................................................ 3

4.2.1 4.2.2 4.2.3 4.2.4

General Minimum Design Requirements Minimum Construction Requirements Applicable in the Design Submissions

4.3

EFFECT OF TUNNELLING ON SURROUNDING STRUCTURES................ 6

4.3.1 4.3.2

General Classification of Damage of Buildings and buried structures due to Tunnelling Methodology for Assessing the Risk of Damage to Buildings due to Tunnelling

3 4 5 6

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4.3.3

2 2

6 8 11

SAFEGUARDING TUNNEL CORRIDORS .................................................. 13

4.4.1

Metro Corridor planning stage:

4.5

TUNNEL EXCAVATIONS WITH TBM ......................................................... 15

4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8 4.5.9 4.5.10 4.5.11

General Selection of TBM Inspections and tests Tunnel Excavation with TBM Operation of TBM Tunnel Excavation Data Reports, Shift Reports As-built Details Safety Regulations Fire Prevention Electrical Specification Environmental Conditions

4.6

TUNNEL EXCAVATION WITH CONVENTIONAL MEANS ......................... 21

4.6.1 4.6.2 4.6.3 4.6.4 4.6.5

General Working Conditions Working Interruptions Safety Measures and Systems Work Execution

4.7

PRECAST CONCRETE TUNNEL LINING SEGMENTS.............................. 23

4.7.1 4.7.2

General Materials

4.8

GROUTING FOR SEGMENTAL LINING, CONTACT GROUTING AND FILLING OF VOIDS ............................................................................. 26

4.8.1

General

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13 15 16 17 17 17 18 18 18 19 20 20 21 21 21 21 21 23 23

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TUNNEL

4.1

PRIMARY SUPPORT OF SPRAYED CONCRETE LINING TUNNELS

4.1.1

Description

1

The Contractor shall, with due regard to the safety and stability of the Works, above ground buildings and all other structures above and below ground, implement a primary support shell in tunnels immediately following excavation using conventional means (i.e. not by TBM), where applicable.

2

The design of the primary support shell of the sprayed concrete lining tunnels of the Works shall aim at their adequate dimensioning, by appropriately addressing any ground improvement applications ensuring:

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The safe construction of the tunnels primary support structure itself;

(b)

The sprayed concrete lining shall arrest ground movement;

(c)

The primary support shell of the tunnels shall not be considered at all in the design of their final lining.

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(a)

Sprayed Concrete Tunnel Design and Analysis Methodology

1

A structural analysis shall be performed for each tunnelling class with the following objectives:

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4.1.2

To verify that the primary support measures foreseen for this class are sufficient, safe and cause acceptable tunnel wall convergence and ground movements; and

(b)

Calculations for the safety factor of the design for this tunnelling class. This shall be achieved by performing a supplementary analysis of a specific tunnelling class, using the geotechnical parameters of the immediately inferior class.

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(a)

The structural analysis shall be performed in two-dimensions (i.e., assuming plane strain conditions). In special cases (e.g. in the design of tunnel intersections or under adverse geotechnical conditions), 3-D analyses shall be performed;

3

Two-dimensional analyses shall include the 3-D effects of the tunnel excavation face by one of the following methods:

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(a)

Internal pressure reduction method, i.e., by reducing the internal pressure of the excavated cross-section to a value compatible with the wall convergence, at the location where the primary lining is installed; or

(b)

Modulus reduction method, i.e., by reducing the modulus of the excavated crosssection to a value compatible with the wall convergence, at the location where the primary lining is installed;

4

The Contractor shall investigate and assess, as necessary, any structures which are below and above the tunnel regarding possible adverse influences on the tunnel works below and address the results of such findings in his design;

5

Given that the presence and the nature of the ground water affect the sprayed concrete lining design, the following factors shall be examined:

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(a)

The range of groundwater pressures during the construction phase, in short-term and mid-term conditions;

(b)

The impact on any structures (i.e. impact on building foundations, subsidence etc.) due to the changed ground water level during the tunnel excavations;

(c)

The impact of water on the geomaterials being excavated, such as looseness, disintegration and/or swelling etc;

(d)

The design of the appropriate drainage system for the works, regarding short-term and mid-term inflows; and

(e)

The local drainage characteristics of the surrounding geomaterials shall be taken into account for the determination of the most appropriate method for excavation and control of the ground water;

TUNNEL FINAL LINING

4.2.1

General

1

The tunnel final lining structures consist of either the following:

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4.2

Reinforced cast – in situ concrete; or

(b)

Reinforced precast concrete segmental rings.

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(a)

These shall be designed and constructed in a manner, which ensures that any movements and deformations, which may result from the most unfavourable possible loading conditions, will not exceed (in any case) limits beyond which these structures lose their structural capacity and integrity, either during construction or during their prescribed design life of 120 years.

3

Tunnel final linings shall be designed in accordance with the provisions of the Design Specification, entitled “Design Loads”.

4

The primary support shells of the tunnels shall not be considered in the design of the tunnels final lining.

5

The design of tunnels final linings shall not allow for any long term relief and/or effect related to ground arching effects (i.e. full overburden pressure shall be taken into account in the design).

6

The distribution of the lateral ground pressures on to the tunnels final linings shall consider the construction method, the relative rigidity of the lining and the interaction of the lining with the ground. The tunnel final linings shall be designed to withstand the at-rest earth pressure (K0 conditions), unless it can be demonstrated and fully justified to the Engineer that these pressures will not occur in the long term after stress relief caused by the excavation. This may be the case where the overburden height (ground surface to tunnel(s) crown distance) is greater or equal to 3 times the tunnel excavation diameter and the existing ground conditions (overlying and surrounding the tunnel(s)) are homogeneous in terms of their stiffness and shear strength characteristics. Any reduced earth pressures shall not be used in the following cases of ground and groundwater conditions, or other cases directed by the Engineer:

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(a)

Extensive karstic depression zones.

(b)

Extensive highly weathered formations.

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(c)

Formations with high swelling potential.

(d)

Areas of high groundwater pressures of “artesian nature”.

The design of the tunnels final linings shall consider the full hydrostatic groundwater pressures, with consideration of the maximum long – term levels of the existing groundwater tables (design groundwater level).

8

Tunnel final linings shall be designed to resist grouting pressure.

9

The design of the tunnels final linings shall comply with the safety requirements of Eurocode 2 (EN1992) for concrete structures, Eurocode 3 (EN 1993) for steel structures and Eurocode 7 part 1 (EN1997-1) in terms of the applicable partial factors and design approaches.

10

Specifically, for fire safety, the design of the tunnels final linings shall comply with the fire safety requirements mentioned in the Design Specification, entitled: ‘Fire Protection and Life Safety Requirements’.

11

For the seismic analysis of the tunnels final linings, this shall comply with the relevant provisions of the Design Specifications, entitled: ‘Tunnel Design Specification’.

4.2.2

Minimum Design Requirements

1

Concrete intended for use in the tunnels shall comply with the specifications of QCS and EN 206 (with the most conservative standard prevailing in the case of conflict) and for:

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Cast in-situ concrete structures the minimum design concrete class shall be C30/37 and the reinforcement shall consist of high ductility bar of minimum category B500C; and

(b)

The tunnels’ precast segmental lining, the minimum design concrete class shall be C40/50 and the reinforcement shall consist of high ductility bar of minimum category B500C, or approved alternative reinforcement.

For the design of the reinforced precast concrete segmental rings, the following are essential: Segmental linings shall be designed not only for the ground and groundwater pressures, but also for all handling, transportation, stacking and erection forces with an allowance for impact. In addition segmental linings shall be designed to resist all forces which may be applied by the equipment used for this;

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For segmental linings, the design shall take into consideration the contact stresses at the joints and the bending caused by the loads eccentricity at the joints. The strains imposed on to the concrete shall be received by specially placed reinforcement in the area of the segment’s face (area where pressure is exerted by the TBM thrust jacks);

4

The layout of the structure and the interaction between the structural members shall be such as to ensure a robust and stable structure. Adequate jointing between precast elements or between precast members and cast in-situ structures shall be achieved using appropriate reinforcement and/or special ties in order to ensure their stability and waterproofing, even when subjected to accidental stresses (such as excessive impact, fire, etc.) and possible differential pressures of the supports.

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Minimum Construction Requirements Applicable in the Design

1

Continuous end-to-end cracking of the concrete is not permitted. The Contractor shall document and justify minimum reinforcement requirements, subject to a SONO from the Engineer.

2

Depending on the soil and ground water aggressiveness, which will be identified after the appropriate sampling and testing, all necessary measures shall be taken, consistent with the overall design life of the Works and as reasonably determined by the Contractor, in order to ensure reduced permeability and increased resistance of the final lining. These measures shall be submitted to the Engineer for a SONO and include (indicatively but not limited to) special concrete mix (admixtures, special cement etc.), construction measures (larger concrete cover, additional surface reinforcement, curing etc.), special design (limitation of cracking etc.), coating of the exterior surface of the lining, by using special resistant materials, special reinforcement, special resistant waterproofing gaskets (for segmental lining) or waterstops (for cast in- situ lining).

3

The presence of a primary support lining shall not be taken into consideration for determining which surface is in contact with water or soil or with lean concrete.

4

In all areas of the Works, for which there is a provision for cross-passages and the connection of the TBM tunnel to shafts, recesses for E/M installations, etc., specific parts of the precast segments of the main tunnel shall be cut. Cuts shall be made in the main TBM tunnel with precision after installation of the TBM tunnel segments, using the undisturbed cutting method, and shall be made only at the intersection of the connecting tunnel with the main TBM tunnel and geometrically correspond to the outer perimeter of the connecting tunnel. The entire procedure shall be performed diligently so as not to cause any damage, displacement, loosening or disconnection of the precast segments of the main tunnel. All relevant designs shall follow and incorporate this method.

5

Tunnels shall be checked for uplift using:

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4.2.3

The dead loads;

(b)

All permanent loads; and,

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The uplift groundwater pressures.

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Regarding ground water levels, the Contractor’s calculations shall be based on the worstcase scenario likely to occur within the design life of the Works, as this will be estimated on the basis of the appropriately evaluated hydrogeological data (including predictions about ground water fluctuations during the design life of the Works). Any possible effects from the presence of the structure on the groundwater flow shall be considered in the calculations.

7

Where necessary, a construction sequence adequately safeguarding against uplift during all stages of construction shall be indicated on appropriate drawings.

8

The tunnels’ uplift safety factor shall be determined on the basis of paragraph 2.4.7.4 and 10.2 of EN1997-1.

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4.2.4

Submissions

1

The design of tunnel final lining shall include, but not be limited to the design report, the calculations, any documents related to additional checking or annexes of the calculations, the construction drawings and any other supporting material needed for the better substantiation of the design.

2

The design report shall include at least the following items: Table with the basic design assumptions;

(b)

Table with the geotechnical and geometrical characteristics of the soil stratigraphy, as well as sketches of the geotechnical cross-sections;

(c)

A separate chapter in which the structural analysis models shall be clearly described and fully substantiated. This chapter shall contain a detailed description of the individual components of the various models, such as their geometry, their supporting and coupling conditions, the moment of inertia and elastoplastic properties of all members, as well as the properties of any springs or elements used for the simulation of the ground – tunnel interaction;

(d)

A separate chapter presenting and justifying in detail all loads exerted onto the model and all loading combinations used in the design, in accordance to the provisions of the Design Specification, entitled: ‘Design Loads’;

(e)

A separate chapter describing, justifying, evaluating and presenting in detail the results of the calculations and the dimensioning of all structural members. For this scope, and as a minimum requirement, the following shall be included:

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moments, shear and normal forces,

(ii)

the deformed structural model including values of the calculated deformations

(iii)

the calculated reinforcement for each structural element.

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EFFECT OF TUNNELLING ON SURROUNDING STRUCTURES

4.3.1

General

1

Description

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4.3

2

(a)

This specification includes the minimum requirements for the assessment of the degree of risk relating to the damage of buildings and structures, caused by the tunnelling works.

(b)

A detailed methodology for risk assessment is described in the Annex of this specification.

Definitions (a)

The zone of influence of tunnelling is the volume of geomaterial influenced by the tunnelling operations. Any buildings or other structures located within this zone shall be subject to the provisions of this specification, in relation to the assessment of risk of damage. The minimum zone of influence for a specific tunnel cross-section, is shown in the following sketch.

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Figure 4.1

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Minimum Influence Zone

Tensile Strain (ε) in a structure is the average tensile strain, defined as the average strain over a gauge length of one metre.

(c)

Critical Tensile Strain (εcrit) is the tensile strain causing visible cracking in masonry and blockwork.

(d)

Volume loss (or Ground Loss - GL) is the ratio of the volume (ΔV) of geomaterial excavated in excess of the theoretical tunnel volume divided by the theoretical tunnel volume (Vo).

(e)

The following drawings provide the definitions of rotation (θ), angular strain (α), relative deflection (Δ), and deflection ratio (Δ/L), tilt (ω), and relative rotation (β): Figure 4.2 Definition of Parameters

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(b)

Rotation or slope, θ, and angular strain, α.

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Relative deflection, Δ, and deflection ratio, Δ/L.

present

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Tilt, ω, and relative rotation, β (angular distortion)

Classification of Damage of Buildings and buried structures due to Tunnelling

1

Buildings with surface foundations

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Visual appearance or aesthetics.

(ii)

Serviceability or function; and

(iii)

Stability.

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From the above three broad categories of damage, six specific categories of damage (numbered 0 to 5 in increasing severity) are defined, as described in Table 4.1. Normally categories 0, 1 and 2 relate to “aesthetic” damage, categories 3 and 4 relate to “serviceability” damage and category 5 represents damage affecting “stability”. The system of classification in Table 4.1 is based on ease of repair of the visible damages.

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(b)

The risk assessment shall be based on the following classification of damage. Three broad categories of building damage shall be considered that affect:

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4.3.2

(d)

In order to classify visible damages it is necessary, when carrying out the survey, to assess what type of work would be required to repair the damage both externally and internally. The Contractor shall take into account the following points: (i)

The classification relates only to the visible damage at a given time and not to its cause or possible progression which are separate issues;

(ii)

Damage shall not be classified solely based on crack width. Ease of repair shall be a key factor in determining the category of damages;

(iii)

The classification was developed for brickwork or blockwork and stone masonry. It can be adapted for other forms of cladding. It is not intended to apply to reinforced concrete structural elements. However, as cracking of in-fill brick walls of frame structures are usually more critical than the structural damage of the structural frames, the method can also be used for assessing the risk of cracking of the brick wall in-fills of frame structures;

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Section 29: Railways Part 04: Tunnel (iv)

(e)

Page 9

In cases where damage could lead to corrosion, penetration or leakage of harmful liquids and gases or structural failure, the Contractor shall follow the same methodology but shall propose more stringent criteria and /or ranking to the Engineer for a SONO.

Besides defining the numerical categories of damage, Table 4.1 also lists the “normal degree of severity” associated with each category. The descriptions of severity given in Table 4.1 refer to standard domestic and office buildings. In special cases such as for a building with valuable or sensitive finishes, this ranking of severity of damage may not be appropriate. In this case, the Contractor shall propose the same methodology but more stringent criteria and /or ranking to the Engineer for a SONO.

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Classification of visible damage to walls

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Table 4.1

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Classification of visible damage to walls with particular reference to ease of repair of plaster and brickwork or masonry

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Description of typical damage (Ease of repair is underlined)

Normal degree of severity

0

Negligible

Hairline cracks less than about 0,1 mm

1

Very slight

Fine cracks which are easily treated during normal decoration. Damage generally restricted to internal wall finishes. Close inspection may reveal some cracks in external brickwork or masonry. Typical crack widths up to 1 mm.

2

Slight

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Category of damage

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Note: Crack width is only one factor in assessing category of damage and shall not be used on its own as a direct measure of it.

Cracks easily filled. Re-decoration probably required. Recurrent cracks can be masked by suitable linings. Cracks may be visible externally and some repointing may be required to ensure watertightness. Doors and windows may stick slightly. Typical crack widths up to 5 mm.

3

Moderate

The cracks require some opening up and can be patched by a mason. Repointing of external brickwork and possibly a small amount of brickwork to be replaced. Doors and windows sticking. Service pipes may fracture. Watertightness often impaired. Typical crack widths are 5 to 15 mm or several > 3 mm.

4

Severe

Extensive repair work involving breaking-out and replacing sections of walls, especially over doors and windows. Windows and door frames distorted, floor sloping 1 1 noticeably . Walls leaning or building noticeably, some loss of bearing in beams. Service pipes disrupted. Typical crack widths are 15 to 25 mm, but also depends on the number of cracks.

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Classification of visible damage to walls with particular reference to ease of repair of plaster and brickwork or masonry


5

Very severe

Description of typical damage (Ease of repair is underlined) Note: Crack width is only one factor in assessing category of damage and shall not be used on its own as a direct measure of it.

This requires a major repair job involving partial or complete rebuilding. Beams loose bearing, walls lean badly and require shoring. Windows broken with distortion. Danger of instability. Typical crack widths are greater than 25 mm, but depends on the number of cracks.

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Category of damage

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Table 4.2 gives the relationship between the category of damage, the limiting tensile strain (εlim) and the maximum acceptable values of “green field” settlements and settlement troughs. Table 4.2

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Relationship between categories of damage Relationship between category of damage, Limiting tensile strain (εlim) and maximum

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Approximately equivalent ground settlements and slopes (after Rankin 1988)

Limiting tensile strain (εlim) (%)

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Category of damage

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acceptable “green field” ground settlements

Max slope of ground* (Δ S/L)

Max settlement of building (mm)*(S)

less than 1/500

less than 10

m

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Local deviation of slope, from the horizontal or vertical, of more than 1/100 will normally be clearly visible. Overall deviations in excess of 1/150 are undesirable.

0

Negligible

0 – 0.05

1

Very slight

0.05 – 0.075

2

Slight

0.075 – 0.15

1/500 to 1/200

10 to 50

3

Moderate

0.15 – 0.3

1/200 to 1/50

50 to 75

4 to 5

Severe to very severe

Greater than 0.3

1/200 to 1/50

greater than 75

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(*) These columns indicate “green field” settlements and settlement trough slopes.

4.3.3

Methodology for Assessing the Risk of Damage to Buildings due to Tunnelling

1

General (a)

Stage 1: Preliminary Risk Assessment A preliminary risk assessment shall be performed prior to the beginning of tunnelling.

(b)

Using the tunnel alignment and depths, the zone of influence of the Works shall be determined.

(c)

A Ground Loss (GL) value shall be selected for each tunnel section, due to tunnelling and the specifics of the tunnel excavation method and shall be submitted to the Engineer for a Statement of No Objection. The Contractor is also referred to the Materials and Workmanship Specification, Clause 13.1.2, Selection of TBM.

(d)

The contours of surface settlements (for “greenfield” conditions) shall be determined over the surface part of the zone of influence.

(e)

Using the above contours of surface settlements, the differential settlement (∆S) and tilt (∆S / L) shall be determined for each building within the zone of influence of the Works.

(f)

Preliminary limiting values of the differential settlement (∆) and slope (∆/L) shall be assessed for each building based on the type of structure, age, structural condition, span width, etc. As an indication, for good quality, average size, reinforced concrete buildings, the limiting differential settlement can be about 10mm and the limiting slope about 1/500. The above indications on limit settlements apply to common constructions. They should not be applied to unusual structures or buildings including high rise buildings or those for which the load intensity is highly non-uniform.

(g)

Buildings with settlement (∆S) and tilt (∆S / L) smaller than the limiting values mentioned previously can be assumed to have negligible risk of damage and be excluded from the following stages of risk assessment.

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(a)

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The Contractor shall apply the following methodology for assessing the risk of damage of buildings due to tunnelling. The methodology includes three consecutive stages as described below.

3

(h)

All other buildings within the zone of influence of the Works shall be subjected to the following two stages of risk assessment.

(i)

The following two stages of risk assessment shall also be performed for all very sensitive and important buildings (including high rise buildings) inside the zone of influence of the Works, regardless of the results of stage 1 risk assessment.

Stage 2: Second Stage Risk Assessment (a)

This stage of risk assessment shall be performed prior to the beginning of tunnelling.

(b)

It shall include all buildings within the zone of influence of the Works exceeding the limiting values of differential settlement (∆S) or tilt (∆S / L) of stage 1 assessment as well as all very sensitive and important buildings inside the zone of influence of the Works.

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(c)

The second stage risk assessment will be based on calculated maximum tensile strains and comparison with the corresponding limits for each category of damage in Table 4.2.

(d)

Specifically the second stage risk assessment shall be based upon either: The facade of any building is represented by a simple beam whose foundations follow the ‘greenfield’ displacements caused by the tunnel excavation. These displacements are calculated from the settlement trough, as described above; or

(ii)

The maximum tensile strains shall be calculated using the methodology described in the annex to this specification. The approach of Potts and Addenbrooke (1997) can also be included at this stage, to account for the structural stiffness in more detail. Ref : “A structure's influence on tunnellinginduced ground movements”, by D M Potts and T I Addenbrooke, Proceedings of the ICE - Geotechnical Engineering, Volume 125, Issue 2, April 1997, pages 109 – 125.

(iii)

For each building under assessment, using Tables 4.1 and 4.2 and the calculated maximum tensile strains, an appropriate category of damage shall be assigned to each such building.

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Figure 4.3 shows an interaction graph for the case of a beam with L/H=1. The Contractor shall make his own assessment of the damage classification for all buildings, by deriving all necessary figures, similar to Figure 4.3, by considering the geometrical characteristics and the structural type of the buildings.

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Figure 4.3

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Example of interaction diagram

Figure 4.3. Example of interaction diagram relating (/L)/εlim to εh/εlim for the case of an isotropic beam with L/H = 1

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Stage 3: Detailed Evaluation of Risk Assessment (a)

This stage of risk assessment shall be performed only for buildings categorized as “Category of Damage” 3, 4 or 5 during stage 2 risk assessment as well as for all very sensitive and very important buildings within the zone of influence of the Works.

(b)

Each building has to be considered in its own right and requires a detailed structural survey. This survey shall consider: (i)

The geotechnical conditions, sub-surface profile and ground-water conditions;

(ii)

The stiffness of the building (timber, masonry or framed buildings);

(iii)

The foundation type; and

(iv)

The sensitivity and usage of the building.

Following the structural surveys, each building will be analyzed by considering the tunnelling sequence, three-dimensional aspects, specific building details and geomaterial/structure interaction.

(d)

For buildings remaining in damage category 3 or higher, the Contractor shall perform special designs as described below.

(e)

Typically, these designs shall be performed using numerical analyses to include the geomaterial – structure interaction and non-linear geomaterial effects due to ground deformations caused by tunnelling.

(f)

These designs shall either include improvement of the ground and/or reinforcement of the building foundations. The objective of the designs shall be to reduce the damage category of the building to a value 2 or lower.

(g)

The Contractor shall perform the above designs and submit them to the Engineer for a SONO.

(h)

For building on pile foundations requiring stage 3 risk assessment, detailed evaluation shall be performed using numerical analyses to include the geomaterial – structure – pile foundation interaction. Typically, non-linear analyses shall be performed including skin friction and lateral loading of the piles due to ground deformations caused by tunnelling. The Contractor shall perform the above designs and submit them to the Engineer for a SONO.

.

(c)

Regardless of the results of the stage 3 analyses, buildings originally classified in damage categories 2 and above shall be monitored by instrumentation installed prior to tunnelling according to the Materials and Workmanship Specification.

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(j)

The instrumentation details for all buildings which at their stage 3 risk assessment have a category of damage 3 or higher shall be presented in the improvement /reinforcement design to be prepared by the Contractor.

4.4

SAFEGUARDING TUNNEL CORRIDORS

4.4.1

Metro Corridor planning stage:

1

The planning corridor width for the Metro Tunnels comprises: (a)

The outlined tunnel structure;

(b)

The construction tolerance zone;

(c)

The exclusion zone;

QCS 2014

(d)

The alignment adjustment zone; and

(e)

The minimum distance between two adjacent tunnel tubes.

Definition of outlined tunnel structure: (a)

3

For the segmental tunnel lining an outer diameter of 7.5m has been assumed.

Definition construction tolerance zone: (a)

4

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For the shield driven tunnels a construction tolerance of 0.5m will be taken into account. The construction tolerance zone is defined as a square with equal sides of 8.5m.

Definition of exclusion zones: For third parties no structures shall be closer than 5m horizontally, 6m from the top and 3 m from the bottom of the outlined construction tolerance zone. For planned structures intruding into this zone approvals from the Employer must be obtained.

Definition of alignment adjustment zones:

The Employer is retaining the flexibility to move tunnels 3m horizontally and vertically 3m towards Ground Level. The zone underneath the tunnels is defined infinite to safeguard maximum flexibility.

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The outline of the Metro Corridor is compulsory for all parties and will be added into the Urban Integration Plans. In certain locations the full tolerance may not be required. The Engineer will advise accordingly.

7

The parameters described above are depicted in Figures 4.4 and 4.5 below.

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Figure 4.4

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Limit of deviation for general Tunnel arrangement

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Figure 4.5

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Limit of deviation for Twin Tunnel arrangement

TUNNEL EXCAVATIONS WITH TBM

4.5.1

General

1

The key issues for the Contractor to manage for the construction of tunnels using tunnelling equipment include:

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its availability/performance/reliability/serviceability;

(b)

assembly, use, removal, with the required equipment; cutter disc wear; its stopping periods;

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(a)

(e)

the availability of the correctly certified technical human resources and the supply of all materials needed.

(f)

TBM work shall be performed in line with international best practice and the conditions at the Site, which contains different geomaterials.

(g)

TBM shall be supplied new and shall be state-of-the-art. The TBM shall be suitable for the ground conditions to be encountered and shall incorporate necessary soil conditioning. They shall be supplied in accordance with all applicable Regulations, and relevant Qatar Construction Specifications, British and European standards. The Contractor shall always use the latest published version of any regulation or standard that relates to health and safety.

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4.5.2

Selection of TBM

1

The operation and control features of the TBM shall be designed to minimize sub-surface and ground settlement. Ground loss arising from the TBM boring and tunnel construction operations shall be limited to a maximum value of 1% of the excavated volume, with more stringent limits on maximum ground loss as specified in the Contract Documents. The TBM operating principles shall govern its use in order to meet these requirements.

2

The Contractor is solely responsible for the selection of the TBMs to be used for the tunnelling operations and shall be according to the Project specifications and requirements detailed herein. As a minimum, the following factors shall be taken into account for TBM selection: The geological, hydrogeological and geotechnical conditions in the zone of influence of the Works;

(b)

The geometry of the tunnel section and its alignment;

(c)

Manufacture and supply of the machines and their back-up equipment;

(d)

Assembly and preliminary tests in the factory, including the grout and soil conditioning system. TBM manufacture shall allow for attendance of the Contractor maintenance and the Engineer during the final assembly and commissioning works;

(e)

Technical assistance during assembly at the worksite;

(f)

Commissioning and tests at the work site;

(g)

Technical assistance during the dismantling operations;

(h)

All applicable environmental regulations and licenses;

(i)

The stability conditions of the tunnel face and the tunnel section;

(j)

The requirements to limit ground and structures deformations below the acceptable levels, as described in the Technical Specification

(k)

Any tests to confirm design assumptions;

(l)

The time constraints regarding the tunnel construction;

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Applicability of supplementary supporting methods if necessary; Availability of spaces necessary for auxiliary facilities behind the machine and around the access tunnels;

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(a)

(o)

Direction control and measurement system;

(p)

The supply and management of spares, consumables and wear parts;

(q)

Design of the tunnel boring machine (TBM) and backup equipment and ongoing input during design and manufacture;

(r)

Operation and maintenance manuals in English and Arabic, provided electronically together with 4 paper copies;

(s)

Technical assistance from the Manufacturer during the tunnel start-up until the specified performance is demonstrated as being achieved, and as necessary thereafter to assist the Contractor in achieving the required performance throughout the tunnel drives as constructed drawings of the TBM, technical documentation and details of planned maintenance requirements prior to commencing TBM and/or Tunnelling Equipment operations including updated operational manuals;

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(t)


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A detailed programme for the design and manufacture of the TBM’s. The Contractor and the TBM Manufacturer shall attend regular meetings with the Engineer to monitor the design and manufacture of the TBM to the Contract schedule.

An excavation control system shall be installed necessary for tunnelling operations, orientation and operation of the TBM excavation, backfill grouting and operation of auxiliary facilities. The system will control accurate alignment, excavation control (belt weighers, laser scanner, flow meters and profilers) to ensure stability of the face of the tunnel and minimum disturbance of the surrounding ground and structures.

4

A TBM operational control and monitoring data acquisition system shall be provided. The system shall be compatible with the project-wide underground construction instrumentation and monitoring requirements. The monitoring system shall record and report the key information that will ensure the reliable and safe operation of the TBM. The monitoring system shall also record all necessary parameters to ensure ground movements are kept within the specified limits. The Contractor and Manufacturer shall submit a list of target programmed TBM control parameters to the Engineer for a SONO.

4.5.3

Inspections and tests

1

Prior to commencing any operation with the TBM the Contractor shall submit a programme for the supply, inspection, testing, transfer, assembly and operation of the TBM.

4.5.4

Tunnel Excavation with TBM

1

The bearing positions of the thrust rams shall be designed for the bearing capacity of the geomaterials and the tunnel lining, in order to avoid failures.

2

The thrust rams shall operate either individually or together in any possible combination.

3

Access must be given to all working or maintenance areas of the TBM. Provision shall be made for emergency exits.

4

All necessary measures to prevent the risk of water ingress shall be taken before commencement of the Works.

5

Immediately upon any work stoppage, the stability of all TBM excavations and the safe condition of the tunnel (including regular inspections) shall be ensured.

6

All lighting used by the Contractor shall ensure uniformly distributed lighting in all working areas.

4.5.5

Operation of TBM

1

All information relevant to the control of the TBM operation shall be accessible to the Engineer in real time.

2

Operation and maintenance of the TBM, shall be according to the guidelines of the manufacturer and the operation and maintenance manuals, which shall always be up to date and available for inspection of the Engineer.

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An air-conditioned control cabin shall be provided at the front end of the back-up system from which the TBM will be driven. This shall contain all the remote controls and visual displays as necessary for the safe operation of the TBM and its environment.

4

A separate above-ground monitoring facility shall be provided for each TBM that will duplicate all the remote controls and visual displays within the respective (sub-surface) Control Cabin.

5

The cutting tools shall regularly be inspected.

6

The TBM bearing shall be regularly inspected. The bearing shall be removable rearward from the front bulkhead with the minimum of disturbance to the other components, in the event of the need for replacement. A replacement main bearing should be available within 12 weeks should the replacement be required.

7

The cutter head shall be a substantial structure, which provides the necessary mechanical support to the tunnel face. It shall incorporate the necessary abrasion protection features to enable the shield to be able to complete excavation of the tunnels through all the expected geological conditions.

8

The cutter head structure and bearing with its support system shall be rated to absorb the maximum forces envisaged in operation. This shall include normal operation and ultimate load condition where full power may need to be used in the event the TBM becomes stuck, resulting in maximum shove loading and maximum torque.

4.5.6

Tunnel Excavation Data Reports, Shift Reports

1

Detailed data for all TBM excavations shall be kept.

4.5.7

As-built Details

1

The Contractor shall keep records of as-built details of the tunnelling works, including ring erection and soil conditions encountered during boring.

4.5.8

Safety Regulations

1

The design and manufacture of the TBM and back-up systems shall comply with all applicable laws and regulations, relevant Codes of Practice relating to safety and relevant Qatar Construction Specifications, British and European standards including, but not limited to, those described below. The Contractor shall always use the latest published version of any regulation or standard that relates to health and safety.

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(a)

EN 12336: 2005 Tunnelling Machines – Safety Requirements.

(b)

EN 12110: 2002 Tunnelling Machines – Air Locks-Safety Requirements.

(c)

BS 6164: 2001 Code of practice for safety in tunnelling in the construction industry.

(d)

The Work in compressed Air Regulations 1996.

(e)

HSE L96 A Guide to the Working in Compressed Air regulations (1996).

(f)

EN ISO 9000 and 9001 Quality management and quality assurance standards.

(g)

EN 60079 Electrical apparatus for potentially explosive atmospheres.

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EN 50402: 2005: Electrical apparatus for the detection and measurement of combustible or toxic gases or vapours or of oxygen. Requirements on the functional safety of fixed gas detection systems.

(i)

EN 981: 1997 Safety of machinery. System of auditory and visual danger and information signals.

(j)

EN 60034-9 Rotating Electrical Machines – Noise Limits.

(k)

EN ISO/IEC 17050 – 1:2004 Conformity assessment. Suppliers declaration of conformity. General requirements.

(l)

EN 981Safety of machinery-System of Danger and Non Danger signals with sound and light.

(m)

EN 61310-1 Safety of Machinery-Indicating, marking and actuating principles; part 1 Visual, audible and tactile signals.

(n)

EN 1012 Compressors and vacuum pumps; Safety requirements.

(o)

EN ISO11688; Parts 1 & 2: Recommended Practice for the design of low noise machinery and equipment.

(p)

EN620:2002 Specification for mechanical and spliced joints in conveyor belting for use underground.

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(h)

Fire Prevention

1

A fire hazard assessment which will identify and mitigate all potential fire sources shall be carried out by the Contractor jointly with the TBM Manufacturer and submitted to the Engineer for a SONO.

2

Subject to the conclusions of the hazard assessment, the TBM and back-up systems shall be provided with:

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The fire suppression system which shall be suitable to mitigate the risks identified in the hazard assessment.

(b)

Emergency plunger buttons at suitable locations to activate a fire alarm. Hand held extinguishers provided with colour coded covers in suitable locations. A means of rapidly shutting off fresh air ventilation to the tunnel face, after the area has been evacuated.

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(e)

Operators and training manuals for use by the Contractor.

(f)

Conveyor belting, rubber covered rollers and other similar parts to be manufactured in materials that reduce the fire risk, fire load, spread of flame and toxic fume risk.

(g)

Hydraulic hoses shall comply with BS EN 853/ISO 1436. The hose covers to be flame retardant and to conform to the requirements of MSHA. All hydraulic hoses shall be fitted with swaged end connections, re-usable fittings are not permitted.

(h)

Gas monitoring for oxygen deficiency, CO2, CO, H2S, NO2, SO2 and CH14.

(i)

Smoke detection and rate of temperature rise.

(j)

Water mist screen to be positioned at the rear of the back-up System.

(k)

Low density foam generators to be sited at high fire risk areas with either automatic or manual operation in the event of fire.

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(l)

Spraying nozzles to be installed at the last sledge to create an anti-smoke curtain in case of fire in the tunnel.

(m)

Essential services shall be protected so that they remain operable during all tunnelling operations for a period of 1 hour. The essential services are: Emergency power supplies

(ii)

All fire suppression systems

(iii)

TBM emergency lighting

(iv)

Environmental monitoring systems

(v)

All controls and tunnel communications

(vi)

The security of the air supply and control systems to the man lock shall remain operable in all emergencies, particularly in the case of fire

(vii)

Emergency evacuation chambers

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Electrical Specification

1

All TBM electrical installations shall comply with all relevant regulations and with all relevant British, European and Qatar standards. The Contractor shall always use the latest published version of any regulation or standard that relates to health and safety.

2

The following list of relevant regulations and standards in non-exhaustive:

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4.5.10

BS 6164 Code of Practice tunnelling

(b)

EN 12336:2005 Tunnelling Machines Safety Requirements

(c)

Electricity at Work Regulations 1989

(d)

BS 7671:2008 Requirements for Electrical Installations

(e)

IEE Wiring Regulations 16 Edition

(f)

BS5304 and EN292 Safety of Machinery

(g)

BS 7430:1988. Earthing

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EN 60204 Safety of Machinery

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(i)

BS7375:1996 Distribution of Electricity on Construction sites

(j)

EN 60529 1992 Degrees of Protection of Enclosures

(k)

BS 6724:1997 armoured cables for low emissions

(l)

BS 5000-3:2006 Rotary Electrical Machines for Particular applications

(m)

EN 60898 1991 Moulded case and miniature circuit breakers

4.5.11

Environmental Conditions

1

Control and monitoring of environmental conditions to include but not limited to: (a)

Fire protection systems

(b)

CCTV monitoring of work areas

(c)

Electrical power

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(d)

Humidity

(e)

Dust monitoring

(f)

Inundation of the cutter head chamber

(g)

Ventilation air supply (including failure)

(h)

Gas detection system for oxygen deficiency, CO2, CO, H2S, NO2, SO2 and CH4. The data acquisition unit shall include provision for the monitoring of tunnel gas alarms throughout the tunnel to provide early warning to the TBM operator of potential gas danger

TUNNEL EXCAVATION WITH CONVENTIONAL MEANS

4.6.1

General

1

This Specification applies to all tunnel excavation Works using conventional mechanical means and the implementation of the tunnel’s primary support. All tunnel excavation Works shall be in accordance with Contractor’s design which has received a SONO.

4.6.2

Working Conditions

1

Safe and continuous access to all tunnels, as well as the required safety conditions shall be ensured throughout the execution of Works.

2

All lighting used by the Contractor shall ensure uniformly distributed lighting in all working areas.

3

Pumping, drainage and mud and water removal equipment shall be installed, operated and maintained, in order to ensure that all Permanent Works shall be constructed in dry conditions and shall be protected against water.

4.6.3

Working Interruptions

1

Upon any work stoppage the stability of all tunnel excavations and the safe condition of the tunnel (including regular inspections) shall be ensured.

4.6.4


1

An emergency power supply shall be available on site to provide power for all electrical installations, which are considered essential for the safety of the tunnel and the working personnel.

2

An emergency evacuation procedure shall be prepared which is also approved by local authorities.

4.6.5

Work Execution

1

Pre-excavation Works

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(a)

Prior to the commencement of the tunnel excavation Works, all necessary measures shall be taken to locate, fill and seal any voids from all investigation boreholes that may be encountered during excavation.

(b)

If required by the design and/or method statement, and prior to commencing any tunnel excavation works, ground improvement works shall be performed.

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Monitoring (a)

Prior to the commencement and throughout the tunnel excavation Works, as well as after their completion, it shall be ensured that all monitoring instruments that have been installed are fully functional, regularly calibrated and monitored.

(b)

The Engineer may instruct the stoppage of the works, when the instruments are not completely installed, or the Contract requirements are not fulfilled.

Geological mapping of the excavation surfaces (a)

Geological mapping of the excavation surfaces shall be performed upon completion of each heading/bench advance, except for where the immediate sealing of the excavation face using shotcrete is required.

(b)

The geological mapping shall be performed concurrently with the excavation. The tunnel’s faces shall be cleaned to the extent possible so as to enable collection of the necessary data for the complete geological mapping and the classification of the geomaterial at the tunnel face.

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Probe drillings

Investigation drillings through the tunnel face and/or through the ground surface for further investigation of ground and groundwater conditions and of possible weak zones, voids wells or any other disturbances shall be carried out.

(b)

The number, location and orientation of probe drillings shall be designed in a manner to collect the maximum possible amount of data, depending on the type and the inclination of strata, the presence of water, the geometry and the tunnel alignment. All drilling logs shall be made available to the Engineer.

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Emergency Conditions in the Tunnel When wells or other voids are encountered during excavation Works, the area shall immediately be protected against collapse, to ensure the safety of the Works and all persons.

(b)

Any damage to the Works or the structures, including local failure of the primary support, shall be reinstated immediately.

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Surveys (a)

The correct construction, orientation and shape of the tunnel, based on the design (such as, alignment data, structural tolerances, convergence tolerances) shall be verified. Measurements of excavated cross sections shall be performed.

(b)

The minimum thickness of the primary support shall always be greater than or equal to the relevant thickness in the design.

Tunnel Excavation Shift Reports (a)

A Shift Report for all underground excavations shall be maintained. This report shall include sufficient data for the full recording of the cycle of Works. The report shall be available to the Engineer at all times.

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PRECAST CONCRETE TUNNEL LINING SEGMENTS

4.7.1

General

1

This Specification concerns the supply of materials and equipment as well as execution of Work for the production and installation of precast concrete segments to be used as the lining of all TBM.

2

The segmental precast concrete lining shall consist of a number of precast segments to form rings.

3

Radial joints in adjacent rings shall be staggered so that there are no continuous joints. The circumferential joints between adjacent rings shall be continuous.

4

Tapered rings shall be used to negotiate horizontal and vertical curves and to correct for line and level.

5

All precast concrete lining segments shall have EPDM gaskets inserted into recesses provided in all four mating surfaces of the individual segments. The size and position of the gasket shall be sufficient to take account of all tolerances for the segments and gaskets. Where it is proposed to erect segmental lining without applying shield jacking forces to compress the gaskets it shall be demonstrated that the required watertightness of the segments joints shall still be achieved by adequately compressing the gaskets or by other acceptable means for the SONO from the Engineer.

4.7.2

Materials

1

Concrete

m Fly Ash intended for use for both the segments shall comply with EN 450.

Microsilica (a)

6

GGBFS intended for use for segments shall comply with EN 15167.

Fly Ash (a)

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The cement shall comply with the requirements of EN 197.

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The concrete shall be a minimum strength of class C40/50 as defined under EN 206.

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Microsilica intended for use for segments shall comply with EN 13263.

Aggregates (a)

Fine aggregates shall be natural or crushed rock sand in compliance with EN 12620.

(b)

Coarse aggregates shall not contain materials which may cause reduction of strength or durability of the concrete. Coarse aggregates shall be crushed aggregate from an approved natural source in compliance with EN 12620.

(c)

The potential alkali aggregate reactivity has to be determined and evaluated either by the relevant ASTM standards ASTM C289 and C1260 and ASTM C227.

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Water (a)

8

Water shall comply with the requirements of EN 1008. Additionally, to account for the high risk of chloride-induced reinforcement corrosion, the maximum allowable chloride content of the mixing water is 250 mg/l.

Admixtures (a)

Admixtures used in the concrete shall conform to EN 934, EN 480 and shall be mutually compatible. They shall be accompanied by full documentation from the manufacturer, which shall be submitted to the Engineer for a SONO. Use and dosage of admixtures shall be in accordance with the manufacturer’s recommendations.

Steel (a)

If reinforcement steel for segmental lining is used, it shall be new. The reinforcement shall consist of high ductility bars of B500C category or approved alternative reinforcement.

(b)

If steel fibre reinforcement is used for segmental lining it shall comply with EN 14889 2 and have a minimum tensile strength of 1100 N/mm .

(c)

Manufacturer’s production certificates shall be supplied.

(d)

Reinforcement bar welding shall be carried out by certified welders in accordance with Standard EN 17660, EN 15609-01, EN 15614-01 and EN 15614-12. The welding quality shall be certified through EN 287-01/A2.

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Specifications for all temporary and permanent fasteners and cast-in fixings shall be provided. All permanent inserts shall be stainless steel.

Segment identification

The following information shall be cast in to the internal (concave) surface of all segments or shall be incorporated on a bar code fixed permanently to the inside face of the segment:

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Fasteners, fixings and fittings screws and bits

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QR – followed by the Contract Number

(ii)

Date of production

(iii)

Mould number

(iv)

Ring type e.g. left hand taper or right hand taper

(v)

Segment type

(vi)

The Contractor shall number the concrete rings in sequential order between the stations, clearly stencilled in clear large durable black numbers on completion of each tunnelled drive.

Tests and Checks during Construction (a)

The concrete mixture shall be regularly checked for conformity with the laboratory concrete mix design. The total water-cement ratio shall be in the range prescribed in the laboratory concrete mix design.

(b)

In addition, chloride penetration tests shall be performed according to NT Build 492. The tests reports shall be available to the Engineer at all times.

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(c)

The compressive strength test shall be performed in accordance to EN 45001 and all other tests with EN 206.

Tests on the Production Line Prior to the beginning of the full-scale production of lining rings, three trial rings shall be built and assembled to check that the required tolerances have been met.

(b)

At least 1 in every 20 segments produced from each mould shall be checked for compliance with the casting tolerances. Checks shall continue throughout the production period and shall be performed on segments selected at random by the Engineer for the control of the production of segments to the required tolerances.

(c)

All segments shall be systematically checked for surface defects and repaired if required.

(d)

Dimensional control of segments shall be made on a daily basis to meet the tolerance ranges. The internal diameter of the completed ring, during tunnel lining construction, will be checked on Site.

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Repair of Segments (a)

A special methodology for the repair of defective segments, addressing all types of repairs shall be provided. The repairs shall include all the methods related to the surface preparation, the work sequence, the appropriate repair materials (depending on the type of defect), the equipment to be used, and the checks to be carried out at each phase of repairing. This methodology shall be submitted to the Engineer for a SONO.

(b)

With reference to the repair of segments, two cases of repair are distinguished. The first case relates to the repair of segments located either in the production plant, or the construction Site area before their final placement in the tunnel. The second case relates to segments that have already been incorporated in a ring within the tunnel. A methodology statement for each of these cases shall be prepared for a SONO from the Engineer.

(c)

Categories of segment defects are defined as minor, medium and major.

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Minor defects on the segments are defined as a broken edge smaller than 25 mm and/or holes due to air bubbles between 5 and 8 mm in diameter. Defects of this category may be repaired.

(ii)

Medium defects on the segments are defined by a crack with width less than 0.1 mm or depth less than 20 mm and/or a surface depression with depth less than 20 mm. Where a medium defect occurs prior to the final placement of the relevant segment in the tunnel it shall be rejected.

(iii)

Major defects on the segments are defined by a crack with width more than 0.1 mm or depth more than 20 mm and/or a surface depression with depth more than 20 mm and / or a broken edge larger than 25 mm. Where a major defect occurs prior to the final placement of the relevant segment in the tunnel it shall be rejected.

Tolerances of Segmentally Lined Tunnels (a)

Tunnels supported with segmental concrete lining, as part of the Permanent Works, shall conform to each of the following tolerances by reference to the axis:


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Segment width: +/- 0.5mm;

(ii)

Segment thickness: +/- 3.0mm;

(iii)

Segment arc length: +/- 0.6mm;

(iv)

Inner radius of a single segment: +/- 1.5mm;

(v)

Deviation of the ‘AS BUILT’ diameter of the inner face of the segments: 1.0mm and from a perfect circle: 5.0 mm;

(vi)

Width of segment grooves: +0.2 mm – 0 mm;

(vii)

Depth of segment grooves: +0.2 mm – 0mm;

(viii)

Axis of segment grooves: +/-1.0 mm;

(ix)

Longitudinal joint evenness: +/- 0.5 mm;

(x)

Ring joint evenness: +/- 0.5 mm;

(xi)

Unevenness of joints causing stress on the section: not permitted;

(xii)

Outer diameter of the constructed ring: +/- 10 mm;

(xiii)

Inner diameter of the constructed ring: +/- 10 mm;

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(xv)

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(xiv) Outer perimeter of the constructed ring: +/- 30 mm; Torsional angle in the longitudinal joint: + 0.04°; and

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(xvi) Angle of longitudinal joint conicity: + 0.01°.

GROUTING FOR SEGMENTAL LINING, CONTACT GROUTING AND FILLING OF VOIDS

4.8.1

General

1

This specification concerns the provision of labour, materials, installations and equipment for filling all voids, including karst voids.

2

This specification applies to tunnels excavated either by TBM or by conventional methods.

3

All voids between the excavation profile and outer limit of the theoretical temporary lining (in sprayed concrete lining (SCL) tunnels) or the segmental lining (in tunnel boring machine (TBM) tunnels) shall be filled with cement grout.

4

Any other voids encountered ahead of the tunnel excavation face shall be filled with cement grout, if their presence prevents or otherwise obstructs the advancement of the excavation face.

5

Grouting for filling karstic voids may require primary and secondary grouting. Primary grouting is the initial grouting which is applied immediately after a unit of lining has been built. Where primary grouting does not completely fill all voids, secondary grouting shall be carried out.

6

Grout shall remain effective for the design life of the tunnel. The grout shall not degrade, shrink or lose strength to an extent that the tunnel would be damaged or become unserviceable as a result.

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END OF PART

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Section 29: Railways Part 05: Cut and Cover Structures

Page 1

5

CUT AND COVER STRUCTURES SPECIFICATIONS ................................. 2

5.1

GENERAL PRINCIPLES ............................................................................... 2

5.1.1

General

5.2

TEMPORARY WORKS .................................................................................. 2

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8

General Principles Design of Temporary Excavation Support Excavation Base Stability Ground Movements Construction Dewatering Dewatering and Groundwater Control Systems Design Methodology Analysis Methodology

5.3

GROUNDWATER MANAGEMENT ............................................................... 5

5.3.1 5.3.2

Minimum Requirements Execution

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5

CUT AND COVER STRUCTURES SPECIFICATIONS

5.1

GENERAL PRINCIPLES

5.1.1

General

1

Cut and cover structures shall be designed in accordance with the following standards: EN1990 Basis of structural design

(b)

EN1991 Actions on structures

(c)

EN1992 Design of concrete structures

(d)

EN1993 Design of Steel Structures

(e)

EN1997 Geotechnical design

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TEMPORARY WORKS

5.2.1

General Principles

1

In general Temporary Works shall be designed in accordance with the same design standards as the Permanent Works. However, the Temporary Works design may take into account the limited duration over which such temporary works are expected to function. The calculations and drawings shall make clear where provision for limited duration has been allowed for, particularly where this may have a substantial influence on the stability of the Temporary Works.

2

The design of Temporary Works shall take account of all the applied external forces and imposed structural deformations and, where applicable, the effects of the removal of load from the ground.

5.2.2

Design of Temporary Excavation Support

1

Excavations for cut-and-cover structures in soft ground or rock shall be supported by suitable retaining structures. Design of these elements shall include full step-by-step analyses of the progressive change in the loading and required temporary support conditions as the excavation proceeds.

2

Braced or anchored excavations shall be analysed by finite element or similar methods, in which the changes in ground stresses are properly related to the deflections which occur in the structural elements, by the use of appropriate stiffness and other parameters. Simplified analytical models and methods shall be employed to calibrate and support the finite element analyses of the various permutations of structure geometry and loading.

3

Temporary Works shall be designed as far as possible to be removed when no longer required, and shall not be left in the ground. Temporary Works which are viewed as being impossible to remove on completion of the Permanent Works shall be dismantled to a minimum depth of 2 metres below the finished ground surface and designed so that there will be no risk of ground settlement or other deleterious effects as a consequence of decay and/or collapse of these Temporary Works.

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Excavation Base Stability

1

The design shall include adequate precautions against any failure of his excavations during construction. The stability of the excavation bases shall be checked in accordance with a method of analysis acceptable to the Engineer, which shall allow for all reasonable loads within and outside of the excavation.

2

The design shall include calculations demonstrating the contribution made to the base stability of the excavation by his proposed method of construction and shall state the factor(s) of safety used in the design. The factor(s) of safety shall relate to the method of construction and to the particular location of the Works, and shall be submitted to the Engineer for a SONO.

5.2.4

Ground Movements

1

The Temporary and Permanent Works designs shall limit ground movement and distortions around the Site to avoid damage to adjacent existing building structures.

2

The Contractor shall carry out a risk assessment for all existing building structures within the zone of influence of the Works. The analyses for the Temporary Works shall be properly related to the conclusions of this risk assessment.

5.2.5

Construction Dewatering

1

Temporary dewatering of construction excavations will be required to provide an undisturbed, stable and dry subgrade to permit construction and backfilling of the Permanent Works under dry conditions.

2

The Contractor shall prepare and submit the design of his construction dewatering system to the Engineer for a SONO. The construction dewatering design shall include determination of subsurface conditions and geotechnical design parameters, analyses to establish feasible methods and system definition in sufficient detail to demonstrate that the general objectives can be achieved without adverse effect on adjacent existing building structures. The selected system shall generally provide for continuous (24-hour-per-day) operation, adequate reserve equipment, and standby power.

3

In general, the groundwater within the excavations shall be maintained at a level that permits achievement of the above and avoids any failure of the excavation.

4

The Contractor shall ensure that the groundwater level inside the excavation pit is at least 1000 mm below the current excavation level at any time during the relevant construction stages.

5

The effects of settlements, distortion or loss of ground due to dewatering shall be considered in the design. For adjacent existing building structures these effects shall be considered in the assessment of impact on these existing building structures.

5.2.6

Dewatering and Groundwater Control Systems

1

Description

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5.2.3

(a)

This specification refers to the design of dewatering, pressure relief systems and of seepage cut offs for all open deep excavations as well as tunnel excavations for the Project.

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(b)

According to the local groundwater conditions, the Contractor shall design, install and monitor a dewatering system or other groundwater control systems.

(c)

The design of these systems shall consider at a minimum:

(ii)

The stratification and permeability characteristics of the geomaterials below the groundwater table into which the excavation extends or which are underneath the excavation;

(iii)

The location and the geometrical characteristics of the excavation;

(iv)

The type of the excavation (i.e. open-cut or tunnel); and

(v)

The existence of nearby structures and especially their current serviceability conditions and foundation systems.

.

The in-situ groundwater conditions and the related types of seepage flow;

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The design of dewatering or water control systems, shall propose measures for controlling the risk of damage that may occur to the excavations, in the event of failure of the dewatering system or other water control systems during the construction period.

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(d)

(i)

Design Methodology

1

The Contractor shall submit to the Engineer for a SONO, the design of dewatering or other water control systems.

2

The design shall include but not be limited the following:

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5.2.7

A brief description of anticipated geological - geotechnical conditions. The geotechnical design models to be adopted shall be compatible with the GIRs;

(b)

The groundwater or piezometric pressure characteristics, which shall include but not be limited to the groundwater and artesian pressure levels, the elevation of the groundwater table and its variation with changes in seasonal effects, pumping from other nearby wells;

(c)

The permeability of the geomaterials which shall be determined by field and laboratory tests;

(d)

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(a)

(e)

Consideration of nearby construction activities of the Contractor and of third parties;

(f)

A detailed description of the necessary monitoring and instrumentation program;

(g)

Calculations, which shall fully account for any variability in geotechnical parameters and groundwater conditions;

(h)

Construction drawings; and

(i)

All other technical information required for safe construction works.

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The availability, reliability and capacity of the power system at the site;

5.2.8

Analysis Methodology

1

The analysis of dewatering or other groundwater control systems shall consider the following as a minimum: (a)

Sources of seepage;

QCS 2014


Page 5

(b)

Boundaries of seepage flow due to the characteristics of the ground formations within and surrounding the Works;

(c)

The number, size, spacing and depth of wells; and

(d)

The rate at which the groundwater must be extracted, in order to achieve the required groundwater levels or pressure relief.

Settlement calculations due to groundwater lowering shall be provided by the Contractor for all structures inside the influence zone of the drawdown curve. The settlement values resulting from these calculations shall be added to those for the excavations, the total of which shall meet the requirements of the Design Specification.

3

Design requirements for dewatering or other groundwater control systems operation and performance control. Monitoring and Instrumentation.

4

The Contractor shall provide in its design the description of a pumping test to be performed immediately before the installation of the dewatering or other groundwater control system.

5.3

GROUNDWATER MANAGEMENT

5.3.1

Minimum Requirements

1

This section includes the control of groundwater during execution of the Works.

2

Where required the Contractor shall design, provide, install, maintain, operate and remove a complete temporary dewatering system for lowering and controlling groundwater levels and hydrostatic pressures to permit excavation, construction and backfilling to be performed in dry conditions.

3

Before commencing dewatering, the Contractor shall submit the method statement, including installation details of the dewatering system including testing to the Engineer for his SONO.

4

The Contractor shall install a pumping system that is available for use at all times and which shall be connected to the dewatering system to allow immediate use.

5

The Contractor shall obtain all necessary permits from the appropriate authorities independently and at his own expense. This also includes compliance with all requirements given by the authorities including but not limited to discharge.

6

The control of groundwater shall be such that softening of the bottom of excavations does not occur.

7

The dewatering system shall be designed and operated so as to prevent removal of the natural soils.

8

The dewatering system shall maintain the groundwater level at 1000 mm below the excavation level.

9

The Contractor shall implement a dewatering system that shall have the necessary capacity and backup.

10

The dewatering system shall be able to dewater and dispose of water without causing damage to public or private property and without causing a nuisance or danger.

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The dewatering system shall be designed, installed and operated so that the groundwater level outside the pit is not reduced to an extent which would cause damage to or endanger adjacent structures or buildings.

12

The Contractor shall supply, install and monitor observation wells/piezometers to monitor and observe the groundwater level outside the pit. For location and length of the wells/piezometers the Contractor shall consider the requirements given in the geotechnical report.

13

The Contractor shall keep the Site free from flood water.

5.3.2

Execution

1

The dewatering system shall only be decommissioned after obtaining a SONO from the Engineer.

2

Records shall be maintained containing elevation readings and groundwater water levels in the observation wells and piezometers.

3

Observation wells and piezometers that become inactive, damaged or destroyed, shall be repaired or replaced within 24 hours.

4

Observation wells/piezometers shall be removed and/or backfilled when no longer required.

5

Sumps and settling basins shall be backfilled with suitable materials when no longer required.

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END OF PART

QCS 2014

Section 29: Railways Part 06: Earthworks and Roadworks

Page 1

6

EARTHWORKS AND ROADWORKS SPECIFICATION ............................... 2

6.1

GENERAL PRINCIPLES ............................................................................... 2

6.1.1

General

6.2

EMBANKMENTS ........................................................................................... 3

6.2.1 6.2.2 6.2.3

Foundations Slope Stability and Erosion Control Cuts

6.3

EXECUTION .................................................................................................. 4

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5

General Excavations Excavation for Structures Backfill Compaction

6.4

EARTHWORKS FOR EMBANKMENT CONSTRUCTION (INCLUDING SUB BASE OR PROTECTION LAYERS) ................................ 5

6.4.1 6.4.2 6.4.3 6.4.4

Excavations for Embankment Foundation Construction equipment Compaction of the base of the embankment Compaction of the embankment

6.5

ROADWORKS ............................................................................................... 8

6.5.1 6.5.2

General Execution

6.6

GROUND IMPROVEMENT ........................................................................... 8

6.6.1

General

6.7

EARTHING AND BONDING .......................................................................... 8

6.7.1

General

2

4 4 5 5 5

5 7 7 7 8 8 8

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6

EARTHWORKS AND ROADWORKS SPECIFICATION

6.1

GENERAL PRINCIPLES

6.1.1

General

1

This chapter is applicable for the design of earthworks bearing the railway track, either with sloping side slopes or with vertical slopes supported by retaining walls, and shallow cuts for the foundation of bridges. Deep cuts for the construction of cut-and-cover structures and various types of tunnels are covered in other sections of this specification.

2

Earthworks Construction Specifications All project related earthworks shall be according to QCS - Section 12 and EN 1997.

Method Statement

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Type of the excavation;

(ii)

Sequence of excavation and placing of material;

(iii)

Methods of ground water handling within and outside of the excavations and disposal of groundwater; and

(iv)

Methods of testing, monitoring and reporting on the performance of the earthworks.

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(i)

The Contractor’s method statement shall include the construction objectives (target compaction, density, moisture content, lift thickness, etc.) and the methods (procedures, tests, frequency etc.) used for ensuring that the target objectives are achieved. This document shall also specify the corrective measures to be taken if the target objectives are not achieved.

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(b)

The Contractor shall submit a method statement giving full details of proposed materials, plant and operations involved in the construction of earthworks to the Engineer for a SONO. It shall include but not be limited to

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(a)

Reinforced earth embankments shall not be used to support railway tracks.

5

Embankments and similar structures shall be designed in accordance with the following standards:

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(a)

EN1990 Basis of structural design;

(b)

EN1991 Actions on structures;

(c)

EN1997 Geotechnical design; and

(d)

UIC 719R Earthworks and Track-bed layers for Railway Lines.

Issues not covered in sufficient detail by the above standards shall be designed according to the relevant British Standards (BS): (a)

BS 6031 : Code of Practice for Earthworks;

(b)

BS 1337 : Methods of Test of Soils for Civil Engineering Purposes; and

(c)

UIC Standards.

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Protection of the slope surfaces from storm-water erosion shall be provided at Temporary and Permanent Works.

6.2

EMBANKMENTS

6.2.1

Foundations

1

The embankments’ foundation conditions shall be assessed on the basis of the shear strength and deformability characteristics of the local subsoil conditions, and design considerations shall be made for the embankments’ construction materials

2

Design considerations related to foundation drainage and / or groundwater lowering shall be determined on the basis of the evaluated long-term groundwater conditions.

3

The design of the embankments’ foundations shall include but not be limited to:

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Short – term and long-term settlement estimation;

(b)

Measures to accelerate settlement;

(c)

Ground improvement techniques;

(d)

Liquefaction checks of potential subsurface fully saturated loose granular soils.

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(a)

Slope Stability and Erosion Control

1

The design of embankments shall include, but not be limited to, the following:

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6.2.2

Ultimate width of top of embankment;

(b)

Loading on top of embankment;

(c)

Geotechnical properties of the foundation and fill materials;

(d)

Restrictions on width of land available; and

(e)

Special conditions to which the embankment would be subject to. This includes for example, tidal waters, active mining operation and natural cavities, and environmental and other economic factors which may influence the final choice of cross section.

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(a)

The inclination of the slopes of embankments shall be adequate to ensure safety against slope stability failure, long-term deformations and erosion.

3

The proposed anti-erosion protection measures shall consider but not be limited to:

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(a)

Planting;

(b)

Installation of geosynthetics (e.g. geocells, geogrids) with hydroseeding, etc.

4

If the embankment is founded on relatively impermeable materials and the groundwater table is high, both undrained and drained conditions shall be checked in the slope stability analyses.

5

Both local and global stability shall be checked. Local stability checks the embankment slope while global stability also considers potential failure surfaces passing through the foundation soils.

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6

Adequate drainage shall be provided at the gutters of the top of the embankment to prevent uncontrolled flow of rain-water towards the slopes of the embankment and thus invigorating surface erosion processes.

6.2.3

Cuts

1

The inclination of the cut slopes shall be adequate to ensure safety against slope stability failure both in the short – term and long – term, as well as control of ground deformation, Cut stability checks shall include but not be limited to:

(i)

Long – term static conditions, assuming the worst case groundwater conditions

(ii)

Long – term earthquake conditions

Temporary Cuts

Short – term static conditions, assuming the corresponding groundwater conditions

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(i)

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(b)

Permanent Cuts

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In case of rock cut slopes where stability is controlled by the existence of unfavourably oriented discontinuities, the frequent mapping of the exposed surfaces is necessary. Possible modifications in the cut slopes design shall be considered (if necessary) on the basis of the evaluation of the mapping results.

6.3

EXECUTION

6.3.1

General

1

The Contractor shall carry out all earthworks in such a manner as to prevent erosion or slips and shall limit working faces to safe slopes and heights. The Contractor shall ensure that all surfaces have at all times sufficient gradients to enable them to shed water without causing erosion.

2

The Contractor shall provide all necessary equipment to keep the earthworks free from water.

3

Construction traffic on the final formation level shall be minimized to prevent damage and/or softening of the subgrade.

4

Surfaces of excavations or filling shall be protected against erosion and climatic influences.

5

Surfaces of excavations or filling, on which plain (unreinforced) or reinforced concrete will be formed, shall be prepared with a layer of lean concrete or in such other manner to provide a suitable surface.

6.3.2

Excavations

1

Demolition materials shall not be used for backfilling.

2

The final level of all excavations shall be free from mud and water, trimmed clean, thoroughly compacted and consolidated.

3

Trench excavation shall be executed by the use of suitable equipment, in such a manner so as to minimise disturbance to the required finished sides and bottom of the excavation.

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Excavation for Structures

1

This work shall consist of all excavation for structures, culverts, headwalls, catch basins, manholes, inlets, and retaining walls and shall include all necessary clearing and grubbing, all necessary bailing, drainage, pumping, sheeting, strutting and the construction of coffer dams or cribs, also the disposal of all material obtained from such excavation and backfilling; it shall include the removal of that portion of existing structures below the ground which is necessitated by the construction of the new structure.

2

Any loose or improperly compacted soil below the structural foundation levels, shall be completely removed, and the void backfilled with suitable material as determined by BS 1377. Any previous excavations shall be excavated and backfilled.

3

All rock or other hard foundation material shall be cleaned of all loose material and cut to a firm surface, either level, stepped, or serrated. All open cracks and discontinuities shall be cleaned and grouted. All loose rock shall be removed.

6.3.4

Backfill

1

Top soil shall not be used for structural backfill.

2

When the weather conditions would adversely affect the placing of backfill, all such work shall be stopped.

6.3.5

Compaction

1

Backfilling around structures shall be made by selected filling material as per EN 1997, thoroughly compacted in layers.

2

Except in the vicinity of structures, excavations shall be backfilled with suitable material, compacted in layers of 300 mm maximum loose thickness to achieve a density of at least 95% of the maximum dry density.

3

Field density shall be carried out by in-situ tests in accordance with EN 1997-2.

6.4

EARTHWORKS FOR EMBANKMENT CONSTRUCTION (INCLUDING SUB BASE OR PROTECTION LAYERS)

6.4.1

Excavations for Embankment Foundation

1

Required excavation for the foundation of embankments shall include:

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6.3.3

(a)

Materials classified as A-7 or A-6 according to AASHTO Specifications;

(b)

Unstable materials incapable of being compacted to the specified density at optimum moisture content using ordinary compaction methods for the equipment being used for compaction. Such materials may include, but not be limited to, organic and highly compressible soil;

(c)

Material too wet to be compacted and prevented from drying in place prior to incorporation into the Works. Such materials may include mud from tide flats and coastal marshes; and

(d)

Materials which are otherwise unsuitable for use in or under the embankment.

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2

Where embankments are constructed across wadis, marshlands, tidal flats, or wet ground, which is soft and compressible and will not support the weight and forces of hauling and compacting equipment, the lower part of the embankment may be constructed by placing successive loads in a uniformly distributed layer (bridging lift) of a thickness not greater than necessary to support hauling equipment, and the placing and compacting of subsequent layers. Such supporting layers shall not be subjected to the compaction requirements specified in the below sections. The remainder of the embankment shall be constructed in layers as specified in this specification.

3

Suitable embankment materials shall meet the following requirements: Materials classified as A-5 or better according to AASHTO Specifications; and

(b)

In areas subject to flood and prolonged inundation of the embankment, the material used in the embankment shall be either rockfill or earth materials classified as A-1-a, A-1-b or A-2-4 according to AASHTO Specifications. The same types of material shall be used for the reinforced embankment and reinforced earth structures.

(c)

Unsuitable rockfill materials include water-soluble rocks, or other types of rocks, which can be either easily disintegrated after their exposure to local weather conditions, or crushed during compaction.

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Suitable non-compacted rockfill materials shall meet the following requirements: Low strength rocks: Microdeval Index (resistance to wear) with the presence of water MDE>40; Los Angeles index (resistance to fragmentation) LA>40;

(b)

Medium strength rocks: Microdeval Index (resistance to wear) with the presence of water 25
(c)

High strength rocks: Microdeval Index (resistance to wear) with the presence of water MDE≤25; Los Angeles index (resistance to fragmentation) LA≤30;

(d)

The percent passing by weight from the sieve of 22.4mm shall be less than 25% and the percent passing by weight from the sieve ISO 565 of 0.063 mm shall be less than 7%;

(e)

The maximum size of the used rock particles (D) shall not exceed 50% of the thickness of the compacted layer. No rock particles having D>500mm shall be used as rockfill materials;

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(a)

(f)

The granulometric curve of the rockfill materials shall meet the requirements of the following Table: Table 6.1 Requirements for rockfill material

Particle size (Sieve opening)

Percent passing by weight (%)

D

90 – 100

D/4

45 – 60

D/16

25 – 45

D/64

15 -35

Where D is the maximum size of the rockfill particles

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Page 7

For reinforcing materials, in reinforced embankments, their quality certificates together with their long term tensile strength and durability shall be provided to the Engineer for SONO. An appropriate certificate shall be submitted proving that the materials are not affected by biological and chemical actions as well as UV radiation. In case of steel reinforcement, all necessary certificates assuring its long term anti-corrosion and durability performance shall be provided to the Engineer for a SONO.

6.4.2

Construction equipment

1

The Contractor shall provide all types, sizes and numbers of equipment which are necessary for loading, hauling, spreading, mixing, watering, compacting and finishing material to form the embankment in accordance with his plans and specifications.

2

Compacting operations shall include adequate blading with motor graders to insure uniformity of the layers of embankments being compacted. The number of blades and rollers in use shall be sufficient to blade and compact adequately all materials being delivered to the embankment.

3

When construction of rock embankment is required, the Contractor shall propose details of the plant and equipment to be used, and include these details in the method statement.

4

The Contractor shall propose the speed of compression rollers and number of passes etc.

6.4.3

Compaction of the base of the embankment

1

When the embankment height is less than 600 mm and the original sub-ground consists of suitable material, the original ground shall be scarified to a depth of 200 mm, watered or dried to obtain uniform moisture content and compacted to 95% of maximum Modified Proctor Density (or equivalent relative density values). If the top 300 mm of original ground does not meet the suitability requirements or there is excessive moisture present, the top 300 mm shall be removed and replaced with material meeting these requirements. This material shall be compacted to 95% of maximum Modified Proctor Density (or equivalent relative density values).

2

When the embankment height exceeds 600 mm, any unsuitable material below the embankment footprint shall be removed up to the necessary depth, until suitable material shall be found. This depth shall not exceed the final embankment height, if no ground improvement techniques are used. After removal of any unsuitable material, the foundation base shall be scarified to a depth of 200 mm, watered or dried to obtain uniform moisture content and compacted to 95% of maximum Proctor Density (or equivalent relative density values).

6.4.4

Compaction of the embankment

1

The Contractor’s method statement for the embankment construction methodology shall include construction method, material types to be used, layer thickness, compaction equipment, compaction objectives, minimum number of roller passes, wetting methodology, compaction control procedures, type and frequency of tests to be performed as well as characteristics required for ensuring compaction sufficiency.

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Prior to the commencement of any embankment construction work, a test embankment shall be constructed using the same materials as those to be used for actual embankment construction. The objective of the test embankment shall be to validate that the construction methodology proposed by the Contractor in his method statement meets the Employer’s Requirements.

6.5

ROADWORKS

6.5.1

General

1

Only materials which achieve the requirements given in the QCS shall be used.

6.5.2

Execution

1

All related roadworks shall be executed in accordance to the QCS.

6.6

GROUND IMPROVEMENT

6.6.1

General

1

Ground improvement may be required:

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In underground works in order to improve stability of the excavation faces and/or walls, reduce ground subsidence due to excavations and its potential adverse effects on surface structures and utilities, reduce the ingress of groundwater in the tunnel, improve the foundation soil of buildings and generally any other related to excavation operations for the needs of the Project;

(b)

In surface works (embankments and elevated railways) in order to found embankments on weak soils and to alleviate the liquefaction potential; and

(c)

Around pile foundations to improve against liquefaction and/or improve lateral capacity of pile foundations.

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(a)

Based on the provisions herein, a detailed specification and method statement shall be submitted for any ground improvement Works to the Engineer for a SONO.

3

Ground improvement Works may include, but are not limited to:

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(a)

permeation and compaction grouting;

(b)

soil stabilization injections of all kinds (cement grout, chemicals etc.);

(c)

jet grouting;

(d)

compensation grouting;

(e)

lime or cement improvement of embankment foundations; and/or

(f)

dynamic compaction, vibro-compaction foundations or around pile foundations.

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vibro-replacement

of

embankment

6.7

EARTHING AND BONDING

6.7.1

General

1

This Section includes the materials and workmanship for the earthing and bonding system.

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2

All earthing and bonding shall be in accordance with EN 50122.

3

The earthing and bonding system shall ensure that continuous operation of the rail way is not jeopardised by lightning strikes.

4

All technical rooms shall be equipped with an earth circuit connector.

5

The earthing system shall include but not be limited to: outdoor lighting;

(b)

pipe systems for heater, gas, water, fire fighting water, sewage water, cooling shafts, etc.;

(c)

escalators, elevators;

(d)

railway earthing;

(e)

cathodic anti-corrosion protection.

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END OF PART

QCS 2014

Section 29: Railways Part 07: Concrete Structures

Page 1

CONCRETE STRUCTURES ......................................................................... 3

7.1

BRIDGE SPECIFICATION ............................................................................. 3

7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 7.1.11 7.1.12

General Principles Design Principles Deck displacements Vibration Fatigue Collision load on piers or decks Temporary Works Foundations Turnout on Elevated Sections Safety Railing Privacy Screening Noise Barriers

7.2

BUILDING DESIGN STRUCTURAL SPECIFICATION .................................. 6

7.2.1 7.2.2 7.2.3

General Principles Design Principles Civil and structural design statement

7.3

STRUCTURAL CONCRETE .......................................................................... 8

7.3.1


7.4

PRESTRESSED CONCRETE ....................................................................... 9

7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.4.8 7.4.9

General Requirements Materials Handling and Storage Surface condition Straightness Post-tensioning Pre-stressing Tendons Grouting of Pre-stressing Tendons Preparation for Casting

7.5

SHOTCRETE ............................................................................................... 11

7.5.1 7.5.2 7.5.3 7.5.4

General Mix Reports Production Quality control

7.6

FORMWORK ............................................................................................... 13

7.6.1 7.6.2 7.6.3

General Requirements Formed finishes Unformed finishes

7.7

WATERPROOFING ..................................................................................... 13

7.7.1 7.7.2 7.7.3

General Waterproofing classes Waterproofing for Cast in Situ Concrete Tunnel Linings

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3 3 5 5 5 5 5 5 5 6 6 6 6 7 7 8 9 10 10 10 10 10 10 11 11 11 11 12 12 13 13 13 13 14 14

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Waterproofing for Precast Concrete Segmental Tunnel Linings Waterproofing for Cut and Cover Structures and Open Troughs

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15 15

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CONCRETE STRUCTURES

7.1

BRIDGE SPECIFICATION

7.1.1

General Principles

1

This section shall be applied for the structural design of temporary and permanent structures of all kind of bridges related to the project, including all bridge substructures such as piers and their foundations, abutments, culverts etc.

2

Bridges and other similar structures shall be designed in accordance with the following standards:

.

7


(b)


(c)

EN 1992 Design of concrete structures;

(d)

EN 1993 Design of steel structures;

(e)

EN 1994 Design of composite steel and concrete structures;

(f)

EN 1997 Geotechnical design;

(g)

EN 1998 Design of structures for earthquake resistance; and

(h)

EN 1337 Structural bearings.

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(a)

Design Principles

1

The design of bridges and their foundations shall include, but not be limited to, the following:

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7.1.2

The selection of the structural system for the bridge structure, the piers and foundations;

(b)

Aesthetics;

Clearances;

Evacuation and emergency access;

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(d)

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(c)

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(a)

(e)

Accidental impact from roads;

(f)

Footbridges-environment within e.g. temperature control, lighting, appearance;

(g)

Method of bridge construction, including Temporary Works and construction sequence;

(h)

Ground/structure interaction, including the effects of Temporary Works;

(i)

Dynamic, seismic loads and displacements;

(j)

Deflection and rotation of bridge structures;

(k)

Ground pressure (including swelling), shear force and bending distribution on structural members during construction and in the long-term;

(l)

Short and long-term ground and groundwater response;

(m)

Other changes in static loads such as excavation, surcharge, live loads, traffic loadings and others;

QCS 2014


Page 4

The variation in ground conditions along the alignment;

(o)

All dewatering and groundwater cut-off systems required to maintain dry and stable conditions within all excavations required for these Works;

(p)

The magnitude of ground and existing building structures settlements, movements, distortions and changes in loading conditions of existing building structures expected as a result of the Works and how these shall be mitigated;

(q)

The presence of existing building structures;

(r)

Maintenance of traffic flows along roads including access to adjoining properties and roads;

(s)

Control of heave, swell, piping and instability of the excavations related to the Works (e.g. excavations required for bridge foundations);

(t)

The effects of vibration so as to minimise disturbance to existing building structures; and

(u)

Effects caused by creep and shrinkage of concrete and the resulting effects (including secondary effects). These effects shall be regarded as permanent loads.

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(n)

Vertical clearance to roads shall be in accordance with the relevant local regulations; the minimum vertical clearance to existing and planned roads shall be 6.50 m.

3

Decks end rotations

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2

Vertical end rotation angle of the decks caused by live load, temperature gradient, creep and shrinkage shall be limited to Ɵ = 0.002 rad at abutments and Ɵ 1 + Ɵ 2 = 0.003 rad between two consecutive decks, refer to figure 7.1.

(b)

Horizontal end rotation of the decks caused by impact, wind, centrifugal force (if any), hunting force, and effect of transverse temperature gradient across the deck shall be limited to 0.0035 rad. Horizontal deformation includes the deformation of bridge deck and substructure, refer to figure 7.1. Figure 7.1 Vertical end rotation angle of the decks

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(a)

Figure 7.2 Horizontal end rotation angle of the decks EQUAL OR SMALLER 3.5/1000

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Page 5

Deck displacements

1

Cyclic movements between adjacent span ends (or expansion joints) shall be limited to ± 3 mm vertically and ± 2 mm horizontally at the running rail centre line;

2

Under braking and traction forces the relative displacement of the individual bridge deck under normal (non-seismic) conditions shall not be more than 5 mm in longitudinal direction. This requirement can be eased if a detailed rail structure interaction calculation demonstrate that the allowable rail stress is within the limits given in UIC 774-3;

3

Under seismic actions the deck shall be designed to satisfy the fundamental requirements of EN 1998, including no-collapse and damage minimisation requirements; and

4

Under seismic actions (including temperature creep and shrinkage effects) the gap between adjacent decks shall be wide enough to prevent contact of adjacent decks.

7.1.4

Vibration

1

The limits of vertical and horizontal vibration shall be as stated in EN 1991.

7.1.5

Fatigue

1

Fatigue calculations shall be in accordance with the requirements of EN 1991.

7.1.6

Collision load on piers or decks

1

Vehicular collision against the pier shall be considered as per EN 1991.

2

Vehicular collision against the deck shall be considered as per EN 1991.

7.1.7

Temporary Works

1

In general, Temporary Works shall be designed in accordance with the same design standards as the Permanent Works. However, the Temporary Works design may take into account the limited time they are expected to function. The calculations and drawings shall make clear where provision for limited duration has been allowed for, particularly where this may have a substantial influence on the stability of the Temporary Works.

2

The design of Temporary Works shall take into account of all the applied external forces and imposed structural deformations.

7.1.8

Foundations

1

The top of the foundation surface or pile cap shall be kept at least 1.0 m below the road or ground level.

7.1.9

Turnout on Elevated Sections

1

Turnouts shall not be placed over expansion joints between adjacent decks of the viaduct. The following minimum distances shall be kept:

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7.1.3

(a)

Expansion joint to begin of turnout (BT) 2.0 m; and

(b)

End of turnout (ET) to expansion joint 0.6 m.

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Page 6

Figure 7.3

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Turnout

Safety Railing

1

Safety railing shall be provided at all locations where the level difference is more than 1.0 m, unless specified in other regulations.

2

Safety railing shall have a minimum height of 1.10 m above finish floor level.

7.1.11

Privacy Screening

1

Privacy screening shall be provided at certain locations. The Contractor shall coordinate the needs for privacy screening with the relevant authorities.

7.1.12

Noise Barriers

1

Noise barriers shall be provided at certain locations. The Contractor shall coordinate the needs for noise barriers with the relevant authorities.

7.2

BUILDING DESIGN STRUCTURAL SPECIFICATION

7.2.1

General Principles

1

This section shall be applied for the structural design of temporary and permanent structures of all kind of buildings related to the project, which are not already covered under sections above.

2

The design shall be in accordance with:

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7.1.10

(a)

Qatar General Organization for Standards and Metrology

(b)


(c)


(d)

EN 1992 Design of concrete structures;

(e)

EN 1993 Design of steel structures;

(f)

EN 1994 Design of composite steel and concrete structures;

(g)

EN 1997 Geotechnical design; and

(h)

EN 1998 Design of structures for earthquake resistance.

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Page 7

7.2.2

Design Principles

1

The design of buildings and their foundations shall include, but not be limited to, the following: The selection of the structural system;

(b)

Aesthetics;

(c)

Clearances;

(d)

Evacuation and emergency access;

(e)

Method of building construction, including Temporary Works and construction sequence;

(f)

Ground/structure interaction, including the effects of Temporary Works;

(g)

Dynamic, seismic loads and displacements;

(h)

Ground pressure (including swelling), shear force and bending distribution on structural members during construction and in the long-term;

(i)

Short and long-term ground and groundwater response;

(j)

Other changes in static loads such as excavation, surcharge, live loads, traffic loadings and others;

(k)

The effects of vibration so as to minimise disturbance to existing building structures; and

(l)

Effects caused by creep and shrinkage of concrete and the resulting effects (including secondary effects). These effects shall be regarded as permanent loads.

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(a)

Civil and structural design statement

1

Prior to the design of the buildings, the Contractor shall submit a civil and structural design statement which shall include: All relevant applicable codes, regulations and specifications;

(b)

Design assumptions; Loads and load combinations;

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7.2.3

2

(d)

Applicable safety factors;

(e)

Deformation and tolerances;

(f)

The proposed structural and foundation system;

(g)

The proposed construction methodology; and

(h)

Materials.

The civil and structural design statement shall be submitted to the Engineer for a SONO.

QCS 2014


7.3

STRUCTURAL CONCRETE

7.3.1


1

Materials and Production

Page 8

All concrete aggregates, additives aggregates, spacers, precast elements and other concrete related construction materials shall be produced and delivered with a certification and CE-mark.

(b)

Detailed specifications for all types of concrete shall be provided to the Engineer for SONO.

(c)

Special provisions shall be made for pre-stressed concrete elements with respect to aggregate gradation, spacers for tendon placement and concrete quality near anchor locations, as specified in the design.

(a)

Aggregates: Fly Ash

Ground Granulated Blast furnace Slag (GGBFS)

Aggregates: Silica Fume

Silica fume for concrete shall comply with EN 13263.

(a)

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(a)

(b)

In case of change of the source of supply, the Engineer shall be notified in advance.

Aggregates: Fine Aggregate Fine aggregates shall be natural or crushed rock sand in compliance with EN 12620.

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GGBFS shall comply with the requirements of EN 15167.

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(a) 6

Fly ash shall comply with the requirements of EN 450.

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(a) 5

All cement shall comply with the requirements of EN 197.

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Aggregates: Cement

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Testing of concrete shall be performed in a laboratory conforming to the requirements in EN 45001.

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(a)

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Concrete

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(a)

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Aggregates: Coarse Aggregates (a)

Coarse aggregates shall be crushed aggregate from an approved natural source in compliance with EN 12620.

(b)

In case of change of the source of supply, the Engineer shall be notified in advance.

Aggregates: Water (a)

10

Water for concrete mixing, ice, washing and cooling of aggregates as well as curing shall comply with EN 1008.

Additives: Admixtures (a)

The admixtures shall conform to the general and specific requirements of EN 934-2, EN 934-4 and EN 934-6.

QCS 2014

(b)

Concrete Mix Design (a)

All concrete mix designs shall be submitted to the Engineer for SONO.

(b)

The Contractor shall calculate the temperatures of the freshly produced concrete, based on the input temperatures of the components of the mix design.

(c)

It shall be documented by an automatic recording system that the batched quantities for each batch are in accordance with the mix design.

Fresh Concrete Properties The testing shall comply with EN 206-1.

(b)

Freshly mixed concrete shall be sampled in accordance with EN 12350-1.

(c)

Tests shall bet in accordance with the following standards:

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Vebe Test:

EN 12350-3

(iii)

Compaction test: EN 12350-4

(iv)

Flow Test:

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EN 12350-5

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(ii)

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EN 12350-2

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Slump Test:

The testing shall comply with EN 206-1.

Curing

Curing and protection shall comply with the requirements of QCS - Section 5.

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(a) 15

(i)

Hardening and Hardened Concrete Properties (a)

14

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(a)

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13

Admixtures shall be delivered to the concrete production site in original sealed packing, clearly marked and labelled to EN 934-2.

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Page 9

Execution of Repair Works

Execution of crack injection using epoxy or acrylic shall be in accordance with the manufacturer's instructions and EN 1504-5.

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PRESTRESSED CONCRETE

7.4.1


1

This document contains minimum requirements for pre-stressed and post-tensioned concrete.

2

Detailed records of the stressing and grouting including steel tests and materials certificates, shall be available for inspection at all times.

3

The minimum quality requirements for materials and workmanship shall be determined by the following documents listed in order of precedence:

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7.4

(a)

Qatar Construction Specifications (QCS - Section 5, Part 18)

(b)

EN 1992, EN 13670 Pre-stressing Tendons.

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Page 10

Materials

1

Steel Wire: Steel wire shall comply with BS 5896.

2

Cold worked high tensile alloy steel bars for pre-stressing shall comply with the requirements of BS 4486.

7.4.3


1

All pre-stressing tendons shall be stored in such a way as to avoid damage of any kind.

2

Each cable shall be tagged with its number from which the coil numbers of the steel used can be identified.

7.4.4

Surface condition

1

Stressing tendons anchorages, blocking devices and internal and external surfaces of ducts shall be clean and free from pitting, loose rust, loose scale and chloride contamination at the time of incorporation during the Work.

2

Slight rusting of the steel, which can be removed by moderate rubbing, is acceptable, but the surface shall not show signs of pitting. Tendons showing pitting are not to be used and shall be removed from Site.

7.4.5

Straightness

1

Pre-stressing bars shall be straight.

2

Bars bent in the threaded portion shall be rejected.

7.4.6

Post-tensioning

1

Anchorages and deflected Tendons

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Proprietary anchorages shall be handled and used strictly in accordance with the manufacturer's instructions and recommendations.

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(b)

Anchorages shall be tested in accordance with the requirements of EN 13391.

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(a)

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7.4.2

Tensioning procedure (a)

Full and detailed records shall be kept of all tensioning operations, including the measured extensions, pressure-gauge or load-cell readings, and the amount of drawin at each anchorage. These records shall be available for inspection at all times.

7.4.7

Pre-stressing Tendons

1

Protection and Bond (a)

The exposed tendons at the anchorages and the anchorages shall be protected from both mechanical damage and corrosion.

QCS 2014

Ducts for bonded tendons (a)

Ducts for longitudinal, transverse or vertical tendons embedded into the concrete shall be of flexible, semi-rigid, or rigid galvanized, ferrous metal capable of withstanding concrete pressures without deforming or permitting the entrance of cement paste during casting of the member.

(b)

Ducts shall retain their shape and be capable of transferring bond stresses.

7.4.8

Grouting of Pre-stressing Tendons

1

General Information

(a)

All ducts shall be thoroughly cleaned before grouting.

(b)

All surplus water shall be removed.

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Grouting Equipment

qa

The mixing equipment shall produce grout of homogeneous consistency and shall be capable of providing a continuous supply to the injection equipment.

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(a)

Injecting Grout

The method of injecting grout shall ensure complete filling of the ducts and complete surrounding of the steel.

(b)

The Contractor shall keep full records of grouting, including the date each duct was grouted, the proportion of the grout and any admixtures used, the pressure, details of any interruptions and topping up required. These records shall be available for inspection at all times.

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(a)

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Ducts

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3

All ducts shall be thoroughly cleaned and all anchorages shall be sealed before grouting.

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(a)

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Preparation for Casting

1

General information

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7.4.9

(a)

Pre-stressing steel for post-tensioning which is installed in members prior to placing and curing of the concrete, shall be continuously protected against rust or other corrosion, until grouted.

7.5

SHOTCRETE

7.5.1

General

1

This specification concerns the provision of materials and workmanship for the production and application of shotcrete.

7.5.2

Mix Reports

1

Reports of each shotcrete mix shall be produced and copies made available on Site for inspection by the Engineer.

QCS 2014


7.5.3

Production

1

Cement (a)

2

Cement used in shotcrete laying and maintenance works shall meet the requirements of EN 197-1. The minimum required content in 3 Type CEM I 42,5 cement shall be 400 kg/m .

Aggregates (a)

3

Page 12

Aggregates used in shotcrete application and maintenance works shall be either natural or crushed and shall comply with EN 12620.

Admixtures All admixtures used in shotcrete laying and maintenance works shall comply with EN 934-2, EN 934-5 and EN 934-6.

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(b)

steel fibres shall comply with the requirements of Annex B of EN 14487-1;

(c)

any fibres for shotcrete reinforcement shall be sufficiently small to ensure their uniform spreading in the mass of the shotcrete and avoid the formation of lumps.

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Application of fibre reinforced shotcrete

The shotcrete curing method shall comply with EN 14887-02.

Quality control

1

In situ checks

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The thickness of any applied shotcrete shall be verified.

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7.5.4

(a)

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Fibre reinforced shotcrete shall be applied in accordance with EN 14487-1, EN 148891 and EN 14889-2.

Curing of Shotcrete (a)

qa

ta

if steel fibres are used, the minimum quantity shall not be less than 30 kg/m ;

(a)

6

3

(a)

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5

Reinforcement

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(a)

Shotcrete quality tests (a)

For each shotcrete mix design, at least three (3) test panels for performing tests shall be prepared, as described below: (i)

test panels as well as the Contractor’s sampling method shall be in accordance with EN 14488.01;

(ii)

one (1) test panel shall be taken for each day of shotcreting;

(iii)

upon initial setting, test panels shall be transferred to the laboratory;

(iv)

the number of cores taken from each test panel, their dimensions and compliance control shall be in accordance with EN 14487.01;

(v)

the strength of shotcrete panels shall be checked in accordance with EN 14488.02. The required cylinder strength for 24 hours shall be class J2, as per paragraph 4.3 of EN 14487.01 and minimum value of 10 MPa;

QCS 2014


Page 13

(vi)

testing of shotcrete already applied shall be performed in accordance with EN 12504.01; and

(vii)

if test results for shotcrete already applied fail, immediate measures shall be taken to preserve the safety and stability of the Works, and the Engineer shall be notified.

FORMWORK

7.6.1


1

This section includes the design, production and installation of formwork in accordance with QCS - Section 5, Part 9.

2

All material for formwork shall be of a quality capable of providing a dense concrete surface.

3

Drawings and calculations shall be sufficiently detailed to document adequate strength, rigidity, and stability to meet all load combinations during the erection of the Permanent Work.

7.6.2

Formed finishes

1

Formed surfaces shall be according to QCS - Section 5, Part 9.

7.6.3

Unformed finishes

1

Unformed surfaces shall be according to QCS - Section 5, Part 9.

7.7

WATERPROOFING

7.7.1

General

1

This section refers to the supply and installation of the waterproofing systems in concrete structures.

2

The purpose of the waterproofing systems is to prevent leakage of groundwater into the structures and to protect the concrete against deleterious chemical influences.

3

All waterproofing works shall be executed in accordance with BS 8102.

4

All the materials to be used for waterproofing shall be compatible with each other, as well as with any bordering materials such as concrete. Any harmful chemical influences shall be prevented.

5

The waterproofing system used shall be suitable for the Works and the local conditions of ground and groundwater. Any expected movement of the structural elements caused by shrinkage, temperature changes and settlements, should not result in the waterproofing system losing its waterproofing properties.

6

All waterproofing systems shall be installed and tested in accordance with the manufacturer’s instructions or recommendations. Testing shall be undertaken as necessary to ensure satisfactory functioning of the system at each stage of the installation. Defective waterproofing systems shall be repaired in accordance with the manufacturer’s instructions or replaced.

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7.6

QCS 2014


Page 14

7

Waterproofing system shall be applied only after effectively sealing of all cracks on exposed surfaces of the external structural members as per the manufacturer’s instructions or recommendations.

7.7.2

Waterproofing classes

1

Waterproofing classes are defined in the following table: Table 7.1 Waterproofing classes Definition for impermeability on the inner soffit

Characteristic of the waterproofed inner soffit General

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Waterproofing Class

Completely dry

Acceptable amount of water in the tunnel structure: no water.

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1

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The inner soffit shall not show any moisture areas.

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On the inner soffit, weak moisture penetration shall only appear on max. 10% of each structure’s section surface (visible as a dark colour change on the concrete surface). On dry hands contacting weak moisture areas, no evident marks of water shall be visible afterwards. Disposed blotting paper or absorbent newsprint shall not change in colour due to moisture absorption.

Largely dry

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2

On the inner soffit, weak moisture penetration shall only appear on 10% of each structure’s section surface (visible as a dark colour change on the concrete surface).

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3

Acceptable amount of water in the tunnel: any quantity less than the acceptable amount of waterproofing class 3.

Slightly wet Acceptable amount of water in the tunnel: general 0.02 litre/m²/d, for less than 50 m of tunnel length 0.1 litre/m²/d.

7.7.3

Waterproofing for Cast in Situ Concrete Tunnel Linings

1

Watertightness (a)

Cast in situ concrete linings for tunnels, cross passages and shafts shall be waterproofing class 1.

(b)

Cast in situ concrete linings for underground plant rooms shall be waterproofing class 1.

QCS 2014


Page 15

7.7.4

Waterproofing for Precast Concrete Segmental Tunnel Linings

1

Watertightness (a)

Precast concrete segmental linings shall be of waterproofing class 1

7.7.5

Waterproofing for Cut and Cover Structures and Open Troughs

1

Watertightness (a)

Cast in situ concrete linings for cut-and-cover and open troughs shall be waterproofing class 1.

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END OF PART

QCS 2014

Section 29: Railways Part 08: Steel Structures

Page 1

8

STEEL STRUCTURES .................................................................................. 2

8.1

STRUCTURAL STEEL .................................................................................. 2

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6

General Products Execution Protection and repairs Bolted connections Welding

8.2

REINFORCEMENT........................................................................................ 4

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8

General Execution – Wire Mesh Execution – Bar Bending Schedules Execution – Bending Execution – Fixing Execution – Reinforcing Steel Testing Steel Fibres Glass Fibre Reinforced Plastics (GRP)

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2 2 2 3 3 3 4 4 5 5 5 5 5 5

QCS 2014


Page 2

STEEL STRUCTURES

8.1

STRUCTURAL STEEL

8.1.1

General

1

This Section includes the production and erection of structural steelwork, as shown on the Contractor’s drawings.

2

All project related steelworks shall be according to QCS - Section 16. Workmanship and materials shall be in accordance with EN 1993 (which shall have priority), EN 10025 and relevant standards.

3

Shop drawings shall include connection designs, complete details and schedules for fabrication and assembly of structural steel members, procedures, diagrams, and erection plans.

8.1.2

Products

1

Materials

rw

Appropriate measures shall be taken to prevent internal corrosion of hollow structural steel members.

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Testing

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The tests shall be in accordance with EN 1993. Test certificates for the materials and welding shall be maintained.

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Tolerances (a)

5

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(b)

(a)

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All structural steel, before and after fabrication, shall be straight unless otherwise specified, and shall be free from twists. The fabrication tolerances shall comply with EN 1993.

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(a)

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3

Fabrication

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2

All structural steelwork, including structural fasteners and welding consumables etc. shall comply with the EN 1993 and EN 10025.

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(a)

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8

The tolerances for erected steelwork shall comply with EN 1993.

Galvanizing (a)

Galvanising shall be in accordance with EN ISO 1461.

(b)

Cold formed or cold worked steel sections shall not be hot dip galvanised.

8.1.3

Execution

1

Erection (a)

Structural steelwork shall be distinctly marked before delivery.

(b)

Permanent bolts shall not be used as service bolts during erection, where such use is liable to cause damage to the protective treatment provided to the bolt.

QCS 2014 (c)

2


Page 3

Welds shall be kept free from slag or other inclusions. All adhering slag shall be removed immediately after the completion of each run. Slag and weld spatter shall be removed from surrounding surfaces after welds have been completed.

Surface preparation (a)

All surfaces shall be clean before protective treatment is commenced and shall comply with EN 1993.

(b)

Blast-cleaned steelwork shall be free from dust.

8.1.4

Protection and repairs

1

General Protective work shall be carried out in accordance with EN ISO 12944, and all damage shall be repaired.

(b)

Protective treatment shall be carried out in the steelwork fabricator's works after fabrication. Shop treatment shall be carried out in a weather-proof structure under clean, dry conditions.

(c)

All protective paint systems to structural steel shall have full compatibility between coats and with the metal substrate. There should be adequate adhesion to substrate and between coats over the operating temperature range and there should be no under-softening to cause lifting, wrinkling or bleeding through of stains. All components of a specific paint system shall be from the same manufacturer.

(d)

All paints and coatings shall be non-toxic and shall not produce toxic fumes or other toxic substances during application and/or when exposed to fire.

(e)

Structural steel shall be degreased prior to painting. Where steelwork is partially embedded in concrete, the steelwork shall be coated over an area extending to at least 100 mm beyond the exposed area.

Paints

All paints shall comply with EN ISO 12944.

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(a)

Bolted connections

1

Bolts shall be threaded only over the length of shank which is outside the parts bolted together. The bolt shall protrude by at least two complete threads and not more than four complete threads beyond the outer face of the tightened nut.

2

Holes shall not be distorted or enlarged by the use of drifts.

3

High strength friction grip bolts shall be fitted in accordance with BS 4604, Part 2.

8.1.6

Welding

1

Welding of structural steelwork shall comply with EN 1011-1.

2

All welders shall possess valid test certificates in accordance with EN 287-1. These test certificates shall be appropriate to the type of work being carried out and shall be always available for inspection.

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8.1.5

QCS 2014

Testing of Welds (a)

Facilities, equipment and qualified personnel shall be provided to carry out any testing and visual inspection of welds. The type of testing shall include but not be limited to the following: (i)

Magnetic particle flaw detection test (to EN 1290);

(ii)

Penetrant flaw detection test (to EN 571-1);

(iii)

Ultrasonic examination (to EN 1714); and

(iv)

Radiographic examination (to EN 1435).

The quality of welds shall be assessed in accordance with the acceptance levels given in EN 15614-1. The visual inspection of fusion welds shall be carried out in accordance with EN 970. All inspection records and test results shall be available on Site for inspection.

(c)

Where failures are identified in the weld tests, the Engineer may require any additional testing.

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(b)

Welding procedure (a)

Details of the proposed welding procedures together with diagrams showing the build up of all main welds shall be included in the Contractor’s method statement.

(b)

No distortion shall be allowed.

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REINFORCEMENT

8.2.1

General

1

This specification sets out the minimum standards, including but not limited to materials and workmanship as follows:

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8.2

the steel shall be produced and classified in accordance with EN 10080;

(b)

spacers shall be in accordance with BS 7973-1, Product performance requirements and BS 7973-2;

(c)

binding wire shall not stain the concrete surface;

(d)

wire mesh shall be constructed of transversal and longitudinal wires using B500A quality steel according to EN 1421-2;

(e)

mechanical couplers may be used;

(f)

galvanised reinforcement shall be hot dip galvanised, after cutting to length and bending;

(g)

galvanising shall satisfy the requirements according to standards EN ISO 1460 and EN ISO 1461;

(h)

stainless steel reinforcement shall comply according to EN 10088.

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8.2.2

Execution – Wire Mesh

1

Wire mesh shall be installed in Sprayed Concrete Lining (SCL) tunnels embedded in shotcrete.

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In cases where, during the installation of the wire mesh its extension is required, the overlapping of the mesh shall, at a minimum be as follows: (a) (b)

At least equal to 300 mm, concerning extension of the main reinforcement (strength) of the mesh; and At least equal to 150 mm, concerning extension of the secondary reinforcement (distribution) of the wire mesh.

The overlapping edges shall be tightly fixed together through wires, or held by means of standard couplers.

8.2.3

Execution – Bar Bending Schedules

1

The minimum lap lengths and effective anchorage lengths for bars under stress shall be full tension lap lengths in accordance with EN 1992-1-1.

8.2.4

Execution – Bending

1

Bars shall be bent in accordance with the provisions of standard EN 1992-1-1.

2

Any reinforcement showing signs of damage shall be rejected and removed from the Site.

3

The reinforcement shall be accurately cut and bent to the form shown on the bending schedules in accordance with standard EN ISO 3766.

8.2.5

Execution – Fixing

1

The steel for stainless steel tying wire shall be grade 1.4404 in accordance with standard EN 10088-1.

8.2.6

Execution – Reinforcing Steel Testing

1

The methods of testing and the methods of attestation of conformity shall be as defined in standard EN 10080.

8.2.7

Steel Fibres

1

The steel fibres shall comply with standard EN 14889-1.

2

The minimum properties of the steel fibres shall be:

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the steel fibres shall be made of low carbon, cold drawn wire (EN 14889: Group 1), have a circular cross section with hooked ends.

(b)

Tensile strength of the wire shall be minimum 1100 N/mm².

(c)

Nominal length of the steel fibres shall be between 40 and 60 mm.

(d)

Aspect ratio (L/D) shall be between 50 and 70.

(e)

The steel fibres shall be distributed evenly within the concrete mix.

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(a)

8.2.8

Glass Fibre Reinforced Plastics (GRP)

1

The design of GRP soft eye structures shall be produced and classified in accordance with standard QCS – Section 8, Part 7.

2

The design of GRP soft eye structures shall be in accordance with standard EN 1992-1-1. END OF PART

QCS 2014

Section 29: Railways Part 09: Drainage

Page 1

9

DRAINAGE .................................................................................................... 2

9.1

DRAINAGE SPECIFICATION ........................................................................ 2

9.1.1 9.1.2 9.1.3 9.1.4

General Tunnel Drainage Drainage on Elevated Sections TRACK WORK DRAINAGE

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9

DRAINAGE

9.1

DRAINAGE SPECIFICATION

9.1.1

General

1

All water entering the completed structures comprising the Works shall be drained into the public drainage systems.

2

Separate drainage systems shall be provided for the following:

3

Tunnel drainage shall deal with water originating from:

(b)

Tunnel washing;

(c)

Testing and discharge of the fire mains;

(d)

Condensate from train air-conditioning;

(e)

Water in case of fire fighting;

(f)

Water from the emergency exits and ventilation shafts;

(g)

Rain water blown into the tunnel or brought into tunnel by wet rolling stock; and

(h)

Any other water ingress.

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Tunnel condensation;

Station drainage shall deal with water originating from: Tunnel condensation;

(b)

Tunnel washing;

(c)

Testing and discharge of the fire mains;

(d)

Condensate from train air-conditioning;

(e)

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Condensate from Environmental Control System (ECS) associated plants; Water tank overflow and drainage;

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6

(g)

All clean water in the station;

(h)

All clean water brought into the station;

(i)

Water in case of fire fighting; and

(j)

Any other water ingress.

Drainage of elevated sections shall deal with water originating from: (a)

rain water;

(b)

testing and discharge of the fire mains; and

(c)

washing water.

Storm water drainage shall deal with all rainwater falling on the station roofs and external areas and shall be directed into the public drainage system.

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Tunnel Drainage

1

Pump sumps shall be located at the lowest points of the tunnels.

2

The discharge pipes from the tunnel pump sumps shall be routed via the stations, ventilation shafts or emergency exits to the public drainage system.

3

Tunnel drainage sumps shall be monitored at the nearest station.

9.1.3

Drainage on Elevated Sections

1

All water collected by structures shall be drained into the road drainage system if possible.

2

If road drainage is not available, soakaways shall be provided for drainage

3

Surface drains at deck level shall be constructed along the viaduct route. Run off shall be collected through surface drains that shall lead to down drains.

4

Provision for silt removal shall be made.

5

Particular attention is required where pipes pass through the structure, particularly at abutments where relative movement is anticipated between the deck and the sub-structure.

6

Drainage pipes shall be concealed and maintainable.

9.1.4

TRACK WORK DRAINAGE

1

All water entering the completed structures comprising the Works shall be drained into the drainage systems of tunnel, elevated and at-grade structures.

2

Drainage of Trackwork sections shall deal with water originating from: rain water;

(b)

condensate from train air-conditioning;

(c)

fire fighting water; washing water; and

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9.1.2

(e) 3

any other water ingress.

Drainage pipes shall be concealed and maintainable. END OF PART

QCS - 2014.pdf

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